Modern Plastics & Polymers - April 2012 by Infomedia18

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EDITORIAL

Budget blues

s the Indian economy really in dire straits or are we pressing the panic button too soon? Union Budget 2012-13, far from taking any bold step to revitalise the Indian growth engine, turned out to predominantly prefer the status quo of the current policy regime. No doubt, it has left a bitter taste even in some of the most optimistic industry observers, who have been hoping to see some economic acceleration to offset the India-bound headwinds from Europe. Call it a missed opportunity or, a cautious approach, this year’s Budget is way off target from the industry’s expectations in terms of reversing the slowing pace of growth by virtue of big-ticket reform mechanisms. Rather, the government seems to have settled for a guarded step towards shoring up weak investment sentiments and unveiling only a handful of anti-deficit measures comprising a hike in the service and excise taxes. That said, the immediate future of the country’s economy does not seem very bright. According to Moody’s, in the absence of new policy initiatives, it will take a combination of improved economic growth, corporate profitability, lower global commodity prices and exchange rate stability to meet the government’s fiscal deficit target in 2012-13. In the absence of any elaboration by this Budget on measures to cap the centre’s subsidy spending to 1.7 per cent of gross domestic product in the next three years, it further observes that unless subsidy cuts and fuel price increases are introduced in the next few months, expenditure targets are likely to exceed again in fiscal 2012-13.

Editorial Advisory Board A E Ladhabhoy Plastics Technologist

Dr Sushil K Verma Former Director General, CIPET

If that is not all, the budgetary proposal to amend the Income Tax Act with retrospective effect has, perhaps, made the biggest dent in the long-term fiscal credibility of the India story, not only outside but within the country as well. This has come as a bolt from the blue when the national economy is pitted against tapering growth on one hand and growing maturity of Indian manufacturing on the other, and hence, a rising confidence in higher foreign investment flow into this domain. Given this scenario, the need of the hour is to exercise ample jurisprudence and ensure that the Indian growth juggernaut continues its growth momentum.

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

Mohan K Jain MD, Indoplast & Past President, AIPMA

Manas R Bastia manas@infomedia18.in

P P Kharas Chairman, Ecoplast

Raman M Patel Chairman, Industrial Products Mfg Co

Vijay Merchant President, Polycraft

April 2012 | Modern Plastics & Polymers

CONTENT S

Injection moulding ................32

Special Focus

Engineering plastics ................................... 52

Robotics in

Innovation edge...................................... 56

injection moulding ................36 PLC-based moulding techniques .............38 Interface: Harminder Singh .......42

Insight & Outlook

Helmut Heinson ........44 February 2012 | Modern Plastics & Polymers

Interface: Raju Desai.................................. 58 Shamik Shah.............................. 60 Sanjay Jain.................................. 62 QRST method ....................................... 64

Roundtable ............................46

Post-Budget 2012 Taking cautious steps towards growth

Automation Trends

Automatic die changers: Steering the manufacturing might

Energy Management

Hybrid machines: Analysing the cost-quality ratio

Policies & Regulations

Expansion projects: Achieving economy of scale with industry-friendly policies

Strategy

Plastic products recycling: Focussing on the economics angle

In Conversation With

Tips & Tricks

Purchasing used injection moulding machinery: Guidelines to strike the right deal

K R Bhuva, CMD, Polymechplast Machines Ltd

Quadrant EPP Surlon India Ltd: Engineering complete solutions under one roof

Event Preview

Die & Mould India 2012: Gearing up for global opportunities

Event Focus: Chinaplas 2012

86 88 90

Event Preview: Heralding unlimited opportunities In the News Product Showcase

Event Report

108

Engineering Expo Aurangabad 2012: Creating yet another success story

Highlights of Next Edition Special Focus: Rotomoulding Insight & Outlook: Plastics in Building & Construction

Facility Visit

REGU L AR SEC T ION S Editorial ................................. 9

Event List............................. 82

News, Views & Analysis ...... 20

Book Review ...................... 111

Technology & Innovation .... 24

List of Products.................. 112

Projects ................................. 80

List of Advertisers .............. 118

Cover photo courtesy: BASF Note: ` stands for Indian rupee, $ stands for US dollar and ÂŁ stands for UK pound, unless mentioned otherwise

April 2012 | Modern Plastics & Polymers

Business Insights •Technologies•Opportunities

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April 2012 | Modern Plastics & Polymers

NEWS, VIEWS & ANALYSIS

Ferromatik Milacron India focusses on futuristic injection moulding solutions

Leading injection moulding machinery manufacturer Ferromatik Milacron India (FMI) had exhibited six live injection moulding machines at Plastindia 2012. FMI believes that innovation is the key to future, and the new machines are built using newer & advanced technologies such as allelectric, two-platen servo, hydron servo, servo pack toggle & hydraulic systems. Key attractions of these technologies are precision and energy savings due to servo technology, Process and Data Analysis (PDA) & higher speeds with fast cyclic with multi-cavity mould. The FMI stall at Plastindia 2012 had the theme ‘One Dream Go Green’, which emphasised on servo drive of injection moulding machines and solutions such as green engagement & green communication. Shrish Divgi, Chief Operating Officer, Ferromatik Milacron India Pvt Ltd, said, “African countries are really growing, particularly those in West and East Africa. These solutions will benefit our domestic customers as well as plastics industry in Africa, which is oriented towards the household and furniture industries. We have recently observed many upgraded activities in other sectors as well.” Annabel Dsouza

PVC price rise in Southeast Asia due to soaring demand Polyvinyl Chloride (PVC) has seen prices hike in Southeast Asian countries with many regional producers up-adjusting their local and export offers. Besides the push from higher input costs, healthy demand from the region has given sellers real support to ask for increases. Also, many buyers find

Modern Plastics & Polymers | April 2012

Intercontinental to build compounding plant in India Indian-American joint venture compounder Intercontinental Polymers Pvt Ltd is building an engineering resins compounding plant in Dahag, Gujarat. The plant will have a production capacity of 44.1 million pound per year, and is aimed at both the country’s growing automotive industry and opportunities to switch conventional metal products to plastics. The new facility will be a tenfold increase in capacity for the company, which is a joint venture of Intercontinental Export Import Inc, in Columbia, and Indian injection moulder, toolmaker and design house Jyoti Plastic Works Pvt Ltd.

The factory will target exports to the US and Europe, where Jyoti has sales offices, and also India’s market for moulded parts made from engineering plastics. “Jyoti is also planning to build a 100,000-sq ft mould making facility on the Khadki campus, targeting export of tooling to western markets,” said Raju Desai, Director, Jyoti Plastic Works Pvt Ltd. The Dahag plant will have four twin-screw extrusion lines, with the equipment likely coming from Western machinery suppliers because the company wants to be able to supply global firms as well. Anwesh Koley

LANXESS to unveil world’s largest Nd-PBR plant in Singapore LANXESS will break ground for its new Neodymium Polybutadiene Rubber (Nd-PBR) plant in Singapore this year. The German specialty chemicals company will invest about € 200 million (SGD 337 million) in a 140,000 metric tonne per annum facility in Jurong Island Chemical Park. The facility will be the largest of its kind in the world and serve the growing market for ‘Green Tyres’, especially in Asia. The plant is expected to start up in the first half of 2015. Engineering work is on-going. The company has received all the necessary internal approvals for the project. “I am pleased to announce that it is now full steam ahead for the second largest investment project domestic prices more competitive and prefer to meet their requirements from their local markets. In Indonesia, local PVC prices have also gone up by $ 50-70 per tonne. Sumit Dhingra, Director, Dhingra Polymers, said, “Now that the demand is improving and supply appears to remain limited in line with the tight availability of Vinyl Chloride Monomer (VCM)

Dr Axel C Heitmann

in our company’s history,” commented Dr Axel C Heitmann, ChairmanBoard of Management, LANXESS. He added, “This announcement falls in our company’s Year of ‘Green Mobility’. The company’s focus on innovation and technology makes it possible to reduce rolling resistance in tyres, and thereby decrease fuel consumption. This is good news for the consumer as well as the environment.” feedstock, the PVC market is likely to maintain its firm trend for a while. Demand has improved in the local market, and we are receiving more inquiries from buyers.” The industry believes that this price rise is due to strong local demand and high feedstock costs, which have also resulted in a tight supply. Anwesh Koley

NEWS, VIEWS & ANALYSIS

Negri Bossi appoints Plastigo as distributor in Poland

Negri Bossi has appointed Plastigo as its exclusive distributor in Poland. Plastigo will offer six injection moulding machine ranges made by Negri Bossi. These include Vesta (a range of full electric machines of 70850 tonne), EOS (a hydraulic technology machine that sets a new record in terms of compactness), Canbio (a range of fully digital, hydraulic machines of 55-530 tonne), Canbimat (a range of multi-material machines with solutions for up to 6 injection units), Vector (a range of hybrid machines of 700-1500 tonne) and Janus (a range of hybrid machines of 160-850 tonne). The Polish company will also provide warranty and post-warranty maintenance services for Negro Bossi’s machines. “Negri Bossi is one of the most widely recognised brands in the European injection moulding machine market. With the introduction of Negri Bossi’s injection moulding machines to its product range, Plastigo aims to target the premium segment of the Polish plastic injection moulding market,” said Asteniusz Mysliwiec, Chief Executive, Asten Group (Plastigo’s parent company). Avani Jain

Vinyl India 2012 to showcase growth prospects in the industry The Indian vinyl chain and chloralkali markets are currently at an exponential growth curve owing to robust demand from agriculture, housing and infrastructure sectors. The vinyl and chloralkali industry is forecast to cross $ 8 billion by 2015. In this backdrop, Vinyl India 2012 brings together industry leaders and specialists to examine the growth trends in this industry. Vinyl India 2012 22

Modern Plastics & Polymers | April 2012

KREYENBORG Group invites for 6th ‘plastics processing’ symposium ‘New trends in the plastics industry’ is an exciting topic for KREYENBORG Group’s symposium, which will be held during May 9-10, 2012, in M u e n s t e r / We s t p h a l i a , Germany. Global competition in the development of plastic applications puts companies from the plastics industry constantly under pressure to improve their technical know-how and develop new solutions. At the symposium, a panel of Keynote speakers will give a hint of the ‘future’, present new ideas and develop these through discussions with many key industry executives. The guest speakers of the industry will give a precise idea of the latest trends in plastics processing in terms of dosing, compounding, extrusion or filtration technology. The symposium will provide insights into KREYENBORG Group’s solutions, new developments and related possibilities for process technology. Participants can see demonstrations of the company’s own laboratory line and participate in open discussions. Some of the leading companies participating in the event include BASF, Starlinger & Co, FraunhoferInstitute, Reifenhäuser Extrusion, among others. will be held on 12-13, April 2012, at Hotel Grand Hyatt, Mumbai. Key highlights of the conference are: Future potential of PVC in India Feedstock to polymer Machinery– compounding, processing & material handling Health, safety and environment Opportunities for China– India collaboration PVC innovations in pipe sector There will be an exclusive dinner speech

Fabian Spitzner now heads sales and marketing at UNICOR GmbH

Fabian Spitzner

The international sales and marketing operation of UNICOR GmbH of Hassfurt, Germany, is now headed by a new sales manager. Fabian Spitzner is the new marketing director at UNICOR, succeeding Volker Sprenger. Spitzner is known in the market as an expert with extensive experience in corrugated pipe plants. Until 2010, he was leading the marketing staff at FRÄNKISCHE in the machinery division. When the corrugator operations of FRÄNKISCHE were taken over by UNICOR, he moved to Hassfurt as Regional Sales Manager at UNICOR, with emphasis on the Balkans, Turkey and the Middle East. Since January 2012, he is heading the global marketing of corrugators of UNICOR GmbH. He has particular experience in the marketing of hi-tech corrugators, which UNICOR manufactures and sells since the machinery division of FRÄNKISCHE was taken over by UNICOR. on understanding ‘Anti-dumping duty’ by eminent experts from the Commerce Ministry and the legal fraternity. Some of the leading industry leaders addressing this conference will be S S Naik, Senior Vice President, Reliance Industries Ltd; Dr Rajiv Kumar, Secretary General, Federation of Indian Chambers of Commerce and Industry; and Dr Ranjit Date, President & Joint Managing Director, Precision Automation Robotics India Ltd. Annabel Dsouza

TECHNOLOGY & INNOVATION

H-PET AE preform manufacturing solution by Husky

Husky’s H-PET All-Electric (AE) preform manufacturing solution is a 32-cavity H-PET AE 180 work-cell that produces a 19-gm EcoBase™ preform for a 1 litre still water bottle application. The H-PET AE system is an efficient, affordable solution for the lower volume preform market that offers customers exceptional value and a high level of quality. H-PET AE is an energy-efficient, flexible, easy-to-use system and has low maintenance requirements. As a complete solution, H-PET AE includes a fully integrated resin dryer, mould dehumidifier and a complete work-cell infrastructure package consisting of both water and electrical distribution as well as a mezzanine. Its tight process controls and accurate mould tolerances, together with Husky’s EcoBase preform design, result in preforms that are up to 2.5 per cent lighter than other lightweight performs. These features also allow moulders to benefit from additional resin savings.

New resin technology from Asahi Kasei Plastics Asahi Kasei Plastics has developed new resin technologies and capabilities resulting in new, improved eco-friendly products. The Xyron™ PV Grades are Modified Polyphenylene Ether (mPPE) for solar panel components. It is compliant for Underwriters Laboratories Inc (UL) and International Electrotechnical Commission (IEC) requirement with 24

Modern Plastics & Polymers | April 2012

Clariant introduces pigments for new colour opportunities Clariant has introduced three azo pigments that offer new opportunities for designers and producers of plastic products in India. The first of the new pigments is PV Fast Red HGR – a High-Performance AZO Pigment with Color Index Pigment Red (PR) 285. This mid-shade red pigment displays a high light fastness and excellent heat stability. Due to its low warping properties and Food and Drug Administration (FDA) compliance, this pigment is suited for food packaging applications. When used in combination with PV Fast Yellow HGR (PY 191), which has similar properties, it provides new opportunities to match

brilliant, economical orange shades. New PV Fast Yellow H4G – Color Index Pigment Yellow (PY ) 151 – is a greenyellow pigment that offers an excellent alternative to inorganic pigments. PV Fast Yellow H4G displays high light fastness and good heat stability. For producers looking for a bright red shade of orange, there is PV Fast Orange H2GL – Color Index Pigment Orange (PO) 64. This brilliant, pure orange pigment has excellent overall properties for colouration of polyolefins, Polyvinyl Chloride (PVC) as well as polystyrene and other select polymers. With its FDA compliance, PV Fast Orange H2GL opens up numerous possibilities for applications in food packaging and consumer goods.

New extruder series by battenfeld-cincinnati battenfeld-cincinnati has introduced a new extruder series solEX and twinEX. The solEX is a series of high-performance 40D single-screw extruders for Polyethylene (High Density) (PE-HD) and Polypropylene (PP) pipe extrusion, and is available in five sizes with screw diameters in the range of 45-120 mm. An outstanding feature of these extruders is high output with low melt temperature. solEX extruders are equipped with a powerful, highly efficient drive train and an optimised processing unit that enable reduction of energy consumption by about 15 per cent. The extruders reach such high throughput levels with excellent melt homogeneity that the next smaller

diameter machine model can be used to reach the same performance level as by conventional 30D extruders. The twinEX series of parallel twinscrew extruders consists of four machines in size range 78-135 mm and is ideal for the production of pipes and profiles. The extruders require approximately 15 per cent less specific energy input with simultaneous increase in output as compared to other counter-rotating twin-screw extruders.

non-halogenated flame-retardants. These grades carry UL’s 5VA and V-0 certifications. The next is Leona™ LG - Polyamide (PA)66 and PA 66/6I with long glass fibres for applications requiring high performance, ie, superior fatigue and creep resistance, modulus greater than 20 GPa with good surface finish or flame-retardant grades with excellent impact strength. The Thermylene® P9 is a short-glass-fibre polypropylene with

higher temperature resistance for Nylon alternative. Its applications include airintake manifolds and other automotive under-the-hood automotive components. This material facilitates weight reduction strategies of 15 per cent or higher. Thermylene® P8 is a glass-reinforced grade with advanced coupling technology as an alternative to long-glass-fibre polypropylene. This grade is commonly used in door modules, motor housings, sunroof frames, shifter bases, etc.

IN CONVERSATION WITH: K R Bhuva

“Compact and

high-speed machines are the need of the hour” …opines K R Bhuva, Chairman and Managing Director, Polymechplast Machines Ltd. In an exclusive interaction with Avani Jain, he underlines that quality has taken precedence across all sectors. Besides, he believes that the increasing demand for plastics in the automobile segment will further drive the growth of the injection moulding machinery market.

Modern Plastics & Polymers | April 2012

K R Bhuva

What are the key demand drivers influencing the growth of injection moulding machines? The demand for injection moulding machines is about 7,000 machines per year. Many new companies are setting up their operations in India and the existing ones are expanding their businesses, and this has given a boost to the industry. In addition, the growth of the automotive industry in the country has increased the demand for injection moulding machines. The increased usage of plastics in all sectors such as construction, electrical and electronics, household, surgical, cosmetics and packaging has also enhanced the demand for these machines.

What technological advancements has the industry witnessed over the years? The industry is gradually moving towards complete automation. Compact and high-speed machines with reduced energy consumption have become the need of the hour and technology is being developed to ensure the same at a reasonable price. Over the last 10 years, the power consumption by machines has been reduced by more than 50 per cent. Earlier, the machines came with analog control but, today, digital controls that ensure high precision are being used.

updating their technology on a regular basis. We are also working towards reducing the cycle times and power consumption, while increasing the speed of machines. The use of servo motors and efficient controls has helped to a large extent in this regard. We use variable displacement pumps and servo motors in the machines, which reduce energy consumption considerably. We also try to avoid environment pollution and improve waste reduction. We manufacture our components such that raw materials are optimally used and nothing goes waste.

What are your growth plans for the company? We are currently producing 200-250 sets per annum and want to expand this to about 500 machines per year. We are aiming to produce higher tonnage machines. In future, we want to manufacture all-electric machines as well.

How has been your journey so far? What are the challenges faced by the industry? The industry faces a number of challenges. The first is competition from oversees manufacturers in terms of volume and cost. Second, the cost of raw material in India is continuously increasing, and this presents a major hurdle for the industry. Third is the fluctuation in the cost of petroleum products. Since plastics is made from petroleum, the rise in petroleum price makes plastics processing and consumption expensive, and this, in turn, affects the machinery manufacturers. A related cause is the heavy fluctuation in currency exchange rates, which is affecting the imports and exports. Further, government policies are not in favour of the plastics industry, and hence it faces a lot of restrictions.

How has the machinery quality improved over the years?

What are the opportunity areas?

Today, quality has become the top priority for all companies, small or large. A decade ago, the scenario was different, as there were only few companies and customers had no choice. But today, with the advent of several processors in the segment, even the small companies have to make quality machines as otherwise their business will not flourish.

People are increasingly switching to plastic products since these are light in weight but offer the same strength as provided by other materials such as wood or metal. Plastics also has an aesthetic value. Thus, there seems no replacement for plastics for the next few decades. The increase in preference for plastic products will boost the processing machinery industry.

How does Polymechplast achieve sustainability in its operations?

What is your outlook for the overall Indian plastics processing machinery?

Sustainability is an ongoing process. The world over, industries are making efforts to reduce their energy consumption and ensure high production efficiency by

developed countries. Thus, the plastics industry and its allied machinery manufacturing industries have a bright scope in the future.

The future of this sector is bright since in India, the per capita consumption of plastics is less as compared to that in

My career in this profession has been a mix of numerous challenges and some major successes as well. So, overall, my journey has been quite satisfactory.

What was the toughest business decision you ever made? Leaving the earlier job and entering into this business was the toughest business decision I have ever made. We had started at a small level, but we took that chance and succeeded.

What are the things you consider while starting something new? You need to check every aspect before taking a decision, for example, whether the new venture will be profitable for your business, will it help sustain your business in the long run and open new opportunities in the future.

What is the business etiquette that you value the most? There must be transparency and honesty in your actions. There is no shortcut to this. Further, one should always try and be simplistic in their approach, as this will go a long way in defining your path of success.

Your message to aspiring and upcoming entrepreneurs in this domain... The aspiring entrepreneurs should take time in selecting the type of work they want to do and they should enjoy it. They must love their work in order to attain success. Email: avani.jain@infomedia18.in

April 2012 | Modern Plastics & Polymers

POST-BUDGET 201 2

Taking cautious steps towards growth The Union Budget 2012 has evoked mixed reactions across the nation’s manufacturing and business fraternity. With emphasis on driving domestic demand and reviving private investment, the Finance Ministry had provided several opportunities for the plastics processing sector. Here are some critical insights into the Budget’s offerings for growth of the plastics industry.

Ashok Goel, President, Plastindia Foundation Against the backdrop of global economic and political instability, the Union Budget’s Gross Domestic Product (GDP) growth estimate of near 6.9 per cent is good but still below expectation. But, this consumption-driven growth may not be sustainable in the long run unless accompanied by investment-driven growth. The fiscal deficit target of 5.1 per cent and central subsidies under 2 per cent of GDP for 2012-13 and the Government’s intentions to further reduce these have steered clear of populist measures. The Budget endeavours to shore up investment in infrastructure

Rajeev Arora, Vice President & Business Head, Shriram Polytech This Union Budget can be termed as neutral. The excise duty has been increased, but the increase in service tax will add to industrial expenditure and is a growth dampener. Growth comes from the availability of funds, but for manufacturers, a rise in cost cannot be entirely passed on to the customers. This will lead to inflation and tighter market dynamics; hence, both the customer and manufactures will suffer. Our profit margins will plummet and customers will have to shell out more. The Budget has not addressed the supply side of the value chain and has taken only fiscal measures. The Government has to raise funds, but there should be a balance between the existing factors. The anti-dumping duty has not been relooked at. Many categories of raw materials are already under this duty and the industry will push to include more of them. Overall, the plastics industry cannot take away any major positive change from this Budget.

Modern Plastics & Polymers | April 2012

with proposals to make more sectors eligible for Viability Gap Funding under the Public Private Partnership scheme and include tax-free bonds of ` 60,000 crore to finance infrastructure projects in 2012-13. Measures announced to boost infrastructure and agriculture are good. The consumption of plastics in these sectors is increasing at fast pace. Further, the Finance Minister has reiterated the commitment towards Goods and Services Tax (GST), indicating an early implementation. Its implementation and harmonisation of the tax structure will have a positive impact on business, particularly on the plastics industry, which is currently fragmented. This will encourage the industry to look for economy of scale.

