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EDITORIAL
Asia-Pacific: The emerging growth ‘moulder’ oing by the buoyancy seen in the global moulded plastics market over the recent months, it seems set on a resurgent mode! This holds especially true when one considers the unparalleled thaw witnessed in many important end-use application areas from 2008 through 2010. According to a new market research report by Global Industry Analysts, the global moulded plastics market (which provides for a wide array of user segments including construction, automotive, packaging, electrical & electronic appliances and healthcare products, to name a few) is projected to exceed 155 million tonne by 2017.
G
The report outlines some of the key demand drivers of this surge as economic revival, rise in spending power, rapid industrialisation and strong demand from end-use markets of packaging, construction and food & beverage. From a geographical perspective, it expects long-term growth stemming from developing markets of Asia, Eastern and Central Europe and the Middle East. Not surprisingly, the Asia-Pacific region, backed by strong domestic markets, would hold the largest share of the world market and is forecast to rise at the highest Compounded Annual Growth Rate (CAGR) of 4.6 per cent through 2017, as per the report on moulded plastics. Standing at the threshold of this crucial milestone is Asia - primarily driven by the burgeoning economies of India and China - which is fast becoming the new centre of balance in the global moulded plastics market. Further, plastics producers from Asia-Pacific and the Middle East are gaining marketshare as the traditional leaders in North America, Japan and Western Europe face increasing pressure from the former in terms of production, price and placement.
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
A deeper analysis reveals an emphasis on expanding the production capabilities in the emerging markets of the moulded plastic products, with a growing focus on the export markets. Out of these, the Middle East is likely to garner nearly half of the new capacity additions during the next five years, and thus, emerge as the world’s leading supplier of polypropylene. In brief, amid swift shifting of global production bases to low-cost Asian countries, increase in foreign investments and rise in the number of new manufacturing establishments, Asia-Pacific is all set to ‘mould’ the growth story of the world in the mediumto long-term period. The question is how much of these India can leverage.
Mohan K Jain MD, Indoplast & Past President, AIPMA
P P Kharas Chairman, Ecoplast
Raman M Patel
Manas R Bastia manas@infomedia18.in
Chairman, Industrial Products Mfg Co
Vijay Merchant President, Polycraft
August 2012 | Modern Plastics & Polymers
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CONTENT S
41 Special Focus
Masterbatches and additives .. 42
Masterbatches & Additives
Quality matters ...................... 44
57
Plastics in paints and coatings ................... 58 Powder coating technology .................... 60 Interface:
Plastic pigments ..................... 46 Interface: Chris Wall ............. 48
Insight & Outlook Paints & Coatings
Roundtable ............................. 52
Geert Hofman ................................ 64 G D Barot ...................................... 66 Polymer compounding ........................... 70 BOPP packaging .................................... 74 Case Study ............................................. 78
February August 2012 | Modern Plastics & Polymers
41
Automation Trends
80
Thermoforming robotic stackers: Key to efficient material handling
Energy Management
84
Hot runner systems: Investing in innovation, harvesting efficiency
Policies & Regulations
88
Import duty on titanium dioxide: Opening trade avenues for Indian industry
Strategy
92
Masterbatch processing units: Preserving quality, preventing contamination
Tips & Tricks
96
Plastic packaging: Steps to boost barrier performance
In Conversation With
80
38
Raman Trikala President and MD, Wacker Chemie India Pvt Ltd
54
Blend Colours Pvt Ltd: Blending quality with innovation
84
Highlights of Next Edition Special Focus: Blow Moulding Insight & Outlook: Plastics in Home Applications
REGUL AR SEC T ION S Editorial ................................. 7 News, Views & Analysis ...... 20 Technology & Innovation .... 29 Technology Transfer ............. 34 Projects ................................. 98
Tenders ............................... 102 Event List........................... 104 Book Review ...................... 106 List of Products.................. 120 List of Advertisers .............. 123
Facility Visit
Cover photo courtesy: Novosystems GmbH Note: ` stands for Indian rupee, $ stands for US dollar and ÂŁ stands for UK pound, unless mentioned otherwise
Details on pg no. 104
August 2012 | Modern Plastics & Polymers
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August 2012 | Modern Plastics & Polymers
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MPP Tab 1 Aug 2012 Ad Name: Alok Pg No. 13
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NEWS, VIEWS & ANALYSIS
Implementation of on-line particle size analysis
A new white paper from Malvern Instruments examines the different strategies open to those adopting on-line particle size analysis, providing guidance on its design and implementation and highlighting the economic & practical benefits of selecting a suitable approach to the project. The proven ability of on-line particle size analysis to transform process control and deliver substantial economic benefits has resulted in its widespread application across industries. Typically, the installation of on-line particle size analysis involves a number of steps, including h ardw are sel e ct ion , process interface design, automation and integration within an existing control platform, validation and commissioning & control optimisation. Taking each project element in turn, this document looks at when each might be handled internally and, more importantly, where external support can be useful. 20
Evolving standards for plastics in food packaging
been having a lackadaisical approach towards setting standards.” Food Safety and Standards Authority of The FSSAI has issued guidelines for India (FSSAI) is working on a mechanism plastic packaging companies to ensure to evolve standards for plastics used in higher barrier properties for food items to be packaging domestically transported over long distances. consumed food items R Mathurbootham, Advisor, imported f rom abroad. Regulatory Affairs, ITC Ltd, Dr K Chandramouli, said, “Food packaging safety is Chair person, FSSAI, as important for exporters as it is said, “Our food exporters for importers. We must use the adhere to various stringent right labeling technology in food set of rules and regulations packaging to prevent piracy and for exporting food, while fraudulence. Plastics used in food Dr K Chandramouli we do not stress on similar packaging has a wider scope than stringency on imported food packaging. metals for safety prerogatives in the form of Thus, it is imperative to evolve standards for labels and bar coding.” domestically consumed food, since we have Anwesh Koley
Americhem applauded for its photochromatic ‘blushing bottle’ technology Americhem Inc, a global provider of custom colour and additive solutions for polymeric products, received an honourable mention from New York-based global materials consultancy Material ConneXion for its photochromatic ‘blushing bottle’ technology. As one of the nine companies selected for the third annual award, the Medium Award for Material of the Year recognises materials entered into the library within the last year. This demonstrates technological innovation and the ability to positively impact and advance design, industry, society & the economy. In 2011, Americhem was selected to showcase its photochromatic ‘blushing bottle’ technology at Material ConneXion. The bottle is designed to change colours, or blush,
PolyOne Corporation to expand via ColorMatrix in Africa ColorMatrix, a subsidiary of PolyOne Corporation and a leading innovator of liquid colour and additives for plastics, plans to open a new facility in Africa. The new facility will be located in the Montague Gardens industrial precinct in Cape Town, South Africa, and is expected to open in August 2012. Services will include sales, technical support and an on-site colour laboratory for rapid colour development. The immediate focus of the operation will be to deepen support for customers who manufacture products such as
Modern Plastics & Polymers | August 2012
when exposed to Ultraviolet (UV ) light. Chosen for the display, a Boston round bottle changes colours in direct sunlight via a thin outer layer made of thermoplastic elastomer that incorporates a UV-sensitive pigment. Bill Podojil, General Manager - Plastics, Americhem Inc, said, “We are honoured to be recognised for this photochromatic technology. We are dedicated to providing our customers with technical innovation, and this award is an example of Americhem’s innovation in action.” A m e r i c h e m’s photochromatic masterbatches can be used on portions of a package or on the entire package. Additionally, the technology enables customers to customise the colours of each bottle before and after exposure to UV light. Anwesh Koley polyethylene terephthalate containers for the beverage and personal care markets. “When PolyOne acquired ColorMatrix last year, we committed to a global ‘invest to grow’ strategy to add value to our customers and shareholders. Our new facility in South Africa illustrates our commitment to this strategy. While these operations will initially focus on ColorMatrix products and services, it affords us an excellent foothold to leverage other PolyOne businesses and services in the region in the future,” said Robert M Patterson, Executive Vice President & Chief Operating Officer, PolyOne Corporation.
NEWS, VIEWS & ANALYSIS
BASF unveils Sustainability Report 2011 at panel discussion on Sustainability & Corporate Reporting
UNP Polyvalves inaugurates its new plant
(L–R): Santhosh Jayaram, Det Norske Veritas AS; Prasad Chandran; Bhaskar Chatterjee, Director General & CEO, Indian Institute of Corporate Affairs; Annapurna Vancheswaran, Director-Sustainable Development Outreach, TERI; and P D Jose, Associate ProfessorCorporate Strategy & Policy, IIM-Bangalore
For discussions on key issues, challenges and benefits of sustainability & corporate reporting and share best practices in reporting, BASF India conducted a panel discussion in association with The Energy and Resources Institute’s Business Council for Sustainable Development (TERI BCSD). Prasad Chandran, Chairman-BASF Companies in India & Head-Asia, said, “Attracting new investments in the private sector dependents on conformance to environmental, social and governance factors. In this context, sustainability reporting responds to the pressing need for improvements in corporate transparency and helps restore trust in the private sector.” At the forum, BASF also published its 2011 sustainability report based on its performance in three dimensions of sustainability – economic, environmental and societal. In its third year of publication, the BASF India Report documents business highlights, sales and employee figures, environmental data, social & educational initiatives undertaken and awards & recognition achieved in 2011.
Plastic packaging market to reach $ 28 million by 2014 Considering the growing demand for plastic packaging, the market is expected to reach $ 28 million by 2014. In a conference organised by Indian Plastics Institute, Ahmedabad, Pramthesh Pandya, Head-Unit & Business Development, Parikh Packaging Pvt Ltd, stated, “The demand for plastic packaging has increased recently as customers are
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To meet the growing demand of corrosion-free valves, pipes and pipe fittings manufactured with advanced engineering plastics, ie, fluoropolymers & thermoplastic, UNP Polyvalves has set up another manufacturing facility in the Makarpura Gujarat Industrial Development Corporation (GIDC), Vadodara, Gujarat. Urmil Shah, Director, UNP Polyvalves (India) Pvt Ltd, said, “We already have two plants in Makarpura GIDC, and this is the third plant of the company. With this, we aim to increase our production capacity by 35 per cent. The total constructed area is about 14,000 sq ft. Considering the space constraints, the manufacturing facility will be divided into three floors, ie, ground plus two floors.” He added, “The demand for these types of valves is majorly in the chemical and petrochemical segment, as these are mainly used for corrosive applications in industries.” The company has been providing solutions to almost every leading chemical and petrochemical giant in India and is also exporting to other countries. It has a wide product range in valves comprising ball, diaphragm, butterfly, ball check, foot, sight glass, sampling, strainers, lined valves, pipes & fittings, etc. Avani Jain
shifting from rigid to flexible packaging. This is because plastics is more cost effective than conventional materials like glass, metal, etc and can be easily processed. Also, due to opening up of lot of untapped areas in food packaging segment, the demand for plastic packaging is increasing. The growth in the pharmaceutical packaging segment has also given a boost to the plastic packaging industry.
Modern Plastics & Polymers | August 2012
Energy-saving recycling solutions
Sikoplast – German plastics recycling company – has introduced its ‘In-Line Recycling process, which aims to achieve material and energy savings in the plastics processing industry. An essential element in the Sikoplast recycling extruder, and a major factor in its success, is the design of the conical feed zone in combination with a single screw. In standard off-line recycling extruders, the complete recycling machine is autarkic, with any plastic scrap input and an output of re-granulates. With this extruder, any grinding process can be saved and combined with dust elimination. It offers low investment costs compared to any off-line execution and up to 50 per cent energy saving. From the operation point of view, the scrap portion increases due to no dust and melting process occurs without oxygen contact. The arrangement reduces space requirement and makes any retrofitting of existing lines possible. It is also possible to make short switches over time between various products, as it directly feeds the melt into the production extruder. On the ban on plastics for tobacco packaging, he said, “This step is taken by the government to indirectly ban the usage of tobacco and will not affect the plastic packaging industry.” He believes that there is huge potential for plastic packaging in India, and one should not say no to plastic packaging, instead find better solutions to save the environment. Avani Jain
NEWS, VIEWS & ANALYSIS
Indian SMEs to participate in Canton Fair in China
(L-R): Rupen Vikamsey, MD, Orbitz Corporate & Leisure Travels (I) Pvt Ltd; Deng Lizhou, Deputy General Manager, Personnel Department, China Foreign Trade Centre; Sanjay Bhide, Convenor & Secretary, Trans Asian Chamber of Commerce & Industry; Niu Qingbao; Suresh Sharma, Vice President, ICECC; Chandrakant Salunkhe, President, SME Chamber of India; and Liu Guoyu, Economic and Commercial Counselor, People’s Republic of China, Mumbai
Despite the sluggish global economy, the vibrant growth opportunities in emerging markets of India and China will be showcased at the Canton Fair – a biannual event – held in Guangzhou,
and is the largest and most comprehensive trade fair in China. It has the broadest distribution of overseas buyers and records an encouraging business turnover from the global industry despite the Euro debt crisis. The previous hosting of Canton Fair in April 2012 attracted over 200,000 buyers and achieved a staggering business turnover of $ 37.9 billion. India’s presence at the fair has been steadily growing with about 9,000 buyers out of a total of 220,000 in the previous edition, which is expected to significantly increase this year. Boosted by China’s promise to open its markets further to foreign goods, and encouraged by the purchasing zeal of Chinese consumers, Indian companies are excited for the prospects of the market. A recently held press conference to introduce the event to the Indian industry was attended by dignitaries and eminent personalities from the corporate world and trade associations,
Technical Seminar on ‘Advancements in Flexible Packaging’ by IPI
(L-R): Atul H Kanuga; Subodh Goel, Regional Manager-Polymers Business (West Zone), Indian Oil Corporation Ltd; Rajiv Vastupal; Rajiv Trivedi; Sunil Jain, President, Rajoo Engineers Ltd; Tushar Parikh, Vice Chairman-IPI Ahmedabad Chapter
To tap new trends in the flexible packaging segment, Indian Plastics Institute (IPI)-Ahmedabad Chapter organised a Technical Seminar on ‘Advancements in Flexible Packaging’. Rajiv Vastupal, Chairman & Managing Director, Rajiv Petrochemical Pvt Ltd, was the Chief Guest for the event, while Rajiv Trivedi, Chairman, IPI-Ahmedabad Chapter delivered the welcome address. The speakers presented on various subjects such as emerging trends/new applications in flexible packaging, cost-effective blown-film technology, flexible packaging processes and economy through automation by auxiliary equipment in blown film. The participants included students as well as industry associates. Atul H Kanuga, Vice President, IPI-Mumbai Chapter, and Partner, Sudeep Industries, said, “The demand for flexible packaging is increasing and there is a lot of innovation in this field. We wanted students as well as the industry to become aware of these.” Avani Jain 24
Modern Plastics & Polymers | August 2012
including Vijay Kalantri, President, All India Association of Industries (AIAI), and Ashish Pednekar, President, Maharashtra Chamber of Commerce, Industry & Agriculture (MACCIA), to name a few. The 112th edition of the Canton Fair will commence in three phases of five days each – Phase 1 (October 15-19, 2012), Phase 2 (October 23-27, 2012) and Phase 3 (October 31, 2012-November 4, 2012). It will be co-hosted by the Ministry of Commerce, China, and People’s Government of Guangdong Province, and organised by China Foreign Trade Centre. Niu Qingbao, Consul General, Embassy of People’s Republic of China, Mumbai, said, “With the establishment of China-India strategic and cooperative partnership for peace and prosperity, recent years have seen a frequent exchange of high-level friendly visits, resulting in business partnerships.” Annabel Dsouza
Co-rotating twin-screw extruder by HPMC Hindustan Plastic & Machine Corporation (HPMC) has introduced its co-rotating twin-screw extruder in India. These extruders, mainly used in plastics and polymer applications, have penetrated several different niche markets. Some of their applications are direct compounding, producing masterbatches, plastic alloys, polyvinyl chloride soft cable grade compounding, in-line compounding, natural and wood fibre composites and recycling using side feeder of the co-rotating twin-screw extruder. Calcium carbonate can be filled in the extruder upto 80 per cent and glass fibres can be filled up to 60 per cent without compromising on the quality of end product. This feature reduces the cost of raw material significantly. In the plastics recycling industry, the use of co-rotating extruders is becoming more of a preferred solution as
compared to traditional technologies (eg, single-screw extruders) in encountering most of the challenges faced by plastics processors. Poonam Kalra, Director, HPMC, said, “These specially designed extruders use a particular degassing and filtering system for treatment of demanding scrap materials that are treated to obtain quality materials ready for new applications. It is a highly efficient machine, as it reduces the cost of production considerably. It has independently controlled vacuum unit, haul-off and cutting unit for each pipe, enabling smooth production of four pipes of different sizes & weight simultaneously.” Anwesh Koley
NEWS, VIEWS & ANALYSIS
Solutia, Sinorgchem and KKPC resolve patent dispute Solutia Inc, Jiangsu Sinorgchem Technology Co Ltd and Korea Kumho Petrochemical Co Ltd (KKPC) have reached a global settlement to resolve all disputes among them involving Solutia’s process patents to produce 4-Aminodiphenylamine (4-ADPA), a chemic al intermediate used to make rubber anti-degradants. Under the terms of the settlement, Solutia grants Sinorgchem and KKPC licence to manufacture 4-ADPA under Solutia’s patents, which will expire after 2019. As licensees, Sinorgchem and KKPC are also granted certain rights to enforce those patents. Rich Altice, President and General Manager, Technical Specialties Division, Solutia, said, “The settlement of these long-standing disputes is a milestone for Solutia and its Santoflex anti-degradant business. We remain committed to using our innovative chemistry to provide value to our customers and shareholders, as well as to protecting our intellectual property rights.” Stephen Choi, Chief Executive Officer, Sinorgchem, commented, “We are pleased to resolve this issue is resolved and put the dispute behind us. As a leading rubber additives producer, we will continue to use technology to provide our customers with greener chemicals.” Further, SungKyu Lim, Senior Executive Vice President, KKPC’s Sales Division, said, “With a focus on our core values of passion, innovation, collaboration and responsibility, we will continue to take initiative in providing world-class products & services to our customers.”
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Anti-microbial masterbatches from Alok Masterbatches Alok Masterbatches Ltd has developed AddNox Tm-Antimicrobial masterbatch that can inhibit microbial growth over plastics and will be effective against Fungi, Yeast, Algae and Bacteria. Applications for this additive include blow-moulded containers of food & pharma packaging, toothbrush handles, medical gloves and face masks, crates, water supply pipes & storage tanks, refrigerator gaskets and sanitary products. The addition level of the same will be 1-1.5 per cent. Such additives in plastics processing have become necessary, as the requirement of safe plastics is increasing. Antimicrobial masterbatches will help in gaining the confidence of end user and
Clariant offers India’s emerging markets sustainability support
Dr Dileep M Wakankar
Clariant urged India’s colourant and personal care industries to improve their business sustainability by considering current trends and preparing for the future, at Federation of Indian Chambers of Commerce’s (FICCI’s) recently concluded ‘Specialty Chemicals Conclave 2012’ in Mumbai. At the Conclave,
Reifenhauser showcases new blown film lines Reifenhäuser Kiefel Extrusion recently displayed the latest technology in blown film extrusion at its state-of-the-art technology centre in Troisdorf. About 140 visitors from over 20 countries from DRUPA – the world’s most important trade show for the printing, paper and converting industries – attended the world of complex plastic film technology and were impressed by the flexibility of the blown film lines from the new generation of blown film technology.
Modern Plastics & Polymers | August 2012
promote the use of plastics as they provide excellent antimicrobial performance, which has no adverse effects on physical properties and remain effective for the lifetime of the product. Amit Singh, Senior Manager (Business Development), Alok Masterbatches, said, “Such masterbatches protect plastics from microorganisms, eg, bacteria, algae, fungi, mould, etc. These can also be used to protect the polymer surface, such as from staining and degradation by microorganisms, and can be instrumental in providing hygienic & health benefits by controlling or decreasing the amount of microorganisms at the polymer surface.” Generally, end user applications include construction products, consumer/household goods & to medical/healthcare. Anwesh Koley Dr Dileep Wakankar, Head of Product Stewardship India – Clariant Chemicals (India) Ltd, delivered a lecture on ‘Pigments – Regulatory issues’. Besides indicating the importance of colourants in everyday life, Dr Wakankar covered the environmental implications associated with selected colourants, and gave global illustrations of regulations affecting food contact & packaging inks. He briefed the audience about European, American and Chinese regulations and outlined differentiation with India’s current restrictions. “It is only a matter of time until similar regulations are enforced in India. To ensure sustained business, India’s colourant industry needs to prepare itself for compliance with such regulations,” said Dr Wakankar. Lionel Alva Today, DRUPA is not only the leading forum for the printing industry, but covers all publishing technologies and processes in a global context related to the flexible packaging industry as well. The Düsseldorf show attracted about 350,000 visitors, most from the plastics and packaging industries. The versatility of plastic materials has an essential influence on packaging technologies, and the advantages these offer are of great importance not only for the visual appearance of food packaging, for example, but are also indicative of the quality of its content.
TECHNOLOGY & INNOVATION
New foam sheet die eliminates spider weld lines
Davis-Standard LLC has introduced a spiderless foam sheet die for processing polystyrene and polyethylene. The new die is capable of producing an extensive range of sheet thickness, width and density. It is also engineered to reduce downtime and maintenance while offering precision capabilities to improve quality and efficiency. The spiderless die eliminates spider weld lines and provides a uniform basis weight and thickness over the entire width of the sheet, thus eliminating the need for edge trim. It also has a unique mechanism to adjust die-lip gap opening and closing, enabling the operator to make modifications during production without stopping the sheet line. This control is enhanced by an external die-lip concentricity adjustment. Other features include streamlined flow channels, upto three zones of temperature control, nickel plating on all wetted surfaces and aluminium constructed internal and external air rings. Modular die-lip inserts allow for easier, inexpensive replacement of a damaged or alternative lip die design. A die lip fast gap allows for quick cleaning of contaminants. The company offers die designs in thicknesses from 0.04 inch to 0.5 inch, and widths from 24 inch to 120 inch.
