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EDITORIAL
SEZ to the rescue!
T
he continuing global economic slump is adversely affecting India’s exports. According to the latest available data, the country’s exports have shrunk by 1.41 per cent to $ 72.4 billion in the first quarter of 2013–14. In a ripple effect, this has led to the widening of the current account deficit, which has touched an all time high of 4.8 per cent of the gross domestic product in 2012–13. Against this backdrop and with the general elections barely few months away, it is not surprising to see heightened activity in the policymaking corridors of the national capital. The moot point here is from where to begin in order to energise exports. In this context, the spotlight seems to return to the significance of Special Economic Zones (SEZs). This is primarily because SEZs have delivered more than 30 per cent of growth in exports, while the country’s trade outflow has witnessed an overall decline of 1.86 per cent during the same period. Before delving into the details, it will help to trace the roots of SEZs in India. The SEZ policy came into existence in April 2000 with objectives that sought to clear the bottlenecks arising out of multiplicity of controls and clearances, to put in place world-class infrastructure and to increase India’s share of foreign direct investments. SEZs were initiated to put India on the fast lane to economic growth as well as to promote the country’s manufacturing might. However, with the passage of time, India’s current SEZ policy seems to be adding little towards sustainably boosting India’s economy, especially in the light of the recent global economic headwinds and a fast-evolving domestic manufacturing ecosystem. The time is thus ripe for a thorough review of this policy in order to launch fresh measures that can broaden the contours of economic reform.
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
As a welcome step in this direction, the Department of Commerce is considering a relaxation of the minimum area requirement for more sectors in the final amendments of the SEZ rules as both the industry and state governments have been facing hurdles in land acquisition. Further, the Ministry of Commerce and Industry has prioritised these proposals and asked its officials to ensure that new norms are put in place at the earliest. On being accepted, these changes will add substantial value to the policy alterations made by the government a few months ago. Moreover, it should rekindle interest among India-bound investors and perhaps help the manufacturing sector regain its lost glory.
P P Kharas Chairman, Ecoplast
Raman M Patel Chairman, Industrial Products Mfg Co
Vijay Merchant
Manas R Bastia manas@network18publishing.com
President, Polycraft
August 2013 | Modern Plastics & Polymers
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CONTENT S
35 Special Focus
70
Automotive plastic coatings........................ 60
Masterbatches processing.......... 42 Roundtable................................ 48
Polymer technology.............................................56
R&D initiatives......................... 38 Interface: Shamik Shah............. 46
Automation
Polymers in paints & coatings.................... 54
Masterbatches & additives........ 36
Masterbatches & Additives
August May 2012 2013 | Modern Plastics & Polymers
53
Interface: Raman Trikala............................. 62
Insight & Outlook Paints & Coatings
Roundtable.................................................. 64 Pyrolytic technology............................................66
35
Trends
Polymer compounding: Leading the way through innovation
Energy Management
74
Extrusion: On the path of energy efficiency
Policies & Regulations
78 A nti-dumping duty: Implications for the Indian plastics processing segment
Strategy 80 Flexible plastic packaging: Lightweighting for reducing costs
Tips & Tricks
83
In Conversation With
Facility Visit
30
S B Dangayach Managing Director, Sintex Industries Ltd
Effective food packaging: Ensuring hygiene and safety3
Event Report 90 K 2013 Preview: Countdown to K 2013 begins 92 IPI Symposium on Resource Efficient Polymer Processing: Stressing on the optimum use of resources
REGU L AR SEC T ION S Editorial.................................. 9 Event List............................. 88 News, Views & Analysis....... 22 Products................................ 93 Technology & Innovation..... 28 Projects.................................. 84 List of Products.................. 102 Tenders.................................. 86 List of Advertisers............... 105
Details on pg no. 88 Note: ` stands for Indian rupee, $ stands for US dollar and ÂŁ stands for UK pound, unless mentioned otherwise
50
A Schulman Plastics India Pvt Ltd: Mastering masterbatches manufacturing in India
Highlights of Next Edition Special Focus: Blow Moulding Insight & Outlook: Polymer Compounding Cover photo courtesy: Clariant
August 2013 | Modern Plastics & Polymers
11
Business Insights •Technologies•Opportunities
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Views and opinions expressed in this magazine are not necessarily those of Network18 Media & Investments Ltd (Network18)*, its publisher and/or editors. We at Network18 do our best to verify the information published but do not take any responsibility for the absolute accuracy of the information. Network18 does not accept the responsibility for any investment or other decision taken by readers on the basis of information provided herein. Network18 does not take responsibility for returning unsolicited material sent without due postal stamps for return postage. No part of this magazine can be reproduced without the prior written permission of the publisher. Network18 reserves the right to use the information published herein in any manner whatsoever. Printed by Mohan Gajria and published by Lakshmi Narasimhan on behalf of Network18. Senior Editor: Manas R Bastia Printed at Print House India Pvt. Ltd. R - 847/2. T.T.C. MIDC, Rabale, Navi Mumbai - 400 701, and published at Network18, ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W), Mumbai - 400 028. Modern Plastics & Polymers is registered with the Registrar of Newspapers of India under No. MAHENG / 2008 / 25265. Network18 does not take any responsibility for loss or damage incurred or suffered by any subscriber of this magazine as a result of his/her accepting any invitation/offer published in this edition. *Ownership of this magazine stands transferred from Infomedia18 Ltd (Infomedia18) to Network18 Media & Investments Ltd (Network18) in pursuance of the scheme of arrangement between Network18 and Infomedia18 and their respective shareholders and creditors, as approved by the Hon’ble High Court of Delhi and the necessary approval of Ministry of Information and Broadcasting is being obtained.
August 2013 | Modern Plastics & Polymers
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NEWS, VIEWS & ANALYSIS
Dave launches patented blow moulding machine in India
Dave Technical Services (DTS), manufacturers of blow moulding & injection moulding machines and moulds & product developers, recently announced the launch of its fully automatic twin station blow moulding machine in India.
Smart announces blow moulding machinery facility in India
The patent-protected design, which is called as the Twin Station Blow Moulding Machine (model DTB 50), offers flexibility where two different products of different materials of different shape, size and thickness can be produced simultaneously. Even two products with different colours can be produced simultaneously on this machine as required. The machine also offers the choice of ‘filling & sealing’ arrangement (Blow FFS), ie it provides complete synchronisation in forming of plastic products with arrangement for liquid filling (volumetric principle) followed by sealing it. Most importantly, the Blow FFS is automatic, fully pneumatic and works on an air compressor, providing considerable power savings.
Smart Machineries and Moulds Pvt Ltd has inaugurated its new plastics extrusion blow moulding machinery manufacturing facility in Western India. The facility will focus exclusively on serving the growing demand for blow moulding products applications. The new facility near Mumbai will manufacture all sizes of extrusion blow moulding machines, which include single and double station machines. Initially, the annual capacity is projected to be approximately 24 to 36 machines. Shreeram Rane, Managing Director, Smart Machineries and Moulds Pvt Ltd, said, “This plant will be dedicated to providing innovative solutions to meet the needs of blow moulding processors in India. By opening this new facility near Mumbai, we are strengthening our position to serve our growing customer base in this attractive market.”
22
Uhde India certified BS OHSAS 18001 and ISO 14001
Uhde India has been certified under BS OHSAS 18001:2007 and ISO 14001:2004. The certifications, which were carried out by TUV India, the certification agency functioning under the aegis of TUV Nord of Germany, are valid up to June 2016. BS OHSAS 18001 (2007 version) certifies that Uhde India has in place an Occupational Health & Safety System, which adequately reaffirms its commitment to Occupational Safety and Health of its employees, contractors and business associates. ISO 14001 (2004 version) certifies Uhde India’s Environmental Management System. It demonstrates Uhde India’s responsibility and commitment to environmentfriendly business practices, with minimal or no impact on the environment. These certifications come after intensive efforts, orientation programmes and in-depth awareness & training programmes across Uhde India offices & construction sites covering an extended period of time. Among the leading engineering consulting companies in India, with a track record in excess of 500 completed projects, Uhde India’s Quality Management System is already certified under ISO 9001 requirements since 1994. The current certification under ISO 9001:2008 is valid up to June 2015.
Athalye receives recognition for six decades of service
Arvind Shankar Athalye was honoured with a Life-time Achievement Award at the recent Indian Plastics Institute (IPI) Awards Function during IPI Day, an event that marked the institute’s completion of 28 years. Being closely associated with the plastics industry in India for the last 50 years, Athalye has been a dedicated crusader working to give plastics a place among the materials serving the needs of mankind. Considered as a guide, philosopher and teacher by many in the plastics industry, this award recognises his unstinted, selfless and unblemished service rendered to the plastics fraternity in different capacities. After graduating in Polymer Engineering from Michigan State University, USA, Athalye began his professional career with Dow Chemicals Corporation in Michigan, USA. On his return to India, he headed the Technical Services Department and Application & Development Group of Polychem Ltd during 1960–65, after which he moved on to Hoechst Dyes & Chemicals as the Head
Modern Plastics & Polymers | August 2013
Arvind Shankar Athalye accepts the award from Vimal Kedia,Managing Director, Manjushree Technopack Ltd, and the Chief Guest of IPI Day
of the Technical Services & Application Development Department. In his quest to take bigger challenges in the industry, Athalye began his 20 years of association with Thakersey Group in 1972. Soon after, he started his own independent activity of Projects Consultancy in the field of plastics and packaging. All along the way, Athalye has spread the knowledge of plastics and its use. He has the experience of publishing technical books covering various subjects and has presented technical papers on plastics processing and end-use applications at various seminars.
NEWS, VIEWS & ANALYSIS
Manjushree Technopack on an expansion drive
Manjushree Technopack, a leading Polyethylene Terephthalate (PET) bottle & preform manufacturer, is looking at consolidating its global operations by setting up its first office in the Middle East, following new business opportunities emerging in the global industry. The company is already exporting to the Gulf region, Thailand and Africa. Another development at Manjushree is the commissioning of its single largest PET preform manufacturing plant in south Asia, boosting the company’s total capacity from 50,000 MTPA to 80,000 MTPA, which is equivalent to 15 per cent of the total PET
Demand for plastic cups and lids to increase 5.9 per cent annually
The global demand for plastic cups and lids will increase 5.9 per cent per year through 2017, outstripping the overall market growth of 5 per cent, according to the report ‘World Cups & Lids’ from Cleveland-based Freedonia Group Inc. While the market for cups and lids will grow 5 per cent to $ 25.9 billion in 2017, the market for plastic cups and lids will increase 5.9 per cent to $ 13.9 billion over the same period. India and China will experience the highest growth rates, followed by Indonesia, Russia, Brazil and Mexico. S B Dangayach, Managing Director, Sintex Industries Ltd, noted, “The demand for plastic cups and glasses is increasing not only in urban areas but even in semi-rural and rural areas. This is because of the various advantages offered by plastics like hygiene, convenience and overall reduction in cost.” Avani Jain 24
Modern Plastics & Polymers | August 2013
consumption in India. The plant is also one of the few green factories in India. Further, the company had committed investments of ` 150 crore to two new greenfield facilities in Harohalli and Bidadi. “The Bidadi facility has been commissioned during the year 2012–13. “The commissioning of the state-of-theart production facility has greatly enhanced our capabilities, particularly in the rapidly growing PET preform segment. In addition to the significant increase in capacity, the level of automation that we have adopted in the new facility is expected to improve efficiencies and reduce manpower costs,” said Vimal Kedia, Managing Director, Manjushree Technopack.
Microscan wins 2013 Ringier Technology Innovation Award
Microscan, a global technology leader in barcode, machine vision and lighting solutions, won a 2013 Ringier Technology Innovation Award in the Pumps & Valves Industry category for its HS-41X Handheld DPM Imager. The award was presented during a ceremony at IE expo 2013, held in the Shanghai New International Expo Center on May 14, 2013. The 2013 Ringier Technology Innovation Awards for the Pumps and Valves Industry are co-organised by Ringier Trade Media and its magazine World Pumps China together with MMI-ZM Trade Fairs (Shanghai) Co Ltd and its trade show IE expo 2013. The HS-41X is a compact handheld imager for decoding low-contrast 2D symbols on substrates (sheet metals, castings, plastics and electronic components). Its dual field optics are optimised to read both linear barcodes and 2D symbols, including challenging marks such as those created by Direct Part Mark (DPM) methods such as dot peen and laser/chemical etch. Integrated with Microscan’s industry-leading X-Mode decode algorithms and innovative brightfield lighting, the HS-41X handheld is the best in its class for DPM reading. This imager is also disinfectant-ready, dust & water resistant and features an IP54rated enclosure – an ideal portable reading solution for automated data application.
Global automotive plastics consumption to grow at CAGR of 13.4 per cent from 2013 to 2018
The global automotive plastics consumption market revenue is expected to grow from $ 21,617 million in 2012 to $ 46,112 million by 2018 at an estimated CAGR of 13.4 per cent from 2013 to 2018, as per MarketsandMarkets. In 2012, Asia–Pacific was leading in automotive plastics consumption volume by 50.5 per cent. Automotive plastics are one of the widely preferred alternatives for lightweighting of automobiles as they offer enhanced properties such as superior impact strength, easy mouldability, improved aesthetics and reduced weight as compared to conventional automotive components such as High Speed Steel (HSS) and aluminium. The increasing demand for passenger cars and the supply to fulfil the same in Asia–Pacific is one of the main drivers for increasing consumption of automotive plastics. Canon Patel, Managing Director, Loxim Industries Ltd, noted, “If you look at India particularly, then more than 50 per cent of the population is below 25–35 years, clearly indicating that the spending power of the economy is much higher than any other economy in the world. It is for the same reason that the number of cars per capita has increased drastically over the years, which means that the automotive sector is booming, directly increasing automotive plastics consumption.” Avani Jain
NEWS, VIEWS & ANALYSIS
Promotions in full swing at India’s biggest upcoming plastics trade show
Arvind Mehta addresses the audience at the meet
The All India Plastics Manufacturers’ Association (AIPMA) has been actively promoting the upcoming PLASTIVISION INDIA 2013. At the recently held IPLEX in Chennai, the Association was seen marketing and promoting the upcoming trade show. The Association also organised a PLASTIVISION INDIA Networking and Business Meet on June 27, 2013 in Chennai. S Mitra, Executive Director - Petrochemicals, Indian Oil Corporation Ltd; Kailas P, Managing Director, Toshiba Machine Chennai Pvt Ltd; Dr S K Nayak, Director General, Central Institute of Plastics Engineering & Technology (CIPET) and Dr Asutosh K Gor, President, AIPMA graced the occasion.
LANXESS technology facilitates production of fuel-efficient tyres
Buna CB PBR 4076 and PBR 4065 are two new Neodymium Polybutadiene Rubber (NdBR) grades from LANXESS for making fuel-efficient tyres. Despite their high molar masses, both these variants are exceptionally easy to process – without compromising on their dynamic mechanical properties. These variants of the LANXESS tyre rubber grades Buna CB 24 and 22 have been optimised using LANXESS technology with the 26
International symposium on various processes for valourisation of polymeric wastes
The Government of India, Ministry of Chemicals & Fertilizers, Department of Chemicals & Petrochemicals (DCPC), is organising an International Symposium on Feedstock Recycling of Polymeric Materials (ISFR). This biennial international symposium focusses on the various processes for the valourisation of polymeric wastes. It aims at bringing together scientists, engineers and industrial experts to brainstorm on the recent developments in plastics. Previous ISFR events were organised in Japan, Belgium, Germany, Korea, China and Spain. This time, the symposium has been allotted to Council of Scientific & Industrial Research (CSIR) - Indian Institute of Petroleum (IIP), Dehradun, and is scheduled to be held on October 23–26, 2013, at India Habitat Centre, New Delhi, India. The event has been conceptualised by DCPC with the objective of providing a common platform for sharing the latest developments and exchange of ideas for both scientific and technological points of view in the areas of waste plastics, e-waste and biomass conversion. specific objective of making them easier to process without any compromises in terms of the tyres’ end properties. Dr Heike Kloppenburg, an expert on tyres and synthetic rubber at LANXESS’ site in Dormagen, Germany, explained, “PBR 4076 matches the tyre performance of the high-Mooney grade Buna CB 22 but can be processed in the same way as Buna CB 24, which has a far lower viscosity. For example, we have significantly increased the rubber’s tackiness on the roller and have done so without adding any processing aids.”
Modern Plastics & Polymers | August 2013
Sonderhoff USA obtains FDA approval for sealing food packaging
Foam gasket application on plastic barrel lids with FERMAPOR K31 polyurethane sealing using a Sonderhoff mixing and dosing system Sonderhoff USA Corporation, Elgin, Illinois, was granted the coveted approval for a two-component flexible foam gasket of the Sonderhoff product line FERMAPOR K31, specifically developed for food packaging. The certificate was issued in accordance with Title 21 of the US Code of Federal Regulation, 21 CFR § 174.5 ‘General Provisions Applicable to Indirect Food Additives’. According to the approval, the polyurethane foam gasket product FERMAPOR K31 with the type description ‘A-LA-384-12-I-2’ in connection with the hardener FERMAPOR K31-B-23 may be used for sealing food packaging. “We are very proud to have been certified within a relatively short period of one year, thus demonstrating that our new flexible foam gasket FERMAPOR K31 A-LA-384-12-I-2 meets the strict FDA standards for food packaging,” said Holger Hülsken, President and Chief Executive Officer, Sonderhoff USA Corporation. To date, the American packaging industry has been using ethylene propylene diene monomer or die-cut gaskets, mainly inserted manually, for sealing food packaging. The Food and Drug Administration-certified polyurethane foam gasket FERMAPOR K31 is applied to the food packaging directly on site and hardens at room temperature. This polyurethane foam gasket provides a seamless seal. In contrast to gasket inserts, the coupling point is not visible and maintains its sealing function even at this position. The certification of FERMAPOR K31 foam seals for food packaging opens up a promising market for Sonderhoff USA in the North American Free Trade Agreement countries of USA, Canada and Mexico.
TECHNOLOGY & INNOVATION
New PC resin to improve in-mould decoration
Teijin Ltd has developed a new Polycarbonate (PC) resin for in-mould decoration. The company claims that the new resin provides an efficient way of decorating plastic parts during injection moulding. The technique also promotes lighter weight parts. Applications can include smartphone, tablet, medical device and auto parts. The use of special glass fibres and additives gives the PC high rigidity and dimensional stability for thin-walled moulded cases. The resin also gives high flatness and 40 per cent greater fluidity than conventional glass-filled PC materials. The new material provides a high degree of flame retardancy.
Developing fire-retardant additives using nanotechnology
A collaborative project in Europe is developing nanotechnologybased fire-retardant additives that can replace conventional non-halogenated additives at much lower addition levels. Phoenix has been a 4-year project composed of 15 partners from eight European countries and coordinated by AIMPLAS in Valencia, Spain. A key goal is to eliminate halogenated fire retardants with materials that can be added at levels of about 15 per cent to plastics – half or less than typical conventional non-halogenated additives now used. Phoenix argues that high levels of non-halogenated types negatively affect a polymer’s physical properties. Phoenix is working on nanoparticle additives alone or in conjunction with each other. It aims to make nanoparticles from carbon-based graphene, modified lignins derived from wood, nanohydroxides and encapsulated phosphorus-based retardants in hollow particles. In addition to better sustainability through lower additive levels, the added benefits will include work safety, consumer safety and low environmental impact.
Blown film external gauge control boosts output
Addex Inc has developed an enhanced automatic External Gauge Control (EGC) system for blown film extrusion lines called the Tandem. The Ta n d e m EGC combines the gauge control efficiency of the company’s EGC air ring with a bubble-stabilising lower air ring that achieves 15–30 per cent greater output. The lower, single-lip air ring sits on the die and matches the die’s diameter. It is fed by a blower that is about half the size of the blower needed for a typical air ring, according to Addex. The blower gently cools the bubble, stabilising it before it goes through the upper, dual-lip automatic gauge control air rind located above it. The more-stable bubble can be run at higher output without jeopardising the gauge control function. The upper EGC air ring is 2” bigger than the die size. That larger diameter for the upper ring, which is equipped with the gauge control, is needed to accommodate for the blow-up ratio.
New FLEXflow electrical cylinder
The HRS Flow Division of Inglass Group SpA has developed the FLEXflow electrical cylinder to accurately adjust valve pins in large-surface applications such as bumpers, instrument panels and door panels. Each valve pin is independently managed during the opening and closing stages by precisely controlling the pin’s position, acceleration, velocity and stroke. The system controls the speed profile of the opening pin. The result is an optimal control of the filling and packing time with a direct benefit on part warpage as well. The new electrical cylinder meets the requirements for high aesthetic quality, removing major defects such as flow marks, weld lines and flash on injection points. FLEXflow works well with multi-cavity moulds. It fine tunes the weld line position when a complex filling pattern balance is required. The new electrical cylinder has several benefits compared to a conventional air/oil cylinder. The advantages include improved part-to-part consistency, thanks to stable process repeatability; optimised balancing, reducing over-packing 28
Modern Plastics & Polymers | August 2013
and clamping force; hydraulic connections are eliminated (no more oil leakage); maximum flexibility in multi-cavity/family tool design; reduced energy consumption; accurate process control; easy to use and easy maintenance. The new HRS flow electrical cylinder is available for the M, G and A series (5, 7 and 10 mm pin diameter), and it can work up to a maximum pressure of 2,000 bar.