Rohit Chopra, GM (Polymer Division), KPL International Ltd The Union Budget has evoked mixed reactions in the plastics industry and overall. While the rise in excise duty will see a hike in prices, it will increase competition in the market. This will discourage new players from entering the polymer industry, particularly the masterbatch sector, which is currently witnessing a flurry of new entrants. In India, the regulations regarding safety standards are not stringent and manufacturers are also non-chalant towards the health issues of workers. The Budget should have addressed these concerns. India lags behind in Research and Development (R&D), as many unorganised players cannot afford huge investments. However, the organised players need to invest more in R&D, and the Government must create conditions in order to encourage manufacturers to come up with ideas and techniques for benchmarking international standards. Such issues have found no mention in the Budget and the industry will have to depend on imports for high-grade polymers.

POST-BUDGET 201 2

Jayesh Mehta, Regional Manager, Prasad Group With regard to the plastics industry, Union Budget 2012 appears rather a disappointing one, despite expectations of a more pragmatic approach to foster the growth of the highly promising plastics industry. The industry at large will have to tread cautiously to leverage the implications of the Budget. This is particularly significant to plastics application in the capital goods market. Since the current financial year has failed to depict any impressive results by key players, the industry has been counting on fiscal measures. Many of the policies brought forth by the Budget appear conducive to the growth of the plastics industry. The provisions of the Budget by far seem to have prioritised 75 per cent of the population, while casting aside any of the requirements of the 25 per cent of the population keeping in mind that the same class will be driving the growth opportunities by providing better employment en masse.

Rajesh Sharma, Business Unit Director, Closures & Containers, SACMI Impianti India The domestic plastics and packaging industry had hoped for a more friendly and conducive Budget. There is a pertinent need to lower and simplify the existing duty structure on imported plastics processing and manufacturing machinery, thereby improving developments across the manufacturing and engineering sectors. The Budget should have been formulated with an emphasis on food and beverage processing. The lack of any facilitation for this industry will have a direct impact on the common man who spends a major chunk of his earnings on food. The revision in direct taxation is welcome considering the extremely high inflation rates for all essential items, but it is partial to certain segments of the population. This would lead to people having more money in their pocket and the resulting increase in purchasing power will fuel the GDP growth and drive the economy of India.

Modern Plastics & Polymers | April 2012

SPECIAL FOCUS

Injection Moulding Injection moulding: Driving performance through light-weighting .......................................................................32

Robotics in injection moulding: Combining precision with safety .............................................................................................36

PLC-based moulding techniques: Precise control for efficient operations .....................................................................................38

Interface: Harminder Singh, AGM-Sales & Marketing, Electronica Plastic Machines Ltd ................42 Helmut Heinson, MD-Sales, ARBURG GmbH + Co KG ...................................................44

Roundtable: Can Indian injection moulding machines compete globally in terms of energy efficiency? ...................................................................................................46

February April 2012 | Modern Plastics & Polymers

SPECIAL FOCUS: Injection moulding

Driving performance through light-weighting

Courtesy: BASF

From bumpers to door panels, light-weight plastics gives cars better mileage and allows designers & engineers the freedom to create innovative concepts that otherwise would not be possible. Anwesh Koley explores the advantages offered by injection moulded plastics, such as heat and chemical resistance, high strength, impact resistance and ease of moulding.

njection moulded parts constitute 70 per cent of the total processed plastics market. From home appliances to automotive components, as well as the construction industry, injection moulded parts today are found everywhere. There was a time when the automotive sector did not favour the use of plastics for the external and internal parts. Gradually, the importance of plastic parts grew as manufacturers understood the importance of weight reduction, which enables fuel efficiency. Intense competition over the years has witnessed the automobile industry use more plastics in strategic areas to provide durability to the vehicle and enhance its visual appeal. Conventionally, metal alloys were synonymous with the auto body exterior 32

Modern Plastics & Polymers | April 2012

design and manufacturing. But, metal alloys are susceptible to dents, dings, stone chips and corrosion. These are also heavier and more expensive than plastics. Sumit Kumar, General Manager, H K Industries, says, “Choosing plastics for auto body exterior parts allows manufacturers to adopt modular assembly practices, lower production costs, improve energy management, achieve better dent resistance and use advanced styling techniques for sleeker, more aerodynamic exteriors.”

Evolution of injection moulding The moulding process was invented only a few years after the invention of plastics. Initially, hand moulding was used. The moulders had a conventional screw barrel set-up and external heating

was applied manually. Even the moulds were opened and closed using the conventional process. As automation began, the injection moulding machine was developed with a circuit installed in it to regulate the machine. “Hydraulic systems were developed during this time. For many years, hydraulic machines were used by a majority of companies. The current generation of injection moulding machines works on servo motors that save electricity, and hence, cost,” adds Kumar. Over the years, hydraulic machines were replaced with Programmable Logic Controller (PLC) units. Injection moulding has always been a step ahead of extrusion in terms of operational versatility. With injection moulding, all that is needed is changing the mould to achieve the desired design. Today, PLC

Injection moulding

Design flexibility

Choosing plastics for auto body exterior parts allows manufacturers to adopt modular assembly practices, lower production costs, improve energy management, achieve better dent resistance and use advanced styling techniques for sleeker, more aerodynamic exteriors. Sumit Kumar General Manager, H K Industries

has become mandatory for machines and servo motors are in vogue as these consume less electricity. Various safety features have also been adopted in injection moulding machines, which regulate the opening and closing of the mould cavity.

Plastics in automotives Automotives is an important market for plastic resins such as polypropylene, polyurethane, nylon and other engineering polymers & thermoplastic polyesters. Light vehicle applications account for over 30 per cent of the demand for each resin. Other resins used include Acrylonitrile Butadiene Styrene (ABS) and Poly Vinyl Butyral (PVB). Some of the typical plastics and composite applications, processed through injection moulding, include exterior panels, trim and bumper fascia, as well as interior trim panels, window encapsulation, headlamp housings, manifolds and valve covers, electronic/electric parts and components, wiring harnesses, steering wheels, insulation, dampening and deadeners, upholstery, mechanical components, safety glass, etc. 34

Modern Plastics & Polymers | April 2012

New processes enable manufacturers to reuse scrap plastics and recycle used plastics cost-effectively. Also, plastic components weigh about 50 per cent less than their steel counterparts. This enables automobile components to be substantially lighter, while retaining the needed strength and contributes to an overall lighter vehicle, and therefore, fewer emissions & improved gas mileage. Automobile design engineers face many constraints while designing with metal. Low-cost, single-unit production of large automobile sections, such as a front grille, is nearly impossible with metal. “Plastics offers auto engineers a variety of practical, cost-effective alternatives and tremendous advantages over conventional automobile production materials,” says Kumar.

Automotive safety The versatility of plastics allows design options that produce lighter and safer vehicles. From concept to reality, injection moulded parts offer a wide variety of advantages to customers, eg, a driveshaft made from plastic composites can help increase torque as well as passenger safety. Conventionally made of steel, a driveshaft transfers power from the transmission to the rear axle of the vehicle. But, if the steel driveshaft fails, it can project shrapnel in all directions and even dig into the ground, catapulting the vehicle into the air. Composite driveshafts are made of carbon and polymer fibre that is designed to break into small fibre fragments or ‘broom’ upon failure, posing little danger. These are light-weight, require less energy to spin and effectively increase the amount of power that the engine can transmit to the wheels. Fibre-reinforced polymer composite materials weigh about 50 per cent less than steel, though according to a carbon fibre manufacturer, these are characterised by a higher absorption of crush energy per kilogram. On impact, carbon fibres can have four to five times higher energy absorption than steel or aluminium. Front-end components made

of these light-weight energy-absorbing composite materials are specially designed to fracture in a manner that utilises impact energy.

Chassis design A chassis is the supporting frame of a car. It is an especially important component that gives the car strength and rigidity and helps increase the car’s crash-resistance through energy absorption. Being the skeletal structure of a vehicle, the moulded plastics offer the required rigidity for automobiles and, in the process, helps in significant weight reduction. Plastics is making inroads into the chassis market as well. Innovations in plastics technology have brought about the development of successful chassis applications that would not be possible using any other materials. Many chassis parts are made with injection moulding. The chassis ensures low levels of Noise, Vibration and Harshness (NVH) in the vehicle. Not only does a reduction in NVH allow for a more pleasant driving experience, but by putting less stress on connecting components, it helps increase the life span of these components. The key determinant permitting reduced levels of NVH is energy absorption. By having a high level of energy absorption, NVH levels are lowered, and passenger protection can be enhanced in the event of a collision.

The non-metallic alternative Plastics has found remarkable acceptance as a substitute for metal in transmission components. Polyetherimide is used extensively in transmissions for its superior dimensional, heat and creep performance, while a single piece of nylon can replace several steel washers. A key factor behind the steady growth of plastics is its recyclability. The use of large quantities of the same or similar materials greatly improves the economics of recycling. As more plastics are used in automobiles, it is likely to witness a trend towards increasing recycling of plastics. Email: anwesh.koley@infomedia18.in

SPECIAL FOCUS: Robotics in injection moulding

Courtesy: EUnited Robotics

Combining

precision with

safety

The versatility offered by injection moulding in terms of design and high production output rates makes it the preferred choice of the plastics industry. Anwesh Koley analyses the current trend towards the advanced usage of robotics, which allows complete automation in the moulding process.

igher output, lower cost and energy efficiency have become the key criteria in the injection moulding industry in India. In order to achieve these, latest technologies need to be adopted either through process optimisation or advanced automation. Industry sources in India show that the injection moulding market has grown at average annual rates of 12-15 per cent in the past eight years, outperforming the overall economy, which grew at roughly 6 per cent.

Industry projections In India, about 60,000 injection moulding machines are currently in operation, serving a wide ambit of sectors. Naveen Gupta, Senior Branch Manager, 36

Modern Plastics & Polymers | April 2012

Polymechplast Machines Ltd, says, â&#x20AC;&#x153;Injection moulding machine sales in India in 1990 was 2,500-3,000 per year, and today it stands at about 8,000 machines a year.â&#x20AC;? During 2010-11, the demand for injection moulding across various plastic processing machines had acquired 70 per cent marketshare. While extrusion machinery boasted of 23 per cent share, blow moulding had 6 per cent of the share and other techniques at 1 per cent. Market projections show that by 2015-16, almost 10,800 injection moulding machines would be serving the plastic processing industry across India.

Latest developments The latest advancements in injection moulding include servo motor for

energy-savings and all-electric machines replacing hydraulic machines, which have precise control and are useful for pharma & automotive products. Demand is increasing for packaging that can be simultaneously labeled during the injection moulding process. This has resulted in the development of well-packed In-Mould Labeling (IML) systems. Besides functional benefits, this complex process offers potential for cost reduction. Along with these, co-injection and multi-colour injection moulding techniques are used to create different designs with Programmable Logic Controller (PLC)-operated system to achieve repeatable design patterns with higher output. Use of robotics

Robotics in injection moulding

and automation reduces manpower and results in consistent output. “The industry has benefitted from numerous innovations over the years. From conventional technology to proportional technology, production processes in injection moulding have come a long way,” says Gupta. The latest technology used today in the injection moulding industry is aimed at developing energy-efficient and automation-oriented final products. The equipment within a moulding machine are now designed to ensure that they are digitally controlled, more precise, fast, compact and easily compatible with the machine controls. Also, manufacturers are modernising their plants and have equipped them with latest CNC machines and other design-oriented software, which help produce quality products and compete in the international market. With the advent of servo control technology, the normal plastic processing has become simpler and engineering plastic processing, which was earlier considered a difficult process, has become easier. Metal Injection Moulding (MIM) and Ceramic Injection Moulding (CIM) parts can now be found in all areas of life from the automotive sector to watches, from dental braces to mobile phones, from IT equipment to Do-It-Yourself (DIY ) tools and many other areas.

Ensuring higher output at lower costs Advanced use of robotics ensures a higher output, but total moulding cost is low due to lower cost of machine. All principal modules – the clamping unit, injection unit, drive, protective covers and control system – are coordinated and geared towards efficient production. Even complex applications are manufactured at the highest reproducibility level. Multi-cavity production reduces the number of machines and manpower with less energy consumption by servo drive and hot runner moulds lower cycle time & ensure zero wastage. The use of robots adds accuracy and speed to the injection moulding process. Injection moulding machines

produce the same results at the same speed every time. “Robots can keep pace and improve the efficiency of the entire system with quick material handling, effective palletising and few, if any, errors,” adds Gupta. Industrial robots add flexibility to the design of plastics and are used for all types and sizes of parts, from minute assembly components to large automotive body pieces. Robots can be quickly programmed to handle different products and palletise or place parts on a conveyor. They can easily tend to more than one machine at once. Also, the use of robotics creates a safer work environment. Typically, workers are required to work in proximity to injection moulding machines, to remove and stack parts repeatedly. Those removing the parts from an injection moulding machine are prone to repetitive movement injuries. Thus, robots minimise human contact with the injection moulding machine.

Even with a population of about one billion, India remains essentially unknown to most moulders from the US. In terms of gross domestic product per head, India lags behind almost all countries in Asia, except Bangladesh. Naveen Gupta Senior Branch Manager, Polymechplast Machines Ltd

Challenges faced The primary challenge to the business is the advent of low-cost Chinese machines. Often, customers do not understand the importance of after-sales and service and opts for Chinese machines. Visibility is another area of concern. “Even with a population of about one billion, India remains essentially unknown to most moulders from the US. In terms of gross domestic product per head, India lags behind almost all countries in Asia, except Bangladesh,” laments Gupta. Comparing this with China, most moulders from the US have either lost their business to Chinese imports or considered relocating some manufacturing to China. The problem of low-cost products needs to be dealt with urgency. While India exports bulk of its products to African markets, China remains the largest exporter to India. Also, there is a need to increase the level of automation within the injection moulding industry, which would ensure higher output, lower wastage and greater production efficiency. Email: anwesh.koley@infomedia18.in

Courtesy: EUnited Robotics

April 2012 | Modern Plastics & Polymers

SPECIAL FOCUS: PLC-based moulding techniqes

Precise control for efficient operations From household items to engineering and automobile parts, the acceptability of plastics has risen over the years, yielding positive results for the injection moulding industry. Here is an insight into the demand and scope for energy- and cost-efficient machines that can provide benefits to processors as well as end-users. Praveen Sharma

s compared to other developed countries, India has a wide scope for growth of the injection moulding industry. Currently, the usage of plastics in India is just 5-6 kg per person per year, whereas in developed countries, this figure is 14-15 kg per person. Therefore, this industry has an immense potential for further growth. On the other hand, the competition is increasing with each passing day, which often reduces the profit margins of companies. As demand increases for the use of plastic components produced through injection moulding machines, the demand for injection moulding machines also increases, and this trend has been witnessed

in the last few years. Many companies, both domestic and international, have expanded their manufacturing facilities to meet the increasing demand of customers. In India, there is still a large segment in the plastics sector that uses manually operated or semi-automatic machines. While majority of the players today are resorting to a phased conversion of these machines into modern automatic Programmable Logic Controller (PLC)based machines, there is much scope and demand for modern and energy-efficient machines, which provide a host of benefits to both the processors and end users.

Technological developments With regard to the developments in this sector, most of the machinery manufacturers started their journey with manual moulding

Energy consumption savings during holding pressure and mould cooling phases in a servo injection moulding machine

Modern Plastics & Polymers | April 2012

or semi-automatic machines. Gradually, the all-electric machines made their foray into the market through increased awareness and changing global trends. This sector has witnessed numerous advancements in the field of Research and Development (R&D). Be it polymers, moulds, injection moulding machines, auxiliary equipment or plant automation, manufacturers have been successful in implementing cost- and energysaving mechanisms. Major developments in this sector are focussed on how to save energy and bring about innovative design concepts for the final product. Today, due to the advancements in polymer science and engineering plastics, most of the parts are made from plastics instead of aluminium, which has resulted in lower cost and lightweight components with better durability of the parts. These components play a major role in the automobile sector, and thus help improve fuel efficiency and achieve cost reduction. The major parts involved in the injection moulding set-up are the moulds and auxiliary equipment. At present, with the availability of latest design software and modern tool rooms with CAD/CAM and CNC machining centres, it is easy to design and manufacture a typical mould within a short time. With the possibility to design typical moulds, the moulds are now available with hot runner, with more cooling points that lead to shorter cycle time, better finished final products and runner-free parts. The injection moulding machine manufacturer plays a major role in terms of product developments for this sector. The last decade witnessed a number of

PLC-based moulding techniqes

improvements, with plastic processors frequently upgrading their technology in this field. In the early 80s, the machines were equipped with simple hydraulics and electrical control. In the late 90s, the machines featured some advanced hydraulics such as variable displacement pumps and microprocessor and, gradually, PLC was introduced. Today, machine manufacturers emphasise more on ways to make their machines more energy-efficient. Aiding this, injection moulding machines currently are made available with advanced hydraulics, energy-efficient servo motordriven pumps and high-speed controllers.

Scope for improvement There is a large scope for improvement in the injection moulding industry. In India, there are few all-electric machine manufacturers and only international companies who provide such machines are present here. These machines have a bright future if the running cost and maintenance cost are reduced; this would bring many potential companies in the ambit of all-electric machines. As a manufacturer of injection moulding machine with a brand like Euro Series, Hind Machinery emphasises on manufacturing energy-efficient and low-maintenance machines that are affordable. These energy-efficient machines save 40-60 per cent of energy as compared to normal injection moulding machines, which run on simple induction motors. Also, new-generation machines are equipped with servo motors having closed-loop hydraulics, as the pressure is sensed by a pressure transducer, which gives feedback to the frequency drive of the servo motor. The company has developed a Euro Star Series (25 and 50 tonne) equipped with a hydraulic clamping unit and a unique feature of bush-less tie-bars, which eliminates the need for lubrication. These machines are also environment-friendly and almost maintenance free. The company manufactures injection moulding machines â&#x20AC;&#x201C; hydraulic and toggle clamping â&#x20AC;&#x201C; with 25-400 tonne clamping force. Indian machinery manufacturers need to have all latest and advanced features and energy-efficient servo motors, with a reliable controller at an affordable price.

Enhancing productivity and cost-efficiency The industry must move towards providing the customer machines with latest technology with superior features, which are reliable and low on maintenance. Few such machines are closed-loop machines, which ensure repeatability with minimum rejection, energy savings up to 40-60 per cent depending on the moulding parameters, giving a higher production rate at a lower cost. The key challenge before the injection moulding industry is competing globally to upgrade the technology and offer excellent quality & cost-effective solutions with higher production rate. Praveen Sharma is Proprietor of Hind Machinery Pvt Ltd. Email: hinds@rediffmail.com

Modern Plastics & Polymers | April 2012

SPECIAL FOCUS: Inter face - Harminder Singh

“Indian products are recognised for better durability and after-sales service” …opines Harminder Singh, AGM-Sales & Marketing, Electronica Plastic Machines Ltd. In a conversation with Anwesh Koley, he highlights the recent trends in the injection moulding industry and challenges of quality and price that are facing companies in India. What is the current scenario of the injection moulding industry in India? The injection moulding industry in India is growing at 14-15 per cent per annum. This is because the per capita plastics consumption in India is one of the lowest in the world. China consumes about 20 kg of plastics per person per year, while in India it is 5-6 kg. In developed countries, this figure goes up to 50-60 kg, with the US being the highest consumer. These numbers provide a vast scope for growth of the plastics industry in India.

What are the reasons for growth of injection moulding industry? The acceptability of plastics has increased with the rising number of industries using plastics. This has bolstered the growth of the injection moulding process. With reagrd to the food packaging industry, packaging requirements have changed along with our eating habits. This industry primarily involves two methods – blow moulding and injection moulding. These techniques run parallelly and end-products may 42

Modern Plastics & Polymers | April 2012

need both; hence, the injection moulding industry has seen a jump in demand.

What innovations has this industry witnessed? Energy-efficient (eg, servo motor) machines consume less power. Earlier, we used only one type of machine and tried to use it for all major applications, but this did not yield the required efficiency in terms of production and energy consumption. Today, we offer machines with various applications. At Electronica, we use toggletype injection moulding machines (as these consume less power and ensure faster production), while many manufacturers are continuing with hydraulic-type machines.

What are the energy-efficiency standards in the industry? Manufacturers in India have still not adopted fully automatic machines on a large scale, as a high availability of manpower warrants increased involvement of manual labour. Globally, hydraulic machines have been almost completely replaced with

automated units, as these require less manpower. Earlier, power was not a major concern for most players in the industry, but with rising infrastructural bottlenecks, manufacturers have been forced to develop machines that yield higher output and ensure energy-efficiency & cost-savings.

What challenges does this industry face? Low-priced import from China is a major threat. Chinese manufacturers receive many benefits such as subsidies and tax concessions from their government. No such schemes are available to Indian manufacturers. Import of finished products is another concern, as importers have to pay much more. India is a price-sensitive and non–quality-conscious market, where companies are initially attracted by the low sticker price; quality considerations arise after the machines are used over a period. But, Indian companies offer better after-sales service. The industry has a bright future, as growth rate is high and the number of applications of injection moulding has also increased. Email: anwesh.koley@infomedia18.in

SPECIAL FOCUS: Inter face - Helmut Heinson

“Indian moulders are realising the benefits of quality over costs” …opines Helmut Heinson, Managing Director-Sales, ARBURG GmbH + Co KG. In an exclusive interaction with Annabel Dsouza, he assesses the potential for futuristic injection moulding solutions in the exponentially growing Indian plastics industry. What are the current trends in the Indian plastics industry? In the Indian market, the technical standards of products is rising and the requirements in terms of product quality and efficient moulded part production are becoming more competitive. Indian moulders are realising the benefits of quality over costs and are demanding high performance and efficiency. Quality production goes a long way in enabling Indian processors to explore global markets through reliable processes and consistent products. We have observed demand for the modular Allrounder injection moulding machine with its extensive range of robotics and unique Selogica machine control system. These solutions are perfectly positioned to meet ambitious demands in terms of precision, reproducibility, productivity and energy efficiency across all sectors.