New moulding machine for packaging KraussMaffei offers MX 650+ model to meet the specific needs of the packaging industry in terms of high cavitations and heavy moulds. Injection rates up to 700 mm/sec are possible, and the machine satisfies the demands for high flexibility in mould variant management. The new machine size extends the clamping force rating spectrum of the MX Series below the MX 850, so far the smallest machine. Optional bracing of the centre platen on the machine bed relieves pressure on the tiebars and mould guides when stack moulds are used. Multi-cavity moulds are used primarily for screw closures and sealing
Advanced pipe coiling & delivery system from PCT PCT has introduced a unique pipe coiling and delivery system that provides the ability to coil pipes PE100 up to DN250 x 250 m without vehicle escorts. PCT’s well-established Low Ovality Coiling Technology has been combined with their newly developed, unique multitrailer road train design, which enables pipe manufacturers to deliver 3 x 250 m coils of DN250 in one delivery. The trailer design also allows free-standing coils or reels of pipe to be dispensed via the builtin roller supports. This is only possible with the use of Low Ovality Technology coiling machinery that allows the pipe to
Light-weight polymer alloy for automotive industry A new material combines an ultra-smooth surface and exceptional dimensional precision – Panlite AM-9937F, has been unveiled by Teijin Chemicals – specifically for automotive applications. This is a light-weight polymer alloy, which is a combination of the company’s own polycarbonate Panlite and polyester resin.
caps. Since short cycle times are demanded, MX 650+ specifically complies with these demands and offers high performance with a compact installation area. The new machine is characterised by high plasticising capacity and energy efficiency from the electric screw drive. HPS-UN plastification, configured especially for the polyolefins used in the packaging industry, is said to produce high specific melting capacities and a uniformly high melt quality at low melting temperatures. Thus, dynamic qualities of the clamping unit are fully exploited with the processor benefitting from short cycle times, quality of moulded parts and long-term production security. be coiled at these tighter bending ratios. Smaller pipe sizes can also be coiled and transported, eg, the three trailers would carry over 1 km of DN180 in three lengths with less than 5 per cent pipe ovality occurring. Coils can be unloaded on-site or alternatively, each trailer can be dropped at points equal to the pipe coil length ready for an on-site tow vehicle to lie out. Either way, this provides the ability to string out and onl y make t h re e butt welds before a string of pipe is ready for installation as compared to having to make 20 times the number of welds if the same pipe (DN250) is delivered in 12-m stick lengths. Main features of the material include flexibility in design, mouldability, high resistance to corrosion, heat and impact, and a low linear expansion coefficient. Automobile manufacturers are provided with an option to minimise the weight of components by about 20 per cent with the new material. Panlite AM-9937F has been used in the LEXUS HS250h hybrid sedan’s luggage door garnish.
August 2012 | Modern Plastics & Polymers
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TECHNOLOGY & INNOVATION
Clariant introduces soyabean oil-derived PVC lubricant
Lybra LGR dosing unit from Piovan
Licocare SBW11 TP is a chemically modified wax that offers technical performance in PVC processing superior to fatty acid esters or complex ester mixtures traditionally used for lubrication. It is suitable for processing of rigid Polyvinyl Chloride (PVC) compounds, especially for calcium/ zinc- and tin-stabilised photovoltaic film & extrusion applications. The lubricant has several performance benefits, eg, better Piovan has launched Lybra LGR – new masterbatch metering unit for Polyethylene Terephthalate (PET ) applications, configured for continuous weight-loss Gravimetric (LG) or Volumetric (LV ) operation. Its distinguishing features are high level of accuracy, advanced control and simple user interface. The unit can accommodate up to two independent dosing stations, which can even be of different capacities and be retrofitted to meet changing production needs. Each dosing station can be configured for individual capacities ranging from 1 gm/sec, up to 170 kg/hr. Lybra is equipped with a 7-inch touchscreen human-machine interface and is connected to external supervision systems. Each dosing station comprises a hopper containing the granules to be dosed and is equipped with a proprietary loss-in-weight control to measure the amount of material carried by the dosing screw to the PET mainstream. The dosing auger is available in three different configurations with single, dual or triple helical shaft, for controlling material dosing in low percentages with high accuracy and repeatability.
Monitoring PET quality in real-time in processing Processing Technologies International has launched a real-time Intrinsic Viscosity (IV ) monitoring system designed to deliver better quality assurance and potentially lower costs for polyethylene terephthalate sheet production. The system allows for material formulation 30
New Borealis polypropylene grade Borealis has launched a unique, high stiffness Polypropylene (PP) grade Bormod™ BH381MO to support manufacturers of industrial pails in meeting their increasing sustainability and product quality goals. New heterophasic copolymer uses Borealis Nucleation Technology (BNT) to achieve a one-of-a-kind balance of excellent stiffness, flow and impact. The PP grade has a Melt Flow Rate (MFR) of 35, which behaves like traditional MFR 45 grades. At the same time, its stiffness level (tensile modulus) of 1,700 MPa is more than 150 MPa higher than that of standard MFR 30 grades, yet with the same impact performance of softer grades. The higher stiffness performance is maintained in hightemperature environments. The combination of characteristics allows for lower processing temperatures and lower injection pressure including the possibility to fill more complex parts. It also
(recycled, virgin or post-consumer) to be adjusted online in order to maximise product performance. The real-time monitoring system is an invaluable process tool since it identifies process deviations online so that they can be corrected to maintain consistent and efficient production. The IV monitoring system works from precise measurements
Modern Plastics & Polymers | August 2012
release and anti-sticking property, no mould deposits due to low volatility and good compatibility with PVC, excellent thermal stability ensuring stable colour, etc. It produces balanced rheological behaviour in material and effective performance at low dosage (0.3-1.0 parts per hundred). It can also be used as a lubricant in PVC injection moulding. Here, the flowability is significantly improved with less influence on the Vicat softening temperature than that of traditional lubricants.
supports easier de-moulding. This creates a spectrum of productivity and associated environment-related advantages for converters within a one-material solution. These include 10-20 per cent reduction in cycle time, with shorter cooling times, possibilities of downgauging and weight reduction, energy & cost savings through low-temperature processing and low injection pressures as well as faster cycles, reduced carbon footprint from less energy consumption and good stacking & drop performance for finished pails of all sizes. of melt temperature and capillary piping pressures. These results are benchmarked against ASTM D4603-86 standard test method for measuring IV. It claims an accuracy of Âą0.02 decalitre per gram. The new system offers distinct advantages over offline solution test methods since these are time-consuming and slow to deliver results.
MPP Aug_2012 Ad Name: Everest Tab-2, Pg No. 31
WITTE
MPP Aug_2012 Ad Name: Goodie Tab-2, Pg No. 32
TECHNOLOGY TRANSFER
Technology Offered As part of our endeavour to spread the technology culture, this section provides a means to promote and facilitate exchange of select technologies. We strive to bring together suppliers of such technologies with suitable users for negotiations and industrial collaboration. Biodegradable polymer The biopolymer nanopartic le technology is based on cost-effective biodegradable and biocompatible polyolefins, copolymer of ethylene & vinyl acetate and Thermoplastic Starch (TPS) blend nanocomposites. These nanocomposites have improved mechanical properties with zero moisture content.
Areas of application Packaging materials, disposable nonwovens, hygiene products, consumer goods, agricultural and horticultural tools and medical
lightguide fibres and handicraft articles made from it. Plastic lightguide fibres are cylindrical fibers with core-clad structure made of two highly transparent polymers, the advantages of which are excellent light transmission, good toughness, light weight & easy to process and use.
(2,000-1,50,000 TPA) and film grade polyester plant (2,000-1,50,000 TPA).
Areas of application
An Indian plastics processing machinery manufacturer is offering screws and barrels for all plastic extruders. The company also repairs worn out equipment. The products are highly energy efficient for washing and drying all types of recycled plastic components.
Photoelectric switches, photosensitive elements, linear accommodation networks, short-distance optical communications, and medical & dental devices
Forms of transfer Technology licensing and equipment supply
Forms of transfer Technology licensing
Conversion of batch-poly plant to C P plant A company from China is interested in providing consultancy for the modification of batch-poly plant to C P plant like polyester plant, polyester chip or direct spinning.
Areas of application Forms of transfer Sub-contracting, turnkey, etc
Turnkey
Plastic recycling technology This technology uses a mix of synthetic urea, ammonium carbonate and ammonia. This chemical mix is used in the treatment of recycled plastics.
Areas of application Plastic compounding and recycling
Areas of application
Forms of transfer
Chemical fibre and plastics
Technology licensing
34
Forms of transfer Sub-contracting, turnkey, etc
Waste plastics conversion This company offers plant technology for converting non-recyclable waste plastics into industrial fuel, which is more sustainable as compared to conventional industrial fuels such as furnace oil or light diesel oil. The company supplies technology to serious clients who would like to get their waste plastics tested at a demo plant. The plant can be custom made for specific requirements. Municipal bodies, industries involved in generation of non-recyclable plastic scrap, plastic scrap dealers who have access of nonrecyclable cheap plastic scrap and entrepreneurs are encouraged.
Areas of application
Forms of transfer
A Chinese R&D institute offers to supply the technology of plastic
Processing machinery
Plastics, textiles, etc
Forms of transfer
Plastic light guide fibres
Technology licensing and turnkey
Areas of application
Plastics, textiles, etc
Turnkey
Forms of transfer
An Indian company offers pilot plants for laboratory or small-scale production purpose. The plant consists of a spinneret, metering pump, spinning beam, candle filter, extruder unit, godet unit, single-screw extruder machine and melt flow index tester machine.
Chemical fibre and plastics
A Chinese company is interested in offering small capacity technology for a wide variety of plants such as polyester plant, polyester chip or direct spinning.
Polymerisation and fibre lines
Plastic additives processing
Areas of application
Pilot plants for small-scale production
Areas of application
Polyester chip plant A company from China offers polyester production plant, polycondensation plant, polymerisation line, hot melt adhesive plant (500-5,000 TPA), polyester chip plant
Modern Plastics & Polymers | August 2012
Plastics scrap recycling for inductrial fule generation
Forms of transfer Consultancy, joint venture, technology licensing, turnkey
TECHNOLOGY TRANSFER
Technology Requested Disposal & recycling of plastic waste
Polyacetal resins
Forms of transfer
A Polish firm seeks the technology for dry processing of all kinds of plastic waste or a magnetic processing method in the electrostatic field. The technology should allow sorting of all kinds of plastic materials, hay-silage foils, PET, HDPE, PVC, etc, by excluding dangerous waste.
A Gulf-based organisation wants to promote projects in the chemicals and petrochemicals sectors in GCC countries. It is looking for technology suppliers for the manufacture of polyacetal resins.
Others
Areas of application
Feasibility study, know-how, equipment, turnkey plant, joint venture
Plastics industry, waste recycling, waste management
Areas of application Chemicals/petrochemicals industry
Forms of transfer
Forms of transfer
Plastics recycling technologies
Others
A Sri Lankan company is seeking latest plastics recycling technologies for automatic sorting, washing, metal detection, granulation process system, washing plants, crushers, extruders, etc.
Lab-scale non-woven and monofilament plant An Indian company is looking for a lab-scale, non-woven and monofilament plant in a single station.
An Indian company requires the technolog y to make materials by transforming waste plastics, which can gel uniformly with road materials. This is for filling potholes in roads. It also needs the know-how regarding products that are made f rom waste plastics, eg, jumble strips, speed breakers, etc.
Areas of application Road transport
Forms of transfer Others
Areas of application Plastics recycling
Areas of application
Forms of transfer
Plastics
Others
Forms of transfer Others
Road filling materials for road maintenance
Recycled PET polyester polyols plant
Utilisation of natural rubber in asphalt A Pakistan-based company needs know-how on utilisation of natural rubber in modified asphalt covering. It requires standards and specifications guiding the use of natural rubber in modified asphalt; appropriate proportion of natural rubber in mixture & handling of the operation; additives needed; and details of improvement in the asphalt properties by using natural rubber.
Plastics recycling
A Poland-based company specialising in recycled PET polyester polyols manufacturing is looking for an alternative proposal of design and engineering of bigger (approximately 25 ktpa) production plant. It plans to start with delivering proper, quality recycled PET flakes in big bags. So, the company needs a complete package offer for this service.
Forms of transfer
Areas of application
Forms of transfer
Others
Plastics and polymers industry
Others
Plastics recycling technologies A Sri Lankan company is seeking latest plastics recycling technologies for automatic sorting, washing, metal detection, granulation process system, washing plants, crushers, extruders, etc.
Areas of application
Areas of application Rubber industry
Information courtesy: ^ _ != ( % ` ' ` +j` ; _` < ! ; ^ ' _ k \ z _ { _ j ^ ; ^ ^ ; _` < ! ) zj;;* ^ } [_ _ ' _ < j ^ ` z _ { _ )} ['j z* zj;; ~ < j+/ < ( <` > > O ; <= > +?>ZQ ?QÂ&#x20AC; )( _ * > +?>ZQ ?Q > )~ * X Y= > + /O Â&#x20AC; O/QJ [ <= ` ] 5 = 5 \_ 5 X ^ _` < ! ^^ Â \< < 5 _` < !J 5 ` ! _ _ < 5 ;` ^ ^ 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.
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 and Polymers ! " # % ' ( ) * +/ 5 ; <= >//+?>>? JOQ V X Y= >//+?>>? JJZZ V [ <= \ ] ^ 5
36
Modern Plastics & Polymers | August 2012
IN CONVERSATION WITH: Raman Trikala
“Quality, innovations and expertise are key to long-term
success”
…says Raman Trikala, President & Managing Director, Wacker Chemie India Pvt Ltd. With experience gained over two decades in the global specialty chemicals industry, Trikala shares his insights into innovations for the paints and coatings industry in India. In an exclusive conversation with Annabel Dsouza, he emphasises the need for green consciousness in the paints and coatings industry.
38
Modern Plastics & Polymers | August 2012
Raman Trikala
What are the growth trends in the paints and coatings industry in India? The Indian paints and coatings industry is expected to grow strongly with projected growth rates at double digits in the next five years. Accordingly, the demand for high-quality and state-of-the-art chemicals is also increasing. Chemical products for advanced paint and coating applications are a major growth driver in this industry. Although these products are currently just starting to raise their profile in emerging economies and developing countries such as India, in the long term, the additional investment will pay off due to quality and durability. After all, quality, innovations and expertise are key to long-term success – and India is no exception.
What are the leading innovations in this industry today? The current trend is to develop reliable, high-quality and high performance solutions for increasing technological demands of the future. The importance of top-quality and cutting-edge base materials is growing constantly – globally and in India. While using local raw materials, it is important to customise products to local needs as well as the regional climate. Attention is being paid to compliance with global codes of practice, as well as to sustainability, user-f riendliness and materials’ environment compatibility & energy-saving potential. Hence, the industry’s Research and Development (R&D) is increasingly focussing on solutions that meet customer needs and key social responsibilities.
How has been Wacker’s journey in India’s paints & coatings industry? Wacker is not new here. We have been supplying chemical products to India since the 1970s. With modest beginnings, today, we have established a strong foothold in the Indian paints & coatings market. The reason is simple; this sector is increasingly in need of highly specialised and technologically
sophisticated chemical solutions, and Wacker is capable of offering these. We have added a lot of value to the Indian community by bringing in chemicals that are used as modern additives in many applications. We are also introducing new technologies such as Vinyl Acetate-Ethylene Copolymers (VAE). These polymeric binders enable the formulation of high-quality interior paints with low odour and reduced emissions. A big step was the establishment of our Technical Center in Mumbai. With our global network of technical facilities, we actively participate in drafting and realising new processing & quality standards. This is important as industry needs vary with culture, climate and the available raw materials. But, given the growth potential in India, this is just the beginning. And we are confident that we can continue to leverage the potential that India offers.
What are the cost-quality pressures facing this industry in India? On one hand, top-quality and cuttingedge materials are becoming increasingly important for India, but demand for advanced chemical products is influenced by higher costs involved. Hence, there is a trade-off here. The focus is now more on efficiency, durability and quality of materials. Still, costs always matter. And here, our VAE products score – the high price of crude oil and lack of supply security following the switch from oil to ethane by American crackers have prompted many manufacturers to turn from products based on styrene butadiene or styrene acrylates to lower-priced VAE dispersions. This trend will continue in India as well.
How has this industry evolved towards sustainable manufacturing? Today, the paints and coatings industry is attaching greater importance to products & processes that significantly contribute to sustainability issues such as reducing emissions, energy efficiency or climate protection. But this is more than just a
current trend. This is also the basis for long-term business success. For instance, environmental and safety concerns related to interior paints & indoor emissions are rising globally. Hence, high-quality binders based on VAE are gaining significance. Specific VAE emulsions are manufactured without using plasticisers, solvents, formaldehyde donors or alkylphenol ethoxylates. Adding to their reduced environmental impact, VAE emulsions can fulfill higher application and performance demands. As a result, these products pave the way for efficient, highquality, low-odour indoor paints, which is the reason for their current success. In future, paints and coatings products not only need technological advances, but must also address ecological and sustainability issues to be successful in the long run.
How do you see the future of paints & coatings in India? What is Wacker’s growth strategy for this market? India is a large and fast growing market. That is why India is an integral part of our global expansion strategy. We are ready to seize these opportunities and participate in future growth. Our Mumbai Technical Center with its training facility, the Wacker Academy, plays a key role here – highly specialised, technologically sophisticated chemicals require profound technical expertise for the correct use and application. Altogether, our approach to India is long-term and strategic.
What has been the most challenging phase of your career and what is your message to the industry? One of the constant challenges has been to keep up the Wacker competitive edge and create value in world markets. I would urge the emerging industry in India to look at the big picture of global mega trends and seek opportunities to create sustainable value through innovative products and business models. Email: annabel.dsouza@infomedia18.in
August 2012 | Modern Plastics & Polymers
39
SPECIAL FOCUS
Masterbatches & Additives Masterbatches and additives: Adding vibrance to the plastics growth story ........................................................................................ 42
Quality matters: Capitalising on product differentiation .................................................................................................. 44
Plastic pigments: Deciphering the colour dispersion code Surinder Minocha, Managing Director, Minocha Enterprises Pvt Ltd ............................................. 46
Interface: Chris Wall, Global Marketing Manager, Dow Corning ..................................................................... 48
Roundtable: Does Indian masterbatch industry have the required economy-of-scale for the surging demand?....... 52
February August 2012 | Modern Plastics & Polymers
41
ADDING VIBRANCE to the PLASTICS GROWTH STORY
Location courtesy: Plastiblends India Ltd Photo: Joshua Navalkar
SPECIAL FOCUS: Masterbatches and additives
Plastic manufacturers today have become more competent in terms of production timing and efficiency owing to severe competition on the domestic and global front. Anwesh Koley tracks the latest developments in the masterbatch industry and its significance for plastics processing.
P
lastics is considered as a reliable material and preferred due to its cost-effectiveness, which makes it an ideal substitute for many materials. There are numerous applications of plastics and its variants. Advancements in new areas of applications have been more frequent and consequential. Engineering and processing technologies have become more ingenious. The use of masterbatches for plastic colour processing, with safer, more economical and better storage has ensured better visibility and enhanced brand appeal for plastics products. V B Lall, Director, SCJ Plastics Ltd, says, “In recent years, vendors have been offering different colours for the home environment, suitable for different processing methods of the masterbatch, allowing processors to provide more advanced options. The flexibility of plastics has made it the leading material. We have also seen various products such as mug, dustbins and jugs in vibrant colours. Plastics can 42
be coloured and used for numerous purposes and fabricated using many equipment. Variety and functionality can be achieved using plastics of different colours.”
Composition and importance Masterbatch gives colour to plastics. It is a concentrated mixture of pigments formed during the heat process with a carrier resin. It is then cooled and cut into a granular shape. Colour masterbatches are easy to use. Mixing of a suggested ratio of the batch can give the desired result. Batches are mixed according to process requirement of plastics and the injection mould. Masterbatches are of many types, which result in the formation of different varieties of products. White masterbatches result in products that are white in colour, while shine & gloss can be achieved using chemicals. R K Aggarwal, Managing Director, Prayag Polytech (Pvt) Ltd, says, “Plastics with excellent dispersion and heat resistance can be achieved by using masterbatches. Injection moulding,
Modern Plastics & Polymers | August 2012
blow moulding, spin dyeing, casting and foaming are the main uses of white masterbatches. Products such as household electronics, packing materials and houseware are made using white masterbatches.” Black masterbatches are used in products that are black in colour. In order into attain a high degree of excellence in blackness some chemicals are mixed to improve the quality. Black masterbatch render properties such as high dispersion, Ultraviolet (UV ) protection, blue tone, conductivity and high loadings. Application areas of black masterbatches include cast and blown film, rotomoulding, fibres and geo-membranes, etc.
Offering variety to plastics The substances used to enhance the property of plastic products are called filler masterbatches. Transparent filler, nano filler and calcium carbonate masterbatches are the three types of filler masterbatches. The first two have low effect but enhance the physical properties of plastic products. Calcium
Masterbatches and additives
carbonate masterbatch is mixed to maintain the character of the product. Other masterbatches are used for different purposes. Masterbatches are like incentives that increase the quality of the plastics. Manufacturers consider the minutest details in the production of masterbatches in order to meet the expectations of consumers.
