Modern Plastics & Polymers April 2013 by Infomedia18

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EDITORIAL

Budget 2013-14: Financially sound reverberations? t first, the Union Budget 2013-14 appears to have treaded rather cautiously by focussing mostly on fiscal fitness. To begin with, the Budget emphasised two specific areas – infrastructure development and Micro, Small and Medium Enterprises (MSMEs) – as the key to fuel the growth of the Indian economy.

The Finance Minister’s proposal for payment of ` 9,000 crore as the first instalment of the balance of Central Sales Tax (CST) compensation is a step in the right direction. Although full-fledged implementation of the Goods and Services Tax (GST) is still months away, the Budget recommendation to extend MSME benefits for a period of three years after moving to a higher category is well timed and meets the need of the hour. This should also motivate home-grown emerging enterprises to take the next big leap in their growth trajectory. The exemption of 15 per cent in investments of more than ` 100 crore to set up plant and machinery should further galvanise industrial activity in the country. In addition, the commitment to increase availability of low-cost funds to the infrastructure sector augurs well for higher investments. Furthermore, the Budget discussed the National Skill Development Programme and a ` 200-crore outlay to fund ‘technology for common man’. Both of these are essential to expand the country’s growth by keeping in mind employment and the abundance of educated youth and their aspirations. Other noteworthy initiatives in this Budget include measures to increase investments in manufacturing and infrastructure, MSME growth and capital market development. These initiatives should also benefit the plastics industry either directly or indirectly.

Editorial Advisory Board A E Ladhabhoy Plastics Technologist

Dr Sushil K Verma Former Director General, CIPET

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

Mohan K Jain

Although this Budget lacks the fireworks of its previous editions, its proposals can be considered as the best possible step by the government in the current complex geo-political climate. Perhaps the government missed an opportunity in this Budget to give a greater thrust to various financial policies. However, only effective implementation of this statement of the government’s action plan would bring results in the current fiscal. All said and done, at a time when the whole world is looking at emerging nations like India to propel the global economic engine, it is imperative for the government to ensure that policy announcements stay on track. The industry, on the other hand, needs to leverage the advantages offered in this Budget to take the India success story a notch higher.

MD, Indoplast & Past President, AIPMA

P P Kharas Chairman, Ecoplast

Raman M Patel Chairman, Industrial Products Mfg Co

Vijay Merchant

Manas R Bastia manas@network18publishing.com

President, Polycraft

April 2013 | Modern Plastics & Polymers

CONTENT S

Injection moulding ................40

Special Focus Injection Moulding

Innovative injection moulding ...42 Lightweight solutions for automotives ...........................44

Insight & Outlook

Interface:

Engineering plastics

Engineering thermoplastics........................ 58 R&D initiatives ............................................ 60 Interface: Dr Harindu Vyas ................................ 64 Satendra Kumar .................................. 66 Roundtable ................................................. 68 Green shoots .............................................. 69 End-of-life applications of recycled plastics ......70 Interface:

Hitesh R Shah .............47 Praveen Sharma ............48

Vishal Jasrapuria ................................. 72

Roundtable ............................50

Dr Prakash Mahanwar ....................... 74 Filament wound composite pipes .............. 76

April 2012 2013 | Modern Plastics & Polymers

Automation Trends

Operator-friendly machines: Increasing production, reducing costs

Reducing energy consumption in plastics processing: Maximise output, minimise consumption

Green packaging norms: Reducing the carbon footprint

Plastic packaging: Applications that enhance product shelf life

Guidelines for efficient equipment: Ensuring safe and efficient processing

Energy Management

Policies & Regulations Strategy Tips & Tricks In Conversation With

Event Report

Indo-German International Seminar: Redefining the future of automotive plastics

Engineering Expo Aurangabad 2013: Exhibiting Aurangabad’s unparallelled potential Engineering Expo Aurangabad 2013 – Panel Discussion: Gauging Aurangabad on the critical parameters

Bipin Shah President, Plastindia Foundation

Toshiba Machine (Chennai) Pvt Ltd: Creating exemplary manufacturing processes

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

REGUL AR SEC T ION S Editorial ................................. 9 News, Views & Analysis ...... 22 Technology & Innovation .... 30 Technology Transfer ............. 32 Projects ................................. 88 Tenders ................................. 89

Event List............................. 90 Book Review ........................ 97 Products................................ 98

Facility Visit

List of Products.................. 106 List of Advertisers .............. 108 Cover photo courtesy: ARBURG

Details on pg no. 90

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

April 2013 | Modern Plastics & Polymers

Business Insights •Technologies•Opportunities

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April 2013 | Modern Plastics & Polymers

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NEWS, VIEWS & ANALYSIS

Plastindia Foundation provides platform for WIINTECH

Members of Plastindia Foundation along with representatives of WIINTECH On March 4, 2013, Plastindia Foundation held an interactive session with WIINTECH to boost the growth of small and medium entrepreneurs in India. WIINTECH – Worldwide Intercluster Initiative for New materials and processes focused on clean TECHnologies – links leading European world clusters belonging to the chemicals and materials sector and combines their expertise with the purpose to address the complete range of technological and business topics in the clean technology space. The delegation addressed the dire need for technology development, innovation and knowledge in the chemicals and materials sector in India. Speaking on the occasion, Bipin Shah, President, Plastindia Foundation, said, “We have received an overwhelming response from the industry. This is the first exposure of Plastindia with WIINTECH and we are certain that the industrial tie-up will evolve after this fruitful day. Based on the network’s success stories, we would like to build bridges based on this method, approach and experience in the plastics industry.” The network links eight European leading worldclass clusters belonging to the chemicals and materials sector such as Poolnet (Portugal), Plastival (Spain), Chemie-Cluster Bayern (Germany), Clusterland (Austria), Plastipolis (France), Proplast (Italy), Veneto Nanotech (Italy), NEPIC (UK) etc. There are more than 2,500 companies and research centres working in the materials and clean technologies sectors. With this initiative, Plastindia created a qualitative and quantitative platform for SMEs to work together, derive motivation and explore progressive technology and mass volume production areas in the international arena. WIINTECH aims to initiate opportunities for business development between European clusters and Indian partner organisations, which include setting up research & development partnerships, encouraging technology transfer and trade arrangements. The network’s focus is on global expanding markets in clean technology such as renewable energy, high-efficiency building & construction, recycling, green transportation, water & air treatment, waste management etc. Sweta M Nair 22

Modern Plastics & Polymers | April 2013

SACMI to manufacture Negri Bossi machines in India Italy’s SACMI Group is setting up a manufacturing plant in India. The company has been assembling Negri Bossi injection moulding machines in a rented space in Ahmedabad since 2009. However, when it opens a new plant at the beginning of 2014, it will graduate from assembly to local manufacturing. “India is a huge market with about 3,500– 4,000 presses sold annually. We could grow in this market locally

Aliaxis buys majority stake in Indian pipe maker Ashirvad Large global pipe maker Aliaxis SA has bought a majority stake in one of India’s largest plastic pipe and fittings makers, Ashir vad Pipes Pvt Ltd, expanding its business in the fast-growing Indian market. “We are very pleased to acquire a majority stake in one of the leading Indian plastic pipe and fittings players. The joint venture will give Aliaxis significant exposure to the Indian building and sanitary market and will allow Ashirvad to access Aliaxis global manufacturing network,

as well as in the neighbouring (South Asia) market and also in the Middle East,” said Selvakumar M, Regional Sales Manager, SACMI Engineering (India) Pvt Ltd. The company has already supplied about 100 hydraulic presses, with clamping forces ranging from 550 to 1,000 tonne, in the Indian market. This year the company is starting to sell the Vector Hybrid press line in India, with a CAN bus controller. The company is targeting sales of 70 presses in 2013. know-how, product expertise and broad product range,” said Yves Mertens, CEO, Aliaxis Group. With this joint venture, Ashirvad will reach to the next level in terms of range of quality products and technologies. Ashirvad has production capacity of 70,000 metric tonne a year, with more than 2,000 employees and a network of 1,200 distributors and 14,000 dealers. Ashirvad mainly manufactures PVC pipes and fittings in the building, plumbing and agricultural markets. It also develops PVC column pipes that are used in submersible boreholes to a depth of 1,000 ft.

Alok Masterbatches expands in India, plans for international growth Alok Masterbatches Ltd is setting up its fifth production facility in India. The facility will cater to customers in southern India and Southeast Asia. The plant, in the southern Indian city of Ranipet, will open in April with an annual capacity of 20,000 metric tonne. The 60,000 sq ft plant will produce a wide range of masterbatches. This region, which has a growing auto industry, is a big market for compounds. The plant will give the company an overall capacity of 60,000 metric tonne annually. Alok has four plants in India, including two in Delhi, plus a plant that opened in Paraguay last year. Alok is considering additional international growth. The company plans to have a plant either in the Middle East or in Vietnam in the next couple of years. This is because Vietnam is also offering incentives to foreign investors setting up plants to cater to the European market.

NEWS, VIEWS & ANALYSIS

Pipe manufacturers converge at India’s first-ever multi-product Open House of Rajoo

O ver 180 professionals representing 90 plus companies across India were part of the Open House organised by Rajoo and Bausano. At this event, there were live demonstrations of a range of machines that redefine manufacturing of high-performance pipes. The company stated, “As expected, the star performer of the show was the Twin Screw PVC Pipe Plant running at 130 kg/hr (pipe outer diameter of 28.6 mm; pipe thickness of 2.12 mm). Most visitors have not been an eyewitness to such a spectacle – a working PVC Pipe Plant that too which started from scratch in just under 5 minutes with less than 4 kg scrap. Further, Rajoo successfully showcased its indigenous raw material compound for the PVC machine. With this, Rajoo

became the first Indian company to successfully demonstrate a PVC pipe machine at an Open House.” Further, the Twin Screw PVC Pipe Plant enthralled the audience when it was being operated at a capacity of 1,000 kg/hr, never before seen in India. The pipe OD is 400 mm and wall thickness is 16.2 mm. With this Open House, Rajoo also marked its strong penetration into the market of drip irrigation pipe plants. The demonstrated line was running at 170 kg/hr with a line speed of 80 mpm, 200 dripper insertions/min, with the wall thickness being 0.7 mm. The success of this pioneering initiative emphasises the company’s belief in innovation – be it in product, in technology or, as in this case, in approach. Avani Jain

PVC prices on a high in Southeast Asia due to soaring demand Price hikes for PVC have surfaced this week in Southeast Asian countries with many regional producers adjusting their local and export offers. Apart from the push from higher input costs, the healthy demand from the region has given sellers real support to ask for increases. At the same time, many buyers find domestic prices more competitive and prefer to meet their requirements 24

Modern Plastics & Polymers | April 2013

Plastic packaging to ride high on growth projections The Associated Chambers of Commerce and Industry of India (ASSOCHAM) has projected that the market size of the cosmetics industry, which is currently estimated D S Rawat at ` 10,000 crore, will double to be worth ` 20,000 crore by 2014 due to emergence of a young urban elite population with rising disposable incomes and increase in working women looking for lifestyle-oriented and luxury products. This is expected to boost the cosmetics packaging industry as the primary cost of cosmetics is packaging. D S Rawat, Secretary General, ASSOCHAM, said, “Plastics companies have started going for rural expansion and are offering specialised products to generate revenues from all the corners of the country. This will give momentum to cosmetics packaging which is almost 70 per cent of the price of a cosmetic product and has become highly evolved over the years.” Products falling under the price range ` 50–200 are in the mass-market category. The middle market price can range from ` 200 to ` 1,000. In the high-end market, pricing can range from ` 1,000 to about ` 10,000. Finally, there is the premium range of products where the pricing can touch up to ` 50,000. The industry has mainly been driven by improved purchasing power and rising fashion consciousness among people as well as industry players spending heavily on promotional activities to increase consumer awareness. Anwesh Koley

from local markets. In Indonesia, local PVC prices have gone up by $ 50–70 per tonne as compared to prices prevalent in February. Sumit Dhingra, Director, Dhingra Polymers, said, “Now that demand is improving and supply appears to remain limited in line with the tight availability of VCM 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 caused tight supply. As it was the case last month, producers are allocating a limited amount for export markets and are planning an increase of $ 40 per tonne for PVC cargoes with the April shipment. Meanwhile, the same producers have revealed their export PVC offers with increases to the region, blaming high feedstock costs. Anwesh Koley

NEWS, VIEWS & ANALYSIS

Vinyl India 2013 to be held in Mumbai With strong stimulus given to infrastructure, agriculture and housing, and India’s gross domestic product growth of over 7–8 per cent in medium to long term, the vinyl industry in India is poised to double every five years. Providing a further impetus and adding to this growth, Vinyl India 2013, which is the 3rd International PVC & Chlor-Alkali Conference, is being organised by ElitePlus Business Services Pvt Ltd (EPBS) and Chemicals & Petrochemicals Manufacturers’ Association (CPMA), All India Plastics Manufacturers’ Association (AIPMA) and Plastindia Foundation. The two-day conference covering the entire vinyl chain will be held on April 11–12, 2013, at Hotel Grand Hyatt, Mumbai. Over 25 countries are expected to participate in this international event. The event will bring together industry leaders and specialists to examine the fastgrowing Indian vinyl industry. It will feature many important sessions focussing on the global scenario, the future of polyvinyl chloride in India, feedstock to polymer, machinery – compounding, processing & material handling, recent developments on the new generation of polyvinyl chloride compounds and more. The conference is expected to attract nearly 600 industry experts and players (Indian and overseas) from the vinyl industry, including raw material providers, compounders, channel partners of domestic resin manufacturers, traders and indentors, additives/plasticisers/ stabilisers suppliers, downstream processors (pipes, calendaring, profiles, fittings, blow moulding) machinery suppliers, analysts, consultants and senior managers, logistics and shipping companies, members from associations and trade bodies (eg CAMA,OPPI, IPI, MCCIA), international bodies and council members. Avani Jain 26

Modern Plastics & Polymers | April 2013

AIPMA organises first-ever job fair in Mumbai The All India Plastics Manufacturers’ Association (AIPMA) recently conducted a job fair in Mumbai, a first of its kind by any polymer association in India. The objective was to serve the industry in the manpower arena with a non-commercial, service-oriented and Dr Asutosh Gor, President, AIPMA, lighting the lamp with AIPMA members Kishore Sampat, cost-effective model. Chairman, Placement Cell and Harshad Desai, The first edition saw the presence of Chairman, Incubation Cell. Also present at Dr Ashutosh Gor, President, AIPMA, the event were Jayesh Rambhia, Chairman, and Hiten Bheda, Secretary, AIPMA. Dr Plastivision Arabia 2014, and Ashok Gor spoke on the future of the industry, Mukherjee, Managing Committee Member while Jayesh Rambhia, Chairman Plastivision Arabia, AIPMA, addressed Brush Machinery (Italy), Plasticon the audience about the upcoming UK, Bajaj Steel Industries, Kuloday events of the Association. Heads of Technopack and others participated as institutions (eg MIT Pune, MIT visiting employers. The fair floated 80 Aurangabad etc) graced the inauguration job openings, of which 90 per cent job ceremony. Support for this event was openings demanded a working experience also extended from Central Institute of of 2–15 years. AIPMA addressed the Plastics Engineering and Technology job requirements and matched befitting (CIPET), L D College of Engineering candidates with employers. At the event, 182 interviews were conducted and (Ahmedabad) and others. The job fair had 14 visiting employer 17 candidates were selected for a second companies participating from segments round of interviews; some even received such as raw materials, compounds/ spot offers. Following the overwhelming response additives, injection moulding, blow moulding, rotomoulding, extrusion of this event, AIPMA is likely to continue (pipe & blown film) and machinery. having such job fairs frequently at various Companies such as Finolex Pipes, Borghi locations across the country.

Total launches thinner film for flexible packaging Flexible plastic packaging converters will be able to reduce film width by up to 25 per cent thanks to a new metallocene polyethylene film material, developed by Total. The Lumicene Supertough 32ST05 is a downgauging breakthrough for multi-layer structures and can be used in compression packaging, such as for heavy mattresses and lightweight diapers. It can also be used for deepfreeze and lamination films, and highly demanding shrink applications, eg glass bottle unitisation. “The downgauging story is a neverending quest to push the thickness limits of packaging down. Where these limits of downgauging are reached, Supertough 32ST05 steps in to give the necessary boost

in toughness to overcome the thickness barrier,” said Carl Van Camp, Senior VP – Polymers Division. The material can be used to make films on extrusion or conversion lines.

NEWS, VIEWS & ANALYSIS

Oriental Energy to build the first UNIPOL Polypropylene (PP) unit in East China Oriental Energy has signed a license with Union Carbide Chemicals & Plastics Technology LLC, a wholly owned subsidiary of The Dow Chemical Company, for UNIPOL™ PP Process Technology for a 400 KTA PP plant. The plant will produce homopolymers, impact copolymers and random copolymers using propylene sourced from their upstream propane dehydrogenation unit. Speaking about this development, Tracy Cleckler, Global Commercial Director, Dow Plastics Licensing &

Global rigid plastic packaging market worth $ 161.11 billion in 2013

Driven by growth in emerging markets, a new report by Visiongain estimates that the global rigid plastic packaging market will reach a value of $ 161.11 billion in 2013 and will be driven by growth in the developing markets, in addition to a number of favourable consumer trends. According to the report Global Rigid Plastic Packaging Market 2013–2023, “Emerging markets will be characterised by clear maturity and strong economic growth, which will increase the quality and quantity of consumer purchases. In addition, low labour costs will provide an incentive for companies to expand the scale of their operations in these markets.” To this, Divakar Vyas, Senior Manager (Sales), Windsor Machines Ltd (Injection Moulding Division), added, “The rigid packaging industry in India is growing at the rate of 16–20 per cent per annum. The growth in this sector is mainly driven by food, pharmaceuticals etc. At present, the focus in the segment is to provide lightweight and recyclable solutions.” Avani Jain 28

Modern Plastics & Polymers | April 2013

Catalysts, said, “With UNIPOL PP Process Technology, Oriental Energy will produce PP resins that will give fabricators the opportunity to produce PP products that are lighter, clearer and cleaner, properties PP customers are always seeking. Oriental Energy will also be able to make PP resins that allow fabricators to run their lines at a faster rate, benefitting from the higher melt flow capability of some of the UNIPOL product grades.” The plant located in Zhangjiagang in Jiangsu province will be the first Dow UNIPOL PP unit in the East China coastal area, the centre of the Chinese PP market. There are currently

48 operating lines worldwide using UNIPOL PP Process Technology from Dow Performance Plastics Licensing and Catalysts. The UNIPOL PP Process Technology is an all gas-phase process for producing the broadest range of PP resins. Its simple design is consistent in terms of product quality and energy efficiency, requiring no equipment for handling, separating or recycling solvents. The system’s fluidisedbed reactors and high-performance CONSISTA™ and SHAC™ catalyst systems give manufacturers the flexibility to produce homopolymers, random copolymers and impact copolymers.

SPE to honour achievements of industry leaders at ANTEC® 2013

Benny Freeman

Tim G Taylor

Four distinguished individuals who have made outstanding contributions to the plastics industry will be honoured by the Society of Plastics Engineers (SPE) at next month’s SPE ANTEC® 2013. The International Award, Business Management Award, Education Award and Research/Engineering Technology Award will be presented to the four individuals as part of the Society’s Annual Awards Program at the SPE Celebrates Banquet on April 21, 2013. Benny Freeman, the Richard B Curran Centennial Chair in Chemical Engineering at The University of Texas at Austin, will receive SPE’s International Award, its top honour that recognises lifetime achievement in the plastics industry. The Business Management Award will be presented to Tim G Taylor for his achievements in management with Chevron Phillips

Dr Robert R Gallucci Dr Robert Y Lochhead Chemical Company. Honouring academic excellence, Dr Robert Y Lochhead who is the author of 300 scientific papers and 22 patents, some for polymers that are used extensively in topical delivery of therapeutics and in cosmetics, will be presented with the Education Award. In a plastics career of more than 36 years, Dr Robert R Gallucci, Chief Scientist, SABIC Innovative Plastics at Mount Vernon, Indiana, has developed many new thermoplastic products, often using extruder chemistry and polymer blend compatibilisation. Recognising his contribution in this field, he will be presented with the Research/ Engineering Technology Award. The upcoming Annual Awards Program will take place on April 22–24 at the Duke Energy Convention Center in Cincinnati, Ohio, USA.

TECHNOLOGY & INNOVATION

New VacuTran breaks parts-per-million WVTR measurement barrier

New NCF series super-tangential granulators from Conair require less floor space, deliver more versatility

New NCF series super-tangential granulators from Conair have footprint dimensions that are at least 30 per cent smaller than many other granulators with similar capabilities. The cutting chamber configuration is ideal for handling lightweight bulky parts (eg bottles) and produces clean uniform granulate from runners and small parts. Different hopper designs and rotor/knife choices are available to maximise performance with a wide variety of scrap types. Four different models feature 8-inch (203-mm) diameter rotors in widths of 10, 14, 19 and 24 inch (240, 360, 480 and 600 mm) and deliver standard maximum throughputs ranging from 68 to 205 kg. The smallest unit is powered by a 5-hp motor, and the three larger sizes have 7.5-hp motors with options up to 15 hp. Standard rotor speed for the NCF 810 is 260 rpm, and standard speed on the larger models is 400 rpm, although rpm of 260, 400 or 840 can be specified on any of the granulators to increase capacity, improve regrind quality and/or minimise energy consumption. A tilt-back hopper and drop-down screen cradle provide easy access to the cutting chamber for maintenance and cleaning. These features contribute to increased productivity and reduced downtime. An optional sound attenuation package also makes the NCF series quieter than other small granulators. The super-tangential chamber design ensures that the rotor All new Anchor Culinary Classics® Convertible grips bulky scrap on the downward stroke, drawing the scrap Containers into the knives and preventing it from bouncing on the rotor. Anchor Packaging has launched Standard tangential and straight-drop in-feed configurations a new Culinary Classics® line, are also available. The rotor itself can be open with three rows which is now available with a of double-angled knives for a clean scissors cut with minimum removable, perforated, hinged heat generation. For tougher materials, a solid rotor can be lid. Available in 9” × 9” and 9.5” equipped with three rows of up to five cassette knives in a × 10.5”, with either one or three staggered array. Cassette knives allow for quick and easy knife compartments, the six containers changes and minimise downtime for service and maintenance. that comprise this product line can handle temperatures up to The knives require no adjusting to maintain a consistent knife 230°F; they can be staged under heat lamps or in warming units gap for improved quality. and are microwavable. All products in the Culinary Classics® line are made of Polypropylene (#5PP) and are microwave-and Improved conductive foam from Sekisui Alveo dishwasher-safe as well as reusable and recyclable. All Anchor Switzerland-based maker of polyolefin foams, Sekisui Alveo, has developed an improved version of its Alveobloc conductive products are BPA-free. To preserve food texture and quality, the unique design of foam, Alveobloc NACO III. Made from laminated foam sheets, the plastic packaging system retains internal temperature while Alveobloc has a uniform closed-cell structure to absorb impact venting excess steam. The new Culinary Classics® Convertible or pressure. It discharges electrical current and static charges Containers feature a cut-proof base, and the removable, generated during manufacture and transport, making it suitable hinged lid offers consumers a convenient dining experience. for the transportation and protection of electronic components With an interlocking base and lid, the containers have good that are sensitive to electrostatic discharge. The manufacturer structural strength that makes them easy to stack and safe for claims that the conductivity of Alveobloc remains constant, regardless of relative humidity, unlike competitive foams. transportation. The launch of VG Scientia’s new VacuTran enables Water Vapour Transmission Rate (WVTR) measurement of barrier layers to better than 10–6 g/m2/day and simultaneous O2 permeation to better than 10–3 cm3/m2/day. The new VacuTran is an innovative, time-saving, vacuum-enabled membrane permeation measurement instrument that heralds the next generation of ultra-sensitive membrane transmission measurement by advancing detection levels by a factor of 50–100 compared with the one-part-in-ten-thousand measurement capability of the current generation of instruments. The advances in time-saving performance and higher sensitivity are significant, with this breakthrough instrument featuring not only a first in WVTR measurement that exceeds the specification requirements but also the welcome reduction in results turnaround to days rather than weeks or months. VacuTran is a step change in order of magnitude for developers and manufacturers involved in ultra-high barrier layer research because until now there has been no commercially available instrument that can measure WVTR to these very low levels or measure WVTR and oxygen transmission rate simultaneously. This is of particular relevance to organic light emitting displays, organic photovoltaic devices and organic field effect transistor device markets in the plastic electronics industry.