What innovations have been witnessed in the global arena? Due to the increasing complexity of applications and rising demand for 44

Modern Plastics & Polymers | April 2012

customer- & branch-specific production cells, machine control systems are gaining increased significance. As the all-important human-machine interface, automation solutions must integrate robotic systems as well as other peripherals and enable simple, intuitive programming & operation of the entire injection moulding system. Arburg continues to develop independently both the hardware and software of the Selogica control system, in line with the principle of ‘Making complex tasks easy’. The developments in the machine and control system area from a single source are coordinated at the appropriate level of detail. The aim of developing new-age injection moulding machines is to continuously increase the efficiency of moulded part production. This enables cost reduction without compromising on quality. Besides machinery performance and availability, cycle time is a crucial determinant. At Arburg, we combine electric clamping units and generously dimensioned injection units with position-

regulated screw and hydraulic accumulator technology. This results in machines that feature energy savings, high productivity and short cycle times, making these perfect for various industries, especially the packaging sector.

What are Arburg’s initiatives for the injection moulding industry in India? For over 20 years, we have been represented on the Indian subcontinent through our trading partner Unimark, with whom we enjoy a highly successful collaboration. In India, high-tech injection moulding machines find applications in various industries, from disposable syringes and complex automotive parts to mobile phone shells, micro-gear wheels and irrigation systems. Arburg also offers customers extensive support at the local level, from sales, through pre-sales and after-sales service, to consulting on applications engineering. Arburg ensures that it provides a uniformly high level of service competence in India and worldwide. Email: annabel.dsouza@infomedia18.in

SPECIAL FOCUS: Roundtable

How can Indian companies raise energy-efficiency of injection moulding machines? Injection moulding machines have multiple applications and are available in different configurations. It thus becomes important for these machines to be energy-efficient while performing throughout several stages of the process cycle. Anwesh Koley speaks to some industry experts on the key requirements to assure manufacturers of efficient energy usage of these machines.

Raj Kumar Director, Micron Hydraulics Pvt Ltd

Sivakumar M

Injection moulding machines today come with new mechanisms to increase output with precision and also maintain energy efficiency. This can be achieved by retro-fitting injection moulding machine hydraulic systems with Variable Speed Drive (VSD). The hydraulic pump motor of injection moulding machines has an average power draw of 30-80 per cent of rated power before retrofit. Installing a VSD retrofit can save 20-50 per cent of power. The pre-retrofit energy use and percentage reduction in energy consumption after installing VSD are functions of most machine and process parameters. VSD raises the power factor of the hydraulic power motor and decreases the amount of thermal energy generated in the hydraulic fluid, reducing thermal load on cooling water system at the plant. This increases savings by 5-20 per cent more than the conventional hydraulic pump motor. Most injection moulding units use a basic hydraulic system or hydraulically actuated system for the clamping unit. Toggle units are more production efficient, but save less energy.

Manager, Woojin Selex Co Ltd

Thankur Singh Dhooper

New-generation servo motors ensure energy savings and low noise levels in injection moulding machines. Revolutions Per Minute (rpm) control the hydraulic servo pump drive system with AC servo motor, saving significant energy. Moulders can save 65-75 per cent energy with these techniques. High precision stability control is achieved by the closed-loop method of hydraulic servo pump-drive system with servo motor reproducibility. A pressurised operation of servo motor enables high responsiveness of the moulding unit. Low-speed and precision positional control allow precision-enabled protection for metallic patterns. Hydraulic moulding with an integrated system ensures precise timing and lower energy consumption. A servo motor rpm control restricts temperature raise of the hydraulic oil, reducing coolant use by 25 per cent and hydraulic oil use by 15 per cent. Mould deformation can be minimised by improving the platen, which prevents flashes and reduces thickness variation in products by ensuring uniform surface pressure of installed mould.

Director, Popular Engineers (India)

Editorial take:

In injection moulding, while using the latest servo motor technology, the hydraulic and screw drive methods are combined to form a synchronous operation based on complex coordination of parts. This reduces the process time by compound moves of mould open/close during charge cycle and ejection during mould open cycle. Increasing the screw rpm by using a high-output servo motor reduces the charge process time. This ensures significant energy savings by optimising fuel flow and reducing noise levels. The use of structural innovations in the injection unit improves precision. If an ‘in-line’ architecture is applied to an injection unit, it becomes highly responsive and optimal for precision moulding through stable high-speed injection. This minimises mechanical friction, improves injection conditions and fine control of back pressure. A ‘Quick Barrel Change’ device can also be used, which saves operation time by applying the plug-and-play method. A combination of electronically controlled high-performance and mechanical features offers precise injection for high-quality production. Email: anwesh.koley@infomedia18.in

While various techniques are used to ensure energy efficiency in injection moulding machines, moulders must select the right equipment to enable precise moulding with efficient production set-up. These steps will ensure product consistency as well as customer satisfaction.

Modern Plastics & Polymers | April 2012

FACILIT Y VISIT: Quadrant EPP Surlon India Ltd

Engineering complete solutions

under one roof

Today, engineering plastics seems to be the perfect solution to demanding engineering applications, while conventional materials are less economical. One of the leaders in engineering plastics for the machinery industry, Quadrant EPP Surlon India Ltd provides world-class solutions to its customers. Anwesh Koley traces the company’s efforts in offering innovation and expertise to its customers.

ngineering plastics is exceptionally easy to machine and even a slight modification in the tools can produce an outstanding smooth surface finish, enhancing the aesthetics & performance of machines. Almost all engineering plastics are easy to machine, which justify their use over conventional materials due to reduced labour time, lower energy cost and faster component production times. As a one stop-shop for engineering plastic components, Quadrant EPP Surlon India Ltd offers solutions to all engineering plastics application needs, from material selection to manufacturing error-free products through precise process control. The general and advanced engineering plastics portfolio developed over the decade includes the broadest range of standard and custom shapes for machining in terms of materials and dimensions. Satendra Kumar, Chairman & Managing Director, Quadrant EPP Surlon 48

Modern Plastics & Polymers | April 2012

India Ltd, avers, “Our unique polymer technology extends the performance boundaries of standard engineering plastics in machined parts. The extra high levels of performance improve the productivity, efficiency, quality and life of equipment beyond the limits of standard materials.” The company is ISO 9001-2000 certified and follows a total quality approach after careful selection of raw materials. Quadrant EPP Surlon India Ltd is a part of Quadrant EPP, a name built on talent and innovation. The history of the company is rooted in leading producers of stock shapes for machining and fabrication and includes former Polymer Corporation & Polypenco companies, Erta and Cestidur, Symalit Fluoropolymers, DSM Engineering Plastic Products and, most recently, Poly Hi Solidur. Now part of the Quadrant group, a global, diversified, high-tech plastics processing company, Quadrant Surlon continues to strengthen its focus on specialised engineering plastics.

State-of-the-art facility Established in 1994, the company’s production facility in Sahibabad is spread over an area of 2,000 sq m. The company also has a larger manufacturing plant in Dehradun, spanning an area of 7,000 sq m. The Sahibabad facility is spread across two floors and offers solutions for every engineering need. Luv Kumar, Director, Quadrant EPP Surlon India Ltd, says, “Our range of materials comply with Food and Drug Administration (FDA) and other standards, and are resistant to various chemicals and solvents, temperatures & mechanical pressures. For requirements outside this delivery programme, we offer custom-designed stock shapes enhanced with or without fillers and reinforcements.” The company boasts of a strong distribution system and guarantees the availability of materials across a wide range of shapes & sizes from the stock. Optimum dimensional stability of machine parts is ensured through consistency in

Quadrant EPP Surlon India Ltd

manufacturing. The company’s ongoing investment in production and logistics sites across the world has resulted in extensive market development for engineering plastics. “In India, Quadrant Surlon offers an exhaustive range of products along with the manufacturing capabilities. The company expanded its manufacturing capabilities to include nylon casting, extrusion, injection moulding and also has a state-of-the-art CNC machining capability,” adds Satendra Kumar.

An illustrious portfolio The company caters to industries such as steel, paper and pulp, material handling and food & beverages. While the company deals in both advanced and general engineering plastics, its METALON series enjoys a wide market appeal due to vast applications and advantages. “Because of its successful performance in diverse engineering applications, Metalon 6 PLA is the most widely used cast nylon in the industry, especially as a bearing material. When used for maintenance requirements of original equipment manufacturers, these cast nylons have replaced bronze, brass, steel, aluminium and other metals, as well as other plastics, wood & rubber. Metalon 6 PLA provides higher wear resistance, high tensile strength and modulus of elasticity. The low coefficient of friction, high mechanical strength and stiffness and other properties make this

series a favourite in the market,” adds Luv Kumar.

High quality systems Competition is intense in the engineering plastics market, and the quality of services and product differentiation is the key to ensure a steady customer base. “Our ability to offer reliable products and service levels are based on Total Quality Management approach reinforced by ISO 9001-2000 standards. Quadrant Surlon meets customer requirements for consistent quality, performance and machinability. The company has set the standard for careful selection of quality raw materials and resins, leading process technologies and highest manufacturing standards,” says Luv Kumar.

Support and service In India, Quadrant Surlon provides application, technical and production support as per customer requirements. “Our teams of technical service, application development engineers and the most comprehensive testing laboratories are based at all major locations in India and abroad. The mission of our technical support team is to help equipment manufacturers, engineers and machinists in material selection through machining, for optimum performance, productivity & cost efficiency,” adds Luv Kumar. The company is seeking ways to utilise the

Material cutting and design

Our unique polymer technology extends the performance boundaries of standard engineering plastics in machined parts. The extra high levels of performance improve the productivity, efﬁciency, quality and life of equipment beyond the limits of standard materials. Satendra Kumar Chairman & Managing Director available resources and influence to bring relevant, accessible & affordable plasticfibre products to people worldwide.

Rapid market growth At every stage of a project, the company extends its support with a thorough evaluation of performance needs and application environment. The selection of the appropriate software enables the company to ensure right material selection. In India, it is mandatory to receive prior certifications for materials and compliance from regulatory agencies. The company has a dedicated team to get all these requirements in place. The market for engineering plastics is growing repidly and customers are demanding quality & reliability from their purchases. “With steady research and development initiatives, which result in path-breaking products, Quadrant Surlon has become a major player in the industry. We plan to increase our production facilities beyond the current limits in order to serve our customers better,” concludes Luv Kumar. Email: anwesh.koley@infomedia18.in

April 2012 | Modern Plastics & Polymers

INSIGHT & OUTLOOK

Engineering Plastics Engineering plastics: Offering high-performance capability.................................................................. 52

Innovation edge: Engineering new avenues for plastics................................................................... 56

Interface: Raju Desai, MD, Compounding Division, Jyoti Group .................................... 58 Shamik Shah, VP-Sales & Marketing, Monachem Additives Pvt Ltd ............ 60 Sanjay Jain, Business Director, DSM Engineering Plastics India ..................... 62

QRST method: A four-step approach for project cost management M Hariharan, Director, Savoir Faire Management Consultancy Pvt Ltd................ 64

April 2012 | Modern Plastics & Polymers

INSIGHT & OUTLOOK: Engineering plastics

Courtesy: design mag

high-performance

With India becoming an automotive hub and the electronics market witnessing a boom, the demand for engineering plastics in India is increasing. Offering greater flexibility, design freedom, robustness and weight reduction, these are fast replacing other materials. Avani Jain drills deeper into the performance and profitability quotient of engineering plastics.

he engineering plastics industry possesses considerable growth potential, as untapped opportunities still exist for metal replacement in cars and trucks, household appliances and other applications. Considering this, the global market for engineering plastics is projected to grow at a Compounded Annual Growth Rate (CAGR) of 9.5 per cent over the next decade. In India, the growth is driven by increasing usage of engineering plastics in segments such as Electrical & Electronics (E&E), construction and automotives. Canon Patel, Managing Director, Loxim Industries Ltd, says, “The demand for engineering plastics [excluding Acrylonitrile Butadiene Styrene (ABS), Polypropylene (PP) and Polyurethane (PU)] is about 100,000 million tonne per annum in India, and the demand growth rate is 14 per cent annually (CAGR for 2009-15).” 52

Modern Plastics & Polymers | April 2012

Concept of engineering plastics

Engineering advantages

Engineering plastics exhibits superior mechanical and thermal properties over commonly used commodity plastics. Engineering plastics usually refers to thermoplastic materials, eg, ABS, Polycarbonate (PC), Polyamide (PA), Polybutylene Terephthalate (PBT), Polyethylene Terephthalate (PET), Polyphenylene Oxide (PPO), Polysulphone (PSU), Polyetherketone (PEK), Polyetheretherketone (PEEK), polyimide, and many more. Patel notes, “Engineering plastics is used for manufacturing household items, circuit breakers, electrical enclosures, luggage shells, gears, bushings & bearings, etc. In the automotive sector, it is used to make fenders, door panels, instrument panel, trims, door handles, wheel cover, etc. It is also used in under-the-hood applications such as air-intake system, engine cover, radiator parts, engine oil systems, brake systems, ignition systems and motors.”

An engineering plastic material is selected based on its range of enhanced physical properties. Patel avers, “The key benefits of engineering plastics are cost-effectiveness, as these have lower manufacturing cost, electrical insulation properties, excellent surface finish, colourability, high production volume, wide range of mechanical properties and transparency. These materials are also corrosion- and chemical-resistant, light in weight, decorative, paintable, flexible and soft.” Engineering plastics offers improved design flexibility to manufacturers more than that by metal, glass or wood. A variety of colour and surface finish can be achieved to meet the desired aesthetical and haptical needs. Patel opines, “Plastics moulding permits more complex shapes and greater geometry details, which is not the case with metal stamping.” Other properties of engineering plastics include high heat resistance, mechanical strength,

Engineering plastics

rigidity, chemical stability and flame retardency.

Automotive applications

For automotive applications, higher melting point and long-term temperature resistance are required to sustain high temperatures typically encountered by components close to the engine. The excellent heat resistance property of engineering plastics, such as PA, has been successful in these areas. Canon Patel Managing Director, Loxim Industries Ltd

The drivers of change in the automotive industry are weight reduction, greater fuel economy and system cost reduction. Patel notes, “Engineering thermoplastics are ideal materials to achieve these goals since their specific gravity is substantially lower than metals. Thus, these materials are increasingly replacing metal in key application areas.” He further adds, “For automotive applications, higher melting point and long-term temperature resistance are required to sustain high temperatures typically encountered by components close to the engine. The excellent heat resistance property of engineering plastics, such as PA, has been successful in these areas.” Polyamide (PA6) and PA66 are among the most important polymers by volume in the engineering plastics market. The excellent strength and toughness displayed during exposure to

hot, aggressive automotive fluids or hot air make PAs useful for manufacturing durable and functional components for automobiles.

Future trends Engineering plastic materials are making inroads in areas where metals once enjoyed a monopoly. The light-weight trend that had come from the automobile industry has spread to the electronics industry as well, with mobile phones, pad computer and notebook becoming more light-weight and smaller. Thus, light-weight has become the mantra of success and is defining new horizons for the engineering plastics industry. Considering the benefits of engineering plastics, their demand is expected to rise globally, driven by the ongoing replacement of metal parts with high-performance plastics. The consumption growth of engineering plastics on an average annual basis is likely to reach 3 million tonne – 18 per cent of the total demand in 2013. Email: avani.jain@infomedia18.in

Business Insights •Technologies•Opportunities

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 1500 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

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a complimentary copy of that particular edition. Published by Infomedia 18 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 Kongbased Ringier Trade Media Ltd (one of the

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Modern Plastics & Polymers | April 2012

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InsIght & OutlOOk: Innovation edge

Engineering new avenues for

plastics

Engineering plastics, which is more of a contemporary development and has completely changed the outlook towards plastics, is now challenging the supremacy of metals in conventional engineering applications. Lionel Alva takes a closer look at how engineering plastics is increasingly being regarded as a saviour for engineers today.

he industry today is seeking a suitable alternative to conventional materials used in engineering applications. There is an increased emphasis on constant technological upgradation so as to maintain a consistency with various challenges and demands that the market brings forth while exploring new vistas for material applications. Thus, engineering plastics is acquiring an increasing fervour owing largely to greater flexibility that it offers. Its nature of application is limited only to the imagination of the engineer, while the possibilities are unlimited. 56

Modern Plastics & Polymers | April 2012

This is mainly because engineering plastics possesses physical characteristics that allow it to perform for prolonged durations in structural applications, over a wide temperature range, under mechanical stress and in unfavourable chemical & physical environments. The demanding nature of the market has made way for a much sought-after panacea. The various factors contributing to this are an increasing need to upgrade the manufacturing cycle while cutting down on wastage and allowing enhanced recyclability of components. There is a need to reduce raw materials usage,

which is pivotal as a cost-saving exercise for an industry that operates on thin margins and is mostly volume-driven.

Understanding the plastics advantage

In comparison with metal, plastics exhibits better chemical and moisture resistance as well as higher shock & vibration resistance. It is lighter in weight and usually either transparent or at least translucent in thin sections. It has the advantage of sound and vibration absorption and some types of plastics possess greater wear & abrasion resistance than metals. Some plastics, such

Innovation edge

as nylons, are self-lubricating. Significantly, one of the most important characteristics of plastics is that it is usually easier to fabricate than metals. Some plastics can also be plated, but a more important property is that plastics can be pigmented in a wide variety of colours. Because of its lighter weight, which gives it an advantage in cost per cubic inch with respect to metal and its easy-to-fabricate characteristic, finished plastics parts are frequently less costly than metal parts. “Engineering plastics is a modern concept for the industry and yields several advantages in terms of being lighter in weight, self-lubricating, high-end performance similar to metals, etc. It helps modern engineers replace softer metals with these materials in order to ensure infinite possibilities of applications. It also depends on how an engineer can consider and formulate different applications for these materials and put it in the best possible use. Today, India is a small market for engineering plastics as compared to much smaller regions such as Europe; hence, this material has a wide scope. People are increasingly becoming aware of the advantages of this material in the plastics industry and as they are learning, the market is growing. Engineering plastics is viable for the industry in terms of the qualities that it imparts to the equipment it is used in. It may require slightly high initial investment as compared to conventional materials such as metal, but the advantages it gives to the equipment are far greater. Features such as reduced downtime, lower maintenance, higher efficiency and performance of equipment nullify the initial cost,” avers Aditya Tandon, Owner, Classic Polymers and Resins.

Role of fillers, additives and reinforcing agents

Plastics also has certain negative properties. To begin with, plastics is not as strong as metal. In general, it possesses lower heat resistance and is flammable. Plastics is characterised by a much larger thermoexpansion, lower ductility than metals and most types are brittle at low

working temperatures. However, the use of reinforcing additives and fillers has mitigated the disadvantages of conventional plastics, while allowing it to be used in applications that were not considered within the span of plastics used earlier. For example, incorporation of glass fibres into a polyolefin will increase its strength, toughness, rigidity, dimensional stability and heat resistance, putting the reinforced material into an entirely different class as compared to a material that has not been so modified. Other reinforcing agents for plastics include asbestos, which increases strength and heat resistance, and carbon black that increases weather resistance and imparts lubricity & electrical conductivity. Addition of metal powders or metal fibres provides thermal and electrical conductivity to plastics, increases the strength of the material and imparts other desirable properties. “Reinforcing additives improves the mechanical properties of plastics and reduces the influence of temperature on these properties. This brings new applications within the range for plastics, for example, replacing light metal castings or housings of sheet steel. Fillers and reinforcing additives can modify the properties of plastics within broad limits. There is no sharp distinction between the two terms but, broadly, fillers denote inorganic materials that lower the price of the plastics and may also improve its modulus of elasticity, thermal resistance and surface quality,” avers Sudhir Koli, Deputy General Manager, Bright Autoplast Ltd.

An indispensable matter

In practically all application areas, plastics has come of age like no other material.World production of plastics in 2004 was close to 225 million tonne, a tenfold increase in less than 40 years, and the current rate of increase is about 5 per cent per year. However, unlike metals, all types of plastics fall within a narrow range of specific weights, ie, 0.9-1.5 gm/cm3. This makes plastics indispensable for creating weight-saving designs. Email: lionel.alva@infomedia18.in

Engineering plastics is viable for the industry in terms of the qualities that it imparts to the equipment it is used in. People are increasingly becoming aware of the advantages of this material in the plastics industry and as they are learning, the market is growing. Aditya tandon

Owner, Classic Polymers and Resins

Reinforcing additives improves the mechanical properties of plastics and reduces the influence of temperature on these properties. This brings new applications within the range for plastics, for example, replacing light metal castings or housings of sheet steel. sudhir koli

Deputy General Manager, Bright Autoplast Ltd

April 2012 | Modern Plastics & Polymers

INSIGHT & OUTLOOK: Inter face - Raju Desai

“The domestic market potential still remains untapped” …states Raju Desai, Managing Director, Compounding Division, Jyoti Group. In an interaction with Lionel Alva, he highlights processing trends in engineering plastics while sharing his vision on the role of plastics in setting the stage to establish India as a major world player. How commercially viable is engineering plastics in India from a manufacturer’s perspective? In the Indian context, plastics pose two advantages from a manufacturer’s perspective. The first is that the demand for engineering plastics is growing and is stronger than in any other part of the world. Also, the domestic market potential still remains untapped. The engineering plastics being produced in India is viable for the industry in terms of the advantages it yields to the equipment that it is put into. While it may have a slightly higher investment initially, its advantages to the equipment in terms of lower downtime, better lubrication, higher efficiency and performance make up for the slightly higher investment cost.

How has engineering plastics helped design more innovative products? Plastics is perhaps the most versatile and cost-effective material known to man. At Jyoti, while dealing with customers, we check the application areas and work to formulate a product for their application requirements. This demands a great degree of Research and Development (R&D), and these efforts of the industry have helped plastics achieve a ubiquitous presence today. Of course, the use of fillers, reinforcing agents and additives confer the core material characteristics that provide unprecedented opportunities for creating innovative products.

What critical applications are driving the demand for engineering plastics in diverse fields? 58

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Any application that uses metals can easily be considered as a critical area that can use plastics. A good example for the use of plastics and that has changed the scenario of the industry is parts for submersible pumps, which were conventionally made from gunmetal and cast iron; the process involved a lengthy and arduous manufacturing process that required several steps such as machining and sandblasting. Even in aerospace, plastics is used to a large extent while allowing for body structure considerations that were not possible earlier for highperformance parts. All industries, from mining and railways to construction, use engineering plastics since these offer several advantages such as improving performance and longevity over their conventional counterparts.