IN CONVERSATION WITH: S B Dangayach
“PLASTICS IS THE GREENEST
MATERIAL, AND THIS POSITION
SHOULD BE TAKEN BY THE INDUSTRY AS WELL” …opines S B Dangayach, Managing Director, Sintex Industries Ltd. In an exclusive interview with Avani Jain, he underlines that the demand for plastics is increasing in all industry segments, especially packaging. He also discusses the major growth drivers for plastics consumption and the company’s unique offering in the environmental segment. How is the plastics industry fairing in the country?
The plastics industry has been recording a growth of about 1.5 times the national average. This has been the trend since the last ten years and will continue to be there for the next decade as well. The growth of the industry is in sync with the overall national growth.
What are the key growth drivers in the segment?
The need for lightweighting, energy efficiency, resource efficiency, reprocessability, cost effectiveness and mass manufacturing and the demand for disposables are driving the growth of plastics. In my opinion, plastics is the greenest material, and this position should be taken by the industry as well. 30
Modern Plastics & Polymers | August 2013
S B Dangayach
At present, which segment is recording the highest consumption of plastics in the country?
The consumption of plastics is the highest in the packaging segment. There is an increase in the demand for packaged food and disposables. The demand for plastic packaging has increased not only in the cities but also in the semi-rural and rural areas, which have recorded high plastics consumption in the form of food plates and disposable glasses for water. Even people from the lower income segment are adopting plastics due to hygiene, convenience and lower costs. Hence, the demand for plastics in packaging is growing. Another area in which plastics consumption is increasing is in building and construction.
Do you think plastics pollute the environment?
This is totally a wrong perception. The problem is not with plastic material but with waste management. If you manage the waste well, ie segregate it properly at source or store it properly and hand it to the waste collecting agencies, or send it to appropriate places – natural landfill, incineration, centres for sorting, segregation and composting, then it will not create any trouble.
What solutions are offered by the company in the environment/green segment?
We have been ahead of many other companies in the segment. We are working on many solutions that address the so-called issue of green and clean growth. We have worked on both dry and wet waste solutions. The wet waste – animal, kitchen or human waste – can be best converted into biogas and manure. Hence, we offer solutions for treatment and conversion of these three wastes at one time in one plant, thus ensuring hygiene and adding substantial value to society. Sintex is well known for its plastic biogas plants, which are unique in the world. We also offer
solutions, such as plastic solar cookers, which ensure energy efficiency. Further, to make big structures energy efficient, one needs insulation, and here our sandwich panels come into the picture. We are one of the pioneers in Unplasticised Polyvinyl Chloride (uPVC)/PVC windows & doors and the Package-type Wastewater Treatment System (PWTS). Almost 90 per cent of India does not have access to a central sewage treatment plant. Therefore, to solve this issue, we have come up with PWTS that can address the need of an individual family or the community. Above all, we are one of the pioneers in the manufacturing of solid waste management containers, ranging from small to big size containers. Sintex also offers plastic rainwater harvesting systems. Thus, our spectrum for green products is very wide. We are a solution-centric company, and we have come up with solutions that are first in the country and in many parts of the world.
impact on me. First is Swami Vivekananda who was a firm believer of Sarva Dharma Sambhava (All religions are equal). Like him, I always adopt an unbiased approach and work with a judicious and just frame of mind. Second, I consider Sardar Patel to be one of the greatest leaders of India, and for me, he is numero uno. Last, I have firm faith in Lord Krishna who always said that no situation is perfect and challenges keep on coming, so one must go on. I gather my strength from Him.
What are the challenges and opportunities faced by the industry?
What are the few things that you check before starting something new?
There are many challenges such as the regulatory, environmental, economic and manufacturing challenges. The competitive landscape is also an issue. However, the opportunities are numerous, eg export opportunities, and the way forward is in niche and value-added applications.
What would be the future trends in the plastics segment?
The demand for plastic products will definitely increase in the future. Plastics will be used in almost every domain. Plastics can replace other materials in many applications. Thus, modern life will become impossible without plastics, and no one would be able to ignore plastics, as by then plastics will become an integral part of life.
Who or what motivates you the most and why?
A few people have made a profound
How do you deal with a tough situation?
One should take total cognizance of the situation, ie understand the problem, look at the different perspectives and keep cool by working on one solution after the other. Success never comes easily, so one must go on. I always believe that life is a long hurdle race, and being a solution-centric person, I always think of the best way to cross various hurdles.
Understanding the project thoroughly and preparing myself by developing the required mindset. One should also carefully think about desired investments and objectives to be fulfilled.
What business etiquette you value the most?
I hold the values of integrity, commitment, hard work, punctuality and innovative thinking to be of utmost importance.
Your message for aspiring professionals…
Always keep up your hard work and maintain transparency in whatever you do. Also, one should maintain their cool in all situations and not get rattled by failures because if you start blaming yourself for your failures, then nothing will work. Email: avani.jain@network18publishing.com
August 2013 | Modern Plastics & Polymers
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MPP AUG _2013_TAB 3_PRAYAG PG_33
MPP AUG _2013_TAB 3_GARDNER 2 PG_34
SPECIAL FOCUS
Masterbatches & Additives Masterbatches & additives:
Innovations for improved performance.................................................................................................... 36
R&D initiatives:
Meeting quality standards at efficient pricing......................................................................................... 38
Masterbatches processing:
Preserving quality, preventing contamination......................................................................................... 42
Interface: Shamik Shah, Vice President – Sales & Marketing, Monachem Additives Pvt Ltd................................... 46
Roundtable:
Does quantity matter more than quality for masterbatches & additives manufacturing in India?....... 48
August May 2012 2013 | Modern Plastics & Polymers
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SPECIAL FOCUS: Masterbatches & additives
INNOVATIONS FOR IMPROVED PERFORMANCE With a rapidly booming plastics industry in India, the masterbatches & additives sector carries a veritable influence on the scope of indigenous innovations. Considering their significance in driving the growth of the plastics industry, Avani Jain notes the recent innovations in the masterbatches & additives industry and the opportunities these offer to Indian plastics processors.
M
asterbatches & additives constitute a highly successful and an essential segment of the global plastics industry. Industry analysts predict that the global masterbatches & additives market will reach $ 8.25 billion by 2017. The last 15 years have witnessed a constantly increasing impact of masterbatches & additives in applications such as anti-statics, foaming agents and flame retardancy. Further, technology developments that help impart desired colour and property to the polymer and simultaneously reduce its cost have aided in turbo charging the market’s growth in the medium to long term, especially given the demands from the end-user industries for high-performance and functional products.
Innovation index Keeping in mind the need from different industry segments these days, various innovations occurring across all industry segments are increasing the demand for plastics masterbatches & additives. In the automotive sector, innovations are in developing anti-scratch applications, lightweight solutions and improving impact resistance. Stabilisation for medium- and high-voltage cables and metal deactivation solutions are leading to innovations in the wire &
cable industry. Further, the packaging industry is continuously demanding better aesthetics, increased shelf-life of food products etc; thus, innovations in masterbatches & additives are happening accordingly. In the infrastructure sector, there is a need for chlorine-resistant solutions for polyethylene pipes, so changes are made accordingly. In the household sector, innovations are happening for improving aesthetics as well as surface and mechanical properties. Similarly, the growth in agricultural and medical sectors is leading to various innovations in the plastics masterbatches & additives segment.
Significant breakthroughs in recent times With several key developments, the past few years have been a rather exciting period for the masterbatches & additives industry: Anti-microbial masterbatches with silver-based technologies: As a metal, silver is well known for its anti-microbial effects. Silver ions and compounds have a toxic effect on some viruses, bacteria, algae and fungi, typical for heavy metals such as lead or mercury, but without the high toxicity to humans normally associated with other metals. There has been a renewed interest in silver
as a broad-spectrum anti-microbial agent. The industry has seen several developments in anti-microbial masterbatches with silver-based technologies to reduce the hazards of hospital-acquired infections. Covering a broad anti-microbial spectrum, including Gram-positive and Gramnegative bacteria, this technology is effective against methicillin-resistant Staphylococcus aureus and vancomycinresistant Enterococcus. Additive systems that improve long-term scratch and mar resistance of plastic automotive products: The luxury impression of an automobile’s interior largely depends on the surface quality of plastic interior trim parts. In higher level vehicles, this is achieved by covering the plastic surfaces with Polyvinyl Chloride (PVC) or Thermoplastic Oleofin (TPO) skins, fabrics or paint. However, cost constraints influence the use of unpainted, moulded colour plastic parts in most vehicles. Typical materials currently used for these parts are Polypropylene (PP), talc-filled PP, talc-filled TPO, Acrylonitrile Butadiene Styrene (ABS), polyamide/ABS and polycarbonate/ABS. The essential factors of these plastic part surfaces are low-gloss appearance with good Courtesy: Mio Group
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Modern Plastics & Polymers | August 2013
Masterbatches & additives
scratch & abrasion resistance, which has improved through extensive development efforts over the past several years. Additives for producing miscible blends from immiscible polymer blends: Dr Harindu Vyas, Consultant, Polymers & Plastics Technologist, notes, “When two or more polymers are completely miscible down to the segmental level, they form a single homogeneous phase and the polymer blend is called a homogeneous blend. However, most polymer blends are non-homogeneous, ie they are said to be immiscible. This results in coarse morphology, which directly affects the performance properties (mechanical, electrical etc) of the polymer blends. To overcome this problem, an intermediate additive which has both polar and nonpolar groups attached is added. The non-polar group gets homogenised with the non-polar part of the immiscible blend, while the polar group gets homogenised with the polar part of the immiscible blend. Thus, a coupling bridge is formed between the immiscible blends, which lead to broad phase boundaries rather than sharp and easily visible phase separation. The additive used for the formation of coupling bridge is known as compatibiliser and helps in compatibilisation of immiscible polymer blends. The main function of the compatibiliser is to increase interfacial attraction and adhesion, strengthen mechanical properties, decrease interfacial energy and tension and finally to reduce domain size and stabilise it.” Masterbatch technology that help colour rigid PVC: One of the major problems associated with PVCu processing is its resistance to flow, which is not uniform. When filled with large quantities of pigment, this problem increases, and coupled with its heat sensitivity, it becomes a major hurdle to overcome. With flexible PVC, the incorporation of
plasticisers negates this tendency, but for PVCu, other ways are required to overcome these difficulties. The essence of the new technology for producing masterbatches that allow adding colour successfully to PVCu is a combination of two additive systems used in the formulation. High-molecular-weight acrylate processing aids are used to help the material flow smoothly. These reduce melt viscosity, overcome melt fracture and reduce sheer burning. Selection of these aids can depend on application (eg when manufacturing tints for crystal compounds, as some grades impart a haze or opalescence to PVCu). Internal lubricants help reduce frictional forces between the polymer molecules and/or pigments. This generally aids dispersion and the melt flow (increased flowability at lower temperatures).
Bright future The Indian polymers industry is growing year on year at twice the rate of the country’s gross domestic product. Because the growth of the masterbatches & additives segment is directly proportional to that of the polymers sector, the prospects appear bright for this segment in India. Further, the competition among plastics processors is intensifying, and each one is looking for differentiation; thus, in such a case, they will have to fall back on masterbatches & additives to provide the niche they seek. Tushar Parikh, Partner, Universal Colorant Company, concludes, “The masterbatches & additives industry is growing at a fast pace because more innovative usages of plastics can be seen in fields such as automotives, packaging, medical and electronics. Thus, companies have started to establish in-house R&D divisions to aid innovation because there are a lot of opportunities with innovative plastics masterbatches & additives for Indian plastics processors.” Email: avani.jain@network18publishing.com
Most polymer blends are non-homogeneous, ie they are said to be immiscible. This results in coarse morphology, which directly affects the performance properties of the polymer blends. To overcome this problem, an intermediate additive which has both polar and non-polar groups attached is added. Dr Harindu Vyas
Consultant, Polymers & Plastics Technologist
The masterbatches & additives industry is growing at a fast pace because more innovative usages of plastics can be seen in fields such as automotives, packaging, medical and electronics. Thus, companies have started to establish in-house R&D divisions to aid innovation. Tushar Parikh
Partner, Universal Colorant Company
August 2013 | Modern Plastics & Polymers
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SPECIAL FOCUS: R&D initiatives
Courtesy: Dongguan Jinfuliang Plastic Materials Co Ltd
MEETING QUALITY STANDARDS AT EFFICIENT PRICING
The global advancements witnessed by the plastics raw material industry are fast making inroads into India. This has led to a rise in the demand for masterbatches & additives that match global quality standards. Keeping this in mind, Avani Jain highlights the need for increased Research & Development (R&D) initiatives in India to increase quality offerings at efficient prices.
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he polymers industry in India is expected to see a steady growth in the future. The per capita consumption of polymers is still low here as compared to developed nations. This brings with it a latent opportunity for the sector to grow. Amit Mahant, Director, PK Plastic International Pvt Ltd, notes, “It is estimated that polymer consumption in India will grow at an annual rate of 15 per cent, and the per capita consumption of plastics will double over the next five years.� Although crude oil prices have been a cause of concern as imports tend to 38
Modern Plastics & Polymers | August 2013
become costly, India is set to become more self-reliant and grow further to suffice its domestic demand for polymers. This will have a direct impact on the industry of masterbatches & additives, which aid in the performance of plastics. Therefore, to meet this growing demand, the need of the hour is increased R&D initiatives to meet the global quality standards and fulfil the demands of customers.
Current trends
Today, a plastics processor is keen to accumulate more knowledge about innovative plastics additives such as
anti-microbial, anti-scratch and halogenfree flame retardants. Another trend is partnerships being formed between an additive supplier and a compounder/ masterbatcher. The plastics additives supplier brings in the knowledge of plastics additives and the compounder brings in the processing skills. Yet another trend is the entry of foreign additives processors into Indian markets. These processors are introducing global quality standards in the Indian plastics industry. Further, global polymer companies have advanced market R&D teams that work towards offering innovative solutions to customers. Thus,
R&D initiatives
Product quality has become a must as India’s plastics processors work more closely with multinational companies. Thus, Indian masterbatches & additives manufacturers have to assure advanced performance with high quality, cost-saving processing efficiency and product safety to support the trend. Amit Mahant
Director, PK Plastic International Pvt Ltd
it has become important for companies to internally conduct market research studies and identify emerging trends in each industry at the local, national and global scale.
Noting product quality
If we talk about the quality of Indian masterbatches & additives, then there is need for consistency. The requirement is to offer customised solutions based on performance need identified at the customer’s end. The industry must come up with different solutions for polymer stabilisation, ultraviolet stabilisation, flame retardancy, improvement of surface properties, increasing impact properties, processing & lubrication, anti-microbial performance etc. Thus, constant R&D efforts are required on this front. Mahant avers, “Product quality has become a must as India’s plastics processors work more closely with multinational companies. Thus, Indian masterbatches & additives manufacturers have to assure advanced 40
Modern Plastics & Polymers | August 2013
performance with high quality, costsaving processing efficiency and product safety to support the trend. They will have to invest systematically in R&D initiatives which should have long-term planning and vision. This will help Indian manufacturers to manufacture world-class masterbatches & additives. Undoubtedly, Indian companies have the potential to manufacture products that meet global quality standards, as the manpower is highly trained and has the will to carry out independent research studies. This can be seen from the fact that India is one of the largest processors and consumers of various masterbatches & additives. Hence, what is required is just more concentrated efforts.”
Price issue
Apart from the need for focussed R&D initiatives for quality products, the primary requirement for the industry is availability of high-grade polymers. The industry currently faces an acute problem of availability of low-quality polymers. The Indian quality is not up to global standards; hence, Indian companies have to import from Europe, especially Germany. Dependence on imported polymers has not changed in the past few years, with manufacturers facing problems in domestic options. Thus, appropriate steps need to be taken to solve this issue. In such a scenario, pricing becomes an important factor in determining the growth of the polymer industry and, in the long run, the competence of a country. The prices of masterbatches have seen an upward trend in the last few years due to sharply rising raw material prices and consolidation of international raw material suppliers. Thus, sourcing quality raw material from consistent and reliable suppliers will be the key in the coming years. New masterbatches players, both domestic and international, will need to keep the selling price competitive, thereby presenting a challenging market scenario and reduction in margins. The volume
growth should help sustain most players but, as in most industries, efficiency and innovation will be required. If the present capacity remains constant, there is a possibility of imports as well, and this may result in higher prices. Prices of masterbatches depend not only on polymer prices but also on pigment prices, and these have been increasing steadily. However, with an increase in the demand for masterbatches, the probability of more manufacturers jumping into the foray is high. This will result in an equilibrium or price where the quality demanded by consumers (at current price) will equal the quantity supplied by manufacturers.
Way forward
There is an aggressive scalable growth potential of masterbatches & additives in the Indian market, as a large number of areas remain untapped and unexplored. Further, plastics additives can be used in many different industries. Also, there is a strong opportunity for a plastics additives supplier and a masterbatcher/ compounder to work together for developing new markets. If we talk about product quality, then, Mahant avers, “In my opinion, the quality standard of masterbatches & additives made in India can stand the competition of global products. Indian manufacturers are following the material safety standards strictly, thus manufacturing quality products. Many companies are manufacturing products that have global quality assurance certification.” Some companies have their own R&D facilities, and those that do not generally outsource research activities to increase their quality. However, the latest technology in polymer processing needs to be supported with infrastructure. Manufacturers are willing to innovate and invest in quality at par with international standards, but without adequate power and land availability, expansion plans cannot be taken forward. Email: avani.jain@network18publishing.com
SPECIAL FOCUS: Masterbatches processing
Quality,
Contamination Preventing
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he increase in the demand for masterbatches is a good sign for the plastics industry. However, as per industry experts, further growth will depend on the quality, production process and product. Thus, companies can achieve this goal by preventing contamination in masterbatches processing units. Dr Premal Vashi, Director – Engineering Plastics, Som Shiva (Impex) Ltd, avers, “Technically, masterbatches manufacturing is not so easy, but Indian manufacturers have taken it in a different way. Basically, the masterbatch is concentrated and has to be diluted as per requirement. Also, colour contamination is normal in masterbatches factories, and thus product quality can be affected. Further, masterbatches contain a high percentage of pigments, and handling pigments is not so easy. Thus, it is important to process masterbatches in a clean and dust-free manufacturing environment.”
Clean processing environment The concept of masterbatches was developed only to avoid the use of direct pigments by end users of injection moulding, blow moulding, extrusion and other applications. Vashi notes, “Masterbatches are made with various base polymers using organic/inorganic 42
Modern Plastics & Polymers | August 2013
With an increase in the demand for masterbatches, regarded as ingredients that make all the difference to processability and functionality of a polymer, manufacturers are constantly involved in adopting new technologies to obtain a better product and prevent contamination of any sort during masterbatches processing. Avani Jain analyses strategies that can be adopted by companies to prevent contamination in masterbatches processing units.
Courtesy: Loxim Industries Ltd; Photo: Vijaykumar Soneji
pigments along with other additive packages. These pigments have micronsized particles that generally float in the air during the blending and feeding stages. To avoid floating and dust, many methods have been incorporated such as the use of waxes and anti-flocculants. It is also to be noted that some of these pigments are hazardous and need to be carefully monitored during the mixing and feeding stages. Further, some of the additives and pigments can affect the performance of the nearby lines and shade variation can occur if not controlled properly. Hence, we need to have a clean environment and proper
practices for protection at all the stages of processing, ie storage of pigments/ fillers, opening of bags and transfer to primary silos or in feeder etc.”
Steps for preventing contamination Various steps can be adopted by companies to prevent contamination in masterbatches processing units. Companies need to have scrubbers at feeding points, ie from silos to feeder. Initiatives should be taken in spreading awareness about cleanliness at all points, and washrooms should be provided for employees working in mixing areas so that they can use these after work
Masterbatches processing
Masterbatches processing is not a continuous process, and it requires multiple machines to produce different colours at a time. These days, companies are adopting highly sophisticated technologies to produce environment-friendly products. Dr Premal Vashi
Director – Engineering Plastics, Som Shiva (Impex) Ltd
Steps should be taken to clean the mixers after every colour change and, if possible, separate mixers should be used for all basic colours. Parag Parikh
Partner, Universal Colorant Company
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is finished. All the mixing activities should be planned away from the processing area, and split feed systems should be used as far as possible. The processing area should be kept clean, and the floors should be washed with water regularly so that colour is not transmitted. Because a dusty atmosphere impacts masterbatches processing, Parag Parikh, Partner, Universal Colorant Company, notes, “The area of mixer and extruder should be separated with a partition wall. Exhaust fans should be used to clear out dusty particles. The surroundings of the extruder as well as the extruder should be kept clean after every colour change, and steps should be taken to keep the shop floor clean from dust/spillage. Dust collectors can also be used.” The cross contamination of pigment can also impact masterbatches processing. “Steps should be taken to clean the mixers after every colour change and, if possible, separate mixers should be used for all basic colours. Also, different pigments (colorants) should be kept separately in closed containers. Further, base polymers should be kept properly covered and at a separate place in stores,” notes Parikh. Many companies in the segment, including Som Shiva (Impex) Ltd, have adopted these steps. Vashi claims, “We maintain an environment-friendly manufacturing environment through a closed loop plant with gravimetric feeding systems, silos and positive air with a proper duct collection system. We have seven different sophisticated lines with all the necessary accessories. We have a facility for different colour production at a time and in different lines without any contamination. Because human safety is important, we regularly educate workers and the manufacturing team through proper training.”