Quality constraints While the variety of masterbatches available in the market fits the bill for all plastic colouring requirements, quality is a major concern. The primary requirement for the industry is availability of high-grade polymers. The final plastic product depends heavily on the quality of raw materials available with the manufacturers. “The industry faces an acute problem of low-quality polymers. The Indian quality is not at par with global standards; hence, we have to import from Europe, especially Germany,” says Aggarwal. Dependence
country. “The prices of masterbatches have seen an upward trend in the last few years due to sharply rising raw material prices and consolidation of international raw material suppliers. Sourcing quality raw material from consistent and reliable suppliers will be the key in coming years,” says Lall. New masterbatch players, both domestic and international, will need to keep the selling prices competitive, thereby presenting a challenging market scenario and reduction in margins. The volume growth should help sustain most players but, as in most industries, efficiency and innovation will be required. If the present capacity remains constant, there is a possibility of imports as well, and this may result in higher prices. Prices of masterbatches depend not only on the polymer prices, but also on the pigment prices, and these have been increasing steadily. However, with an increase in demand for masterbatches, the probability of more manufacturers jumping into the foray is high. This will result in an equilibrium price where the quantity demanded by consumers (at current price) will equal the quantity supplied by manufacturers.
The prices of masterbatches have seen an upward trend in the last few years due to sharply rising raw material prices and consolidation of international raw material suppliers. Sourcing quality raw material from consistent and reliable suppliers will be the key in coming years. V B Lall Director, SCJ Plastics Ltd
The way forward
Courtesy: Americhem Inc
on imported polymer has not changed in the past years, with manufacturers finding it difficult to look for domestic options. The industry requires imports of specific materials such as Polyvinyl Chloride (PVC), which is in short supply.
The right price Pricing is an important factor determining the growth of the polymer industry and, in the long run, determines the competence of a
The latest technology in plastics helps in better detection of the material according to specific requirements. Some companies have their own research and development facilities and those that do not, generally outsource research activities to achieve a more customer-centric final output. The latest technology used in the raw material production machinery ensures that more customisation can be achieved along with higher rigidity. The latest technology in polymer processing needs to be supported with infrastructure. Manufacturers are willing to innovate and invest in quality at par with international standards, but without adequate power and land availability, expansion plans cannot be taken forward. Email: anwesh.koley@infomedia18.in
The industry faces an acute problem of low-quality polymers. The Indian quality is not at par with global standards; hence, we have to import from Europe, especially Germany. R K Aggarwal Managing Director, Prayag Polytech (Pvt) Ltd
August 2012 | Modern Plastics & Polymers
43
SPECIAL FOCUS: Quality matters
Capitalising on
product differentiation Courtesy: Americhem Inc
Of all choices available to processors today for colouring polymers, masterbatches or colour concentrates are overwhelmingly preferred. Masterbatches offer numerous benefits to processors such as competitive operating costs, maximum equipment utilisation and optimal process flexibility. Anwesh Koley scrutinises the colourful world of masterbatches and their advantages.
T
he polymer industry in India is expected to see steady growth in future. Per capita consumption of polymers is still low here as compared to developed nations, which brings with it a latent opportunity for the sector to grow. Although crude oil prices have been a cause of concern as imports tend to become costly, India is set to become more self-reliant and grow further to suffice its domestic demand for polymers. This will have a direct impact on the masterbatch industry, as it aids the design versatility offered by plastic products. The plastics industry caters to various sectors where colouring plays an important role. Rajeev Bhatia, Chief Executive Officer, Premier Pigments & Chemicals, says, “Colour differentiates one product from another. It sends a clear message about the expected or intended use of a product. Studies have proven that a product’s colour and appearance 44
are key factors in consumers’ purchasing decisions. This is precisely the role of masterbatches. Thus, colour has become, and will continue to be, a critical element in successful marketing of a product.”
Industry imperatives The primary requirement for the industry is availability of high-grade polymers. The final plastic product depends heavily on the quality of raw materials available with manufacturers. The industry currently faces an acute problem of availability of low-quality polymers. The Indian quality is not up to global standards; hence, Indian companies have to import from Europe, especially Germany. On the quality front as well, consistency is required. Shamik Shah, Vice President–Sales & Marketing, Monachem Additives Pvt Ltd, says, “There is a need to offer customised solutions based on the performance need
Modern Plastics & Polymers | August 2012
identified at the customer’s end. The industry must come up with different solutions for polymer stabilisation, ultraviolet (UV ) stabilisation, flame retardancy, improvement of surface properties, increasing impact properties, processing and lubrication, anti-microbial performance, etc.” Dependence on imported polymer has not changed in the past years, with manufacturers facing problems in domestic options. The industry requires imports for specific materials such as PVC, which is in short supply.
Making the right choice An ideal masterbatch for a specific end use is one whose Melt Flow Index (MFI) matches as closely as possible with that of base resin. This is easy with titanium dioxide-based (white) masterbatches and some additive masterbatches, but not as simple with black masterbatch because of the reinforcing nature described above. If
Quality matters
the masterbatch is to be compounded into the base polymer using high-shear mixing equipment such as internal mixer or twin-screw extruder, it is possible to choose a fairly low MFI carrier resin and still achieve excellent incorporation. Polymer producers generally follow this practice when making pipe or cable compounds in order to not affect the final performance properties of the compound. â&#x20AC;&#x153;If poor distribution occurs while simultaneously feeding masterbatch and resin into an injection moulding or extrusion process where the shear forces are slightly lower, the processor can adjust equipment operation conditions such as increased back pressure, use of turbine mixing heads or cavity transfer mixers at the end of the extruder screw,â&#x20AC;? says Bhatia. To maintain output rates, the processor usually specifies a masterbatch that is compatible with the base resin and operating conditions. MFI of a masterbatch is important because it indicates the relative ease with which a masterbatch can be distributed during a compounding operation or in injection moulding machines and film extruders.
Additive masterbatches Brand manufacturers, designers and others who work on the colour strategy
Courtesy: Americhem Inc
should familiarise themselves with the polymer, surface, wall strength and manufacturing process. Another important factor in the development of a masterbatch is the use of additives to achieve physical advantages in the end product. The geometry of the finished product, the rheological relationship and the choice of polymer have a significant influence on the selection of colouring agent. â&#x20AC;&#x153;Global polymer companies have advanced market research & development teams, which work towards offering innovative solutions to customers. It is important to internally conduct market research studies and identify emerging trends in each industry at the local, national and global scale,â&#x20AC;? adds Shah. Based on this research, companies identify plastic additive solutions through their global knowledge network and work with key Indian partners by sharing with them information about innovative additive solutions and work together to commercialise it.
Studies have long proven that a productâ&#x20AC;&#x2122;s colour and appearance are key factors in consumersâ&#x20AC;&#x2122; purchasing decisions. Thus, colour has become, and will continue to be, a critical element in successful marketing of a product. Rajeev Bhatia j` ^ [Y _ Â&#x2030;^{ _ Premier Pigments & Chemicals
Future opportunities The demand for plastics is witnessing an upward trend around the world and, with India presenting a wide scope for expansion, the masterbatch industry has reasons to cheer. Applications for masterbatches will see an increase in the automotive sector with anti-scratch applications, thereby making the final product lighter and improve its impact resistance & soft touch functions. Even the agricultural sector will benefit f rom better light stabilisation requirements for agrofilms. Chlorine-resistant solutions for polyethylene films will aid inf rastructural needs. Improving aesthetics in household appliances as well as enhancing surface and mechanical properties, replacing Bisphenol A-based polycarbonate with polypropylene for baby bottles, etc will ensure that the common man gets more from regular plastic products. Email: anwesh.koley@infomedia18.in
Global polymer companies have advanced market research & development teams, which work towards offering innovative solutions to customers. It is important to internally conduct market research studies and identify emerging trends in each industry at the local, national and global scale. Shamik Shah Â&#x160; _ z Â&#x2039;' < Monachem Additives Pvt Ltd
August 2012 | Modern Plastics & Polymers
45
SPECIAL FOCUS: Plastic pigments
the colour
dispersion code
Pigments are highly coloured bodies available as minute particles. For colouring thermoplastics, pigments are dispersed in a plastic medium. Perfect dispersion of pigments is required to achieve the perfect colour. Here is how masterbatch processors can create aesthetically coloured plastics for product differentiation. Surinder Minocha
I
n a brilliantly coloured plastic object under high magnification, the colour observed is not continuous, but made up of many tiny coloured dots, each dot representing a pigment particle. Normally, the eye sees the aggregate colour. The problem encountered in using pigments is that particles tend to clump together to form specks or agglomerates. Unfortunately, although a speck can be made up of hundreds of individual particles, it contributes no more to the final colour than it does to one of the ultimate particles. If the speck becomes big enough to be seen with the naked eye, it could result in a rejected piece. Thus, to use pigments efficiently with maximum value, perfect dispersion is a must.
Pigment dispersion The separation of pigment particles in a plastic medium is called dispersion. 46
Achieving a perfect dispersion is the beauty of colour on one hand and economy on the other. The better dispersed a pigment is, the less the amount needed to colour a given job. Most colours are obtained from more than one pigment. All particles of each pigment must be perfectly dispersed. If one pigment is developed more efficiently than another, the colour will be inappropriate. Perfect dispersion is essential for masterbatches due to the high colourant loading of this method. This is because, in use, the concentrate is diluted many times and under varying conditions. Pigment dispersion must be perfect, so that despite dilution, the colours remain true and the pigments do not agglomerate.
has multiple colouring powers. It readily gives up its colouring power to colour a much larger quantity of plastic material. The requisite amount of natural material is mixed with the concentrate. This is put through a screw-based machine, and the product is uniformly coloured and matched. This allows the fabricator to compound and colour products without running an in-house colour laboratory. Masterbatches can also be filled with glass, talc, rubber, stabilisers, slip agents, foaming agents, flame retardants, antistats, etc. But the principle remains the same. The concentrate manufacturer disperses the desired component in vast excess. The moulder or extruder acquires a reservoir of the materials needed.
The differentiating factor
Dispersion and distribution
The pigment level is vastly increased, by 20-200 times. This multiple is a colour concentrate. It is a reservoir of perfectly dispersed colour-matched colourants. It
Dispersion refers to the process of creating the concentrate. For example, it is the green concentrate consisting of a white, yellow and green pigment,
Modern Plastics & Polymers | August 2012
Plastic pigments
plus the matrix. The colour concentrate producer must thoroughly mix these pigments with the plastic base, and each particle of colour must be completely encapsulated in plastics. If dispersion is incomplete, a defect may arise in the finished part, resulting in a streak of individual colourants (green, white or yellow). Such defects are difficult to correct at the process level, and the concentrate should be returned to the producer for correction. However, before taking this action, one must determine whether the specks or streaks are inherent in the concentrate and are not dirt specks or oil stains. Distribution refers to the process operation (moulder or extruder) in which the concentrates and matrix material are thoroughly mixed to form a uniform colour. Failure to melt evenly and mix completely will show up as a series of light & dark areas in the finished part. This is a common problem and the solution lies in maximum use of the screw. The basic principle is early
melting of the screw contents, thereby utilising maximum length of the screw for colour mixing. Step one: The crucial step is increasing heat in the feed zone. The changes needed are not substantial, and the heat should be raised gradually by 25-50째F. The objective is to bring the temperature of the rear feed zone above that of the rest of the machine. Because only the feed zone temperature is raised, it is possible to frequently decrease the overall temperature of the machine. Step two: Decrease the screw return speed along the cooling portion of the cycle as much as possible. Target screw speed should be 40-60 rpm. These two steps should solve the greatest portion of distribution problems. One should also consider the following: The machine should have an initial inspection to ensure proper working of all areas A heater may be defective A thermocouple may be displaced, giving erroneous readings
Usually, a minimum dwell time in a machine is needed for the plastic material and the concentrate to be plasticised and mixed. Occasionally, following problems may be encountered: High cavity volume The cycle is too short, and the time in the cylinder is inadequate In such extreme cases, it may be necessary to transfer the mould to a larger machine with greater plasticising capacity or increase the cycle time. In some cases, the concentrate producer can supply the concentrate in a smaller pellet size, thus improving the ratio of concentrate pellets to plastic pellets. Close synergy between masterbatch producer and processor eliminates potential distribution problems or identify them in the sampling stages in order to take corrective action. Surinder Minocha is Managing Director of Minocha Enterprises Pvt Ltd. Email: smm@mepl-india.com
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SPECIAL FOCUS: Inter face - Chris Wall
“Additives may seem expensive, but they provide value for money” …asserts Chris Wall, Global Marketing Manager, Dow Corning, while emphasising the importance of masterbatches and additives in plastics applications. In an interaction with Lionel Alva, he focusses on how India is a major market for the plastics industry and is expected to record high growth figures. What are the key market trends for the additives and masterbatches market in India? Dow Corning sees India as a key market, since India is expected to witness maximum growth in additives and masterbatches at a doubledigit compounded annual growth rate for the next few years, driven mainly by automotive and construction industries. The per capita consumption in India is onefifth or one-tenth of the global average. One of the biggest segments in India is agriculture.
What are the recent innovations in this sector? The plastics industry is currently witnessing an unprecedented change. With the pressure on natural resources as well as cost reduction, plastics is seen as the most efficient solution to tackle these global challenges. Plastics is gaining pace in terms of sustainability, as compared to standard/ traditional materials. Its carbon footprint is the lowest in most cases. In applications such as green energy, eg, solar panels or wind turbines, plastics offer ever-improving material properties. Light-Emitting Diode (LED) is another example where plastics enables weight saving, durability and versatility. Plastics has revolutionised the field of medicine, contributing to a reduction in medical costs, infectious disease and pain management.
How do additives and masterbatches help develop halogen-free plastics? What are their advantages? Halogen-free flame retardant solutions are in demand today more than ever. The additives commonly used today for flame retardance such 48
Modern Plastics & Polymers | August 2012
as halogens, phosphorous and nitrogen-based compounds & hydrates – come at a cost, whether it is mechanical, environmental or financial performance. Designers must balance flameretardant properties, mechanical properties, regulatory requirements and public perception for various applications & markets. Many industry players are looking for new ways to meet these varied needs without making compromises. Dow Corning’s plastics and composite additives can help in optimising this balance by providing better flame-retardant and smoke-suppression performance, while maintaining or improving mechanical properties.
How do additives and masterbatches contribute to a sustainable plastics industry? Without additives, plastics would not be as safe, clean, tough and colourful as it is today. Additives may seem expensive but they actually enable reduction in production costs and make products last longer, thus providing value for money. They help the industry save money and preserve the world’s raw material reserves. Additives have the capability to turn basic polymers into useful plastics.
What are the challenges for the additives and masterbatches industry in India? And, what is its future outlook? The priority for the plastics industry is to work on its image to ensure that it is clearly positioned as providing solutions to some of the world’s biggest challenges. The second challenge will be to make a smooth transition from a highly fragmented compounding industry towards a more consolidated structure. Despite the challenges, this industry has a bright future and is in a unique position to make our life simpler, safer and more sustainable. Email: lionel.alva@infomedia18.in
MPP AUG _2012_TAB 3_EVEREST PG_49
Gardner
MPP AUG _2012_TAB 3_GARDNER PG_50
SPECIAL FOCUS: Roundtable
masterbatch industry economy-of-scale surging demand?
Does Indian have the required for the
While the plastics industry has grown by leaps and bounds in recent years, it is in a unique situation where demand outpaces supply and masterbatch manufacturers find it challenging to keep pace with market requirements. Lionel Alva assesses how various industry players are gearing up for such scale-related challenges. Anik Patel Director, Add Plast
India has the capability to produce masterbatches that meet international standards of quality. At present, we do not have the required large-scale capacity due to lack of investment and several other factors. There are a few players who can do so, but they are few and far between. However, when it comes to quality, it is possible to acquire high-grade masterbatches at the local level. It is expected that in the next few years, there will be a sea change in the availability of additives and masterbatches for the domestic market. There is an urgent need to attract investors, and the government can also help by creating a favourable atmosphere for investment. Masterbatches and additives constitute a fast growing market, and it is also important to keep pace with innovations; moreover, once economies-of-scale are achieved, it would be possible to tap into new areas of application that fits local needs.
Nitin Nemade Director, Tushar Polymers & Tradings
Several problems prevent the widespread facilitation of plants for managing large capacity production. Problems in infrastructure and power supply, lacklustre quality of Indian masterbatches and fluctuating prices across manufacturers make it difficult for the industry to remain competitive at the domestic level. Thermoforming, blow moulding and extrusion sectors are major consumers of masterbatches, and it is important that local masterbatch manufacturers focus on quality to acquire the confidence of major players in this segment. Currently, we do not have the economies-ofscale to cater to large manufacturers or fulfill demand in the local context. This is a necessary step to ensure commercial viability and healthy growth of the polymer industry. However, with an optimistic outlook, India is set for a paradigm shift in terms of possibilities in the local context since there is a visible cognisance among local masterbatch manufacturers to bring production on par with international standards.
Parag Parikh Director, Universal Colorant Company
There has been a surge in domestic demand and tremendous opportunities are available for domestic masterbatch producers. While capacity exists with some big organisations at the domestic level, quality does not conform to international standards, thus creating barriers for domestic producers. There is heavy reliance on imports and with surging exchange rates in recent years, there is a need to look at viable options within the country. The industry is making efforts to ramp up production capacity and enhance quality for renewed interest in domestic production. Contamination issues must be addressed before production is ramped up. This is vital for the plastics industry as a whole and also for enhancing core production competency with new avenues for plastics being explored in several unconventional areas of application such as the construction industry. The rise in raw material costs has also deeply affected the competency of the Indian masterbatch market.
Editorial take: Email: lionel.alva@infomedia18.in While the Indian plastics industry is witnessing a surge in growth prospects, it is imperative that the capacity to develop raw material be created indigenously. This is because in the long run, a weaker rupee might significantly impact the plastics industryâ&#x20AC;&#x2122;s prospects, especially in international trade. 52
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FACILIT Y VISIT: Blend Colours Pvt Ltd
Blending quality with innovation The global plastics industry has conquered new heights of excellence through the power of performance additives and masterbatches. Bringing global innovations to Indian shores, Blend Colours Pvt Ltd has carved a niche for itself in terms of quality innovations and customer focus. Annabel Dsouza traces the company’s progress towards growth and excellence.
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he rapid strides taken by the Indian plastics industry have necessitated global standards of quality and innovation. Masterbatches are essential ingredients for the plastics processing industry, which is growing at a rate twice as much as national Gross Domestic Product (GDP). With progressive demographics and increased consumption patterns, plastics is making inroads into the manufacturing sector to boost production at competitive costs.
Imparting value Masterbatches are used to impart colour and various special properties to products manufactured from plastics. Although the cost and volume of masterbatches in the final plastic product is low, they are an integral component of the final compound and are important for attaining the desired properties of the required application. The masterbatch market in India has been growing at a rate of 15 per cent in the last few years, driven by demand from end-user segments, eg, packaging, automotives, irrigation, etc. 54
Among key manufacturers of additives and masterbatches in India, Blend Colours Pvt Ltd has served the domestic plastics industry with a wide variety of products and services driven by a culture of quality, commitment and consistency. Incorporated as a member of the erstwhile Shree Group of Companies in 1998-99, Blend Colours has emerged as an important player in South India’s plastics processing scenario. The company began with an initial capacity of 300 Million Tonne Per Annum (MTPA) and, today, it boasts of a total capacity of 14,000 MTPA spanning two manufacturing facilities in the Kattedan and Mankhal regions of Hyderabad. This is symbolic of the strong growth synergy between Blend Colours and the nation’s plastics industry.
Manufacturing might Blend Colours currently operates seven compounding lines with automated twin-screw extruders dedicated to black, white and colour masterbatches. With continuous focus on the industry’s application requirements, the company
Modern Plastics & Polymers | August 2012
has evolved into a well recognised manufacturer, supplier and exporter of colour masterbatches and specialty additives. Today, the company also boasts of India’s highest installed capacity for black masterbatches at 5,000 MTPA. As ISO 9001:2000 certified processor of masterbatches, Blend Colours observes high standards of quality assurance and authentication. Sharad Rathi, Director, Blend Colours Pvt Ltd, avers, “As part of our continuous efforts to bring innovative and sophisticated products to the market, we consider Research and Development (R&D) as an integral function to our overall growth strategy. Developing new products to meet the changing needs of customer base is an ongoing mission and our unmatched experience and application know-how ensures that Blend Colours remains at the forefront of product development for this industry in India.”
Commitment to quality The experience and expertise of Blend Colours in assuring some of the most challenging customer requirements stem
Blend Colours Pvt Ltd
R&D in action
from its commitment towards bestin-class manufacturing practices and stringent quality control processes. The company ensures that it maintains its productsâ&#x20AC;&#x2122; consistency in each supply. The quality control procedures begin with random testing of incoming raw materials such as pigments, additives and minerals to final output consisting of masterbatches. The pigments and additives are selected with utmost care keeping in mind end-use performance and process conditions to achieve the best results. Rathi asserts, â&#x20AC;&#x153;Every product batch is tested thoroughly on the parameters of dispersion, Melt-Flow Index (MFI), density, carbon/filler content, opacity, whiteness, gloss, etc, as well as specific tests like impact and tensile strength for specific applications. We commit ourselves to producing quality masterbatches and compounds for all applications, consistently and on time, bearing in mind our customersâ&#x20AC;&#x2122; benefit and our brand equity.â&#x20AC;?
Focus on R&D Product obsolescence is a common feature in additives and masterbatches; hence, product innovation is the master key to future growth. Focus on R&D has enabled Blend Colours to introduce new solutions apart from manufacturing more than 300 grades of masterbatches. Higher consumption trends combined with the need for constant innovation is driving Blend Colours to develop more sophisticated products for small-scale plastics processors, thereby enhancing market competitiveness. Beside its expertise in colour matching, Blend Colours draws on its long experience of application knowledge to customise its
Compounding process line
Focus on quality and consistency
products and solve common processing challenges. The company strives to achieve global standards in all R&D projects, with special focus on the following parameters: Match standards with international requirements Make dispersion perfectly suitable for end use application Maintain batch-to-batch consistency and quality Prompt customer service for colour matching Rathi elaborates, â&#x20AC;&#x153;With significant strides in the domestic market, we are now focussing on the surging export potential. We are among the top 10 largest processors of additives and masterbatches in the Indian industry. While commodity products such as black, white and coloured masterbatches have always been our key strength, we are increasingly focussing on specialty applications such as automotives and non-woven fibres, etc to compete in global markets.â&#x20AC;?