What R&D initiatives have you undertaken with regard to engineering plastics? We have a one-stop shop right from design, engineering analysis, assembly and supply. We have in-house capabilities for product development and product & stress analysis. We are, perhaps, the only company specialised in designing plastics. Recently, we had developed low-cost computer parts for Bharat Electronics, which came to be known as the lowest cost tablet PC in the world. Jyoti Plastics has also won a Plasticon Gold Award this year for the most innovative product design where the assembly line required three assembly parts and converted these three into one complete part by using injection moulding, which shortened the manufacturing cycle considerably. Email: lionel.alva@infomedia18.in

INSIGHT & OUTLOOK: Inter face - Shamik Shah

“Plastic additives can be used across different industries” …opines Shamik Shah, Vice President–Sales & Marketing, Monachem Additives Pvt Ltd. In an exclusive conversation with Avani Jain, he states that plastic additives confer a unique innovative edge to a plastic processor for differentiating his products in the market place. and a compounder/masterbatcher. The plastic additive supplier brings in the knowledge of plastic additives and the compounder brings his processing skills. Yet another trend is the entry of foreign additive processors into Indian markets, which introduces global quality standards in the Indian plastics industry.

What are some of the innovations in this segment?

What is the demand for additives in the Indian plastics industry? The demand for plastic additives is increasing in India. This growth is directly proportional to the extent of innovation happening within the plastic processing industry; government regulations; global standards [eg, fire retardant standards, Restriction Of Hazardous Substances (ROHS), Food and Drug Administration (FDA), environmental standards, etc]; and dissemination of knowledge of various performances that plastic additives offer to all users of plastics, including the final consumer.

What are the current trends in the industry? Today, a plastic processor is keen to gain more knowledge of innovative plastic additives such as anti-microbial, anti-scratch and halogen-free flameretardants. Another trend is forming partnership between an additive supplier 60

Modern Plastics & Polymers | April 2012

Numerous innovations are taking place across all industries, thus increasing demand for plastic additives. In the automotive sector, several innovations are happening for developing anti-scratch applications, lightweight solutions and improving impact resistance. Stabilisation for medium- and high-voltage cables and metal deactivation solutions are some innovations happening in the wire & cable industry. The packaging industry continuously demands better aesthetics, increased shelf-life of food products, etc. The infrastructure sector requires chlorine-resistant solutions for Polyethylene (PE) pipes. In the households sector, innovations are happening to improve aesthetics, surface and mechanical properties, which are replacing Bisphenol A (BPA)-based Polycarbonate (PC) with Polypropylene (PP) for baby bottles and other similar items. Similarly, numerous innovations are happening in the agricultural and medical sector, driving the demand for plastic additives.

What are the challenges faced by the industry? Some of the challenges faced by this industry include fluctuating price of additives, compliance with international standards entering the Indian market, which are

pushing the Indian plastic processors to use specific additives. Despite the challenges, there are opportunities for growth of the industry as well. There is an aggressive scalable growth potential of additives in the Indian market, as many areas remain untapped. Plastic additives can be used across different industries. There is a strong opportunity for plastic additive suppliers and masterbatchers/compounders to work together for developing new markets.

What are your growth plans for the company? We want to build on our core strengths, which are to offer the widest range of plastic additives solutions from a single source, quality products with consistency and high performance from leading brand manufacturers across the world, quality service in terms of response time, application support and R&D. Currently, the company offers solutions for improving processing and flow to ensure cost reduction, improving mechanical and surface properties, halogenated & non-halogenated flame-retardant solutions for various polymers, heat & Ultraviolet (UV ) stabilisation solutions for improving the usage life of plastics, phenol-free stabilisation for PP fibres, nonylphenol-free liquid antioxidant for improved colour & gas fade performance, stabilisation solutions for medium- & high-voltage XLPE cables, solutions to reduce breakage of PP totes & bins for retailers, reduction of water carry over for PP/PE tapes used in Flexible Intermediate Bulk Container (FIBC) and polyvinyl chloride replacement solutions for the medical industry. Email: avani.jain@infomedia18.in

INSIGHT & OUTLOOK: Inter face - Sanjay Jain

“Engineering plastics are finding place in the competitive Indian market” …believes Sanjay Jain, Business Director, DSM Engineering Plastics India. In this exclusive interaction with Annabel Dsouza, he traces the trend of innovations, cost efficiency and sustainability of engineering plastics in India. overall system cost reduction. Applications in the electrical and electronics industry are driven by use of less hazardous materials & replacement of conventional materials such as thermosets.

What are the latest innovations in the world of engineering polymers?

What are the current application dynamics for engineering plastics in India? The current application dynamics for engineering plastics are driven by the end-use market, which includes automotive, electrical and electronics and general industry. Applications in the automotive industry arise from entry of existing applications in new car models and conversion of complex metal parts to plastics for higher fuel efficiency, weight down, improving Noise-Vibration-andHarshness (NVH) performance and 62

Modern Plastics & Polymers | April 2012

New ideas and innovations in engineering polymers are the result of increased awareness in major end-markets for ‘Green’ materials – for example, bio-based polymers and halogen-free flame retardant compounds. Bio-based polymers are partly based on renewable raw materials. The raw materials are not oil-based, but produced from vegetable sources or by fermentation. Some bio-based polymers can also be biodegradable. EcoPaXX™ developed by DSM is an example of innovative green high-performance plastics. EcoPaXX is carbon neutral, as CO2 generated in the production process is compensated by absorption in the growth process. It has been well received by many global automotive Original Equipment Manufacturers (OEMs) and is being evaluated by all major OEMs. Another example is the Arnitel® Eco – a high-performance Thermoplastic Co-Polyester (TPC) partially made from renewable resources, in which rapeseed oil is used instead of mineral oil.

How cost competitive is engineering plastics for the Indian market? The Indian engineering plastics market has been using materials ranging from high-performance materials such as polyether ether ketone, Stanyl Polyamide (PA)46 and polyethylenimine to more commoditised materials such as

polyoxymethylene. Thus, engineering plastics with various price points are finding a place in the competitive Indian market. The challenge is not with engineering plastics being cost competitive, but has more to do with having the right capability to identify, design and develop applications that create real value for all in the business chain as compared to the incumbent solution and deliver total lower cost of ownership.

How does DSM assess sustainable performance of engineering plastics? Engineering plastics is a recyclable material. The extent of recycling depends on various factors, including its end-use. As far as engineering plastics is concerned, the use of renewable/halogen-free raw materials is not sufficient to make a product ‘green’, but the sustainability of the product must also be assessed. DSM has commissioned Life Cycle Assessment (LCA) of its products to prove that their new solutions are indeed reducing the impact on the environment. For example, to assess its reduction in greenhouse gases, Arnitel Eco was measured against classic co-polyesters using a so-called ‘cradle-to-grave’ LCA. The study was carried out in accordance with ISO 14040/14044 standards. The IPCC 2007, GWP 100a method was used to quantify the global warming potential of Arnitel Eco as compared to classic co-polyesters. The international norm to measure renewability is ASTM D6866. This norm uses the difference in isotopes of new carbon from plants and old carbon from oil to calculate the renewable carbon content. Email: annabel.dsouza@infomedia18.in

INSIGHT & OUTLOOK: QRST method

A four-step approach for project cost management

In any project by a company, the actual costs generally exceed the estimated costs and schedule, as a result of which budget takes a backseat. Cost management is the bottom line for any companyâ&#x20AC;&#x2122;s projects. Here is an outline of the QRST method for minimising deviations in the expected cost over-runs. for timely corrective actions Projection of estimated cost to completion as per study of trends & technical analysis Suggest corrective actions to minimise cost over-runs, manage review & final decision Analyse costs incurred on each construction contract package

M Hariharan

oday, any individual handling a project can be found talking about cost over-runs, budget over-runs, time over-runs. Why do most people face such problems? Is there no solution for these problems? In project management, the first question that arises is how to complete the project on time, but one fails to understand the cost impact of this over-run on the overall profit of the firm. Here, Project Cost Management (PCM) comes into picture.

Purpose of PCM Ensuring that the plan is in place and tracking & minimising the deviations from the plan is critical for preventing or minimising cost over-runs. Thus, project cost control must ensure the following: Identifying early trends of cost variances on Quantity-RateSpecification-Time (QRST) basis

Levels of PCM PCM requires three ingredients to be effective: Cost budgeting: It means estimating costs of resources needed to complete project activities and allocating overall cost estimate to individual work activities Actual cost tracking: It involves capturing actual costs incurred at the Work Breakdown Structure (WBS) level when it incurs (not approximation of cost incurred across WBS elements) Cost control: It includes tracking changes to the project budget, identifying

trends and ensuring on-time at-cost completion

Cost drivers The reasons for deviations in the actual project cost from the budget are Quantity, Rate, Specification and Time (QRST): Q: Implication on cost due to change in quantity from change in design and scope, extra work not specified in the contract, rework due to modification at post-installation, incorrect installation, failure of installation & design R: Implication on cost due to change in rate caused by statutory variations, tax structure, inflation, demand & supply S: Implication on cost due to change in specification in terms of materials, physical design, quality characteristics & safety standards T: Implication on cost due to time factors â&#x20AC;&#x201C; delay resulting in idle time of resources and crashing of activities

Earned Value Management (EVM)

Earned value graph

Modern Plastics & Polymers | April 2012

EVM manages project cost on an on-going basis by measuring project performance related to three variables: Budgeted Cost of Work Scheduled (BCWS) [Planned Value (PV)]: Physical work to be done, including the estimated value of this work BCWS to be completed on an activity or WBS component up to a given point in time Budgeted Cost of Work Performed (BCWP) [Earned Value (EV)]: Physical work actually accomplished, including estimated value of this work

QRST method

Budgeted cost for work actually completed on schedule or WBS component during a given time Actual Cost of Work Performed (ACWP) [Actual Cost (AC)]: Actual costs incurred to accomplish the earned value Total cost incurred in completing work on schedule or WBS component in a given period. This must correspond in definition and coverage to that budgeted for BCWS & BCWP

Performance metrics for EVM EVM uses the following key performance metrics to manage project costs: Cost Variance (CV): Indicates if the work accomplished using labour and materials costs more or less than was planned in the project (measured as BCWP minus ACWP) Schedule Variance (SV): Overall assessment in monetary terms of the progress of work packages in the project scheduled to date (measured as BCWP minus BCWS) Cost Performance Index (CPI): Measures cost efficiency of work done to date. CPI<1 indicates cost over-run and CPI>1 indicates that the costs are within budget (calculated as BCWP/ACWP) Schedule Performance Index (SPI): Measures scheduling efficiency and predicts completion date. It is used with CPI for projecting project completion status. SPI <1 indicates that the project is behind schedule and SCI>1 indicates that the project is ahead of schedule (calculated as BCWP/BCWS).

Prediction metrics of EVM For a project manager, it is critical to have a mechanism that pre-empts the cost and schedule over-run to plan its completion on schedule. EVM uses two metrics for this – Estimate At Completion (EAC) and Estimate To Complete (ETC). EAC is a forecast of most likely total project costs based on project performance and risk quantification. EAC is measured as ACWP plus ETC. ETC is a forecast of additional costs that will be incurred in future. This is calculated by considering future cost trends and corrective actions to be taken to manage EAC. 66

Modern Plastics & Polymers | April 2012

Triggers for cost over-runs Cost over-runs triggered at different phases of a project: Proposal phase (failure to understand customer requirements, unrealistic appraisal of in-house capabilities, underestimating time requirements) Planning phase (omissions, inaccuracy of work breakdown structure, misinterpretation of information, use of wrong estimating techniques, failure to identify and concentrate on major cost elements, failure to assess & provide for risks) Negotiation phase (forcing a speedy compromise, procurement ceiling costs, negotiation team that must ‘win this one’) Contractual phase (contractual discrepancies, difference in statement of work and request for proposal requirements, difference in proposal & project teams)

uantity

ate

pecification

ime

QRST of cost variations

Design phase (accepting customer requests without management approval, problems in customer communication channels, data items & design review meetings) Production phase (excessive material costs, unacceptable specifications, manufacturing and engineering disagreement)

Recovery actions for PCM On the basis of EVM, project cost management has to manage ETC to ensure that EAC is within acceptable limits. Some recovery actions that can be taken are as follows: Push for compliance- Try and maintain original plan and do not accept potential changes Recover in later tasks- Future plans must reflect in the project schedule

Add resources- Get additional help, consider potential increase in project expenditure and possibility of diminishing returns when adding resources Accept substitutions- When something is unavailable or expected to be late, substitute a comparable item and consider any potential effects on performance Use alternative work methodsFind an expedient way to complete the work and check its impact on cost & schedule Accept partial deliverablesDelivering only some of the items may keep the project moving forward Offer incentives- Offer bonus or other inducements to improve performance Renegotiate cost and schedule targets- Extend deadline or increase budget Reduce scope- Reduce quality and performance requirements of deliverables to reduce the work required, but all stakeholders must agree on this course of action

In a nutshell PCM must influence the factors affecting cost baseline; ensure that requested changes are agreed upon; manage the changes; monitor cost performance to detect variances from cost baseline; record all changes against cost baseline; prevent incorrect, inappropriate or unapproved changes from being included in the reported cost or resource usage; and work to bring expected cost over-runs within acceptable limits.

M Hariharan practises consultancy in the field of cost management, lean thinking, constraint management, management control system and business excellence as Founder Director at Savoir Faire Management Services. Savoir Faire helps organisations to improve their profitability by aligning their people and processes to customer value and articulate the bottomline impact using the cost excellence (CE©) model. Email: hari@sfccostmanagement.com

AUTOMATION TRENDS: Automatic die changers

Steering the manufacturing

might

The ever-evolving nature of the plastics industry is driving technological sophistication, with automation being a key ingredient for a more streamlined manufacturing process. Lionel Alva highlights the changing dynamics of plastics manufacturing, the significant role of automatic die changers for injection moulding machines and their effect on the plastics processing.

he high cost of initial design in terms of time, money and marketshare is well understood. With the die-making process at the helm of the manufacturing process, due care must be taken to ensure its smooth functioning. Another key reason is that many plants in India still do not take an integrated approach to invest in modernisation. The focus, instead, is on the production capacity of machines. A more systemised approach that would help streamline the production process is often neglected due to focus on the production capacity of machines. However, industrial paradigms strongly depict how the profitability of investing in reducing setup times allows for a remarkable 70-90 per cent savings potential over conventional, completely manual methods for making moulds and dies. Thus, it is crucial that manufacturers work to reduce this set-up time in order to stay ahead of the competition. Since most engineering thermoplastic parts are fabricated by injection moulding, the use of an 68

Modern Plastics & Polymers | April 2012

automatic die changer for such machines will enhance the quality and consistency in high-output plastics processing. But, to achieve this, the designer must have a keen understanding of the overall manufacturing process.

Need of the hour Considering the competition in the industry, the emphasis has increased on a standardised approach that utilises just-in-time inventory techniques for production. Also, lead times are crucial to the success of an organisation, and greater pre- and post-production planning is required. With the Indian plastics industry being largely fragmented and driven by Small and Medium Enterprises (SMEs), this provides a significant challenge since there is little scope for error in this era of cut-throat competition driven by complete enterprise solutions. Thus, there is a pertinent need to develop techniques that can improve lead times and enhance quality & consistency in production. A quick die-change system is perhaps the most crucial aspect of

a paradigm shift in the manufacturing approach. Anand Kshatriya, Manager-New Product Development, Renata Precision Components Pvt Ltd, emphasises, â&#x20AC;&#x153;Automatic die changers are the need of the hour that focus on consistency of output by making a process cleaner and saving valuable time. With rising industrial standards, the injection moulding process is expected to deliver the highest output at the lowest possible cost. Automatic die changers can considerably reduce the downtime of machines while changing the mould, and with minimum possible labour involvement. Changing die in less than three minutes is practically possible, this increases the total output of the machine and is integral to the highly competitive Indian scenario. This will allow for standardisation of moulds for particular machines, and hence ensure better control on manufacturing.â&#x20AC;? He further adds, â&#x20AC;&#x153;Hydraulic and hydromagnetic automatic die changers facilitate controlling the entire clamping mechanism with one button, and are

Automatic die changers

more convenient and technologically advanced than conventional mechanisms. This will improve the quality of output due largely to mechanised manufacturing systems with quality checks in place. With implementation on a trial basis started by medium- to large-scale industries, this flawless system with a quick changeover aimed at cost reduction would be the driving force behind the popularity of such systems in the near future.”

Design considerations Melting the plastic material and injecting it into the mould are the functions of the plastifying and injection system. The rate of injection and pressure achieved in the mould are controlled by the machine hydraulic system. Injection pressures are in the range of 35-138 MPa (5,000-20,000 psi). The melt temperature varies between a low value of 205°C (400°F) for acetal resins to a high value of about 300°C (570°F) for some of the glass-reinforced nylon and Polyethylene Terephthalate (PET) thermoplastic polyester resins. Vinod Sutariya, Head of Department - Marketing, Indo German Tool Room, Ahmedabad, avers, “The automobile industry and heavy parts manufacturers are among the key users of this technology. It bears relevance especially with engineering plastics where the mould weight is higher and production lead time is important. The role of an injection moulding machine manufacturer is important in this regard since machines have to be designed in accordance to specifications provided by the customer.” Various design considerations for Quick Mould Change (QMC) system are as under: Size of the machine (tonnage) and machine & moulds Mould fixed and moving side-platen thickness must be standardised Direction of the mould change could be vertical or horizontal Rail construction Mould positioning slot and mould plate chamfering

Two systems for QMC – hydraulic clamp-type and magnetic machine platen-type – as well as machine & mould design Hydraulic circuit design for QMC and weight & size of the mould – for selection of mould clamping device If pressure drops, the system can add pressure automatically and become interlocked with the machine to avoid mould damage Adjustable height range of machine Mould positioning slot An important point is that the moulding cycle can be as short as two seconds or as long as several minutes, with one part to several dozen products ejected each time the mould opens. The cycle time can be limited by heat transfer capabilities of the mould, except when machine dry cycle or plastifying capabilities are limiting.

Time saved is money saved A quick die-change system could be a game changer for plastics manufacturers, especially those involved in manufacturing of engineering plastics. The foreseeable advantages are apparent both in the long term and short term since it leads to a considerable reduction in manufacturing cycles, giving room to manufacturers to respond quickly to client needs. It will provide them with an opportunity to survive in an unfavourable economy with periodic changes in demand. While the initial cost of such an automation process may be high, it is more than offset by the significant advantages it offers to the manufacturer where profit is the key to survival in a largely volumedriven market. Also, a standardisation of the process would reduce the need for constant maintenance at every stage of the manufacturing cycle while improving on the quality and consistency of production. While it may not be something as a drastic as re-inventing the wheel, automatic die changers are of great significance for an assembly line. Email: lionel.alva@infomedia18.in

The injection moulding process is expected to deliver the highest output at the lowest possible cost. Automatic die changers can considerably reduce the downtime of machines while changing the mould, and with minimum possible labour involvement. Anand Kshatriya Manager - New Product Development, Renata Precision Components Pvt Ltd

The automobile industry and heavy parts manufacturers are among the key users of this technology. It bears relevance especially with engineering plastics where the mould weight is higher and production lead time is important. Vinod Sutariya Head of Department - Marketing, Indo German Tool Room, Ahmedabad

April 2012 | Modern Plastics & Polymers

ENERGY MANAGEMENT: Hybrid machines

Injection moulding has been the preferred processing technology for part manufacturing that requires high output and accuracy. Of the various types available in this segment, hybrid injection moulding machines are gaining wide acceptance due to a number of reasons. Avani Jain assesses the cost-quality ratio of these machines.

he Indian injection moulding machinery industry is incessantly setting up new highs year over year, thanks to the increased ability of Indian machinery suppliers to accommodate into their machines enhanced technologies available across the world. An injection moulding machine can be classified into following types – hydraulic, mechanical, electric and hybrid. Of these, hybrid injection moulding machines are gaining prominence due to the benefits these provide to customers.

Types of machines Ostensibly, the predominant type available in the market is the hybrid injection moulding machine. The mechanical machines use the toggle-type system for building up tonnage on the clamp side of the machine. The electric or allelectric injection moulding machines are new in the market but are becoming popular due to their energy efficiency, greater cleanliness, quick start-up, better repeatability and noiseless operations. But, the cost of these machines is higher by 50-200 per cent than the conventional hydraulic systems. The fourth type – hybrid injection moulding machine – 70

Modern Plastics & Polymers | April 2012

combines the best features of hybrid and electric systems. Amit Mahant, Director, PK Plastic International Pvt Ltd, notes, “It is predicted that by the end of 2012, as many as 20-25 per cent of all installed machines would be all-electric or hybrid machines, concentrating in the 50- to 500-tonne range.”

help increase energy efficiency, leading to smaller footprint and low operational costs. Servo drive when idle, during the cooling time, does not consume energy, ie, it saves the flushing energy. Moreover, the amount of energy needed for oil cooling is lower in hybrid machines.”

Eliminating the demerits Identifying the merits The hybrid machines combine features of both the electric and hydraulic machines. Mahant says, “These features include hybrid clamping design with electric servo motor, core pull, part ejection and carriage movement powered by a gas accumulator & variable-volume hydraulic pump.” As compared to conventional hydraulic machines, hybrid machines are better in many ways. Mahant notes, “These are noiseless and can save power by 25-30 per cent, which depends on product cycle to cycle. Also, compared to electric machines, these cut down energy consumption significantly, thus reducing operating costs & addressing some of the associated environmental concerns.” Hybrid injection moulding machines ensure low cycle times and are environment-friendly. Mahant notes, “The servo drive in the hybrid machines

Hybrid injection moulding machines also suffer from certain limitations. Mahant notes, “Their merits are less when compared to electric machines. The electric machines are quieter, faster and have higher accuracy than hydraulic machines. Contamination and oil maintenance is not a problem with electric machines. Further, in case of hybrid machines, manufacturer has to take care of the servo drive against dust and contamination. Also, these require an in-built voltage stabiliser to prevent fluctuations in power ratings.”

The cost factor With regard to the cost of hybrid machines, Mahant says, “At present, hybrid injection moulding machines are costlier than conventional hydraulic machines by 35-40 per cent. The cost of these machines is 20-25 per cent lower than all-electric injection moulding machines.

Hybrid machines

The main reasons for this are servo drives, variance in machine specifications by manufacturers and application-based machine models.” He adds, “In future, the price can be reduced by making available different types of servo drives and manufacturing more number of machines. Other factors may also affect the market for hybrid injection moulding machines in the future.”