Maintaining safety and quality standards Quality is now a prerequisite in India. No company will survive without product quality and consistency of products.
“The market is very competitive, and if we fail to deliver product quality, then we will be out of the market. The general points that manufacturers should keep in mind for processing masterbatches are ensuring the use of masks during blending operations, the use of protective glasses for eyes during the extrusion process and fire extinguishers to be kept at all points near processing areas and in the mixing room. These are mandatory as some of the pigments may create problems in mixing and develop volatile products,” notes Vashi. Various steps can be adopted by companies to manufacture quality products. Parikh notes, “Testing of raw material for quality is very important. Tests should also be conducted on finished goods for their shade, strength etc.”
Defining a bright future The processing of masterbatches in India is slightly different as compared to international markets. Vashi notes, “Indian manufacturers are not techno-savvy and do not prefer to use sophisticated technologies, but gradually things are changing. Now, manufacturers are upgrading technologies to compete against multinational companies. Basically, new technologies, sophisticated extruders, feeders and downstream equipment are important in masterbatches industries.” New technologies are surfacing every now and then so as to achieve good quality of products. Vashi says, “Masterbatches processing is not a continuous process, and it requires multiple machines to produce different colours at a time. These days, companies are adopting highly sophisticated technologies to produce environment-friendly products. Thus, as the world is now targeting the Indian market, and big players are establishing their plants in India, it is the right time to upgrade ourselves with proper technology and infrastructure so as to provide quality products to customers.” Email: avani.jain@network18publishing.com
SPECIAL FOCUS: Inter face – Shamik Shah
“The plastic additives market growth is directly proportional to the innovation and new applications being developed in the plastics industry” …opines Shamik Shah, Vice President – Sales & Marketing, Monachem Additives Pvt Ltd. In an exclusive conversation with Avani Jain, he states that plastic additives provide plastics processors with an innovative edge to create a unique value proposition for their final products. He also underlines the challenges and opportunities faced by companies in the times of slowdown. How is the plastic masterbatches & additives market fairing in India?
The plastic additives market growth is directly proportional to the innovation and new applications being developed in the plastics industry. Due to the overall softness in the demand in India and weakening of the Rupee, sectors in the plastics industry are being challenged in terms of actual sales against projected sales along with margin pressures. Due to this pressure, the focus of investing time and money in creating new innovative products has reduced considerably as the industry is busy in terms of only sustaining business. However, these uncertain times are also an opportunity to invest time and money in creating innovative solutions that would assist masterbatchers or compounders to differentiate themselves from ‘me too’ products, which will always be under margin pressure.
What are the recent trends and growth opportunities in the segment?
India has been projected as one of the key growth plastics markets by foreign companies for the long term, and many foreign companies are looking to invest in India to become part of this growth story. Along with the long term, there are growth opportunities in the short term to mid-term depending on the approach of organisations in each sector for applications such as automotives, packaging, medical, electrical & electronics and household products. The key success factor for growth and opportunity for organisations is to identify problems faced by customers and provide solutions rather than following the ‘me too’ approach. In addition, the opportunity lies in offering 46
Modern Plastics & Polymers | August 2013
proposition around it. Plastic additives offer this unique advantage to plastics processors in creating a unique value proposition for their final product range.
What are your growth plans for the company?
knowledge-based solutions wherein plastic additives play a major role in offering unique performance to plastics.
What are the challenges and opportunities faced by the manufacturers in the segment?
The challenges faced are the depreciating Rupee, and hence increase in raw material costs, and softening of market demand which is creating margin pressures to a majority of companies in the plastics segments. Another challenge is the weakening sentiment in terms of sustaining sales of volumes due to uncertainty of demand. However, the biggest challenge that the industry is facing today is uncertainty for the short term (ie next 3–6 months) due to a volatile business environment. Despite the challenges, there are few opportunities as well. The opportunity is to utilise this time of uncertainty for getting stronger in terms of building on the core competence in terms of the product range that a company offers. This could be done by realising the current product strength of the organisation in the market place and then building a stronger value
During these uncertain times, we are working closely with our customers as well as the whole value chain of plastics processors and original equipment manufacturers by sharing with them the new performances our plastic additives range has to offer in terms of cost reduction as well as adding new unique performances to plastics in various applications such as automotives, packaging, electrical & electronics, medical and household applications. Our success as an organisation lies in the success of our customers. Hence, we are working on that premise by working closely as a customised solution provider of plastic additives. Few advantages offered by the new plastic additives solutions launched by us include improved mechanical, nucleation, clarity & heat deflection temperature properties for polypropylene; cost reduction for the flexible intermediate bulk container industry; weight reduction, improvement of surface properties & dimensional stability for the automotive industry; improved mechanical properties, reduction in cycle time & improved clarity for nylon injection moulding and improved clarity & barrier properties in nylon films. Overall, our growth plans depend on our success of exceeding the expectations of our customers by offering them customised solutions based on plastic additives. Email: avani.jain@network18publishing.com
SPECIAL FOCUS: Roundtable
DOES
QUANTITY MATTER MORE THAN QUALITY FOR MASTERBATCHES & ADDITIVES MANUFACTURING IN INDIA?
While the plastics industry has grown by leaps and bounds in the recent years, it is in a unique situation where demand outpaces supply. Domestic masterbatches & additives manufacturers are also finding it challenging to keep pace with multinationals and the market requirements. Avani Jain gauges the opinions of industry experts on the issue of quality versus quantity in masterbatches & additives manufacturing. Anik Patel Director, Add Plast
Quality matters more for SMEs as against quantity as additives are developed only to serve unique customer demands. If quality falls, then companies will incur huge losses. SMEs cannot compete with the quality offered by multinationals in the segment, but they certainly have an edge when it comes to prices. Products manufactured by multinationals are very highly priced and, with the exception of large-scale companies, nobody can afford these products. Here, SMEs in the masterbatches & additives manufacturing segment stand to gain as against multinationals. However, it is possible to manufacture high-grade masterbatches & additives at the local level. Undoubtedly, quality products will rule the market as quality and not quantity governs the masterbatches & additives market. Indian SMEs have the capability to manufacture products that not only can compete with multinationals but also can meet international quality standards.
Editorial take:
M M Biswal
Business Head – Polymers, Loxim Industries Ltd
Devang Pathak
Owner, Natraj Colour Chem
As compared to multinationals, SMEs in the masterbatches & additives segment are faring well due to their prices. Further, SMEs are mostly quantity driven. This is not to say that they produce extremely lowquality products; they do not have the equipment/technology required to manufacture high-quality products as compared to multinationals in the segment. However, if some SMEs are able to procure that technology, then they definitely incline towards quality, as quality products are here to stay. However, until the time, SMEs acquire such equipment/technology, they will tend to focus on quantity, which reduces their production cost, thus affecting the overall product price. If the order is for small quantities, an SME will shift focus to quality rather than quantity. While if we talk about multinationals, then they have everything in their favour for producing excellent quality products.
SMEs focus on quantity rather than quality. This is because if they solely focus on quality, then they would need more investments. Moreover, the product will become costly and hence they will lose on their domestic customers who look for products at cheaper prices. While on the other hand, multinationals, undoubtedly, focus on quality and bring out excellent products, but these products have limited demand in the Indian market. SMEs in the masterbatches & additives manufacturing segment know this very well and act accordingly. As a result, they opt for bulk production, which reduces their investment cost and results in more sales. Here, one should note that these SMEs do not manufacture absolutely low-quality products. The quality is good but not typically matching with the quality offered by multinationals. This fact hardly matters when the demand from local buyers is constantly increasing. Email: avani.jain@network18publishing.com
Although many SMEs have started operations in the masterbatches & additives segment, they are faced with issues pertaining to quality. Because these SMEs have low investments, they tend to opt for mass production. While they may not compete with multinationals when it comes to quality, in terms of prices and market penetration, SMEs clearly steal the show as the products offered by them are cost-effective. 48
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FACILIT Y VISIT: A Schulman Plastics India Pvt Ltd
Photo: Saloni Agarwal
MASTERING MASTERBATCHES MANUFACTURING IN INDIA
The demand for plastics is witnessing an upward trend around the world, with India presenting a wide scope for expansion; thus, the Indian masterbatches industry has reasons to cheer. It is for the same reason that multinational companies like A Schulman Inc have started their masterbatches manufacturing plant in India. Avani Jain sheds light on the operations of A Schulman Plastics India Pvt Ltd’s new masterbatches manufacturing facility at Vadodara.
T
he Indian plastics industry is growing at a very fast pace since the last few years. Thus, the masterbatches business in India is slated to benefit in such circumstances. This has also strengthened the scope for expansion of masterbatches manufacturing facilities in India. Not only are new domestic masterbatches manufacturing companies surfacing on the scene but also many multinationals have entered the market. One such company is A Schulman Inc, which has recently inaugurated its plastic masterbatches manufacturing facility in India. S Mannar Manan, Country Head – India, A Schulman Plastics India Pvt Ltd, says, “The masterbatches industry in India is growing at a compounded annual growth rate of 16–18 per cent and will continue to grow at the same rate. Further, talking about our new facility, it will manufacture masterbatch products for India’s surging food packaging industry, especially the flexible packaging market. Later, we will target other segments as well.” 50
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The new venture
Tapping on the growing demand for flexible packaging in India, the company inaugurated its new plant in Vadodara, Gujarat, in April this year. This plant is the company’s first manufacturing facility in India and its fifth in the Asia–Pacific region. Manan notes, “The facility is spread over an area of 50,000 sq m, of which 12,000 sq m is the constructed area. Nearly ` 40 crore is invested on the plant and machinery.” Manan adds further, “We are currently manufacturing white and additive masterbatches. In the additive masterbatches category, we have two segments – value-added masterbatches, which involve high technology and formulation, and normal commodity masterbatches.” Shedding light on the reasons behind opening this facility in India, Manan says, “First, the Indian market is growing at a very fast pace, so it was good to start a manufacturing plant in the country. Second, it is always better to come closer
to customers. Third, earlier, we were mainly exporting the products, but then, when you export, you cannot cater to a large number of customers. Fourth, there are not many multinational companies in India that manufacture masterbatches, especially white and functional masterbatches, so there is huge scope for growth. Lastly, we chose Gujarat in particular, as it is the only state that has surplus electricity. Strategic location and proximity to suppliers, customers and the port were also the main reason for establishing a plant in Gujarat.”
Infrastructure
The manufacturing facility can be divided into raw materials warehouse, manufacturing bay, finished goods warehouse, trading warehouse, dispatch and quality section. Manan notes, “We are the only company that has a single line to manufacture 10,000 tonne annually. Further, in order to maintain Schulman’s standards, we have high-tech feeding systems and various automatic systems
A Schulman Plastics India Pvt Ltd
within the shop floor area. Thus, our aim is to install better technology and infrastructure at the plant.”
cylindrical ones. The finished products are then tested and dispatched.”
Manufacturing
There is no special technology centre at this facility because the company already has R&D centres in North America and Europe. As per the company’s policy, each facility need not have a separate technology centre, and all of the recipes come to each facility from these centres. Manan notes, “We do not conduct any R&D here as the basic concept remains the same everywhere. However, a little modification might be necessary to suit Indian needs.”
A global software system, mandatory at all Schulman facilities, is installed at this facility as well. Thus, India is linked globally to all plants. On the manufacturing process, Manan elaborates, “Our product involves five or six ingredients. Almost all the raw materials are imported and have their own product codes, identification numbers etc. These ingredients are tested. If they are found to be good, then they are stored in silos. Later, based on individual grades to be manufactured, these ingredients are brought to the feeding station. In the feeding station, as per the recipe, these five or six ingredients are fed into feeders. The amount of material is computer controlled; hence, errors are avoided. Then, the materials are transported to a mixer by a conveyer. During conveying, the various materials are physically blended. Afterwards, in the mixer, the materials are mixed at a very high speed to form a mixture, which is passed on to an extruder. In the extruder, the mixture is melted, mixed, compounded and then passed through a dye. Before the mixture comes out of the dye, it passes through a filtering system, where any unwanted particles are screened and eliminated. After screening, the melt comes out of the dye, and it then proceeds to underwater palletising, which is a system possessed by very few Indian companies. Hence, you see spherical granules and not
White masterbatches
Research and Development (R&D)
Quality and safety
Talking about quality, Manan avers, “As per our policy, we are bound to test the raw materials and finished goods thoroughly. The quality control parameters and specifications are uniform throughout the world. Every plant has to use the same testing equipment and procedures. We will also soon acquire ISO 9002 certification.” Safety is a part of the company’s core strategy. Manan notes, “Safety of men, machines and materials is our main concern. We emphasise on the usage of personal protective gear, such as helmets, shoes, masks, earplugs etc, for safety of employees. As for addressing the environmental concerns, we will soon acquire ISO 14000 and 18000 certifications.”
Vision on growth
The future of the masterbatches industry is very bright. Manan avers, “In the future, we want to expand our masterbatches
We are currently manufacturing white and additive masterbatches. In the additive masterbatches category, we have two segments – value-added masterbatches, which involve high technology and formulation, and normal commodity masterbatches. S Mannar Manan
Country Head – India, A Schulman Plastics India Pvt Ltd
capabilities and manufacture hi-tech & coloured masterbatches. The board has already sanctioned for another line. The infrastructure is ready at the shop floor; hence, we just have to bring the equipment and install it. Further, when the demand increases, we can install more lines at this facility. There is lot of open space at this facility, so two more units other than the existing one can be established, ie three or four more lines can be installed. Last but not the least, my vision is to create a sense of confidence in the products we supply to the market.” Email: avani.jain@network18publishing.com
Manufacturing bay Photo: Saloni Agarwal
August 2013 | Modern Plastics & Polymers
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Blow Moulding
Paints & Coatings Polymers in paints & coatings:
Exploring decorative and industrial applications.........................................................................54
Polymer technology:
Latest advancements in waterborne coatings................................................................................ 56
Automotive plastic coatings:
Colours & coats for cars................................................................................................................ 60
Interface:
Raman Trikala, Director, Wacker Chemie India Pvt Ltd.............................................................. 62
Roundtable:
How critical is the role of engineering polymers in powder coating technology?......................64
Pyrolytic technology:
Energy generation from plastic waste Namrata R Bhalerao and Prof G S Zamare, College of Engineering and Technology, Akola............66
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INSIGHT & OUTLOOK: Polymers in paints & coatings
Since its humble beginning, the Indian paints industry has come a long way from being a merely decorative paints market. Today, it has become a well-diversified market. The current growth in the country is primarily driven by the domestic demand in both decorative and industrial paints. Sweta M Nair discusses the applications of polymers in these promising paints segments.
B
inders are polymers (resins) forming a continuous film on the substrate surface and are one of the main ingredients used in paints. They are responsible for good adhesion of the coating to the substrate and hold the pigment particles distributed throughout the coating. The binder is dispersed in a carrier – water or organic solvent – either in molecular form (true solutions) or as colloidal dispersions (emulsions or sols). Polymeric binders are valuable raw materials used in coatings and in construction. The properties of the final product strongly depend on the type and nature of the applied binder. Some common binders are as follows: Alkyd resins – prepared by the condensation polymerisation in the reaction of fatty acid and polyols (commonly glycerol) with polybasic acids Acrylic resins – prepared by polymerisation of acrylic or methacrylic esters Latex, a vinyl polymer – prepared by free radical vinyl polymerisation of the monomer vinyl acetate 54
Modern Plastics & Polymers | August 2013
Phenolic resins, thermosetting polymers – prepared by the reaction of simple phenol with aldehydes (eg formaldehyde) Urethane resins, Polyurethanes (PUs) – prepared by the step-growth polymerisation of isocyanates reacting with monomer molecules containing hydroxyl (alcohol) groups Epoxy resins, thermosetting polymers – formed as a result of cross-linking a resin containing short molecules in the presence of a hardener Chlorinated rubber – prepared by polymerisation of degraded natural rubber
Aesthetic value
The two main categories of paints are decorative and industrial. “The total coatings market in India is valued at about ` 25,000 crore, split 75:25 between the decorative and industrial segments. Polymers are the backbone of paints as the film formers. A variety of polymers, such as alkyds, polyesters, acrylics, epoxy and PU, are used in coatings depending on the end application. Currently, two
innovation platforms are high solids polymers and waterborne polymers. The driver for both is the ecology and sustainability consideration,” says Ravi Kapoor, Managing Director, Heubach Colour Pvt Ltd. Decorative paints account for over 70 per cent of the overall paints market in India. The demand for decorative paints arises from household painting, architectural and other display purposes. Major segments in decorative paints include exterior wall paints, interior wall paints, wood finishes and enamel and ancillary products such as primers, putties etc. “Polymers are used as binders in decorative paints. They help in forming a coherent and substrate-adhering film. Mainly, solvent-borne alkyds and waterborne acrylics are used in decorative coatings,” says Kapoor.
Rough conditions
The industrial paints segment is far more technology intensive than the decorative paints segment. The three main areas in the industrial paints segment are automotive coatings, powder coatings
Polymers in paints & coatings
and protective coatings. User industries of industrial paints include automobiles, engineering and consumer durables. Explaining the applications of polymers in industrial coatings, Christophe Cazabeau, Chief Executive, Coatings Solutions, BASF India, says, “In coil coatings, aluminium and steel bands, known as coils, are coated with coil coatings before further processing. These are processed into a wide range of products in the construction, equipment and vehicle industries. The coating for façade elements, for instance, should be especially durable and weather-resistant. Washing machine housings, on the other hand, require a surface that will reliably protect the machines against detergents throughout their lifetime. In most cases, the paints used contain polyester binders. When more specialised or particularly challenging requirements are to be met, PU and Polyvinyl Chloride (PVC) binders are used. BASF supplies different technologies for different requirements. Another of our offerings is PU coatings. These are particularly effective paint systems in which PU or polyester resins are used and cross-linked with isocyanates. Compared with polyester coatings, this approach improves important material properties such as durability, adhesion and resilience. However, these benefits also entail higher material costs. Due to their excellent surface properties, PU coatings are outstandingly suitable for household appliances as well as for textured surfaces, such as on roller shutters, gutters and façades.” Other developments in BASF include resistant & durable coatings based on PVC dispersions. “Whereas polyester and PU coatings have film thicknesses of 15–30 μm, PVC coatings with their greater film thicknesses of 150–200 μm offer very good protection even in an aggressive industrial atmosphere and feature outstanding surface properties and extremely high flexibility. New developments with optimised ultraviolet resistance show greater resistance still, even under exposure to extreme weather conditions,” shares Cazabeau.
Niche applications
Coatings solutions are designed to help improve the productivity and environmental performance of carmakers. Improved coating technology means that car owners can now enjoy the ‘new car’ effect for much longer. “For this area, a new innovation example is the clearcoat iGloss. Previous standard clearcoats for cars have consisted almost exclusively of organic material, referred to as polymers, which are longchain branched hydrocarbons. In contrast, iGloss combines two kinds of materials in a nanostructured hybrid. Between 90 and 95 per cent of the hybrid material, depending on the area of application, consists of organic material that forms the paint matrix. This makes the finish flexible & elastic and ensures a high level of weathering resistance. Five to ten per cent of the inorganic material is embedded in the organic matrix. The organic & inorganic components are covalently and elastically bonded. This allows the clearcoat to immediately spring back to about 90 per cent, for instance, when hit by the bristles of a car wash brush. This is referred to as ‘elastic recovery’ or ‘instant reflow’ by paint experts. Conventional clearcoats only attain reflow rates of approximately 70 per cent. With the new BASF clearcoat, the microscratches that occur are significantly flatter and therefore less visible,” says Cazabeau. Other heavy-duty applications include the topcoats on highly stressed rotor blades that are used for generating wind energy. Explaining BASF’s offering in this space, Cazabeau says, “RELEST® Wind coating is used for the highly stressed surfaces of rotor blades. This system consists of a gel coat, filler, edge protection and topcoat, and it is based entirely on solvent-free, two-component PU compounds, thus complying with present volatile organic compound directives. RELEST Wind HS Topcoat - the new environment-friendly rain erosion-resistant topcoat is based on PU compounds. It effectively protects rotor blades against possible damage and improves their resistance up to five times compared to conventional products.” Email: sweta.nair@network18publishing.com
PVC coatings with their greater film thicknesses of 150–200 μm offer very good protection even in an aggressive industrial atmosphere and feature outstanding surface properties and extremely high flexibility. Christophe Cazabeau
Chief Executive, Coatings Solutions, BASF India
A variety of polymers, such as alkyds, polyesters, acrylics, epoxy and PU, are used in coatings depending on the end application. Currently, two innovation platforms are high solids polymers and waterborne polymers. Ravi Kapoor
Managing Director, Heubach Colour Pvt Ltd
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INSIGHT & OUTLOOK: Polymer technology
LATEST ADVANCEMENTS IN WATERBORNE COATINGS
Recent innovations in the area of polymer colloids and hybrid materials offer new opportunities to develop novel coatings for metal protection. By choosing the appropriate technology, it is possible to design acrylic binders with improved barrier properties, low water uptake and improved anti-corrosion properties. Sweta M Nair takes a look at innovations in this segment.