Expansion plans In the near future, Blend Colours hopes to introduce two new compounding lines and expand existing capacities to 30,000 MTPA. Rathi concludes, â&#x20AC;&#x153;Although economies of scale are critical to achieve growth targets in an increasingly competitive global plastics industry, we would like to differentiate our strategy by unflinching commitment to quality and innovation. We are looking at global machinery suppliers and technical partners
the domestic market, we are now focussing on the surging export potential. We are looking at global machinery suppliers and technical partners to gain a truly commercial edge in the export market. Sharad Rathi Director
to gain a truly commercial edge in the export market. We are among the most cost-competitive players in the Indian market, offering quality solutions at costs that are 10-15 per cent lower than the largest players in the country. Although we want to take our cost competence to the world market, we are committed towards creating a culture of quality and excellence in the global plastics industry.â&#x20AC;? Photo: Suresh Vengapally Email: annabel.dsouza@infomedia18.in
August 2012 | Modern Plastics & Polymers
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INSIGHT & OUTLOOK
Paints & Coatings Plastics in paints and coatings: Painting a sustainable future ......................................................................................................... 58
Powder coating technology: Engineering a smooth surface finish ............................................................................................ 60
Interface: Geert Hofman, General Manager, Performance Additives (Worldwide), Akzo Nobel ......64 G D Barot, Chairman and Managing Director, Gunjan Paints Ltd .................................. 66
Polymer compounding: Precision through innovation Satish Padmanabhan, Global CEO, STEER Engineering Pvt Ltd ................................................. 70
BOPP packaging: New-age material solution Ashish Kothavade, Senior Manager-Business Development, Plastiblends India Ltd ...........................74
Case Study: Virtual designing for enhanced productivity Courtesy: Autodesk Inc ..................................................................................................................... 78
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INSIGHT & OUTLOOK: Plastics in paints and coatings
PAINTING a sustainable future High performance demands of industrial paints and coatings have increased the use of solvent-based paints, which have high Volatile Organic Compound (VOC) emission rates. Lionel Alva assesses how plastic resins have helped reduce VOC emissions of paints, while providing performance similar to solvent-based paints.
O
Courtesy: Wacker Chemie AG
rganic solvents are widely used in the industry today in a number of processes. Typically, the metal coating industry uses trichloroethylene, xylene, Methyl Ethyl Ketone (MEK) and white spirit, mainly in paints and for cleaning & thinning processes. These and other organic solvents lead to emission of Volatile Organic Compound (VOC) vapours. This is primarily because VOCs create a low level of air pollution and are a health hazard, while affecting crops and natural vegetation and also because they contribute to global warming. At present, the levels of these VOCs in the atmosphere are a cause of much concern, making it imperative to look for eco-friendly and viable alternatives. Solvent-based paint processes are known to create air and water pollutants, and water-borne coatings produce hazardous waste. The air pollutants contribute to photochemical smog.
Plastic resins in solvent-based paints
Courtesy: Wacker Chemie AG
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There are two ways to reduce pollution – by installing expensive equipment to treat pollutants or by eliminating the source of pollutants. The second method is clearly more pragmatic. Equipment installed merely to prevent the discharge of pollutants to the environment represents an extra expense, which does not contribute to profitability at
Modern Plastics & Polymers | August 2012
all. Production processes that minimise the production of pollutants at their source are a more positive solution and less expensive in the long run. However, the paints and coatings industry is looking for alternative, more eco-f riendly solutions to reduce or eliminate VOC emissions from solventbased coatings. Paint is of two types – acrylic latex, often called latex paint, and oil-based paint called alkyd paint. Acrylic latex paint is essentially made from water and an acrylic resin binder. Oil-based paint most often uses a hydrocarbon-based solvent as an alkyd resin. All paints are composed of a solid (or binder) and a vehicle. Acrylic latex paint uses acrylic resin as the binder and water as the vehicle. The binder in acrylic latex paints binds various pigments and water to form a film that covers the paint surface. Binders are the major components that provide the paint with its application properties. Conventional solvent-based paints consist of a surfacecoating material – generally a pigment with a binder resin – dissolved in an organic solvent. Typical conventional paints contain 60-80 per cent solvent (720-960 gm VOCs/litre of coating), ie, 20-40 per cent coating solids by weight. During application and drying of the paint, solvent evaporates from the coating leaving a durable, pigmented coating on the surface of the metal.
Plastics in paints and coatings
The paint is dried either by drying in ambient air or by stoving. Increasing concerns about the impact of chemicals on health and the environment are being translated into strict legislation that may have significant impact on the use and disposal of plastics, particularly those used in electrical and electronic equipment. Original Equipment Manufacturers (OEMs) and their moulders & extruders must carefully look at emerging legislations around the world to ensure compliance. Fortunately, innovative plastics are currently available as alternatives to companies that are facing regulatory restrictions. The use of pigmented resins instead of paint can reduce VOC emissions and lower production costs, while providing new design options. Acrylic latex paint, often advertised as 100 per cent acrylic latex, is a water-based paint and is generally considered as the highest quality. Other resins used in latex paint include styrene, epoxy and polyvinyl acetate. Of the acrylic latex paints available, vinylacrylic latex paints are the most popular. The acrylic used as binder in acrylic latex paint is a type of synthetic polymer or plastics. A number of synthetic polymers are used for various applications. However, latex paints use only one polymer – elastomer. As the name implies, elastomers are quite flexible – or elastic – and give acrylic latex paints their dry flexibility.
Challenges faced The long-term growth prospects of the paints and coatings market in India are healthy with the optimism of the Gross Domestic Product (GDP) growth bouncing back to the levels of 7-7.5 per cent, growing demand in Tier-II and Tier-III markets as well as the substantial middleclass households with increasing disposable income and willingness for discretionary expenditure. India has one of the lowest per capita consumption of paint (less than a litre), indicating a huge opportunity, as compared
to the per capita consumption to 20 litre in developed economies. Renewed investment in infrastructure and growth in industries such as auto, oil & natural gas, marine and construction will provide an impetus to the paint & coatings industry. “The increase in energy and feedstock costs is the biggest challenge and a potential hurdle to growth in this industry. Paints and coatings are raw material intensive, with raw material accounting for 60 per cent of net sales. High cost and erratic availability of raw materials is a massive challenge. Most of the raw materials are petroleum-based and vulnerable to rise in crude prices. This coupled with currency devaluation of 13-14 per cent compared to last year, is shrinking the margin, with companies barely being able to pass on the increase in cost to the customer,” avers M R Shankar, Purchasing Manager, India & South Asia, Akzo Nobel India Ltd. Another external challenge is the remote possibility of the macro-economic situation of the country not being corrected and the GDP growth slippage not witnessing a reversal in the short term as well as the continuously diminishing demand.
Most of the raw materials are petroleum-based and vulnerable to rise in crude prices. This coupled with currency devaluation of 13-14 per cent compared to last year, is shrinking the margin, with companies barely being able to pass on the increase in cost to the customer. M R Shankar Purchasing Manager, India & South Asia, Akzo Nobel India Ltd
Sustainable solutions Considering how the focus is increasing on environment sustainability, plastic resins allow for creation of high-quality solvent-based paints, while reducing the threat of high VOC emission rates. This is indicative of the industrial paints & coating industry viewing plastics as a long-term solution towards creating high-performance paints & coatings. This means that the paints and coatings industry in India is all set to witness a paradigm shift, while furthering the avenues of innovation with paints and coatings. The use of plastic resins will also enable reduction of costs, thus creating a win-win situation for the industry that has borne the repercussions of creating products that would be a hazard to the environment. Email: lionel.alva@infomedia18.in
Courtesy: Wacker Chemie AG
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INSIGHT & OUTLOOK: Powder coating technology
ENGINEERING A SMOOTH SURFACE A SMOOTH SURFACE FINISH
Courtesy: Universal Colorant Company
As the coating industry worldwide grows rapidly, companies are fast adopting new materials such as engineering plastics to enhance efficiency and appeal. Avani Jain discusses the benefits of using engineering plastics in powder coating technology for enhancing performance and sustainability.
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owder coating is a type of coating that is applied as a free-flowing, dry powder, and is the latest surface finishing technique commonly used today. Unlike conventional liquid paint, powder coating does not need a solvent to keep binder and fillers together in liquid form. This method was first used in 1967 in Australia. It is the technique of applying dry paint to a part. Technology advancements in powder coating have spurred growth in the industry. End-users are increasingly using powder for reasons of economy, ecology and high-end performance.
Coating advantages The reason for increased growth and popularity of powder coating is that it generates low Volatile Organic Compounds (VOCs) and delivers highperformance coatings. High performance is fortified by the use of additives in powder coating formulations. Additives increase the service life of the coating by reducing the effects of Ultraviolet (UV) damage, providing better temperature 60
stability and improving corrosion resistance. In addition, the usage of engineering thermoplastics enhances performance and sustainability. Canon Patel, Managing Director, Loxim Industries Ltd, notes, “Typically, engineering plastics are chosen for their broad range of enhanced physical properties, ie, they are highly impact resistant and polyamides are highly resistant to abrasion. The key benefits of engineering plastics are cost-effectiveness, as they have a lower manufacturing cost, corrosion/chemical resistant, light weight (lower density), excellent surface finish (no secondary operations required), colourability (by addition of pigments/ dyes), aesthetic, paintable, flexible & soft.” Other properties of engineering plastics include high heat resistance, mechanical strength, rigidity, chemical stability and flame retardance. Patel notes, “The mechanical properties of engineering plastics, which enable their wide usage in various industries, particularly powder coating industry, include specific strength and stiffness,
Modern Plastics & Polymers | August 2012
high impact, durability, surface finish and high-heat performance (strength & stiffness at elevated temperatures).” The electrical properties include surface and flame resistance.
Engineering thermoplastics in powder coating technology There are two common ways of applying powder coating - electrostatic spray and fluidised bed powder coating - the latter is the original powder coating technique. Fluidised bed powder coating is still the primary technique used for application of engineering thermoplastic powders. Several other processes have been developed, but they are used infrequently. These include flame spraying, spraying with a plasma gun, airless hot spray and coating by electophoretic deposition. The most common application for powder coatings is for covering industrial metal parts to protect them from corrosion and chemical etching, thereby increasing durability. There are two types of powder coatings – engineering thermoplastics and thermosetting polymers. Engineering
Powder coating technology
The mechanical properties of engineering plastics, which enable their usage in various industries, particularly powder coating industry, and stiffness, high impact, high-heat performance. Canon Patel Managing Director, Loxim Industries Ltd
The most important property of engineering plastics that make them so useful in the powder coating technology is that these can easily withstand atmospheric changes and moisture. They possess good lubrication properties. Dr Harindu Vyas President (Technical & Development), Signet Industries Ltd
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thermoplastic powder coatings melt and flow upon applying heat, but continue to have the same chemical composition after these cool and solidify. Engineering thermoplastic powders exhibit excellent chemical resistance, toughness and flexibility. These are applied mainly by the fluidised bed application technique, in which heated parts are dipped into a vat where the powders are fluidised by air and used in many thick-film applications. These are generally applied to a surface that has been preheated to a temperature significantly higher than the melting point of the powder. As an engineering thermoplastic powder material is applied to the hot surface it will melt and fusion bond to the surface and then flow out into a strong, continuous film. Upon cooling, the film develops its physical properties. Dr Harindu Vyas, President (Technical & Development), Signet Industries Ltd, says, â&#x20AC;&#x153;The most important property of engineering plastics that make them so useful in powder coating technology is that these can easily withstand atmospheric changes and moisture. They possess good lubrication properties. These are the main reasons for their use in coating of metal parts, eg, Teflon coating.â&#x20AC;? He adds, â&#x20AC;&#x153;Engineering plastics are used for various purposes including powder coating of water turbines in order to avoid siltation, which cuts the metal parts. Thus, polymeric coating is done to avoid such problems. This enhances the life of the part that is powder coated, thus increasing sustainability and performance.â&#x20AC;?
Types of engineering thermoplastics Nylon powder-coating materials are the most commonly used engineering thermoplastic powders. Acrylic powder is also used where decorative requirements and resistance to ultraviolet rays from sunlight for a longer period of time is critical. Many critical automotive trim components are coated with acrylic powder. Even urethane powder coatings feature characteristics of excellent gloss retention and long-term resistance to humidity and corrosion in thin-film applications. Its typical applications include agricultural
Modern Plastics & Polymers | August 2012
Courtesy: AkzoNobel
equipment, air conditioners, construction equipment, electrical enclosures, garden equipment, lawn furniture, light fixtures, office furniture, recreational equipment, under-hood automotive as well as wheels & rims.
Future trends In India, a robust, long-term growth in industrial coatings is expected, as emphasis has increased on manufacturing of high-tech products such as automobiles, locomotives, passenger and military aircrafts, consumer electronics and other technology-driven products. This has led to higher consumption of specialised industrial coatings, including powder coating technology in the country. Further, the future of the powder coating industry is bright also due to the boom in construction segment. With the resurgence in automotive and consumer durable industries, the Indian powder coating and paint industry is heading towards an exciting phase of growth and profitability. Therefore, going forward, a better focus on supply chain or distribution mechanism backed by aggressive promotion will drive the fortunes of the Indian powder coating and paints industry like never before. The growth in the powder coating industry has directly impacted the engineering plastics segment in the country. The consumption growth of engineering plastics on an average annual basis is likely to reach 3 million tonne, which is 18 per cent of the total demand in 2013. Looking at the benefits offered by engineering plastics in powder coating technology, their demand is expected to rise globally. Email: avani.jain@infomedia18.
INSIGHT & OUTLOOK: Inter face - Geer t Hofman
“Our R&D initiatives focus on reducing carbon footprint” …asserts Geert Hofman, General Manager, Performance Additives (Worldwide), AkzoNobel. Besides highlighting the technology advancements and consumer requirements of the paints & coatings industry in an interaction with Lionel Alva, he delineates some of the measures to make this industry even more sustainable. What is the role of resins in the paints and coatings industry? Resins perform several essential functions such as rheology modification, setting, controlling, spraying and splatter resistance; setting control on vertical surfaces and leveling on horizontal surfaces; water retention for solvent-based paints, etc. Cellulose ether is a cost-effective specialty additive used in both interior and exterior architectural & decorative coatings. Cellulose ether–based products can thicken aqueous solutions and control flow properties with economical advantages. Other advantages are: Excellent thickening and stabilising agent, leading to in-can stability, brushability, leveling & customer appeal Superior water retention, leading to longer open-time, which has become more critical with strict regulations for Volatile Organic Compounds (VOCs) Excellent price performance Easy dispersion and quick dissolution, making paint processing fast & easy Improved performance in spattering behaviour, adhesion and colour float resistance 64
What are the recent innovations in polymer technology for paints and coatings applications? One of the innovations is cellulose ether technology, which possesses higher tensile strength, better colour resistance, pigments used improve paint finish. Cellulose ether is made from natural resources that are completely renewable. It is manufactured by reaction of purified cellulose with alkylating reagents under heterogeneous conditions, usually in the presence of a base, typically sodium hydroxide, and an inert diluent. We have modified these core properties, which induce better tensile resistance. Thickness of pigments used in cellulose ether must strike the right balance.
What is the difference between waterbased and solvent-based paints? Water-based paints emit low VOCs as compared to solvent-based paints. Waterbased paints are used extensively for both interior and exterior surfaces, while solvent-based paints are used in general, non-masonry type applications. Since cellulose ether has strong water retention properties, it is used predominantly in water-based paints.
Modern Plastics & Polymers | August 2012
What technologies are used to produce cellulose ethers? Cellulose fibres are converted into a valuable cellulose derivative, which is easily marketable with additional properties. Two most important technologies are used to produce cellulose ethers: first is reacting cellulose with monochloro acetic acid, resulting in carboxy methyl cellulose. Second is reacting cellulose with ethylene oxide which is the leading technology for producing cellulose ether. For the latter, AkzoNobel has a substantial sustainability edge over its competitors by using more environmental friendly process.
What are your Research and Development (R&D) initiatives for this industry? Our R&D initiatives focus on reducing the carbon footprint for our customers. We not only work on paint formulations, but also on improving the quality of substrates on which paints are applied, since poor plastering of walls due to sub-optimum quality of cement or gypsum, or seepage of water through walls, negatively affects paint performance. Email: lionel.alva@infomedia18.in
INSIGHT & OUTLOOK: Inter face - G D Barot
“Future of this industry is bright as the consumption is increasing” …opines G D Barot, Chairman & Managing Director, Gunjan Paints Ltd. In a conversation with Avani Jain, he highlights the growth and demand for decorative and industrial paints in the country, as well as the recent trends & challenges faced by the industry. How is the paints and coatings industry faring in India? The growth rate of paints and coatings industry has been 10-12 per cent since the last few years. This reduced to 7-8 per cent during the economic slowdown, but the demand is still good with the increasing awareness about this industry and more people demanding decorative paints for various purposes. The major usage of decorative paints is in the construction industry, as people today paint their houses almost every year. In case of industrial paints, there is good demand because companies want protection from rusting and corrosion. Further, the moist climate in India and high humidity level increases the demand for paints, especially anti-corrosive paints. The demand for industrial paints in the automotive segments is increasing by 10-12 per cent since last two years. This trend is seen in Gujarat, particularly as many foreign companies in automotive segment are entering the State owing to attractive schemes offered by the Government, and this has greatly enhanced the demand for industrial paints. With regard to the specialised category in the segment, ie, powder coating technology, the demand for paints has increased due to various reasons. For example, earlier, people used synthetic enamels for painting metal parts, but these had shorter life, ie, lasting for only 2-3 years as against powder coating, which has longer life and remains the same for 10-15 years. Despite remarkable growth trends, the paints and coating industry may see a slower growth rate at present due to fall in the real estate segment and slower industrial growth in the times of economic uncertainty. 66
paints segment, we are coming up with a luxurious paint that will be named as ‘Beauty Queen.’ This product will have an excellent surface finish, smoothness and shine.
What are the challenges and opportunities faced by the industry?
What are the recent market trends? Today, customers have become quality conscious and even a slight variation in shade is not acceptable to them. The industry has also become technologically advanced with multinationals coming from China, Sweden, etc. Further, the demand for low-temperaturecured coating is increasing as it helps in reducing energy needs. These days, people are also moving towards quick drying paints as against slow drying paints since these yield good results. Another trend is that people are buying products from Small and Medium Enterprises (SMEs) in this segment as they find their products economical and of good quality.
What are the R&D initiatives of your company? In the industrial paints segment, we are going to launch floor coating with longer life and inorganic zinc silicate coating later this year. In the decorative
Modern Plastics & Polymers | August 2012
The major challenge before this industry is fluctuating prices of raw materials. The rise in crude oil prices is impacting the refineries and they are forced to increase their prices, which is impacting this industry. Unfavourable government policies in terms of high Value-Added Tax (VAT) and Excise Duty are also major concerns for the industry. The Excise Duty is 12-15 per cent and VAT is almost the same. The industry is forced to pay both taxes and this creates cost pressures. Further, there are no subsidies or benefits provided to the small-scale industries in this segment. That is a huge challenge for SMEs. Also, there is cut-throat competition in the segment, not only because of the various local players but also due to the entry of multinationals in the country. At present, the industry is also facing problem due to market slowdown. But, despite the challenges, the future of the industry is bright as the consumption of paints and coatings is increasing in India day by day.
On the future outlook of the Indian paints and coating industry... The demand for decorative paints in the construction segment will definitely increase. With the growth of the industries in Gujarat, the demand for industrial paints will also increase steadily. Email: avani.jain@infomedia18.in
MPP Aug_2012 Ad Name: Prayag Tab-4, Pg No. 67 MPP Aug_2012 Ad Name: Prayag Tab-4, Pg No. 67
TOSHIBA
MPP Aug_2012 Ad Name: Toshiba Tab-4, Pg No. 68
MPP Aug_2012 Ad Name: Toshiba Tab-4, Pg No. 68
INSIGHT & OUTLOOK: Polymer compounding
Precision through
innovation
Features such as quick material change to reduce downtime, lowest possible usage of expensive raw materials through precision feeds and obtaining high-grade polymers in a single mass, make compounding the preferred choice for plastics processors. Thus, polymer compounding has emerged as an efficient processing technique for the plastics industry. Satish Padmanabhan
P
olymer compounding is an environment-friendly process due to the source of the raw material that it uses to make Polyvinyl Chloride (PVC) resin. Salt is used to create the resin, and this involves the process of compounding. While designing central drying stations, energy management is a priority. For example, a heat exchanger is employed in the regeneration process for its desiccant beds. This ensures that energy from hot,
humid outgoing air can be recovered and used to heat the incoming air. Closedloop cooling systems, used in the cooling phase of regeneration, conserves energy by preventing the absorption of moisture before the bed switches over to drying. Since PVC pipes last for decades, they are used in one of the most common applications of compounding and cost less for recycling in the long run. Compounding is used to create light-weight materials that are easily transportable per truck load than metal pipes. Thus, lesser fuel is used in transportation of the material.
Latest innovations and technologies The gradual shift from kneaders to co-rotating twin-screw extruders with high output leads to a reduction in power consumption without compromising effective and efficient dispersion & distribution of constituents that make up the compound. The latest innovation in the compounding machinery industry is the control over the residence time and its distribution. Throughput per litre per hour has been increased from 100-150 kg per litre per hour to over 400 kg per litre per hour.
Courtesy: Certech ASBL
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Polymer compounding
Currently, equipment such as two-roll mills, Banbury mixers, continuous mixers, kneaders and co-rotating twin-screw extruders are used in compounding. The individual requirements are die face cutting, underwater pelletisation and strand pelletisation, Sioplast technology for polyethylene power cables, conical and parallel counter-rotating extrusion systems for PVC dry blends into pipes and profiles. The industry is moving towards the use of automation to overcome problems associated with human resources and skills. Human machine interface and integration of all upstream and downstream equipment is paving the way for improved productivity and reduced wastage.