Future projections The future trends for improving the quality and reducing the cost of hybrid machines will include multiple factors. “The performance and quality of machines can be improved by using more electric servo drives, greaseless tie bars, etc. Hybrid machines need to have two or three servo drive to eliminate more number of hydraulic systems, oil tanks or reservoirs. Greaseless tie bars will help eliminate part contaminations,” suggests Mahant. In future, hybrid machines will face tough competition from the all-electric

machines. The only disadvantage with electric machines at present is that these are costly and only few companies in India are manufacturing these machines. Further, these machines cannot go beyond a certain tonnage such as 100-140 tonne, and thus are not suited for large-scale productions. In such a scenario, the hybrid injection moulding machines can win the competition, as these are better than the conventional hydraulic machines and less costly than all-electric injection moulding machines. Thus, both all-electric and hybrid injection moulding machines will find major applications in the automotive, agriculture, electrical & electronic, packaging and medical sectors because of their energy-saving claims. In today’s competitive world, machines with higher output and lower power consumption per unit of output will be the winners. Thus, the industry must be proactive in bridging the technology gap in high-end processing machines and processes. Email: avani.jain@infomedia18.in

The performance and quality of machines can be improved by using more electric servo drives, greaseless tie bars, etc. Hybrid machines need to have two or three servo drive to eliminate more number of hydraulic systems, oil tanks or reservoirs. Greaseless tie bars will help eliminate part contaminations. Amit Mahant Director, PK Plastic International Pvt Ltd

April 2012 | Modern Plastics & Polymers

POLICIES & REGULATIONS: Expansion projects

Achieving economy of scale

with

industry-friendly policies In this era of many astonishing industrial developments, probably no industry has undergone such rapid growth and development as the plastics industry. In order to consolidate their presence in a growing market, industry players are planning major expansion drives. Lionel Alva and Annabel Dsouza highlight some critical factors prompting the industry to raise the stakes.

he rapidly expanding sphere of influence of the plastics industry within a short span of time has deeply impacted key economic sectors in India, such as agriculture, infrastructure, healthcare and consumer goods. But, the nature of this growth is subjective and the core competence of the Indian plastics industry as a whole is questionable since the future of the industry seems uncertain. All seems to be going well for India’s plastics industry, whose remarkable growth has outpaced the country’s Gross Domestic Product (GDP). It has emerged as a ` 85,000-crore industry, employing directly and indirectly over four million people and has achieved an export turnover

Modern Plastics & Polymers | April 2012

of ` 13,000 crore. In contrast, per capita consumption of plastics in India is among the lowest in the world, and the industry lies fragmented and largely driven by Small and Medium Enterprises (SMEs) that lack the necessary technological prowess to compete globally. Much needs to be done to consolidate the industry’s prospects to help it acquire its true potential.

On an expansion drive The forecast for the plastics industry seems to be positive, with unprecedented opportunities in both domestic and international market. Credit Rating and Information Services of India Ltd (CRISIL) states that the world

trade in plastics is expected to reach 140 Million Metric Tonne (MMT) by end of 2012, providing a lucrative opportunity for India. However, considering its meagre 1.5 per cent share in world export volumes, the country is not well equipped to capture this opportunity. The Indian plastics industry needs to strengthen capacity, upgrade facilities, improve productivity and increase use of critical plastics applications. This will facilitate economy of scale, allowing industries to adopt better technology and waste management strategies while enhancing quality & consistency in production. In this regard, India is performing well, as 60 per cent of plastics here is recycled as compared to the world average of 20-25 per cent. Uday Shah, Managing Director, Star Technocrates Pvt Ltd, says, “Some crucial factors to consider while undertaking expansion projects include demand from the local customer base and export potential. Having the new site located close to a well-connected port significantly reduces the cost of internal logistics and enables new production to be market-ready & sustainable.” He adds, “Another factor is the use of latest technology. With the Indian plastics industry competing on the global scale in terms of products and solutions, one must invest in state-of-the-art manufacturing technology & practices. Technology is critical in plastics processing and enables long-term returns on initial investment. Break-even period varies with the type of expansion, so manufacturers must be cautious while planning expansions.”

Expansion projects

Tapping domestic potential While every government report on the plastics industry has emphasised the need for a facilitative policy to foster growth for this industry, little has been seen in terms of initiative. The Indian plastics industry faces several handicaps such as cost of capital, feedstock, electricity and local taxes & tariffs as compared to producers in the US, Europe and other parts of Asia. Today, India has the lowest import duties in the world even though producers here do not enjoy any competitive advantage in raw material, capital cost, energy or other conversion cost. Saudi Arabia has emerged as a major producer of plastic raw materials due to huge advantage in feedstock, which costs one-tenth of current prices elsewhere in the world, and the country levies 12.5 per cent import duty on polymers to protect its industry. In contrast, India, with no significant advantage in the cost of feedstock, energy or capital levies 5 per cent import duty on polymers. Here, import duty on polymers is lower than in the US, European Union, China, Malaysia

and other Asian countries. Further, Government of India is aggressively pursuing Free Trade Agreement (FTA) with many of these countries and trading blocs proposing to bring import duty to zero. This move will further deteriorate the position of Indian producers, taking away the employment opportunities offered by the industry. It is necessary to break away from the bureaucracy and the government must bring forth initiatives to boost the development of this sector. Despite globalisation, the domestic market for manufacturing has not acquired the support it needs. A greater awareness is required as there is a lot of misinformation, due to which a facilitative policy regime for growth has not been established yet. There is a need to tap the tremendous demand in the domestic market. The plastics industry has grown despite tough conditions, and a favourable policy will position it such that India can establish itself as a major world player. Email: lionel.alva@infomedia18.in Email: annabel.dsouza@infomedia18.in

With the Indian plastics industry competing on the global scale in terms of products and solutions, one must invest in stateof-the-art manufacturing technology & practices. Technology is critical in plastics processing and enables long-term returns on initial investment. Uday Shah Managing Director, Star Technocrates Pvt Ltd

April 2012 | Modern Plastics & Polymers

STRATEGY: Plastic products recycling

Focussing on the economics angle With increasing focus on sustainable development, the plastics industry is making efforts to recycle plastics. Recycled plastic products have many applications and offer a cost-effective solution across industries. Avani Jain analyses the profitability quotient attached to this business.

lastics finds immense applications in nearly all verticals of the manufacturing industry – from automotives to packaging. But, the industry is realising the vast opportunities offered by recycled plastics. In India, about 3.6 million tonne of plastics is recycled every year. The major types of plastics recycled include Polyethylene (PE), Polypropylene (PP), Polyethylene Terephthalate (PET), Polyvinyl Chloride (PVC), Acrylonitrile-Butadiene-Styrene (ABS), Polystyrene (PS), Nylon, Polycarbonate

Modern Plastics & Polymers | April 2012

(PC), High-Impact Polystyrene (HIPS), Poly(Methyl Methacrylate) (PMMA) and other engineering plastics.

recycled plastics will offer more benefits than normal plastics.

Application areas Current trends Not many companies are involved in recycling of plastic products. K M Shah, Managing Director, NU-VU Conair Pvt Ltd, notes, “Recycled plastic products find usage in definite market segments. Recycled plastics cannot be used in all industries, such as food and medical industries.” However, there are various sectors in which innovative use of

Plastic bags can be recycled and reused further. Recycled plastics can be used in various areas, such as in making artificial goods and road construction. At present, recycled plastics finds maximum usage in the artificial goods industry. Its use in road construction is a relatively new concept, which is slowly growing in India. The advantage of using plastic waste in road construction is noteworthy, as it does not need employing new and/or costly high-tech machinery. It improves the performance of the road and helps it last longer, thus solving the problem of disposal of harmful plastic waste. Apart from channelising waste material towards building the nation’s infrastructure, roads made from recycled plastics have enhanced longevity and overall performance. The cost of plastic road construction may be slightly higher than that of conventional methods. But this should not be a deterrent to adoption of the technology, as the benefits are significantly higher than the cost. Recycling or reuse of materials for road construction can have direct and indirect economic benefits. It also reduces transportation and production costs since materials are reused. In packaging, recycled PET (rPET) sheets can be effectively used for pharma and blister packaging. The increased usage of PET bottles has resulted in high availability of PET bottle flakes, and this is bound to grow further. The rPET sheets can be converted into products such as carpet fibre, strapping, moulding compounds

Plastic products recycling

One must select the right method with all precautions and appropriate machinery for building proﬁtability through efﬁcient recycling of plastic products. There are numerous applications for recycled plastics, such as road constructions and buildings. K M Shah Managing Director, NU-VU Conair Pvt Ltd

and non-food containers. Recycled PET is accepted as the preferred material due to its numerous superior properties that include crystal-like clarity and sparkle, toughness, lightweight, good gas barrier, etc. It is also resistant to solvents as well as corrosion, besides being recyclable and regrindable.

Cost factor Every process has a cost involved but that must be justified. Shah says, “Recycling of plastics is a cost-effective solution, which needs to be developed in a better way. It gives an edge to convertors in today’s competitive market. There are certain areas where recycled plastics in tolerable percentage can be used effectively. This can make the products cost-effective.” Recycling of plastic products is definitely a profitable business but a few points must be taken into consideration. If plastics is recycled using correct technologies and machines, then the end product will be of good quality and yield good margins to manufacturers. Manufacturers are gradually identifying the advantages of recycling plastic products and, in future, this industry will see a progressive growth.

Smart strategies

We manufacture machines that recycle plastic wastes. This is proﬁtable because we do not have to buy fresh plastics and can make products from the available resources. But, customers are not showing much interest in such products, and hence their perception needs to be changed. Bharat Mistry Partner, Ash Win Engineers

Modern Plastics & Polymers | April 2012

Many companies have taken up the task of recycling plastic products and are also reusing them. Bharat Mistry, Partner, Ash Win Engineers, avers, “ We manufacture machines that recycle plastic wastes. For example, the entire plastic tanks are cut into small pieces by a scrap cutter, and these pieces are fed into a solid granulator where their size is further reduced to 10 mm. These are then put into a recycling extruder in which fine plastic granules are obtained; these granules are used to make entirely new product. Therefore, we are not only making the machine, but also reusing the plastic waste.” He further adds, “This is profitable because we do not have to buy fresh plastics and can make products from the available resources. But, customers are not showing much interest in such products, and hence their perception needs to be changed.”

Many companies are developing new technologies that enable efficient recycling of plastic products. Shah says, “We manufacture machinery (auxiliary equipment) that can help processors in regrinding their plastic materials. We are also directly involved in recycling of plastic wastes. The main waste at our unit is injection and blow moulding screws. These are ground by our granulators and reused further.”

Future trends In the near future, recycled plastics materials are expected to be increasingly used in road construction. As a result, India will have strong, durable and eco-friendly roads, which will solve the problems associated with plastic wastes. Going further, this will improve the environment while also creating a source of income. Much has been said about recycling of plastics, but integration of conventional waste management methods with commercial viability requires skills and technologies. Shah notes, “One must select the right method with all precautions and appropriate machinery for building profitability through efficient recycling of plastic products. There are numerous applications for recycled plastics, such as road constructions and buildings. Thus, in the time to come, there will be many companies taking interest in this area.” The trend is setting in, but this industry is still at a nascent stage. Further, unlike foreign countries, companies in India still consider it as a secondary task and do not employ proper technologies for recycling of plastic products. Thus, in order to build profitability through recycling of plastic products, companies need to invest in latest technologies and trends. Taking into consideration the ongoing efforts by various companies, the goal of the plastics industry is to become more environment-f riendly in the future. Further, with the latest machinery and methods making inroads to the country, the recycling industry will reach new heights and recycled plastics will see maximum application in various industries. Email: avani.jain@infomedia18.in

TIPS & TRICKS: Purchasing used injection moulding machiner y

Guidelines to strike the right deal Injection moulding is one of the most preferred methods in plastic processing. Hence, with the rise in demand for injection moulded parts, the market for used injection moulding machines is also on the rise. Anwesh Koley explores various points that must be considered before purchasing a used injection moulding machine. Anwesh Koley

ith the anti-dumping duties levied on Chinese plastics injection moulding machines, buyers in India are now looking for used plastics injection moulding

machines, considering the lead times of domestic machine manufacturers being more than two month. This leads to processors turning to used plastics injection moulding machines, which are readily available at 45-50 per cent of the price of the new machine. To provide market processors with high-quality

used machines at affordable prices, the secondary market for injection moulding machines has seen a host of improvements over the years. Email: anwesh.koley@infomedia18.in (With inputs from Rohan Shahane, Regional Director â&#x20AC;&#x201C; South East Asia, MachinePoint Group)

Following are some points to consider before purchasing used plastics injection moulding machines:

Installing AC drive systems on the right injection moulding machine can yield remarkable results. But, it is not easy without the right combination of equipment and experience to determine if a system is justified in a given situation. Thus, before buying a used machine, one must ensure that the AC drive has long cooling time and an integrated electrical system.

Used machinery offered for sale should be properly checked and inspected in terms of functionality and condition, especially the electrical parts, by the buyers to ensure that they get what they pay for. This proves beneficial in terms of productivity and saving money for a company that is unable to invest a huge amount.

In most injection moulding machines, under most circumstances, the hydraulic oil pumped to run the machine is not used but dumped back into tank through a relief valve. A valve is the hydraulic equivalent of a mechanical brake, which converts energy to heat. Thus, while purchasing used injection moulding machine, the hydraulic oil around the valve should be checked to avoid congestion.

While choosing a used injection moulding machine, one must consider the different forms of power available. Although hydraulic machinery is the most conventional, a hybrid equipment can increase energy efficiency, strength and accuracy. In the early stages of development of business, a used device is more costefficient and gives time to familiarise the company with the productâ&#x20AC;&#x2122;s advantages.

The condition of the screw/barrel assembly and mould components must be inspected, as often, the machines do not undergo regular maintenance or service contracts by original equipment manufacturers. Each equipment used in an injection moulding machinery has specific applications. The buyer must have a thorough knowledge of the usage of a component in the mould machinery.

Used machinery is usually not warranted; hence, one must know the extent of refurbishment and the actual state of the machinery. One should find out about the state of maintenance and look for worn out parts. It is advisable to insist on a test run and be alert for signs of machine ill-health such as unusual vibrations or noise.

Modern Plastics & Polymers | April 2012

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.

New facility

moulding and automated tape layup. Construction of the facility will begin shortly, and Carbures plans to have the facility online in the second quarter of 2012. It will employ 50 people.

Project news

Project location

Lubrizol Corporation has proposed to set up a ` 1,175-crore Chlorinated Polyvinyl Chloride (CPVC) industrial unit in a joint venture at Dahej Gujarat Industrial Development Corporation (GIDC), Bharuch, Gujarat. The construction of the unit will start in January 2013 and the production by October 2014. CPVC products have great demand in South-East Asia, Middle East and Africa. Considering the investor-friendly and transparent policies and best infrastructural facilities in Gujarat, the company has chosen the state for setting up this unit.

Greenville, USA

Project location

Plastic additives

Dahej, Gujarat

BASF

Project cost

Project type

` 1,175 crore ($ 245 million)

New facility

Implementation stage

Project news

Proposed

BASF has broken ground on a previously announced multi-million dollar plastic additives facility at the Bahrain International Investment Park, with production of Customer Specific Antioxidant Blends (CSB) to start in 2012. The company said that the investment was spurred by a supply agreement with Astra Polymer, the Damman, Saudi Arabia-based supplier of masterbatch, additives and compounds, as well as opportunities presented by the countries of Gulf Cooperation Council (GCC), which represent one of the fastest growing sectors of polyolefin production worldwide. The new operation will become one of the world’s largest CSB plants with an annual capacity of about 16,000 metric tonne.

Chlorinated Polyvinyl Chloride (CPVC) Lubrizol Corporation

Project type

Contact details: Aant Pant Lubrizol India Pvt Ltd 9/3, Thane Belapur Road, Turbhe Navi Mumbai - 400705 Tel: 022-27672568-74 Fax: 022-27632407 Email: apan@lubrizol.com

Composites processing Carbures

Project type New facility

Project news Spain-based Carbures plans to invest $ 6.5 million to build a composites manufacturing plant in Greenville, USA. The company selected the location in part due to its proximity to potential customers like Lockheed, Boeing, Proterra and BMW. Processes will include hand layup, resin transfer 80

Modern Plastics & Polymers | April 2012

Project cost $ 6.5 million (€ 4.9 million)

Implementation stage

Planning Contact details: Reinhold Lutz BASF Bahrain PO Box 18696 Al Seef, Bahrain Tel: +973-17585251 Fax: +973-17583400 Email: reinhold.lutz@basf.com

Planning

Polysilicon Contact details: Carbures USA 5, Hercules Way Donaldson Center Airport Greenville South Carolina - 29605 Tel: +1-864-593 3934 Email: info@carbures.com

Project location Bahrain

Project cost Not known

Implementation stage

Punj Lloyd

Project type New contract

Project news Punj Lloyd has bagged an Engineering, Procurement and Construction (EPC) contract to set up Qatar’s first plant for manufacture of polysilicon, the raw material used to build solar cells. The contract has been awarded by Qatar Solar Technologies (QSTec) and is scheduled to be commissioned by mid-2013. The EPC contract awarded to the Indian conglomerate involves the establishment of 4,000 Tonne Per Annum (TPA) of polysilicon manufacturing capacity. The total envisaged capacity of the plant is 8,000 TPA of high-purity solar grade polysilicon at an investment of $ 1 billion. The work under the contract involves residual basic engineering & design, detailed engineering, procurement, supply, manufacturing, construction and commissioning, among others.

Project location Ras Laffan Industrial City, Qatar

Project cost $ 1 billion approx

Implementation stage Planning Contact details: Punj Lloyd House 17-18 Nehru Place New Delhi - 110019 Tel: 011-26466105 Fax: 011-26427812 Email: info@punjlloyd.com

EVENT LIST

National Vinyl India 2012

Die & Mould India 2012

Packplus South 2012

This conference is dedicated to the surging vinyl and chlor alkali sectors of the Indian chemical industry. This event will witness industry leaders sharing their perspectives on the current scope and future potential of PVC applications, feedstock availability and pricing as well as trends in health, safety and environment; April 12-13, 2012, at Hotel Grand Hyatt, Mumbai

With plastics processing scaling new heights in India, the die & mould industry is of particular significance to plastic parts manufacturing. This event will focus on tooling, CAD/ CAM solutions, rapid prototyping & modeling, moulding machine/die casting machine, texturising, gauges, die spotting, etc; April 19-22, 2012; at Bombay Exhibition Centre, Mumbai

This will be an opportunity to focus on the emerging opportunities in the fast industrializing markets of South India. This event will emphasize on plastics packaging applications through its latest trends and technologies, especially by SMEs; July 6-9, 2012; at Hyderabad International Trade Exposition Centre (HITEX), Hyderabad

For details contact: Nidhi Verma ElitePlus Business Services Pvt Ltd 61, Radheya, 14th Road, Plot 359 Khar (W ), Mumbai 400052 Tel: 022-26000556/26000555 Mob: 09322335560 Fax: 022-26000556 Email: nidhi.verma@eliteplus.co.in Website: www.eliteplus.co.in

For details contact: Tool & Gauge Manufacturers Association of India (TAGMA) A-33, Nandjyot Industrial Estate Safed Pool, A K Road Mumbai - 400 072 Tel: 022-28526876/28508976 Fax: 022-28503273 Email: mumbai@tagmaindia.org Website: www.tagmaindia.org

For details contact: Prateek Kaushik Print Packaging Pvt Ltd E-6, 1st Floor Lajpat Nagar 2 New Delhi, India Tel: 011-2981 2833/2981 2934/2981 2834 Mob: 09313011029 Fax: 011-4172 2130 Email: www.print-packaging.com

International Chinaplas 2012 This edition of Chinaplas will continue the legacy of bringing solutions to the global plastics industry while highlighting the opportunities within Asia. The exhibition will showcase the most innovative and advanced plastics and rubber machinery and raw materials; April 18-21, 2012; at Shanghai New International Expo Centre, PR China For details contact: Lillian Tse Adsale Exhibition Services Limited 6th Floor, 321 Java Road North Point Hong Kong Tel: +852 2516 3374 Fax: +852 2516 5024 Email: publicity@adsale.com.hk Website: www.chinaplasonline.com

forefront of technology and innovations. This event will highlight machines for foam, reactive and reinforced resins, laboratory control & test equipment, ancillary equipment, raw materials, acrylics, polyamides, polyolefinics, styrenes, vinylics, thermoplastic polyesters, masterbatches, fillers, reinforcements, additives, etc; May 8-12, 2012; at Fiera Milano, Milan, Italy For details contact: Promaplast Centro Direzionale Milanofiori Palazzo F/3 - 20090 Assago Milan, Italy Tel: +39 02 8228371 Fax: +39 02 57512490 Email: info@promaplast.org Website: www.plastonline.org

Plastivision Arabia 2012 PLAST 2012 Among the world’s leading markets for plastics processing machinery, Italy is at the 82

Modern Plastics & Polymers | April 2012

While serving as an international platform for the Indian plastics industry, this exhibition will facilitate business

prospects for all major global players in the region. The event will promote opportunities and provide exposure to manufacturers of raw material & machinery, auxiliary equipment, pigments & additives, dies & moulds, etc; May 14-17, 2012; at Expo Centre Sharjah, United Arab Emirates For details contact: AIPMA House A-52, Street No. 1 MIDC Marol Andheri (E), Mumbai - 400 093 Tel: 022-28217324/25, 28352511 Fax: 022-28216390 Email: office@aipma.net Website: www.plastivisionarabia.org

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

EVENT PREVIEW: Die & Mould India 2012

Gearing up for global opportunities Over the years, Die & Mould India has emerged as a leading platform that represents the aspirations and concerns of Indian tool rooms. As the tooling industry strives for global standards of excellence, Annabel Dsouza unveils the potential of Die & Mould India 2012 and the opportunities awaiting the industry.

ith the global tooling industry progressing towards high-tech solutions across all applications, the 8th edition of Die & Mould India will expose Indian tool rooms to global standards of quality and consistency, thus keeping pace with higher growth rates in the manufacturing sector. Organised by Tool & Gauge Manufacturers Association of India (TAGMA), Die & Mould India 2012 will be held from April 19-22, 2012, at Bombay Exhibition Centre, Mumbai. P N Surendranath, Executive Director, TAGMA, says, â&#x20AC;&#x153;Tool rooms today are under tremendous pressure from shrinking budgets and production cycle times. The solution lies in a concerted team effort of software technologists, tool-cutting engineers, machinery manufacturers, CAD/CAM solution providers, etc. Die and mould technology covers the entire manufacturing sector from the largest to the smallest application, beginning with dimensional research, prototype development and production. Indian tool rooms are currently under pressure 84

Modern Plastics & Polymers | April 2012

from Original Equipment Manufacturers (OEMs), who demand faster product turnover at competitive prices.â&#x20AC;?