Modern Plastics & Polymers | April 2013

TECHNOLOGY & INNOVATION

Engel unveils largest robot in its class

Koch extends dosing system range

Engel, the Austrian injection moulding machine maker, has unveiled a new linear robot with a nominal load-bearing capacity of 120 kg, which the manufacturer claims is the biggest in its class. The latest member of the Viper range, the Viper 120 can be ordered in conjunction with Engel injection moulding machines as well as a replacement for existing equipment or for use with injection moulding machines by rival brands. The Engel Viper 120 has a mould take-off stroke of 3,000 mm and a reach of 3,550 mm. The use of laser-welded steel sections has kept the dead weight of the robots low, enabling the load-bearing capacity to be raised. The robot can be fully integrated with Engel injection moulding machines or can be supplied with an independent control unit that allows it to work with other machines via a Euromap 67 interface.

Koch-Technik, the Germany-based ancillaries maker, has introduced two new models of its gravimetric Graviko dosing system. The Graviko machines dose individual components, such as grains, powder, ground material or coarse powders, into the weighing container using a slider or by volume. Quantities can be dosed with an accuracy of 0.001 s. Precision dosing coupled with a gravimetric weighing system produces a control circuit to ensure that dosing is carried out correctly regardless of bulk materials used. The patented system offers accuracy with a tolerance of ±4 grains per 1,000, a level the company claims is better than any conventional dosing system. The GK 65 is for machine throughputs of up to 80 kg/ hr. The GK 200 is for machine throughputs of up to 250 kg/ hr. Both are suitable for four dosing stations. Depending on the throughput of the processing machine, up to four different components can be processed.

New range of environmentally improved films Amcor Flexibles has launched Amcor Light, a completely new range of environmentally improved films for fresh and dairy applications that offer optimum weight while retaining perfect visual appearance and sealing integrity. Amcor Light reduces packaging weight and its cradle-to-gate carbon footprint is lower

Blow moulding ‘Stanyl’ grade introduced for automotive air ducts

DSM has introduced Stanyl® Diablo OCD 2305 BM, a high-temperature Polyamide (PA) developed for blow-moulded ducts for use in automotive applications. The company said air ducts made of the material are

by up to one-third compared to standard films. Thanks to the high level of film clarity and the same functional properties

lighter than parts made of metal or Polyphenylene Sulphide (PPS) and can handle continuous temperatures up to 230°C. The material is a heat-stabilised blow moulding grade of ‘Stanyl’ PA 4.6, developed specifically for hot charge air ducts. DSM claims that it is the first hightemperature PA suitable for processing by extrusion-blow moulding and offers significant cost benefit compared to PPS due to its lower weight and scrap rate. Part weights can be reduced by 7 per cent, thanks to improved wall thickness distribution.

as Polyethylene (PE)-based films, it satisfies customers’ needs for improving their environmental credentials and at the same time guarantees on-shelf appeal. The Amcor Light range offers solutions for flowpack as well as for lidding applications. The main families are OPA Light (replacing the traditional OPA/PE films) and OPET Light (replacing the OPET/PE family of films).

Hasco introduces flexible mould temperature control line Hasco Hasenclever GmbH & Co KG has introduced a flexible mould temperature control line. It reduces pressure loss because there are no sharp angles. TempFlex products cool quicker than conventional channels embedded in the mould because the flexible lines are made of braided stainless steel hose with quadratic cross sections and change direction through arcs rather than abrupt corners. Further, the lines are simple to assemble and adaptable to the desired groove process. According to the company, deflecting the coolant in the new lines through 10 arcs rather than through 10 conventional 90° deflections results in 300 per cent less pressure loss. TempFlex is available in metric and imperial measurements. These lines can be retrofitted onto existing moulds plagued by insufficient cooling performance. April 2013 | Modern Plastics & Polymers

TECHNOLOGY TRANSFER

As part of our endeavour to spread the technology culture, this section provides a means to promote and facilitate exchange of select technologies. We strive to bring together suppliers of such technologies with suitable users for negotiations and industrial collaboration.

Technology Requested

Technology Offered Biodegradable polymers A company offers biopolymer nanoparticle technology based on cost-effective biodegradable & biocompatible polyolefins, copolymer of ethylene & vinyl acetate and thermoplastic starch blend nanocomposites. These nanocomposites have improved mechanical properties with zero moisture content.

Areas of application

Disposal and recycling of plastic waste A Polish company seeks the technology for dry processing of all kinds of plastic wastes or a magnetic processing method in the electrostatic field. The technology should allow sorting of all kinds of plastic materials, (PET, HDPE, PVC), hay-silage foils, etc by excluding dangerous waste.

Packaging materials, disposable non-wovens, hygiene products, consumer goods, agricultural & horticultural tools and medical instruments

Areas of application

Forms of transfer

Others

Technology licensing

Plastics industry, waste recycling, waste management

Forms of transfer

Conversion of batch-poly plant to C P plant

Laboratory-scale non-woven and monofilament plant

A company from China is interested in providing consultancy services for the modification of batch-poly plant to C P plant such as polyester plant, polyester chip or direct spinning.

woven and monofilament plant in a single station.

Areas of application

An Indian company is looking for a laboratory-scale, non-

Areas of application Plastics

Chemical fibres and plastics

Forms of transfer

Others

Turnkey

New and rebuilt screw and barrels for all-plastic extruders An India-based company is manufacturing screw and barrels for all-plastic extruders and is efficiently rebuilding worn out screws. It is making an energy-efficient washing and drying plant for all-plastic waste. It employs the most cost-effective and efficient washing and drying units for plastic scrap.

Areas of application Plastics manufacturers and plastic waste recycling unit

Polyethylene Terephthalate (PET) polyols A trading-based company plans to manufacture PET polyster polyols. The small-scale project will involve procuring recycled PET flakes locally. Land available for manufacturing is 28,000 sq ft.

Areas of application Polyols

Forms of transfer

Equipment supply and turnkey

Others

Information courtesy: Information courtesy: Dr Krishnan S Raghavan, In-Charge, Technology Transfer Services Group, Asian and Paciﬁc Centre for Transfer of Technology (APCTT) of United Nations Economic and Social Commission for Asia and the Paciﬁc (UNESCAP), APCTT Building, C-2, Qutab Institutional Area, New Delhi 110 016, Tel: 011-3097 3758 (Direct), 011-3097 3710 (Board), Fax: 011 - 2685 6274, Email: srinivasaraghavan@un.org, Website: www.apctt.org For more information on technology offers and requests, please log on to www.technology4sme.net and register with your contact details. This is a free of cost platform provided by APCTT for facilitating interaction between buyers and seekers of technologies across the globe. After submitting technology offer or request to this website, you are requested to wait for at least two weeks for receiving a response from a prospective buyer/seeker through this website, before contacting APCTT for further assistance.

Modern Plastics & Polymers | April 2013

Share and Solicit Technology The mission of Modern Plastics & Polymers is to spread the technology culture. Here is an opportunity to be a part of this endeavour by sending your technology on offer or technology requirements. If you belong to any of these two categories, you are invited to furnish the techno-commercial details for publication. The write-up needs to be as per the format of this section with information about the particular technology offered or requested, its areas of application and forms of transfer.

Contact: Modern Plastics & Polymers Network18 Media & Investments Ltd, ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W) Mumbai 400 028. Tel: 022-3003 4671 • Fax: 022-3003 4499 • Email: claylan.menezes@network18publishing.com

MPP APR _2013_TAB 3_EVEREST PG_33

MPP APR _2013_TAB 3_MATSUI 2 PG_34

IN CONVERSATION WITH: Bipin Shah

“PLASTICS A

HAVE BECOME

WAY LIFE” OF

…says Bipin Shah, President, Plastindia Foundation, when referring to the material that has become the fabric of life. At a time when international companies are making a beeline to enter the country, Shah talks to Sweta M Nair about the prevailing domestic conditions, potential development areas and his new role as the President of one of the country’s most revered plastics associations.

Drawing on your vast experience, how has the course of the Indian plastics industry changed? In all these years I have spent in the industry, the growth of plastics has been inevitable. Although it was predicted twenty years ago that plastics 36

Modern Plastics & Polymers | April 2013

were not going to last due to scarcity of oil, the scenario has changed due to the discovery of alternative sources of energy. The question now is about which route we should take: oil-based, gas-based, naptha-based or biomass.

The current per capita consumption of plastics is 4–6 kg in India, whereas it is 42 kg in China and 62 kg in the US. So comparing the rate of consumption will not be ideal in this situation. Within the country, we need to focus on industry segments such as building & construction,

Bipin Shah

water management, road construction, telecommunications etc, where maximum utilisation can take place. Plastics have become a way of life, and the key issue now is on energyefficient utilisation of plastics. During a recent visit to Karad, we chanced upon a prevalent phenomenon where the women in a particular village travel a distance of three kilometres everyday just to fetch water. Imagine the relief polyvinyl chloride pipes can bring into their lives where their commute will be cut and clean water will be available just by turning on the tap! To a certain extent, even the enormity of waterborne diseases could be controlled in such areas. Additionally, the hours of manpower could be put into other productive areas. Another area that has changed significantly is the usage of plastics in consumer durables, followed by automobiles, fertilisers, food packaging and footwear soles. I believe plastics in food packaging is growing at a tremendous rate and will continue to grow. I think this segment still has untapped potential in increasing the shelf life by ninety days. For that matter, even plastic bottled water has replaced the iconic water flask. To put it in simple words, increase in disposable income, constraints on time and the convenience factor will influence the course of plastics in the coming times.

With the change in trends, how have the priorities of Plastindia Foundation changed? Also, what is your agenda as the newly elected President? As President of Plastindia Foundation, the road that I want to take is based on knowledge-driven issues more than the ones that are purely focussed on revenue. It is knowledge that can empower the industry. Here, I am referring to practical knowledge more than mere resource-based information. I emphasise the former because although I graduated with a distinction in engineering, I lacked practical knowledge. Perhaps

this is an issue with most courses in the country where importance is given to theory. On the other hand, American institutes are known for their cohesive training programmes and hands-on approach to problem solving. This is one of the main reasons as to why the Foundation has decided to start the Plastindia International University (PIU). In association with University of Massachusetts Lowell (U-Mass Lowell) and University of Wisconsinâ&#x20AC;&#x201C;Madison, the PIU will be set up in Vapi, Gujarat, where the state government has provided 35 acre of land. The undergraduate engineering programme at the PIU will incorporate all the components of the curriculum that has made the U-Mass Lowell Plastics Engineering programme an international success. Over a period of five years, we are going to invest ` 130 crore to create quality manpower for the plastics industry. In addition, we are going to focus on growth by implementing the right technology; hence, technology collaboration is going to be another area. Among these developments, we will continue to focus our attention on environment-friendly initiatives and programmes.

Since India is an agricultural economy, what efforts are being taken up by the Foundation with regard to agriculture? In Maharashtra, the number of suicides of marginal farmers has become a serious issue. They borrow but in most cases are unable to pay off loans. Because the agricultural sector is the backbone of the countryâ&#x20AC;&#x2122;s economy, this sector is of much significance to us. Efficient utilisation of plastics can help farmers get more yields. One of our programmes includes offering drip irrigation systems to farmers. With timely inputs of water, fertilisers and pesticides, production improved by 400 per cent. After proving successful, we are now involving non-governmental organisations so that farmers can benefit from this system. Other than agriculture, increasing the usage of plastics in public infrastructure is also picking up pace.

What are your thoughts on the recent ban of plastic bags across various states in the nation? Plastic bags are banned in Delhi, Chandigarh and Kerala. In Delhi, even manufacturing of plastic bags is not allowed. The authorities deem jute, cloth or paper to be better options. By no way are we in favour of plastic bags of less than 40 micron, but bags that can be recycled should be supported. Compared to plastics, the deemed alternatives require more energy for production. Moreover, 60 per cent of a customerâ&#x20AC;&#x2122;s buying is impulsive; I do not know how many will find it convenient to always carry with them an extra bag just in case they decide to shop.

In the light of such events, what consumption rates do you predict? Our projected consumption of plastics will be nothing less than 15 million tonne by 2020. Hence, this opportunity must be showcased to international entities associated with the industry. The question now remains on whether the country can become a mass producer like its competitor. Perhaps the organisation of clusters will resolve this issue and put an end to its fragmented nature.

As a veteran of the industry, what remains a challenge for you and the plastics industry? Commercialisation of innovation. I have made more than 40 one-of-its-kind products in my life. Commercialising these innovations has been and remains a challenge. In addition, this industry lacks the presence of young blood. Firstgeneration entrepreneurs are not alluring second-generation entrepreneurs into the same business. This is a prevalent problem. We need to set the right examples so that the second generation is encouraged to enter this field. Further, getting manpower with practical knowledge and problem-solving ability has been a problem. With the PIU, we hope to be able to do away with this problem. Email: sweta.nair@network18publishing.com

April 2013 | Modern Plastics & Polymers

SPECIAL FOCUS

Injection Moulding Injection Moulding: Igniting increased innovations................................................................................................................. 40

Innovative injection moulding: Automation for perfection ....................................................................................................................... 42

Lightweight solutions for automotives: Improving performance, design and safety ............................................................................................. 44

Interface: Hitesh R Shah, Business Head â&#x20AC;&#x201C; Injection Moulding Machines, Windsor Machines Ltd................ 47 Praveen Sharma, Managing Director, Hinds Plastic Machines Pvt Ltd .........................................48

Roundtable: Have Indian moulders been able to significantly improve efficiency in injection moulding?............... 50

April 2012 2013 | Modern Plastics & Polymers

SPECIAL FOCUS: Injection moulding

IGNITING INCREASED

INNOVATIONS

Courtesy: Davis-Standard, LLC

Injection moulding has been the preferred processing technology for part manufacturing that requires high output and accuracy. Thus, the increase in demand for all-electric and micro-injection moulding machines has given rise to new technologies and innovations in the segment. Avani Jain notes the cost–quality ratio of these two categories of injection moulding machines.

he accessibility of plastics has increased with the rising number of industries using plastics. This has bolstered the demand of injection moulding machines that is persistently setting up new highs year over year, thanks to the increased ability of Indian machinery suppliers in incorporating better technologies available in the world in their machines. The new technologies that have gained a widespread acceptance in all the segments are all-electric and microinjection moulding machines.

Micro innovations, big impact Micro-moulding relates to moulding a part that is measured in micron. This process has opened the door to manufacturing tiny parts in a relatively easier manner at a lower cost and at a higher speed. This translates into increased profitability through material conservation as less resin is used to create more parts. 40

Modern Plastics & Polymers | April 2013

Amit Mahant, Director, PK Plastic International Pvt Ltd, notes, “Micromoulding is a very specialised, precision injection moulding technique geared specifically to mould micro-miniature electronic components. There are a number of benefits that can be achieved by the micro-injection moulding process while moulding electronic components.” Micro-moulding is designed specifically for producing the smallest components, typically with component weights below 0.25 g and less. The process has many advantages, such as greater accuracy in the finished part. As the process is designed for smaller parts, a few mould cavities are used in micro-moulding. Therefore, accuracy and reliability achieved in micromoulding far exceed those achieved in conventional moulding.

Cost–quality analysis In moulding of electronic components

in particular, micro-moulding can offer a range of cost-effective alternatives for components that are miniature, complex and require high precision tolerances. Mahant notes, “The one big reason for companies using this technology is cost savings. This is because the amount of time it takes to mould a component is a fraction of what it takes to machine a component. Also, these machines help cut down the cost of part per piece.” He adds, “Micro-moulding also gives more freedom to designers to introduce intricate features in products, thereby enhancing their ability to create more innovative products. Further, small parts require high-speed automation to maintain part consistency, which can only be achieved by the micro-moulding process. Micro-injection moulding is a low-cost solution, it leads to dimensionally stable production process with no particle contamination and complex geometries

Injection moulding

(eg radii) can be achieved through it. Also, it makes use of alternate resins or fillers to improve mechanical and/or electrical properties and leads to better surface finish.” Some other benefits include reduced tool sizes, increased part accuracy, improved cycle times, reduced part cost and defined colours. Mahant notes,“The usage of all-electric and micro-injection moulding machines for moulding electronic components can also offer various benefits along with precision and accuracy. They can lead to energy savings up to 80 per cent and help achieve accuracy with repeatability. In the future, these machines can also make use of the tie bar-less mould clamping structure that can result in much larger mould space and can be equivalent to the wide platen style. This will also help in accurate and stable clamping and lead to equalised force on the mould. Further, the machines can incorporate a mechanical ejector with servo control to enhance the efficiency of the machine.” Thus, due to the various cost benefits offered by micro-moulding solutions, their demand in moulding small parts will continue to increase in the future.

Electrifying the path of energy savings In addition to micro-injection moulding machines, the demand for all-electric injection moulding machines is increasing these days as these help in saving energy cost to a very large extent. Rohan Shrikant Shahane, Regional Director – South East Asia, Machine Point Consultants SL, says, “The energy consumption in different injection moulding machines depend on how the drives are powered. A conventional hydraulic machine uses one or more pumps as a central unit to drive the machine. Two of the most wasteful aspects of a hydraulic machine are the architecture of the system and the wasted pump power when there is no demand. However, all-electric injection moulding machines reduce losses by using highspeed servo motors to drive the injection moulding process. In fact, it is believed that the all-electric injection moulding machines have the potential to reduce

energy costs for a moulder by 30–60 per cent, depending on the moulding and the machine.”

Cost advantages without compromising on quality All-electric injection moulding machines save on cost, primarily the energy cost of the processors to a very large extent. These moulding machines consume electric power only when necessary. This is because, to put it simply, allelectric injection moulding machines are much less mechanically complex. They are driven by digitally controlled servo motors that operate efficiently and at high speeds. With fewer steps in the process, less energy is lost. In fact, these machines often consume less than half the electrical power consumed by hydraulic machines. Shahane notes, “All-electric injection moulding machines allow machine movements to be integrated directly with the control system. This greatly improves machine set up, adjustment and process control. Also, all-electric injection moulding machines use less water. Depending on the product, water consumption can be reduced by up to 65 per cent. Moreover, there is a substantial reduction in maintenance cost as the electric machine eliminates the need for hydraulic oil, thereby eliminating the need to store, dispose, maintain and cool the oil. Further, a shorter product cycle makes it more productive than hydraulic injection moulding machines. All-electric injection moulding machines are more accurate, precise and extremely good for repetitive operations.” In a nutshell, the all-electric injection moulding machines can significantly reduce energy consumption and production cost in moulding. Hence, these machines are increasingly becoming popular and their demand will definitely increase because of their energy efficiency, greater cleanliness, quick start up, better repeatability, quiet operations, easy maintenance and, above all, the ability to save production cost for processors. Email: avani.jain@network18publishing.com

The one big reason for companies using this technology is cost savings. This is because the amount of time it takes to mould a component is a fraction of what it takes to machine a component. Also, these machines help cut down the cost of part per piece. Amit Mahant Director, PK Plastic International Pvt Ltd

It is believed that the allelectric injection moulding machines have the potential to reduce energy costs for a moulder by 30–60 per cent, depending on the moulding and the machine. Rohan Shrikant Shahane Regional Director – South East Asia, Machine Point Consultants SL

April 2013 | Modern Plastics & Polymers

SPECIAL FOCUS: Innovative injection moulding

AUTOMATION FOR PERFECTION

Courtesy: Cherry Electrical Products

igher output, lower cost and energy efficiency have become the key criteria in the injection moulding industry in India. In order to achieve these, it is important to adopt the latest technology through either 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 for the past eight years, outperforming the overall economy, which grew roughly at 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, Polymechplast Machines Ltd, says, “Injection moulding machine sales in India in 1990 stood at 2,500–3,000 per year, which today stands at about 8,000 machines a year.” During 2010–11, across various plastics processing machines, injection moulding 42

Modern Plastics & Polymers | April 2013

machines had acquired 70 per cent market share, extrusion machines boasted of 23 per cent share, blow moulding machines had 6 per cent of the pie and machines for other techniques stood at 1 per cent. Market projections show that by 2015– 16, almost 10,800 injection moulding machines would be serving the plastics processing industry across India.

Latest developments The latest advancements in injection moulding include servo motors for energy-saving and all-electric machines replacing hydraulic machines, which have precise control and are useful for pharma and automotive products. Harminder Singh, AGM – Sales & Marketing, Electronica Plastic Machines Ltd, says, “Demand is increasing for packaging that can be simultaneously labelled during the injection moulding process. This has resulted in the development of well-packed in-mould labelling systems. In addition to functional benefits, this complex process offers potential for cost reduction.”

The versatility offered by injection moulding in terms of design and high production output rates makes it the preferred choice in the plastics industry. Anwesh Koley analyses the current trend towards the advanced usage of robotics, which allows complete automation in the moulding process. Along with these, co-injection and multi-colour injection moulding techniques are used to create different designs with a programmable logic controller-operated system to achieve repeatable design patterns with higher output. The usage of robotics and automation reduces manpower and results in consistent output. “The industry has benefitted from a variety of 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 the latest computer numerical control machines

Innovative injection moulding

and other design-oriented software, which helps in producing quality products as well as in competing in the international market. “With the advent of servo control technology, normal plastics processing has become simpler, and engineering plastics processing, which was earlier considered a difficult process, has become easier,” opines Singh. Metal injection moulding and ceramic injection moulding parts can now be found in all areas of life, from automobiles to watches, from dental braces to mobile phones, from IT equipment to do-it-yourself tools and many other areas.

How it works The injection unit is responsible for both heating and injecting the material into the mould. The first part of this unit is the hopper, a large container into which the raw plastic is poured. The hopper has an open bottom, which allows the material to feed into the barrel. The barrel contains the mechanism for heating and injecting the material into the mould. This mechanism is usually a ram injector or a reciprocating screw. A ram injector forces the material forward through a heated section with a ram or plunger that is usually hydraulically powered.

Higher output at lower costs Advanced usage of robotics ensures that output is higher, but total moulding cost is low due to lower cost of the machine. All principal modules – the clamping unit, injection unit, drive, protective covers and control system – are coordinated and geared towards efficient production. Even complex products are manufactured at the highest reproducibility level. Multicavity production reduces the number of machines and manpower, with less energy consumption by the servo drive, and hot runner moulds lower cycle time with zero wastage. The usage 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 are able to keep pace and improve the efficiency of the entire system with quick material handling, few mistakes, if any, and effective palletising,” adds Gupta. Industrial robots add flexibility to the design of plastics. It is used for all types and sizes of parts, from tiny assembly components to large automotive body pieces. Robots can be quickly programmed to handle different products. They can also easily tend to more than one machine at a time. These can also be programmed to palletise or place parts on a conveyor. Also, the usage of robotics creates a safer work environment. “Typically, workers are required to work in close proximity to injection moulding machines, reaching to remove parts and stack them repeatedly. Those removing the parts from an injection moulding machine are prone to repetitive movement injuries. With robots, human contact with the injection moulding machine is minimised,” says Singh.

Robots are able to keep pace and improve the efﬁciency of the entire system with quick material handling, few mistakes, if any, and effective palletising. Naveen Gupta Senior Branch Manager, Polymechplast Machines Ltd

Challenges faced The primary challenge is the advent of Chinese machines that are priced low. Often customers do not understand the importance of after-sales and service and opt 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. 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 inputs 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 energy efficiency. Email: anwesh.koley@network18publishing.com

With the advent of servo control technology, normal plastics processing has become simpler, and engineering plastics processing, which was earlier considered a difﬁcult process, has become easier. Harminder Singh AGM – Sales & Marketing, Electronica Plastic Machines Ltd

April 2013 | Modern Plastics & Polymers

IMPROVING PERFORMANCE, DESIGN AND SAFETY

Courtesy: CN Moulding

SPECIAL FOCUS: Lightweight solutions for automotives

From bumpers to door panels, lightweight plastics give cars better mileage and allow designers and 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 impact strength and ease of moulding.

njection moulded parts constitute 70 per cent of the total processed plastics market. From home appliances to parts for automobiles, as well as the construction industry, injection moulded parts are found everywhere today. There was a time when the automotive sector was not in favour of using plastics for parts. Gradually, the importance of plastic parts grew as manufacturers understood the importance of weight reduction, which aids fuel efficiency. With the automobile industry witnessing intense competition over the years, plastics have been used in strategic areas to provide durability and enhance visual appeal of vehicles. Engineering plastics provide strength due to their inherent properties. Conventionally, metal alloys were synonymous with auto body exterior design and manufacturing. However, metal alloys are susceptible to dents, 44

Modern Plastics & Polymers | April 2013

dings, stone chips and corrosion. They are also heavier and more expensive than plastics. Ayush Lohia, CEO, Lohia Auto 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 Moulding has a rich history in the plastics industry. The moulding process was invented only a few years after the invention of plastics. Initially, hand moulding was used. Moulders had a conventional screw barrel setup, and external heating was applied manually. Even the moulds were opened and closed in a similar manner. Gradually, as automation began, the injection moulding machine as we know

today was developed with a circuit installed in it to regulate the machine. “Hydraulic systems were developed during the same 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 thus saves cost,” adds Lohia. Over the years, hydraulic machines have been replaced with Programmable Logic Controller (PLC) units. Ashwani Aggarwal, President, Brose India Automotive Systems Pvt Ltd, says, “Injection moulding has always been a step ahead in terms of operational versatility than extrusion. With injection moulding, all that is needed is changing the mould, and one can achieve the desired design. Today, PLC has become mandatory for machines, and servo motors are also in vogue as these consume less electricity. Various safety features have also been

Lightweight solutions for automotives

adopted in injection moulding machines, which essentially regulate the opening and closing of the mould cavity.”