Evolution of compounding process Combining of a base plastics resin with colours, modifiers, additive, reinforcements, fillers or other polymers is carried out in over 3,000 plants globally. This is because 55 million metric tonne of plastic materials, constituting roughly half of the plastics consumed in the world, are not used as base resin. The compounding process is employed to convert raw polymer or base resin to desired plastics that is more effective, uniform and can be used in varied applications. The product made from such a compound also has improved characteristics such as better performance, lower costs, ease of manufacturing and more attractive appearance. Over 300 grades of Acrylonitrile-ButadieneStyrene (ABS) and more than 10,000 different grades of plastic materials are manufactured using the compounding process. Plasticisers, reinforcements, flame retardants, colourants, carbon black, impact modifiers, lubricants, heat stabilisers, UV stabilisers, antioxidants, organic peroxides, blowing agents, antimicrobial agents, antistatic agents as well as macro, micro and nano fillers are some of the most common additives that are compounded. Other additives include clarifying agents, cross-linking agents, coupling 72
Advantages of co-rotating twin-screw extruders Narrow residence time distribution Lowest operating cost due to reduction of process steps Maximum process control due to continuous addition of material in various sequences without human intervention High levels of melting and mixing ability (dispersive, distributive and pure kneading) agents, deodorants, fragrance, nucleating agents, slip agents and vulcanising agents. These are added separately or in combination with one or several different resin types forming products with unique characteristics suited for myriad applications. Further, these are added in different stages of the process in the form of liquids or solids, either separately or in mixtures to achieve the required properties in the final compound. Compounding extrusion process mixes one or more polymers with additives to yield plastic compounds. The feeds may be pellets, powder and/or liquids, but the product is usually in pellet form, to be used in other plastic-forming processes such as extrusion and injection moulding. Machine size varies from tiny laboratory machines to the biggest extruders in the industry, running as much as 20 tonne per hour. Usually twin-screw extruders are preferred because they give better mixing at lower melt temperatures. Most of these have screws and barrels made up of smaller segments (mixing, conveying, venting and additive feeding) so that the design can be changed to meet the production and product needs. Singlescrew extruders can also be used for compounding, especially with appropriate screw design and static mixers after the screw. Selection of the components to be mixed (eg, viscosities, additive carriers) is as important as the equipment. Globally, over 30,000 processing units comprising single-screw extruders, internal mixers or dispersive kneaders, reciprocating single-screw extruder
Modern Plastics & Polymers | August 2012
(co-kneaders) and twin-screw extruders are currently used for compounding. Over the years, co-rotating twin-screw extruders have played a dominant role in compounding â&#x20AC;&#x201C; used by resin suppliers, proprietary and custom compounders or end-users, thus making it the most preferred processing equipment. This dominance is due to some clear advantages of co-rotating twin-screw extruders over other process equipment.
Research initiatives Backward integration into critical extruder parts and associated Research and Development (R&D) in metallurgy to withstand wear and corrosion is the latest in terms of research witnessed by the compounding industry. With its patented elements, companies have paved the way for most applications that were limited by feed to be now limited by torque. The R&D initiatives have led to narrow residence time, resulting in the ability to process sensitive materials. Processing companies have addressed fatigue caused due to high throughputs. Vacuum side stuffer technology introduced in the market has resulted in continuous production without stoppages for cleaning the blocked vents and preventing wastage of material.
Industry challenges Lack of academic study in developing compounds based on low-cost fillers and agro-based fibres as reinforcement is a problem. Inadequate experience and lack of facilities to develop composites for strategic requirements, such as bulletproof vests and aerodynamic parts, result in loss of man-hours and resources for the industry. It is necessary to develop the required facilities to support technical requirements of compounding without loss of productivity and energy efficiency. Satish Padmanabhan is Global Chief Executive Officer at STEER Engineering Pvt Ltd. Email: satish@ steerworld.com
INSIGHT & OUTLOOK: BOPP packaging
New-age material solution Besides supporting goods transportation and distribution, plastics packaging has become a significant factor determining marketing success, particularly in the consumer goods segment. With Biaxially Oriented Polypropylene (BOPP) being a preferred packaging material today, here are some interesting insights into the advantages as well as future prospects of BOPP film in the Indian packaging industry. Ashish Kothavade
A
bout 30 years ago, Biaxially Oriented Polypropylene (BOPP) was introduced as a supplement to cellophane, but only recently this material has become the most preferred material for functional flexible packaging. The term biaxially oriented means that the polypropylene film is stretched in both the Machine Direction (MD) and Cross Direction (CD). Because of its superior strength at low gauges, flatness, clarity and excellent printability, BOPP has become the material of choice for flexible packaging.
Processing practices BOPP can be manufactured as heatsealable or nonâ&#x20AC;&#x201C;heat-sealable material and in both cases produced as white opaque, pearl lustre or clear transparent 74
films. Certain additives improve its properties related to slip, blocking, modifying the heat-seal temperature and anti-static requirements. The basic BOPP manufacturing plant comprises compounding, feeding, extrusion, casting, orientation, gauging, winding, recycling, corona treatment and profile control systems. The main line plant is imported, while auxiliary equipment and utilities are indigenously obtained.
Packing in the advantages Today, technological advancements have created a practical and efficient outlook among people, which also includes their choice of product packaging. The improvements in peopleâ&#x20AC;&#x2122;s economic welfare have stimulated the demand for more hygienic and aesthetic packaging to attract consumers. Due to stiff competition, packaging is no longer just
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a supporting element in the distribution of goods, but determines marketing success, particularly for consumer goods. Thus, there has been a shift in the role of packaging. Plastic film, especially BOPP, is becoming a popular alternative material for the flexible packaging industry. BOPP film is not only more cost-efficient than other materials, such as cellophane film, kraft paper and aluminium, but also has greater resistance to pull and shock, temperature changes and gas penetration. BOPP film has an advantage in terms of its physical appearance owing to technological advancements in flexible packaging and rotogravure printing. Owing to its unique features, BOPP film is the most popular plastic film for use in flexible packaging as a substitute for cellophane film. It is more attractive and resistant to humidity. It is produced in plain and special film forms. BOPP film
BOPP packaging
Features and applications White/opaque/matte 13%
Metalised 12%
Transparent 75% Marketshare of different types of BOPP
is used for packaging of various products, including food products, cigarette and adhesive tape. By function, six types of BOPP film are available – plain, heat sealable, white pearlescent, metallisable/ metalised and Polyvinylidene Chloride (PVDC)-coated films. Currently, the demand for BOPP film in food packaging is growing due to the rapid strides in the country’s food processing industries such as instant noodles, snack foods and biscuits. About 55 per cent of the national BOPP film production is used for packaging of food products. The cigarette industry uses BOPP film in significant quantities, accounting for about 16 per cent of the national BOPP film production. Other industries contributing to the growth of the BOPP film industry in India include adhesive tape, album and lamination. The strong demand for BOPP film has encouraged investors to enter the BOPP film industry, as indicated by the existing investment plans in the industry.
Types of BOPP Various grades of BOPP are available today. Following are the characteristics and application areas of these grades: Transparent and opaque non–heatsealable film: This grade of film is generally used in conjunction with waxcoated paper. Non–heat-sealable films are used for pressure-sensitive tapes, overlay in print lamination, as release agents in decorative laminates and, most importantly, in lamination with other substrates selected to add sealability and other characteristics. The use of an opaque film further reduces light penetration and protects the products against Ultraviolet (UV) radiation. 76
Transparent, heat-sealable film: This grade of film is mostly used to pack snack products, either alone or as a laminate with other films. This film is manufactured in combination with several materials such as EthylenePropylene (EP) copolymers and broad seal-range polymers. This grade of BOPP is the most economical and widely used film. Opaque, heat-sealable film: Generally, opaque films are white pigmented to act as a light barrier. The opacity of the film can be up to 80-90 per cent, thus preventing the product from rancidity, which is caused by exposure to UV light. This grade of film is usually used in packing of biscuits, wafers, cough lozenges, etc. Pear lised BOPP: Beside opacity, this film provides a shiny, eye-catching, pearly appeal. Its low density enables the convertor to pack more products per quantity of film. Thus, the pearlised film is mainly used to pack confectionery items. Metalised, heat-sealable film: Metallisation is the process of depositing a thin layer of aluminium over the film under vacuum. The deposition of aluminium drastically improves the light, moisture vapour and oxygen barrier of metalised films. It eliminates the problem of pin holes and poor flex resistance, which often occur in bare aluminium foil. An optical density of about 2.0 is maintained so as to achieve better barrier properties. This film is available either alone or as a laminate with other films and is commonly used for packaging of cream biscuits, stuffed biscuits, pan masala, supari, etc.
Modern Plastics & Polymers | August 2012
BOPP film combines several good qualities, which make it a versatile and cost-effective packaging material. Yield: BOPP has the lowest specific gravity, and, for the same weight and thickness, it yields more area than any other packaging film. Tensile strength: This is a crucial parameter for certain applications, such as pressure-sensitive tapes. BOPP film has higher tensile strength than other films, making it a unique combination of strength and economy. Moisture-absorbing capacity: BOPP has the lowest absorption rate. This makes it a superior packaging material in providing protection to packed contents. This property is also useful in applications such as print laminations and tea chest linings to pack water-sensitive products. Moisture Vapour Transmission Rate (MVTR): BOPP has low MVTR, which enhances its ability to protect packaged food products from moisture accumulation, which increases the shelf-life of the packed products. This property of the BOPP film makes it suitable for packaging biscuits, snacks and confectionery. Tear strength: BOPP by far has the best tear strength as compared to all other films. This property signifies the stress it can handle before snapping. BOPP has high tear initiation strength. Low tear propagation of BOPP can also be used as an advantage by providing notches to a sealed pack to enable the customer to tear open a pack with ease.
Strength in uniqueness Owing to its numerous unique features, BOPP film is widely used in the packaging industry and suitable for both general packaging purposes and operations such as printing, coating and lamination. Ashish Kothavade is Senior Manager-Business Development at Plastiblends India Ltd. Email: ashish. kothavade@kolsitegroup.com
INSIGHT & OUTLOOK: Case Study
Virtual designing for enhanced productivity In this day and time, delivering high quality plastic parts in the shortest possible time, thereby optimising production costs, in a prerequisite to win business. Considering these aspects, Primera Plastics utilised the Autodesk Moldflow injection moulding simulation software to hone its competitive edge.
F
rom its humble beginnings in 1994, Primera Plastics has grown to become a top manufacturer of precision-moulded plastic products. Today, it operates 30 injection moulding presses at its award-winning facilities in Zeeland, Michigan, USA. The company produces custom plastic parts for a range of international customers, including premier furniture manufacturers and automotive Original Equipment Manufacturers (OEMs). For delivering competitively priced, high-quality plastic parts quickly, Primera Plastics relies on Autodesk® Moldflow® software. The company uses this software to produce more accurate quotes for prospective customers and optimises injection mould designs prior to manufacturing. With Autodesk Moldflow, Primera Plastics has been able to: Estimate and optimise production cycle times
Improve part quality and aesthetics Deliver more customer quotes with greater accuracy
Struggling with the challenge In order to win business in Michigan’s struggling economy, Primera Plastics had to bid competitively and deliver high-quality, aesthetically attractive plastic parts in the shortest possible time. The company bases its bids, largely on projected production costs and cycle times, which are difficult to estimate accurately. “Before Autodesk Moldflow, we approximated cycle time on the basis of part volume and our previous experience. After bidding, we were locked into a quote, so we always estimated conservatively to reduce our risk,” explains Scott Leatherman, Project Engineer, Primera Plastics Inc.
Design simulation for quality and cost competitiveness Source: Primera Plastics Inc
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Modern Plastics & Polymers | August 2012
Also, since many of the parts manufactured at Primera Plastics are used in automotive interiors and office furniture, high quality and aesthetics are critical features. Leatherman says, “A majority of plastic parts that we produce must be pleasing in appearance. If a part is manufactured to specifications and is dimensionally correct, but has an unintended visual defect, we are in trouble.”
The winning solution The Autodesk Moldflow software has helped Primera Plastics to perform simulations for developing more accurate quotes after receiving requests for plastic parts. Engineers run a range of simulations to study the flow of melted plastics, evaluate various runner systems and gate configurations, determine the most efficient cooling systems and predict volumetric shrinkage. With Autodesk Moldflow, one can virtually explore a range of issues before delivering a quote and starting manufacture. A big problem that can arise with quoting is under- or overestimating cycle times. “Underestimating cycle times cuts profits, but overestimation might not help get the business,” opines Leatherman. With Autodesk Moldflow, Primera Plastics can now more accurately predict the time taken for a plastic part to reach ejection temperature and identify the time taken for the part to warp. He adds, “This software informs about the time required to keep the part in the injection mould. With more accurate predictions of cycle times, we are more confident in our quotes.”
Case Study
tooling vendors after the mould is produced. But with Autodesk Moldflow simulations, our vendors can accurately design the moulds as per specifications. Before a mould is built, we are confident that it will be optimised for our injection moulding requirements.â&#x20AC;? Design validation before production Source: Primera Plastics Inc
Precision in moulds The cost of creating injection moulds often plays a major role in the total cost of manufacturing a plastic part â&#x20AC;&#x201C; in some cases, up to 75 per cent. â&#x20AC;&#x153;If the mould is not designed correctly, it can create problems for the entire production process. And if the estimated cost for the mould is wrong, our profit margins can be affected.â&#x20AC;? Thus, Primera Plastics must effectively communicate the exact tooling specifications necessary to mould a particular part to the thirdparty vendors that it uses to create its moulds. â&#x20AC;&#x153;Considerable time and money is wasted if we have to go back to our
Predictability in results Autodesk Moldflow simulations help Primera Plastics find and fix potential defects such as short shots, air traps and weld lines well before manufacturing begins, thus helping the company speed up production times & lower costs. â&#x20AC;&#x153;With Autodesk Moldflow software, we can pinpoint exact areas of concern, eg, incorrect draft wall or variations in part thickness. It helps us address possible defects inexpensively during the design phase, rather than later during production,â&#x20AC;? explains Leatherman.
can now communicate more effectively with customers about optimising plastic part designs and the injection moulding process. Leatherman says, â&#x20AC;&#x153;Autodesk Moldflow software helps us rise above our competitors who do not conduct similar validation before production. We can inform our customers if we find a specific area of concern and help them optimise their products & reduce their costs.â&#x20AC;?
Tool for triumph
Effective customer communication
With Autodesk Moldflow software, Primera Plastics can create more accurate and competitive quotes, thus protecting and expanding the companyâ&#x20AC;&#x2122;s profit margins. â&#x20AC;&#x153;Thanks to Autodesk Moldflow, we can easily save production time and cost. We can now study every aspect of the injection modeling process before manufacturing. Autodesk Moldflow is a valuable tool that has helped us maximise our profits,â&#x20AC;? concludes Leatherman.
Using the insight gained from Autodesk Moldflow simulations, the company
Courtesy: Autodesk Inc
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August 2012 | Modern Plastics & Polymers
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AUTOMATION TRENDS: Thermoforming robotic stackers
Key to efficient material handling
Increasing competition and a rising retail sector emphasise the use of automation in improving the economics of a process, particularly thermoforming. Lionel Alva outlines how thermoforming robotic stackers help augment the dynamics of a highly competitive industry, especially food processing where safety and precision are a prerequisite. Illustration: Chaitanya Dinesh Surpur
I
n the food industry, the approach towards material handling is a key consideration since hygiene and safety are essential facets of the manufacturing process. This becomes particularly difficult since market trends depict an increasing need for high volume production, with a tendency towards a more automated manufacturing setup. The degree of planning for an automated process to work effectively for a long time along with high initial setup costs requires a concerted effort. However, when properly executed, it can help in the creation of an exemplary manufacturing process that is in tune with demanding market conditions. This calls for smart manufacturing decisions where a keen cost-utility analysis is necessary, thus requiring 80
that technology is not necessarily top of the line or highly expensive, but fulfills manufacturing criteria. Another requirement for automation is the need for highly skilled and dependable labour that can understand a complicated automated setup.
Labour and manufacturing cost reduction Thermoforming machine automatic robotic stackers can significantly lower thermoforming labour and material costs, thereby shortening changeover times. A robotic stacker, designed for use with thermoforming machines, is mounted above the stacking station with its main beam either in line with the direction of the web, designated L-type, or transverse to the web direction, designated X-type. While
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the L-type stacker transfers part stacks to the end of the machine, the X-type stacker places stacks of parts on a conveyor belt running on the side and parallel to the web. The robotic stacker consists of a robotic arm and the kit gripper using up to six-axis servos and is placed in front of the thermoforming machine. The robotic stackers, with dual-gripper heads capable of handling two part stacks simultaneously, are used for fast-cycle thermoforming machines. The robot gripper head of an automated robotic stacker withdraws the part from the mould and rotates from the vertical to the horizontal plane to stack the parts on a conveyor. Using a robotic stacker, manpower requirements are reduced and, in an ideal situation, only one operator is needed to remove the stacks of parts from the end
Thermoforming robotic stackers
The machines are usually programmable, offering a and high energy savings,
offer, robotic stackers provide immense help in a cost competitive, volume-driven environment where there is little margin for error. Vijay Chauhan Vice President, Artek Enterprises Pvt Ltd
The number of products on a stack can be programmed as per requirement. As soon as the preset count is reached, the conveyor belt moves forward to deliver the stack to the following packaging unit or further processing unit such as hole punching press, rim rolling and bag making. Hari Gangi Project Manager, Godrej Efacec Automation & Robotics Ltd
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of the machine compared. Furthermore, operator health/safety is improved since the usual operator twisting and turning motion is eliminated, significantly lowering the incidence of back injury to the operator. Robotic stacking can also improve material usage by up to 20 per cent. As each part is lifted individually by the robot, using grippers or vacuum pads, there is no need to provide clear uninterrupted lines of space between part rows. This allows individual parts to be staggered and more closely spaced than with mechanical stacking, which makes for more efficient use of the thermoform sheet. With mechanical stacking, operators sometimes cannot keep up with the machine output, which can cause significant scrap rates to incur. Robotic stacking can easily provide anti-nesting to avoid stacking parts too tightly together by rotating successive parts through 90° or 180°, thus eliminating expensive mould undercuts otherwise required to provide for anti-nesting. After thermoforming is complete, the products are picked by the robotic stacker and placed on the conveyor belt or magazine as per the product shapes. â&#x20AC;&#x153;The number of product on a stack can be programmed as per requirement and as soon as the preset count is reached, the conveyor belt moves forward to deliver the stack to the following packaging unit or further processing unit such as hole punching press, rim rolling and bag making,â&#x20AC;? avers Hari Gangi, Project Manager, Godrej Efacec Automation & Robotics Ltd.
Stackers offer reliability The stacker is built to withstand the rigours of the modern, high-speed thermoforming environment. The product is stacked onto a primary conveyor in a combination of A-B-C rows, with the servo-controlled arm decrementing the nest height with each stack (eg, minus 5 mm at a time.) Once the stack height count is reached, product is fed onto an accumulating conveyor. Depending on stack height and machine speed/setup,
Modern Plastics & Polymers | August 2012
the accumulating conveyor will hold typically 20-30 minutes of production. As products are stripped, the stacker tooling automatically matches the machine transport speed and distance. This helps when the formed product is not 100 per cent cut and strips poorly. Individually operated vacuum generators allow for A, AB or ABC stacking (if three are fitted.) One option is to add a 90° rotation (cylinder) to this mount head. Therefore, products that need to be stacked across the sheet can be accommodated. Tooling consists of an inexpensive 6-mm laser cut aluminium plate fitted with vacuum cups, air line and fittings where the cups/fittings can be continually reused on any number of stack plates. â&#x20AC;&#x153;Robotic stackers are important, especially in the food industry where hygiene is a prime consideration. The machines are usually programmable, lending them a great degree of flexibility and high energy savings, and are extremely efficient. Considering the benefits they offer, robotic stackers provide immense help in a costcompetitive volume-driven environment where there is little margin for error,â&#x20AC;? avers Vijay Chauhan, Vice President, Artek Enterprises Pvt Ltd.
Manufacturing automation Considering the demanding nature of the market today, where cost, efficiency and speed of production can make or break an organisation. It is imperative for medium- to large-scale industries to incorporate automation within the manufacturing process. Moreover, this is ideal when an organisation is looking to achieve economies-of-scale with a high-volume and high-quality output. This will allow organisations in India to set a precedent and bring forth a new level of efficiency and profit. It would also reduce dependence on highly skilled labour, reducing the slightly convoluted nature of the manufacturing process while making it far more approachable and accessible. Email: lionel.alva@infomedia18.in
ENERGY MANAGEMENT: Hot runner systems
Courtesy: Husky Injection Molding Systems Ltd
Investing in innovation, harvesting efficiency
With intensifying global competition for moulding plastic parts, the pressure is rising on reducing per piece moulding cost and energy consumption in the injection moulding process. This has increased the demand for hot runner systems. Avani Jain analyses the benefits of hot runner systems in reducing energy consumption during the plastic injection moulding process.
T
oday, keeping energy concerns in mind, the demand for hot runner systems is growing by the day. It is one of the important enhancements that manufacturers can incorporate into their mould to improve part quality, reduce production times & energy usage and remain price competitive. Rajendran Kasi, Regional ManagerSAARC Nations, Husky Injection Molding Systems Pvt Ltd, says, “Demand for direct gating of plastic parts is increasing. Hot runners continue to replace cold runner technology, thus allowing customers to run faster cycles and achieve more efficient production. In fact, the hot runner industry is growing faster than the overall plastics industry.”