Tapping the plastics potential Indian tool rooms are increasingly focussing on plastic moulding due to a healthy growth with rising demand for highquality plastics. This is further led on by a surge in demand for high surface finish and precision moulds with shorter moulding cycles to achieve optimum productivity & quality. The key considerations for moulding machines are tonnage, clearance between platen, injection pressure, distance

In a nutshell What: Die & Mould India 2012 When: April 19-22, 2012 Where: Bombay Exhibition Centre, Mumbai Net exhibition space: 20,000 sq m No of visitors: 30,000+ No of exhibitors: 300+ Key exhibitor range: Press tools & gauges, hot runner systems, CAD/CAM system, accessories for machine tools, etc

between tie bars, height of closed mould, height of fully open mould, etc. The injection mould manufacturing process includes machining of steel plates, converting flats and rounds to core/cavity inserts and other critical parts with Computer Numerical Control (CNC) milling, CNC Electrical Discharge Machining (EDM), CNC wirecut, etc. Reducing the amount of metal used, wall thickness of plastic products and improving efficiency of the final product, all require continued efforts.

Concurrent event Die & Mould India offers a complete range of technologies for plastics injection moulding, hot runner systems and latest automation & measuring solutions. Being the biggest die & mould focussed event, the exhibition leaves no stone unturned in consistently meeting the expectations of both exhibitors and visitors. Many international and national exhibitors will present modern technology and solutions, helping industry professionals connect, network and explore business prospects with market leaders. Email: annabel.dsouza@infomedia18.in

EVENT FOCUS: Chinaplas 201 2

Chinaplas 2012 Event Preview: Heralding unlimited opportunities ........................................................................................................................................ 86

In the News ........................................................................................................................................................................ 88 Product Showcase ............................................................................................................................................................ 90

April 2012 | Modern Plastics & Polymers

EVENT PREVIEW: Chinaplas 2012

Heralding unlimited opportunities Now in its 26th edition, Chinaplas has established itself among the foremost trade shows in the world and is one of the most sought-after events in Asia. This edition also promises to demonstrate technology and concepts that will set the pace for a definitive growth of the region’s plastics industry. Here are some of the highlights to watch out for. Lionel Alva

s it marks the beginning of a new epoch in the success story of the plastics industry, Chinaplas 2012, to be held during April 18-21, 2012, in Shanghai, will be of great interest to the latent observer and especially those associated with the plastics industry. The event promises to provide a unique opportunity to understand the varied pan–Asian plastics industry with experts envisaging robust growth trends. As per industry statistics, consumption of plastics is expected to reach 297.5 million tonne by 2015. This growth is largely driven by the booming market in the Asia-Pacific region, with China and India being the key players. The event will highlight the key factors spurring the unprecedented growth of the plastics industry, such as development of new-age plastic materials, new applications while also addressing environmental concerns, which are changing the outlook towards plastics. The event, being held at the Shanghai New International Expo Centre, will serve as a gateway to enter Asia’s growing plastics industry for the trade and industry associations from across the world. While allowing established players to consolidate their presence on a global stage, the event will provide them with new avenues for growth and help discover novel applications and also acquire a greater cognisance of trends that are driving the industry today.

Sustainability efforts The previous edition depicted an unprecedented interest in environment-friendly plastics such as bioplastics and biodegradable plastics. With growing environmental concerns worldwide, there is an increasing emphasis on ‘green’ technologies such as bioplastics processing and recyclable solutions. This edition has increased the space allotted to the bioplastics zone by 40 per cent in order to provide an impetus to and recognise the enormous potential that bioplastics has for the market today. Concurrent with Chinaplas 2012, the fourth International Conference on Bioplastics and Applications will be held, which will provide an in-depth focus on this segment. World’s leading bioplastics suppliers will display their products at the event. Some of the 86

Modern Plastics & Polymers | April 2012

Chinaplas 2012

Event spotlight Recognised as the second biggest event in the world Estimated to attract more than 100,000 trade visitors 100+ group of buyer delegations expected Exhibition area of over 200,000 sq m Over 2,600 international exhibitors renowned exhibitors in this field include Cardia, Danisco, Ecomann, Esun, Hisun, Kingfa, Mirel Plastics, NatureWorks, Nuvia and Demag. Overseas and Chinese plastics associations will continue to support the conferences, which are expected to reach over 70 sessions this year. The organiser of Chinaplas, Stanley Chu, Chairman-Adsale Exhibition Services Ltd, asserts, “The complicated and changing global economic situation will bring new challenges to China’s economy. Today, enterprises are perplexed by

shortage of labour and electricity in China, and elimination of backward production capacity due to the growing pressure of energy-savings. Chinaplas 2012 will display products such as robot hands, energy-saving servo motors, all-electric injection moulding machines and bioplastics materials, which will offer solutions to address the problems of environmental protection, raw material shortage & new recycling technologies.”

Exploring growth avenues Besides the growing demand from the automobile, mining, chemical, construction and agricultural industries, the Asia-Pacific (APAC) market is propelled by trends such as globalisation and demand for durable products. With rapid urbanisation taking place in the region and lucrative opportunities offered by the APAC market, the plastics sector is set to grow by leaps and bounds in the future. The growth of the plastics industry is attributed largely to a steady rise in engineering plastics, which has been at the forefront of innovation and technological development.

A concurrent event ‘Future Zone’ will be held to display creativity in plastics applications. Its first part, ‘Nurturing Our Future’programme, is for university students and experts from the automotive, plastics & rubber industries to combine plastics & rubber applications and technology to create a new design for ‘Future Car’. The second part, ‘Premium Design Gallery’, will showcase new products from local and overseas companies, which fall in the categories of future transportation vehicle, appliances, architecture and packaging.

Surmising event expectations While tracing the phenomenal rise of the Asian plastics industry, the event is expected to gain attention from companies the world over and focus on ‘green innovation’ that will lead to a paradigm shift in plastics concepts. With advancements in plastic material science and mounting demand for product innovation through highperformance polymers, the global plastics industry is expected to flourish further. Email: lionel.alva@infomedia18.in

April 2012 | Modern Plastics & Polymers

IN THE NEWS

Chinaplas 2012 to focus on energy-efficient LED solutions

Solutions and materials dedicated to the lighting industry, particularly Light Emitting Diode (LED) applications, will be the focus at Chinaplas 2012. Lighting consumes about 20 per cent of China’s overall electricity supply, making power supply tight. Reducing power consumption in lighting is a significant step by China for saving power. LED, due to its energy-efficient and environmentfriendly features, is expected to flourish in the lighting industry. Generally, plastics and rubber composites are used for LED production, eg, polybutylene terephthalate, polymethyl methacrylate, polyethylene, silicone rubber,polycarbonate,glass fibrereinforced epoxy, etc. According to Gong Xiaozhi, Secretary General-Shanghai Illumination Electric Appliance Trade Association, “Applications of plastics and rubber in the lighting industry are expected to grow by 15-20 per cent annually in China. Materials for encapsulation, light reflection, diffusion, dodging, heat dissipation, production of lens, etc, will be in great demand, offering the plastics and rubber industry an opportunity for further growth.”

LANXESS emphasises on ‘Green Mobility’ LANXESS will display a series of its latest technologies and environmentfriendly products under the theme of ‘Green Mobility’ at Chinaplas 2012 – a renowned trade fair in the field of plastics and rubber in Asia. The company will highlight its premium products predominantly used in the electronics, automotive, construction 88

Modern Plastics & Polymers | April 2012

Theme at Chinaplas 2012: The future is in plastics and rubber Aimed at uniting the direction of industry development and building an effective platform to assist the industry in implementing the green concept, Chinaplas 2012 actively aligns itself with the rapid development of China’s plastics & rubber industries by showcasing advanced products, technologies and solutions from local & overseas, under a new theme ‘The future is in plastics and rubber’. A concurrent event ‘Future Zone’ is being organised to display unlimited creativity on plastics applications. The first part of this event, ‘Nurturing Our Future’, programme aims for a collaboration between university students

and experts from the automotive, plastics & rubber industries to combine plastics & rubber applications, technology and innovations to create a brand new design of ‘Future Car’. The second part, ‘Premium Design Gallery’, will feature a series of unique designs of various plastic end-products. Kingfa Sci & Tech Co Ltd, DuPont Titanium Technologies (Shanghai) Co Ltd and Bayer MaterialScience will display products in the automotive, electronics & electrical appliances as well as packaging categories. Plastics and Rubber Processing Machinery and Moulds Manufacturers Association (ASSOCOMAPLAST) will also showcase Italian designed plastic products.

Key buyers from auto industry to visit Chinaplas 2012 Chinaplas 2012 signals a strong relationship of the plastics and automotive industries with many renowned buyers from the automobile and auto components industry joining the event. The automotive industry is enthusiastically supporting the drive towards efficient energy-saving measures and sustainable growth, resulting in faster development of plastics and rubber machines & equipment as well as the mould industries. Advanced moulding techniques combined with injection moulding machinery and hot runner systems, featuring highprecision, efficient, energy-saving and environment-f riendly designs will have a significant effect on research and development & manufacturing and plastics coating industries. It will display its engineering plastics for the automotive industry with a range of Durethan® polyamides and Pocan® polysters, which exhibit features such as high load resistance, halogen-free flame, flame retardancy and good flowablility. LANXESS’s subsidiary Rhein Chemie (RCH) will exhibit its new additive BioAdimide™. This additive enables production of renewable bio-

processes. Some of the key buyers from automobile and auto parts industry have registered for Chinaplas 2012, including BMW, Honda, Great Wall Motor, TE Connectivity and Yanfeng Visteon. An event ‘Future Zone’ will be held concurrent to Chinaplas. It includes a ‘Nurturing Our Future’ competition for which students have been invited to submit their designs combining plastic and rubber applications, technology & innovation to build a brand new ‘Future Car’. based polymers for durable applications with low environment impact. The company’s line of customised range of inorganic pigments for colouring plastics Bayferrox® and Colortherm® will also be featured. These pigments impart features such as ease of dispersion, high thermal stability, excellent weather stability, light-fastness, making these an optimal choice for eco-friendly colouring of plastics.

IN THE NEWS

Key buyers from E&E industry register for Chinaplas 2012 The rapid development of Electronics and Electrical (E&E) industry has increased demand for plastics and rubber. Offering advantages such as low density, light weight, high chemical corrosion resistance, high insulation, flexible design and high recyclability, with the market trend towards high-performance, safe and sustainably developed ecofriendly materials, plastics and its numerous applications have become a major development in the E&E industry. Followed by popularity of personal intelligent telecommunications devices, the application of transparent and electrically conductive thin film used on touch panels is expanding.

W&H emphasises green and clean extrusion & converting technologies

Many renowned buyers from the E&E industry have registered for Chinaplas 2012, eg, Philips, BYD, Panasonic, Schneider Electric, Mitsubishi and Samsung. The event will display a wide range of plastic materials used in the E&E industry, including LightEmitting Device (LED) applications. Plastics and rubber composites are used for LED production, eg, polybutylene terephthalate, polymethyl methacrylate, polyethylene, silicone rubber, polycarbonate, epoxy resins, glass fibrereinforced epoxy, etc.

At Chinaplas 2012, German-based Windmöller & Hölscher (W&H) will display solutions for packaging production with efficient use of energy and raw materials. The company’s VAREX universal blown film line operates on one of the lowest specific energy consumption levels in the industry. With 0.3–0.35 kW/kg, VAREX is about 30 per cent more energy-efficient than its closest competitor. The individual components of the line are optimally tuned to each other to deliver an absolutely constant bubble circumference. When producing flat film, this eliminates the need for trimming the film, resulting in significant savings in material and energy for reprocessing. Each VAREX line features OPTIFIL P, the innovative thickness profile control system. Better film gauge with lower thickness tolerance permits production of thinner films without compromising mechanical strength, resulting in substantial savings of plastic resin during film extrusion. Its automation module, EASY-CHANGE eliminates the need to stop the line for size changes, saving about 100 kg of resin per changeover. PROFILE BOOSTER quickly narrows down film thickness tolerances after line start-up, reducing by 60 per cent the time needed to reach full production levels through waste reduction.

April 2012 | Modern Plastics & Polymers

PRODUCT S SHOWCASE

This section provides information about the national and international products available in the market Co-extrusion blown film machine

Thermoplastic elastomers

The new water cooling downstream 3-layer co-extrusion blown film machine is equipped with water cooling system, 360-degree oscillating nip roller device, EPC and auto-tension controller winder. This machine is suitable for production of food packaging, zipper bags, chips, PP+PE+PP film, PE+PP+PE, PP film, PE film, etc. Material composition is two layers of A+B structure and three layers of A+B+C or A+B+A. The die head is made of highquality alloy steel with nitride and quenching treatments to make sure non-transformed of material under high temperature. Flow channels are hard chrome-plated and highly polished & treated. The PE+PP+PE film has clear and transparent look.

Everlon compounds are high-performance thermoplastic elastomers designed specifically for the production of moulded and extruded products on conventional thermoplastic processing equipment and do not require vulcanisation. It can be seen in numerous processing techniques in which it is used, such as injection moulding, blow moulding, compression moulding, extrusion, etc. In all these processes, Everlon scrap is recycled without loss of its physical properties.

Chyi Yang Industrial Co Ltd Taoyuan County - Taiwan Tel: +886-3-3288686 Email: cymw@cymw.com.tw Website: www.cymw.com.tw

Booth No E6 K05

Ever Polymer Co Ltd Taoyuan - Taiwan Tel: +886-3-3125717 Email: everlon@everlon.com.tw Website: www.everlon.com.tw

: Booth No 1 N4 M3

Gearbox

The EN series injection moulding machine is available in the range of 30-3500 tonne and offers different demands in wide production requirements. Not only servo motor, but to apply energy-savings on the hydraulic system, cooling system and heater system, makes the total energy saving rate much higher than the machines only with servo motor. The new energy-saving injection moulding machines save about 78 per cent consumption.

The Sun Lung gearbox adopts pioneer energysaving greasy chipping adsorption installation design. It has features such as greasy chipping clearance under machinery operation, no need to stop the production line, best transmission efficiency & high-torque and sufficient safety coefficient design, precision of gear grinding up to DIN 1~3 grade, operation noise is below 80 dB, forced lubrication and built-in the cooling & filter system ensure excellent hear dissipation, top-quality SKF bearings to be selected, incorporated with Japanese NOK oil seals, seats being special treatment ensures longer durability, diversified output orientation design, CE & TUV certificated, achieved Germany, Japan, Taiwan, China and other worldwide patents.

Enaiviv Machinery Industrial Co Ltd Tainan City - Taiwan Tel: +886-6-2544328 Email: enaivivs@ms19.hinet.net Website: www.enaiviv.com.tw

Sun Lung Gear Works Co Ltd Tainan City - Taiwan Tel: +886-6-2639969 Email: david@slgear.com.tw Website: www.slgear.com.tw

Injection moulding machine

Modern Plastics & Polymers | April 2012

: Booth No E6 J21

: Booth No E6 M61

PRODUCT S SHOWCASE

Co-extrusion blown film line The three-layer co-extrusion blown film line has Ø250-mm die with production output of 450 kg/hr. It has a continuous type loss in weight gravimetric dosing unit (German-made) and auto thickness profile control (auto air ring) air ring height adjustable, high-efficiency cooling and high output rate (German-made). The IBC computer control system is of US-make. This line has a 360-degree thickness profile measurement with oscillating rail of Germany-make along with width measurement also of German-make. The co-extrusion blow film line has horizontal oscillating take-up unit and back-to-back automatic surface-type winding unit. Kung Hsing Plastic Machinery Co Ltd Chia Yi - Taiwan Tel: +886-5-2374466 Email: ks.sales@kunghsing.com.tw Website: www.kunghsing.com.tw

Booth No E6 K27

High-torque gearbox The TST series super hightorque gearbox is a co-rotating twin-screw extruder gearbox. This gearbox is used for twinscrew extruders starting from a centre distance between screws of 21.5 mm up to a centre distance between output shafts 116 mm. The new system of torque distribution has enabled the company to increase considerably the output speed and also the density of the transmissible torque. The TST gearbox is available in the range starting with a centre distance of 21.5-116 mm. This gearbox is developed by featuring excellent compactness. Also, for this series, the axial thrust is supported by an axial rollertype swivel thrust-bearing of the 294-E series, coupled with thrust bearings assembled in tandem. Zambello Riduttori Group Milan - Italy Tel: +39-331-307616 Email: info@zambello.it Website: www.zambello.it

Booth No E2 C61

Extruder and cutting machine The EDC-08-05 multilayer extruder and cutting machine is used in coextrusion systems for combining different types of materials. Therefore, the characters of single layer tube cannot compete with the complex characters of co-extrusion tube, such as glossy surface, extensive 92

Modern Plastics & Polymers | April 2012

colour combination, excellent barrier property, scratch and dust-free, etc. Moreover, the extrusion linear speed of EDC-08-05 is 10 m/min for ø35 mm tube (EDC-16-05: 20 m/min), and cutting speed is 100 pcs/min (EDC-16-05: 200 pcs/min). The EDC-08-05 can produce tube diameter range of ø16 to 60 mm and easy-to-change tooling in different sizes of tube produced. Bonmart Enterprise Corp New Taipei City - Taiwan Tel: +886-2-22994281 Email: angus@bonmart.com.tw Website: www.bonmart.com.tw

Booth No E6 Q31

Thermoplastic elastomer compounds Phoenix transparent Thermoplastic Elastomer (TPE) compounds are developed for transcending current standards. Styrenic Block Copolymer (SBC) compounds offer classic water clear transparency and softness. These fulfill users’ pursuit of aesthetic and attractive products, but at the same time, without compromising on quality and performance. State-of-the-art compounding technology offers maximum diversity of features. Though it is used for direct injection moulding, extrusion or blow moulding, this product family is capable of satisfying users’ requirements. Compounded with SBC compounds, the Phoenix transparent TPE compounds contribute varied performance and properties. Phon Tech Industrial Company Youlin County - Taiwan Tel: +886-5-5574567 Email: phon.tech@msa.hinet.net Website: www.phon-tech.com.tw

Booth No C7 A29

Eco-friendly synthetic rubber The eco-friendly synthetic rubber (SSBR) reduces not only the consumption of gasoline, but also the emission of waste gas. The property of SSBR differs from the traditional rubber and is customised according to the processing and application demands. SSBR is mainly used in energy-conserving (low rolling resistance), high-performance and allseason tyres. The tyre reduces fuel consumption and carbon dioxide emission in line with environment protection concerns, and provide added value to end-users. TSRC Corporation Taipei City - Taiwan Tel: +886-2-37016000 Email: tsrcsales@tsrc-global.com Website: www.tsrc.com.tw

Booth No N3 E31

PRODUCT S SHOWCASE

Mould-temperature controller and chiller The mould temperature controller and special custom-made chiller are new products that include cold-hot all-in-one mould temperature controller, diecasting mould temperature controller, quick-cooling & heating mould temperature controller, two machines in one water circulation temperature controller, and rubber/high temperature/ roller mould temperature controller. These machines are intended for processes such as plastic injection moulding, extrusion moulding, blow moulding, chemical industry, dye-casting, reaction axe rubber tyre, rubber vulcanisation, electric wire, calendar, printing, ban-burying and other related industries. Weichi Enterprise Co Ltd Guangzhou - China Tel: +86-020-36850626 Email: weichimaster@163.com Website: www.weichigz.com

Modern Plastics & Polymers | April 2012

Booth No E6 L41

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PRODUCT S SHOWCASE

Quick mould change system The complete single-source system solutions available include Quick Mould Change (QMC) and Quick Die Change (QDC) systems for plastic injection moulding industry and for metal stamping applications. Magnetic Clamping Systems (MCS) are used for injection moulds and dies. Mono-coupler, manual and automatic multi-coupler systems are for general industry use. Mould and die rotation units, die splitters and other tool handling & storage equipment are also offered. EAS Mould & Die Change Systems Co Ltd Wujiang City - China Tel: +86-512-63093091 Email: sales-china@easchangesystems.com Website: www.easchangesystems.com

: Booth No E3 S41

Pellet screening system Super Platon is the latest generation of pellet screening system for plastics industry. This system detects black spots or offcolour contaminants as small as 0.1 mm in a pellet stream by using four high-resolution line sensor cameras. The Super Platon is installed inline or offline after a vibratory sizing screener to detect and remove defective pellets. Kubota Corporation Shanghai City - China Tel: +86-21-63298843 Email: obahideaki1224@yahoo.co.jp Website: www.keisoku.kubota.ne.jp/chinese/

Some characteristics of the Moki patent hot runner system mould include short cycle time (shortest time up to 3.2 sec with advanced blowing technology), high productivity and good stability. It is suitable Modern Plastics & Polymers | April 2012

Mo Chyi Enterprise Co Ltd Changhua County - Taiwan Tel: +886-4-7354681 Email: lcn11111@ms23.hinet.net Website: www.food-mold.com

Booth No E5 D07

Engineering plastics Engineering plastics are based on Polyamides (PA 6 and 6.6) and Po l y b u t y l e n e Terephthalate (PBT) that are available under the brands Durethan and Pocan. Durethan and Pocan high-tech plastics are enablers for greener mobility. These replace metal parts with lightweight plastic, thus offering excellent fuel savings and carbon emission solutions to the automotive industry. Apart from the automotive segment, also available is a variety of offerings for hightech plastics solutions apt for a wide range of industries. Lanxess Chemical (China) Co Ltd Shanghai - China Tel: +86-021-61096666 Email: korie.jiang@lanxess.com Website: www.lanxess.com

Booth No N1 E01

Extrusion machine

: Booth No E3 Q31

Hot runner system mould

for lightweight and extra-thin (thinnest up to 0.3 mm) disposable products. Other features are wastes reducing, production cost lowering, high stability of finished products and low defect rate, and strong mould structure, floating structure, thin finished products, average thickness, stable quality and long life of mould.