Plastics in automotives

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. Ayush Lohia CEO, Lohia Auto Industries

The automotive market is an important market for plastic resins such as polypropylene, polyurethane, nylon, other engineering polymers and thermoplastic polyesters. “Light vehicle applications account for over 30 per cent of the demand for each resin. Other resins used include acrylonitrile butadiene styrene and polyvinyl butyral. Engineering polymers such as nylon, polycarbonate and others are supplanting metals in many applications,” adds Aggarwal. Typical plastics and composite applications include exterior panels, trim & bumper fascia, interior trim panels, window encapsulation, headlamp housings, manifold & valve covers, electronic/electric parts & components, wiring harnesses, steering wheels, insulation, dampers & deadeners, upholstery, mechanical parts & components and safety glass. Most of these are processed through injection moulding.

Design flexibility

Light vehicle applications account for over 30 per cent of the demand for each resin. Other resins used include acrylonitrile butadiene styrene and polyvinyl butyral. Engineering polymers such as nylon, polycarbonate and others are supplanting metals in many applications.

New processes enable manufacturers to reuse scrap plastics and recycle used plastics cost-effectively. Also, plastic components weigh approximately 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 with improved mileage and less emissions. Low-cost, single-unit production of large automobile parts, such as a front grille, is nearly impossible when using metal. “Plastics offer auto engineers a variety of practical, cost-effective alternatives and tremendous advantages over conventional automobile production materials,” says Lohia.

Automotive safety

Ashwani Aggarwal President, Brose India Automotive Systems Pvt Ltd

Modern Plastics & Polymers | April 2013

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. For example, 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. If a 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 less danger. Composite driveshafts are also lightweight and require less energy to spin, effectively increasing the amount of power that the engine can transmit to the wheels. Plastics are 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 family of materials. A lot of chassis parts are also made through injection moulding. Fibre-reinforced polymer composite materials weigh about 50 per cent less than steel, though 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. Frontend components made of these lightweight energy-absorbing composite materials are specially designed to fracture in a manner that utilises impact energy.

Non-metallic alternative Plastics have found remarkable acceptance as a substitute for metal in transmission components. These performance characteristics can be tailored by material suppliers to meet the particular needs of automotives. The usage of additives, fillers and reinforcements will cause variations in the properties of plastics to meet specific customer requirements. 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. Email: anwesh.koley@network18publishing.com

SPECIAL FOCUS: Inter face – Hitesh R Shah

“The future growth in the segment will be solely defined by customer demand” …opines Hitesh R Shah, Business Head – Injection Moulding Machines, Windsor Machines Ltd. In an exclusive conversation with Avani Jain, he talks about the demand for plastics processing machines in the country. He further elaborates on the current trends, challenges and opportunities in the industry. How is the demand for plastics processing machines in the country? Ease of manufacturing and versatility have made plastics the most preferred material in the industrial & consumer products segment, and plastics are fast replacing other materials such as glass, wood and metal. Their demand is continuously growing in the automotive, construction, packaging, electrical & electronics, pipe fittings, agriculture, houseware, medical and pharmaceutical sectors. All this has constituted a huge demand for highprecision plastics processing machines and moulding equipment. The plastics processing machinery industry is growing at a compounded annual growth rate of 15 per cent, indicating a healthy growth. Apart from good domestic growth, there is an increase in demand for plastics processing machines in the neighbouring and African countries.

What are the recent trends in the segment? Earlier, the demand for higher tonnage machines was less and smaller tonnage machines were sold in a large number. However, with changing times, the demand for higher tonnage machines is also increasing. Another trend is that with the growth of the automotive, pharmaceutical and healthcare segments, the demand for plastics processing machines is also growing, and the focus is on technology that gives higher efficiency at a lower cost. Further, the demand for machines that consume less energy is increasing.

What are the leading innovations making headway in the segment? Hybrid technology and all-electric machines are really picking up well in the market. Wherever there is need to

standards and reducing the overall cost of machines. This will also increase the demand of machines and help the segment to overcome challenges. Also, growing awareness and adoption of IT solutions can increase the productivity of machines, thus increasing the demand.

What could drive the future growth in this segment?

maintain a clean environment such as in healthcare and medical applications, the demand for all-electric machines is increasing. The usage of servo technology is also increasing as it helps in decreasing energy consumption to a large extent. In addition, innovations are being made in machines to increase productivity without increasing the cost.

What are the challenges and opportunities for the injection moulding machinery segment in India? Various challenges before the industry include raw material availability and their fluctuating prices, requirement of trained manpower and automated solutions. In addition, competition from global players in terms of low-cost machines is a major challenge. The import of used machines and other high-end machines in large volumes is another major challenge for the industry. Despite these challenges, there are opportunities for growth as well because awareness on the injection moulding process is increasing. Further, processors are continuously involved in improving operational efficiencies by focussing on productivity, meeting quality

The future growth in the segment will be solely defined by customer demand. Machines that ensure accurate repeatability of the process, faster cycle times, 24/7 failure-free operation, low energy consumption, less noise and address environmental concerns will be more in demand. A company capable of making such plastics processing machines will rule the market. Further, in the global competitive market, every producer is required to offer high quality and efficient machines at lower costs; thus, this serves as a major driver for growth in the future.

What are the growth plans of your company? In the last few years, we have been focussing on the overall growth of the company and not only on increasing productivity. We have focussed on employee development, infrastructural development, improving manufacturing practices by moving towards zero defect products etc, thus ensuring that the total culture of the company improves and customer expectations are met. We have also taken up new product development with reducing the cost as a major concern. Hence, we want to and are providing total solutions to the customer. Last, but not the least, we want to continue to grow at the pace at which we are growing since the last few years. Email: avani.jain@network18publishing.com

April 2013 | Modern Plastics & Polymers

SPECIAL FOCUS: Inter face – Praveen Sharma

“Without automation, manufacturing energy-efficient machines would not be possible” ...avers Praveen Sharma, Managing Director, Hinds Plastic Machines Pvt Ltd. In an interaction with Anwesh Koley, he explains the various reasons for the growth of the injection moulding industry in India and the various challenges it faces today.

What is the current scenario of the injection moulding industry in India? The injection moulding industry is quite positive overall, but the current demand for injection moulding varies according to the different sectors that use injection moulded parts. In the automobile sector, the demand has decreased in the last 3–4 months as the overall economic growth has shown signs of slowing down. However, if we consider commodity plastics and packaging, the demand is quite high. In this sector, the demand is regularly increasing and has shown a good scope for Injection Moulding Machines (IMMs). The market is very competitive; therefore, every player is conscious about the existing price and quality.

What are the key reasons for the growth of injection moulding? Most sectors use plastics or things related to plastics, and today, plastics play a major role in everyone’s life, whether it is a household item, engineering item or automobile part. As compared to other developed countries, there is a large scope for growth of the injection moulding industry in India. At present, the per capita usage of plastics is 5–6 kg in India, whereas it is 14–15 kg in developed 48

Modern Plastics & Polymers | April 2013

countries. Therefore, this industry has potential to grow further. Various research and development initiatives in sectors like agriculture have also bolstered the growth of injection moulding. The drip irrigation system and new tools used in farming have provided a great scope and have opened new channels and avenues for injection moulding. In addition, most manufacturers are now going into the conversion mode towards more modern automatic programmable logic controlled machines. Thus, a lot of scope and demand for modern and energy-efficient machines is currently being generated.

What are the latest innovations witnessed by the industry? Many developments have been witnessed by this sector, whether it is polymers, moulds, IMMs, auxiliary equipment or plant automation. Major developments in this or any other sector are focussed towards saving energy and optimising costs. The latest development being biopolymers and green plastics, both of which are environment friendly. Following similar trends, machine manufacturers are also making machines that reduce wastage, have lower noise levels, are highly energy efficient and environment friendly. Due to the advancements in polymer science and developments in engineering plastics today, most of the parts are being converted from aluminium to plastics, which results in lower cost and lightweighting with more durable parts. These components play a major role in the automobile sector, which helps in improving fuel efficiency and aids in cost reduction.

What is the extent of automation and the energy-efficient standards in the industry? Automation

involved

every

stage of moulding, from the initial production stage to the final packaging phase. In plastics processing industries, automation plays a major role, whether it is moulds, machines or in the postmoulding process. In the current scenario, moulds are advanced and automated, and they are equipped with hot runner systems that produce parts with minimum rejection and effective cooling systems that lead to shorter cycle times. In injection moulding, automation plays a major role in increasing production and in ensuring accurate moulding. Without automation, manufacturing energy-efficient machines would not be possible. The current crop of IMMs are energy efficient and equipped with hydraulic pumps driven by servo motors that save up to 40–60 per cent energy, depending on the moulding parameters.

What are the challenges faced by the injection moulding industry? The main challenge faced by IMM manufacturers in India is to compete with international manufacturers. Most materials used in making the machine, with the exception of raw materials, are imported, whether it is the servo system, programmable logic controller or advance hydraulics or robotics. After payment of customs and duties, the parts become more expensive and thus affect pricing of machines. These machines are eventually unable to compete in the international market. There are no definite schemes by the government to provide infrastructure or for the procurement of raw materials at subsidised rates. This makes it difficult for small and emerging businesses to survive in the market. Email: anwesh.koley@network18publishing.com

SPECIAL FOCUS: Roundtable

Have Indian moulders been able to significantly improve efficiency in

injection moulding?

High productivity and energy efficiency have characterised the injection moulding industry for a long time. However, with global advancements making rapid strides in India, it is important to gauge whether Indian injection moulders have been able to remarkably improve their productivity to cater to the ever-increasing market for injection moulded products. Anwesh Koley interacts with industry experts and shares their views on the current scenario of the injection moulding industry in India. Jagmeet Ratra Manager, R S Associates Pvt Ltd

The Indian market is price sensitive and non-quality conscious. Companies are initially attracted by the low sticker price, and quality considerations come after the machines are used over a period of time. However, Indian companies offer better aftersales service. Since the majority of the market for injection moulding machines is in the unorganised sector, manufacturers do have a reason to smile. The future of the injection moulding industry is bright as the growth rate is high and the number of applications of injection moulding has gone up. Indian machines are now being considered globally because of durability and after-sales service. The Middle East and Africa are the largest importers of Indian injection moulding machines. Indian processors import the largest number of machines from China; these low-priced imports are a major threat. Unlike in India, Chinese manufacturers get benefits of subsidies and tax concessions from the government.

Kewal Krishan Ajimal Director, Vishavakarma Hydraulic Pvt Ltd

Currently, the injection moulding industry uses energy-efficient machines called servo motor machines that consume less power. Earlier only one type of machine was used, and if it worked well, it was used for all major applications. However, this did not provide the required efficiency in terms of production and energy consumption. Today, companies offer machines with different kinds of applications. Thin-walled applications require specific machines; PET bottle manufacturing requires another technique. This results in higher output at lower costs. Toggle-type injection moulding machines are in vogue, while many manufacturers continue with hydraulic ones. A toggle-type machine consumes less power with faster production. Manufacturers in India have still not adopted fully automatic machines on a large scale as the availability of manpower is high. However, they now develop machines that not only produce higher output but also save energy and cost.

Thankur Singh Dhooper Director, Popular Engineers (India)

Current generation servo motors used in injection moulding ensure energy saving and low noise levels. The rpm control of the hydraulic servo pump drive system with AC servo motor ensures energy savings and noise reduction. Moulders can achieve almost 65 to 75 per cent energy savings through these techniques in comparison with a fixed-type pump motor-based system. High-precision stability control can be achieved through the closed-loop method of hydraulic servo pump drive system with servo motor reproducibility. This ensures optimum usage of power and consistency in operations. The hydraulic method and the screw-drive method are combined to form a synchronous operation based on the various complex coordination of parts. This improves productivity by reducing the process time. Increasing the screw revolutions per minute using a high-output servo motor helps reduce the charge process time. This system also accommodates tandem mould and stack mould usage.

Editorial take: Email: anwesh.koley@network18publishing.com While there are varieties of techniques that can be used to ensure energy efficiency in an injection moulding machine, it is important to choose the right equipment and system to enable precise moulding along with efficient production set up. This will result in product consistency and customer satisfaction. 50

Modern Plastics & Polymers | April 2013

MPP Apr_2013 Ad Name: Prayag Tab-4, Pg No. 51

MPP Mar_2013 Ad Name: Sacmi Tab-4, Pg No. 52

SACMI

FACILIT Y VISIT: Toshiba Machine (Chennai) Pvt Ltd

Creating exemplary manufacturing processes From its rich lineage to setting benchmarks in manufacturing techniques, Toshiba Machine (Chennai) Pvt Ltd plans to increase its foothold in the Indian injection moulding market. Sweta M Nair visits its facility in Chennai to assess if the company’s aspirations have a physical backing.

onsidered one of the prime processes for producing plastic products ranging from micro to large components, injection moulding is virtually used in all sectors of manufacturing. Size flexibility, design freedom and maintenance of production quality have enabled processors to extend the boundaries of plastics. Capitalising on the growing prowess of the plastics sector is Toshiba Machine (Chennai) Pvt Ltd. While this company has achieved a turnover of ` 226 crore and is known for its range in injection moulding machines and auxiliary equipment, its innovative manufacturing processes are now gaining much attention.

An interesting lineage Located on the Chennai–Bengaluru Highway, the manufacturing facility of Toshiba Machine is spread over an area of 9.16 acre. With a workforce of 220 employees, the company has been setting benchmarks by successfully implementing and executing processrelated innovations. This facility is not only a testament of the changing times but also an enabler of transmitting indigenised adaptations to the company’s range of machines. Explaining the lineage of Toshiba Machine, Parameswaran Kailas, Managing Director, says, “The Toshiba Machine (Chennai) you see today is a result of a number of successful collaborations that have occurred in the past. Our plastics machinery business started in 1991 when we at L&T were in 54

Modern Plastics & Polymers | April 2013

technical collaboration with world leaders Demag, Germany [now Sumitomo (SHI) Demag]. In 2001, the management of Demag and L&T sensed the untapped potential of this business. This led to the formation of a 50:50 joint venture. We moved to this modern facility on October 2, 2005. In 2008, Demag was acquired by Sumitomo Japan, which then came to be called as Sumitomo (SHI) Demag. This acquisition was soon followed by the company offloading its shares, all of which were bought by L&T. In January 2009, the company became a fully owned subsidiary of L&T and renamed as ‘L&T Plastics Machinery Ltd’. In order to grow multifold, in 2010–11, L&T management decided to exit from its non-core businesses. What followed shaped the present company. On September 28, 2012, Toshiba Machine Co Ltd, Japan, acquired all of the shares in the Indian firm of L&T Plastics Machinery Ltd and made it a subsidiary of their company. The latest identity Toshiba Machine (Chennai) Pvt Ltd is a member of the Toshiba Machine Group, Japan. Toshiba’s idea of acquiring L&T Plastics Machinery was for obtaining a wider product reach and for accessing the Indian market in a big way.”

Divisions and processes The spacious facility, now in its eighth year, has received accolades time and again from Frost & Sullivan for its design and machine manufacturing systems. The main building houses the administration

Assembly and testing area

Toshiba Machine (Chennai) Pvt Ltd To

The 10-stage single-piece flow moving assembly

office and shop floor. The latter is well ventilated and is divided into three bays. As per process, the first bay is for the entry of materials and the assembly of parts. Smaller tonnage injection moulding machines (up to 180 tonne) are assembled in the middle bay. The last bay is utilised for assembling machines belonging to the middle and higher tonnage machines. “For us, any machine that ranges between 180 and 300 tonne falls in the middle tonnage category, whereas machines that range from 350 to 1000 tonne are categorised as higher tonnage machines,” says M Kumar, Head – Manufacturing. Other sections include a display of products that can be produced by the machines, a cut-section of components used in manufacturing, storage units and a paint booth. The facility also houses sections for the manufacturing of auxiliary equipment for the plastics processing industry and other supporting facilities like canteen, parking, wastewater processing, an organic converter for compost unit etc. At Toshiba Machine, the number of initiatives to encourage innovation among employees is remarkable. One such initiative ‘Hunt for Innovative Thoughts (HINT)’ is where on-line suggestions for improvements/new manufacturing concepts are brought to light. Another initiative is the ‘Stride Towards Excellence Programme (Step)’. Toshiba Machine is the first injection moulding machinery manufacturer in the country to have started assembling machines on a moving platform. Recipient of the Indian Machine Tool Manufacturers’ Association – SIEMENS Productivity Championship Award, this concept is a 10-stage paperless,

single-piece flow moving assembly. Every stage has a dedicated set of tools, and assembly activity is electronically stored. On an average, the machine moves to another stage (or level of completion) after 2 to 3 hours, which signifies that this single-piece flow facility allows the company to produce three machines in a shift of 8 hours. In the consecutive shift, the feeding of the material takes place. Unlike conventional methods, this platform is levelled to perfection, which ensures that testing of machines is carried out seamlessly. The congenial attitude of the company of encouraging innovations has lead to a number of productive developments on the shop floor. For instance, the creation of a cell quantum, consisting of prismatic, round and hydraulic block cells, is where minimum testing is conducted in this facility.

Practical efficacy Along with paying attention to product, quality and safety, this ISO 9001:14001 company emphasises its economical, environmental and social role. Falling in line with this philosophy, the company has installed three solar panels on the rooftop of its canteen so as to enable solar cooking. “For the panels, with an investment of ` 9.6 lakh, we have received a government subsidy of about ` 3.5 lakh. With this system in place, we have managed to save one industrial gas cylinder everyday, which approximately costs ` 3,500. Due to the good dividends that we have received, we are contemplating in implementing solar technology in our office building. Moreover, the waste food from the canteen

By providing additional safety features that protect the machines against power spikes, ﬂuctuations and cuts – general phenomena in India, we have been able to suitably modify our machines with international technology to suit Indian conditions to a certain extent. Parameswaran Kailas Managing Director

is used to prepare manure in our very own organic converter plant. We are a zero water discharge facility, where the waste water is treated and used for nourishing the lush greenery in the facility,” affirms Kailas. Automotive, packaging, construction, electrical accessories, medical components and writing instruments are major markets for Toshiba Machine. According to plan, the company aspires to start the manufacturing of all-electric injection moulding machines in this facility by October 2013. Extending its product base in hydraulic machines and introducing die-casting machines are also tentatively planned. “By providing additional safety features that protect the machines against power spikes, fluctuations and cuts – general phenomena in India, we have been able to suitably modify our machines with international technology to suit Indian conditions to a certain extent. Amid these introductions, our attention will be fixed on providing after-sales support to all our customers,” states Kailas. Email: sweta.nair@network18publishing.com

April 2013 | Modern Plastics & Polymers

INSIGHT & OUTLOOK

Engineering Plastics Engineering thermoplastics: Turning the heat on metals! ........................................................................................................ 58

R&D initiatives: Improving the inherent properties of engineering plastics ......................................................... 60

Interface: Dr Harindu Vyas, Consultant, Polymer & Plastics Technologist........................................64 Satendra Kumar, CMD, Quadrant EPP Surlon India Ltd .............................................. 66

Roundtable: How have engineering plastics revolutionised lightweighting for automotives? ........................ 68

Green shoots ........................................................................................................................... 69 End-of-life applications of recycled plastics: Setting benchmarks! .................................................................................................................... 70

Interface: Vishal Jasrapuria, Director, Shree Sadguru Plastic Industries ............................................ 72 Dr Prakash Mahanwar, Head â&#x20AC;&#x201C; Dept of Polymer and Surface Engineering, Institute of Chemical Technology ...........................................................................................74

Filament wound composite pipes: Technological triumph for Indian industry Sangeeta Baksi and Soumitra Biswas, TIFAC, Department of Science & Technology, Government of India; and Leena Modi and Jayrah Shah, EPP Composites Pvt Ltd ....................... 76

April 2013 | Modern Plastics & Polymers

INSIGHT & OUTLOOK: Engineering thermoplastics

TURNING THE

HEAT ON

METALS! Engineering thermoplastics are now the accepted replacement solution in demanding engineering applications where traditional materials are less economical. Sweta M Nair delves deeper to gauge the enhanced usage of engineering plastics in thermo-sensitive applications.

ngineering thermoplastics exhibit higher performance than commodity materials and are suitable for applications that require engineering to design parts that perform. In the past, these plastics were not considered in application areas that require high temperature. Instead, metals and other conventional materials were used. Due to primitive manufacturing techniques, in some cases, even production technologies were clumsy, which resulted in difficulty while assembling. The usage of traditional plastics in thermo-sensitive applications also had limitations. To begin with, service temperature requirements and limitations in product design were a couple of issues in engineering safety. Components in automotive, electrical & electronics and aeronautical & space applications need thermoresistant materials. Satisfying this crucial requirement, engineering plastics are thus replacing metal, rubber, glass, paper 58

Modern Plastics & Polymers | April 2013

Courtesy: Arkema Inc

and, in some cases, even concrete. “Along with being thermo-sensitive, engineering plastics are corrosion-free and have better noise dampening characteristics. They offer ease of processing or production, lightweighting and more freedom in product design. In the last decade, the usage of engineering plastics has been extended to automotive applications including replacement of bumper, fuel tank, metal fuel lines and other fluid transport lines. In the infrastructure industry, these plastics have given designers freedom – from fluid transport management to replacement of wood and glass – with better safety, ease of handling and durability. The enhanced usage of these plastics in white goods is to make products better and attractive with flame retardant and higher safety index features. Lighter and attractive

electronic goods like vacuum cleaners, coffee makers, washing machines, metalfree refrigerator interiors, smarter and lighter mobile phones and replacement of other metal parts in electrical & electronic items are achievements of engineering plastics,” says Mandar Amrute, Sales and Market Development Manager, Speciality Polyamides, Arkema India.

The hot ones When referring to heat-resistant engineering plastics, the demand is skyrocketing around the globe by the minute. A specific set of thermoplastics caters to this niche requirement beautifully. The most common being Polycarbonate (PC), which not only has strength similar to non-ferrous metals but also has good impact strength, ductility and durability. Due to excellent clarity,

Engineering thermoplastics

any colour blends well with it. PC has broad applications, including safety lamp cover, signal lamp, high-rise building glass, aircraft cockpit glass, glass and sheet material substitutes and storage optical discs. Because of superior mechanical and chemical properties, Polyoxymethylene (POM), dubbed as ‘super steel’, can be used for various precise micron gear, instrument elements and components with geometrically sophisticated surfaces, bib nozzles and valves for the deflagrator pipeline. In fact, POM is used in applications where metal and non-metallic materials are sometimes incompetent. Polybutylene Terephthalate (PBT) is a type of thermoplastic polyester with qualities such as high insulativity and wet strength. Non-enhanced PBT has good workability and electrical properties. With extensive uses in electrical & electronics and automotive industries, it is low in glass transition temperature, and therefore, short in processing cycle. It can be crystallised even when the mould temperature is at only 50°C. PBT has applications in production of kickback transformer of television sets, automobile section boards and ignition coils, exterior components of various automobiles, fans of air conditioners, bases of electronic ovens etc. Talking about the advantages of engineering plastics, Geetha Baskaran, Director, Suba Plastics Pvt Ltd, affirms, “Faster cycle times in production and lightweighting in automotives, which leads to economical fuel consumption, are the brightest aspects. We can further push the boundaries in lightweighting by using MuCell™ Molding Technology.”