Functioning of hot runners A hot runner system is an assembly of heated components used in plastic injection moulds that inject molten plastics into the mould cavities. A hot 84
runner system usually includes a heated manifold and several heated nozzles. The main task of the manifold is to distribute the molten plastic material entering the mould to various nozzles, which then meter the melt precisely to the injection points in the cavities. Hot runners are one of the most sophisticated components of an injection mould – key to achieving profitability and part quality. Kasi notes, “Decreased energy consumption can be achieved in two ways. First, better insulation, which enhances energy efficiency by using appropriate materials with low thermal conductivity in places where hot steel touches the cold plate. Secondly, more efficient heaters and the use of electrical actuated valve stems versus pneumatic or hydraulic actuation systems. This can be achieved through the use of hot runner systems.” In a nutshell, hot runners are fairly complicated systems that have to ensure the plastic material inside are heated uniformly, while the remaining part of
Modern Plastics & Polymers | August 2012
the injection mould is cooled in order to solidify the product quickly.
Types of hot runner systems Hot runner systems are of two main types – insulated and heated. Insulated runner moulds have oversized passages formed in the mould plate. The passages are of sufficient size through which, under conditions of operation, the insulated effect of the plastic material (frozen on the runner wall) combined with the heat applied with each shot maintains an open, molten flow path. For heated runner systems, there are two designs – internally heated and externally heated. In the internally heated system, the plastic melt flows directly over slender heaters inside oversized runners. This system takes advantage of the insulating effect of the plastic melt to reduce heat transfer (loss) to the rest of the mould. On the other hand, the externally heated system consists of a cartridge-heated manifold with interior flow passages. The manifold is designed with various
Hot runner systems
insulating features to separate it from the rest of the mould, thus reducing heat transfer (loss).
Shorter cycle time, reduced energy usage
Cold runners often have a higher pressure drop than hot runner moulds. The extra energy (higher machine pressure) required to fill the cavity with a cold runner is wasted as the pressure drops. This is not the case with the hot runner system. Rajendran Kasi Regional Manager-SAARC Nations, Husky Injection Molding Systems Pvt Ltd
Hot runner systems offer high rates of efficiency and productivity. Most notably, these cut production costs dramatically. The elimination of cold runners makes hot runners the preferred solution for clean room production and for achieving energy efficiency. Amit Mahant Director, PK Plastic International Pvt Ltd
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The cycle time of any mould is largely influenced by the cooling cycle – how fast the resin can be sufficiently cooled so that the part can be ejected without permanent deformation. The usage of hot runners systems help in reducing the overall moulding cycle by individual time reductions of the various processes involved, thereby contributing to increased output per unit time. The shorter cycle time also results in less energy consumption. Although hot runner systems are more expensive capital investments upfront, they are a significantly more cost-efficient means to keep production costs to a minimum over the long run and reduce energy consumption to a large extent. Husky has made many changes in their hot runner systems to help moulders achieve maximum energy efficiency. Kasi notes, “Two of our recent developments help reduce overall energy consumption to a large extent in the injection moulding process. The electric actuated valve gates consume 70 per cent less energy compared to a similar pneumatic or hydraulic actuation system. Further, our new side-gating technology allows customers to direct gate plastic parts that previously would have to be gated with a cold runner.”
Additional advantages Since there is no cold runner to discard or recycle, resin consumption is reduced. They also help reduce the labour cost as secondary operations such as manual part de-gating and trimming are eliminated with a hot runner system. Further, they help in mould cost savings, as a smaller cavitation hot runner-equipped mould may be able to satisfy production quotas using a smaller number of cavities since it runs at a faster cycle. Hot runners allow reduced injection pressures during packing, as the system
Modern Plastics & Polymers | August 2012
does not have to deal with injecting resin through a cooled runner. Thus, the use of hot runner systems not only improves energy efficiency to a large extent but offers other benefits as well. Amit Mahant, Director, PK Plastic International Pvt Ltd, says, “Hot runner systems offer high rates of efficiency and productivity. Most notably, these cut production costs dramatically. The elimination of cold runners makes hot runners the preferred solution for clean room production and for achieving energy efficiency.”
Hot versus cold runner systems Hot runner systems help in better energy savings than cold runners. Kasi avers, “With cold runner tools, a significant amount of resin needs to be melted just for the purpose of filling the cold runner to reach the cavity. Even if re-used, this resin serves no other purpose than to transport the resin to the cavity. In contrast, with a hot runner mould, the amount of resin required for filling the cavity is prepared in the injection unit, which leads to reduced shot volume. Further, cold runners often have a higher pressure drop than hot runner moulds. The extra energy (higher machine pressure) required to fill the cavity with a cold runner is wasted as the pressure drops. This is not the case with the hot runner system.”
Future outlook Despite the higher initial cost, the long-term benefits of equipping a mould with a hot runner system can be easily justified. In future, every plastics moulder will focus on maximising productivity and efficiency by using hot runner systems. “When compared to cold runner technology, hot runner technology helps customers achieve this goal by allowing parts to be produced at faster cycle times and with less resin. In addition, increasing labour costs are driving the need for more automation and precision. Therefore, hot runner systems are a key technology to achieve a higher degree of automation, productivity and precision,” claims Kasi. Email: avani.jain@infomedia18.in
POLICIES & REGULATIONS: Impor t duty on titanium dioxide
Opening trade avenues for Indian industry The import duty structure for sourcing of titanium dioxide has adversely affected the core competency of the domestic masterbatch market, resulting in fluctuation of raw material prices in India. Lionel Alva assesses the influence of this duty structure on titanium dioxide and its impact on the masterbatch industry as well as the plastics industry as a whole.
R
aw materials’ supply in the plastics and polymers industry face severe limitations owing to the growing menace of unrestricted dumping. The rising cost of power, energy, financial services and equipment are adding to the woes, making raw material production an incredible challenge that is threatening to dampen the prospects of a promising masterbatch industry in the country.
Titanium dioxide in masterbatches Titanium dioxide is widely used by the paint industry and in the dyes & pigments sector, besides production of white masterbatches in the plastics & polymers industry. These sectors are 88
promising and growing fast. Various chemicals such as titanium dioxide, antimony oxide, zinc oxide and zinc sulphide are used to provide plastics properties. Some of the major reasons for the use of titanium dioxide are for its special properties, eg, average particle size (0.19-0.22 μm), high refractive index, etc. Titanium dioxide is perhaps the most critical of these components. At present, the Custom Duty on rutile grade titanium dioxide is 10 per cent. Various forms of titanium dioxide can be used in masterbatches or similar polymer compositions. One form of titanium dioxide – pigmentary titanium dioxide – is used for producing a white composition and/or improving opacity.
Modern Plastics & Polymers | August 2012
Titanium dioxide is also used in the formulation of masterbatches, which is often called ‘transparent’ titanium dioxide since, due to its particle size, the attenuation of visible light is low. This form of titanium dioxide has a high attenuation for Ultraviolet (UV) light; therefore, it is added to plastic compositions to provide protection from UV light. Titanium dioxide can be prepared by various processes such as the ‘sulphate’ or ‘chloride’ process, and may be in the anatase or rutile crystal form, although rutile titanium dioxide is the preferred form. Considering that a principal use of treated inorganic pigments is the formulation of masterbatch
Impor t duty on titanium dioxide
Anomalies in the import duty structure rate for sourcing of titanium dioxide have put a strain on the core competency of the domestic masterbatch market, leading prices of raw materials and, conversely, making import of masterbatches a cheaper and sustainable alternative. Aditya Tandon Director, Classic Polymers & Resins
It is important to rethink the duty structure since titanium dioxide is among the most crucial components of plastic masterbatches and makes producers look towards reformulation of masterbatch production when batch production does not meet the right appeal or Manoj Dugar Chairman, Dugar Group of Industries
90
compositions for pigmented plastics, the particle size of inorganic solids will be such that the material is suitable for this purpose. Among several pigmented films, almost all are found to consist of higher concentrations of hydroperoxide species before and after thermal oxidative ageing as compared with the control unpigmented polymer film. Thus, titanium dioxide pigments play an important role in the photothermal oxidation of polyethylene through their ability to catalyse thermal oxidation of the polymer. The primary purpose of titanium dioxide has been to impart white colour to plastics films. Each year, the demand for masterbatches has increased at a sporadic rate and their overall demand level has also increased. Functionalities such as weather resistance and optical reflectance are in high demand from masterbatches. Evidently, titanium dioxide is an integral aspect in the formulation of high-performance masterbatches. â&#x20AC;&#x153;Anomalies in the import duty structure rate for sourcing of titanium dioxide have put a strain on the core competency of the domestic masterbatch market, leading to a fluctuation in the prices of raw materials and, conversely, making import of masterbatches a cheaper and sustainable alternative. They are integral to not only the plastics industry, but also chemicals industry at large, which forms the backbone of the Indian industries,â&#x20AC;? avers Aditya Tandon, Director, Classic Polymers & Resins.
Need to rethink the import duty structure The cost of titanium dioxide as a commodity has been spiraling upwards, with an appreciation of 5-6 per cent in the last one month. This has had a great impact on plastic masterbatch manufacturers who have seen little respite from the already sporadically high duty structure. Moreover, with masterbatch imports coming in easily from countries in close proximity such as China and Thailand have further exacerbated the current scenario. It would make little
Modern Plastics & Polymers | August 2012
sense for masterbatch manufacturers to ramp up their production capacity since they would find few takers, thus making large-volume business a difficult and expensive proposition in terms of risk. This is also critical for the plastics industry since the actual content and particle size of titanium dioxide in masterbatch formulation have significant impact on non-homogeneity of mixing of masterbatch formulation and cause to reduce optimised pigment colouration. Manoj Dugar, Chairman, Dugar Group of Industries, asserts, â&#x20AC;&#x153;Globally, there is extreme shortage of titanium dioxide, which makes production a difficult endeavour. It is important to rethink the duty structure since titanium dioxide is among the most crucial components of plastic masterbatches and makes producers look towards reformulation of masterbatch production when batch production does not meet the right appeal or specification, and this affects the cost of manufacturing, production schedule and customer satisfaction. This also complicates the production process since the use of other additives need processing and refinement, but titanium dioxide does not need much work. This is the primary reason why Indian masterbatches are not on par with international standards.â&#x20AC;? Therefore, a positive change in outlook requires a better cognisance of the plastics industry by the bureaucracy.
Strengthening policy structure In the present context, where the country is not doing well fiscally, the impact of a weak policy on the industry is all the more severe. It is imperative that the burden on the industry be lessened by re-thinking the policy framework on several chemicals that are integral to maintaining the competency of the Indian industry. A reformulation towards a lesser duty levied on imports would ease the burden on producers and establish homogeneity in bringing the efforts of the raw material industry towards fruition, leading to strong economic machinery that can overcome minor price fluctuations. Email: lionel.alva@infomedia18.in
STRATEGY: Masterbatch processing units
With increasing demand for quality masterbatches, manufacturers are constantly adopting new technologies to achieve a better product and prevent contamination during masterbatch processing. Avani Jain highlights methods that companies can adopt to prevent contamination in masterbatch processing units. Some additives and pigments can also affect the performance of the surrounding lines; shade variation can also occur if not controlled properly. Hence, a clean environment with proper practices are mandatory for processing safety at all stages, ie, storage of pigments/fillers, opening of bags, transfer to primary silos or feeders, etc.”
A
dditives and masterbatches constitute a highly successful and essential segment of the global plastics industry. The last 15 years have witnessed a constantly increasing impact of masterbatches in applications such as antistatics, foaming and flame retardancy. The masterbatches market in India has been growing at a rate of 15 per cent in the last few years, driven by demand from end-user segments. At present, the Indian masterbatches industry has a total capacity of 350,000 Tonne Per Annum (TPA), comprising organised (25 per cent) and unorganised (75 per cent) players. This increase in demand is a good sign for the industry, encouraging quality focus. Companies can achieve this goal by preventing contamination in masterbatch processing units. Dr Premal Vashi, Director-Engineering Plastics, Som Shiva (Impex) Ltd, avers, “Technically, masterbatch manufacturing is not easy, but Indian manufacturers have taken it in a different way. Masterbatch is a concentrated pigment and has to be diluted as per requirement. Also, colour contamination is a normal 92
occurrence in masterbatch processing, which affects product quality. Masterbatches contain a high percentage of pigments, and handling pigments is a difficult task. Thus, it is important to process masterbatches in a clean and dust-free manufacturing environment.”
Cleanliness in processing environment The concept of masterbatches was developed to avoid direct use of pigments by end-users, ie, injection moulding, blow moulding, extrusion and other applications. Dr Vashi explains, “Masterbatches are made with various base polymers using organic/inorganic pigments along with other additive packages. These pigments have particle sizes in microns and generally float in the air during the blending and feeding stage. To avoid floating and dusting, many methods have been incorporated such as the use of waxes and anti-flocculants. It must also be noted that some of the pigments are hazardous in nature and must be carefully monitored during the mixing and feeding stage.
Modern Plastics & Polymers | August 2012
Preventing contamination Companies c an adopt various steps to prevent contamination in masterbatch processing units. They must have scrubbers at feeding points, ie, from silos to feeders. All mixing activities should be planned away from processing area and split feed systems should be used to the maximum extent possible. The processing area should be kept clean and floors washed regularly to avoid colour contamination. D ust y atmosphere impacts masterbatch processing. Parag Parikh, Partner, Universal Colorant Company, comments, “The area of mixer and extruder should be separated with a wall. There should be exhaust fans to remove dust particles; the extruder and its surroundings should be kept clean after
Masterbatch processing units
Indian manufacturer are not techno-savvy and do not prefer to use sophisticated technologies, but things are changing gradually. Today, manufacturers are upgrading technologies to compete against multinational companies. Dr Premal Vashi Director-Engineering Plastics, Som Shiva (Impex) Ltd
Steps should be taken to clean mixers after every colour change and, if possible, separate mixers should be used for all basic colours. Different pigments (colourants) should be kept separately in closed containers. Parag Parikh Partner, Universal Colorant Company
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Location Courtesy: Loxim Industries Ltd Photo: Vijaykumar Soneji
Clean room practices for compounding lines
every colour change; and steps should be taken to keep the shop floor clean from dust/spillages. Dust collectors can also be used.” Cross-contamination of pigment can also impact masterbatch quality. “Steps should be taken to clean the mixers after every colour change and, if possible, separate mixers should be used for all basic colours. Different pigments (colourants) should be kept separately in closed containers. Also, base polymers need to be stored and covered in separate areas,” notes Parikh. Many companies in the segment have adopted the above-mentioned steps. Dr Vashi claims, “We maintain environment-f riendly manufacturing through a closed-loop plant with gravimetric feeding systems, silos and positive air with proper dust collection system. We have seven different sophisticated lines with all necessary accessories. We have a facility to take up different colour production at a time in different lines without any contamination. Human safety is equally important for us and we regularly educate the workers and train our manufacturing teams.”
Safety and quality Quality today is a key word in the industry. No company can survive without ensuring product quality and consistency. “The market is competitive and if we fail to deliver product quality, we will be out of the market. The general points a manufacturer should consider during masterbatch processing include
Modern Plastics & Polymers | August 2012
the use of proper masks during blending operations, protective eye-glasses during extrusion process, fire extinguishers at all points near the processing areas and in the mixing room. These points are mandatory as some of the pigments may create problems in mixing and yield volatile products. The finished goods should be tested for their quality and properties, eg, shade, strength, etc,” asserts Dr Vashi.
Strategies for a bright future Masterbatch processing in India is slightly different as compared to international standards. Dr Vashi emphasises, “Indian manufacturers are not techno-savvy and do not prefer to use sophisticated technologies, but things are changing gradually. Today, manufacturers are upgrading technologies to compete against multinational companies. New technologies, sophisticated extruders, feeders and downstream equipment are important in masterbatch industries.” New technologies keep surfacing every now and then for ensuring good quality. Dr Vashi concludes, “Companies today are adopting highly sophisticated technologies to produce environment-f riendly products. As the world is now targeting the Indian market and big players are establishing their plants in India, the time is now right to invest in proper technology and infrastructure, thereby providing quality products to customers and the industry at large.” Email: avani.jain@infomedia18.in
TIPS & TRICKS: Plastic packaging
STEPS TO BOOST
barrier performance
Plastic packaging often requires barrier properties that are specific to the contents inside. Hence, it is important for packaging companies to choose the right additives and masterbatches for the right applications. Anwesh Koley enlists some of the key requirements of raw materials for packaging.
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mong plastics’ attributes for applications in packaging are flexibility, clarity, low cost, shelf appeal, ease of transport and storage. The most important feature for food and beverage packaging is delivering fresh & safe
products to the consumer. This often involves maintaining performance over long intervals between actual production and eventual consumption. This time interval, commonly known as ‘shelf life’, is increasing as food and beverage producers seek to distribute
their products on a global basis and as plastics makes inroads into areas that were previously the domains of metal and glass packaging. Email: anwesh.koley@infomedia18.in With inputs from Sumit Dhingra, Director, Dhingra Polymers
Following are some of the key requirements for better barrier properties:
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Right coating: Both flexible films and rigid containers are coated with ultra thin layers of materials that provide high intrinsic barrier. A variety of vapour deposition technologies are used for coating of aluminium and silicon oxides. A new variant uses microwave plasma deposition to deliver amorphous carbon coatings onto the interior surfaces of beverage containers.
Medium barrier properties: This is a cost-driven approach that requires small micelles of high-barrier polymer to be created and evenly distributed. High-barrier plastics usually has refractive index different from its medium-barrier hosts. But blend levels are only in high single digits before clarity suffers, limiting this approach to shorter shelf-life applications.
Oxygen scavengers: Nanoclay is usually used as a barrier layer of a multilayer structure. Commercial oxygen scavengers are incorporated into polyethylene terephthalate or polyamides, while commercial nano-clays are incorporated primarily into polyamides. As these additives become part of the polymer matrix, concerns about adherence, scratching and delamination are minimised.
Spray or dip technology: Packaging external surface is coated with high barrier epoxies, using spray or dip technology. Coated articles are limited by the adherence between the coating and plastic substrate. The rigours of filling and transportation can compromise the coating, and hence packaging shelflife. Exterior coatings can scratch off while interior ones can crack or delaminate.
Barrier enhancing additives: Although this concept is not new, it has only recently become feasible with the advent of advanced material technology. Two commercial approaches are in use – oxygen scavengers and nano-clays. As the additive term implies, the approach consists of incorporating functional materials directly into a plastic matrix, and then using the upgraded plastics as a component of an article.
Oxidative polyolefins: Conventional polyolefins are not biodegradable due to their high molecular weight. Besides, biodegradation occurs in an aqueous medium, whereas polyolefins are hydrophobic. Oxidatively degraded polyolefins are polar molecules of lower molecular weight that are conducive to biodegradation. Traditional polymers undergo slow oxidative degradation.
Modern Plastics & Polymers | August 2012
PROJECT S
New projects and expansion activities are the barometers of industrial growth. These also present business opportunities to service providers like consultants, contractors, plant & equipment suppliers and others down the value chain. This feature will keep you updated with vital information regarding new projects and capacity expansions being planned by companies in the plastics, polymers and allied industries.