M
ost research and development efforts in paints & coatings are focussed on reducing Volatile Organic Compounds (VOCs). Because film formation in polymer dispersions is greatly assisted by the use of organic solvents, the pursuit of low VOC formulations can be detrimental to film formation and, therefore, results in poor barrier properties. “Polymers used as binders in decorative paints contribute to properties such as adhesion to the substrate, gloss, washability and durability. In addition to these properties, resistance to chemicals, heat and abrasion is achieved by proper selection of polymers in industrial paints. I estimate that the industrial paints market in India is about ` 56
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8,000 crore,� says Vinod Joshi, Partner, Galaxy Coating Industry. Although new waterborne paint technologies (high-performance acrylics, epoxy esters, alkyds, zinc-rich epoxies, fluoropolymers, polysiloxanes etc) have been launched, waterborne systems still hold a relatively low share of the total market for anti-corrosive coatings. The average growth rate of waterborne coating technology is larger than that of conventional solventborne coatings. Other benefits of waterborne coatings are reductions in worker exposure to organic solvents and in fire hazards in confined areas.
Improved performance Water-based acrylic anti-corrosion resins are not new to the market. They have gone through different developments in the last
20 years with the aim of replacing solventbased systems. The first waterborne systems appeared in the market in the 1960s and were based on formulations containing simple acrylic copolymers with red lead or zinc chromate. Further developments led to lead- and chromatefree systems. The next generation systems, well established and state of the art, combine more sophisticated modified acrylics with modified zinc phosphates and borates. Nevertheless, there is still room for improvements in aqueous anticorrosion paints, eg in barrier properties, increasing their potential and, in turn, widening their application spectrum. Thus, it should be possible to reach the required properties to equal the performance of traditional solvent-borne systems, offering the opportunity for substitution.
Polymer technology
material costs (one coat versus many) and the lack of the necessity of using active pigments. DTM coatings, however, do not often display the superior properties of a multi-coat system and are typically used in light-duty applications.
Polymers used as binders in decorative paints contribute to properties such as adhesion to the substrate, gloss, washability and durability. In addition to these properties, resistance to chemicals, heat and abrasion is achieved by proper selection of polymers in industrial paints. Vinod Joshi
Partner, Galaxy Coating Industry
Waterborne acrylic dispersions are mainly used for mid- and light-duty coatings in maintenance (bridges, plant and industrial equipment, repainting, towers etc), transportation (trucks, buses, trains, tractors, mining trucks etc) and do-it-yourself (repair, general maintenance, steel building panels etc). Very often, these coatings are applied as multi-coat systems that include several layers: Primers – the function of providing good corrosion protection and adhesion to the metal surface Intermediate coats – act as a barrier to moisture & aggressive chemicals and help increase film thickness Topcoats – responsible for aesthetics, better impermeability and weatherability Alternatively, a mono-coat may be applied, the so-called Direct-to-Metal (DTM) coatings with minimal surface preparation. DTM coatings are attractive due to the reduction in application steps (no surface preparation and only one applied coating), the reduction in raw 58
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Special formulation A typical anti-corrosion paint formulation is composed of four main components – a binder, one or several co-solvents, barrier & active pigments and fillers and additives. The binder constitutes the backbone of the coating system (comprising about 40 per cent of the total formula) and helps to bind the pigment particles together and achieve a good adhesion of the coating to the metal surface. Generally, styrene acrylic binders are preferred because they provide better water and alkali resistance than straight acrylics. Typically, self-crosslinking binders are used with a glass transition temperature above 20°C. To achieve good film formation and complete coalescence of polymer particles at the application temperature (typically <60°C), co-solvents (glycol ethers, glycol ether acetals, alcohols etc) are added in small amounts. They are used to reduce the minimum film forming temperature of the binder, typically in a mixture of hydrophilic (butyl glycol) and hydrophobic (dipropylene glycol n-butyl ether) solvents. The push from the market to further reduce VOCs (by reducing the organic solvent content) and obtain environmentally friendlier paint formulations can have a negative influence on the film quality, resulting in a poor particle coalescence, poor barrier properties and, therefore, an early failure of the coatings. To further reduce VOCs in waterborne paints, it is necessary to move from standard styrene acrylics towards more sophisticated polymer architectures that allow optimal film formation under low VOC content conditions. To avoid early failure of the coating and ensure good corrosion protection, the use of a well-performing binder is a must; however, it is not the only factor playing a key role. In addition, to achieve an optimal film formation and thus avoid an early failure of the coating, good
substrate preparation, development of an appropriate formulation and drying conditions are as important as selecting an appropriate binder system for the coating. Oils, corrosion and contaminants must be removed from the metal substrate prior to applying the paint. This is of paramount importance because, in many cases, early failure of coatings is caused by either inadequate surface preparation or improper application of the coating to the substrate. In the special case of DTM coatings, there may be little or no surface preparation before coating. Often, such coatings are applied over oily substrates without previous cleaning or other type of substrate preparation. Proper formulation will enable the manufacture of paints that overcome this challenge.
Applicable conditions Coating quality is quite susceptible to climatic factors, especially at low temperatures and high relative humidity. Thus, it is important to consider the drying conditions under which the paint is applied and to keep in mind that they can lead to poor film formation under conditions of extreme temperature and relative humidity, despite the use of an excellent binder and formulation. Recent innovations in polymer colloids and hybrid materials offer new opportunities to develop novel coating formulations for anti-corrosion applications. Companies are developing a new generation of water-based anti-corrosion resins with improved performance. Although the different approaches are based on designed particle morphologies, engineering the water phase and the use of hybrid materials, a deep understanding of how to use the polymer microstructure to influence anticorrosive properties is necessary. Waterborne acrylic dispersions are commonly prepared via emulsion polymerisation. Here, polymers are synthesised with higher molecular weights. This reduces the need of postcuring the coating to obtain appropriate mechanical properties. Email: sweta.nair@network18publishing.com
INSIGHT & OUTLOOK: Automotive plastic coatings
COLOURS & COATS FOR
C A R S Consistency, smooth application characteristics and colours that look great and continue to look great on the car are the primary requirements of paints & coatings in the automotive industry. Sweta M Nair looks into the segment of automotive coatings and tracks the latest trends...
C
ars and trucks can be made attractive to improve sales, and one way that automakers do this is by adopting the latest trends in colours and special effects. One such trend is increasing the use of multilayer systems, where a ground colour is set as base and then effect colours form the top base. For Original Equipment Manufacturers (OEMs), this poses several challenges because their lines are not set up to apply multilayer systems. Two other trends worth mentioning are the trend towards matte finishes, though this is more of a niche market, and the use of tinted clear coat technolog y. “Automotive coatings technology has shown a rapid growth in the last decade. When referring to the coating for the car body, primers having wet-onwet applicability are gaining popularity to save energy and improve productivity. Stone chip-resistant primers are becoming the need of the hour to enhance the 60
overall life of vehicles,” shares Pravin Chaudhari, Executive Director – Auto Division & Supply Chain, Kansai Nerolac Paints Ltd.
When plastics meet paints
Increasing the percentage of plastics in automotives is clearly indicative of the kind of cost and weight savings that automakers have been harping on. “The use of plastic is seen to be increasing in the two- and four-wheeler segment due to obvious reasons. When talking about coatings on plastics, wet-onwet three-coat pearl systems that complement a car’s body colour are gaining popularity. The use of conductive primers to make plastic conductive before application of subsequent coats is the key as this allows the electrostatic application of subsequent coats on plastic to reduce paint wastage and reduction in Volatile Organic Compounds (VOCs). The use of common primer/adhesion promoter for all types of plastics, such as acrylonitrile butadiene styrene, polypropylene, nylon
Modern Plastics & Polymers | August 2013
Automotive plastic coatings
and polycarbonate, is also gaining popularity in the market as it reduces the process cost due to the ability of painting on all types of plastics together. The candy finish, especially for the twowheeler segment, is becoming popular due to its vibrant look and the use of bright shades,” says Chaudhari.
What’s the hue about? Vibrant vehicle colours that offer a high degree of clarity and colour depth are always sort after. However, consumer preferences for fairly conservative hues such as silver, black, white and grey remain. In the Indian automotive market, metallic colours are catching up with conventional hues. From sparkling to pure and smooth, metallic colours are catering to a growing affluent demand. These colours appear to have different characteristics depending on the time of the day or whether they are in direct sunlight or in shade. In Chaudhari’s view, “In metallics, the major shift is seen in the following areas:
(a) Three wet innovative coating systems in which all the three coats – primer, base coat and clear coat – are applied in wet-on-wet conditions to reduce cost per vehicle, for energy & space saving and to improve productivity; (b) Effect pigments or pearl pigments; (c) High solid paints, especially metallic base coats. Such base coats are being commonised for suitability of application on metal as well as plastics.” In addition, greater emphasis on sustainability at present has paved the way for waterborne paints or very low VOC paints and other features such as fast-drying products that require less energy. “Recent innovation includes the use of proprietary acrylic & polyester polymer in clear coats & top coats and the use of automotive grade approved pigments that have a proven track record for durability and tested for more than two years for natural durability,” concludes Chaudhari. Email: sweta.nair@network18publishing.com
Recent innovation includes the use of proprietary acrylic & polyester polymer in clear coats & top coats and the use of automotive grade approved pigments that have a proven track record for durability and tested for more than two years for natural durability. Pravin Chaudhari
Executive Director – Auto Division & Supply Chain, Kansai Nerolac Paints Ltd
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INSIGHT & OUTLOOK: Inter face – Raman Trikala
“The industrial PAINTS & COATINGS market is growing”
…confirms Raman Trikala, Director, Wacker Chemie India Pvt Ltd. He talks with Sweta M Nair about several innovations in polymer technology, the company’s offerings as a raw material supplier and its contributions to the growing paints & coatings industry. What are the benefits of using polymer dispersions in the decorative paints segment?
WACKER is the largest supplier of dispersions based on Vinyl Acetate Ethylene (VAE) copolymers that are marketed under the VINNAPAS® brand. These dispersions are mainly used in decorative interior paints as a polymer binder. They offer several technical benefits such as high pigment-binding capacity, good formulation properties, excellent scrub and early water resistance. Moreover, specific VINNAPAS dispersions are manufactured without the use of plasticisers, solvents, formaldehyde donors or Alkylphenol Ethoxylate (APEO)based surfactants. Therefore, they have a low Volatile Organic Compound (VOC) and APEO footprint and comply with environmental regulations in both Europe and Asia. At the European Coating Show in March, we introduced VINNAPAS LL 3019, a new dispersion for high-quality outdoor & indoor paint and plaster applications. This binder offers excellent pigment compatibility, extremely good colour stability, improved rheology and excellent processing characteristics. It is an ideal and inexpensive alternative to high-quality styrene acrylate and acrylate dispersions.
How big is the industrial paints & coatings segment? What role do polymers play in this segment?
The industrial paints & coatings market is growing. Take heat-resistant coatings as an example. According to experts, this market was roughly $ 544 million in 2009 and has been growing by 4 to 6 per cent each year. The binder most frequently used is silicone resin, and there are several reasons why. For instance, 62
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the coating significantly, providing heat protection for up to 120 minutes. Moreover, the water-based binder is free of organic solvents or additives and is manufactured without the use of APEOcontaining materials.
What are the recent innovations in polymer technology for applications in paints & coatings?
the underlying organic and inorganic structure of silicone resins imparts exceptional properties on powder and exhaust system coatings, especially those that are continuously exposed to extreme temperatures and rapid temperature fluctuations. Coatings formulated with WACKER’s SILRES® silicone resins readily withstand temperatures over 600°C without being destroyed or suffering adhesion failure. Silicone resins can also be used for water-based formulations that significantly reduce the VOC content in heat-resistant coatings. WACKER also offers polymer binders for intumescent coatings. These special fire-protection coatings encase steel girders and swell in the event of a fire, thus delaying the melting or warping of the building’s supporting structure. According to market experts, intumescent coatings was valued at $ 240 million in 2010, and the market is growing because of increasing safety requirements. Our new dispersion, VINNAPAS LL 3112, improves the protective properties of
We introduced several innovations at the European Coatings Show in March. For instance, our SILRES BS 1303 silicone resin emulsion is a new building protection product that is suitable for formulating facade coatings with moderately hydrophobic surfaces. In silicone resin plasters, SILRES BS 1303 also prevents pinholing of the plaster. Another innovation is our new polymer dispersion VINNAPAS LL 3019 for high-quality outdoor and indoor paint and plaster applications. This versatile binder offers excellent pigment compatibility, extremely good colour stability, improved rheology and excellent processing characteristics. In addition, it allows paints to be formulated with a low content of VOCs. Low means less than 1 g/l VOC. The binder is thus ideal for the production of solvent-free, low-emission, matt interior paints and interior plasters. Another innovation is WACKER’s cyclodextrin technology for paint applications. For example, as a process auxiliary in polymerisation, cyclodextrin allows processors to modify the thermal stability selectively and can be used as a rheology-control additive. The biodegradable molecules produced from renewable raw materials thus offer a sustainable and environment-friendly alternative for many applications in the paints & coatings industry. Email: sweta.nair@network18publishing.com
INSIGHT & OUTLOOK: Roundtable
HOW CRITICAL IS THE ROLE OF
ENGINEERING POLYMERS IN
POWDER COATING TECHNOLOGY? Invented in the 1950s, powder coating is a method of finishing a metallic surface by the application of dry powder. Initially, only thermoplastic resins were used in a fluidised bed application system. The development of thermosetting epoxy, polyurethane and polyester resins in the 1960s and 70s, combined with new spray techniques, further increased the applications of powder coatings. Sweta M Nair interacts with industry members to discern the role played by engineering polymers. Christophe Cazabeau
Chief Executive, Coatings Solutions, BASF India
At BASF, we produce polymer dispersions for the coatings industry. We offer a diverse & comprehensive raw materials’ portfolio for environmentfriendly & innovative decorative coatings with low volatile organic compounds and anti-formaldehyde & anti-bacterial features. Engineering plastics play an important role in powder coating technology. In powder coating, charged paint particles are bombarded on the plastic surface through an electrostatic gun. To attract charged particles, the plastic surface needs to be conductive enough for good paint adhesion. At the same time, plastics should withstand the backing temperature of powder-coated paint, which is normally in the range 135–150°C. Nowadays, conductive primers are available to improve affinity of the plastic surface towards charged paint particles. Some conductive engineering plastics are also used in the direct powder coating process.
Editorial take:
Sachin Upadhye
Marketing Manager – Kynar® PVDF, ARKEMA India
Ajit Vasudevan DGM – Industrial & Marine Sales & Operation, Goa Paints and Allied Products Pvt Ltd
The role of engineering polymers is very critical in powder coating technology. Powder coatings have several significant advantages over solvent-based liquid paints. Liquid paints can contain up to 70 per cent solvent, whereas powder coatings contain no solvents, and therefore eliminate solvent release into the environment. This technology is recyclable, which means oversprayed powder can be reclaimed and reused, allowing up to 95 per cent material utilisation and reducing waste. Fewer variables in film properties mean more uniform properties of powders, and the elimination of thinners and solvent balancing lead to a more consistent paint film in just one coat. Polymers offer various properties to the paint film – scratch resistance, gloss and corrosion resistance are only a few. In the automotive industry, the vehicle silencer is powder coated to achieve high heat resistance. Overall, polymers offer good film integrity.
The paints industry (divided into liquid paints & powder coatings) in India is worth ` 21,000 crore. Engineering plastics – plastic materials with better mechanical and/or thermal properties than the more widely used commodity plastics – are used in powder coatings. We generally go for thermoplastics because of the vast difference between thermoplastics and thermosets. Thermoplastics, coated on a cool surface, can be reheated and will become hard once cooled. They do not undergo chemical change in their composition when heated and can be moulded repeatedly. However, thermosets melt and take shape once; after they have solidified, they stay solid. In thermosetting, an irreversible chemical reaction occurs. The life of paints & coatings has been extended from 36 months to 60–120 months by improving the hybrid qualities of polymers and the type of formulae adapted. Email: sweta.nair@network18publishing.com
In industrial paints & coatings, different types of polymers with varied functions are used. Earlier natural polymers, such as rubber, were used. However, synthetic polymers are now used in the making of paints & coatings. Engineering polymers are widely available and help meet the demands of obtaining toughness as well as corrosion and ultraviolet resistance in powder coatings. 64
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INSIGHT & OUTLOOK: Pyrolytic technology
ENERGY GENERATION FROM
PLASTIC WASTE
Pyrolysis Pyrolytic technology is a method of harnessing energy from wastes and providing a good method of disposing waste without affecting the ecological system. It provides an opportunity to dispose plastic waste in the most environment-friendly way. Here are different types of pyrolysis as well as its system structure and operation. Namarata R Bhalerao, Prof G S Zamare
W
aste materials are widely considered a valuable resource, but there is debate on the best method to realise this value. Modern waste management systems define many types of wastes – Municipal Solid Waste (MSW ); construction & demolition waste; institutional, commercial & industrial waste; medical waste; hazardous waste; radioactive & electronic waste and biodegradable waste. Plastic waste is a part of many of these types of wastes. Over the years, various methods have been adopted for management, treatment and disposal of plastic waste, besides conventional options of landfill and incineration. Emphasis is now shifting to technologies that are acceptable to end users. One such technology is pyrolysis.
Pyrolysis
Pyrolysis is a technique of incineration or a process of thermal degradation that chemically decomposes organic materials by heating in the absence of oxygen. Thermal cleavage occurs in complete or partial absence of air, with simultaneous generation of pyrolysis oils and gases suitable for chemical utilisation or energy 66
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generation. It is an effective method for preserving petroleum resources, besides preserving the environment by decreasing the volume of nondegradable waste. Plastics are degraded by heating at high temperatures, where macromolecules breakdown into smaller fragments consisting of a valuable mixture of hydrocarbons (gas, liquid and solid). As the reaction time and temperature increase, the composition of products evolves towards more stable compounds. Pyrolysis typically occurs under pressure and at operating temperatures above 430°C. In practice, it is not possible to achieve a completely oxygen-free atmosphere. Because some oxygen is present in any pyrolysis system, a small amount of oxidation occurs. If volatile or semi-volatile materials are present in the waste, thermal desorption will also occur. Plastic waste is continuously treated in a cylindrical chamber, and pyrolytic gases are condensed in a specially designed condenser system. Plastics are pyrolysed at 370–420°C, and pyrolytic gases are condensed in a series of condensers. This yields a hydrocarbon distillate comprising straight and branched chain aliphatic, cyclic aliphatic & aromatic hydrocarbons. The resulting mixture is equivalent to petroleum distillate.
Types of pyrolysis
On the basis of speed (residence time of waste), pyrolysis is categorised into two main types – fast and slow. Fast pyrolysis: Also called flash pyrolysis, it occurs in less than two seconds at 300–550°C. Char accumulates quickly and must be removed frequently. It is further categorised as follows: Ablative fast pyrolysis – Pressure is applied to biomass to increase decomposition speed by using centrifugal or mechanical force. Larger particles of biomass can be used in this process. Cyclonic (vortex) fast pyrolysis – It separates solids from the non-condensable gases and returns them to the mixer. Rotating cone fast pyrolysis – It uses a compact, high-intensity reactor in which biomass of ambient temperature is mixed with hot sand. On mixing with hot sand, the biomass decomposes into 70 per cent condensable gases, 15 per cent non-condensable gases and 15 per cent char. Slow pyrolysis: It requires more residence time than fast pyrolysis. It utilises temperature up to 3,500°C and yields product with more composition of liquid & bottom paraffin waxes.
INSIGHT & Pyrolytic technology OUTLOOK: Pyrolytic technology
On the basis of catalyst used, pyrolysis is classified into two major classes – catalytic and non-catalytic. Catalytic pyrolysis – It is carried out in the presence of a catalyst. One can target a specific product with this process. Temperature requirement is less and composition of liquid product is more than that of gases. It makes the process efficient, and its only drawback is high cost. Catalysts used include zeolite, zeolite socony mobil-5, silica-alumina, fluid catalytic cracking etc. Non-catalytic pyrolysis – It is carried out in the absence of a catalyst. It requires higher temperatures. It offers good process efficiency and low cost. However, this process cannot target specific products. On the basis of types of gas used for purging, there are two major classes of pyrolysis – oxidative and non-oxidative. Oxidative pyrolysis – It allows the measured amount of oxygen in the system, uses carbon dioxide as the purging gas and requires low temperature. Non-oxidative pyrolysis – It does not allow oxygen in the system and uses nitrogen as the purging gas, besides requiring high temperatures. On the basis of temperature used, pyrolysis is classified as high- and lowtemperature pyrolysis: High-temperature pyrolysis – It occurs at 500–1,000°C, requires less residence time and gives more gaseous product. Low-temperature pyrolysis – It occurs below 500°C, requires more residence time and gives more liquid product.
Material suitability for pyrolysis
Material suitability for pyrolysis depends on two main factors – low decomposition temperature and absence of heteroatoms. Materials with low decomposition temperature are suitable for pyrolysis. Materials such as polycarbonate and polyethylene terephthalate are not suitable for pyrolysis as these require higher 68
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temperature for degradation. Materials containing heteroatoms, eg polyvinyl chloride (chlorine is heteroatom) and polysulphide (sulphur is heteratom) are not suitable because heteroatoms may cause corrosion of the reactor and emission of hazardous gases. Pyrolysis can process commingled and miscellaneous waste plastics, eg plastic packaging scrap from material recovery facilities, oil & detergent bottles, mulch film & silage wrap, mixed post-consumer plastics, rejected bottles etc.