Like hot cakes In the last five years, engineering plastics have entered new industry segments and have growing usage in spacecraft and automotive applications. Because there is a strong drive to replace metals, Amrute adds, “Many traditional under-the-bonnet car parts are being made with thermosensitive engineering plastics. This grade has also made significant improvement in packaging for chemicals as well as microwaveable food packs. It has also

gained a strong foothold in the medical industry for applications such as artificial transplants and better surgical equipment like skin-feel gloves, anti-static textiles and so forth. The latest usage is in temperature-sensitive decorative paints or films for exterior and interior applications in the infrastructure industry.” When talking about demanding applications such as bearings, piston parts, pumps, compressor plate valves and cable insulation, a colourless organic polymer thermoplastic that comes to mind is Polyetheretherketone (PEEK). Considered an advanced biomaterial used in medical implants, PEEK is extensively used in the aerospace, automotive and chemical process industries. The other variety nylon 6-6 is used frequently when mechanical strength, rigidity and stability under heat are required. This polymer is made of hexamethylenediamine and adipic acid. It is used for ball bearing cages, electroinsulating elements, pipes, profiles and various machine parts. “With the usage of engineering plastics increasing in underthe-bonnet applications, we are seeing more glass-filled nylon, POM and glassfilled polypropylene. The usage of PBT and PEEK has increased in applications where resistance to high temperature is required. PC is being used increasingly in headlamps as well. At Suba Plastics, we specialise in automotive components such as high-abrasive plastic gears with close tolerances, gear housing and engine belt tensioners that work closely with the engine belt drive. In our products, we have used carbon fibre-filled nylon 4-6 for some special applications. We make components with nylon 6-6 with 50 per cent glassfilled material for gears for starter motor applications. These components made from engineering plastics can withstand temperatures of more than 150–200°C. They are also proven to perform well in extreme climatic conditions. New additive technology is being used to make it more heat resistant. In the next ten years, I believe engineering plastics will take over at least 40 per cent of all under-the-bonnet applications,” says Baskaran. Email: sweta.nair@network18publishing.com

Along with being thermosensitive, engineering plastics are corrosionfree and have better noise dampening characteristics. They offer ease of processing or production, lightweighting and more freedom in product design. Mandar Amrute Sales and Market Development Manager, Speciality Polyamides, Arkema India

Faster cycle times in production and lightweighting in automotives, which leads to economical fuel consumption, are the brightest aspects. We can further push the boundaries in lightweighting by using MuCell™ Molding Technology. Geetha Baskaran Director, Suba Plastics Pvt Ltd

April 2013 | Modern Plastics & Polymers

INSIGHT & OUTLOOK: R&D initiatives

Improving the inherent properties of engineering plastics Valued for their outstanding mechanical and optical properties, engineering plastics have many diverse applications in the automotive and electronics segments. Good chemical resistance, dimensional stability, low moisture absorption and good flow properties are the other known attributes. Sweta M Nair brings to light the continued Research & Development (R&D) initiatives that are taking place in this space.

he untapped potential and growing opportunities in the engineering plastics industr y are gaining worldwide attention. Replacing metal with plastics in cars & trucks, household appliances and building & construction is becoming the order of the day. In such circumstances, high endurance, performance, wear resistance and antistatic properties of engineering plastics are areas of maximum effort in R&D. Driven by the ongoing replacement of metal parts with engineering plastics, the demand is expected to rise globally. In Asia, the usage of engineering plastics has increased in segments such as electrical & electronics, construction and automotives. As forecasted by TechNavio, the global engineering plastics market will reach $ 69.12 billion by 2016. The report covers the Americas, Europe, the Middle East and Africa (EMEA) and Asia-Pacific (APAC) regions. The reason for this rise in demand has been attributed to the increasing demand for lightweight products.

Inherent assets Components made from engineering 60

Modern Plastics & Polymers | April 2013

plastics are usually used in tough environments. The reliability of working in harsh conditions coupled with durability gives engineering plastics an edge over generic plastics. For instance, engineering plastics in hydraulic gear pumps have a working life of 50,000 hours. Apart from industrial applications, the usage of engineering plastics in body implants requires that these plastics go through sterilisation of ultra-violet or gamma radiation. This signifies that the chemical resistance of engineering plastics is higher than that of generic plastics. Talking about the present scenario, Nanda Kishore, Director, Jayashree Horologicals Pvt Ltd, says, “Engineering plastics are here to replace metals, and they can also emulate the look and feel of metals. This is achieved by reinforcing the base material with glass, sand or talc-filled additives. Much R&D to obtain certain anti-static grades of engineering plastics is currently ongoing for electronic applications.” With the stiffness and toughness exhibited by these plastics, continued research is aimed at outperforming traditional metal applications while providing many advantages. In this era

when weight reduction is the key to fuel efficiency, engineering plastics have a high strength-to-weight ratio and are lighter than metals. Reflecting his thoughts on new application areas, Scott E Fleming, Vice President & Business Manager, Nylon Division, Teknor Apex Co, says, “Engineering applications are less expensive than metals in terms of raw material cost and provide substantial cost savings as a result of their design freedom. This freedom makes possible parts consolidation and moulded-in multi-functionality, replacing the time and labour required for metal fabrication and assembly. Finally, by resisting corrosion and providing inherent thermal and electrical insulation, engineering plastics are less expensive on a lifetime cost basis. The automotive sector is the largest market for the Nylon Division of Teknor Apex. New automotive applications keep appearing as a result of two trends – continued proliferation of electronic devices & information systems and an increasing demand for weight reduction.”

Beneficial shift When it boils down to the basic process

R&D initiatives

Engineering plastics are here to replace metals, and they can also emulate the look and feel of metals. This is achieved by reinforcing the base material with glass, sand or talc-filled additives. Nanda Kishore Director, Jayashree Horologicals Pvt Ltd

Engineering applications are less expensive than metals in terms of raw material cost and provide substantial cost savings as a result of their design freedom. This freedom makes possible parts consolidation and moulded-in multi-functionality. Scott E Fleming Vice President & Business Manager, Nylon Division, Teknor Apex Co

Modern Plastics & Polymers | April 2013

itself, metals require heat energy of up to 1,200° C to enter into a molten stage, whereas any kind of polymer can be plasticised at 300°C. Highlighting this point, Kishore talks about the advantage that engineering plastics brings to his line of horological business, where tolerance levels are very critical. “Earlier, generic plastics were used for horological applications where a lot of shrinkage used to happen. After considerable research from the solutions provider side, the expertise in polymer blending helped us reduce the shrinkage rate. Engineering plastics respond well to the production process, thereby helping us reduce shrinkage and rejection rate. For instance, our watch movement holders were made using polyoxymethylene, but now we have shifted to grylamide (a nylon co-polymer). Because grylamide has excellent dimensional stability, it has helped us do away with shrinkage.” The successful penetration of engineering plastics into various segments is based on different criteria. Research is being extended to areas such as under-the-bonnet parts, exterior parts (window wiper holders & exterior mirror housing), high heat distortion temperatures and electrical insulation. The telecommunications sector has similar uses for engineering polymers, notably used in mobile phone casings, through the desire for light and durable phones. Other applications may include building, textile bobbins, meter housings and small niche applications. Although most of these research studies are still in a pilot stage, there have been a few commercially successful innovations. Regarding Teknor Apex’s work in this area, Fleming says, “Our Chemlon® 813 CI and 830 GHI fibre-reinforced compounds, based on the nylon 6/12 polymer, are in commercial use and provide the excellent chemical resistance and low moisture absorption required in fuel line components. The 13 per cent loading of carbon fibre in the Chemlon 813 CI product also provides anti-static conductivity often called for in fuel line components. Chemlon 830 GHI

compound has a 30 per cent loading of glass fibre for enhanced strength and rigidity in applications such as connectors. The new compounds pick up only slightly more moisture than nylon 12 and achieve acceptable finished part dimensions in tooling previously used for nylon 12. At the same time, Chemlon 800 series materials process in shorter cycles and at higher melt temperatures than nylon 12. We are now fully commercial with a new range of compounds incorporating recycled nylon, chiefly nylon 6 and 6/6. We are offering these compounds under the brand name Recyclon and have customers ranging from automotive manufacturers to patio furniture makers.”

Unlocking potential With lightweighing becoming a focus of attention, engineering plastics are being harnessed into new applications with the right R&D support. Kishore would like to see some miraculous developments where the property of heat and light transfer could occur using engineering plastics. He believes that if this property could be given to all grades available in the market, then the application areas would grow manifold. For Teknor Apex, its latest R&D initiatives include working on flame retardant formulations of nylon compounds to meet new, more stringent requirements for under bonnet components from one major automotive original equipment manufacturer, where the components must pass the V-0 flame test. Another area of research is to develop new nylon 6/10 and nylon 6/12 alternatives from nylon 12. For this company, automotive industry mandates for sustainability have also led to a systematic programme designed to recover used nylon products and recycle them into valuable compounds. From an outsider’s perspective, recycling could be the next big R&D area for engineering plastics. However, research forms a stepping stone to success, whether these will become commercially viable is a factor only time can tell. Email: sweta.nair@network18publishing.com

INSIGHT & OUTLOOK: Inter face – Dr Harindu Vyas

“The demand for engineering plastics in the country is increasing by 4–8 per cent annually” …opines Dr Harindu Vyas, Consultant, Polymer & Plastics Technologist. In an exclusive conversation with Avani Jain, he talks about the demand for engineering plastics in the country. He further elaborates on the advantages offered by engineering plastics and future trends. days, the usage of thermoplastic polyester, acrylonitrile butadiene styrene, acetal polymers, nylon, phonilics, PA-imide and PC has drastically increased in a variety of applications.

What are the benefits offered by engineering plastics as compared to commodity plastics?

How is the demand for engineering plastics in the country? Today, the total worldwide market for engineering plastics is estimated to be more than $ 30 billion. Polyamide (PA), Polycarbonate (PC) and Polyoxymethylene (POM) are the dominant products in the market. Within the spectrum of engineering plastics, the annual growth rate is 10 per cent for PA, 9 per cent for PC and 5 per cent for POM. In India, the consumption of engineering plastics in the automotive and electrical & electronics industries is more than half of the total demand of engineering plastics. Compact discs, where only PCs are used, represent 11 per cent of the total market. PA films shares 4 per cent of the total market. Thus, the demand for engineering plastics in the country is increasing by 4–8 per cent annually. On a larger scale, the demand of engineering plastics is growing at the fastest rate (8 per cent) in Asian countries, in comparison to Europe and America (5 per cent).

What are the recent trends in the segment? A recent trend is using engineering plastics in a variety of products. These 64

Modern Plastics & Polymers | April 2013

The most important benefit of engineering plastics over commodity plastics is that it can be used as a replacement to metals. Engineering plastics have excellent electrical properties, such as high breakdown voltage, tracking resistance, arc resistance etc, in comparison to commodity plastics. Further, some of the engineering plastics have excellent dimension stability, heat resistance, low coefficient of friction, abrasion resistance, fatigue endurance and resistance to creep, but general commodity plastics lack these properties.

What are the leading innovations making headway in the segment? Engineering plastics – through research and development, we can engineer these plastics for any desired property that is required. The innovations that are making headway are as follows: Polyetheretherketone (PEEK): This semi-crystalline thermoplastic has a high operating temperature that is apt for injection moulding. It is tough, strong, rigid, resistant to ultraviolet light, steam and creep. PEEK is used in the nuclear, electronics, aerospace and medical industries. Polimide (PI): This polymer is heat & fire resistant, with a self-lubricating property. It is used in semi-conductors, aircraft, off-road vehicles etc. Polyphenylene Oxide (PPO): This innovative engineering plastic is a combination of polyphenylene oxide

& styrene. It has excellent hydrolytic & dimensional stability, low moisture absorption and good electrical properties. It has a wide area of applications in medical, automotive and electrical & electronics industries. Polyphenylene Sulphide (PPS): It offers the best chemical resistance in comparison to any other engineering plastic. It is used in chemical reactors, halogen lamp sockets, medical devices, pump housing etc. Polyphenylsulphone (PPSU): This amorphous engineering plastic has better resistance to chemicals and impact than polysulphone and polyetherimide. It can be used for making medical instruments.

What are the challenges and opportunities faced by the industry? The industries that are using engineering plastics have a bright future, as research is going on in the area of specialised engineering plastics that can replace expensive metals. In such a scenario, industries have the opportunity to develop new products from engineering plastics. These plastics have huge scope in the areas of building & construction. The only challenge that the industry has to face is the high raw material cost. This problem will persist till more research in the synthesis of specialised engineering plastics is carried out to reduce the cost.

What will be the future trends? To replace metal parts with engineering plastics as these possess properties of minimum wear & tear, lightweight and easy processability. The future trend also lies in the reactive compounding of engineering plastics with general purpose plastics to reduce cost without compromising on the properties. Email: avani.jain@network18publishing.com

INSIGHT & OUTLOOK: Inter face – Satendra Kumar

“Engineering plastics have transformed the wind energy generation industry across the globe” …opines Satendra Kumar, CMD, Quadrant EPP Surlon India Ltd. In an interaction with Anwesh Koley, he explains the various innovations brought about by engineering plastics in the field of wind energy generation and the way forward for plastics in key industrial operations. impact the financial performance of a project and business significantly.” Valves, bearings, seals, guiders and rolls require regular maintenance. High-grade engineering plastics solutions can increase equipment lifetime, improve mean time between repairs, reduce waste and limit replacement needs. Thus, it is important for plastics used in turbine technology to meet the highest challenges concerning temperature, chemical resistance, corrosion, wear and stability.

What are the future component development trends witnessed by you? What are the various opportunities for engineering plastics in wind generation? Alternative energy sources account for a significant part of the total global energy production today, and their importance is constantly increasing. Engineering plastics have transformed the wind energy generation industry across the globe. Engineers are using engineering plastics worldwide to improve product quality and increase profitability of manufacturing processes and equipment. Parts and components made from high-quality materials support the technical development in all major sectors of alternative energy generation. Preserving or maximising energy is the key requirement of energy generation and forms the top priority for the government and generation companies today. However, certain natural cautions are required to be observed while generating energy through wind turbines. Abrasion, erosion and wear of critical parts in a facility and the equipment within the production chain cause immense loss. Related maintenance services and production downtime can 66

Modern Plastics & Polymers | April 2013

New component developments will significantly change materials usage patterns. Generally, there are trends toward lighter weight materials, as long as the life cycle cost is low. Most rotor blades in use today are built from glass fibre reinforced plastic (GRP). Other materials that have been tried include steel, various composites and carbon fibre reinforced plastic (CFRP). As the rotor size increases on larger machines, the trend will be toward high strength, fatigue-resistant materials. As the turbine designs continually evolve, composites involving steel, GRP, CFRP and possibly other materials will likely come into use. Rotor blades are either GRP, wood-epoxy or CFRP. The step-up gearbox used on large turbines today is expected to be replaced in future machines. Most small turbines designed for battery charging use a variable speed, permanent magnet, variable frequency generator connected to a rectifier. As high-power solid-state electronics are improved, larger machines are likely to use AC-DC-AC cycloconverters. This trend will increase the usage of magnetic materials in future turbines. Large epicyclic gear boxes used

in large ships may continue to be the drive system for some large turbines.

What kinds of innovative solutions do you offer at Quadrant? Competition in the engineering plastics market is intense, and quality of services and product differentiation are the key to ensure a steady customer base. Our ability to offer reliable products and service levels are based on the Total Quality Management approach reinforced by ISO 9001-2000 standards. Quadrant can meet your requirements for consistent quality, performance and machinability. As the first to line mark shapes materials, Quadrant set the standard for careful selection of raw materials and resins, leading-edge process technologies and highest quality of manufacturing. Keeping pace with industry standards, the company has developed quality systems that comply with industry needs. Engineering plastics are exceptionally easy to machine and a slight modification in the tools produces an outstanding smooth surface finish that helps with aesthetics and performance of machines. Because almost all engineering plastics are easy to machine, it further broadens the gap between traditional materials due to reduced labour time and reduced energy cost due to faster component production times. The market for engineering plastics is growing by the day, and customers demand quality and reliability from their purchases. With steady research and development initiatives that result in path-breaking products, Quadrant has already become a major player in the industry. We plan to increase our production facilities beyond the current limits to help us serve our customers better. Email: anwesh.koley@network18publishing.com

INSIGHT & OUTLOOK: Roundtable

How have engineering plastics revolutionised lightweighting for

automotives? The usage of plastics in automotives is now touching upon points such as efficiency and aesthetics besides providing design functionality and freedom. Being less dense than metals, engineering plastics are being used in automobiles where they face some highly commanding circumstances. Sweta M Nair interacts with experts who bring out interesting insights on this trend. Mandar Amrute Sales & Market Development Manager, Speciality Polyamides, Arkema India

Presently, the automotive industry is looking at alternatives to cut down CO2 emissions. Some of the possible ways of achieving this is by exploring alternative vehicles, but that is still in the pilot stage. Engine refinement is not a cost-effective option, and new propelling energy sources are accompanied with availability issues. Thus, the proven and easiest way of achieving weight reduction is by replacing metal and rubber with engineering plastics that also have better designing ability. By using engineering plastics in automotives, one can achieve weight reductions of 10–12 per cent with better aerodynamic designs, 1–2 per cent with better air conditioning designs and 4–5 per cent with better wheel and tyre designs. Further, significant weight reduction can be brought about by weight modularity in the range 12–20 per cent. With metal and rubber replacement in power train inclusive gearbox, fuel lines and other fluid transport lines, one can reduce weight to about 45–55 per cent.

Geetha Baskaran Director, Suba Plastics Pvt Ltd

Engineering plastics have found wide application areas. They are now used in front-end modules, air intake manifolds, bearings, motor parts and so forth. In automotives, engineering plastics play an important role in the under-the-bonnet area, where these special plastics are able to perform at temperatures above 170°C. At such high temperatures, engineering plastics are creep resistant and offer better retention over service life. In addition, by using a higher impact balanced resin, the weight of the component or part can be reduced by lessening wall thickness. Thus, the applications of engineering plastics are definitely increasing. Casing or housing that was made of castings earlier is now being replaced by engineering plastics. These plastics are also being used in fuel injection systems and door panels. Engineering plastics are replacing metal in many applications. To a certain extent, I believe that engineering plastics can help build economical vehicles, where one can get more mileage due to lightweighting.

T K Purushothaman Managing Director, Rosti Technical Plastics (India) Pvt Ltd

Engineering plastics have innumerable applications in automotives because of being light in weight, durable and easy to manufacture. The wide range of applications includes: interiors – pillars, instrument panel, dash board, seats, door trims and steering wheel; exteriors – bumpers, lamp holders, rear view mirrors, handles, spoilers, wipers, wheel caps and mud flaps; underthe-bonnet parts – oil pans, radiator tanks, fans, cylinder head covers and manifolds. Plastics are replacing metal in almost every area thought to be impossible two to three decades ago. With a variety of long and short fibres, plastics have increasingly become popular and can provide incomparable products with superior performance, aesthetics, safety and durability. With increasing global oil prices, the weight of automotives has become the key factor as it influences fuel efficiency to a large extent. From a mere 5 per cent of overall body weight during the 1970s, the plastic content in automotives has increased to more than 50 per cent now.

Editorial take: Email: sweta.nair@network18publishing.com While passenger cars are required to adhere to mandatory safety requirements, environmental norms, better aesthetics, entertainment, communication and comfort features are still going to be in demand. Achieving these at a reduced price is a difficult feat. Although engineering plastics are replacing metal in many applications, further reduction in their cost would increase their adoption. 68

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INSIGHT & OUTLOOK: Green Shoots

With numerous green initiatives on the horizon, we bring to you in association with the United Nations Industrial Development Organization (UNIDO) this section ‘Green Shoots’ – the latest to keep you updated on the green phenomenon and to help promote the eco-friendly manufacturing philosophy. We will get you closer to several green practices, products and technologies that not only have a lower impact on the environment but are also safer for company personnel. Read on to get more eco-friendly, energy-saving and economical solutions that can give Indian companies a global business edge.

April 2013 | Modern Plastics & Polymers

INSIGHT & OUTLOOK: GREEN SHOOT S: End-of-life applications of recycled plastics

SETTING

BENCHMARKS!

Recycling plastics is a multi-dimensional activity. Recovering scrap from plastic waste and reprocessing the material into a completely different product is referred to as an end-of-life application. Material recycling will continue to be the primary end-of-life option for plastics, followed by energy recovery for non-recyclable materials. Sweta M Nair illustrates processing phenomena that exemplify end-of-life applications.

n activity that involves the efficient working of the entire eco-system, recycling of plastics involves meeting recovery targets, improving collection procedures and encouraging product users to recycle. In the long run, the focus will be on smarter product design, more efficient use of resources during manufacturing, reducing transportation costs and encouraging communication among parties involved in the plastic life cycle. End-of-life applications accommodate industry segments such as packaging, construction and automotive products. Currently, recycling is one of the most sustainable end-of-life options for plastics. The infrastructure and facilities for alternative processing options, such as energy recovery and composting (for 100 per cent degradable plastics), have not been developed commercially, although they may provide alternative processing options for non-recyclable plastics in the future. Thus, some of the factors influencing end-of-life applications are the overall public welfare, adherence to waste management plans, meeting international recovery benchmarks and recovered material as a potential resource as raw material prices increase.

Major outlets Recycled plastics can be used in almost as many applications and products as 70

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prime plastics. In packaging, recycled Polyethylene Terephthalate (PET) and High-density Polyethylene (HDPE) are increasingly used in primary packaging by retailers and branded manufacturers for bottles and trays. Brands such as Coca Cola, Marks & Spencer, Boots, The Body Shop etc are currently using recycled plastics in select product lines. Recycled PET flakes are spun into thread and yarn that is gaining popularity as a fabric used in the clothing industry. Polyester fibre is the single largest market for recycled PET bottles worldwide. Polyester fleece clothing and polyester filling for duvets, coats etc are frequently made from recycled PET bottles. This can be used

either alone or in combination with other fibres to create a wide variety of fabrics. These fabrics are generally strong and durable. Other major outlets for recycled PET are food-contact or non-food-contact containers, injection-moulded engineering components and some building materials. HDPE is processed into plastic lumber, tables, roadside curbs, benches, truck cargo liners and other high in-demand durable plastic products. When referring to cost-competitiveness, street furniture, seating, bins, street signs and planters are made from recycled plastics as the preferred material because it is resistant to vandalism as well.

GREEN SHOOT S: End-of-life applications of recycled plastics

Additional applications Due to the lack of incentive to invest in the compactors and logistical systems required, most polystyrene products are currently not recycled. As a result, manufacturers cannot obtain sufficient scrap. Expanded Polystyrene (EPS) scrap can be easily added to products such as insulation sheets for construction applications. This foam scrap can also be used in the manufacture of clothes hangers, park benches, flower pots, toys, rulers, stapler bodies, seedling containers, picture frames and architectural moulding. Recycled EPS is also used in many metal casting operations. In order to save energy and landfill space, the percentage of recycled plastics being used in new building and construction applications is increasing every day. These plastics can be blended with virgin plastics to reduce cost without sacrificing performance. Such plastics are being used to make polymeric timber for use in everything from picnic tables to fences. It is widely being used in mainstream construction products such as damp-proof membrane, drainage pipes, ducting and flooring. Because recycled plastics are durable, low maintenance, vandal resistant and resistant to rot, these plastics are the ideal material to be used in the making of walkways, bridges, fences and signboards.