Coextruded plastic sheets Xpro India Project type New facility Project news As part of its long-term consolidation strategy, Xpro India is implementing a co-extruded plastic sheets manufacturing unit in Maharashtra. This facility will feature state-of-the-art equipment in light of the much anticipated demand in the near future. Xpro India believes that the plastics industry is in for a paradigm shift by 2015, and there already exist enormous prospects in the market. Project location Pune, Maharashtra Project cost Not known Implementation stage Planning Contact details: Xpro India Ltd 1, Industrial Area, NIT Faridabad - 121001, India Tel: 0129-2233915/17 Fax: 0129-4028300 Email: xprocorp@birlas.com
Contact details: Coles Supermarkets PO Box 2000, Glen Iris VIC 3146 Tel: +1800-061 562 Fax: +1800-0829-3818 Email: recycling.mac@coles.com.au
In-line polymer inspection system Ibanez Extrusoras Project type Expansion Project news This project proposes to develop a compact, non-invasive, real- time sensor based on an ultrasonic piezoelectric transducer for in-line measurements during polymer processes. Project location Spain Project cost â&#x201A;Ź 12 million Implementation stage Planning Contact details: Ibanez Extrusoras SL calle Doctor Fleming Quart de Poblet, Valencia, Spain Tel: +34-961549411 Fax: +34-961533197 Email: rico.guarda@ibanezextrusoras.co.es
Coles mixed plastic recycling Coles Supermarkets Project type Services Project news Coles Supermarkets will conduct a six-month trial that provides Victorian customers with a convenient and responsible way to recycle a range of plastics that are currently not included in the kerbside recycling programme. Project location Australia Project cost $ 254,220 Implementation stage Ongoing
Packaging and hot runner systems Husky Injection Molding Systems Project type New facility Project news The Canada-based company will make large plates for its packaging and hot runner systems produced at its Shanghai regional headquarters and manufacturing plant, where it is running out of space. Since it started operations in China in 2004, the new facility will be located in Suzhou, Jiangsu Province. The company has doubled its footprint and more than tripled its regional workforce. Project location Suzhou, Jiangsu, China
Project cost â&#x201A;Ź 39.8 million Implementation stage Planning Contact details: Husky Injection Molding Systems 500 Queen Street South Bolton ON L7E 5S5, Canada Tel: +905-951-5000 Email: murquhart@husky.ca
Petrochemical complex Rosneft Petroleum Company Project type New facility Project news The construction of a petrochemical production plant in the Primorsky (maritime) Territory (PT) will be conducted with a strict observance of all environmental norms. It is planned that Rosneftâ&#x20AC;&#x2122;s new plant near Nakhodka will produce monoethylene glycol, polyethylene, polypropylene, aromatic hydrocarbons and ethyl benzene. Petroleum, supplied via the Eastern Siberia-Pacific Ocean oil trunkline, and will be used as feedstock. Construction of this petrochemical complex will stimulate processing sectors in the Far Eastern Federal District, giving a boost to PTâ&#x20AC;&#x2122;s foreign economic activities to increase the portâ&#x20AC;&#x2122;s cargo handling capacity and create new jobs in the area. Project location Primorye krai, Russia Project cost $ 10 billion Implementation stage Planning Contact details: 26/1, Sofiyskaya Embankment 117997, Moscow, Russia Tel: +07-4957774422 Fax: +07-4957774444 Email: pr@rosneft.ru
Information courtesy: Tendersinfo.com 1, Arch Gold, Next to MTNL Exchange, Poisar, S V Road, Kandivali (W), Mumbai - 400 067, Maharashtra, India ; <= >// / OOO ?J V X Y= >// / > ? Q V [ <= \ 5 ] ^ 5_
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Modern Plastics & Polymers | August 2012
TENDERS
Latest Popular Tenders brought to you by www.tendersinfo.com Collection bags
Recanning wooden chairs with cane plastic
Org TRN Desc BOD Loc BT
Org : Military Engineer Services TRN : 11821620 Desc : Recanning of different type of wooden chairs with cane and plastic. Repair of wooden and steel furniture items in Pathankot BOD : 14 August, 2012 Loc : India BT : Domestic competitive bidding
: : : : : :
Ministﾃｩrio da Educaﾃｧﾄバ 11775067 Purchase of bags for material collection 10 August, 2012 Brazil International competitive bidding
Plastic bottles Org : Uttarakhand Jal Sansthan TRN : 11734348 Desc : Supply, installation, testing and commissioning of plastic bottles BOD : 13 August, 2012 Loc : India BT : Domestic competitive bidding
Plastic crates for perishable agricultural commodities Org : Empresa Municipal de Mercados (EMMSA) TRN : 11810494 Desc : Plastic crates (350,000) for perishable agricultural commodities BOD : 13 August, 2012 Loc : Peru BT : International competitive bidding
Processing of polypropylene granules Org : Al Furat Company TRN : 11795615 Desc : Processing of Polypropylene (PP) granules for factory plastic bags with PP amount at 1,000 tonne BOD : 13 August, 2012 Loc : Iraq BT : International competitive bidding
Paper and/or plastic bags Org TRN Desc BOD Loc BT
: : : : : :
Southern District Health Board 11749593 Supply of paper and/or plastic bags 14 August, 2012 New Zealand International competitive bidding
Plastic water tanks Org TRN Desc BOD Loc BT
: : : : : :
Lake Victoria North Water Services Board 11808451 Supply and delivery of plastic water tanks (in three lots) 14 August, 2012 Kenya International competitive bidding
102 Modern Plastics & Polymers | August 2012
Paper and plastic articles Org TRN Desc BOD Loc BT
: : : : : :
Troms Fylkeskommune 11487408 Paper and plastic articles 15 August, 2012 Norway International competitive bidding
Automatic toggle machine Org TRN Desc BOD Loc BT
: : : : : :
Ordnance Factory Board 11620653 Supply of automatic toggle machine 17 August, 2012 India Domestic competitive Bidding
Injection moulded axle box front cover Org : South East Central Railway TRN : 11632591 Desc : Supply of injection moulded thermoplastic polyster elastomer [Hytrel] axle box front cover for BG main line and EMU coaches BOD : 17 August, 2012 Loc : India BT : Domestic competitive bidding
One unit bioreactor Org : Municipality Of Linamon, Lanao Del Norte TRN : 11829195 Desc : Supply & delivery of one unit bioreactor (0.5 tonne capacity), one unit plastic densifier with 50 kg capacity and one unit shredder BOD : 17 August, 2012 Loc : Philippines BT : International competitive bidding
TENDERS
Latest Popular Tenders brought to you by www.tendersinfo.com Plastic waste processor
Loc
: India
Org TRN Desc BOD Loc BT
BT
: Domestic competitive bidding
: : : : : :
Public Works and Government Services Canada 11774079 Plastic waste processor 20 August, 2012 Canada International competitive bidding
Cardboard, paper and plastic Org
: Renovasjonsselskapet GlĹ&#x2122;r Iks
TRN : 11606263 Desc : Provide cardboard, paper and plastic BOD : 24 August, 2012
Plastic water tanks
Loc
: Norway
Org TRN Desc BOD Loc BT
BT
: International competitive bidding
: : : : : :
Lake Victoria North Water Services Board 11741453 Supply and delivery of plastic water tanks 21 August, 2012 Kenya International competitive bidding
Plastic packaging Org TRN Desc BOD Loc BT
: : : : : :
Poczta Polska SA 11811619 Supply of plastic packaging 21 August, 2012 Poland International competitive bidding
Laboratory twin-screw extruder Org
TRN : 11796039 Desc : Laboratory twin screw extruder BOD : 24 August, 2012 Loc
: Germany
BT
: International Competitive Bidding
Plastic pipes and fittings for water pipes Org
: Dunea NV
TRN : 11741829 Desc : Supplying plastic pipes and fittings for water pipes made of PVC and PE to
Injection moulding plastics for high school godart roger Org : Conseil RĂŠgional Champagne Ardenne TRN : 11676425 Desc : Injection moulding plastics for high school hydraulic godart roger BOD : 22 August, 2012 Loc : France BT : International competitive bidding
: Universität des Saarlandes
500 mm diameter BOD : 28 August, 2012 Loc
: Netherlands
BT
: International competitive bidding
Co-kneader Org
: UniversitĂŠ Jean Monnet
TRN : 11796041
Plastic trays Org : Department of Posts TRN : 11764980 Desc : Supply, install/commissioning of 20,000 LSM and 60,000 MMS plastic trays to be installed at AMPC Delhi and Kolkata BOD : 22 August, 2012
Desc : Acquisition and installation of a co-kneader for laboratory research and development of formulations based on thermoplastic polymers and thermosets BOD : 6 September, 2012 Loc
: France
BT
: International competitive bidding
Org: Organisationâ&#x20AC;&#x2122;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 ; <= >// / OOO ?J V X Y= >// / > ? Q V [ <= \ 5 ] ^ 5_
August 2012 | Modern Plastics & Polymers 103
EVENT LIST
National
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Indiaâ&#x20AC;&#x2122;s premier industrial trade fair on products and technologies related to Machine Tools, Hydraulics & Pneumatics, Process Machinery & Equipment, Automation Instrumentation, Packaging & Auxiliaries, IT Products, Electrical & Electronics, Material Handling and Safety Equipment.
For details contact: Network18 Media & Investments Ltd Network18 Media & Investments Ltd, Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028. ; <= >// ?>>? JOÂ&#x20AC; V X Y= >// ?>>? JJZZ V [ <= Y\ ] ^ 5 V = 5 + Y\ 5_
Specialty Films and Flexible Packaging Global Conference 2012 This one-day conference is dedicated to the surging flexible packaging sector in India and the opportunities & challenges faced by the industry. With representative speakers from the Indian as well as global industry, this event will offer key insights into the developments in flexible packaging materials and processing machinery; September 11, 2012; at Hotel Grand Hyatt, Mumbai For details contact: Nidhi Verma Elite Plus Business Services Pvt Ltd 61, Radheya, 14th Road, Plot 359 Khar (W ) Mumbai - 400052 Tel: 022-2600 0555/56 Fax: 022-26000556 Email: register@eliteplus.co.in Website: www.eliteplus.co.in
India Chem 2012 As the Indian industry is soaring in terms of commodity plastics and engineering polymers, this event will highlight the specialty polymers, fine chemicals, agro plastics, masterbatches, pigments, additives, etc, with emphasis on sustainable processing and effluent management; October 4-6, 2012; at Bombay Exhibition Centre, Mumbai For details contact: Vishal Ganju FICCI Mumbai
33/B, Krisnamai Building Pochakanwala Road, Worli Mumbai â&#x20AC;&#x201C; 400030 Tel: 022-2496 8000, 2496 6633-39 Fax: 022-2496 6631/32 Email: vishal.ganju@f icci.com Website: www.indiachemgujarat.com
Ind plast This is an initiative to promote India as a leading producer of plastics and specialty polymers on the global platform. The event will also facilitate interaction and international investments in the domestic market; October 5-8, 2012; at Science City Ground, Kolkata For details contact: Vishal Ganju FICCI Mumbai 33/B, Krisnamai Building Pochakanwala Road, Worli Mumbai â&#x20AC;&#x201C; 400030 Tel: 022-24968000, 24966633-39 Fax: 022-24966631/32 Email: vishal.ganju@f icci.com Website: www.indiachemgujarat.com
Plast Expo 2012 This is a unique opportunity for exhibitors to develop a direct relationship with their clients. It will be an interactive platform to display raw materials, chemicals and auxiliaries, equipment & services, moulds, dies, etc; October 7-10, 2012; at Rajkot Race Course Ground, Rajkot, Gujarat
104 Modern Plastics & Polymers | August 2012
For details contact: Brijesh Purohit Saurashtra Plastic Manufacturers Association, â&#x20AC;&#x2DC;Laxmanâ&#x20AC;&#x2122; 3rd Floor, Paramount Hall Bhutkhana Chowk, Rajkot â&#x20AC;&#x201C; 360 002, Gujarat Tel: 0281-2228802, Mob: 09426249072 Fax: 0281-2223798 Email: spma@plasticmanufacturer.org Website: www.plasticmanufacturer.org
Plexpo India 2013 In its 6th edition, Plexpo India offers a platform where the Indian plastics industry can showcase its machinery and equipment expertise. This event will bring together manufacturers, dealers, traders, suppliers of raw materials, machinery & equipment, ancillary equipment, testing equipment, chemicals & additives to consolidate the growth of the plastics industry in India; January 8-13, 2013; at Mahatma Mandir, Gandhinagar, Gujarat For details contact: Archana Kansara Gujarat State Plastics Manufacturers Association 7th Floor, Span Trade Centre Near Paldi Char Rasta, Ellisbridge Ahmedabad-380 006 Tel: 079-26579204 / 26578227 Mob: 9925017136 Fax: 079-26579204 Email: archana.kansara@plexpoindia.com Website: www.plexpoindia.com
EVENT LIST
International PLASTEX 2012 This is an important international trade fair dedicated to the plastics machinery, components, raw materials and chemicals in the Middle East and North Africa. It will present products and services, technologies & innovations for global trade markets. It is an international meetingplace for worldwide suppliers and regional manufacturers; September 6-9, 2012; at Cairo International Convention & Exhibition Centre, Nasr City, Egypt
manufacturing solutions; October 16-20, 2012; at Friedrichshafen Exhibition Centre, Germany For details contact: P E Schall GmbH & Co KG Messeunternehmen, Gustav-Werner-StraĂ&#x;e 6 D-72636 Frickenhausen Tel: +49-70259 2060, Fax: +49-70259 2066 Email: info@schall-messen.de Website: www.fakuma-messe.de
Plast Eurasia 2012
Composites Engineering Show 2012 For details contact: Ahmed Mostafa 41 Street No 269, New Maadi, Cairo, Egypt Tel: +202-2753 8401, Fax: +202-2753 8323 Email: ahmed@acg-itf.com Website: www.plastex-online.com
Taipeiplas 2012 This biennial trade show is well positioned to attract the global plastics industry with exciting opportunities in the Far East and South East Asia. Taiwan is ranked the worldâ&#x20AC;&#x2122;s fifth largest producer and fourth largest exporter in plastics & rubber processing machinery. With quality design and competitive price, Taipeiplas 2012 is the global sourcing hub for plastics & rubber processing machinery; September 21-25, 2012; at Nangang Exhibition Hall Taipei World Trade Center, Taiwan For details contact: Taiwan External Trade Development Council (TAITRA) 333 Keelung Road Section 1, 5-7 Floor, Taipei 11003, Taiwan Tel: +886 (2) 2725-5200 Fax: +886 (2) 2757-6245 Email: tiec@taitra.org.tw Website: www.taipeiplas.com.tw
FAKUMA 2012 This international trade fair for plastics processing is celebrating its 30th anniversary. It will show plastics advantages in conservation of resources, lightweight design engineering and energy efficiency. It will provide the industry with opportunities for futuristic
Tel: +44-01939 250383 Fax: +44-01939 251118 Email: info@rapra.net Website: www.smithersrapra.com
Building on the success of its previous editions, this show will bring together more designers, engineers, technicians, materials specialists, procurement & management teams from the global composites industry. It will highlight the latest developments in engineering composites and their applications in automotives, oil & gas, construction and consumer goods manufacturing; November 7-8, 2012; at NEC, Birmingham, United Kingdom
This trade show plays an important part in the expansion of plastics industry to new markets and influences machinery & technology investments. This event will witness some leading innovations in precision plastics moulding and recycling; November 29 â&#x20AC;&#x201C; December 2, 2012; at TĂźyap Fair Convention and Congress Center, Istanbul, Turkey For details contact: Tamer GĂźzelaydin E â&#x20AC;&#x201C; 5 Karayolu Ă&#x153;zeri, GĂźrpÄąnar KavĹ&#x;aÄ&#x;Äą 34500 BĂźyĂźkçekmece, Istanbul, Turkey Tel: +90-212 8671100, Fax: +90-212 8869399 Email: tguzelaydin@tuyap.com.tr Website: www.plasteurasia.com
Arabplast 2013 For details contact: Ian Stone Leading Edge Events & Media Ltd 4 The Mews, 53 High Street, Hampton Hill, TW12 1ND, United Kingdom Tel: +44 (0) 208 783 3574 Mob: +44 (0) 790 857 6050 Email: ian.stone@uktechevents.com Webiste: www.compositesexhibition.com
This exhibition and conference is among the leading trade shows for the global petrochemicals & plastics processing industry. The petrochemical industry in the GCC region has become a major investment opportunity for the Gulf countries as they become the worldâ&#x20AC;&#x2122;s largest source of polyethylene and polypropylene; January 7-10, 2013; at Dubai International Convention & Exhibition Centre, UAE
Thermoplastic Elastomers 2012 In its 15th edition, this international conference is a great opportunity to network with leaders in the surging global thermoplastics industry. From medical applications to automotives and consumer durables, this event will highlight the current & future trends in thermoplastics applications; November 13-14, 2012; at Berlin Exhibition Centre, Germany For details contact: Smithers Rapra Shawbury, Shrewsbury, Shropshire SY4 4NR, United Kingdom
For details contact: Jeen Joshua Al Fajer Information & Services PO Box 11183, Dubai, United Arab Emirates Tel: +9714-340 6888 Fax: +9714-340 3608 Email: jeen@alfajer.net Website: www.arabplast.info ;` ^ \ < ` ` _ \ ` < ^ ` ! ` \ _+ 5 ! _ \ ` ^
August 2012 | Modern Plastics & Polymers 105
BOOK REVIEW
Fire & Polymers IV Editors : Charle A Wilkie and Gordon L Nelson Price : ` 9,550
Polymeric Nanofibers Editors : Darrell H Renekar and Hao Fong Price : ` 10,900
Fire is a worldwide problem. It claims thousands of lives and causes significant loss of property every year. Polymers are materials of choice due to their versatility and use in various application sectors. Therefore, the relationship between fire and polymers is an important social issue. American Chemical Society (ACS) had organised a symposium in 2004. Thirty-eight papers were presented at the symposium and 28 papers are compiled in the book Fire & Polymers IV, which include synthetic thermoplastics and thermoset class of plastics. This book covers the latest research at the intersection of fire and polymers. Polymers or plastics are combustible materials and additives are used to make them flame retardant. This is a billion-dollar business worldwide. This book gives a good account of traditional halogen-based additives and has papers on non-halogen fire retardants as well as nano-scale additives. These 28 papers have been grouped under various topics â&#x20AC;&#x201C; nanocomposites, specific flame retardants, specific polymers, modeling & toxicity and new high temperature polymers. This is because there is lot of interest among researchers in nanocomposites due to their ability to impart best of flame retardant properties to polymers. The book focusses on research that improves fire retardance of polymers through a detailed understanding of polymer degradation chemistry, new and refined analytical techniques & analysis, mathematical fire models as well as a new approach by creative chemists to achieve more thermally stable polymer structures.
The textile fibre industry has always relied on synthetic fibres with larger diameters. Synthetic polymeric fibres with nanometre-scale diameters could never become an important part of the textile fibre industry. As the broad field of nanotechnology gained widespread recognition in 1990s, it became apparent that electro-spinning provides a route to the creation of long fibres with nanoscale diameters. Earlier, there have been successful efforts with polymeric nanofibres. However, the technology was maintained as trade secret by the US Defense and Soviet Union. However, the 1990s witnessed a rapid growth in nanomaterials, nanotechnology and nanofibre applications & technology. All the contributors have tried to unveil this aspect. Therefore, a pioneering spirit pervades this book. Each chapter describes the earlier successes of polymeric nanofibres, produced mostly by electro-spinning and reveals a promise of future efforts. The earlier applications of polymeric nanofibres were in the field of filtration and gas masks for protection of soldiers, while today they are considered as scaffolds for the growth of artificial biological organs, membranes with engineered porosity and tissue engineering. This book is based on the American Chemical Society (ACS) Symposium on Polymeric nanofibres held in September 2003. This book includes only original research and review papers.
Reviewer: Dr Yatish B Vasudeo, President, BY INNOVATIONS Consultancy (I) Pvt Ltd Avaliable at: Wisdom Book Distributors, Hornby Building, 1st floor, 174, D N Road, Mumbai 400 001 ; <= >//+//>Q JJ JÂ&#x2022;OO? ZÂ&#x20AC; V ; < ^ Y= >//+//>? J>Â&#x20AC; V [ <= ` ] <5_
106 Modern Plastics & Polymers | August 2012
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 Pneumatic-driven large beam robot
Injection moulding machine
Cobra series is applicable to all types of horizontal injection machines of 450t to 4,000t for take-out of products and sprues. It can be added with a runner arm for three-plate mould to clamp product and sprue at the same time. Light, high-rigidity alloy aluminium extrusion beam applied in kick and vertical axles, realises high speed, high efficiency, low vibration and long life expectancy of the machine. Installation of robots will increase productivity, reduce defect rate, ensure safety of operators, reduce manpower and accurately control the output to reduce waste.
Model DCM-250T2C two-component horizontal injection moulding machine that features hydraulic clamp is particularly suitable for either two-colour or two-component injection mouldings. It features super-wide rotary table and super-large mould thickness available. Dual hydraulic clamping cylinders minimise possible distortion of the rotary table. Electric servomotor-driven rotary table ensures accurate and fast positioning. It also offers lubrication-free and easy maintenance operations.
Dongguan Alfa Automation Machinery Ltd Guangdong - China Tel: +86-769-83180326 Email: dgalfa@hotmail.com; info@alfarobot.com Website: www.alfarobot.com
Multiplas Enginery Co Ltd Taoyuan - Taiwan Tel: +886-3-318-0090 Email: sales-gt@multiplas.com.tw Website: www.multiplas.com.tw
Energy saving system
Masterbatch feeder
Jon wai AC synchronous servo power saving system integrates all the excellent features such as energy efficiency water saving, hydraulic oil saving, easy operation and precision moulding. The system closes the gap between hydraulic and all-electric machines, which can offer a new green solution at low cost. Jon wai servo system is available for all series machines. Its advantages are electricity saving, water saving, hydraulic oil saving, quick response, moulding stability, quiet operation, reliability, reliable holding pressure and unique motor control design.
Ya n n B a n g â&#x20AC;&#x2122;s masterbatch feeder mixes with resin automatically without changing frequently and keeps product in good quality. With the patented throat adapter (TAIWAN PAT. M336147, CHINA PAT. 96215963.8), the masterbatch and resin will not be stocked between the inlet and screw unit, the masterbatch, additives, smooth powder, regrinded resin and virgin resin are able to mix consistently and accurately with less rejects. Its unique design to change screw easily can help save time and cost in clean working place. Feeder for powder series is also available.
Jon Wai Machinery Works Co Ltd Taipei - Taiwan Tel: +886-2-25954867 Email: infor.tw@jonwa.com.tw Website: www.jonwai.com
Yann Bang Electrical Machinery Co Ltd Taichung City - Taiwan Tel: +886-4-22710000 Email: yb@yannbang.com Website: www.yannbang.com
108 Modern Plastics & Polymers | August 2012
PRODUCT S
Laboratory chiller
Cleanroom mould
Polystat Laboratory Chiller has quick ramp-up and cooldown with all operational and preventive maintenance accessed through the front panel. Designed to provide temperature control with the flexibility needed for demanding applications, they fit comfortably on a laboratory bench top. These chillers feature a temperature range of -10°C to 80°C. The chillers allows the user to choose between five temperature set points. The air-cooled refrigeration system eliminates the need for external water source and the small internal reservoir limits evaporation. With built-in energysaving mode, this series provides an environment-friendly option for any laboratory. This mode activates a responsive control that will allow the chillers to operate with minimal energy consumption.
Adapplicator, Alu cap, Snap cap, PE bottle pack cap, PE twin-port cap are some of the many cleanroom moulds from Braunform. Highly sensitive packaging and m e a s u r i n g components, caps for use in dental and insulin fields, dialysis components, hygiene products & the Adapplicator system developed by Braun, are spray alternatives to needle injection. Application areas are medical and cleanroom moulds, IML & IMD moulds, multi-cavity, multi-component & stack moulds and rotary table programmes.
Cole-Parmer India Pvt Ltd Mumbai - Maharastra Tel: 022-67162224/2222 Email: response@coleparmer.in Website: www.coleparmer.in
Neejtech India Ahmedabad - Gujarat Tel: 079-26561312 Mob: 09825040231 Email: info@neejtech.com Website: www.neejtech.com
Plastic injection moulding machine
Strapping band extruding line
The JC-ST series strapping band extrusion line has a wide range of production capability from 80 kg/hr up to 400 kg/hr and low energy consumption. JC-ST series strapping band extrusion line is merged with JC-ST/PP and JC-ST/PET series. The JC-ST/PP series conceived for making PP polypropylene straps. Extruder available from dia 65 mm to dia 120 mm for 2, 4, 6, up to 8 strap extrusion. The JC-ST/PET series extruder is available from dia 85 mm to dia 120 mm for 2, 4, up to 8 strap extrusion.