Structure of the system
The system comprises stock in-feed system, pyrolysis gasification chamber, catalytic converter, condensers, centrifuge, oil recovery line, off-gas cleaning and adulterant removal. Waste plastic materials are loaded via a hot-melt in-feed system directly into the main pyrolysis chamber. When the chamber temperature is raised, agitation commences to even the temperature and homogenise the feedstock. Pyrolysis commences to the point of product gasification. Non-plastic materials fall to the bottom of the chamber. The gas enters the catalytic converter and is converted into distillate fractions by catalytic cracking. The distillate then enters the recovery tank after cooling in the condensers. From the recovery tank, the product is sent to a centrifuge to remove contaminants such as water or carbon. The cleaned distillate is pumped to the reserve tank and then to storage tanks.
Pyrolysis operation
The prime chamber performs the essential functions of homogenisation, controlled decomposition and outgassing in a single process. The process requires minimal maintenance (besides carbon residue removal) and produces consistent quality distillate from mixed & low-grade plastic waste. The essential steps in the pyrolysis of plastic materials include purging oxygen from the pyrolysis chamber, evenly heating the plastics to a narrow temperature range with minimum temperature variations,
pyrolysing plastics, passing the gases through a catalytic converter, managing carbonaceous char by-product before it acts as a thermal insulator and lowering heat transfers to plastics as well as careful condensation & fractionation of pyrolytic vapours. The polymer is gently ‘cracked’ at relatively low temperatures to yield predominantly straight-chain aliphatic hydrocarbons with little formation of by-products. These hydrocarbons are selectively condensed and further cleaved catalytically to produce the average carbon chain length required for distillate fuel.
Parameters affecting pyrolysis
Temperature: It varies for different types of pyrolysis. Presence of catalyst results in degradation of polymer at low temperature compared to original temperature of degradation. The nature of gas used for purging affects the temperature requirement of pyrolysis. Material property: Most commodity hydrocarbon plastics are suitable for pyrolysis. The larger the substituent in the side chain, the easier plastics can be degraded. Density of material used for pyrolysis has a marked effect on pyrolysis.
Future scope
Pyrolysis not only utilises plastic waste but also transforms it into the most valuable product – fuel. It solves the problem of resource and energy conservation. Studying the utility and efficiency with minimum cost can help make pyrolysis a widely accepted technique for plastic waste recycling. Namarata R Bhalerao holds a B Tech in Polymer Technology and is currently pursuing her Masters in Chemical Technology. Email: namarata_bhalerao@rediffmail.com Prof G S Zamare holds an M Tech in Chemical Technology. He is an Assistant Professor at College of Engineering & Technology, Akola, and has published articles in various national & international magazines. Email: gszamare@gmail.com
AUTOMATION TRENDS: Polymer compounding
LEADING THE WAY THROUGH INNOVATION
Polymer compounding has emerged as an efficient processing technique for the plastics industry owing to various reasons. Quick material change to reduce downtime of the production line, lowest possible usage of expensive raw materials through precision feeds and obtaining high-grade polymer compound in a single mass, all make compounding the preferred choice for plastics processors. Anwesh Koley looks into the various advancements in compounding technology made possible through automation solutions. common applications of compounding and will cost less to recycle in the long run. Additionally, compounding is used to create lightweight materials that are easily transportable per truck load than metal pipes. This fact means that the fuel used in transportation of the material is reduced.”
Latest innovations and technologies
P
Illustration: Sharad Bharekar
olymer compounding is environment-friendly because of the source of the raw material used, primarily to make Polyvinyl Chloride (PVC) resin. Besides, salt is used to create the resin involved in the process of compounding. When designing central drying stations, close attention is paid to energy management. For example, a heat exchanger is employed during the regeneration process because of its 70
Modern Plastics & Polymers | August 2013
desiccant beds. This ensures that energy from hot, humid outgoing air can be recovered and used to heat the incoming air. Closed-loop cooling systems, used in the cooling phase of regeneration, conserve energy by preventing the absorption of moisture before the bed switches over to drying. R Varadrajan, Senior Country Technical Manager – India & SAARC, Dassault Systèmes, SolidWorks, says, “Because PVC pipes last for decades, it is one of the most
The gradual shift from kneaders to co-rotating twin screw extruders with high output leads to reduction in power consumption without compromising on effective & efficient dispersion and distribution of constituents that make up the compound. The latest innovation in the compounding machinery industry is the control over the residence time and residence time distribution. Throughput per litre per hour has been increased from 100–150 kg/L/hr to over 400 kg/L/hr. Two roll mills, Banbury mixers, continuous mixers, kneaders and co-rotating twin screw extruders are the current equipment used in compounding. Die face cutting, underwater pelletisation, strand pelletisation, Sioplas technology for polyethylene power cables, conical & parallel counter rotating extrusion systems for PVC dry blends into pipes and profiles are individual requirements. “The industry is moving into use of automation to overcome problems associated with human resources and skill. Use of human–machine interfaces and integration of all upstream & downstream equipment are paving the way for improved productivity and reduced wastage,” adds Varadrajan.
Polymer compounding AUTOMATION TRENDS: Polymer compounding
The industry is moving into use of automation to overcome problems associated with human resources and skill. Use of human–machine interfaces and integration of all upstream & downstream equipment are paving the way for improved productivity and reduced wastage. R Varadrajan
Senior Country Technical Manager – India & SAARC, Dassault Systèmes, SolidWorks
Compounding process
Combining a base plastic resin with colours, modifiers, additives, reinforcements, fillers or other polymers is being carried out in over 3,000 plants at a global level. This is because 55 million metric tonne of plastic materials, constituting roughly one half of the plastics consumed in the world, are not used as base resin. The compounding process is employed to convert raw polymer or base resin to desired plastics that is more effective, uniform and also to be used in varied applications. The product made from such a compound also has improved characteristics such as better performance, lower costs, ease of manufacturing and more attractive appearance. There are over 300 grades of acrylonitrile butadiene styrene alone and more than 10,000 different grades of plastic materials manufactured using the compounding process. Macro, micro & nano fillers, plasticisers, reinforcements, flame retardants, colourants, carbon 72
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black, impact modifiers, lubricants, heat stabilisers, ultraviolet stabilisers, anti-oxidants, organic peroxide blowing agents, anti-microbial agents and anti-static agents are the most common additives that are compounded. Other additives include clarifying agents, cross-linking agents, coupling agents, deodorants, fragrance, nucleating agents, slip agents and vulcanising agents. These are added separately or in combination to one or several different resin types forming products with unique characteristics suited for myriad applications. Further, these are added in different stages of the process in the form of liquids or solids, either separately or in mixtures, to get the required properties in the final compound. Compounding extrusion is a process that mixes one or more polymers with additives to give plastic compounds. The feeds may be pellets, powder and/or liquids, but the product is usually in the pellet form, to be used in other plasticforming processes such as extrusion and injection moulding. In the industry, machine size varies from small laboratory machines to big extruders, running as much as 20 tonne per hour, as used by chemical companies that make base resins. Usually twin-screw extruders are preferred because they give better mixing at lower melt temperatures. Most of these have screws and barrels made up of smaller segments (mixing, conveying, venting and additive feeding) so that the design can be changed to meet the production and product needs. Single-screw extruders can be used for compounding as well, especially with appropriate screw design and static mixers after the screw. Selection of the components to be mixed is as important as the equipment.
Evolution to the co-rotating twin screw Globally, over 30,000 processing units comprising single-screw extruders, internal mixers or dispersive kneaders, reciprocating single-screw extruders (co-kneaders) and twin-screw extruders
are currently used for compounding. Over the years, the co-rotating twinscrew extruder has played a dominant role in compounding and is used by resin suppliers, proprietary and custom compounders or end-users, making it the most preferred processing equipment. This dominance is due to the clear advantages of using a co-rotating twin-screw extruder over other process equipment.
R&D initiatives in polymer compounding
Backward integration into critical extruder parts and associated Research and Development (R&D) in metallurgy to withstand wear and corrosion are the latest in terms of research in the compounding industry. Also, compounding has seen major investments in process development to continuously improve extruder configuration and compound quality. “With patented elements, companies have paved the way for most applications that are limited by feed to be now limited by torque. R&D initiatives have led to narrow residence time resulting in the ability to process sensitive materials. Processing companies have addressed the higher wear that occurs due to high throughputs. Vacuum side stuffer technology introduced in the market has resulted in continuous production without stoppages for cleaning the blocked vents and wastage of material,” adds Varadrajan.
Industry challenges
Lack of initiatives in developing compounds based on low-cost fillers and agro-based fibres as reinforcement is a problem. Inadequate experience and lack of facilities to develop composites for strategic requirements, such as bulletproof vests and aerodynamic parts, result in loss of man hours and resources for the company. It is necessary to develop the required facilities to support the technical requirements of compounding without loss of productivity and energy efficiency. Email: sweta.nair@network18publishing.com
ENERGY MANAGEMENT: Extrusion
ON THE
Illustration: Sharad Bharekar
PATH OF ENERGY EFFICIENCY
The extrusion machinery market is growing at a fast pace in India. To provide a boost to the industry, appropriate steps need to be taken for energy efficiency and heat management. Avani Jain highlights the steps that can be taken by the industry for attaining energy efficiency.
T
he extrusion process is highly dependent on electricity, and most of the energy used is directly related to machine operation. For example, for profile extrusion, the energy used to drive the extruder is 50 per cent of the total, and the remaining energy is used for items such as ancillaries and utilities. Thus, various steps are needed to reduce energy consumption and for heat management in plastics extrusion processes. Mrunal Ramanuj, Director, Ocean Extrusions, says, “Technology has undergone enormous changes in recent times. In order to ensure maximum energy efficiency, machine designs have undergone drastic changes over the years.
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Although, in terms of power consumption, today’s machines consume 50 per cent less power, the energy consumption is still high. Thus, appropriate steps need to be taken for energy efficiency and heat management during the extrusion process.”
Using efficient motors in the extruder
The initial cost of energy-efficient extruders is generally high, but it can be beneficial in the long run. Options such as high-efficiency AC motors, variable speed drives and servo motors can be used in the extruder section for higher energy efficiencies. The servo drive also facilitates high energy efficiency, accuracy, precision and good control.
Appropriate screw design
A high percentage of the total energy requirement (up to 30 per cent) for moulding and extrusion equipment is used to plasticise material. Thus, after addressing the issue of efficient motors in the extruder, it is also essential to check the screw diameter and design. The heart of this extruder is the extruder screw. This is a long cylinder with a helical flight wrapped around it. The screw is important because conveying, heating, melting and mixing of plastics are mostly determined by the screw. The stability of the process and the quality of the extruded product are dependent on the design of the screw. The screw rotates in a cylinder that fits closely around it.
Extrusion
In order to ensure maximum energy efficiency, machine designs have undergone drastic changes over the years. Although, in terms of power consumption, todayâ&#x20AC;&#x2122;s machines consume 50 per cent less power, the energy consumption is still high. Mrunal Ramanuj
Director, Ocean Extrusions
Barrier-type screw designs are the most widely used screw designs in the extrusion industry and help in achieving energy efficiency. The advantages derived from properly designed barrier screws are improved production rate, lower melt temperature and improved melt quality. Because of their mechanism of melting, barrier screws produce higher internal pressures through the barrier section and help increase the melting of the material. A general purpose screw does not produce as high internal pressures at the end of the transition section as barrier screws do. Primarily, barrier screws are designed to increase the throughput in single-screw extruders and to improve the melt quality. Extrusion screws have undergone tremendous changes over the past decade. The latest technology in screw and barrels is the introduction of a bimetal. Bimetallic construction provides a protective wear surface fused to the high-strength backing material. The design delivers efficient energy transfer between the bore and the backing material. This feature allows for rapid detection of process condition changes, quick response to heat & cool commands, precise control and uniformity of barrel zone temperatures. The engineered ID lining improves component compatibility between the screw and barrel wear surfaces, minimises wear gap and prolongs productive life.
Regulation of speed and temperature
The most energy-efficient extrusion operations are those where most of the heat is supplied by the extruder screw, with only a small amount of heating by the barrel and die heaters, and without any need for cooling of the extruder. Jaymin Pithwa
Director, Konark Plastomech Pvt Ltd
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Optimising the extruder speed maximises heat from mechanical work and minimises the amount of electrical energy needed by the extruder. Provided the downstream equipment does not limit the output, the energy consumption can decrease by nearly 50 per cent by doubling the rotational speed of the extruder. The energy use in the extrusion process is directly related to the melt discharge temperature. Energy use increases with melt temperature; therefore, it is important to run extruders at the lowest possible melt temperature. Low melt temperatures will also reduce the need for cooling. Thus, accurate temperature control is needed for good
extrusion because excess temperature is a waste of energy. Poor screw design is a common cause of overheating plastics and is usually the reason barrel cooling is needed. Operations where multiple extruder zones are cooled at 100 per cent are inherently inefficient. Thus, it is important to minimise barrel cooling to save energy and avoid resin degradation. Barrel cooling occurs when the extruder screw generates more heat than necessary. In most cases, it indicates that the screw is not properly designed. Thus, screw design is critical. Jaymin Pithwa, Director, Konark Plastomech Pvt Ltd, notes, â&#x20AC;&#x153;The most energy-efficient extrusion operations are those where most of the heat is supplied by the extruder screw, with only a small amount of heating by the barrel and die heaters, and without any need for cooling of the extruder.â&#x20AC;? The best solution to overheating by poor screw design is to change the screw geometry. If an extruder with poor screw design runs at 0.25 kWh/kg and that with a good screw design runs at 0.20 kWh/ kg, the energy savings will be $ 36,000/ year at $ 0.10/kWh and a throughput of 1,000 kg/hr (2,200 lb/hr) running 24 hr/day and 300 days/year. This example indicates that a well-designed extruder screw can pay for itself relatively quickly, just based on reduced energy cost. In addition, various benefits are offered by a well-designed screw such as lower melt temperatures, less degradation of the plastic, better physical properties in the extruded product, better product appearance, consistency etc. Screw design technology is constantly evolving, and processors are always involved in gauging the appropriate screw diameter, geometry and length-to-diameter ratio appropriate to a specific material and plasticising rate.
Energy-efficient future
In a complete extrusion process, several components consume a large amount of energy. Hence, companies will have to adopt various measures in the future for decreasing their energy consumption in the plastics extrusion process. Email: avani.jain@network18publishing.com
POLICIES & REGULATIONS: Anti-dumping duty
IMPLICATIONS
FOR THE
INDIAN PLASTICS
PROCESSING SEGMENT
The opinion on the anti-dumping duty imposed by the Indian government on Chinese plastics machines remains divided. However, what cannot be denied is the implication of trade ties between the two countries that will attract the attention of the international fraternity. Anwesh Koley explores the various propositions spurred by this decision.
A
major concern for manufacturers of plastics processing machines in India was the advent of Chinese machines at substantially lower prices. The industry had been urging the government to take steps to prevent Chinese suppliers from exporting their machines to India. Finally, the Indian government in 2009 levied an anti-dumping duty of 223 per cent on imports of Chinese Injection Moulding Machines (IMMs). It justified its stance by saying that these products that flood the Indian market are affecting the profitability of manufacturers in the country and causing damage to market share.
Implications of the ban
The Finance Ministry had imposed definitive anti-dumping duty on imports of certain plastics processing machines or IMMs from China. The levy was to be in force for five years from May 12, 2009, the date on which the provisional antidumping duty was imposed. The specified percentage is in the range of 60–174 per cent, depending on the producer. Based on a petition filed by a Chennai-based machine manufacturer, the designated authority in the Commerce Ministry had initiated anti-dumping investigations on imports of plastics processing machines from China in 2008. The Revenue Department had specified that the anti-dumping duty 78
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would be a percentage of the Cost, Insurance and Freight (CIF) value of imports. However, blow moulding, vertical injection moulding, all-electric injection moulding, multi-colour/multi-mould and rotary injection moulding machines for making footwear were excluded from the levy. While machine manufacturers have since then seen favourable times, plastics processors fear that their margins will be hit by 20–25 per cent due to the anti-dumping duty on imports of certain plastics processing machines or IMMs from China. Indian machines cost at least 25 per cent more than Chinese machines. While the price of machines varies with size, quality and degree of automation, Chinese machines cost between ` 5 lakh and ` 10 crore on an average. Machines and moulds account for nearly 70 per cent of the cost of setting up a plastics processing business. Indian customs levied on Chinese imports of tariff margin amount will be based on final determination of the dumping case to make adjustments.
Pros and cons
Over 5,000 injection moulding units are present across the country, of which over 50 per cent are in the small and mediumsized category. India’s net polymer capacity is about six million tonne per annum, with Gujarat accounting for
nearly 60 per cent of the net production. The net size of the sector could be ` 70,000–100,000 crore. Praveen Sharma, Managing Director, Hinds Plastic Machines Pvt Ltd, says, “The demand for Indian-made machines has gone up after the anti-dumping duty was levied, and many small & mid-sized companies have gone ahead with their expansion plans. The current requirements are not as high as during the time of the announcement, but machine manufacturers are content.” However, scepticism still prevails over the ability of Indian manufacturers to meet overall market requirements. Despite rapid expansion plans, a considerable gap between demand and supply might remain. Therefore, the use of plastics may decrease, and the end-users of plastic end products will suffer because product costs will increase in the major plastics applications sectors such as automobiles, fast-moving consumer goods and houseware. Although Indian makers increase the production capacity of machines, it will take time to create new infrastructure and, within this time, the demand for machines will increase again; as a result, Indian machine manufacturers will find it difficult to meet the demand for machines. If anti-dumping duty remains in vogue for long, there is a concern that Indian machine manufacturers will try to get much higher prices than now, as there is no global competitor. This
Anti-dumping duty
The demand for Indian-made machines has gone up after the anti-dumping duty was levied, and many small & mid-sized companies have gone ahead with their expansion plans. The current requirements are not as high as during the time of the announcement, but machine manufacturers are content. Praveen Sharma
Managing Director, Hinds Plastic Machines Pvt Ltd
is also a concern as Indian machine manufacturers can never meet the dispatch target because of their way of working and infrastructure; this is a major reason why clients in India opt for Chinese machines. However, this can be addressed. “With the increase in our order books, delivery times have gone up, albeit marginally, and with further increase in demand, we will see significant improvement in our dispatch times,” adds Sharma. Another area that has benefitted is the market for used machines. With the anti-dumping duty levied on Chinese IMMs, buyers in India are now looking for used IMMs, considering the lead times of domestic machine manufacturers being more than two months. This leads to processors turning to used IMMs, which are readily available at almost 45–50 per cent of the price of the new machine. The reasons for domestic machine manufacturers being in favour of the anti-dumping duty are numerous. “We have to compete with Chinese products on the basis of price, which becomes a setback in the initial stages. The financial and fiscal support provided by the Chinese government to their manufacturers cannot be compared to our duty structure,” says Sharma. While the Indian government has, from time to time, provided incentives to domestic manufacturers, it still did not make them as export-centric as China. “In India, there is a huge domestic demand, so our initial plans catered to this market quite well, but the advent of Chinese machines has provided even cheaper alternatives to plastics processors, which have eaten into our markets,” laments Sharma. While cost is an area where Chinese companies score over Indian companies, quality has remained the stronghold of Indian manufacturers. Indian IMMs are well accepted globally because of high component quality and longevity. Another advantage enjoyed by Indian manufacturers after the levy of the antidumping duty is in after-sales service. Indian manufacturers are now appreciated for their valuable customer service. Email: sweta.nair@network18publishing.com
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STRATEGY: Flexible plastic packaging
LIGHTWEIGHTING FOR REDUCING COSTS With rising interest in saving costs, the packaging industry in India is moving towards lightweight flexible packaging materials, which not only help in reducing the overall product weight and logistics cost but also help companies in achieving sustainability. Avani Jain notes the benefits offered by flexible plastic packaging. Courtesy: International Plastics Inc
I
n recent times, flexible packaging solutions have come to represent the entire packaging industry. This is primarily due to flexible films advantages in terms of relatively low cost, good barrier properties against moisture & vapour, heat sealability, easy handling and convenience for the manufacturer, retailer and consumer. Thus, keeping in mind the environmental and logistics concerns, plastic packaging companies are exploring the possibility of lightweighting solutions and downgauging packaging material for cost and resource reduction, and here lightweight flexible packaging assumes importance. For example, just a gram or two saved in the weight of a package can have a tremendous impact on the environment and lead to cost and resource reduction when the net gain of millions of individual packages are factored.
Need for lightweighting
Issues such as the energy and cost required 80
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for producing and transporting packaging as well as the pollution created during package manufacturing and use is worrying companies in the segment. This has led companies to rethink their strategies, the result of which is lightweight flexible packaging solutions. These solutions offer more than one benefit, including reduction in logistics cost. Lightweight packaging means consumption of lesser amount of raw material to make the product, which reduces the cost of materials & transportation and lessens the waste & energy demand. Lightweight packaging materials especially help in reducing logistics cost, as their usage in packaging directly means lighter loads or fewer lorries needed to ship the same amount of products, helping to reduce transportation energy, decrease emissions and lower shipping costs. It also helps in reducing the amount of waste generated. Thus, lightweight flexible packaging helps in saving the environment and leads to sustainable development.