Societal commitment Recycling plastics is an environmentally safe process that can help companies gain a competitive edge. Elaborating on this aspect, Vishal Jasrapuria, Director, Shree Sadguru Plastic Industries, says, “Reprocessed plastics can be used anywhere and everywhere where virgin plastics are used. If virgin plastics give you a 100 per cent result, then good quality reprocessed plastics can give you results varying from 90 to 95 per cent. Major areas where there is a good scope for end-of-life reprocessed plastics are construction, automotives, warehousing & material movement solutions, agriculture, household & furniture etc. Depending on the type of plastic, on an average, it can be

recycled about 5–10 times. Reprocessed plastics can be used over and over again, only the applications would keep changing depending on the quality of the material. For example, if the material has been recycled once, then it can be mixed with some percentage of virgin material to manufacture toothbrushes. However, after that, when it is reprocessed again, then the application would change maybe to either furniture or something else depending on the quality of the material and the end use application of the product. If the quality of reprocessed plastics is excellent, then 80 per cent of it can be mixed in manufacturing of a certain product along with virgin materials. The next time, the percentage of mixed reprocessed material would reduce and the percentage of virgin material would increase. Thus, applications would keep changing according to the quality of the material.” Recycling materials uses far less energy than creating them anew. As the world becomes more eco-friendly and environmental hazards increase, recycling and reusing plastics are expected to continue on a much larger scale. Cristina Monge Frontinan, General Director, Plastival, which is a cluster that ensures the interests of the plastics sector in Valencia, Spain, summarises the scenario well. She elaborates, “The percentage of applications of recycled plastics is increasing. It is gaining a lot of attention. Moreover, recycled plastics are able to address the increasing demand for raw materials to a certain extent. With furniture and pipes constituting the main segment of end-of-life applications of recycled plastics, new applications are being researched. New regulation allows recycled material to be used in secondary food packaging material. Also, the business of recycling is picking up pace globally. The problem of recycling material is prevalent all around the world. For India, the growth is only beginning so the problem might not appear to be that grave at this moment. Having systems put in place right now would help in the long run.” Email: sweta.nair@network18publishing.com

Major areas where there is a good scope for end-of-life reprocessed plastics are construction, automotives, warehousing & material movement solutions, agriculture, household & furniture etc. Vishal Jasrapuria Director, Shree Sadguru Plastic Industries

With furniture and pipes constituting the main segment of end-of-life applications of recycled plastics, new applications are being researched. New regulation allows recycled material to be used in secondary food packaging material. Cristina Monge Frontinan General Director, Plastival

April 2013 | Modern Plastics & Polymers

INSIGHT & OUTLOOK: GREEN SHOOT S: Inter face – Vishal Jasrapuria

“Fringe players throw the market off balance” ...opines Vishal Jasrapuria, Director, Shree Sadguru Plastic Industries, when talking about the Indian recycling segment. In a one-on-one with Sweta M Nair, he brings to light the challenges faced by processors of recycled plastics.

How has the plastics recycling sector grown? As compared to other raw materials like wood and metal, plastics have various benefits. Since plastics are inert and non-corrosive, they have broad applications in different products. Plastics are light in weight, easily available and relatively cheaper. According to an industry report, the per capita consumption of plastics is a meagre 5 kg in India as compared to 90 kg in North America, 65 kg in West Europe, 12 kg in China, 39 kg in the Gulf, 18 kg in Latin America and 10 kg in South East Asia. India is also a large importer of hydrocarbons and virgin plastic compounds. I believe that recycling can reduce the outflow of currency on account of polymer purchases to a certain extent. It can also address issues related to the efficient disposal of plastics. The usage of recycled material not only reduces the cost of plastics but also increases their viability for low-end applications. Although this particular segment has grown well over the last decade, there is still scope for growth and improvement in the recycling industry. I believe that the current market size is just a tip of the iceberg. 72

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What are the challenges you have faced as a manufacturer of reprocessed plastics? There are no entry barriers in our industry. Any fringe player can enter our market without proper technology and with minimal investment. These fringe players throw the market off balance by reducing the prices to unsustainable levels and then start compromising on the quality and consistency. When customers deal with these fringe players, they do not get proper quality inputs consistently and thus hesitate using reprocessed material. Due to these reasons and because they are not able to partner with the right kind of manufacturer, customers are not reaping the benefits of using reprocessed materials in a big way. Also, as manufacturers of recycled plastic material, we face shortage of manpower since this is a labour intensive industry.

What are the possible solutions to overcome these challenges? Industry associations can act as a catalyst to grow this industry by organising workshops and seminars for the potential customer industries whereby they can be made aware of the benefits of recycled material as well as the means to unlock these benefits. The customers

should differentiate between quality manufacturers and fringe players, and strike a balance between the pricing and quality. I can see that this has already started happening. The government can also aid this industry segment by giving it a ‘Green Industry’ status and help us scale up by providing incentives like interest subsidy on capital expenditure, duty exemption on import of machinery etc. The recycling industry is important for the proper disposal of plastics. We at Shree Sadguru Plastic Industries are associated with many industrial and environmentfriendly organisations like Indian Centre for Plastics in the Environment (ICPE).

What should the industry do in order to increase the recycling of plastics? In order to grow, serious differentiation has to be made between fly-by-night operators and quality-conscious suppliers. Customers need to be assisted to achieve a balance between price and quality. By avoiding the short-cut route of low pricing and quality, the industry would be able to grow at a much faster rate. This is a sunrise industry, which is at a very nascent stage. The industry should take a long term view and focus on maximising the growth opportunities. Email: sweta.nair@network18publishing.com

INSIGHT & OUTLOOK: GREEN SHOOT S: Inter face – Dr Prakash Mahanwar

“Plastics is not a by-product of urbanisation” …says Dr Prakash Mahanwar, Head – Dept of Polymer and Surface Engineering, Institute of Chemical Technology, when talking about end-of-life applications of plastics that could benefit society. In an exclusive conversation with Sweta M Nair, he brings to light the abominable conditions prevailing in this segment and the measures required for improvement. How is the reprocessed plastics segment in India? The plastics recycling segment in the country is extremely unorganised. Businesses in this segment are mostly micro and small scale enterprises. Labourers in these sorting units work in extremely unhygienic conditions. With no skilled manpower, safety norms are openly flouted. To fund their day-to-day sustenance, workers segregate consumer waste plastics with their bare hands and without wearing face masks. This is the prevalent scenario only in the recycling segment; you will never find such depressing working conditions in units processing virgin material. Although few prominent players have a turnover of about ` 2–3 crore, the industry is plagued by the inability to invest in modern technology due to the lack of funds. The reason being that modern technology for segregating consumer plastics waste comes at a high price – perhaps a reason as to why the industry is in such a dismaying state. On a daily basis, we need cutting-edge technology to separate and process the fifty tonne of consumer waste that is offloaded in Dharavi, Mumbai. Even though the plastics waste is collected and deposited, the thin polyethylene bags, which are neglected by rag pickers, create societal problems. These thin polyethylene bags, as well as small chocolate wrappers, 74

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shampoo sachets etc, do not fetch a good price.

What sort of government support would you suggest that is needed to get to the crux of this matter? Recently, I have put forth a proposal to the Ministry of Petroleum & Natural Gas regarding the menace of thin consumer plastics waste. I have proposed that the authorities create and support technology that will make use of such waste to create fuel. Recycling is a societal matter that needs governmental intervention. If a plastics recycling processor wants to use new technology, then it would involve high capital. This coupled with a long gestation period is not commercially viable for companies; hence, we require subsidies in this segment. To begin with, the local authorities need to make sure that rag pickers are well compensated to collect small wrappers. Although the end result after processing is low in quantity, the authorities must subsidise these processes so that it becomes profitable to companies.

What are the possible solutions to these problems? Plastics is not a by-product of urbanisation. We need solutions that will address local problems. At the onset, we need to sort out manpower requirements,

improve hygiene conditions and create awareness among processors. The government could start by setting up common collection and automatic segregation centres. When segregated, the material can be sold to processors. The government needs to invest funds in Research & Development (R&D) on plastics recycling. Businesses are not going to invest in R&D activity because it involves high capital and high gestation period. Also, commercial success is uncertain. Considerable research must take place in waste plastics for fuel generation, to create comingled plastics for roads, new technology for composites (where it can be reinforced with fillers) and utilisation of additives that can help in degradation of plastic materials.

From a processor’s perspective, what are the other end-of-life applications of reprocessed plastics? Road dividers, sideboards, drainage pipes (made from reprocessed polyvinyl chloride) are made from recycled plastics. Recycled e-waste is used in automotive applications and in road construction. In the latter, we need to degrade the plastics to a certain level so that it can become a homogeneous mass with asphalt. Roads laden with plastics are proving to be better than roads made of concrete. Email: sweta.nair@network18publishing.com

INSIGHT & OUTLOOK: Filament wound composite pipes

TECHNOLOGICAL TRIUMPH for INDIAN INDUSTRY

Developments in technology have resulted in high-performance polymers and glass fibrereinforced plastics (composites) that find extensive applications in making pipes and pipe fittings, especially for the oil & gas industry. Here is an overview of what makes this material ideal for use in aggressive environments. Sangeeta Baksi, Leena Modi, Soumitra Biswas and Jayrah Shah

dvancements in exploration and production technologies have helped locate and recover supply of oil and natural gas from major reserves across the globe. As a result, the emphasis on pipelines has been gaining major significance, as these offer a more ecofriendly, safe and cost-effective mode of transportation of fluids. Pipeline designers and operators are looking at alternative materials to conventional steel pipes in order to meet the increasing demands and maintain safety & reliability. High-performance polymers, rubber, glass fibre-reinforced plastics (composites) etc are increasingly used for pipes and pipe fittings. Being highly corrosion resistant, composite pipes have found extensive applications in the oil & gas industry since the last 76

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two decades. Applications of composite piping are increasing following the concurrent knowledge generation in the area, with some key advantages such as lightweight, high strength-to-weight ratio, excellent flow characteristics, low thermal conductivity and low thermal expansion, corrosion resistance and size variability. Besides, high cost of replacing steel piping in retrofit applications and increased longevity in new construction drive the use of composites, which can withstand severe conditions as experienced in offshore environment. India has witnessed aggressive growth in exploration and production in the oil & gas sector, which would attract enormous capital investment in the future. Composite pipes in the last five years have gained a strong foothold in India and are gaining wide acceptance for application in the transportation of potable water, sewage, desalination,

offshore oil production, paper & pulp industry, power plant etc. The demand for composite pipes from the oil & gas sector alone is expected to grow by 9-10 per cent Compounded Annual Growth Rate (CAGR) over the next five years, thus driving the overall demand growth in India at 8-9 per cent CAGR.

Reinforcement material As a reinforcement material, fibre is the primary contributor to the stiffness and strength of composite pipes. The dominant, commercially available fibres are glass, aramid and carbon/graphite systems. Fibre glass, when combined with thermosetting resin, cures to form a rigid composite structure, which is suitable for a variety of applications. The different types of fibre glass used are single- or multi-end roving, woven roving, textile yarn, chopped strand, chopped strand mat, combo mat, veil, multi-axial or unidirectional fabrics, wet chop etc.

Filament wound composite pipes

Advantages of GRE pipes

Physical properties of GRE pipes Physical properties Specific gravity Density Coefficient of thermal expansion Barcol hardness

Unit

Value

1.8

kg/m3

1,800

mm/mm/Â°C

1.8 Ă&#x2014; 10-5

Degree of cure

Â°C

150

Glass content

% wt

60-65

Resin content

% wt

40-35

Mechanical properties

Unit

Value

Hydro test for one minute

mPa

Mill pressure test (1.5 * design)

mPa

Axial tensile strength

mPa

60-65

Hoop tensile strength

mPa

155-165

Hoop tensile modulus

mPa

20,000-25,000

Axial tensile modulus

mPa

9,000

External collapse pressure

mPa

0.8

Initial stiffness factor Beam bending modulus

mm3.kPa

113

mPa

8,200

Matrix

Auxiliary raw materials/additives

The resin is the ideal matrix that holds the fibres together, providing the load transfer mechanism between the fibres that are wound into structural forms. The resin matrix also provides corrosion resistance, protects the fibres from external damage and contributes to the overall composite toughness from surface impacts, cuts, abrasion & rough handling. Different types of resins are used for composite pipes, viz isophthalic, vinyl ester and epoxy, depending on the extent of chemical properties required for the final product. The resin system is chosen for its chemical, mechanical and thermal properties. Epoxy resins are used primarily for the manufacture of small-diameter piping, while polyester resins are commonly used for largediameter piping and storage tanks. Although glass fibre resists a wide range of chemicals and temperatures, it requires the right design, fabrication and installation to match the appropriate application. For example, glass fibre may undergo chemical attack from hydrolysis, oxidation, pyrolysis or incompatible solutions. Therefore, a proper resin/glass matrix will help minimise chemical attack.

Other raw materials such as catalysts, accelerators, inhibitors, aggregates and pigments are used in resin and fibre reinforcements to achieve desired properties of the composite product. A catalyst is an organic compound which when added to resin in the presence of an accelerator initiates the polymerisation reaction at ambient temperature. An accelerator is a chemical compound used together with a catalyst to accelerate the polymerisation process. An inhibitor is added to the resin to reduce its reactivity at ambient temperature. Often, sand is used as filler during the winding process to increase wall thickness in certain cases.

Glass Reinforced Epoxy (GRE) technology A valid alternative to carbon steel pipes, especially for use in corrosive, aggressive and normal environments, is GRE pipe technology. It is based on the discontinuous filament winding process, where continuous glass fibres are helically wound at predetermined angles and bonded with the epoxy resin. GRE pipes offer a unique

Wide range of diameters from 1 inch (25 mm) up to and including 54 inch (1,400 mm) Standard lengths of 6, 9 and 12 m Adhesive, locked bell/spigot, lamination and flanged joining systems Corrosion-free in most environments Long life (50 years) + zero maintenance = low life cycle cost Ultra-violet resistant; can be safely installed above ground Conductive pipe and fittings available Fast, low-cost assembly due to lightweight and simple joining techniques Lighter support needed for aboveground systems

combination of good mechanical, thermal and chemical resistance, which is obtained by a selection of high-performance components and a proper design of the structure. GRE pipes, with smooth internal surface resulting in reduced friction and high flow rate, are commonly used in oil transportation calling for lower resistance to crude oil, paraffin build-up and high internal pressure. Low thermal conductivity of GRE pipes as compared to steel minimises the cost of insulation and heat loss. Another major benefit of GRE pipes is that once installed, these are virtually maintenance-free. Sangeeta Baksi and Soumitra Biswas are from Advanced Composites Programme, Technology Information, Forecasting & Assessment Council (TIFAC), Department of Science & Technology (Government of India), New Delhi. Email: compotifac@gmail.com Leena Modi and Jayrah Shah are from EPP Composites Pvt Ltd, GIDC Lodhika Industrial Estate, Rajkot, Gujarat. Email: jayrajshah@atikagroup.com

April 2013 | Modern Plastics & Polymers

AUTOMATION TRENDS: Operator-friendly machines

INCREASING PRODUCTION, REDUCING COSTS With the advent of automation and the demand for operator-friendly machines growing in the plastics processing segment, many companies in the country have started employing machines with PC-based automation or control systems. Avani Jain takes a closer look at the benefits of using such operator-friendly machines and how they help in increasing production without increasing the costs.

he Indian plastics processing industry has seen major innovations in the recent past, which have resulted in a long-term impact on the functioning of machines. With overall cost reduction and quality improvement being the main driving forces, the plastics processing industry offers a comprehensive choice of technologies and application techniques. Some of the major trends for increasing the operating efficiency and reducing costs in all the sectors of the plastics processing machinery segment, such as injection moulding, blow moulding and extrusion, include usage of Supervisory Control and Data Acquisition (SCADA) system, Programmable Logic Controller (PLC) and PC-based control systems. 78

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Jaymin Pithwa, Director, Konark Plastomech Pvt Ltd, notes, “With each passing day, companies are developing new technologies that can generate maximum output at a lower cost. These days, customers want highly automatic and synchronised systems so as to improve their product quality & efficiency and reduce overall costs. Thus, at present, although priced a bit higher, highly automatic machines are demanded by every customer.”

PC-based operation The most important aim of any control system for equipment in the plastics industry is to provide a simple but powerful user interface. Its function must be intuitive and easy to use, and

depending on the familiarity level of the user, the complexity of the functions can increase. At present, machines with PC-based control systems are the most operator-friendly machines available in the market. PC-based automation basically includes a PC platform and a Windows-operating system. It ensures a host of benefits to the plastics industry, ranging from higher quality parts, improved equipment uptime, faster cycle times and more predictable production flow to reduced employee turnover. A PC-based system solution offers a style of operation similar to desktop PC applications, which any individual can use today. Further, the installation of software with a colourful graphical user interface on PCs not only makes machine operations interesting and motivating to operators but also shortens the learning curve for them. Thus, machine operations become more enjoyable to the operator, and at the same time, production is improved.

Simple button click In a PC-based system, at the press of a button, the set-up person can select a completely different procedure or adapt its function to the required procedure. The ‘simple view’ selections of triedand-tested standard procedures of the controller are available to the operator for different automation applications. The set-up person does not require any programming know-how; one can simply select a procedure and then adapt the process sequences to the requirements demanded by changing variants. All settings necessary for a sequence (position, speed and time) are displayed on a clearly

Operator-friendly machines

arranged setting page. Commands to be inserted are simply selected from an extensive functions list and placed at the desired point in the sequence. Pressing the symbols in the sequence editor immediately calls up the respective screen page on which the parameters can be set. Even complex sequences can be quickly configured. An operator is able to create movement sequences for linear robots and thus can learn to program articulated-arm robots within minimum time. Thus, all the tasks can be performed by just clicking the button, thereby reducing the need of labour for performing each task manually. This leads to reducing the labour costs and the production is increased.

The ‘soft’ware touch One of the key benefits of process control system based on PC technology is that it is easy to use because the software is running on a familiar platform and that makes it cost-effective too. Because these systems are software-based, they are more powerful and more flexible. PC-based systems are inherently userfriendly, and operation can be intuitive. The biggest convenience for users is the ability to see the ‘big picture’. Instead of viewing process conditions in isolation, this type of system allows users to readily see data of all equipment from a single, central monitoring station and view that data over time via trending screens.

User-friendly Human Machine Interface (HMI) These days, machines with PC-based controls are equipped with user-friendly HMI, which is easily accessible for process parameters. It provides excellent troubleshooting guidelines along with the help and alarm menu pages. It has features such as functionally oriented screen layouts; process parameter monitoring in real-time and feeding value on absolute basis; simple & pictorial diagrams to enable operator understanding; auto temperature and temperature profile selection for homogenous melt from the first shot; extruder overrun for uninterrupted auto

cycle; auto heating start, shut down and standby to save time and energy during operation; intrusion insert moulding, gas assist interface, core pulling etc for multi-tasking utilisation; auto purging for smooth shutdown; mould cooling, mould gate option, sprue break, nozzle shut-off valve, cold slug removal etc for various applications and smart input/ output for uninterrupted production.

PLC and SCADA systems for reducing labour dependence The controls in use at present make use of microprocessor-controlled highspeed PLC and SCADA systems, which also help in reducing the overall costs and increase production. Rajiv Trivedi, Vice President (Marketing), Prasad Group & Chairman, Indian Plastics Institute – Ahmedabad Chapter, notes, “The machines with this system help in achieving zero rejection. Further, these systems help in reducing the labour costs to a large extent as you need to have only one skilled personnel to set the parameter once, and then repeatable operations can be carried out automatically. Hence, production is improved and increased.”

With each passing day, companies are developing new technologies that can generate maximum output at a lower cost. These days, customers want highly automatic and synchronised systems so as to improve their product quality & efﬁciency and reduce overall costs. Jaymin Pithwa Director, Konark Plastomech Pvt Ltd

Future trends The plastics processing industry is in the midst of a transformation as far as machine construction and system engineering are concerned, leading to the development of versatile and innovative control technology. Despite increasing complexity, the user-friendliness of systems and processes requires to be maintained as well as improved. The operator must only be confronted with one central operating concept and user interface. Therefore, control systems that enable the integration of peripherals, a uniform operating concept, simple programming, clear representation of complex processes, a high degree of process reliability and comprehensive motoring functions for quality assurance are required to increase machine user-friendliness for increased production at lower costs. Email: avani.jain@network18publishing.com

These systems help in reducing the labour costs to a large extent as you need to have only one skilled personnel to set the parameter once, and then repeatable operations can be carried out automatically. Rajiv Trivedi Vice President (Marketing), Prasad Group & Chairman, Indian Plastics Institute – Ahmedabad Chapter

April 2013 | Modern Plastics & Polymers

ENERGY MANAGEMENT: Reducing energy consumption in plastics processing

Maximise output,

MINIMISE CONSUMPTION The blow moulding process involves various complex stages of operations, coupled with high-speed precision moulding techniques. Moulders are increasingly opting for energyefficient mechanisms that complement high productivity standards. Anwesh Koley analyses the challenges in achieving production efficiency in blow moulding and the measures required to rectify them.

lthough energy conservation is not a major factor in the field of machine building, there are possibilities to reduce energy consumption of injection, blow moulding or hydraulic machines. Over the years, processors have realised the long-term benefits of reducing energy consumption in plastics processing as it not only helps achieve higher output but also saves cost substantially. Moulding machines are used to manufacture a complex array of industrial products. Ravi Kumar, Director, Shiv Pooja Plastics, says, “To offset rising production costs stemming from demanding applications, manufacturers turn towards machines that can deliver higher precision levels, greater cost efficiencies and maximum flexibility.” For decades, companies have developed blow moulding technology to help them remain at the forefront of high-performance motion control technologies for hydraulic blow moulding machines, which reduce time and result in increased energy savings through the moulding process.

Modern Plastics & Polymers | April 2013

However, there are various challenges in ensuring energy savings in this process while providing quality output. Manufacturers are fast realising the challenges in managing the required compressed air systems from an energy efficiency standpoint using high-speed precision equipment.

Reducing energy consumption High-speed electric feeder solutions help machines consume up to 30 per cent less energy than competitive hydraulic machines. These produce higher quality and more repeatable parts today. End users are continually searching for the edge in product quality, from plastic bottles that utilise 30 per cent less material to complex package designs. High-speed precision motion control would ensure uniform wall thickness and guarantee that all parts meet quality specifications.

The compact design of high-speed electric solutions helps save valuable floor space, which means customers can increase the number of machines at work at any given time. “To ensure safe operations, built-in safety features including failsafe and slow set-up mode help reduce unplanned downtime and foster operator safety,” adds Kumar. Efficient engineering will help facilitate future blow moulding machine technologies. High-performance engineering means that a blow moulding machine is always ready for the latest advancements in machine technology. Today, blow moulding machines are used to make everything from vessels to toys to car petrol tanks. To offset rising production costs from evermore demanding applications, customers need blow moulding machines of even higher accuracy, efficiency and versatility. Neeraj Garg, Partner, Suruchi Industries, says, “To solve the challenge of accurate positioning

Reducing energy consumption in plastics processing

under high-speed motion, it is important to ensure more accurate parison thickness control for highest product quality and lower production costs.” A complete system of high-response servo valves, the machine controller and an advanced man–machine interface will help overcome technical challenges. Highly accurate multi-axial control system yields faster and more stable close-loop mould movement speed. The hardware/ software design of the machine controller should provide control of cover wall thickness, weight temperature, motion and other measured values. To address upgrading requirements, the controller must integrate intelligent temperature control, closed-loop motion control, dedicated wall thickness control and a servo valve current drive. By focussing on specific requirements, high-speed blow moulding solution providers are able to provide highperformance solutions that ensure energy savings at various stages during the moulding process. “Today, it is important to ensure commitments that go beyond the initial collaboration to facilitate reliable and flexible products worldwide. For smooth functioning of a technology as well as timely delivery of the final product, service technicians worldwide are ensuring timely and precise repair of components,” adds Garg. Machinery manufacturers are focussing on developing efficient and low-cost plastics processing equipment. Such equipment will be smaller, multi-functional and flexible.

Challenges for compressed air Rotary Reheat Stretch Blow Moulding (RSBM) machines from leading manufacturers across the globe provide challenges to the efficiency of compressed air systems. These challenges include significant pressure drops in the RSBM machine with large instantaneous air demand swings. High horsepower for individual compressors increase consumption of compressed air, and the usage of high historical pressure equipment also add to the problem. Besides, a single facility may have multiple pressure

requirements, making steady monitoring a tough task. Despite these challenges, it is possible to achieve 15 per cent energy savings on the supply side with another 15 per cent achievable by focussing on the pressure drops in blow moulding machines.