The LIN-90II-TS is a performance-based machine designed to accommodate large containers with outstanding cycle time. It produces from 200 ml to 4L of PE/PP and PVC/PTEG, and the productivity reaches 4500 pc/hr and 860 pc/hr, respectively. To ensure quality, mechanical and electrical components from leading brands are used for this machine. Akei Plastic-Machine Mfy Ltd Hong Kong - Hong Kong Tel: +852-+852-27411312 Email: akeisimon@akei.com.cn

: Booth No W5 B41

PRODUCT S SHOWCASE

Injection moulding machine The new model CLF-230AE allelectric injection moulding machine is equipped with advanced Siemens (Germany) servo drive and servo control system, which offer superior performance, including high-speed, accuracy, quiet, clean and energy saving. This is in addition to the innovation multi-functional technology with multi-axis and multi-tasking control providing high-cycle, highoutput, high-stability and automotive moulding process. The model CLF-230AE has high price-performance rate and wide application range on the worldwide parts market. Chuan Lih Fa Machinery Works Co Ltd Tainan Hsien - Taiwan Tel: +886-6-2532111 Email: clf@clf.com.tw Website: www.clf.com.tw

Booth No E6 B41

Plastic injection moulding machine The PET-LINE is based on the platform with 3500 kN clamping force covering moulds with 48128 cavities. This machine offers solution to cope with the rising demand from the beverages and foodstuffs industry. Numerous optimisations such as the simplified product removal and aftercooling unit or the increased injection pressure to shorten the cycle time make the PET-LINE a economical system solution for production of PET preforms. Netstal-Maschinen AG Naefels - Switzerland Tel: +41-55-6186111 Email: marketing@netstal.com Website: www.netstal.com

Booth No E1 J01

Wood plastic composites

The Wood Plastic Composites (WPC) are thermo-plastically processible materials made from wood and plastics (PP, PE, PVC, PS, ABS) for use in building, furniture, automotive, consumer goods, housing industry, etc. In order to operate under optimum function, upstream and downstream equipments are designed for the best matched with the extrusion line. For further improving the output of extrusion line, each 100 Modern Plastics & Polymers | April 2012

processing device and computer-controlled possibility (eg, PLC, PC base) is recommended perfectly to suit different usersâ&#x20AC;&#x2122; demand. Intype Enterprise Co Ltd Tainan - Taiwan Tel: +886-6-2614196 Email: extruder@intype.com.tw Website: www.intype.com.tw

Booth No K11

Multi-rotation section extruder The MultiRotation Section (MRS) extruder is ideal for processing of PET-r. It permits the processing of PET without pre-drying, but by using a simple water ring vacuum system to process the PET to a high-quality product. This is achieved by means of its unique and patented processing section. Based on a conventional single-screw extruder, MRS is a drum containing eight satellite single screws, driven by a ring gear and pinion transmission. The devolatilising performance is 50 times greater than that of a conventional single-screw extruder, and this is at a vacuum of only 25-40 mbar. Gneuss Kunststofftechnik GmbH Bad Oeynhausen - Germany Tel: +49-5731-5731530710 Email: gneuss@gneuss.com Website: www.gneuss.de

: Booth No E1 C17

In-mould labelling system The new A-Pack Inmold Labeling (IML) system has vacuum and static label absorbing, which reduces the cycle time and saves total production cost. The A-Pack IML turnkey solution is applied to all kinds of beverage and food package, such as tea, coffee, juice, water, yogurt and dairy product. It consists of four components including FCS AF series, hi-speed hybrid close loop injection moulding machine, hot-runner mold, robot, product stacking system and label inserting system. Also provided is a customised label for the turnkey solution. Fu Chun Shin Machinery Manufacture Co Ltd Tainan County - Taiwan Tel: +886-6-5950688 Email: fcsco@fcs.com.tw Website: www.fcs.com.tw

Booth No E6 E41

PRODUCT S SHOWCASE

Robotic automation The Sepro Robotique S5 line of high-performance robots features fast, precise servo-driven robots, including three different models to serve injection moulding machines in the range of 30-800 tonne. The S5 line of robots is developed with longer strokes and larger payload capacities than units of comparable size in Seproâ&#x20AC;&#x2122;s earlier Generation 4 (G4) range. There are three models in this series. All S5 robots are equipped with the top-of-the-line Sepro Visual 2 controller as standard equipment. At its core is a high-speed PLC, featuring scan rates as fast at 100 millisecond. Demag Plastics Machinery (Ningbo) Co Ltd Zhejiang - China Tel: +86-574-86181500 Email: sales.cn@dpg.com Website: www.sumitomo-shi-demag.eu

Booth No E2 J41

T-shirt bag-making machine The automatic electronic Tshirt bag-making machine (4-lines) comes with auto punching. Model P-30S-2Ă&#x2014;4+SS is specially designed for mass production of T-shirt bags. The high speed is up to 500 pieces/minute. Four sets of independent filmfeeding motors can keep film feeding smoothly. Conveyor pad delivers the finished bags in pile according to priority. The performance of the machine is stable and reliable.

and barrel manufacturing capabilities include screw dia x length 450 mm x 8,000 mm, and barrel hole dia x length 450 mm x 8,000 mm. Nan Yun Industrial Co Ltd Tainan Hsien - Taiwan Tel: +886-6-2017773 Email: a2546200@ms22.hinet.net Website: www.nyi.com.tw

Booth No E6 P01

Specialty chemicals The Millad NX 8000 offers important sustainability benefits enabling PP to be processed at significantly lower temperatures versus standard clarified PP. The superior clarifying performance enables broader use of PP, a lowdensity, easily recycled plastic, to replace less-sustainable materials in packaging, household and food storage applications. Hyperform HPN nucleating agent for polyolefins is a family of high-speed nucleating agents, which allow for faster crystallisation rates, improved processing and higher throughputs. Hyperform HPR synthetic reinforcing agents for polypropylene improve mechanical properties, while reducing part weight as compared to traditionally filled automotive compounds. Milliken Asia Pte Ltd Singapore Tel: +65-65931319 Email: tiffany.tay@milliken.com Website: www.millikenchemical.com

: Booth No N2 M41

In-mould labelling equipment Daidan Machinery Co Ltd Foshan City - China Tel: +86-0757-28396777 Email: daidan@vip.163.com Website: www.daidan.cn

: Booth No N5 S01

Screws and barrels A full series of screws and barrels applied for various extruding machines and plastic injection moulding machines are offered. Also designed and manufactured are screws with special alloys and special flight geometry to meet specific customer applications. Solutions to help customers solve extruding and injection moulding problems are also offered. The extra large screw 102 Modern Plastics & Polymers | April 2012

Supreme in-mould labelling (IML) equipment is reliable and sustainable. The IML equipment is offered on turnkey basis to customers. This label supply machine, integrated with technology knowledge, has features like both electrostatic and vacuum, easy understanding, durable quality, low abnormal, cost-down and simple maintenance, simultaneously available machine for containers with varied shapes, suitable for different label options, etc. Supreme Technic Package Co Ltd Kalol - Taiwan Tel: +886-7-6141505 Email: emd@emdpack.com.tw Website: www.emdpack.com.tw

Booth No E6 L25

PRODUCT S SHOWCASE

Thermoplastic elastomers Thermoplastic elastomers are intended for applications in the consumer, medical, industrial or automotive sector. These thermoplastic elastomers offer optimal adhesion properties on materials, such as PA (nylon), ABS or ABS/PC and ensure excellent elastic recovery. The new DW compounds (drinking water series) are offered for the first time. These satisfy the most important European drinking water standards. Due to their smooth, dirt- and limescale-repellent surface, thermoplastic elastomers are suitable for use particularly in the sanitary and drinking water sector. Kraiburg TPE Wadhwan - Germany Tel: +49-8638-9810278 Email: lars.goldmann@kraiburg-tpe.com Website: www.kraiburg-tpe.com

Booth No N1 S01

Cup forming machine The thermorunner KTR 5 speed cup forming machine combines intelligent technology, perfect quality and optimum production rates with low costs. This high-speed machine is used for producing drinking cups from PET material and features perfect integration of a new innovative inline stacking system. With the integration of the new inline stacking system, BEST 78/40, Kiefel also sets new trends when it comes to automation. Also future-oriented, the video control system, Simotion is supplied by Siemens. An integrated system for positioning control and SPS directly at the drive system ensures minimum cycle times and best functional results. Co-ordinated multi-axis movements are fast and precise. Kiefel GmbH Freilassing - Germany Tel: +49-8654-78182 Email: kiefel@kiefel.de Website: www.kiefel.de

Booth No E1 G41

Blow moulding machine The complete XBLOW X07 series with platen widths of 350-700 mm is offered. The new single- and double-station machine is available with all-electric (EBLOW ) as well as hydraulic (HYBLOW ) drives. No modifications are required to 104 Modern Plastics & Polymers | April 2012

use existing Bekum customer blow moulds on these machines. Continuity of the machine operation, apart from certain extended capabilities is taken into consideration. The machine platens are designed for good accessibility and ease-of-maintenance. Bekum Maschinenfabriken GmbH Berlin - Germany Tel: +49-30-74900 Email: c.richard@bekum.de Website: www.bekum.de

Booth No E1 B51

Water heater The model STM-MW water heater is used to heat up the mould and maintain constant temperature. High-temperature water from the mould is returned to the cooling tank and cooled by direct cooling. It is then pressurised by the high-pressure pump, sent to the heating tank and finally to the mould with a constant temperature. The water heater adopts magnetic pump instead of mechanical pump to reduce the leakage of media water and it employs brand-new controller, which ensures stable temperature controlling and abundant expandable function. Shini Plastics Technologies Inc New Taipei City - Taiwan Tel: +886-2-26809119 Email: shini@shini.com Website: www.shini.com

: Booth No 1 W4 J4 E2 P61 &

Hot runner controller The TC5200 multi-cavity hot runner controller features a 12~60 point temperature combination control and multi-machine networking. Maintenance operations are simplified with its modularised device design and requirement-based configuration. The GUI based user interface, along with its adjustable perspective angle, is easy for fast adoption in multipoints control. The RS485 communication function enables users to setup multiple controls at once to simplify the required operations. The built-in and practical current sensor and indicator functions benefit various applications, especially automotive industry, bottle billet injection and medical supplies, by realising the concept of one-stop control. Arico Technology Co Ltd Tainan County - Taiwan Tel: +886-2-29101266 Email: info@arico.com.tw Website: www.arico.com.tw

: Booth No E4 M71

product s showcase

Masterbatches The high-speed T-shirt bag making machine (model ST-88/ST-88) is computer-controlled in the whole process. From film roll to final bag, there is one process flow, while the servo motor, as standard attachment, makes it easy to adjust the bag length and the production speed. Component self-testing function is available. Automatic film feeding, coordination is free from tension adjustment. The machine automatically stops when there is a problem or jam.

A wide range of masterbatches are available along with colouring solutions. The product range includes universal plastic masterbatches, specialised ABS/PC/PET/PA masterbatches, grain/wooden/marble/ metallic effect masterbatches, phosphorescent/fluorescent/pearl/ golden, silver series masterbatches, shelly-shining effect series/ UV masterbatches, halogen-free masterbatches, frosted white masterbatches and high-gloss black masterbatches.

Cosmo Machinery Co Ltd Taipei Hsien - Taiwan Tel: +886-2-26806116 Email: yarzar@cosmo886.com.tw Website: www.cosmo886.com.tw

: Booth No 5 w p43 e6 d61 &

Blow moulding machine

: Booth No 9 M3

New Particle Chemical Colors Corp N4 Taoyuan County -Taiwan Tel: +886-2-82094051, Email: npccolor@seed.net.tw Website: www.npc-color.com.tw

Bag making machine The PP woven bag making machine comes with cutting and sewing machine and printing machine. This machine is highly durable, of good quality and enables efficient operation. The machines are easy to operate and enable customers to achieve desired quantity. Rey Long Machinery Co Ltd Dou-Liu City - Taiwan Tel: +886-5-5571565 Email: t6960638@ms45.hinet.net Website: www.reylong.com.tw

T-shirt bag making machine

Booth No e6 t73

These blow moulding machines are targeted to produce plastic containers such as bottles, drums, tanks and other types of containers with volume ranging from 20 ml to 220 ltr. Available is a continuous type the blow moulding machine is used for containers below 25 ltr. The accumulator die head type-blow moulding machine is used for containers above 25 ltr. Chen Way Machinery Co Ltd Tainan City - Taiwan Tel: +886-6-2434077 Email: chenwaym@ms35.hinet.net Website: www.chenway.com.tw

Booth No e6 t41

The information published in this section is as per the details furnished by the respective manufacturer/ distributor. In any case, it does not represent the views of Business Insights â&#x20AC;˘Technologiesâ&#x20AC;˘Opportunities

106 Modern plastics & polymers | April 2012

EVENT REPORT: Engineering Expo Aurangabad 2012

AURANGABAD February 17-20, 2012 Ayodhya Nagari Ground

Creating yet another

success story The maiden edition of Engineering Expo held at Aurangabad was a runaway hit among the growing manufacturing and general engineering sector, as well as small and medium enterprises based in and around the historical city. The Expo had a positive impact on the developing manufacturing industry in Aurangabad and is poised to come back with more offerings and opportunities for the exhibitors and visitors in the next edition. Nishi Rath

n this era of ‘glocalisation’ where every leading company is trying to establish its footprint in regional markets and create a stronghold, sensing the pulse of customers is one of the old and most powerful adages. In order to explore the tremendous opportunities to get established in regional markets, trade shows play a critical role. Known for organising multi-location trade shows, Engineering Expo is a brand to reckon with. Keeping

up with its rich tradition and fresh vigour & enthusiasm, the maiden edition of Engineering Expo Aurangabad portrayed the poised locational advantages to the manufacturing community. The latest edition of Engineering Expo, an established trade show from the stable of Network 18, with support from Aurangabad Industrial Suppliers Association (AISA), held f rom February 17-20, 2012, turned out to be a huge success in terms of its quest towards bringing out the message to the entire Indian manufacturing fraternity

of an emerging manufacturing hub – Aurangabad. One of I n d i a’s largest multi-location Small and Medium Enterprise (SME) gatherings, Engineering Expo has become a definitive place for Indian as well as foreign companies to exhibit their products & services and interact with buyers & sellers. According to the industry, the Expo is an ideal platform for companies to foster growth through reach and awareness to their right target audience. And Engineering Expo Aurangabad provided a perfect platform for SMEs and manufacturing & engineering companies to exchange ideas.

Expo takes off on a high note

Dignitaries unveiling the Exhibitors’ Directory during the inauguration ceremony of Engineering Expo Aurangabad

108 Modern Plastics & Polymers | April 2012

Dignitaries including Mukund Kulkarni, President, Chamber of Marathawada Industries and Agriculture (CMIA), and Managing Director, Expert Group Solutions; Millind Kelkar, Owner, Grind Master; Jayant Soni, President, AISA; Ravindra Naidu, Joint President, Birla Precision Technologies; Sunil Daga, Senior Vice President-Business Banking, Kotak Mahindra Bank, along with Sudhanva Jategaonkar, Associate Vice President, Infomedia 18, were present at the Expo’s inauguration function.

Engineering Expo Aurangabad 2012

Elaborating on how Engineering Expo is all set to offer a fillip to the trade prospects of Aurangabad, Naidu said, “This is one of the largest SME gatherings in Aurangabad. As we all know the potential this place has, this Expo comes across as a catalyst that will further boost its growth. It is a matter of pride for Aurangabad. Earlier, it was only known as a historic city; but now, it is also known as an automobile hub.” Complementing Naidu’s views, Soni, co-organiser, added, “We were looking for a platform in Aurangabad and now, with Engineering Expo, we found the best and one of the most preferred platforms. This Expo has brought a show of international standard to the doorstep of users. The small and medium business units will reap a lot of benefits from the Expo.” Offering a financial perspective, Virat Diwanji, Executive Vice President & Head-Branch Banking, Kotak Mahindra Bank, said, “We are delighted to be associated with Engineering Expo. SMEs are the backbone of India’s economy. The sector has played a critical role in achieving wide measures of industrial growth, and is instrumental in generating large-scale employment across the country. We, at Kotak Mahindra Bank, believe that with the right mix of capital, technology and innovative ideas, SMEs have the potential to push

India’s growth to the next level. Our customised business solutions, backed with customer-f riendly service, are designed to meet the challenges and growing requirements of this sector.”

Opening a new account at Aurangabad The latest edition of Engineering Expo highlighted the potential that a new and developing place like Aurangabad has to offer. The fast-paced industrial growth in Aurangabad will not only improve the employment avenues, but will also raise the standard of living in this city, opined Kulkarni. He added, “A trade show like Engineering Expo is vital for the competitiveness of industry, especially for SMEs.” Offering an organiser’s perspective on the choice of a new location for organising Engineering Expo, Jategaonkar said, “Engineering Expo has come a long way by becoming one of India’s largest multi-location trade shows (other places include Ahmedabad, Chennai, Indore, Pune, Rudrapur and, now, Aurangabad). Over the years, it has successfully delivered its goal of becoming a preferred destination for SMEs, manufacturing and engineering companies to connect, transact & leverage ideas to foster the growth of organisations as well as that of the industry at large.”

Prelude to Engineering Expo Aurangabad Panel discussion on shifting status from ‘Why Aurangabad’ to ‘Why not Aurangabad’ The panel discussion was organised by Infomedia 18 in association with Aurangabad Industrial Suppliers Association prior to the Expo. The endeavour was a part of its value additions intended to bring the manufacturing and dealer community of Aurangabad to discuss critical issues related to the growth of the region, with an aim to position Aurangabad and the surroundinig areas as the most sought-after manufacturing hub.

SME Meet: An informal discussion on the pain and gain areas of SMEs A large gathering of SMEs shared their pain and gain areas of working in and around Aurangabad. Some of the major issues discussed during the meet included banking and government policies, availability & procurement of land, which deters expansion, and, most importantly, the shortage of skilled labour in & around the region. The major solutions that were arrived at include amendments in regulatory laws and a clear exit policy to change the product line.

Quick Stats: Engineering Expo Aurangabad

250+ exhibitors 18,013+ visitors 1,00,000 kg machinery moved 17,000+ business leads generated 6,250+ products displayed 1,00,000 sq ft exhibition area ` 70 core+ business transaction Delegations who visited the Expo… Endurance Technologies Varroc Engineering Forbes & Company Larsen & Toubro NRB Bearings Videocon Wipro Crompton Greaves Bajaj Auto

Exhibitors attract audience Engineering Expo Aurangabad boasted of huge industry participation from various manufacturing areas, including machine tools & accessories, material handling equipment, hydraulics and pneumatics, automation & instrumentation, light and medium engineering, safety & security and packaging machinery, among others. Elaborating on the excellent response generated at Engineering Expo Aurangabad, S J Gijare, GM – Equipment Division, CTR Manufacturing India, articulated, “Engineering Expo has helped the SME sector, which is fast growing in Aurangabad, in finding potential customers. We showcased some of our best products here and even received good response. CTR already has a strong presence in the segment and by participating in this Expo, we want to retain that position in the years to come.” Discussing the scope Aurangabad offers, Aniket Nanajkar, Profit Centre ManagerMechanical Division, Phoenix Mecano, April 2012 | Modern Plastics & Polymers 109

EVENT REPORT: Engineering Expo Aurangabad 2012

Guests of honour assesing futuristic technology

explained, “Engineering Expo has provided us a good platform to understand the market demands here. We were delighted to find potential customers visiting our stall at the Expo.”

Visitors in awe The responses from visitors were encouraging as well. Most visitors emphasised that more such events should be organised in future. “Engineering Expo provided companies an excellent platform to know more about new technologies. It helped local manufacturers meet global standards. The Expo was well-organised and garnered huge success among visitors. Trade shows of this stature will help this growing manufacturing hub,” said Satish Adsul, AGMCorporate Purchase, Endurance Technologies (Casting Division). Rajesh Baheti, DGM-Corp Materials & VEPL-Head, Varroc Engineering, who was also present at the Expo, visited stalls and interacted with various exhibitors. “In its first edition itself, the Expo has become a huge success. We saw various companies showcasing their best products and solutions here. This will definitely help the SMEs located in and around Aurangabad. Considering the fact that Aurangabad is developing, organising such events will definitely boost the growth prospects of this region,” Baheti added. Engineering Expo Aurangabad also attracted overseas visitors. Russell Small, Sales Manager, Asia-Pacific, Precision Polymer Engineering, England, was in Aurangabad mainly to attend the Expo. “I saw some of the best automation products displayed here by quality exhibitors. Such trade shows can be helpful for a developing place like Aurangabad,” he exclaimed.

Promising times ahead With various other companies looking forward to investing in Aurangabad, the region is set to witness further growth over the coming years. The huge turnout at the Expo is proof enough of the increasing awareness among local businessmen about new technologies and their value-added benefits. With an optimistic outlook, Jategaonkar asserted, “As we look forward to making further value additions for an even better experience and reach to the target audience, we welcome large, medium & small industries in the manufacturing and servicing sectors to be a part of the Expo in its exciting journey.” With this huge success, Engineering Expo is slated to make it even bigger in the next edition, with more promising opportunities to be tapped and more areas to be covered. Email: nisi.rath@infomedia18.in 110 Modern Plastics & Polymers | April 2012

BOOK REVIEW

Twin Screw Extrusion: Technology and Principles Authors : James L White and Eung K Kim Price : ` 9,093

Understanding Additive Manufacturing Author : Andreas Gebhardt Price : ` 4,893

Screw extruders are the major processing machines for thermoplastic products such as polyethylene films. The most common and widely used products include pipes, sheets, films, monofilaments, monoaxially oriented tapes (raffia), box strapping and compounding. This is a comprehensive volume on twin-screw extrusion technology and twin-screw & modified extrusion lines. It gives detailed views on screw geometry, various screw configurations, co-rotating screws, intermeshing co-rotating twin-screw extruders, modular intermeshing co-rotating twin-screw extruders with right- and left-handed screw elements, modular intermeshing co-rotating twin-screw extruders. It also covers variations such as intermeshing counter rotating screw, flow visualisation studies of intermeshing counter-rotating twin-screw extruders, which only few technical individuals would have studied, understood and applied. The book presents the technology, flow mechanisms and dispersive mixing, which involve the break-up of particle agromerates and droplets of dispersed melt phases. It covers a wide range of variations in twin-screw extrusion lines and, hence, will be a good reference not only for processing of polyvinyl chloride, but also for manufacturers of masterbatches and compounds. This book is recommended for manufacturers of extrusion lines, research and development groups and enterprising processors wishing to explore non-conventional segments of extrusion.

Additives manufacturing is a comparatively young technology, and since a long time, almost no efforts were made for standardisation except some preliminary work in Germany in the early 1990s. In 2009, the American Society of Mechanical Engineers (ASME) in cooperation with the American Society of Testing Materials (ASTM) started developing standards for all plastics and related products. Following this, most countries, including the UK, Germany and India, began developing such standards. With rapid growth in the production and usage of plastics in various end-uses from home appliances to highly sophisticated and critical components covering a broad spectrum of end products, the need for standardisation was evident. With wider usage and acceptance of plastics in almost all fields, from consumer products to highly critical, precise and engineering components as well as healthcare & medical devices, the need arose for developing customised polymers by using specialty plastics and additives. This book includes a wide spectrum of additives for all polymers manufactured today for meeting specific end-use performance requirements. It gives an exhaustive coverage of rapid tooling and additive manufacturing processes, focussing on industrial components including automobile parts. The book covers all technical aspects of additives manufacturing. It is recommended for progressive plastics processing units as well as research and development groups.