Lightweighting can be achieved by using low-density materials, by developing novel multi-layer thin film or foamed sandwich structures. Ketan Bhatt, Owner, Drashti Packaging, says, “Various lightweight packaging materials are available in the market today. Some major products that enable manufacturers to create sustainable packaging include biaxially oriented polypropylene films, multi-layer Polyethylene (PE) films etc. Further, new specialty films also offer an opportunity for reducing packaging weight and transportation cost.” He adds further, “With growing awareness about sustainable packaging, flexible packaging is outperforming conventional methods of packaging, as it weighs less than many other types of rigid packaging, eg Polyethylene Terephthalate (PET) & glass containers, and incurs lower transportation cost and also reduces the weight of the product.”
Flexible plastic packaging
Life Cycle Analysis (LCA) of flexible packaging
With growing awareness about sustainable packaging, flexible packaging is outperforming conventional methods of packaging, as it weighs less than many other types of rigid packaging. Ketan Bhatt
Owner, Drashti Packaging
LCA of flexible packaging shows that by using lightweight packaging, such as flexible pouches, companies can reduce the amount of fuel used and greenhouse gases emitted during transportation. It generates less waste, reducing landfill discards. Also, innovation and technology have enabled flexible packaging manufacturers to use fewer natural resources in their packaging. In addition, lightweight flexible packaging results in less transportationrelated energy & fossil fuel consumption and environmental pollution. In fact, flexible packaging offers large energy savings per year in manufacturing and transportation. The potential for reducing actual petroleum use by reducing package weight in transport is impressive.
Strategies adopted
We have taken to optimisation of flexible packaging materials after proper stability study. We are also making use of new generation polymers and films to provide higher strengths at lower thickness. Rajesh K Pandya
Vice President – Operations, Parikh Packaging Pvt Ltd
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With the sole aim of reducing the overall weight of products, plastic packaging companies have adopted various steps for downgauging of packaging materials and moving towards flexible packaging. Rajesh K Pandya, Vice President – Operations, Parikh Packaging Pvt Ltd, notes, “We have taken to optimisation of flexible packaging materials, ie film and laminate structures, after proper stability study. We are also making use of new generation polymers and films to provide higher strengths at lower thickness. By taking this step, we are able to reduce per pack weight, thereby leading to less material usage, less energy consumption and less cost incurred without compromising on the basic properties.” He adds further, “In 2010–2011, we developed a new lightweight packaging solution for a snack food company in India. We reduced the thickness of the laminate from 66–68 g/sq m to 52 g/sq m. That proved to be a benchmark of our efforts towards sustainable development. Further, we are manufacturing biodegradable and thin laminates. To pack one tonne of biscuit, 300 kg of laminates was needed. Today, there are laminates available in the market that are thinner, ie using only 220 kg but providing similar types of
barrier. Thus, it leads to saving of almost 22 per cent of valuable raw material as well as the cost.”
Growth prospects
Today, manufacturers of packaged goods are constantly challenged to reduce packaging for cost and resource reduction while ensuring it still serves the primary purpose, ie protects the contents and helps sell the product. PE, the most widely used flexible packaging material, has come a long way, and packaging engineers have capitalised on these advances by designing flexible packages that are thinner and lighter than ever. Flexible pouches, such as sachets, are replacing PET bottles, which use lesser amount of fuel and lead to reduced greenhouse gas emission during transportation. Thus, in order to achieve the goal of reducing logistics costs and the amount of materials used for packaging, companies are increasingly adopting lightweight packaging solutions such as flexible packaging, which means that less fuel is needed to ship the packages to companies and, in turn, to stores or retail consumers. Hence, flexible packaging proves its usefulness and value for business, consumers and the environment. Innovations in flexible packaging have increased product protection and consumer convenience, enhanced retail shelf impact and improved manufacturing efficiencies, while ensuring lesser use of natural resources and reducing energy consumption and transportation cost.
Future trends
According to the study ‘The Flexible (Converted) Plastic Packaging Market 2012–2022’ by Visiongain, “the global flexible plastic packaging market reached a value of $ 137 billion in 2012, as the trend of convenience and low cost drives global demand. Further, the flexible plastic packaging market will record strong growth over the next decade, with a significant portion of the growth derived from the emerging markets.” Thus, the future of the flexible packaging market in the country is very bright. Email: avani.jain@network18publishing.com
TIPS & TRICKS: Safety tips for food packaging
Ensuring
HYGIENE and
SAFETY
Entrepreneurs in the food industry are often overwhelmed when making decisions regarding food packaging design. Packaging materials that fit the budget plus guarantee the safety of food content are essential. Besides being an important marketing tool for companies in the food items business, plastic packaging should perform and protect. Anwesh Koley provides a few pointers to help manufacturers and consumers to ensure that food is always safe.
F
ood companies in developing countries are not always as well organised and developed as those in the industrialised world. Moreover, the problems of
growing population, urbanisation and lack of resources to deal with pre- & post-harvest losses in food as well as food hygiene issues mean that food systems in developing countries continue to be
stressed, adversely affecting quality and safety of food supplies. It is therefore important for food packaging companies to ensure that plastic packaging adheres to certain safety norms. Email: sweta.nair@network18publishing.com
Few guidelines that can be followed to keep food safe: Plastic packaging units for food should be careful not to reuse packaging with a different type of food than the one intended, eg if water bottles are reused to hold fruit juice, the acidity may cause chemicals to move from the plastic into the drink. Chemicals are also less likely to transfer from packaging to food at lower temperatures. If puréed food is to be frozen in ice cube trays, care must be taken that the food is cooled before filling trays.
From the consumers’ perspective, the manufacturer’s instructions on plastic containers must always be followed. Containers should be reused on a like-for-like basis. If a container (on purchase) was used for cold food, it should not be used to package hot food while reusing it. Currently, only plastic containers for microwave-heated food are clearly labelled ‘microwave safe’.
M a n u f ac t u re r s need to make sure that the packaging used is safe for the intended purpose. Specific tests should be conducted to check that plastic packaging is suitable for use and that the limits set in the legislation are met. Plastic food packaging is often designed to be used once with one type of food. It might not be safe for use with other foods or for a different packaging purpose.
The way in which food has been packed has a direct influence on its shelf-life. It must be ensured that the food package is kept air-tight, water-tight and resistant to steam, grease and odour. If sealable plastic bags are used, then all of the excess air must be removed before sealing. The smaller the package, the easier it is for cold to penetrate. For easy storage, plastic packages should be of a regular shape.
Flexible plastic bags are preferred for packaging because of their irregular shapes. All air should be removed from the bag before closing or sealing it. W hen packaging food items that have strong colours or odours, the food container should be lined with a silver foil. Silver foil and cling film can be c om p l e t e l y wrapped around the food, which can then be sealed with special sticky tape.
Plastic containers should not be used for flame cooking. S i m i l a r l y, microwave-safe plastic containers should not be used to heat oil or cook food with oil in the microwave (eg popcorn with hot oil in a plastic container). Cling film can be used to pack on-the-go food such as sandwiches. This plastic film can also help in protecting food from dust and harmful germs and insects.
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PROJECT S
New projects and expansion activities are the barometers of industrial growth. These also present business opportunities to service providers like consultants, contractors, plant & equipment suppliers and others down the value chain. This feature will keep you updated with vital information regarding new projects and capacity expansions being planned by companies in the plastics, polymers and allied industries.
Injection moulding machines
JH Welltec Machines (India) Pvt Ltd
Project type New facility Project news The company plans to set up an injection moulding machines production facility in Ahmedabad to bridge the demand–supply gap of machinery in the rapidly growing Indian plastics industry. The plant, expected on a 2.3 acre plot in Ahmedabad, should begin operations by August 2014. Project location Ahmedabad, Gujarat Project cost NA Implementation stage Planning Contact details: JH Welltec Machines (India) Pvt Ltd B/3, Mayurpankh Apartments B/H Daxini Society, Maninagar Ahmedabad, Gujarat
Plastic bottles/caps/closures and similar articles Creative Proplast
Project type New facility Project news Creative Proplast is planning to set up a new plastics project at Haridwar in Uttaranchal. The project involves manufacturing of plastic bottles/caps/closures and similar articles of manufacture (excluding items reserved for SSI sector and household items). Project location Haridwar, Uttaranchal Project cost NA Implementation stage Planning Contact details: Creative Proplast 501, 5th Floor, Embassy Centre Nariman Point Mumbai 400 021
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Plastic park in Andhra Pradesh Department of Chemicals & Petrochemicals
Project type New facility Project news The Central Government, Department of Chemicals & Petrochemicals, is planning to set up a plastic park in Andhra Pradesh during the 12th Plan period. The plastic park scheme involves a plastics industry cluster where a plastics reprocessing & recycling plant and waste management system are set up in public–private partnership mode. Project location Andhra Pradesh Project cost ` 40 crore Implementation stage Planning Contact details: Department of Chemicals & Petrochemicals Ministry of Chemicals & Fertilizers Janpath Bhawan (3rd Floor, B-Wing) Janpath, New Delhi 110 001 Tel: 23715370 Fax: 23725114
Plastic park in Haryana
Department of Chemicals & Petrochemicals
Project type New facility Project news The Central Government, Department of Chemicals & Petrochemicals, is planning to set up a plastic park in Haryana during the 12th Plan period. The plastic park scheme involves a plastics industry cluster where a plastics reprocessing & recycling plant and waste management system are set up in public–private partnership mode. Project location Haryana Project cost ` 40 crore Implementation stage Planning
Contact details: Department of Chemicals & Petrochemicals Ministry of Chemicals & Fertilizers Janpath Bhawan (3rd Floor, B-Wing) Janpath, New Delhi 110 001 Tel: 23715370 Fax: 23725114
Plastic park in Orissa
Department of Chemicals & Petrochemicals
Project type New facility Project news The Central Government, Department of Chemicals & Petrochemicals, is planning to set up a plastic park in Orissa during the 12th Plan period. The plastic park scheme involves a plastics industry cluster where a plastics reprocessing & recycling plant and waste management system are set up in public–private partnership mode. Project location Orissa Project cost ` 40 crore Implementation stage Planning Contact details: Department of Chemicals & Petrochemicals Ministry of Chemicals & Fertilizers Janpath Bhawan (3rd Floor, B-Wing) Janpath, New Delhi 110 001 Tel: 23715370 Fax: 23725114
Plastic park in Punjab
Department of Chemicals & Petrochemicals
Project type New facility Project news The Central Government, Department of Chemicals & Petrochemicals, is planning to set up a plastic park in Punjab during the 12 th Plan period. The plastic park scheme involves a plastics industry cluster where a plastics
PROJECT S
reprocessing & recycling plant and waste management system are set up in public– private partnership mode. Project location Punjab Project cost ` 40 crore Implementation stage Planning Contact details: Department of Chemicals & Petrochemicals Ministry of Chemicals & Fertilizers Janpath Bhawan (3rd Floor, B-Wing) Janpath, New Delhi 110 001 Tel: 23715370 Fax: 23725114
Plastic park in Rajasthan
Department of Chemicals & Petrochemicals
Project type New facility Project news The Central Government, Department of Chemicals & Petrochemicals, is planning to set up a plastic park in Rajasthan during the 12th Plan period. The plastic park scheme involves a plastics industry cluster where a plastics reprocessing & recycling plant and waste management system are set up in public–private partnership mode. Project location Rajasthan Project cost ` 40 crore Implementation stage Planning Contact details: Department of Chemicals & Petrochemicals Ministry of Chemicals & Fertilizers Janpath Bhawan (3rd Floor, B-Wing) Janpath, New Delhi 110 001 Tel: 23715370, Fax: 23725114
Plastic park in Uttar Pradesh Department of Chemicals & Petrochemicals Project type New facility
Project news The Central Government, Department of Chemicals & Petrochemicals, is planning to set up a plastic park in Uttar Pradesh during the 12th Plan period. The plastic park scheme involves a plastics industry cluster where a plastics reprocessing & recycling plant and waste management system are set up in public–private partnership mode. Project location Uttar Pradesh Project cost ` 40 crore Implementation stage Planning Contact details: Department of Chemicals & Petrochemicals Ministry of Chemicals & Fertilizers Janpath Bhawan (3rd Floor, B-Wing) Janpath, New Delhi 110 001 Tel: 23715370, Fax: 23725114
Himachal Pradesh Horticultural Produce Marketing & Processing Corporation Ltd
Project type New facility Project news UPI Polymers is planning to implement a polyethylene pipe and corrugated pipe manufacturing unit in Nellore. Project location Nellore, Andhra Pradesh Project cost ` 165 crore Implementation stage Planning Contact details: UPI Polymers Pvt Ltd #6-3-600/3, A2-Girishikara Apartment Hilltop Colony, Erramanzil Hyderabad 500 082 Tel: 040-30420460, Fax: 040-23370460 Email: info@upipolymers.net
Polyethylene Terephthalate (PET) bottle and preform Manjushree Technopack Project type Facility expansion
Contact details: Manjushree Technopack Plot No. 60 E&F Bommasandra Industrial Area Hosur Road, Bengaluru 560 099 Karnataka
PET juice and drink bottles
Polyethylene pipe and corrugated pipe UPI Polymers Pvt Ltd
Project news PET bottle and preform manufacturer Manjushree Technopack is increasing its capacity from 50,000 MTPA to 80,000 MTPA by constructing its largest PET preform production facility in Bidadi, India. Project location Bidadi, India Project cost NA Implementation stage Planning
Project type Facility expansion Project news Himachal Pradesh Horticultural Produce Marketing & Processing Corporation Ltd is planning to expand its packing of juices and drinks in PET bottles. The expansion plan intends to utilise the various processing and packing facilities in Northern and Central India for the packaging of juices and drinks in PET bottles of 200, 500 and 1,000 ml capacity on job work basis. Project location India Project cost NA Implementation stage Planning Contact details: Himachal Pradesh Horticultural Produce Marketing & Processing Corporation Ltd Nigam Vihar Shimla 171 002 Himachal Pradesh Tel: 0177-2623832, 38, 36 Fax: 2623834 Email: hpmcshimla@live.com
Information courtesy: Tendersinfo.com 1, Arch Gold, Next to MTNL Exchange, Poisar, S V Road, Kandivali (W), Mumbai 400 067, Maharashtra, India Tel: 022-28666134 • Fax: 022-28013817 • Email: parmeet.d@tendersinfo.com
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TENDERS
Latest Popular Tenders brought to you by www.tendersinfo.com Polymer Org : Energy, Water and Sanitation Authority TRN : 16986519 Desc : Supply of 2,000 kg of polymer Synthofloc 8022 Tw BOD : 12 Aug 2013 Loc : Rwanda BT : Global (ICB)
Polyvinyl chloride flooring sheets Org : East Coast Railway TRN : 16801621 Desc : Supply of flexible polyvinyl chloride flooring sheets BOD : 12 Aug 2013 Loc : Bhubaneswar, Orissa BT : Domestic (NCB)
Polystyrene Org : Ordnance Factory Board TRN : 16627221 Desc : Supply of side packing piece expanded polystyrene BOD : 13 Aug 2013 Loc : Pune, Maharashtra BT : Domestic (NCB)
Waste bags and sacks Org : Joensuun Seudun Hankintatoimi TRN : 16667961 Desc : Supply of waste bags and sacks BOD : 13 Aug 2013 Loc : Finland BT : Global (ICB)
Trash bags Org : Corporació Sanitària Parc Taulí y Entidades Adheridas TRN : 17019596 Desc : Supply of trash bags BOD : 14 Aug 2013 Loc : Spain BT : Global (ICB)
Biodegradable bags Org : Communauté de Communes du Bassin de Pompey TRN : 16666935
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Desc : Supply of biodegradable bags for the collection of biodegradable waste BOD : 19 Aug 2013 Loc : France BT : Global (ICB)
Plastic bags Org : Ministerio de Salud Publica TRN : 17019933 Desc : Acquisition of plastic bags BOD : 19 Aug 2013 Loc : Guatemala BT : Global (ICB)
Plastic containers Org : KD Cistoca D.O.O. TRN : 17024152 Desc : Supply of plastic containers for waste collection BOD : 19 Aug 2013 Loc : Croatia BT : Global (ICB)
Garbage bags Org : Hospilim VZW TRN : 16803278 Desc : Supply of garbage bags BOD : 20 Aug 2013 Loc : Belgium BT : Global (ICB)
Polyethylene garbage bags Org : IVBO TRN : 16741747 Desc : Purchase of 10,700,000 polyethylene garbage bags over a period of 2 years BOD : 20 Aug 2013 Loc : Belgium BT : Global (ICB)
Waste bags Org : Bærum Kommune TRN : 16891574 Desc : Procurement of waste bags BOD : 26 Aug 2013
TENDERS
Latest Popular Tenders brought to you by www.tendersinfo.com Loc : Norway BT : Global (ICB)
Blood bags Org : 6i Ygeionomiki Perifereia Peloponnisoy Ionion Nison Ipeiroy Dyt Elladas TRN : 16822907 Desc : Supply of blood bags BOD : 29 Aug 2013 Loc : Greece BT : Global (ICB)
Garbage bags
TRN : 17053566 Desc : Procurement of gunny bags (large size 100 cm × 71 cm) N8105-000009 gunny bags (27 cm × 21 cm) N8105-P061131 high-density polyethylene bags (size 1,200 mm × 900 mm) BOD : 5 Sep 2013 Loc : Mumbai, Maharashtra BT : Domestic (NCB)
Garbage bags
Org : Smictom du Chinonais TRN : 16956463 Desc : Supply of garbage bags BOD : 2 Sep 2013 Loc : France BT : Global (ICB)
Org : Centre Hospitalier Universitaire de Liège TRN : 16690393 Desc : Providing garbage bags BOD : 6 Sep 2013 Loc : France BT : Global (ICB)
Polythene waste and refuse sacks and bags
Garbage bags
Org : ASIA Napoli SpA TRN : 16563354 Desc : Provision of polythene waste and refuse sacks and bags BOD : 2 Sep 2013 Loc : Italy BT : Global (ICB)
Trash bags Org : Department of King Khalid .Military City TRN : 17028008 Desc : Supply of trash bags BOD : 4 Sep 2013 Loc : Saudi Arabia BT : Global (ICB)
Gunny bags and high-density polyethylene bags Org : Ministry of Defence
Org : Groupement Collèges et Lycées du Finistère TRN : 16961864 Desc : Supply and delivery of garbage bags BOD : 6 Sep 2013 Loc : France BT : Global (ICB)
Blood bags Org : 1I YPE Attikis G.N. Attikis KAT TRN : 16915497 Desc : Provision of blood bags BOD : 9 Sep 2013 Loc : Greece BT : Global (ICB)
Org: Organisation’s name, TRN: Tendersinfo Ref No, Desc: Description, BOD: Bid Opening Date, Loc: Location, BT: Bidding Type. Information courtesy: Tendersinfo.com 1, Arch Gold, Next to MTNL Exchange, Poisar, S V Road, Kandivali (W), Mumbai 400 067, Maharashtra, India Tel: 022-28666134 • Fax: 022-28013817 • Email: parmeet.d@tendersinfo.com
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EVENT LIST
National
Pune
Chennai
Jaipur
Oct 18–21, 2013
Nov 14–17, 2013
Nov 29–Dec 2, 2013
Maharastra
Tamil Nadu
Ludhiana Aurangabad
Rajastan
Punjab
Dec 20–23, 2013
Maharastra
Jan 10–13, 2014
Indore
Madhya Pradesh Jan 31–Feb 3, 2014
Kolkata Ahmedabad West Bengal
Feb 21–24, 2014
Gujarat
Mar 7–10, 2014
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: Network18 Media & Investments Ltd
Network18 Media & Investments Ltd, Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028 Tel: 022-30034651 • Fax: 022-30034499 • Email: engexpo@infomedia18.in • Web: www.engg-expo.com
Pharmapack Expo
Pharmapack Expo is the most cost-effective marketing opportunity and is the best opportunity to meet senior buyers and decision makers from all facets of the user industry. The exhibits will include packaging materials & products, glass & plastic jars and bottles, aluminium & plastic tubes, corrugated & cardboard boxes, dosing machines for liquids & powders, filling machines, blister packing machines, strip packing machines, labels & labelling equipment, form-fill-seal machines etc; September 12–14, 2013; at Bombay Exhibition Center (BEC), Mumbai For details contact: Intel Trade Fairs & Expositions Pvt Ltd 113, New Sonal Link Industrial Estate Building No. 2, Link Road Malad (W) Mumbai 400 064 Tel: 022-26003977 Email: info@intelexpo.com Website: www.pharmapackexpo.in
PlastShow
PlastShow is dedicated to offering a comprehensive range of plastic products and processing equipment. The event strives to offer complete information about the recent innovations in the plastics manufacturing sector. The exhibitors find this exhibition to be the perfect business meeting place 88
where the exhibiting companies get an opportunity to establish themselves and promote their brands; September 27–30, 2013; at Vapi Industrial Association Ground, Vapi, Gujarat
S G Highway, Thaltej Ahmedabad, Gujarat Tel: 079-32410602 Fax: 079-26851716
For details contact: Brijesh Purohit Sunline Infotech 118, Lotus Arcade Opposite Automotive Show Room Gondal Road Rajkot, Gujarat Tel: 0281-2460135
Designed to help exhibitors and visitors to discover potential markets, Plastivision India will be the 9 th in the series of national exhibitions and seminars organised by the All India Plastics Manufacturers’ Association (AIPMA). With participation from more than 45 countries and visitors from over 61 countries, the event will include exhibitors ranging from categories such as raw materials & chemicals, plastic packaging machinery & equipment, machinery & equipment for processing, recycling, pre & post processing machines, plastic extrusions, thermoforming/films/thermoplastics etc. The five-day exhibition will be an ideal place to meet leading members from the plastics industry; December 12–16, 2013; at Bombay Exhibition Center (BEC), Mumbai
Saurashtra Plast
Saurashtra Plast is a great event for the plastics industry where the leaders and innovators of the profession come together to collaborate and discuss their ideas in order to move the discipline forward. The event has been known in the past to facilitate an electrifying level of professional interaction among decision makers and other key professional figures. Businesses also find the event as a great opportunity to form strong business networks and connections; September 29–October 02, 2013; at Rajkot Race Course Ground, Rajkot For details contact: Rakesh Nair KMG Business Technology C/ 3- 803, Anushruti Tower Near Thaltej Circle