Pressure-drop situations in the processor Stabilising air pressure is a primary objective. Pressure fluctuations occur in most stretch machines and are significantly lower than expected. Correcting this can lead to increased productivity and reduced air consumption. “Blow moulders must understand the air pressure requirements of their blow moulding machines. For example, the blowing process consumes about 60 per cent of the air. The remaining pneumatic applications, using 40 per cent of the air for control components and packaging or decorating, will typically require lower pressures. The blow moulder must install a dedicated piping system to the blow air circuits to reduce air consumption during the blowing process,” says Garg. In process industries, companies are taking most of the measures available to optimise their processes in order to gain on productivity and reduce waste. “As compressors have the largest motors among the auxiliaries, consuming millions of dollars worth of electric power every year, anything we can do to save its energy remains our focus,” adds Kumar. By adding air recovery systems to blow moulding machines, the used highpressure air can be recycled after blowing the bottles for machine running, thereby reducing energy consumption. Such a process has various advantages. When using the low-pressure air compressor with same specifications, this system would extend the rest time of the air compressor, reduce its energy consumption and extend the service life of the machine. After adopting the air recovery system, the blow moulding machine can be equipped with a smaller low-pressure air compressor, thereby decreasing energy consumption and reducing production costs. Email: anwesh.koley@network18publishing.com

To offset rising production costs stemming from demanding applications, manufacturers turn towards machines that can deliver higher precision levels, greater cost efﬁciencies and maximum ﬂexibility. Ravi Kumar Director, Shiv Pooja Plastics

To solve the challenge of accurate positioning under high-speed motion, it is important to ensure more accurate parison thickness control for highest product quality and lower production costs. Neeraj Garg Partner, Suruchi Industries

April 2013 | Modern Plastics & Polymers

POLICIES & REGULATIONS: Green packaging norms

REDUCING THE

CARBON FOOTPRINT

Carbon emissions from plastics processing techniques have been under the scanner for a long time. Although the per capita emission of greenhouse gases by India is quite low, plastics processors have undertaken numerous initiatives to ensure sustainable processing that yields environmental benefits in the long run. Anwesh Koley analyses the various imperatives that must be observed to achieve successful green packaging norms.

egulatory frameworks across the globe have shown tremendous enthusiasm in bringing down the carbon footprint generated by business houses in order to create a sustainable manufacturing environment with healthier practices. Plastics generally have a poor or negative image in comparison with other materials, in particular with regard to their perceived impact on the environment and use of resources. This also has to do with various government initiatives banning the use of plastics below certain thickness for packaging purposes. While plastics from renewable resources are now being developed, their current market penetration is not high enough to have a significant effect on the overall results.

Material regulations The choice of materials used to produce 82

Modern Plastics & Polymers | April 2013

plastic food packaging is evolving, and the considerations for materials are increasingly influenced by cost, environmental impact and the ability to be recycled. Deepak Takkar, Proprietor, Takkar Industries, says, “Packaging companies that use plastics are looking at ways in which mineral content can be combined with plastics to produce packaging that changes the balance of raw materials used. There is also pressure on the industry to reduce the weight of packaging. Major retailers across the globe have agreed to follow green packaging norms with the aim of having less food products and packaging ending up as household waste. The packaging industry is supporting this through the design of containers and materials used, while making sure that food safety is not compromised.” In the case of flexible food packaging, the average pack weight has

been reduced by almost 25 per cent over the past half decade.

Shop-floor initiatives The manufacture of plastic packaging is energy intensive and as a result contributes to the carbon footprint. However, this is an area where negative environmental impact can be reduced. R Varadrajan, Senior Country Technical Manager – India & SAARC, Dassault Systèmes, SolidWorks, says, “Over the past five years, the production process in most countries has changed dramatically. For example, originally the production of hollow thermoformed bottles consisted of relatively inefficient ‘flatbed’ thermoforming machines alongside energy-efficient rotary machines. These flat-bed machines have now been phased out, and they have been replaced by high-output rotary machines. This has

Green packaging norms

resulted in a reduction in energy use, thereby reducing the carbon footprint substantially.” Various processing companies have reduced the amount of energy used by almost 30 per cent through such practices. Over time, this efficiency is expected to result in meaningful cost savings.

Proper recycling and disposal of plastics In theory, plastic packaging has the capability of being a cradle-to-cradle product – a product that can be recycled or reused with no loss of quality. This is the way in which glass is currently disposed, where facilities collect and recycle waste glass. However, there are a number of obstacles that currently prevent this happening with plastics. Only very few plastic products consume more energy than their possible substitutes made of different materials. Most plastic products need lesser energy to be produced than their alternatives. Additionally, many plastic products save significant amounts of energy during the use phase. On an average, 85 per cent of waste plastics go to landfill, about 10 per cent is incinerated and about 5 per cent is recycled. However, even less can go back into food packaging because of food safety issues with recycled plastics and because customers still prefer virgin materials. “If better collection services existed for plastic trays and if there was a common standard for local authorities collecting recyclable plastics, plastic packaging has the potential to be as recyclable and reusable as glass or tin,” believes Varadrajan. According to research studies by the Waste and Resources Action Programme (WRAP), the collection of mixed plastic packaging is ‘technically and economically viable’ on a commercial scale. The challenges that now lie ahead for local authorities are the provision of collection and dropping sites, and encouraging consumers to utilise these services.

Role of plastics in generating renewable energy Plastics play an increasing role in the generation of renewable energy. Examples are the plastic rotor blade of a wind

turbine and thin film photovoltaic units, where non-silicon semiconductors, both metal and organic, are printed on plastic films. Wind power turbines ensure high greenhouse gas emission savings within the use phase. These are 140 times higher than the emissions from conventional production because one-third of greenhouse gas emission savings enabled by the wind power plant are allocated to the rotor.

Deriving energy-efficient polymers It is important to understand the possible future role of renewable resources in the plastics industry. “Two categories of plastics are possible from renewables. One option is the production of monomers to make new polymers such as polylactic acid. Here, the commercial challenge is to compete with existing large-volume plastics in terms of production economics and adapting processing equipment. The other route is to make high volume monomers such as ethylene or other ethylene derivatives from ethanol derived from renewable sources. These can then be used in existing polymerisation plants making the well-known polyethylene grade ranges,” says Takkar. In both cases, the chemistry is proven, but a key consideration will be the amount of nonrenewable energy used in the overall manufacturing chain.

Major retailers across the globe have agreed to follow green packaging norms with the aim of having less food products and packaging ending up as household waste. The packaging industry is supporting this through the design of containers and materials used. Deepak Takkar Proprietor, Takkar Industries

Towards a sustainable future While efforts are being made globally towards reducing carbon footprint from plastics processing, it is important that the packaging industry continues to work together to drive innovation in design, materials, production processes and disposal. “While the ebb and flow of the economy will present varying financial demands on the packaging industry, the challenges posed by the need to reduce the carbon footprint are sustained and long term. It is by mirroring this need with a long-term and credible plan to tackle these challenges that will ensure that plastics are not looked down upon,” adds Takkar. The plastic packaging industry can then evolve in a way that meets the retail demands of convenience and cost, while reducing the carbon footprint. Email: anwesh.koley@network18publishing.com

If better collection services existed for plastic trays and if there was a common standard for local authorities collecting recyclable plastics, plastic packaging has the potential to be as recyclable and reusable as glass or tin. R Varadrajan Senior Country Technical Manager – India & SAARC, Dassault Systèmes, SolidWorks

April 2013 | Modern Plastics & Polymers

STRATEGY: Plastic packaging

APPLICATIONS THAT ENHANCE PRODUCT SHELF LIFE The right material is crucial for the success of any packaging application. With continued innovations, new grades of plastics are being developed to extend the shelf life of packaged food products. Although studying the total system for a complete analysis is required, Sweta M Nair presents the latest in this segment that is making big waves.

dvantages that plastic packaging brings to the table are many. Besides fulfilling packaging requirements, it makes a good medium for advertising and presenting products. Ease of transportability and extending the shelf life of packaged products are the other benefits of using plastics as a packaging material. Plastics such as Polypropylene (PP), Polystyrene (PS), Polyvinyl Chloride (PVC), Low-density Polyethylene (LDPE), High-density Polyethylene (HDPE), Polycarbonates (PC) and Polyethylene Terephthalate (PET) are being used by food processors for packaging food. However, some grades of plastics do have certain disadvantages when they come in direct contact with food. For instance, grades such as PVC, PS and PC leach chemicals that are way above the acceptable limit. These plastics also have limitations in terms of prolonging the shelf life of packed products in controlling microbial, enzymatic and biochemical reactions of the internal environment of the packaging via strategies such as oxygen removal, controlled release of salts etc. However, there are new varieties that do not affect the quality of food products but instead increase shelf life. Playing a 84

Modern Plastics & Polymers | April 2013

protective role, modern plastics are doing a lot more than their key functions.

Multi-layer films Multi-layer co-extruded or laminated flexible materials are a significant development in modern packaging technology. Most extruded multi-layer structures are based on polyolefins because of their low cost, versatility, processability, chemical inertness and high moisture barrier properties accompanied by their poor ability to inhibit oxygen and aroma transitions. These multi-layer structures are produced by processing commodity plastics such as PE and PP, tie resins and centre barrier resins [eg ethylene vinyl alcohol (EVOH) and polyamide]. An extruder, a feed block and a die are used to produce a five-layer film. The multilayer films could be of seven layers or nine layers depending on the number of extrusion lines when a multi-layer film is made. Polyamide resins are also an important class of polymers used in the packaging industry and owe their popularity to good barrier properties against oxygen, aromas and organic solvents along with high tensile strength and toughness. â&#x20AC;&#x153;The thin barrier layer, which is usually made of EVOH, Polyvinylidene Chloride (PVDC), polyester, acrylic co-polymer or

similar material, is designed to preserve freshness and lengthen shelf life by preventing the migration of gas in or out of the package; for example, to keep oxygen out of a frozen food package or to keep carbon dioxide inside a beer bottle,â&#x20AC;? says Dr Subhas Chandra Shit, Professor & Head-HLC, Department of Chemicals & Petrochemicals, Central Institute of Plastics Engineering & Technology (CIPET), Ahmedabad. Multi-layer containers have a layer of EVOH sandwiched between PP and any other plastic grade. EVOH provides oxygen and moisture barrier properties to the container. This keeps the product in the container fresh with a shelf life of over 12 months.

Blends and nanomaterials Cyclic Olefin Copolymers (COC) are also being increasingly used in polyolefin blends to produce barrier films for packaging because it has one of the highest moisture barriers of any polymer (four to five times better than LDPE). COC is not considered to have a high gas barrier, but it is still significantly better than LDPE. When COC is added to Linear Low-density Polyethylene (LLDPE), it increases modulus by two times while maintaining low haze. Similarly, when HDPE is blended with polyamide, its

Plastic packaging

barrier properties increase significantly. Nanocomposites are also at the forefront of food packaging development. Nanocomposite film enriched with an enormous number of silicate particles reduces the entry of oxygen and other gases and the exit of moisture, thus preventing food from spoilage. Dr Shit adds, “Some companies have developed nanocrystals for making a nanocomposite that would be used in beer bottles. Most polymer composite materials are based on fossil fuel derivatives; however, research on biopolymers is offering biodegradable alternatives. The inherent drawbacks of pure bio-polymers that depend on type can include poor barrier properties or poor mechanical properties can be mitigated by the inclusion of nanofibres to form nanobiocomposites.” Most nanocomposite materials employed or being developed for use in the food packaging industry contain nanoclay particles; however, other composites containing nanoparticles, nanotubes or nanofibres of metals, metal oxides, biopolymers or other carbon-based material are being developed.

New systems and films To arrest oxygen, new polymer systems with special barrier properties are used on the surface of the plastic container. A recent study conducted by Dr Philip Labuschange and his team claimed that the developed polymeric system (inter polymer complexation system – close-knit polymer network formed by hydrogen bonds with a high density) reduces oxygen permeability by a factor of about 20 (for polyester-based plastics) and by a factor of about 150 (for polyolefin-based plastics). This simply increases the shelf life of any oxygen-sensitive beverage in plastic containers by up to 150 times. In the food sector, multi-layer films occupy the major share of the food packaging market since nanobased materials are yet to be effectively commercialised and are presently priced at a high cost. “Nanostructured material will have better capability than others because of the high barrier capacity and environment-friendly character,” affirms Dr Shit. Email: sweta.nair@network18publishing.com

Some companies have developed nanocrystals for making a nanocomposite that would be used in beer bottles. Most polymer composite materials are based on fossil fuel derivatives; however, research on biopolymers is offering biodegradable alternatives. Dr Subhas Chandra Shit Professor & Head – HLC, Department of Chemicals & Petrochemicals, CIPET, Ahmedabad

April 2013 | Modern Plastics & Polymers

TIPS & TRICKS: Guidelines for ef ficient equipment

Ensuring

SAFE and EFFICIENT processing

The plastics processing industry requires heavy maintenance and constant monitoring of numerous equipment that are used in order to remain in optimum working conditions. Anwesh Koley notes various pointers to ensure seamless processing and cost efficiency.

he growth witnessed by the plastics industry has a direct implication on the performance of the ancillary equipment sector, which forms the backbone of the plastics machinery

industry. The numerous machines used in the plastics industry require a host of equipment that depend upon the application and requirement of the final product. The global trend towards faster processing equipment

and better accuracy in terms of productivity has led manufacturers across the country to adopt technologies that help achieve higher end user satisfaction. Email: anwesh.koley@network18publishing.com

Follow these pointers for effective ancillary equipment maintenance:

Energy efficiency and conser vation have become imperative for ancillary equipment usage. Minimising energy input in processes, decreasing energy losses and recovery of waste heat need to be seamless. This is important in drying, granulation, temperature control and chiller systems, which are energy intensive. Lowering costs through reducing inputs, wastage and labour has been the focus in blending and conveying systems.

Being environment-friendly is a key requirement for equipment in plastics processing. Use of consumables that are recyclable or environmentfriendly must be adopted. Water is being increasingly used as heat transfer medium instead of thermal oil in temperature control units. Refrigerant units use environment-compatible refrigerants, and lead soldering of printed circuit boards has been given up by most processors.

When the processing unit has reached a consistent temperature, the extruder machine is ready to be turned on. It is important to speed up the screw rod manually and start the feeding process of the material into the machine. Also, the material must be checked on its way out of the machine to make sure there are no impurities, no foam, no coke burning and no colour change.

The current trend in user-friendly networked controls is towards graphical, menu-driven touch screen controls. Different parts of the system can communicate with each other through CANbus or ethernet p ro t o c o l s . Ancillar y equipment are designed with digitally controlled, more precise, fast, compact graphical interfaces that are easily compatible with machine controls.

It must be ensured that before commencing operation, the water, electricity, gas levels and temperature systems are properly checked and in good working order. When this inspection is complete, the die head must be calibrated and installed. This is essential as equipment break down might occur during nonworking hours. After this is done, the heating power may be turned on.

Latest technology aids in efficient processing. Advanced features are options for connectivity with Wi-Fi & SCADA solutions through which all the machines are connected with a single PC, or a smart phone through which processors can access their machine production and status from anywhere in the world. These must be installed at all levels to achieve the desired results.

Modern Plastics & Polymers | April 2013

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.

High-density polyethylene/ polypropylene/nylon/polyester and their products including fishing ropes, fishing nets and fishing twines Tufropes Pvt Ltd Project type New facility Project news Tufropes Pvt Ltd is planning to set up a new polymers project at Vadodara in Gujarat. The project involves manufacturing of all types of high-density polyethylene/ polypropylene/nylon/polyester and their products including fishing ropes, fishing nets and fishing twines. Project location Vadodara, Gujarat Project cost NA Implementation stage Planning Contact details: Tufropes Pvt Ltd 507, Embassy Centre Nariman Point Mumbai – 400 021 Tel: 022-40502600 Fax: 022-22844167 Email: tufropes@vsnl.com

High-density polyethylene/ polypropylene woven sacks Ankit Polysack India Pvt Ltd Project type New facility Project news Ankit Polysack India Pvt Ltd is planning to set up a new polymers project at Tikamgarh in Madhya Pradesh. The project involves manufacturing of highdensity polyethylene/polypropylene woven sacks. The company has received industrial license from Secretariat of Industrial Assistance (SIA), Department

of Industrial Policy and Promotion, Government of India, for setting up the project. Project location Tikamgarh, Madhya Pradesh Implementation stage Planning Project cost NA Contact details: Ankit Polysack India Pvt Ltd No. 431, Tal Kalol Santej–Vadsar Rd Ahmedabad – 382721 Gujarat Tel: 027-64286673

Plastic polymer plant Indian Oil Corporation Ltd (IOC) Project type New facility Project news Indian Oil Corporation Ltd (IOC) is planning to set up a polybutylene terephthalate, semi-crystalline thermo plastic polymer plant. The refinery will also include a petrochemical complex with a 553,000 tonne/year purified terephthallic acid production facility from naphtha supplied by the Panipat and Mathura refineries in close proximity. Project location Panipat Project cost NA Implementation stage Planning Contact details: Indian Oil Corporation Ltd (IOC) 3079/3, J B Tito Marg Sadiq Nagar New Delhi – 110 049 Tel: 011-26260000

Plastic shopping bags National Small Industries Corporation Ltd Project type New facility Project news Supply of one set of plastic shopping bags. Project location India Project cost NA Implementation stage Planning Contact details: National Small Industries Corporation Ltd NSIC Bhawan Okhla Industrial Estate New Delhi – 110 020 Tel: 011-26926275, 26926370 Fax: 011-26932075

Tarpaulin made of high-density polyethylene and polypropylene bags JBS Rasayan Pvt Ltd Project type New facility Project news JBS Rasayan Pvt Ltd is planning to set up a new polymers project at Burdwan in West Bengal. The project involves manufacturing of tarpaulin made of high-density polyethylene Leno bags, polypropylene jumbo bags and cement/fertiliser bags. Project location Burdwan, West Bengal Project cost NA Implementation stage Planning Contact details: JBS Rasayan Pvt Ltd 24, Hemanta Basu Sarani Kolkata – 700 001 West Bengal

Information courtesy: Tendersinfo.com 1, Arch Gold, Next to MTNL Exchange, Poisar, S V Road, Kandivali (W), Mumbai - 400 067, Maharashtra, India Tel: 022 28666134 • Fax: 022 28013817 • Email: parmeet.d@tendersinfo.com

Modern Plastics & Polymers | April 2013

TENDERS

Latest LatestPopular PopularTenders Tendersbrought broughttotoyou youbybywww.tendersinfo.com www.tendersinfo.com Garbage bags and sacks Org TRN Desc BOD Loc BT

: : : : : :

Thisted Kommune 14976438 Provision of garbage bags and sacks 10 Apr 2013 Denmark Global (ICB)

Silicone rubber and rims Org : Fars Regional Electric Co TRN : 15225218 Desc : Supply of 80 and 120 kN silicone rubber and rims BOD : 10 Apr 2013 Loc : Shiraz, Palestine BT : Global (ICB)

Polythene bags Org TRN Desc BOD Loc BT

: : : : : :

Ordnance Factory Board 15162162 Supply of polythene bags 11 Apr 2013 Kanpur, Uttar Pradesh Domestic (NCB)

Moulding machine Org : Plastyko Word SRO TRN : 14976520 Desc : Supply, installation and commissioning of special thermoforming moulding machine BOD : 12 Apr 2013 Loc : Czech Republic BT : Global (ICB)

Plastic seats Org : North Western Railway TRN : 15060588 Desc : Supply of plastic seat, ie bottom top for commode of coaching stock BOD : 12 Apr 2013

Loc BT

: Jaipur, Rajasthan : Domestic (NCB)

Low-density polyethylene film Org TRN Desc BOD Loc BT

: : : : : :

India Government Mint 15161245 Procurement of low-density polyethylene film 16 Apr 2013 Hyderabad, Andhra Pradesh Domestic (NCB)

Plastic films and bags Org : ICDI TRN : 14976268 Desc : Acquisition and recycling of plastic waste – planting pots, plastic film (polyethylene) and expanded polystyrene (frigolite) from parks, recycling ICDI and delivery bags BOD : 16 Apr 2013 Loc : Couillet, Belgium BT : Global (ICB)

Polyvinyl chloride flooring sheet Org : Central Railway TRN : 15140302 Desc : Supply of flexible polyvinyl chloride flooring sheet BOD : 18 Apr 2013 Loc : Mumbai, Maharashtra BT : Domestic (NCB)

Carbon molecular sieve Org

: Tamil Nadu Generation and Distribution Corporation Ltd TRN : 15224227 Desc : Carbon molecular sieve for pressure swing adsorption in N2 adsorption tower BOD : 19 Apr 2013 Loc : Ramanathapuram, Tamil Nadu BT : Domestic (NCB)

Org: Organisation’s name, TRN: Tendersinfo Ref No, Desc: Description, BOD: Bid Opening Date, Loc: Location, BT: Bidding Type. Information courtesy: Tendersinfo.com 1, Arch Gold, Next to MTNL Exchange, Poisar, S V Road, Kandivali (W), Mumbai - 400 067, Maharashtra, India Tel: 022 28666134 • Fax: 022 28013817 • Email: parmeet.d@tendersinfo.com

April 2013 | Modern Plastics & Polymers

EVENT LIST

National

Hyderabad Andhra Pradesh May 31-Jun 3, 2013 India’s premier industrial trade fair on products and technologies related to Machine Tools, Hydraulics & Pneumatics, Process Machinery & Equipment, Automation Instrumentation, Packaging & Auxiliaries, IT Products, Electrical & Electronics, Material Handling and Safety Equipment.

For details contact: Network18 Media & Investments Ltd, Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028. Tel: 022 3003 4651 • Fax: 022 3003 4499 Email: engexpo@infomedia18.in Web: www.engg-expo.com

IPLEX Chennai

PlastShow

The Tamil Nadu Plastics Manufacturers Association, the organiser of IPLEX, has come forward to exhibit various moulds and dies, equipment and machinery exclusively required by the plastics manufacturing sector of India. The exhibitors are well versed with the respective range of products so that attendees can select the best for their firms; June 27–30, 2013; at Chennai Trade & Convention Centre, Chennai, Tamil Nadu

PlastShow is dedicated to offering a comprehensive range of plastic products and processing equipment. The event strives to offer complete information about the recent inventions of the plastic manufacturing sector. The exhibitors find this expo to be the perfect business meeting place where the exhibiting companies get an opportunity to establish themselves and promote their brands; September 27–30, 2013; at Vapi Industrial Association Ground, Vapi, Gujarat

For details contact: Senthil Kumar N The Tamil Nadu Plastics Manufacturers Association C-1, First Floor, Rams Square Village Road, Nungambakkam Chennai Tamil Nadu Tel: 044-28250107

Compack 2013 displays one of the most impressive and efficient collection of packaging equipment and materials which are of advanced technology. This event will demonstrate the most important packaging and processing solutions. The visitors coming to Compack 2013 will comprise high profile executives from the packaging and transportation sectors; June 7–9, 2013; at Chennai Trade & Convention Centre, Chennai, Tamil Nadu For details contact: Narendar Bafna Smart Expos New No. 116, Manickam Lane Mount Road, Guindy Chennai - 600 032 Tamil Nadu Tel: 044-22501986/1987 Mob: 09952966752 Email: compackexpo@smartexpos.in Website: www.compackexpo.com 90

Modern Plastics & Polymers | April 2013

Plastivision India

Pharmapack Expo is the most cost-effective marketing opportunity and is the best opportunity to meet senior buyers and decision makers from all facets of the user industry. The exhibits will include packaging materials & products, glass & plastic jars and bottles, aluminium & plastic tubes, corrugated & cardboard boxes, dosing machines for liquids & powders, filling machines, blister packing machines, strip packing machines, labels & labelling equipment, form-fill-seal machines etc; September 12–14, 2013; at Bombay Exhibition Center (BEC), Mumbai

Designed to help exhibitors and visitors to discover potential markets, Plastivision India will be the 9 th in the series of national exhibitions and seminars organised by the All India Plastics Manufacturers Association (AIPMA). With participation from more than 45 countries and visitors from over 61 countries, the event will include exhibitors ranging from categories such as raw materials & chemicals, plastic packaging machinery & equipment, machinery & equipment for processing, recycling, pre & post processing machines, plastic extrusions, thermoforming/films/thermoplastics etc; December 12–16, 2013; at Bombay Exhibition Center (BEC), Mumbai

For details contact: Intel Trade Fairs & Expositions Pvt Ltd 113, New Sonal Link Industrial Estate Building No. 2, Link Road Malad (W ) Mumbai - 400 064 Tel: 022-26003977 Email: info@intelexpo.com Website: www.pharmapackexpo.in

For details contact: AIPMA A-52, Street No. 1, M I D C, Marol Andheri (East), Mumbai Tel: 022-28217324/28217325/ 28352511/283 Fax: 022-28216390 Email: marketing@plastivision.org Website: www.plastivision.org

Pharmapack Expo Compack Chennai

For details contact: Brijesh Purohit Sunline Infotech, 118, Lotus Arcade Opposite Automotive, Gondal Road Rajkot, Gujarat Tel: 0281-2460135

EVENT LIST

International Plastic Japan

Alex Plast

Plast-Ex

Plastic Japan is one of the biggest trade show of the plastics industry in Japan. Over the course of three days, 25,000 professionals of the plastics industry are expected to visit the event this year to discuss business and expand their client base. Plastic Japan will be visited by key players of the plastics industry of the country; April 10–12, 2013; at Tokyo International Exhibition Center (Tokyo Big Sight), Tokyo, Japan