Reviewer: Arvind S Athalye, Founder & CEO, Arvind Athalye Technology Transfer Pvt Ltd Avaliable at: SCI-TECH Books & Periodicals, 414, Janki Centre, Veera Desai Road, Andheri (W), Mumbai 400 053 Tel: 022-2673 5260/6697 0507 â&#x20AC;˘ Telefax: 022-2673 5424/2673 5260 â&#x20AC;˘ Email: scitech@vsnl.com

April 2012 | Modern Plastics & Polymers 111

LIST OF PRODUCT S To know more about the products featured in this magazine, fax us on 022-3003 4499 or tear and post to us the â&#x20AC;&#x2DC;Product Inquiry Cardâ&#x20AC;&#x2122; by following the 5 easy steps given there. Alternatively, you may also write to us at michael@infomedia18.in or call us on 022-3003 4684, and we will send your inquiries to the advertisers/companies directly to help you source better. Sl No Product 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79

Pg No

Accumulator high-speed injection machine ......99 Additive masterbatches ....................................COC Additives ............................................................... 23 Adhesives ............................................................ 121 Air audits blower................................................... 39 Air chiller .............................................................. 25 Air-conditioner parts ........................................ FGF Ammonia liquid chiller ....................................... 107 Automation panel ................................................. 97 Automation system ............................................... 83 Automation ........................................................... 43 Bag making machine .................................40, 106 Barrel screw ........................................................... 19 Bed knives ............................................................. 55 Bio-degradable additives ................................. 23, 45 Bio-degradable masterbatches..........................COC Black masterbatches ................................... COC, 23 Blender ................................................... FIC, 21, 93 Blending unit .................................................... FGF Blow moulding machine ....................... 18, 104, 106 Blower ................................................................... 83 Blown film extrusion system ............................... BC Bottle testing equipment..................................... 120 Bulk milk cooler.................................................. 107 Butterfly valve ..................................................... 107 CASI products............................................... 121 Chiller ................................................................. 110 Circular weaving loom ........................................ 122 Circular weaving machine ..................................... 14 Cleanroom applications......................................... 15 Cluster facia ...................................................... FGF CNC vertical machining centers ................... 67, 79 Co-extrusion blown film line................................ 92 Co-extrusion blown film machine ........................ 90 Colour additives .................................................... 23 Colour mark sensor ............................................... 97 Colour masterbatches................................. 23, COC Compact chiller..................................................... 25 Compound injection moulding machine .............. 99 Compounds ........................................................... 23 Compressor ........................................................... 39 Conductive compounds....................................COC Conical twin-screw extruder ........................... 59, 61 Connector ......................................................... FGF Control system ...................................................... 97 Conveying system ................................................. 43 C-PVC pipe .................................................... 10, 17 Crane control system ............................................ 97 Cup forming machine ......................................... 104 Cutting and stitching machine ............................. 14 Cyclic olefin copolymer ..................................... BIC Dairy machinery ............................................ 107 Dehumidified air dryer .................FGF, FIC, 25, 47 Die face cutter....................................................... 55 Die plate................................................................ 55 Digital panel meter ............................................... 12 Digital temperature controller ............................ 105 Door trim .......................................................... FGF Dosing and blending machine .............................. 43 Dosing and mixing machine ................................. 83 Drive ............................................................. 41, 105 Dry-break coupling ............................................... 39 Dryer .................................................................. FIC Drying and dehumidifying system ....................... 83 Drying system ....................................................... 43 Dual channel with modbus................................. 105 Dye stuff ............................................................... 75 Dynamic controller ............................................. 105 Eco-friendly synthetic rubber ...........................92 Ejector ................................................................... 39 Elastomer refinery and petrochemicals ............... 121 Electric injection moulding machine gearbox ........ 7 Electrical panel...................................................... 97 Engineering plastics .............................................. 98 Exhibition - Plastivision Arabia-2012 .................. 50 Extruder and cutting machine .............................. 92 Extruder machine............................................ 33, 35 Extruder screw ...................................................... 55 Extrusion coating line ........................................... 14

Sl No Product 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156

Pg No

Extrusion lamination machine ............................ 103 Extrusion lamination plant ................................. 103 Extrusion machine ................................................ 98 Extrusion system ................................................. BC Extrusion tape stretching machine ..................... 103 Extrusion tape stretching plant........................... 103 Extrusion ............................................................. BC Feed roll machine ............................................55 Feeding and conveying system.............................. 83 Filler compound .................................................... 23 Film cutter............................................................. 55 Flame-retardant components ................................ 23 Flexo printing machine ......................................... 40 Fluorescent ............................................................ 75 Four-axis shaft gearbox ......................................... 94 Fueling system....................................................... 39 Gearbox for injection machine .........................94 Gearbox for plastic extruder ................................. 94 Gearbox ................................................................. 90 Granulating and recycling system ......................... 83 Granulator blade ................................................... 55 Granulator .................................................... FIC, 25 Green purified gearbox ......................................... 94 Grinder.................................................................. 25 HDPE woven sack manufacturing plant .........103 Head lamp and tail lamp .................................. FGF Heart valve frame ............................... 71, 73, 87, 98 Heating and cooling system............................ 43, 83 High-cavitation system ......................................... 15 High-speed mixer ........................................... 33, 35 High-speed precise injection moulding machine . 99 High-speed rotogravure printing machine ........... 40 High-torque gearbox............................................. 92 Hopper dryer......................................................... 25 Hopper loader ....................................................... 25 Hot runner controller.......................................... 104 Hot runner system mould..................................... 98 Hot-air dryer .......................................FGF, FIC, 47 Hot-runner system ................................................ 83 Hot-runner temperature controller ....................... 97 Hydraulic injection moulding machine ................ 99 IML technique ................................................15 Industrial automation .......................................... 101 Infrared heater ...................................................... 97 Injection moulding machine ...................................... FGF, 18, 29, 65, 90, 99, 100, 115, 116, 117, 119 Inks ..................................................................... 121 In-line drip irrigation plant .................................. 30 Inline drip tubing system ................................ 10, 17 In-mould labeling and injection moulding machine ................................. 99 In-mould labelling equipment ............................ 102 In-mould labelling system .................................. 100 Insert machine ...................................................... 18 Instrumentation and control ................................. 97 Jumbo bag manufacturing machine ................103 Jumbo blown film plant ...................................... 122 Knobs and switches......................................FGF Lamination machine ........................................40 Lamination plant for tarpaulin ........................... 122 Large flow water heater ........................................ 83 Liquid crystaline lymer ...................................... BIC Loader ................................................................ FIC Loading arms ........................................................ 39 Masterbatches and plastic compounds ............121 Masterbatches ............................................... 23, 106 Material dryer system ..................................... 21, 93 Material testing instruments ............................... 120 Medical mould ...................................................... 15 Melt pressure transducer ....................................... 97 Mono- and multi-layer sheet line ......................... 14 Mono-filament line ............................................... 14 Mono-filament plant........................................... 122 Monolayer blown film line ................................. BC Mono-layer blown film ................................... 10, 17 Mould temperature controller ......................... 25, 47 Moulding machine ................................................ 15 Moulds ............................................................ 33, 35 Mould-temperature controller and chiller ............ 94

Sl No Product 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235

Pg No

MTC .................................................................. FIC Multi-component mould ...................................... 15 Multi-layer blown film line............................BC, 14 Multi-layer blown film.................................... 10, 17 Multi-layer cast film line ...................................... 14 Multi-layer co-extrusion sheet line ....................... 16 Multi-rotation section extruder .......................... 100 Napkin dies .....................................................55 Neat resin .............................................................. 75 Oil cooler ......................................................110 Optic sheet extrusion line ..................................... 16 Optical brightener ............................................COC Panel cooler ...................................................110 Paper chemicals ..................................................... 75 Paper lamination plant ........................................ 122 Paperless recorder.................................................. 12 Parallel and right-angle axes gearbox ..................... 7 Pellet screening system.......................................... 98 Pelletiser parts ....................................................... 55 Pelletisers............................................................... 55 PET bottle testing equipment ............................ 120 PET dehumidified dryer.................................... FIC PET perform dedicated machine ......................... 63 PET sheet extrusion machine............................... 16 PET/PE washing line ........................................... 14 Pharmaceuticals and cosmetics ........................... 121 Pipe extrusion line for PVC/PPR/PE ................ 119 Plastic board production system ............................. 8 Plastic compounds ................................................ 23 Plastic conveyor belt ............................................. 33 Plastic injection machine ...................................... 94 Plastic injection moulding machine .................... 100 Plastic masterbatches ............................................ 53 Plastic moulding machine ................................... 121 Plastic processing machine.................................... 14 Plastic processing machinery ancillaries and spare19 Plastic sheet extrusion plant ............................... 103 Plastic textile and machinery ................................ 77 Plastics machinery............................................... 106 Plate heat exchanger ........................................... 107 Plug valve ............................................................ 107 Plybutylene terepthalate ..................................... BIC Pneumatic valve .................................................. 107 Polymer conveyer belt ........................................... 25 Polyolefin pipes ............................................... 10, 17 Polyphenylene sulfide ......................................... BIC PP woven sack manufacturing machines ............ 103 Pplyacetal copolymer ......................................... BIC PP-R pipe ....................................................... 10, 17 Precision gear ........................................................ 94 Precision machine ............................................. FGF Pre-form injection moulding machine.................. 99 Presses ..................................................................... 8 Priming valve ........................................................ 39 Printing and cutting/rewinding machine .............. 14 Printing press .......................................................... 8 Process controller .................................................. 12 Process tank ........................................................ 107 Profile controller ................................................. 105 Programmable logic controller ............................ 105 Pulveriser disc ....................................................... 55 Pulveriser ......................................................... 33, 35 Pumps ................................................................... 39 PVC foam core pipe ....................................... 10, 17 PVC mixer cooler ........................................... 10, 17 PVC palletising line ........................................ 10, 17 PVC pipe plant ................................................... 122 PVC pipes ....................................................... 10, 17 PVC products...................................................... 121 PVC profile line .............................................. 10, 17 Quick mould change system.............................98 Rail tanker.....................................................107 Recycled polymer .................................................. 23 Recycling line ........................................................ 14 Recycling machine ................................................ 40 Recycling system ................................................... 43 Refrigerant pump................................................ 107 Refrigeration system ........................................... 107 Reprocessing plant .............................................. 122

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

112 Modern Plastics & Polymers | April 2012

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LIST OF PRODUCT S

Sl No Product 236 237 238 239 240 241 242 243 244 245 246 247 248 249 250 251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291 292 293 294 295 296 297 298 299 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315

Pg No

Rigid injection moulding machine ....................................................................... 99 Robot system................................................................................................... 25, 65 Robot ................................................................................................................. FIC Robotic automation............................................................................................. 102 Rock-n-roll machine ....................................................................................... 33, 35 Rotary automatic hot colour marking machine .................................................... 91 Rotary cutter ......................................................................................................... 55 Rotary dies ............................................................................................................ 55 Rotogravure printing machine .............................................................................. 40 Round table carrousel ........................................................................................... 33 Safety access equipment .............................................................................. 39 Sandwich BOPP lamination............................................................................... 103 Screw compressor ................................................................................................ 107 Screws and barrels ............................................................................................... 102 Screws ................................................................................................................... 19 Sealants ............................................................................................................... 121 Sensors .................................................................................................................. 97 Servo drive ............................................................................................................ 97 Servo energy saving machine ................................................................................ 63 Sheet calendering line .............................................................................................8 Side sealing-bag making machine ........................................................................ 40 Single mill pulveriser ...................................................................................... 33, 35 Single screw extruder gearbox.................................................................................7 Single screw extruder plant .............................................................................. 59,61 Slitting machine .................................................................................................... 40 Speciality chemicals ............................................................................................ 102 Stack moulds ......................................................................................................... 15 Storage tank equipment ........................................................................................ 39 Stretch blow moulding machine ........................................................................... 18 Switching device ................................................................................................... 97 System solutions.................................................................................................... 83 Tank truck equipment................................................................................. 39 Tanks and silos .................................................................................................... 107 Tape stretching line............................................................................................... 14 Tarpaulin manufacturing machine ...................................................................... 103 Technical moulds .................................................................................................. 15 Temperature controller ................................................................................... 12,105 Testing instruments............................................................................................. 120 Thermoformers ................................................................................................... BC Thermoforming and PS foam ............................................................................ BC Thermoforming machine .................................................................................... BC Thermoplastic alloys ............................................................................................. 75 Thermoplastic compound ..................................................................................... 75 Thermoplastic elastomer compounds ................................................................... 92 Thermoplastic elastomers ............................................................................. 90, 104 Thermoplastic polyurethanes ................................................................................ 81 Thermoset ........................................................................................................... 121 Thick and wide plastic sheet extrusion line.......................................................... 16 Three arm bi-axial roto machine .................................................................... 33, 35 Three axis shaft gearbox ....................................................................................... 94 Transmissions and PTOs ...................................................................................... 39 T-shirt bag-making machine ...................................................................... 102, 106 Twin mill pulveriser ........................................................................................ 33, 35 Twin-screw co-rotating extruder......................................................... 71, 73, 87, 89 Twin-screw element ............................................................................ 71, 73, 87, 89 Twin-screw extruder gearbox ..................................................................................7 Twin-screw extruder ........................................................................... 71, 73, 87, 89 Twin-screw extrusion line ............................................................................... 59, 61 Two color cane plant........................................................................................... 122 Two-layer blown film ...................................................................................... 10, 17 Two-platen injection moulding machine .............................................................. 99 Ultrasonic flow meter.................................................................................. 12 Universal controller ............................................................................................. 105 UV stabiliser.....................................................................................................COC Vacuum dryer.............................................................................................. 47 Vacuum forming machine ................................................................................... BC Vacuum loader................................................................................................... FGF Vacuum pump and system .................................................................................... 39 Variable displacement pump energy-saving machine ........................................... 63 Vertical machining centre ..................................................................................... 99 Vibroscreen ..................................................................................................... 33, 35 Warehouse....................................................................................................8 Water heater........................................................................................................ 104 Water jetting machine........................................................................................... 39 WFR .................................................................................................................. FIC White masterbatch.....................................................................................COC, 23 Winders............................................................................................................... 122 Wire EDM ..................................................................................................... 67, 69 Wood plastic composites..................................................................................... 100 Woven sack tape plant for PP/HDPE ............................................................... 122

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

116 Modern Plastics & Polymers | April 2012

LIST OF ADVERTISERS Advertiser’s Name & Contact Details

Pg No

Advertiser’s Name & Contact Details

Pg No

Hindustan Plastic And Machine Corporation .............................. 59, 61

Adroit Control Engineers ............................. 97 T: +91-011-47600700 E: sales@adroitcontrol.com W: www.adroitcontrol.com

T: +91-11-25473361 E: poonam@hindustanplastics.com W: www.hindustanplastics.com

Aerodry Plastics Automation Pvt Ltd............ 43

Huarong Plastic Machinery Co Ltd .............. 99

T: +91-120-4766777 E: info@aerodry.com W: www.aerodry.com

T: +91-9825739634 E: j.v.papaiyawala@huarong.com.tw W: www.huarong.com.tw

Aeromec Marketing Co Pvt Ltd .................... 91

IDMC Limited ...........................................107

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

T: +91-2692-225399 E: idmc@idmc.coop W: www.idmc.coop

AVI Additives Pvt Ltd .................................. 23

Ishan International....................................... 40

T: +91-40-23550551/2/3/4 E: info@aviadditives.com W: www.aviadditives.com

T: +91-9737992000 E: sales@ishan-intl.com W: www.ishan-intl.com

Boge Compressed Air System ....................... 45 T: +91-44-43009610 E: s.sriram@boge.com W: www.boge.in

J.P. Extrusiontech Ltd................................... 14 T: +91-2646-222163 E: info@jpextrusiontech.com W: www.jpextrusiontech.com

Bombay Hydrolic India................................. 94 T: +91-161-2494216 E: bombayhydraulic@yahoo.co.in W: www.info@bombayhydraulic.com

Kabra Extrusion Technik Ltd................... 10, 17 T: +91-22-2673 4822 E: sunil@kolsitegroup.com W: www.kolsite.com

Bonfiglioli Transmissions (Pvt) Ltd .............. 41 T: +91-44-43009610 E: sales.buins@bonfiglioli.com W: www.bonfiglioli.com

L & T Plastics Machinery Ltd .................. FGF T: +91-44-26812000 E: handigolg@larsentoubro.com W: www.larsentoubro.com

Expo Centre Sharjah .................................... 50 T: +971-6-5770000 E: info@expo-centre.ae W: www.plastivision.ae

Larsen & Toubro Ltd ..................................101 T: +91-22-6752 5656 E: ss-ccd@lth.ltindia.com W: www.larsentoubro.com

Ferromatik Milaon India Pvt Ltd .................. 25 T: +91-79-25890081 E: salesfmi@milacron.com W: www.milacronindia.com

Lohia Starlinger Ltd ..................................... 77 T: +91-11-30641770 E: prom.lsl@lohiagroup.com W: www.lohiagroup.com

Freeze Tech Equipments Pvt Ltd .................110 T: +91-44-42152387 E: info@freezetechequip.com W: www.freezetechequip.com

Loxim Industries Limited ............................. 75 T: +91-2717-308000 E: info@loxim.com W: www.loxim.com

Gardner Denver Engineered Product India Pvt Ltd................................... 39

Lubrizol Advanced Materials India Pvt Ltd .. 81

T: +91-79-40089312 E: info.ahm@gardnerdenver.com W: www.gardnerdenver.com

T: +91-22-66027800 E: Estane-SA@lubrizol.com W: www.estane.com

Glaves Corporation ...................................... 55

Matsui Technologies India Ltd ..................... 47

Advertiser’s Name & Contact Details

Pg No

Mona Chem Additives Pvt Ltd ....................121 T: +91-261-2894847 E: sales@monachem.com W: www.monachem.com Mould Master .............................................. 67 T: +91-422-4502171 E: mmiplinfo@moldmasters.com W: www.moldmasters.com N.A. Corporation ......................................... 35 T: +91-79-25840374 E: info@naroto.com W: www.naroto.com Neejtech India (Niigata) ............................... 29 T: +91-9909974224 E: contact@niigataindia.com W: www.niigataindia.com Neejtech India(Braun) .................................. 15 T: +91-79-26561312 E: info@neejtech.com W: www.neejtech.com Plastiblends India Ltd ..............................COC T: +91-22-67205200 E: rsd@kolsitegroup.com W: www.plastiblendsindia.com Poly Mechplast Machines Ltd....................... 18 T: +91-265-2631211 E: goldcoin@polymechplast.com W: www.polymachplast.com Polyplastics Marketing (India) Pvt ............. BIC T: +91-22-67587668 E: tushar.birje@polyplastics.com W: www.polyplastics.com Prasad Koch Technik Pvt Ltd ....................... 33 T: +91-79-25830112 E: plastics@prasadgroup.com W: www.prasadgroup.com Prayag Polytech Pvt Ltd ............................... 53 T: +91-11-47262000 E: delhi@prayagmb.com W: www.prayagmb.com Presto Stantest Pvt Ltd ................................120 T: +91-129-4085000 E: gaurav@prestogroup.com W: www.prestogroup.com Procon Technologies Pvt Ltd ........................ 12

T: +91-120-4243862 E: rahuldeep@mass.motherson.com

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

Gujarat Machinery Pvt Ltd..........................103

Mifa Systems...............................................105

R R Plast ..................................................... 16

T: +91-79-29295988 E: growth@gujaratmachinery.com W: www.gujaratmachinery.com

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

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

T: +91-141-2460324, +91-9983330808 E: sales@glaves.biz, axj@glaves.biz W: www.glaves.biz

Our consistent advertisers

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

118 Modern Plastics & Polymers | April 2012

LIST OF ADVERTISERS Advertiser’s Name & Contact Details

Pg No

Advertiser’s Name & Contact Details

Rajoo Engineers Ltd....................................BC T: +91-2827-252701 E: kcdoshi@rajoo.com W: www.rajoo.com Remica Platics Machinery Manufactur ........122 T: +91-79-25712741 E: remicaplastic@dataone.in W: www.remicaplastics.com S&T Engineers ............................................ 79 T: +91-422-2590810 E: stycm@stengineers.com W: www.stengineers.com Sacmi Engineering India Pvt Ltd .................115 T: +91-7600003968 E: sales@negribossi.in W: www.negribossi.com Sanity International ..................................... 19 T: +91-79-65227458 E: info@sanityindia.com W: www.sanityindia.com Shanghai Forward Machinery Co. Ltd ............ 8 T: +9186-21-5990-8899 E: forward_sale@exalt.com.tw W: www.forwardsh.com Shini Plastics Technologies I Pvt Ltd............ 83 T: +91-250-3021166 E: jnbhat@shiniindia.com W: www.shini.com Our consistent advertisers

Pg No

Advertiser’s Name & Contact Details

Pg No

Shuenn Jaan Machinery Co. Ltd ..................116

Unimark (Maguire)....................................... 93

T: +91-886-6-233-9590 E: www.soongiant.com.tw W: www.soongiant.com.tw

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

Sri Sai Plasto Tech ....................................... 63

Unimark (Arburg Gmbh) .............................. 21

T: +91-44-42994365 E: sspt_plastics@live.in W: www.srisaiplastotech.com

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

Steer Engineering Pvt Ltd ............ 71, 73, 87, 89

Unimark (Staubli Faverges Sca) .................... 65

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

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

Sun Lung Gear Works Co. Ltd ..................... 94

Windsor Machines Ltd ................................119

T: +91-886-6-263-9969 E: david@slgear.com.tw W: www.slgear.com.tw

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

Suresh Engineering Works ........................... 30

Wittmann Battenfeld India Pvt Ltd ............FIC

T: +91-731-2527872 E: suresen@aittelmail.in W: www.sureshengg.com

T: +91-44-42077009 E: info@wittman-group.in W: www.wittmann-group.com

Toshiba Machine (India) Pvt Ltd .................117

Zambello Riduttori S. R.I............................... 7

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

T: +91-39-0331-307-616 E: info@zambello.it W: www.zambello.it

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

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April 2012

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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 Month.