Modern Plastics & Polymers | August 2013
Plastivision India
For details contact: AIPMA A-52, Street No. 1, M I D C, Marol Andheri (East), Mumbai Tel: 022-28217324/28217325/ 28352511/283 Fax: 022-28216390 Email: marketing@plastivision.org Website: www.plastivision.org
EVENT LIST
International China Plastics & Rubber Industry Exhibition
China Plastics & Rubber Industry Exhibition provides the latest and the best in plastic materials for all manufacturing and processing industries. Exhibitors include constructors, manufacturers, suppliers of machinery and equipment for the plastics and rubber industries, producers and suppliers of raw materials, manufacturers and processors of plastic materials, institutions and information agencies; August 15–17, 2013; Qingdao International Convention & Exhibition Center, Qingdao, China For details contact: Qingdao Jinnoc Int’l Expo Co Ltd 902, Fulin Building 87, Fuzhou Road Qingdao, Shandong, China Tel: +86-532-55552901 Fax: +86-532-55552903
Plastech Brasil
Plastech Brasil is one of the leading fairs in its category in Latin America. The fair will display the latest technology in the sphere of thermoplastics and thermosetting. The event enjoys the support of most of the representative entities in its industry. The event has parallel activities planned alongside the exhibition that include special lectures by internationally acclaimed guests and a fundamental course on safety in injector machines; August 27–30, 2013; at Centro de Feiras e Eventos Festa da Uva, Caxias Do Sul, Brazil For details contact: Plastech Brasil Rua Ítalo Victor Bersani, 1134 Bairro Jardim América 95050-520 - Caxias do Sul Rio Grande do Sul Brazil Tel: (54) 228.1251/8135.1182/8114.0013 Email: plastech@plastechbrasil.com.br Website: www.plastechbrasil.com.br
Philplas
Philplas 2013 is one of the biggest plastics machinery, equipment, tools, accessories, raw material, products and services exhibition in Philippines. The event will provide a perfect platform to meet professionals from the industry. Profile for exhibit includes auxiliary/ ancillary equipment, eco-friendly processing technologies, extruders & extrusion lines, injection & blow moulding machines; August 28–31, 2013; at World Trade Center Metro Manila, Manila, Philippines For details contact: Angie Barrios Mai Market Access & Innovations Management Philippines Unit 315-B, 3rd Floor LRI Business Plaza 210 Nicanor Garcia Street Makati City Manila, Philippines Tel: +63-2-8992642/8989272 Fax: +63-2-8982198
Asian-Pacific International Plastics & Rubber Industry Exhibition
Vietnam Plas
The 13th Vietnam International Plastics & Rubber Industry Exhibition is a premium exhibition providing the latest and the best in plastic materials for manufacturing and processing industries alike. The unique feature of this exhibition is the presence of the entire spectrum of plastic and rubber products manufacturers; September 3–6, 2013; at Saigon Exhibition & Convention Center (SECC), Ho Chi Minh City, Vietnam For details contact: Tracy Chan Chao International Co Ltd 3-F, No. 185, Kangchien Road Nei Hu District, Taipei, Taiwan Tel: +886-2-26596000 Fax: +84-2-827 9157
K 2013
H e ld a n n ua l l y, A sian -Pacific International Plastics & Rubber Industry Exhibition (APPLAS) is one of the important shows in the plastics and rubber industries. This is the 13th edition of the exhibition, which has developed into the most important event for plastics and rubber in China. It is also the only exhibition that is sponsored and supported by national authority organisations; September 3–6, 2013; at Shanghai New International Expo Centre (SNIEC), Shanghai, China For details contact: APPLAS Co Ltd (AP) 33, Xinhuangchenggen South Street Xincheng District Beijing, China Tel: +86-10-66039351/66039043
Fax: +86-10-66067681 Email: applas@applas.com
K 2013 is one of the world’s leading trade fairs for the rubber and plastics industries. This event has a record of bringing international exhibitors and trade visitors with great decision-making powers under one roof. This event covers the entire segment of the rubber and plastics industries from basic products and innovations to efficient high-tech solutions; October 16–23, 2013; at Dusseldorf Exhibition Centre, Dusseldorf, Germany For details contact: Messe Dusseldorf GmbH Stockumer Kirchstrasse, 61 Messeplatz Dusseldorf, Germany Tel: +49-211-4560900/4560175 Fax: +49-211-4560668/4560740 Email: k-online@messe-duesseldorf.de Website: www.k-tradefair.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
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EVENT REPORT: K 2013 Preview
Countdown to K 2013 begins
Demonstrating a dynamic, innovative and confident stance, members of the plastics and rubber industries have been working on their latest innovations to impress experts visiting the industry’s most important trade show K 2013 from 16 to 23 October 2013. Before this year’s K trade show, the organisers Messe Düsseldorf organised a special K 2013 Preview for select journalists in order to update them on the current state of affairs in the run up to K 2013. Sweta M Nair
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bout 3,100 exhibitors from all segments of the industry will present their latest developments at K 2013. The range of companies includes global players as well as start-up companies, and the products on show encompass standard polymers as well as highly specialised products such as tailor-made moulds. Among the exhibits are essentials for creating ideal production conditions such as industrial feedstock, machines and systems as well as complex solutions for diverse user industries. At the K 2013 Preview held in Düsseldorf, Germany, which took place from 1 to 3 July 2013, about 80 journalists with a special focus on the plastics and rubber industries from 90
Modern Plastics & Polymers | August 2013
more than 30 countries received an update on the current state of affairs in the run up to the trade show. The organisers of K 2013 informed their guests of the latest trends in the global plastics and rubber markets. Thirteen renowned exhibitors provided a preview of their trade show premieres that will be on display at the exhibition in Düsseldorf in October.
Bouncing back Although the economic conditions might not be very encouraging in Europe, where many countries are confronted with the Euro crisis, Ulrich Reifenhäuser, President, K 2013, is carefully optimistic. Despite the slightly upbeat verdict of the German Institut für Weltwirtschaft, which has currently detected a slight improvement in the
global economy, the predominant market dynamic seems slow and easily disrupted. “The present situation is very complex and hard to assess. Some global regions such as Japan show significant growth, others, like the US, are experiencing a slight recovery, and China is anticipating a 7 per cent rise of its economic growth rate for 2013, despite the general downward trend. Meanwhile, Europe’s economies remain weak. Nonetheless, the associations of the plastics and rubber industries are rather optimistic. We anticipate a stable year, at worst, a slight decline, but more likely some growth. We are convinced that K 2013, the most important trade show, will revitalise the industry. Thanks to the abundance of innovations presented in October in Düsseldorf, we are confident
K 2013 Preview
A session in progress
Journalists noting new developments
that the industry will experience a new impetus,” said Reifenhäuser. Among the companies from 60 countries, suppliers from Europe and particularly from Germany, Italy, Austria, Switzerland and France will again be out in strength. Particularly heartening is that the countries of southern Europe such as Italy, Spain and Greece – so strongly affected by the Euro crisis – will have a stable or even stronger presence at K 2013 than in 2010. A definite advantage for trade visitors from all over the world who do not have to miss out on the products and processes from these countries. At the same time, the situation presented at K 2013 provides a clear indication of the ongoing changes in the global market. Since the last K exhibition in 2010, the number of exhibitors from Asia and the overall area booked by Asian businesses have increased significantly. The net exhibition area of the largest five Asian exhibiting nations of China, Taiwan, India, Japan and South Korea has grown by almost one third (more than 25,000 sq m in 2013 compared to 18,000 sq m in 2010).
raw materials, processing and application technology than at the K trade show in Düsseldorf. “As always, the impressive number and international provenance of our exhibitors guarantee that all segments of the industry are represented at the world market level. They stand for a wide range of products and maximum innovation density. I am sure that many good deals will be made in Düsseldorf this year and that the specialist industry will see many new developments with potential for the future,” said Dornscheidt. At the K trade show, rubber is also a firm and indispensable element. Compared to the plastics industry, the rubber industry is rather small, but it is highly innovative and plays a major role for important consumer industries. The Rubber Street of Hall 6, a firmly established part of the K trade show in Düsseldorf, will comprise ten exhibiting companies. In the wake of the current trend, the rubber industry will not only exhibit traditional rubber types but also provide an insight into developments in the thermoplastic elastomer segment.
Current trends
The highly diversified product and service range presented by K exhibitors will be enhanced by a range of accompanying events, which promises additional benefits for visitors. Apart from the special show ‘Plastics move the world’, the premiere of
Werner M Dornscheidt, President and CEO, Messe Düsseldorf, is convinced that nowhere else in the world one receives such a comprehensive overview of the sheer variety and the complete range of
A glimpse of what is in store
the new Science Campus is well worth a visit. A new Innovation Compass, which shows a direct way to the highlights of all exhibitors, will help visitors navigate the abundance of new developments. It comprises a search matrix for innovations that introduce important improvements or even groundbreaking changes. The Innovation Compass will be made available on the K website about six weeks prior to the trade show and will allow visitors to prepare their personalised visit to the exhibition area in Düsseldorf. Although K 2013 has not yet started, the action behind the scenes is already well under way. In the run up to the event, visitors can access general information on the trade show’s official website. The preliminary list of exhibitors – updated daily – is one such feature of this diversified online service. News from the industry, new developments in different plastics-related research areas and links to specialist media and science institutes will also provide users with a leading information edge. With about 200,000 specialists from all over the world expected to visit K 2013 in Düsseldorf from 16 to 23 October 2013, the trade show will present the industry’s complete value chain, from raw material production to machine engineering, including a comprehensive overview of downstream equipment and processing systems. Email: sweta.nair@network18publishing.com
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EVENT REPORT: IPI Symposium on Resource Ef ficient Polymer Processing
Stressing on the optimum use of resources The Indian Plastics Institute (IPI) organised an informative symposium on ‘Resource Efficient Polymer Processing’ at the National Sports Club of India, Mumbai, on June 8, 2013. Marking IPI’s successful completion of 28 years of disseminating knowledge, information and manpower training, the symposium delved into ideas and views that will define the future path of the industry.
Guests of Honour releasing the souvenir to mark IPI Day
Sweta M Nair
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symposium on ‘Resource Efficient Polymer Processing’ that included informative and interesting lectures on topics related to energy savings and polymer processing was held on June 8, 2013, at the National Sports Club of India, Mumbai. N K Balgi, IPI Chairman, welcomed the guests Vimal Kedia, the Chief Guest, and Y R Anand, the Session Chairman, along with other dignitaries of the audience. He briefly described IPI and its significant role of spreading knowledge on plastics, including plastics’ benevolent role in the life of mankind. Besides, he shared his observation on the optimum use of resources to make production energy efficient. He pointed out that our per capita plastics consumption could be 14–15 kg instead of 8–9 kg for finished plastic goods.
Informative sessions Y R Anand, Managing Partner, Unimark, was the Session Chairman, and, being a professional from the field, conducted each session proficiently. Shirish V Divgi, MD, Ferromatik Milacron India Pvt Ltd, was the first speaker of the evening. He gave 92
Modern Plastics & Polymers | August 2013
Dignitaries on the dais during the symposium
an interesting presentation on ‘Resource Efficient Polymer Processing – Modern Trends in Injection Moulding’. The next speaker was Bhargav Joshi, DGM, Bosch Rexroth India. He gave an informative presentation on ‘Energy Efficiency UP, Unit Cost DOWN’. These were followed by sessions by Venkatraman Kannan, MD, Mold-Masters Technologies Pvt Ltd, who spoke on ‘The Coolest Way to Use Hot Runners – Efficient Use of Energy in Hot Runners’. Jayesh Mehta, Regional Manager, Sales & Marketing, Prasad Group, gave a presentation on ‘Innovative Solutions for Zero Waste in Plastics Processing by Auxiliary Equipment’. Ajit Patel, Manager, Technical Services PARC, Reliance Industries Ltd, delivered a lecture on ‘Innovations in Polymers & Additives – For Productivity Enhancement and Energy Savings’. The last session was presented by Shantanu Sharma, Area Manager – Industrial Lubricants, ExxonMobil Lubricants Pvt Ltd, who delivered a lecture on ‘A New Generation Energy-efficient Hydraulic Lubricant for the Injection Moulding Industry’. Every presentation was followed by a Q&A session. The symposium was attended by more than 150 participants who included both members &
non-members of IPI, special invitees, Chairmen & representatives from various chapters and former Presidents & Chairmen.
IPI Day celebrations The symposium coincided with celebrations of the institute completing 28 successful years. On this joyous occasion, Dr Y B Vasudeo, President, IPI, shared his vision for the institute with all the attendees. The inaugural address was followed by a speech from the Chief Guest Vimal Kedia, MD, Manjushree Technopack Ltd. He spoke on removing myths surrounding plastics and stressed that valuable positives of plastics should be highlighted to improve the image of the industry. Kedia also released the IPI Day souvenir. Imtiaz Ahmed, Regional Manager (West) – Industrial Lubricants, ExxonMobil Lubricants Pvt Ltd, was the Guest Speaker of the evening. He briefed participants about ExxonMobil, its activities and forecast on energy outlook for 2040. The event concluded with the IPI Award Function, where Francis Pinto, Past Chairman, IPI, and Kavita Shah, Director, Plastemart.com, announced the awards and read out the citations. Email: sweta.nair@network18publishing.com
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EOAT grippers for automotive industry
Parison controller
Neejtech India Ahmedabad, Gujarat Tel: 079-26561312, Mobile: 09825040231 Email: info@neejtech.com Website: www.neejtech.com
B&R Industrial Automation Pvt Ltd Pune, Maharashtra Tel: 020-41478999 Fax: 020-41478998 Email: sales.in@br-automation.com Website: www.br-automation.com
EOAT grippers are mainly used in the automotive industry for handling parts such as door trims, instrument panels, front & rear bumpers, lighting parts, spoiler, dashboard, floor carpet, fenders etc. EOAT grippers and spares are also used in glass & solar panel manufacturing industries for ease of handling. The EOAT system eliminates production part breakage, increases productivity, reduces cycle times, eases handling parts from inattentive areas and eliminates false operation of manpower. Large and complex EOAT systems can be built and spares are supplied.
The parison controller can be used as a part of full machine control or as a stand-alone control. This machine features ready-to-use application with help, alarms and I/O diagnostics with individual selection of neck cut de-flashing and left and right stations. Users can also develop total machine sequence control with precise parison controlling. The interlock selection is mounted directly on the panel. This machine is configurable as a stand-alone parison control with password-protected screens.
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PRODUCT S
Mini blow moulding machine
The mini blow moulding machine features fully automatic, semi and manual cycle options for simple and easy operations. It is fully pneumatic (no motor in the machine) and works on an air compressor, providing considerable power savings. The design is compact (space saving) with robust construction. For precise performance, it includes variable weight adjustment in the head for quick mould changes. The machine is fitted with a universal platen that accommodates bigger volume moulds, providing flexibility of producing a wide product range on the same machine (0.5â&#x20AC;&#x201C;200 ml). The machine operates on single and three phase, and it is ideal for entrepreneurs and rural area installation. With the benefit of low initial investment and low working capital, the mini blow moulding machine is suitable when starting a unit. The option of programmable logic controller/ microprocessor-based controls is also available.
Dave Technical Services Mumbai, Maharashtra Mobile: 9820606601, 9820699234, Fax: 022-29275639 Email: contact@davetechnical.com Website: www.davetechnical.com
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Ultimate light speed digital control technology
This 5th generation all-electric injection moulding machine has state-of-the-art light speed digital control technology. The CPUâ&#x20AC;&#x2122;s response speed is 55 microseconds, which is about 6,364 times faster than our eyes blink. The optical communication cables are applied in-between communication of servo amps. This drastically cuts the surrounding noise and prevents the machineâ&#x20AC;&#x2122;s false operation. Upgraded electrical devices increase the durability and operability for ultimate errorless control. Furthermore, light speed control (PAT.) for pressure feedback, tested to be the fastest feedback control system in the industry, is added to crank up the response time. Neejtech India Ahmedabad, Gujarat Tel: 079-26561312, Mobile: 09825040231 Email: info@neejtech.com Website: www.niigataindia.com
PRODUCT S
Viseal induction seal liners
Viseal induction seal liners are a range of induction heat cap seal liners that provide a hermetic seal and increase the storage life of the product. These induction seals are developed to be sealed onto the container mouth with induction sealing technology. Viseal induction seal liners provide customers with proof of tamper evidence and act to discourage pilferage. They can be printed or embossed on the surface and hence provide an ideal platform for further brand promotion and aesthetic appeal. All induction sealing materials can be divided into two components, viz base liners and sealing materials. These two components are wax laminated in two-piece induction seal liners and welded in one-piece induction seal liners. Sealing materials have aluminium foil available in thickness of as low as 9â&#x20AC;&#x201C;60 micron and a sealant as per the container requirement. The broadly used base lining materials in induction sealing are duplex board pulp board, folding box board/pulp board and expanded polyethylene foam. Vora Packaging Pvt Ltd Mumbai, Maharashtra Tel: 022-24012330 Fax: 022-24035297 Email: pankaj@vorapack.com Website: www.vorapack.com
Brush-making machine
This 3-axis, one filling, one drilling machine is ideal for making both household and industrial brushes. Industrial brushes usually require lower production but high quality and precision. This machine is an ideal choice for the brush industry because of its vast options and economical cost. Moreover, the filling can be from synthetic fibre, natural fibre, abrasive fibre or steel wire. All this is possible on the same machine by using the right kind of filling tool. In fact, several possibilities exist in offering customers a machine that makes rollers, discs, flat brushes and even special shapes as per customersâ&#x20AC;&#x2122; requirements. Borghi Brush Machinery Pvt Ltd Mumbai, Maharashtra Tel: 022-22006477/66346816 Fax: 022-22006556 Email: rajiv.satellite@gmail.com Website: www.borghiindia.com August 2013 | Modern Plastics & Polymers
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PRODUCT S
Masterbatches
A masterbatch is a concentrated mixture of pigments and/or additives encapsulated during a heat process into a carrier resin which is then cooled and cut into a granular shape. Masterbatches with a high concentration of pigments help provide good dispersion and prevent loss of mechanical, physical and aesthetic properties. The different types of masterbatches include additives masterbatch, flame-retardant masterbatch, ultravioletresistant masterbatch and mineral-filled masterbatch. These have properties such as excellent colour dispersion, light stability, no migration, good opacity and non-toxic for food & healthcare applications. They are applicable for extrusion coatings, woven tapes, agriculture & courier bags, profile and garden furniture. Welset Plastics / J&K Industries Mumbai, Maharashtra Tel: 022-28353586/28329031 Fax: 022-28382365 Email: jnkindustries@vsnl.net Website: www.jnk-welset.com
On-line pipe coder
The on-line pipe coder is ideal for automatic on-line coding on various types of tubes and pipes during their extrusion process. The message to be printed is easily composed by just assembling the stereos (easily changeable) on to the print wheel. The inking system consists of a rechargeable circular cartridge, which is fully enclosed, allowing the use of fast-drying and indelible solventbased inks. The whole assembly is directly mounted in front of the extruder where the extruded pipe passes over the rollers of the system. The programmable logic controller receives the signal from the digital encoder. It passes the signal to the DC stepper motor that turns the print wheel automatically at the synchronised speed with the pipe for the coding/printing after every preset distance.
Advanced Industrial Micro Systems Mumbai, Maharashtra Tel: 022-32964272/28766351/28756353 Fax: 022-28766352 Email: SamirGarg.AIMS@gmail.com/info@coding-india.com Website: www.coding-india.com/www.printpackaging.in
Hopper dryer
The SHD series ‘Standard’ hopper dryer offers an effective and low-cost method for plastic material drying. Hot air is used to dry wet materials during packaging, transportation and recycling cycles. The hopper dryer can be directly mounted on the moulding machine for quick drying and space saving. It adopts hot air diffuser to gain an even hot airflow from bottom to the top of the hopper with capacity ranging from 12 to 1,000 kg to improve drying efficiency. It adopts a heat-insulated blower to prolong its lifespan. An optional 24-hour timer is available for each model. Shini Plastics Technologies India Pvt Ltd Thane, Maharashtra Tel: 0250-3021166/88, Fax: 0250-3021100 Email: india@shini.com Website: www.shini.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 •Technologies•Opportunities
August 2013 | Modern Plastics & Polymers
97
An invite that rewards as well...