Alex Plast will help make technical and professional experts related to the plastics industry aware of the latest trends and techniques to help advance the plastics industry. It will bring to light the importance & value of machinery & equipment for plastics, reinforced plastics and technical parts in the recent times. This expo will also provide useful information to contractors, consultants and engineers; May 1–4, 2013; at Alexandria Fairgrounds, Alexandria, Egypt

Being organised by Canon Communications Llc, Plast-Ex is one of the largest shows for attracting a large number of people from the plastics, printing and packaging sectors worldwide. Plast-Ex is an eminent show that will be hosted in Canada and will offer an exhibiting space for displaying machinery related to plastics, rubber, packaging and printing; May 14–16, 2013; at Toronto Congress Centre, Toronto, Canada

For details contact: Plastic Japan Show Management Jun-yeup Lim Reed Exhibitions Japan Ltd 18F Shinjuku-Nomura Bldg 1-26-2 Nishishinjuku, Shinjuku-ku Tokyo 163-0570, Japan Tel: +81-3-3349-8518 Fax: +81-3-3349-8530 Email: plastic@reedexpo.co.jp Website: www.plas.jp/en

For details contact: Trust International Group 20 El-obour Building Salah Salem St Nasr City, Cairo, Egypt Tel: +(20)-(2)-22600986 Fax: +(20)-(2)-24012121 Email: info@alex-plast.com Website: www.alex-plast.com

Plastic Expo

Plastpol Expo

Plastic Expo is one of the premium exhibitions providing the latest and the best in plastic materials for all manufacturing and processing industries alike. It enables foreign and Tunisian professionals to assess industry situations, develop their business relationships in the domestic and international markets, secure technological watch, study and compare prices, delivery times and quality, launch partnerships, seek new raw materials sources, supplies and potential clients etc; April 24–27, 2013; at Tunis Exhibition Center, Tunis, Tunisia

Plastpol Expo is a prestigious show for the rubber and plastics industries as professionals will get to exhibit new and advanced machinery that will help in increasing productivity. The expo is the perfect place where new products will be launched and the attendees will also get to know about the recent developments made in this sector. The popularity of the show has brought in the participation of leading companies from the domestic and international market; May 7–10, 2013; at Kielce Trade Fair Centre, Kielce, Poland

For details contact: Foires Internationales De Tunis B. P. N-1, 2015 Le Kram, Tunis, Tunisia Tel: +(216)-(71)-730111 Fax: +(216)-(71)-730666 Email: itf.com@fkram.com.tn Website: www.plasticexpo.com.tn

For details contact: Kielce Trade Fairs (Targi Kielce S.A.) 1, Zakładowa Str 25-672 Kielce, Poland Tel: +4841 365 12 22 Fax: +4841 345 62 61 Email: biuro@targikielce.pl Website: www.targikielce.pl

For details contact: UBM Canon 2901 28th Street, Ste. 100 Santa Monica, CA 90405 United States Tel: 310/445-4200 Email: exhibitor.services@ubm.com Website: www.canontradeshows.com/expo/ plastex13

Feiplastic International Plastics Trade Fair Feiplastic International Plastics Trade Fair is not just an ordinary trade event but is one of the largest and most informative international gatherings of its kind in Latin America. Recent innovative plastic products will be showcased and reputed brands in this domain will gather to exhibit products and services through this international platform, which strives to attract top professionals from Brazil and abroad; May 20–24, 2013; at Anhembi Parque, Sao Paulo, Brazil For details contact: Reed Exhibitions Alcantara Machado R. Bela Cintra 1200 - 7th Floor Cerqueira Cesar Sao Paulo, Brazil Tel: +(55)-(11)-30605000 Website: www.feiplastic.com.br The information published in this section is as per the details furnished by the respective organiser. In any case, it does not represent the views of Business Insights •Technologies•Opportunities

April 2013 | Modern Plastics & Polymers

EVENT REPORT: Indo-German International Seminar

Redefining the future of automotive plastics From the seventies when plastics comprised only 6 per cent in automotives to the present scenario where these wonder materials command a 20 per cent role in European and American cars, plastics have come a long way. The increasing usage of plastics in automotives is significant and here to stay. With this trend in focus, the 2-day Indo-German International Seminar on ‘Plastics in Automotives – Redefining Possibilities’ was just what the industry needed – a fresh perspective on the latest available technology. Sweta M Nair

f the future of automobiles was to be described in simple words, then reducing manufacturing costs and reducing weight to meet fuel consumption regulations would become the global mantra. Integration of functionality coupled with new processing technologies would be the perquisite here, but keeping the innovative spirit burning would also be crucial in the competitive atmosphere. The 5th edition of the two-day IndoGerman International Seminar on ‘Plastics in Automotives – Redefining Possibilities’ that was held on March 7–8, 2013, at the Trident, Chennai, presented compelling cases on this revolutionising mantra. With support from the Department of Chemicals and Petrochemicals, Automotive Component Manufacturers Association of India (ACMA) and Society of Indian Automobile Manufacturers (SIAM), the seminar was organised by the Organization of Plastics Processors of India (OPPI) and sponsored by the Verband Deutscher Maschinen- und Anlagenbau (VDMA) – German Engineering Federation. The seminar kicked off with an inauguration ceremony where the Chief Guest Manfred Geiss, CEO, Geiss AG, Germany, addressed the audience members in his welcome note. What followed shortly were sessions with speakers from companies such as Arburg, Engel, Geiss, Hennecke, Kautex, Kiefel, KraussMaffei, Kuka, Kurs, Sumitomo Demag, Unicor and Wittmann-Battenfeld. These sessions highlighted technology that help achieve reduction in energy consumption and increase in production with less running cost.

Speakers of the event along with members of OPPI and VDMA

such as original equipment manufacturers, plastics raw material manufacturers, plastics processors producing plastic components for automotives, automotive paint producers, plastics processing machinery manufacturers, consultants, robot manufacturers etc. At the conclusion of day one, Srinivas Sonti, General Manager – Sales, Ferromatik Milacron India Pvt Ltd, who was a moderator at one of the sessions, said, “I believe the seminar has been very informative for senior management as well as for individuals at the operating level. Although some of the technologies showcased here are a bit advanced for the industry in India, sooner than later, it will arrive here as well. Companies will imbibe on this level of technology soon.” A power-packed Q&A session concluded most of the speaker’s presentations. The high level of participation proved a fruitful exchange for problem-solving. Each presentation at the seminar detailed trends of globalisation, lightweighting and cost reduction.

High level of participation The seminar was attended by about 215 individuals who belonged to segments 92

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Solutions for the industry Some of the sessions highlighted

the challenges but were also quick to provide useful solutions. Modern manufacturing techniques with competitive advantages through efficient production where parts or components can be produced at the lowest possible cost in the highest possible quality were discussed extensively in between breaks. Selection and combination of materials, defining tolerances especially for plastics, integration of functions, minimising production steps, reduction in wall thickness thereby saving material were other topics that sprung up during the Q&A sessions. Lilli Rudnick, Exhibitions – EUROMAP, VDMA, in her feedback complimented the OPPI for the excellent organisation of the 5th Indo-German International Seminar. She said, “The speakers were impressed by the number of participants at this event. We hope that this conference has contributed towards bringing exciting new technology to the Indian plastics processing industry and that the attendees gathered new and interesting insights that will find a place in their future strategic plans.” Email: sweta.nair@network18publishing.com

EVENT REPORT: Engineering Expo Aurangabad 2013

AURANGABAD February 22–25, 2013 Ayodhya Nagari Grounds

Exhibiting Aurangabad’s unparallelled potential Since the last few years, Aurangabad has emerged as one of the fastest growing industrial hubs. The region already has a huge industrial presence with a large number of engineering services, auto ancillary and pharmaceutical research companies setting up facilities here. The ever-evolving industrial scenario and the enterprising spirit of its entrepreneurs have helped Aurangabad grow into an industrial area of repute. Engineering Expo Aurangabad 2013 proved to be the right ‘growth tonic’ for boosting the region’s industrial might. Mahasang; and Mansingh Pawar, Past President, MASSIA, among others.

Officially approved

Dignitaries unveil the Exhibitors’ Directory at the inauguration of Engineering Expo Aurangabad 2013

Nishi Rath

t was in 1960 that the region of Marathwada was merged with Maharashtra. This was the time when the industrial development of Marathwada began. Over time, the Maharashtra Industrial Development Corporation (MIDC) acquired land and set up industrial estates, which provided a boost to the region’s tremendous growth. Aurangabad is now one of the classic examples of efforts towards balanced industrialisation with factors such as availability of labour, comparatively lower cost for setting up base and a developing market attracting an array of industries to the city. Additionally, the presence of renowned MNCs and domestic giants in Aurangabad has further catalysed the city’s industrial growth by offering Small & Medium Enterprises (SMEs) a boost. Reflecting the city’s industrial growth was the second edition of 94

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Engineering Expo Aurangabad. Held during February 22–25, 2013, at Ayodhya Nagari Grounds, the four-day Expo was inaugurated in the presence of an esteemed set of Guests of Honour including Kala Ojha, Mayor, Aurangabad; Sanjay Shirsat, MLA, Aurangabad West; Pradeep Jaiswal, MLA, Aurangabad Assembly Constituency; G M Ambhore, Director, MSME Development Institute; P Udayakumar, Director, The National Small Industries Corporation; Sudhanva Jategaonkar, Associate Vice President, Network 18 Publishing; and Vijay N Jaiswal, President, Aurangabad Industrial Suppliers Association (AISA). The inauguration also witnessed the presence of Sunil Raithatha, President, Chamber of Marathwada Industries and Agriculture (CMIA); Dr Uday Girdhari, President, Marathwada Association of Small Scale Industries and Agriculture (MASSIA); Adesh Palsingh Chabda, President, Aurangabad Zilla Vyapari

Organised by Network 18 Publishing with AISA as supporting partner, the Expo played host to various industry giants and market leaders who showcased their best products and services at the trade show. Balasaheb Thorat, Minister of Revenue, Government of Maharashtra, also graced the Expo. He said, “Engineering Expo Aurangabad has become a platform for new industries developing in the region. It has also proved to be the best platform for students as it gives them exposure to the real industrial world. I feel more events on similar lines should be organised in the near future.” Rajendra Darda, MLA & Minister of School Education, Government of Maharashtra, also marked his presence at Engineering Expo Aurangabad. “The whole experience here was worth the visit. The Expo was well organised and provided a platform for local entrepreneurs. We look forward to many more such events,” he added.

Bright future for SMEs According to experts, the historical background of the place helps attract foreign investors. Aurangabad boasts of a strong brigade of young and enthusiastic first-generation entrepreneurs, who not only implement new ideas but also steer the growth. “Aurangabad has a lot of potential when it comes to the industries. The small scale industries here have a

Engineering Expo Aurangabad 2013

great future. They are keen to grow and play a key role in the growth of any particular region,” said Udayakumar. Engineering Expo Aurangabad focussed on providing SMEs an opportunity to demonstrate their capabilities, to offer a platform to industries across the country and enable exhibitors to formalise business alliances for mutual growth. “The trade show truly opened up a new world of opportunities for the small and medium scale industries here. The enthusiasm among exhibitors was encouraging. It was a good experience to be a part of this grand show,” asserted Shirsat.

Upbeat exhibitors The exhibitors were overwhelmed by the positive response they received from the visitors. They were looking forward to generating more business gauging from the enquiries that they received at the Expo. Manoj Kumar, Director, Apex Group, who exhibited at the trade show, said, “We have had a lot of enquiries; I cannot gauge how many will turn out to be good business leads, but yes, I am pleased with all the enquiries. It proves that we have managed to attract the target customers and create our brand visibility.” Another exhibitor, Nitin Bagul, Director, Technovision Instrumentation Solution Pvt Ltd, expressed, “We participated in Engineering Expo Aurangabad last year

Highlights of this edition Pan India participation by 223 exhibitors Spread across more than

10,914 sqm 18,528 business visitors visited from across India Business transactions worth ` 74.78 crore* More than 11,533 business leads generated* 8,500+ products displayed from different industries More than 90,000 kg machinery moved in for display

Balasaheb Thorat, Minister of Revenue, Government of Maharashtra, being felicitated with a memento by Network 18 Publishing and AISA team

as well; it helped us build good contacts. Aurangabad is an industrial hub and the number of industries is increasing by the day. This is a good place for such an event; only awareness among the masses has to be increased.” Anand Pahade, Proprietor, Chintamani Electricals, who also exhibited at the trade show, said, “We participated in this trade show as we wanted to create our brand image on which customers can bank on. The response we have received has been mixed. Expos such as these should work towards creating awareness among the masses in Aurangabad.”

Initiatives in action Engineering Expo Aurangabad saw some great initiatives in action. The ‘National Vendor Development Programme’ acted as a crowd puller both in terms of exhibitors and visitors. Organised by the MSME Development Institute, Ministry of MSME, Government of India, the event became an instant hit. It saw participation from organisations such as Western Railways, State Transport, Hindustan Petroleum Corporation Ltd, Indo German Tool Room and Central Institute of Plastics Engineering and Technology. Speaking at the event, Ambhore stated, “Our main objective is to identify and explore the business opportunities in the highly competitive area. We also encourage benchmarking for meeting the challenges in the best way.” Engineering Expo Aurangabad was not all about exhibitors but it also offered a lot to the visitors.

Visitors make the most of Expo Commenting on how an Expo of this stature acts as a growth catalyst, Mayur Parikh, Senior Manager Marketing, Sah Petroleum Ltd, said, “Exhibiting companies fully utilised this platform at the Expo. Such trade shows always help the industrial circuit of a particular region. It was great to be part of the Expo as a visitor.” Another visitor opined that the turnout, despite the recession, was commendable. “Taking into consideration the recession, the turnout was good. Engineering Expo is a great platform for small and medium scale industries to connect and understand the market requirements,” averred Abhay Sharma, Director, Extreme Ro System Pvt Ltd. Students too had a great chance to get hands-on experience at the Expo. Starting from market trends to new technology, the Expo turned out to be a helpful lesson for them. “Students can learn a lot here; where else can they find the latest technologies and machines at one place?” opined Ojha.

Marking a new beginning Adding another feather to its cap, Engineering Expo came to an end with a promise to come back with more enthusiasm and better opportunities for Aurangabad. The next edition of Engineering Expo will be held in Hyderabad, Andhra Pradesh, during May 31 to June 3, 2013. Email: nishi.rath@network18publishing.com

April 2013 | Modern Plastics & Polymers

EVENT REPORT: Engineering Expo Aurangabad 2013 – Panel Discussion

Gauging Aurangabad on the critical parameters A panel discussion was organised on the sidelines of Engineering Expo Aurangabad 2013. Held on February 22, 2013, the panel discussion on ‘Trade, trends & technology: Gauging Aurangabad on the critical parameters’ was good food for thought.

(L–R) Maithilee Tambolkar, Director, Sanjeev Auto Parts Manufacturers Pvt Ltd; SG Rajput, GM, DIC & Superintendent Industries Officer, Aurangabad; Archana Tiwari-Nayudu, Editor, Network 18 Publishing; Ram Bhogale, Director, Umasons Auto Compo Pvt Ltd; P Udayakumar, Director, NSIC; and Mukund Kulkarni, Director, Expert Global Solutions & Ex-President, CMIA, voice their views at the panel discussion

Nishi Rath

urangabad has carved a niche for itself among the industrial leaders in the country. In the era of liberalisation and intensive competition, Aurangabad is resolutely addressing the challenge of moving to a higher growth trajectory in the industry. Taking a peek into this growth story, Network 18 Publishing with support from Aurangabad Industrial Suppliers Association (AISA) organised a panel discussion on the sidelines of Engineering Expo Aurangabad 2013. Held at Taj Presidency on February 22, 2013, the panel discussion served as food for thought for more than 150 industry leaders and professionals. L eading industr y exper ts such as Ram Bhogale, Director, Umasons Auto Compo Pvt Ltd; S G Rajput, GM, District Industries Center (DIC) & Superintendent Industries Officer, Aurangabad; Mukund Kulkarni, Director, Expert Global Solutions and Ex-President Chamber of Marathwada Industries and Agriculture (CMIA); P Udayakumar, 96

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Director, The National Small Industries Corporation (NSIC) and Maithilee Tambolkar, Director, Sanjeev Auto Parts Manufacturers Pvt Ltd, enlightened the audience on the opportunities Aurangabad can provide. The panel discussion was moderated by Archana Tiwari-Nayudu, Editor, Network 18 Publishing.

Is Aurangabad underrated? The first non-stick pan came from Aurangabad; one of the best white goods brands and electronics is offered by this city; it also supplies the best microfinishing machines, which also compete with the world’s best. However, it seems to lack visibility. “We export to 72 countries and, in the last two years, Aurangabad-based organisations have done acquisitions overseas. But we are still understated because we have been underestimating ourselves. It is high time we move ahead,” said Kulkarni. “We have created brands but were never given that status. This is because we were overshadowed by major industrial hubs such as Mumbai and Pune. But I think it is time for us to come out of that shadow and prove our calibre,” observed Bhogale.

Taking the discussion ahead, Tambolkar added, “There is no denying that Aurangabad is underrated as a manufacturing hub, one of the reasons being the presence of various first-generation entrepreneurs. Every business has to go through a cycle and most of them are completing the cycle now. So, this is the time.” Giving the discussion a twist, Udayakumar said, “I look at it in a positive way. In the age of competition, it can be seen as an opportunity. Entrepreneurs can focus on their resources and future plans, when no one looks at you as a threat.”

Technology takes the lead According to the panellists, investing in technology and innovation will take Aurangabad to a new level. “What we have focussed on is right investment and right technology; investing in the latest technology will always pay back in the long term. This strategy has helped us too,” added Tambolkar. Speaking up for technology, Bhogale stated, “Investing in technology is one of the reasons why we have witnessed growth. Aurangabad is a good mix of innovation and tradition. There are people who have innovatively managed their traditional ways. That has given them a competitive edge.” Kulkarni added, “Investing in the best technology is key; the short-term costs may be higher, but the longterm gain is what people should be looking at. Managing time, quality, productivity and safety will also make us competitive.” The panel discussion received an overwhelming response from the industry, who actively participated as the audience. The insightful discussion was followed by a lively question and answer session. Email: nishi.rath@network18publishing.com

BOOK REVIEW

Plastic Films in Food Packaging: Materials, Technology, and Applications Editor: Sina Ebnesajjad Price: ` 14,350 Plastic packaging of foods is not only obvious and omnipresent in developed economies but also increasingly commonplace in the developing world, where plastic packaging is instrumental in decreasing the proportion of the food supply lost to spoilage. This new handbook is a combination of new material, unrevised chapters and updated chapters chosen by the author from recently published books on the subject. The handbook offers a practical source for engineers, scientists and managers working in the food packaging industry, providing a tailor-made package of science and engineering fundamentals, best practice techniques and guidance on new and emerging technologies. By covering materials, design, packaging processes, machinery and waste management, all in one book, the editor enables the reader to take a lifecycle approach to food packaging. The handbook addresses questions related to film grades, types of packages for different types of foods, packaging technologies, machinery and waste management. Additionally, the book provides a review of new and emerging technologies. Two chapters are devoted towards development of barrier films for food packaging and the regulatory and safety aspects of food packaging.

Polyethylene: End-Use Properties and their Physical Meaning Author: Yury V Kissin Price: ` 6,850 This book serves to bridge the values of engineering end-use parameters of Polyethylene (PE) resins and their scientific molecular and structural characteristics. The main goal is to translate common parameters such as melt flow index of a resin or the dart impact strength of a film sample into the universal language of polymer science. After this translation, many facets of the resin properties become apparent and explainable. The contents of the book include topics such as manufacture, structure and mechanical properties of PE resins, melt index and melt flow ratio of PE, melting point of PE resin, crystallinity degree & density of PE, enduse mechanical properties of PE film, end-use testing of high molecular weight high-density PE and medium-density PE resins. This valuable sourcebook is apt for undergraduate students who have taken polymer physics as well as for practising professionals in the industry.

Reviewer: Dr R Rangaprasad, Experienced Polymer Professional Available at: SCI-TECH Books & Periodicals, 414, Janki Centre, Veera Desai Road, Andheri (W), Mumbai – 400053 Tel: 022-26735260/66970507 • Fax: 022-6735424/26735260 • Email: scitech@vsnl.com

April 2013 | Modern Plastics & Polymers

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Tarpaulin two-in-one heat sealing machine

The EX series 3, 4 and 5-axis CNC vertical machining centre possesses versatility and capacity to carry out the maximum range of jobs within the working envelope with very high precision of dynamic positioning with total geometric, mechanical and thermal stability in structural parts. EX 1680 with X/Y/Z (1600/800/800 mm) has all axis movement on spindle head and a 20-tool ATC. Equipped with a fixed table (2000 × 800 mm), it has a high table load carrying capacity of 4500 kg with various variants in table configuration, while C-Axis option of rotary table-in-table of 700 × 800 mm is also available. Delivering heavy metal removal rates with precision and accuracy, wide working window for operator ease, machining ability from complex small parts to bigger heavy engineering works, the EX series caters to industries like automotive, railways, machine construction, injection moulding and many other applications from heavy engineering to complex die and mould components.

The two-in-one heat sealing machine is fabricated from high grade raw material, which is procured from trusted and renowned vendors. The two-in-one machine will be on robust structure fit for both centre and side sealing of 70 to 450 GSM fabric up to 6 ft max. Its seals are of HDPE/ PP laminated fabric, LD sheet of above 500 gauge and PVC coated, SRF nylon sheet, flex banner (poster) and polyester fabric coated material. The machine has 6 ft guide rolls at the side where the fabric enters and sealed fabric falls at the bottom where it can be folded easily with one side open. The centre cantilever has a heavy steel structure to mount electrical controls, air blower and pressure system assemblies. This machine has 2 unwind, with braking attachment shafts. It also has 7.5 hp power consumption, seals 25 to 60 mtr each, side and centre sealing fabric of 70 to 450 GSM per minute. Its size is 10 × 3 × 3 ft and has a capacity of minimum 600 kg per shift.