Dear Reader, Modern Plastics & Polymers solicits original, well-written, application-oriented, unpublished articles that reflect your valuable experience and expertise in the plastics & polymers industry. You can send us Technical Articles, Case Studies and Product Write-ups. The length of the article should not exceed 1,500 words, while that of a product write-up should not exceed 100 words. The articles should preferably reach us in soft copy (either E-mail or a CD). The text should be in MS Word format and images in 300 DPI resolution & JPG format. The final decision regarding the selection and publication of the articles shall rest solely with Modern Plastics & Polymers. Authors whose articles are published will be sent a complimentary copy of that particular edition. Published by Network18 Media & Investments Ltd, Modern Plastics & Polymers is one of the leading monthly magazines exclusively meant for producers and user fraternities of the plastics industry. Well supported by a national readership of over 80,000 and our strong network of 26 branch offices across India, this magazine reaches out to key decision makers among the Indian manufacturers of plastics products, machinery and allied sectors. Brought out in association with Hong Kong-based Ringier Trade Media Ltd (one of the world’s largest trade publishing houses with more than 200 special interest titles and offices in every major country), it ensures that advertisers are able to promote their products and services across the globe at no extra cost. So get going and rush your articles, write-ups, etc…
Yours sincerely,
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Senior Editor Modern Plastics & Polymers Network18 Media & Investments Limited ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W) Mumbai 400 028 India
D +91 22 3003 4669 T +91 22 3024 5000 F +91 22 3003 4499 E manas@network18publishing.com W www.network18publishing.com
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LIST OF PRODUCT S
Looking For A Specific Product?
Searching and sourcing products were never so easy. Just type MPP (space) Product Name and send it to 51818
eg. MPP Moulding and send it to 51818
Product
Pg No
Product
Pg No
Product
Pg No
AC / DC panel for pipe plant......................................73
Crystalliser............................................................................. 69
Flame retardant masterbatch.............................................. BIC
AC drive................................................................................. 43
Cylinder engraving - lenticular & optical roll mould............ 97
Fueling system........................................................................ 34
Acoustic enclosure............................................................. 11,47
Dehumidified dryer..................................................FIC
Fully automatic strapping plant............................................. 65
Additive master batch.................................................... 81,BIC
Dehumidifying air dryer...................................................... 107
Furnace................................................................................... 63
Air audits blower.................................................................... 34
Dehumidifying dryer.............................................................. 39
Gear pump............................................................... 108
Air bubble sheet plant............................................................ 65
Desiccant compressed air dryer.............................................. 61
Granulating & recycling........................................................ 77
Air compressor....................................................................... 63
Die face cutter........................................................................ 32
Granulator.............................................................. FIC, 69,107
Air cooled die face pelletiser.................................................. 18
Die plate................................................................................. 32
Granulator blade.................................................................... 32
Air treatment.......................................................................... 63
Digital panel meter................................................................ 12
Gravimetric blender............................................................. 107
Air-conditioning plant........................................................... 63
Digital temperature controller................................................ 94
Gun drilling process............................................................... 23
All electric machine............................................................... 21
Dosing & blending.................................................................. 6
Hdpe pipe plant..........................................................73
Aluminium die casting machinery diesel generator............... 63
Dosing & mixing................................................................... 77
Heart valve frame................................................................... 59
Automatic material handling system..................................... 18
Double column vertical machining centre............................. 45
Heat transfer rolls................................................................ 108
Automation.............................................................................. 6
Drive...................................................................................... 94
Heater cooler mixer............................................................... 18
Automation system................................................................ 77
Dry van pump................................................................... 11,47
Heating & cooling.............................................................. 6,77
Barrel....................................................................... 108
Dry-break coupling................................................................ 34
High cavitation...................................................................... 17
Barrels for plastic & rubber injection moudling.................... 23
Drying...................................................................................... 6
High performance screw...................................................... 108
Bed knife................................................................................ 32
Drying & dehumidifying....................................................... 77
High speed mixer.............................................................. 27,71
Black master batch.............................................................. BIC
Drymax air-hot air dryer.................................................... FIC
HM/HDPE/LDPE/LLDPE................................................ 65
Blender................................................................................ FIC
Drymax dryer...................................................................... FIC
Hopper loader...................................................................... 107
Blower series.......................................................................... 77
Drymax pet-dehumidified dryer......................................... FIC
Hot air dryer................................................................... 39,107
Blown film extrusion system................................................ BC
Dual channel with modbus.................................................... 94
Hot runner system................................................................. 77
Brush-making machine.......................................................... 95
Dynamic controller................................................................ 94
Hydraulic block...................................................................... 23
Carbon black..............................................................93
Ejector.......................................................................34
Hydraulic injection moulding machine.................................. 21
Cast film line......................................................................... 65
Electric injection moulding machine gearbox.......................... 7
Hydraulic piston ram............................................................. 23
CIM mould............................................................................ 49
EOAT grippers for automotive industry............................... 93
Hydraulic press....................................................................... 18
Clean room application.......................................................... 17
Evaporative cooling tower...................................................... 63
IML technique...........................................................17
Cleaning oven...................................................................... 108
Exhibition - plastivision 2013................................................ 52
Industrial coolers.................................................................... 63
CNC machine........................................................................ 45
Extruder machine.............................................................. 27,71
Injection mold........................................................................ 95
CNC vertical machining center............................................. 67
Extruder screw....................................................................... 32
Injection moulding machine................................. 5,25,75,FGF
Co-extruded sheets and telecom cable.................................. 29
Extrusion..........................................................................49,BC
Inline drip tubing.............................................................. 10,19
Colour masterbatch........................................................ 15,BIC
Extrusion coating lamination plant........................................ 65
Jumbo bag dumping station.........................................18
Compact chiller.................................................................... 107
Extrusion die............................................................................ 8
Lab extruder...............................................................18
Compressed air dryer............................................................. 69
Extrusion machinery.............................................................. 23
Lab mixer............................................................................... 18
Compressor............................................................................ 34
Extrusion system.................................................................. BC
Large flow water heater......................................................... 77
Conical twin screw extruder............................................. 16,18
Feed roll.....................................................................32
Liners barrel........................................................................... 20
Continuous screen changer.................................................. 108
Feeding & conveying........................................................ 69,77
Loader................................................................................. FIC
Conveying................................................................................ 6
Filler masterbatch.................................................................. 81
Loading arm........................................................................... 34
CPVC pipe........................................................................ 10,19
Film cutter............................................................................. 32
LSR machine......................................................................... 49
FGF - Front Gate Fold, FIC - Front Inside Cover, BIC - Back Inside Cover, BGF - Back Gate Fold, BC - Back Cover
102 Modern Plastics & Polymers | August 2013
LIST OF PRODUCT S
Product
Pg No
Product
Pg No
Product
Pg No
Manual & hydraulic screen changer.......................... 108
Pp/Hdpe raffia tape line........................................................ 65
Tank truck equipment.................................................34
Manufactures of cast film line, stretch,
Priming valve......................................................................... 34
Technical mould..................................................................... 17
cling masking, blister evt,& cpp film..................................... 14
Printing machine.................................................................... 49
Temperature controller...................................................... 12,94
Masterbatch............................................................... 29,97,BIC
Process controller................................................................... 12
Thermoformer...................................................................... BC
Masterbatch mixer................................................................. 18
Process machinery.................................................................. 63
Thermoforming.................................................................... BC
Material storage................................................................... 107
Profile controller..................................................................... 94
Thermoforming & PS foam................................................ BC
Medical mould....................................................................... 17
Pulvariser disc........................................................................ 32
Three arm bi-axial roto moulding machine...................... 27,71
Mfrs of co rotating twin screw extruder................................ 20
Pulveriser........................................................................... 27,71
Tie bar.................................................................................... 23
Mould repair.......................................................................... 97
Pump............................................................................ 11,34,47
Toggle injection machine....................................................... 21
Mould temperature controller................................................ 39
PVC compound..................................................................... 29
TPE/TPU compound......................................................... BIC
Moulding................................................................................ 17
PVC foam core pipe......................................................... 10,19
TPU masterbatch................................................................... 15
Monolayer blown film....................................................... 10,19
PVC mixer cooler............................................................. 10,19
Trade show organiser............................................................. 57
Monolayer blown film line................................................... BC
PVC palletising line.......................................................... 10,19
Transmissions & PTOS......................................................... 34
Mould................................................................................ 27,71
PVC pipe.......................................................................... 10,19
Twin - screw co-rotating extruder......................................... 59
Mould temperature controller.............................................. 107
PVC profile lines............................................................... 10,19
Twin - screw element............................................................. 59
MTC................................................................................... FIC
Recycled plastics granule............................................96
Twin mill pulveriser.......................................................... 27,71
Multi component mould........................................................ 17
Recycling.................................................................................. 6
Twin roll mill......................................................................... 18
Multilayer blown film.................................................10,19,BC
Resin dehumidifier................................................................. 69
Twin screw extruder gearbox................................................... 7
Multilayer blown film plant................................................... 65
Resin dryer........................................................................... 103
Twin screw extrusion line...................................................... 16
Napkin die..................................................................32
Robot................................................................................... FIC
Twin screw pipe plant for RPVC pipes................................. 73
Nitrogen generator................................................................. 61
Rock n roll machine.......................................................... 27,71
Twin screw side feeder etc..................................................... 20
Non phthalate plasticisers...................................................... 79
Roots blower..................................................................... 11,47
Two layer blown film........................................................ 10,19
On-line pipe coder......................................................97
Rotary cutter.......................................................................... 32
Two platen injection moulding machine............................... 21
Oxygen generator................................................................... 61
Rotary dies............................................................................. 32
Ultra sonic flow meter.................................................12
Paperless recorder.......................................................12
Round table carrousel............................................................. 27
Underwater pelletiser............................................................. 18
Parallel & right angle axes gearbox......................................... 7
Safety access equipment..............................................34
Universal controller................................................................ 94
Parison controller................................................................... 93
Segmented barrel.................................................................... 20
Universal masterbatch......................................................... BIC
Pelletiser.......................................................................... 32,108
Segmented screw.................................................................... 20
UV & PU masterbatch....................................................... BIC
Pelletiser part.......................................................................... 32
Servo energy saving machine................................................. 41
UV masterbatch..................................................................... 81
Pet box strapping plant.......................................................... 65
Servo system........................................................................... 43
Vacuum booster pump............................................ 11,47
Pet master matches............................................................. BIC
Shut off nozzle..................................................................... 108
Vacuum dryer......................................................................... 39
Pet perform dedicated machine............................................. 41
Single bag feeding system...................................................... 18
Vacuum forming machine.................................................... BC
Petline injection moulding machine...................................... 21
Single mill pulveriser......................................................... 27,71
Vacuum pumps & system...................................................... 34
Plastic conveyor belt............................................................... 27
Single screw extruder............................................................. 18
Vacuum system.................................................................. 11,47
Plastic machinery................................................................... 63
Single screw extruder gearbox.................................................. 7
Variable displacement pump energy-saving machine............ 41
Plastic masterbatch................................................................ 33
Single screw extruder plant.................................................... 16
Vertical machining centre...................................................... 45
PLC ...................................................................................... 94
Single screw pipe plant for RPVC........................................ 73
Vibro screen...................................................................... 27,71
PLC and HMI....................................................................... 43
Software for central monitoring............................................ 69
Viseal induction seal liners..................................................... 95
Polyolefin pipe................................................................... 10,19
Stack mould........................................................................... 17
Volumetric dosing unit........................................................... 69
Power generator shaft............................................................ 23
Storage tank equipment......................................................... 34
Water chiller...............................................................69
Pp glass filled compound.................................................... BIC
Strand pelletiser..................................................................... 18
Water jetting.......................................................................... 34
Pp mineral filled compound............................................... BIC
Stretch.................................................................................... 14
WFR................................................................................... FIC
Pp -r pipe.......................................................................... 10,19
Submicron filter..................................................................... 61
White masterbatch......................................................... 81,BIC
Pp tq plant............................................................................. 65
Switch gear............................................................................. 43
Wire EDM............................................................................ 67
Pp/ Hdpe-semi automatic strapping plant............................ 65
System solution...................................................................... 77
FGF - Front Gate Fold, FIC - Front Inside Cover, BIC - Back Inside Cover, BGF - Back Gate Fold, BC - Back Cover
104 Modern Plastics & Polymers | August 2013
LIST OF ADVERTISERS Advertiser’s Name & Contact Details
Pg No
Advertiser’s Name & Contact Details
Pg No
Advertiser’s Name & Contact Details
Pg No
Aerodry Plastics Automation Pvt Ltd............... 6
Everest Blowers Systems .......................... 11, 47
T: +91-120 4766777
T: +91-11-45457777
E: info@aerodry.com
E: info@everestblowers.com
T: 86-10-5900-3588
W: www.aerodry.com
W: www.everestblowers.com
E: jingcheng_times@vip.163.com
All India Plastics Mfrs Association................ 52 T: +91-22-28217324 E: pvi13@plastivision.org W: www.plastivision.org Alok Masterbatches Ltd................................ 15 T: +91-011-41612244 E: sales@alokindustries.com W: www.alokmasterbatches.com Blend Colours Pvt Ltd................................ BIC T: +91-40-2436 1499 E: info@blendcolours.com W: www.blendcolours.com Bry-Air (Asia) Pvt Ltd..................................103 T: +91-011-2390677 E: bryairmarketing@pahwa.com W: www.bryairsystems.com C & G Extrusion Machines........................... 73 T: +91-9272235867 E: cgext@hotmail.com W: www.cgext.com CJ Shah & Co............................................... 79 T: +91-022-43436969 E: mkmishra@cjshahgroup.com
Continental Carbon India Ltd....................... 93 T: +91-120-6721200 E: rkatiyar@continentalcarbonindia.com W: www.continentalcarbonindia.com
Ferromatik Milacron India Pvt Ltd................ 21 T: +91-79-25890081 E: salesfmi@milacron.com W: www.milacronindia.com
Jingcheng Times (Beijing) Plastics Machinery Co Ltd............................................................ 8
W: www.jc-times.com Jyoti CNC Automation Pvt Ltd..................... 45 T: +91-2827-287081 E: info@jyoti.co.in
Gardner Denver Engineered Pro. (I).............. 34
W: www.jyoti.co.in
T: +91-79-40089312
Kabra Extrusion Technik Ltd......................... 10
E: info.ahm@gardnerdenver.com W: www.gardnerdenver.com
T: +91-22-2673 4822 E: sunil@kolsitegroup.com
Gem Equipments Ltd.................................... 63
W: www.kolsite.com
T: +91-0422-2363800
Kabra Extrusion Technik Ltd......................... 19
E: sales@gemindia.com
T: +91-22-2673 4822
W: www.gemindia.com
E: sunil@kolsitegroup.com
Glaves Innovations Pvt Ltd........................... 32
W: www.kolsite.com
T: +91-141-2460324,
Karan Engineering Co................................... 49
E: sales@glaves.biz, axj@glaves.biz W: www.glaves.biz Hindustan Plastic and Machine Corporation... 16 T: +91-011-25473361
T: +91-022-40214997 E: sundaram@karanengineers.com W: www.karanengineers.com Konark Plastomech Pvt Ltd........................... 65
E: poonam@hindustanplastics.com
T: +91-79-22891670
W: www.hindustanplastics.com
E: sales@konarkplastomech.com
Indo-Tech Engineers..................................... 23 T: +91-79-22870368
W: www.konarkplastomech.com Korea Trade Centre (Kotra)............................. 5
E: info@indotechengineers.com
T: +91-9810043265
W: www.indotechengineers.com
E: in@wjpin.com; greenyc@wjpim.com
J P Extrusiontech Ltd.................................... 14 T: +91-2646-222163
W: www.plaimm.com Larsen & Toubro Ltd.................................... 43
E: info@jpel.in
T: +91-022-67525733
W: www.jpel.in
E: jm.ccd@lth.ltindia.com
Jacobsen Lenticular Tool & Cylinder Engraving
W: www.lntebg.com
Engineering Expo.........................................101
Technology Co ( Jaco Tech)............................ 97
Matsui Technologies India Ltd...................... 39
T: +91-09819552270
T: 1-630-467-0900
E: engexpo@infomedia18.in
T: +91-0120-4243862
E: gj@jacotech.com
E: rahuldeep@mass.motherson.com
W: www.engg-expo.com
W: www.jacotech.com
W: www.matsuiindia.com
Our consistent advertisers
FGF - Front Gate Fold, FIC - Front Inside Cover, BIC - Back Inside Cover, BC - Back Cover
August 2013 | Modern Plastics & Polymers 105
LIST OF ADVERTISERS
Advertiser’s Name & Contact Details
Pg No
Advertiser’s Name & Contact Details
Pg No
Advertiser’s Name & Contact Details
Pg No
Messe Dusseldorf GmbH.............................. 57
Piovan India Pvt Ltd..................................... 69
Shini Plastics Technologies I Pvt Ltd............. 77
T: 49-211-4560-01
T: +91-22-27782367
T: +91-250-3021166
E: k-online@messe-duesseldorf.de
E: amit.bajaj@piovnindia.com
E: jnbhat@shiniindia.com
W: www.k-online.de
W: www.piovan.com
W: www.shini.com
Mifa Systems................................................. 94
Prasad Koch Technik Pvt Ltd......................... 27
Specific Engineering..................................... 20
T: +91-79-26870825
T: +91-79-25830112
T: +91-265-2646871
E: info@mifasystems.com
E: plastics@prasadgroup.com
E: info@specificgroup.com
W: www.mifasystems.com
W: www.prasadgroup.com
W: www.specificgroup.net
N.A. Corporation.......................................... 71
Prayag Polytech Pvt Ltd................................ 33
Sri Sai Plasto Tech........................................ 41
T: +91-79-25840374
T: +91-011-47262000
T: +91-044-42994365
E: info@naroto.com
E: delhi@prayagmb.com
E: sspt_plastics@live.in
W: www.naroto.com
W: www.prayagmb.com
W: www.srisaiplastotech.com
Neejtech India (Braunform)........................... 17
Prism Design and Tooling Technology Pvt Ltd..... 95
Steer Engineering Pvt Ltd............................. 59
T: +91-79-26561312
T: +91-2114-661003
T: +91-80-23723309
E: info@neejtech.com
E: aditya@prismtooling.net
E: info@steerworld.com
W: www.neejtech.com
W: www.prismtooling.net
W: www.steerworld.com
Neejtech India (Niigata)................................ 25
Procon Technologies Pvt Ltd......................... 12
Superpack (A Divn. Of Bajaj Steel Ind Ltd)...... 81
T: +91-9909974224
T: +91-79-27492566
T: +91-0712-2720071
E: contact@niigataindia.com
E: info@procon.co.in
E: superpackmb@bajajin.com
W: www.niigataindia.com
W: www.procon.co.in
W: www.superpackmb.com
Neoplast Engineering Pvt Ltd....................... 18
Rajoo Engineers Ltd....................................BC
Toshiba Machine (Chennai) Pvt Ltd.......... FGF
T: +91-79-40194030
T: +91-2827-252701
T: +91-044-26812000
E: info@neoplastindia.com
E: kcdoshi@rajoo.com
E: handigolg@toshiba-machine.co.in
W: www.neoplastindia.com
W: www.rajoo.com
W: www.toshiba-machine.co.in
Nidhi Enterprises.......................................... 96
S&T Engineers............................................. 67
Trident Pneumatic Pvt Ltd............................ 61
T: +91-9999214040
T: +91-422-2590810
T: +91-422-2400492
E: nikhil@nidhienterprises.net.in
E: stycm@stengineers.com
E: sales@tridentpneumatics.com
W: www.nidhienterprises.net.in
W: www.stengineers.com
W: www.tridentpneumatics.com
Nordson X-Aloy Asia (Thailand) Ltd............108
Sacmi Engineering India Pvt Ltd................... 75
Wittmann Battenfeld India Pvt Ltd.............FIC
T: +91-79-40327380
T: +91-7600003968
T: +91-044-42077009
E: m.sanghvi@th.xaloy.com
E: sales@negribossi.in
E: info@wittman-group.in
W: www.xaloy.com
W: www.negribos3si.com
W: www.wittmann-group.com
Nu-Vu Conair Pvt Ltd..................................107
SCJ Plastics Ltd............................................ 29
T: +91-9376783206
T: +91-011-25439950
T: 39-0331-307-616
E: salesindia@conairgroup.com
E: vball@scjgroup.net
E: info@zambello.it
W: www.conairgroup.com
W: www.scjindia.com
W: www.zambello.it
Our consistent advertisers
106 Modern Plastics & Polymers | August 2013
Zambello Riduttori Group.............................. 7
FGF - Front Gate Fold, FIC - Front Inside Cover, BIC - Back Inside Cover, BC - Back Cover
August 2013
110
Modern Plastics & Polymers
Reg No: MH/MR/WEST/234/2012-2014 RNI No: MAHENG / 2008 / 25265 Licence to Post 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 Previous Month.