Jyoti CNC Automation Ltd Rajkot - Gujarat Tel: 02827-287081, 287082 Email: info@jyoti.co.in Website: www.jyoti.co.in

Shri Gurukrupa Engineering Works Vadodara - Gujarat Tel: 0265-3042371, 2637718, Mob: 09898885273 Email: shrigurukrupaengg@yahoo.com, shrigurukrupaengg@rediffmail.com Website: www.shrigurukrupaengg.in

Multilayer polyethylene film The multilayer polyethylene film is coated with pressure sensitive adhesive. A wide range of innovative solutions for protection of PVC section with an extensive range of adhesion level, film thickness of 50 micron to 80 micron and colour are available. It has a maximum length of 1000 m per roll and maximum width of 1550 mm. It provides outdoor weather resistance. The protective film peels out easily after finishing operations. It preserves the quality of surface without leaving residue or any marks once the protective film is removed. It provides uniform and stable adhesion throughout the life cycle of the product. Ecoplast Ltd Mumbai - Maharashtra Tel: 022-26830064, 26840359 Email: info@ecoplastindia.com Website: www.ecoplastindia.com 98

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Injection moulding Injection moulding technology is used across the range of polymer families from polyolefins to engineering polyamides, styrenes and various special compounds to meet the specific needs of the parts. Parts from sizes as small as a button to as large as the front hood of heavy commercial vehicles are moulded, covering products of both technical and aesthetic requirements. It has the most advanced technology ranging from 50 tonne to 3000 tonne across reputed brands in the industry. Application areas include production of HVAC unit, rack system for retail, ice twister, radiator grill, bumper system, blower case, truck front panel, fan unit, pillars, door bin and washing machine tub. Mutual Industries Ltd Mumbai - Maharashtra Tel: 022-66895300 Website: www.mutual-industries.com

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3-Axis CNC double column machining centre NX series double column CNC vertical machining centre is an ideal heavy duty machine for both roughing and finishing of bigger components greatly increasing work envelope, permitting large workpieces to be machined and a wider range of tool lengths to be used in the same set-up. With a load capacity range of 10,000 kg, this series has been designed to accommodate large mould and mould base machining. With the architecture of Y-axis on cross beam, moving table on X-axis and Z-axis on ram-type head, greater extensions from head-stock and better reach to table area is achieved without much interference of axis elements. Wider gaps are maintained between columns to accommodate large size components. NX 2215 has X/Y/Z (2200/1500/800 mm) and 24-tool ATC. Thus, with mentioned machining features, symmetrically designed heavily ribbed cast iron structure with wider columns providing high level machining geometric stability, wider door opening various options in head and spindle, the NX series becomes an ideal choice for modern machine shops. Jyoti CNC Automation Ltd Rajkot - Gujarat Tel: 02827-287081, 287082 Email: info@jyoti.co.in Website: www.jyoti.co.in

Low cost PID temperature controller

Low cost intelligent PID temperature controller provides thermocouple input like thermocouple K, E, J, N, RTD Pt100 and relay or SSR voltage output. It also facilitates maximum two alarm relay outputs. This model is available in different sizes of 48 X 48 mm², 72 X 72 mm² and 96 X 96 mm². It has measurement accuracy of 0.3%FS±1oC and temperature display resolution of 1oC. Different control mode can be configured as on or off, artificial intelligence control, including fuzzy logic PID control and advanced control algorithm with the function of parameter auto tuning. It has a built-in switch mode power supply voltage rating of 100-240VAC/ 50-60Hz and consumes only 2W. Micon Automation Systems Pvt Ltd Ahmedabad – Gujarat Tel: 079 - 32900400 Email: sales@miconindia.com Website: www.miconindia.com April 2013 | Modern Plastics & Polymers

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Universal PID controller

The universal PID controller adopts digital calibration technology for input measurement with input measurement accuracy 0.3 per cent FS. Non-linear calibration tables for standard thermocouples and RTDs are available in the instrument. All other linear inputs such as 4–20 mA, 0–10 VDC etc are also available. It can satisfy the requirements of various applications, make quick delivery and is easy to maintain. Its friendly and customised operating interface leads to easy learning and simple manipulation. It has high quality and performance hardware design, using high-performance tantalum capacitor or ceramic capacitor. Compared to competing models, it consumes less electricity, experiences less temperature shifting, provides higher stability and reliability and can work in a wider range of temperatures. Micon Automation Systems Pvt Ltd Ahmedabad – Gujarat Tel: 079 - 32900400 Email: sales@miconindia.com Website: www.miconindia.com

Dual-control water-type mould temperature controller The dual-control water-type mould temperature controller is a single machine that can simultaneously control the temperature requirements of different male and female moulds. The male and female moulds require different temperature degrees. Dual-control series lets you control two different temperatures accurately. The size is decreased by 40 per cent to save space. It does not need constant replacement which helps in acquiring substantial savings with regards to cost and time and improves work efficiency. The patented ‘Heat-insulated’ design improves safety, extends the machine’s life and makes repair and maintenance more efficient and safer. The water-type series does not produce oil and gas, thereby reducing pollution in the work place which is useful in electronics, medical and cosmetic industries. In the water-type series, the cooling effect increases efficiency and does not pollute the mould. It is economical and has widespread applications. The imported PID temperature controllers are used for accurate control of temperature within ±0.1°C. Yann Bang Electrical Machinery Co Ltd Taichung -Taiwan Tel: 886-4-22710000, Fax: 886-4-22711988 Email: yb@yannbang.com Website: www.yannbang.com 100 Modern Plastics & Polymers | April 2013

Hot runner system mould

Some characteristics of the Moki patent hot runner system mould include short cycle time (shortest time up to 3.2 s with advanced blowing technology), high productivity and good stability. It is suitable for lightweight and extra-thin (thinnest up to 0.3 mm) disposable products. Other features are waste reduction, lower production cost, high stability of finished products, low defect rate, strong mould structure, floating structure, thin finished products, average thickness, stable quality and long life of mould. Mo Chyi Enterprise Co Ltd Changhua County - Taiwan Tel: +886-4-7354681 Email: lcn11111@ms23.hinet.net Website: www.food-mold.com

Pellet screening system Super Platon is the latest generation of pellet screening system for plastics industry. This system detects black spots or off-colour contaminants as small as 0.1 mm in a pellet stream by using four highresolution 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

Copolymer emulsion Dipicryl 03D6 is vinyl acetate, butyl acrylate copolymer emulsion, which is slightly viscous and of medium particle size with excellent flow properties. It is specially developed for making highly pigmented emulsion paints. It has a milky white appearance with free flowing dispersion and particle size of 0.5 to 0.8 microns. It forms tough and flexible film above 7°C which is clear, non-tacky and free from bits. Dipicryl 03D6 has good compatibility with pigments, extenders, protective colloids, plasticisers and other acrylic emulsions. It is used in making premium quality interior and exterior coating wall paints. Speciality Polymers Pvt Ltd Mumbai - Maharashtra

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PRODUCT S

Tel: 022 - 22063534, Fax: 022 - 22063533 Email: spdp@vsnl.com, import@specialitypolymer.com, export@specialitypolymer.com Website: www.specialitypolymer.com

and downstream equipments are designed for the best match with the extrusion line. For further improving the output of extrusion line, each processing device and computer-controlled possibility (eg PLC, PC base) are recommended to suit different usersâ&#x20AC;&#x2122; demands.

Mould-temperature controller and chiller

Intype Enterprise Co Ltd Tainan - Taiwan Tel: +886-6-2614196 Email: extruder@intype.com.tw Website: www.intype.com.tw

The mould temperature controller and special custom-made chiller are new products that include cold-hot all-in-one mould temperature controller, die-casting mould temperature controller, quickcooling & 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

Anti-static plastic pallet This anti-static plastic pallet is available in various sizes. It is made from virgin foodgrade plastic materials and is used in pharmaceutical and foodbased industries. Also offered are grain storage pallets, steel reinforced plastic pallets, drum pallets, moulded plastic pallets, rackable plastic pallets etc. Ergen Plastic Industries Jodhpur - Rajasthan Tel: 0291-2433737, Mob: 09414195707 Email: info@ercon.co.in Website: www.indiamart.com/plastic-pallets

Wood plastic composites

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 with optimum function, upstream

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 low-density and 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

Extrusion machine The LIN-90II-TS is a performance-based machine designed to accommodate large containers with outstanding cycle time. It produces from 200 ml to 4 L of PE/PP and PVC/PTEG, and the productivity reaches 4,500 and 860 pc/hr, respectively. To ensure quality, mechanical and electrical components from leading brands are used in this machine. Akei Plastic-Machine Mfy Ltd Kowloon - Hong Kong Tel: +852-27411312 Email: akeisimon@akei.com.cn Website: www.akei.com.hk April 2013 | Modern Plastics & Polymers 103

PRODUCT S

Thermoplastic rubber

One must consider the cost of the product before ed purchasing so as to secure deﬁnite and assur returns over the period of time.

Manisha Kadam (Assistant Manager) Ashok Industry

Thermoplastic rubber is primarily an elastomer which combines the performance traits of a rubber and processing ability of plastic. It exhibits excellent physical and mechanical properties, high tensile strengths and tear strengths, good thermal properties and excellent resistance to water, alcohol, acids and bases. It finds a wide use of applications as gasket support and hose connectors, automobile dust cover, boots and grommets, flexible cords and coiled cords, weather stripping for doors and windows etc. Welset Plast Extrusions Pvt Ltd Mumbai – Maharashtra Tel: 022-28215734, 28387054 Email: info@welset.com Website: www.welset.com

Long fibre rigid thermoplastic polyurethane

One must identify the product that best suits his/her organisation with regards to the cost and quality.

Suhas Kulkarni (Product Manager Marketing) Kohler India Corp Pvt Ltd

RTP 2300 series long fibre rigid thermoplastic polyurethane surpasses rigorous set of tests for reinforced shoes. The long fibre TPU compound can be injection moulded into toe caps. A VLF TPU toe cap can exceed ANSI specifications requiring that a cap must withstand 7500 pound of direct impact and 2500 pound of static load. With this compound, it is possible to almost double the static load standard for safety toe caps. Compared to steel, this material has high strength, weight reduction and, being nonconductive, will not activate metal detectors, insulates against heat and cold, non-magnetic and static-free. Although this material is ideal for safety work boots and shoes, their use has greatly expanded into other markets such as the military. RTP Company Chennai – Tamil Nadu Tel: 044-42147313 Email: srengasamy@rtpcompany.com Website: www.rtpcompany.com

The information published in this section is as per the details furnished by the respective manufacturer/ distributor. In any case, it does not represent the views of Business Insights •Technologies•Opportunities

104 Modern Plastics & Polymers | April 2013

LIST OF PRODUCT S

Looking For A Specific Product? Searching and sourcing products were never so easy. Just type MPP (space) Product Name and send it to 51818

eg. MPP Moulding and send it to 51818 Product

Pg No

3, 4 and 5-Axis CNC vertical machining centre ...........98 3-Axis CNC double column machining centre .................... 99 AC/DC panel for pipe plants......................................89 Acoustic enclosure ................................................................. 33 Additive masterbatch ............................................................ 45 Air audits blower................................................................... 18 Air compressor ...................................................................... 49 Air treatment......................................................................... 49 Air-conditioner part .......................................................... FGF Air-conditioning plant .......................................................... 49 All electric machine .............................................................. 23 Aluminium die casting machinery ........................................ 49 Anti-static plastic pellet ...................................................... 103 Automation system ............................................................... 75 Barrel ...................................................................... 110 Bed knife ............................................................................... 63 Biodegradable masterbatch ................................................... 45 Black masterbatch ................................................................. 45 Blender ..................................................................... FIC,19,61 Blending unit .................................................................... FGF Blow moulding ...................................................................... 35 Blower series ......................................................................... 75 Blown film extrusion system ............................................... BC Carbon black .............................................................85 Circular weaving machine ..................................................... 14 Clean room application ......................................................... 25 Cleaning oven ..................................................................... 110 Cluster facia ...................................................................... FGF CNC Machine ...................................................................... 29 CNC vertical machining centre ............................................ 73 Colour masterbatch .......................................................... 15,45 Compact chiller ................................................................... 109 Compounding extrusion........................................................ 20 Compressed air dryer ............................................................ 65 Compressed air system ....................................................... BIC Compressor ................................................................... 18,BIC Conductive compound .......................................................... 45 Conical twin screw extruder ................................................... 6 Connector.......................................................................... FGF Continuous screen changer ................................................. 110 Coploymer emulsion ........................................................... 100 CPVC pipe....................................................................... 10,21 Crystalliser............................................................................. 65 Cutting and stitching machine ............................................. 14 Cylinder engraving - Lenticular and optical roll mould ...... 99 Dehumidified dryer.................................................FIC Dehumidifying air dryer ........................................... 109, FGF Dehumidifying dryer ............................................................. 34 Die face cutter ....................................................................... 63 Die plate ................................................................................ 63 Diesel generator .................................................................... 49 Digital panel meter ............................................................... 12 Digital temperature controller............................................... 93 Door trim .......................................................................... FGF Dosing and mixing................................................................ 75 Double column vertical machining centre ............................ 29 Drive...................................................................................... 93 Dry van pump ....................................................................... 33 Dry-break coupling ............................................................... 18 Drying and dehumidfying..................................................... 75 Drymax air - Hot air dryer ................................................ FIC Drymax dryer ..................................................................... FIC Drymax Pet - Dehumidified dryer .................................... FIC Dual channel with modbus ................................................... 93 Dual control water-type mould temperature controller...... 100 Dynamic controller ............................................................... 93 Ejector.......................................................................18 Electric injection moulding machine gearbox......................... 7 Evaporative cooling tower ..................................................... 49 Exhibition - Plastivision 2013 .............................................. 38 Extruder machine ............................................................. 27,67 Extruder screw ...................................................................... 63 Extrusion ............................................................................. BC Extrusion coating lines (Lamination Ant)............................ 14 Extrusion dies.......................................................................... 8 Extrusion machine .............................................................. 103 Extrusion system ................................................................. BC

Product

Pg No

Feed roll ....................................................................63 Feeding & conveying ....................................................... 65,75 Film cutter............................................................................. 63 Fueling system ....................................................................... 18 Furnace .................................................................................. 49 Gear pump .............................................................. 110 Granulating and recycling ..................................................... 75 Granulator .............................................................. FIC,65,109 Granulator blade ................................................................... 63 Gravimetric blender ............................................................ 109 HDPE pipe plant.......................................................89 Head lamp and tail lamp .................................................. FGF Heat transfer roll ................................................................. 110 Heating and cooling.............................................................. 75 High cavitation ..................................................................... 25 High performance screw ..................................................... 110 High speed mixer ............................................................. 27,67 Hopper loader ..................................................................... 109 Hot air dryer ..........................................................FGF,34,109 Hot runner system ................................................................ 75 Hot runner system mould ................................................... 100 Hydraulic injection moulding machine................................. 23 IML technique ..........................................................25 Industrial coolers ................................................................... 49 Injection moulding ........................................................... 35,98 Injection moulding machine ............................FGF,5,16,17,52 Inline drip tubing ............................................................. 10,21 Knob and switch ....................................................FGF Largeflow water heater ...............................................75 Loader ................................................................................ FIC Loading arm.......................................................................... 18 Long fiber rigid thermoplastic polyurethane ...................... 104 Low cost PID temperature controller................................... 99 Manual and hydraulic screen changer ....................... 110 Material dryer .................................................................. 19,61 Material storage .................................................................. 109 Measuring and control equipment ........................................ 99 Medical mould ...................................................................... 25 Mono and multilayer sheet line ............................................ 14 Monofilament line................................................................. 14 Monolayer blown film ...................................................... 10,21 Monolayer blown film line.................................................. BC Mould .......................................................................... 20,27,67 Mould repair ......................................................................... 99 Mould temperature controller ............................................... 34 Mould temperature controller ............................................. 109 Mould temperature controller and chiller ........................... 103 Moulding............................................................................... 25 MTC .................................................................................. FIC Multi component mould ....................................................... 25 Multilayer blown film ...................................................... 10,21 Multilayer blown film line ..............................................14,BC Multilayer cast film line ........................................................ 14 Multilayer polyethylene film ................................................. 98 Napkin dies ...............................................................63 Optical brightner .......................................................45 Paperless recorder ......................................................12 Parallel and right angle axes gearboxes ................................... 7 Pellet screening system ........................................................ 100 Pelletiser parts ....................................................................... 63 Pelletisers ........................................................................ 63,110 PET Preform dedicated machine ......................................... 53 PET/PE Washing line .......................................................... 14 PETline injection moulding machine................................... 23 Plastic conveyor belt.............................................................. 27 Plastic machinery .................................................................. 49 Plastic masterbatch................................................................ 51 Plastic processing machine .................................................... 14 PLC....................................................................................... 93 Polyolefin pipe.................................................................. 10,21 Power saving.......................................................................... 35 PP-R pipes ....................................................................... 10,21 Precision moulding............................................................ FGF Priming valves ....................................................................... 18 Printing and cutting/Rewinding machine ............................ 14 Process controller .................................................................. 12 Process machinery ................................................................. 49

Product

Pg No

Profile controller.................................................................... 93 Pulveriser ..................................................................... 20,27,67 Pulveriser disc........................................................................ 63 Pump ................................................................................ 18,33 PVC foam core pipe ........................................................ 10,21 PVC mixer cooler............................................................. 10,21 PVC palletising lines........................................................ 10,21 PVC pipes ........................................................................ 10,21 PVC profile lines.............................................................. 10,21 Rational mould ..........................................................20 Rational moulding machine ................................................. 20 Recycling lines....................................................................... 14 Resin dehumidifier ................................................................ 65 Robot.................................................................................. FIC Rock n roll machine ......................................................... 27,67 Roots blower ......................................................................... 33 Rotary cutter ......................................................................... 63 Rotary dies ............................................................................ 63 Round table carousel ............................................................. 27 Safety access equipment .............................................18 Servo energy saving machine ................................................ 53 Servo pump ........................................................................... 35 Shut off nozel...................................................................... 110 Shuttle remoulding machine ................................................. 20 Single mill pulveriser........................................................ 27,67 Single screw extruder gearboxes.............................................. 7 Single screw extruder plant ..................................................... 6 Single screw pipe plant for RPVC........................................ 89 Software for central monitoring............................................ 65 Specialty chemicals.............................................................. 103 Stack mould .......................................................................... 25 Storage tank equipment ........................................................ 18 System solution ..................................................................... 75 Tank truck equipment................................................18 Tape stretching line with inverter driven cheese winders ..... 14 Tarpaulin two-in-one heat sealing machine ......................... 98 Technical mould .................................................................... 25 Temperature controller ..................................................... 12,93 Testing ................................................................................... 99 Thermoformer ..................................................................... BC Thermoforming ................................................................... BC Thermoforming & PS foam ............................................... BC Thermoplastic rubber .......................................................... 104 Three arm bi-axial rotational moulding machine ............ 27,67 Toggle injection machine ...................................................... 23 TPU masterbatch .................................................................. 15 Transmissions and PTOs ...................................................... 18 Twin mill pulveriser ......................................................... 27,67 Twin screw co-rotating extruders........................................ 107 Twin screw elements ........................................................... 107 Twin screw extruder gearbox .................................................. 7 Twin screw extruders........................................................... 107 Twin screw extrusion line ....................................................... 6 Twin screw pipe plant for RPVC pipes ................................ 89 Two platen injection moulding machine .............................. 23 Two-layer blown film ....................................................... 10,21 Ultra sonic flow meter ................................................12 Universal controller ............................................................... 93 Universal PID controller ..................................................... 100 UV stabilisers ........................................................................ 45 Vacuum booster pump ................................................33 Vacuum dryer ........................................................................ 34 Vacuum forming machine ................................................... BC Vacuum loader ................................................................... FGF Vacuum pumps & systems .................................................... 18 Vacuum system ...................................................................... 33 Variable displacement pump energy-saving machine ........... 53 Vertical machining centre ..................................................... 29 Vibratory screening system ................................................... 20 Vibro screens .................................................................... 27,67 Volumetric dosing unit.......................................................... 65 Water chiller ..............................................................65 Water jetting ......................................................................... 18 WFR .................................................................................. FIC White masterbatch ................................................................ 45 Wire EDM ........................................................................... 73 Wood plastic composites ..................................................... 103

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

April 2013 | Modern Plastics & Polymers 105

LIST OF ADVERTISERS Advertiser’s Name & Contact Details

Pg No

Advertiser’s Name & Contact Details

All India Plastics Mfrs Association ............... 38

Pg No

Glaves Innovations Pvt Ltd .......................... 63

Advertiser’s Name & Contact Details

Neejtech India (Braunform) .......................... 17

T: +91-22-28217324

T: +91-141-2460324,

T: +91-79-26561312

E: pvi13@plastivision.org

E: sales@glaves.biz

E: info@neejtech.com

W: www.plastivision.org

W: www.glaves.biz

W: www.neejtech.com

Hindustan Plastic and Machine Corporation .. 6

Alok Masterbatches Ltd ............................... 15

T: +91-011-25473361

T: +91-011-41612244

E: poonam@hindustanplastics.com

E: sales@alokindustries.com

W: www.hindustanplastics.com

W: www.alokmasterbatches.com

J P Extrusiontech Limited ............................ 14

Baumuller India Pvt Ltd ............................... 35

T: +91-2646-222163

T: +91-020-40160303

E: info@jpextrusiontech.com

E: scrvopump@bumuller.in

W: www.jpextrusiontech.com

W: www.bumuller.com

Jacobsen Lenticular Tool & Cylinder Engraving Technology Co., ( Jaco Tech) ......................... 99

Boge Compressed Air System .................... BIC

Pg No

Neejtech India (Niigata) ............................... 25 T: +91-9909974224 E: contact@niigataindia.com W: www.niigataindia.com Nordson X-Aloy Asia (Thailand) Ltd. ..........110 T: +91-79-40327380 E: m.sanghvi@th.xaloy.com W: www.xaloy.com Norka Instruments Shanghai Co., Ltd. ......... 99

T: +91-044-43009610

T: 1-630-467-0900

T: 86-21-6118-4181

E: fc.jayakaran@boge.com

E: gj@jacotech.com

E: support@norka.com.cn

W: www.boge.in

W: www.jacotech.com

W: www.norka.com.cn

Jingcheng Times (Beijing) Plastics Machinery Co., Ltd.......................................................... 8

Nu-Vu Conair Pvt. Ltd ................................109

C & G Extrusion Machines .......................... 87 T: +91-9272235867 E: cgext@hotmail.com

T: 86-10-5900-3588

W: www.cgext.com

E: jingcheng_times@vip.163.com W: www.jc-times.com

Continental Carbon India Ltd ...................... 85

Jyoti CNC Automation Pvt. Ltd.................... 29

T: +91-120-6721200

T: +91-2827-287081

E: rkatiyar@continentalcarbonindia.com

E: info@jyoti.co.in

W: www.continentalcarbonindia.com

W: www.jyoti.co.in

Engineering Expo......................................... 56

Kabra Extrusion Technik Ltd................... 10, 21

T: +91-09819552270

T: +91-22-2673 4822

E: engexpo@network18publishing.com

E: sunil@kolsitegroup.com

W: www.engg-expo.com

W: www.kolsite.com

Everest Blower Systems ................................ 33

L & T Plastics Machinery Ltd .................. FGF

T: +91-11-45457777

T: +91-044-26812000

E: info@everestblowers.com

E: handigolg@larsentoubro.com

W: www.everestblowers.com

W: www.larsentoubro.com

Ferromatik Milacron India Pvt Ltd ............... 23

Matsui Technologies India Ltd. .................... 34

T: +91-79-25890081

T: +91-0120-4243862

E: salesfmi@milacron.com

E: rahuldeep@mass.motherson.com

W: www.milacronindia.com

W: www.matsuiindia.in

Gardner Denver Engineered Pro. (I) ............. 18

Mifa Systems................................................ 93

T: +91-79-40089312

T: +91-79-26870825

E: info.ahm@gardnerdenver.com

E: info@mifasystems.com

W: www.gardnerdenver.com

W: www.mifasystems.com

Gem Equipments Ltd ................................... 49

N.A. Corporation ......................................... 67

T: +91-9376783206 E: salesindia@conairgroup.com W: www.conairgroup.com Piovan India Pvt Ltd .................................... 65 T: +91-22-27782367 E: amit.bajaj@piovnindia.com W: www.piovan.com Plastiblends India Ltd .................................. 45 T: +91-022-67205200 E: rsd@koisitegroup.com W: www.plastiblendsindia.com ....... Prasad Koch Technik Pvt. Ltd...........................27 T: +91-79-25830112 E: plastics@prasadgroup.com W: www.prasadgroup.com Prayag Polytech Pvt Ltd ............................... 51 T: +91-011-47262000 E: delhi@prayagmb.com W: www.prayagmb.com Procon Technologies Pvt Ltd ........................ 12 T: +91-79-27492566 E: info@procon.co.in W: www.procon.co.in Rajoo Engineers Ltd....................................BC

T: +91-0422-2363800

T: +91-79-25840374

T: +91-2827-252701

E: sales@gemindia.com

E: info@naroto.com

E: kcdoshi@rajoo.com

W: www.gemindia.com

W: www.naroto.com

W: www.rajoo.com

Our consistent advertisers

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

106 Modern Plastics & Polymers | April 2013

LIST OF ADVERTISERS

Advertiser’s Name & Contact Details

Pg No

Advertiser’s Name & Contact Details

Pg No

Advertiser’s Name & Contact Details

S&T Engineers ............................................ 73

Specific Engineering ...................................107

T: +91-422-2590810

T: +91-265-2646871

T: +91-22-25506712

E: stycm@stengineers.com

E: info@specificgroup.com

E: infomum@unimark.in

W: www.stengineers.com

W: www.specificgroup.com

W: www.unimark.in

Sacmi Engineering India Pvt Ltd .................. 52

Pg No

Unimark (Maguire)....................................... 61

Sri Sai Plasto................................................ 53

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

T: +91-7600003968

T: +91-044-42994365

T: +91-044-42077009

E: sales@negribossi.in

E: sspt_plastics@live.in

E: info@wittman-group.in

W: www.negribossi.com

W: www.srisaiplastotech.com

W: www.wittmann-group.com

Shini Plastics Technologies I Pvt Ltd............ 75

Toshiba Machine (India) Pvt. Ltd. ................ 16

Woojin Plaimm Co Ltd .................................. 5

T: +91-250-3021166

T: +91-011-43291111

T: +91-9810043265

E: jnbhat@shiniindia.com

E: dineshelija@toshiba-machine.co.in

E: in@wjpin.com

W: www.shini.com

W: www.toshiba-machine.co.jp

W: www.plaimm.com

Shree Momai Autocast Containers................ 20

Unimark (Arburg)......................................... 19

T: +91-2668-266440

T: +91-22-25506712

T: 39-0331-307-616

E: iyer@shreemomai.com

E: infomum@unimark.in

E: info@zambello.it

W: www.shreemomai.com

W: www.unimark.in

W: www.zambello.it

Our consistent advertisers

Zambello Riduttori Group ............................. 7

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

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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108 Modern Plastics & Polymers | April 2013

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