This injection moulding machine provides complete plastics processing solutions. The machine is used to mould plastics into the desired shape. This is designed as per the current technical developments and is quality tested. The plastic injection moulding machine comes with an auto-centralised lubrication system and a motorised mould height adjustment.
Jenn Chong Plastics Machinery Works Co Ltd Tai Pao City - Taiwan Tel: +886-5-2376175 Email: sales@jennchong.com.tw Website: www.jennchong.com.tw
Sarada Machinery Company Hyderabad – Andhra Pradesh Tel: 040-23076557, Mob: 09849546022 Email: info@saradamachinery.com Website: www.saradamachinery.com August 2012 | Modern Plastics & Polymers 109
PRODUCT S
Dehumidifying dryer These are carousel plus dehumidifying dryers. With these dryers, users can have greater control over drying dewpoint and temperature than ever before, in a package that is simpler, smaller, lighter, more energy efficient and easy-touse & maintain. Some of their features include reduced energy costs, maximum uptime & maximum reliability as well as precise, adjustable dew point control. Nu-Vu Conair Pvt Ltd Ahmedabad - Gujarat Tel: 079-32985993 Email: salesindia@conairgroup.com Website: www.conairgroup.com
Extrusion coating lamination plant The extrusion coating lamination plant offers various substrates required for PP/HDPE woven fabric, non-woven fabric, paper poly coating requirements, etc. These machines consist of unwinder turret or mechanical type, corona treater, anchor coating, extruder 75 mm with 28:1 screw ratio, coat hanger-type die, laminator unit with line speed of 120 mpm, sandwich unwinder, winder turret or surface type, AC control panel cabinet and heating panel cabinet. Ocean Extrusions Ahmedabad - Gujarat Tel: 079-22902200 Mob: 09724325401 Email: oceanextrusions@gmail.com Website: www.oceanextrusions.com
Rotomoulding machine
The Speed-90 rotomoulding machine is equipped with the latest features keeping in mind all inconvenience that users face with their exisiting machines. Newly designed heating system, better powerful arms, sensors and speed controllers, etc, are some of the features. The machine is built to manufacture with high efficiency, eg, water tank. N A Corporation Ahmedabad - Gujarat Tel: 079-25840374 Email: info@naroto.com Website: www.naroto.com
Engineering plastic materials Aarkaymid range of engineering plastic materials saves lubricants as well as cuts down on maintenance and downtime. The product is non-corrosive and wear resistant. Besides being light-weight, it facilitates easy handling, transport and storage, especially during monsoon when metal parts call for great attention. The product is available in different sizes and shapes to suit all sorts of engineering requirements. Classic Polymers & Resins Mumbai - Maharashtra Tel: 022-24465251 Email: sales@classicpolymers.co.in Website: www.classicpolymers.com
Swing-arm robot The SS series swing arm robot is useful for those using injection moulding machine. This robot is designed for rapid and precise removal of sprue & runner from the injection moulding machine and place them into granulator for recycling. The robot is suitable for injection moulding machines under 250-T clamp force. Swing arm robot is equipped with various useful mechanisms in arm, swing, kick stroke and base. Shini Plastics Technologies (India) Pvt Ltd Thane - Maharashtra Tel: 0250-3021132 Email: info@shiniindia.com Website: www.shini.com
110 Modern Plastics & Polymers | August 2012
PRODUCT S
Plastic milk cans A wide range of plastic milk cans in various sizes and designs are offered. These cans are apt for the Indian dairy farms and are a perfect substitute for aluminium cans. Costeffectiveness, light weight and durability are some of the core traits of the plastic milk cans. Samruddhi Industries Ltd Sangli - Maharashtra Tel: 0233-264573 Mob: 09423677084 Email: samruddhi@samruddhi.com Website: www.samruddhi.com
Granulator The efficient range of granulators is available for different types of materials and products. Its capacity starts from 20 kg/hr to 400 kg/hr with low and high speed of crushing. The granulators are also available with various options such as titaniumcoated blade, strong 2-axis crushing blades. These are easy to move with a handle, easy to check blade through transparent window with CE certified controller. Yudo Hot Runner India Pvt Ltd Thane - Maharashtra Tel: 0250-2451155 Email: sales@yudo.co.in Website: www.yudo.com
Polymer application pack The polymer FT-IR application pack is a quality control tool for the polymer industry. This offers fast, reliable, simple and cost-effective analysis. The selection of right technology helps in obtaining good quality data and not extracting desired sample information. Additional efforts and time are required 112 Modern Plastics & Polymers | August 2012
to extract information and convert into knowledge from the data generated. PerkinElmer Thane - Maharashtra Tel: 022-33261700 Mob: 09930137484 Email: aniruddha.pisal@perkinelmer.com Website: www.perkinelmer.com
Plastic raw materials These are BioAdd range of biodegradable additives. Heat, oxygen and sunlight are used to cause degradation benefits. Flame-retardant masterbatches are used for engineering and commodity plastics. Also offered are colour and special effect masterbatches, filler masterbatches for raffia, blown film & moulding and performance additives leading to biodegradation. AVI Additives Pvt Ltd Hyderabad - Andhra Pradesh Tel: 040-23550551 Email: info@aviadditives.com Website: aviadditives.com
Thin film dryer The wiped and agitated thin film dryer comes in a spectrum of sizes, tailored to suit customersâ&#x20AC;&#x2122; application needs. The design varies according to the applications. These dryers come in horizontal (predominantly) and vertical configurations, with a variety of proprietary wiping and scraping arrangements, accompanied by solvent-recovery systems where required. Alpha Process Engineers Chennai - Tamil Nadu Tel: 044-28111351 Email: apeepa@vsnl.com Website: www.alphaprocessengineers.com
PRODUCT S
Plastic injection moulding machine The range of plastic injection moulding machine is suitable for manufacturers and engineering industries. Designed using latest technology, the range is known to perform better even in harsh conditions. This plastic injection moulding machine is available in various specifications to suit different requirements of engineering and manufacturing industries. Mechatronics Machinery & Tools (India) Delhi Tel: 011-27830809, Mob: 09810129642 Email: mcs109@yahoo.co.in Website: www.mechatronicsmachinery.com
Plastic brighteners/shiners and whiteners These plastic brighteners, shiners and whiteners are used for natural transparent, colours and milky white end products. These are also used for adding clarity and gloss finish to natural transparent polymers. The products give shining and bright finish colours to end products. These remove yellowness and dullness from the end products and make them super milky white. The products are used in virgin, second, dull natural or milky white sutli, ropes, twine, reprocess granules, HDPE-LDPE-PVC pipes & profiles, etc. Plast Fine Polymers Ahmedabad - Gujarat Tel: 079-65242332, Mob: 09825587152 Email: plastfine@indiatimes.com
Blown film extrusion line The monolayer blown film extrusion line is used for HM-HDPE/ LLDPE/LDPE/PP. It comes in widths of 90 mm to 1,300 mm and has an output of 20-70 kg/hr. The plant is available with stationery and rotating die. Applications are in plastic bags, vest bags, liners, garbage bags, packaging films, stretch films, shrink films, detergent bags, etc. 114 Modern Plastics & Polymers | August 2012
Dura Exports Pvt Ltd Mumbai - Maharashtra Tel: 022-26744053, Mob: 09930476588 Email: info@duraexports.com Website: www.duraexport.com
Temperature controller and waterflow regulator This temperature controller controls the temperature of manifold block and the nozzle with correct circuit connection and parameters on the panel. It also maintains a constant temperature within the system. The water flow regulator is designed to work with mould heaters, water chillers and cooling towers, which can be connected to more than one mould connector. It has functions like temperature and flowrate display, flowrate control in order to meet the requirement of different working conditions. Modularised combination ensures installation and maintenance. It is a necessary equipment for modern plastics industry to improve its moulding efficiency. Shini Plastics Technologies (India) Pvt Ltd Thane - Maharashtra Tel: 0250-3021132 Email: info@shiniindia.com Website: www.shini.com
Mould-temperature controller and chiller The mould temperature controller and special custom-made chiller are new products that include cold-hot all-in-one mould temperature controller, die-casting mould temperature controller, quick-cooling & heating mould temperature controller, two machines in one water circulation temperature controller, and rubber/ high temperature/roller mould temperature controller. These machines are intended for processes such as plastic injection moulding, extrusion moulding, blow moulding, chemical industry, dye-casting, reaction axe rubber tyre, rubber vulcanisation, electric wire, calendar, printing, ban-burying and other related industries. Weichi Enterprise Co Ltd Guangzhou - China Tel: +86-020-36850626 Email: weichimaster@163.com Website: www.weichigz.com
PRODUCT S
Quick mould change system The complete single-source system solutions available include Quick Mould Change (QMC) and Quick Die Change (QDC) systems for plastic injection moulding industry and for metal stamping applications. Magnetic Clamping Systems (MCS) are used for injection moulds and dies. Mono-coupler, manual and automatic multicoupler systems are for general industry use. Mould and die rotation units, die splitters and other tool handling & storage equipment are also offered. EAS Mould & Die Change Systems Co Ltd Wujiang City - China Tel: +86-512-63093091 Email: sales-china@easchangesystems.com Website: www.easchangesystems.com
Robotic automation The Sepro Robotique S5 line of high-performance robots features fast, precise servo-driven robots, including three different models to serve injection moulding machines in the range of 30-800 tonne. The S5 line of robots is developed with longer strokes and larger payload capacities than units of comparable size in Seproâ&#x20AC;&#x2122;s earlier Generation 4 (G4) range. There are three models in this series. All S5 robots are equipped with the top-of-the-line Sepro Visual 2 controller as standard equipment. At its core is a high-speed PLC, featuring scan rates as fast at 100 millisecond. Demag Plastics Machinery (Ningbo) Co Ltd Zhejiang - China Tel: +86-574-86181500 Email: sales.cn@dpg.com Website: www.sumitomo-shi-demag.eu
In-mould labelling equipment Supreme in-mould labelling (IML) equipment is reliable and sustainable. The IML equipment is offered on turnkey basis to customers. This label supply machine, integrated with technology knowledge, has features like both electrostatic and vacuum, easy understanding, durable quality, low abnormal, cost-down and simple maintenance, simultaneously
available machine for containers with varied shapes, suitable for different label options, etc. Supreme Technic Package Co Ltd Kalol - Taiwan Tel: +886-7-6141505 Email: emd@emdpack.com.tw Website: www.emdpack.com.tw
Plastic flap loaded foot valve The new range of plastic flaploaded foot valve is most popular due to its friction-free low cost design. It gives better linear flow of water in the suction lines than CI foot valves. These products exhibit some of the distinguished features, such as durability, friction-free design, corrosion resistance, leakage-proof and dimensional accuracy. Technical specifications include standards as per IS:10805:1986 of BIS, thread as per IS:554:1985 of BIS, body test pressure at 0.5 MPa, seat test pressure at 0.02 MPa, normal bore size 21/2" and 3" (65 mm and 80 mm), and materials of construction: PP body, PP strainer & PVC washer. Arti Products Rajkot - Gujarat Tel: 0281-2388908, Mob: 09428155144 Email: arti_product@sify.com Website: www.artiproducts.in
Dehumidifying dryer The SDD series dehumidifying dryer uses honeycomb dehumidifier with elegant and semi-integral appearance. This model contains dehumidifying and drying into same unit. The drying hopper comes with downwards dry air blowing system, which improves drying efficiency. It also reduces energy consumption and is most economical for customers using it. The dehumidifier of SDD contains two coolers inside it, which ensures low return air temperature and low dew point. This equipment is microprocessor controlled and compact. It has applications in plastic processing industries and is unique for processors who use PA, PC, PBT, PET, etc. All models come with process heaters and insulated drying hopper. Shini Plastics Technologies (India) Pvt Ltd Dist Thane - Maharashtra Tel: 0250-3021132 Email: info@shiniindia.com Website: www.shini.com August 2012 | Modern Plastics & Polymers 115
PRODUCT S
Air-cooled compressor A unique range of aircooled compressors is offered for industries that demand oil-free air at their application point. The nonlubricated compressor offers advantages of low energy consumption and low running costs. The air-cooled design eliminates the need for water cooling systems, thereby saving industrial water costs. Two-stage air-cooled aftercooler has a 0.25-kW single-phase motor driving a cooling fan. This eliminates the need for cooling towers, water circulation pumps and the associated piping, thus reducing the initial investment. This also reduces the installed power. Elgi Equipments Ltd Coimbatore - Tamil Nadu Tel: 0422-2589326, Mob: 09790039326 Email: enquiry@elgi.com Website: www.elgi.com
Thermic fluid heater The thermic fluid heater and hot water generator have capacities ranging from 30,000 kCal/hr to 20,00,000 kCal/hr. Maximum operating temperature is 300°C for thermic fluid and 130°C for hot water. Concentric coil is made from MS seamless tube of Asthma 106 GR-B. The unit is equipped with high efficiency oil/gas burner with air pre-heater arrangement giving high thermal efficiency of 87 ±2 per cent on NCV. The unit is outside the purview of IBR. Aero Therm Systems Pvt Ltd Ahmedabad - Gujarat Tel: 079-25890158, Mob: 09825008720 Email: contact@aerothermsystem.com Website: www.aerothermsystem.com
PVC perforated cable tray Shital rigid PVC perforated cable tray is an ideal replacement to MS tray. It is not affected by any corrosive chemicals and is waterproof. The tray is UV stabilised to resist ultraviolet rays of the sun, and hence can be used outside for prolonged period. The PVC cable tray is available in 116 Modern Plastics & Polymers | August 2012
widths in the range of 50-500 mm, with flange heights of 25, 50 and 75 mm and standard length of 2.9 metre. It is light-weight and maintenance-free. The cable tray is joined by socketed jointing system, which means no coupler plates incorporated. Supreme Electroplast Industries Mumbai - Maharashtra Tel: 022-28873428, Mob: 09820306252 Email: supshitl@vsnl.com Website: www.supshitl.com
Injection moulding machine The two-platen injection moulding machine is available in 850-3,500 tonne. This machine takes less space, and is provided with four sets of hydraulic cylinders, which are on the moveable platen instead of fixed platen. The design not only ensures precise and accurate clamping force, but also gives large space for operator to work on the fixed platen. Mouldopen position is more accurate. The tie bars and hydraulic cylinder pistons are isolated. There is no need to dismantle hydraulic cylinders and there is no risk of damaging seals while changing tie bars. Jon Wai Machinery Works Co Ltd Taipei - Taiwan Tel: +886-2-25954867 Email: jonwai.mc@msa.hinet.net Website: www.jonwai.com
Plastic planters These coloured plastic planters are made from optimum quality and hard plastics. Durable in nature and sturdy by frame, the plastic planters are offered in various colours and design patterns. The plastic planters are ideal for indoor as well as outdoor applications. These are used to hold plants and enhance the decor of surroundings. The products comply to all national and international standards set by the industry. Samruddhi Industries Ltd Sangli - Maharashtra Tel: 0233-264573, Mob: 09423677084 Email: samruddhi@samruddhi.com Website: www.samruddhi.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 %XVLQHVV ,QVLJKWV 7HFKQRORJLHV 2SSRUWXQLWLHV
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LIST OF PRODUCT S
Looking For A Specific Product? Searching and sourcing products were never so easy. Just type MPP (space) Product Name and send it to 51818
eg. MPP Moulding and send it to 51818 Product
Pg No
Product
Pg No
Product
Pg No
Accumulator high-speed injection moulding machine111
Counters ......................................................................... 121
Gear pump ............................................................... 32, 126
Acoustic enclosure ............................................................ 31
CPVC pipes ................................................................. 8, 19
Granulating & recycling .................................................. 91
Additive masterbatches .................................................... 51
Crystalliser........................................................................ 83
Granulator .................................................. 21, 83, 112, 125
Adhesives.......................................................................... 25
Curing .............................................................................. 63
Granulator blades ............................................................. 71
Air audit blowers.............................................................. 50
Cutting and stitching machine ........................................ 12
Gravimetric blender ....................................................... 125
Air chiller ......................................................................... 21
Cyclic olefin copolymer (COC).................................... BIC
Gravimetric dozer .............................................................. 4
Air-cooled compressor ................................................... 116
Dehumidifying air dryer ..................21, 85, 110, 115, 125
Grinder ............................................................................. 21
Analog timers ................................................................. 121
Delphi ATDC brake motor ............................................. 27
HDPE pipes & blown films ........................................ 4
Ancillary equipment ......................................................... 61
Delphi three-phase motor ................................................ 27
HDPE tarpaulin heat-sealing machines ........................ 101
Automation system .................................................... 69, 91
Die face cutters ................................................................ 71
Heart valve frame........................................................... 107
Baking & drying ........................................................63
Die plates ......................................................................... 71
Heat transfer rolls .......................................................... 126
Barrel screws..................................................................... 97
Digital panel meter .......................................................... 10
Heating & cooling ..................................................... 69, 91
Barrels............................................................................. 126
Digital temperature controller.......................................... 77
Helical inline geared motors/reducers.............................. 40
Bed knives ........................................................................ 71
Dosing & blending .......................................................... 69
High cavitations ............................................................... 35
Biodegradable additive ..................................................... 33
Dosing & mixing ............................................................. 91
High-performance screws .............................................. 126
Biodegradable masterbatches ........................................... 51
Drives ............................................................................... 77
High-speed mixer ...................................................... 37, 87
Black masterbatches ................................................... 51, 99
Dry van pump .................................................................. 31
High-speed precise injection moulding machine........... 111
Blenders .................................................................. 4, 17, 75
Dry-break couplings......................................................... 50
Hopper dryer .................................................................... 21
Blow film extrusion line ................................................. 114
Drying .............................................................................. 69
Hopper loader .......................................................... 21, 125
Blow moulding machines ................................................. 18
Drying & dehumidifying ................................................. 91
Hot air dryer ............................................................ 85, 125
Blower series .................................................................... 91
Dual channel with modbus .............................................. 77
Hot runner system ........................................................... 91
Blown film extrusion systems ........................................ BC
Dynamic controller .......................................................... 77
Hydraulic injection moulding machine.......................... 111
Bottle testing equipment .................................................. 81
Ejectors .....................................................................50
IML technique ..........................................................35
Box series wormgear units ............................................... 27
Elastomer refinery/petrochemicals ................................... 25
Infrared (IR) .................................................................... 63
CASI (coating) ..........................................................25
Electric injection moulding machine gearboxes................. 5
Injection moulding machine15, 56, 68, 108, 111, 116, BGF
Center seal.......................................................................... 3
Energy saving system ..................................................... 108
Injection moulding ....................................................... 4, 99
Circular weaving machine ................................................ 12
Engineering plastic materials ......................................... 110
Inks................................................................................... 25
Cleanroom applications.................................................... 35
Engineering plastic compounds ....................................... 99
Inline drip tubing ......................................................... 8, 19
Cleaning ovens ............................................................... 126
Extruder machine ....................................................... 37, 87
Inline shaft mounted helical geared motors/reducers ...... 40
Cleanroom moulds ......................................................... 109
Extruder screws ................................................................ 71
In-mould labeling & injection moulding machine ........ 111
Co-extruded sheets and telecom cables ........................... 49
Extrusion ........................................................................ BC
In-mould labelling equipment ....................................... 115
Co-kneader....................................................................... 61
Extrusion coating lamination plant................................ 110
Insert moulding machines ................................................ 18
Co-rotating extruder ...................................................... 107
Extrusion coating lines (lamination plant) ...................... 12
Laboratory chillers ...................................................109
Colour masterbatches ..................................... 13, 51, 61, 99
Extrusion pumps .............................................................. 32
Large flow water heaters .................................................. 91
Compact chiller ........................................................ 21, 125
Extrusion systems........................................................... BC
Liquid crystalline lymer (LCP)..................................... BIC
Compressed air dryer ....................................................... 83
Feed rolls ...................................................................71
Loading arms ................................................................... 50
Compressors ..................................................................... 50
Feeding & conveying ................................................. 83, 91
Manual & hydraulic screen changers ........................126
Conductive compounds .................................................... 51
Fibre grade masterbatch ................................................... 99
Manufacturing plastic auxiliary equipment...................... 28
Conical twin-screw extruder ........................................ 6, 14
Film cutters ...................................................................... 71
Masterbatch/plastic compounds ....................................... 25
Continuous screen changers ........................................... 126
Fueling systems ................................................................ 50
Masterbatch feeder ......................................................... 108
Conventional phase failure relays ................................... 121
Gearbox .....................................................................40
Masterbatches................................................................... 49
Conveying ........................................................................ 69
Gear motor ....................................................................... 40
Material dryers ........................................................... 17, 75
FGF - Front Gate Fold, FIC - Front Inside Cover, BIC - Back Inside Cover, BGF - Back Gate Fold, BC - Back Cover
120 Modern Plastics & Polymers | August 2012
LIST OF PRODUCT S
Product
Pg No
Product
Pg No
Product
Pg No
Material storage ............................................................. 125
Polymer application pack ............................................... 112
Single-screw extruder plant.......................................... 6, 14
Material testing instruments ............................................ 81
Polymer conveyer belt ...................................................... 21
Software for central monitoring....................................... 83
Medical moulds ................................................................ 35
Polyolefin pipes ............................................................ 8, 19
Stack moulds .................................................................... 35
MFRS of injection moulding machines .......................... 18
Polyphenylene sulphide ................................................. BIC
Storage tank equipment ................................................... 50
Mould temperature controllers ........................................ 85
Pouch maker....................................................................... 3
Strapping band extruding line ....................................... 109
Moulding.......................................................................... 35
PP-R pipes ................................................................... 8, 19
Strech blow moulding ...................................................... 18
Mono and multilayer sheet line ....................................... 12
Presses .............................................................................. 73
SV power-cooled motor ................................................... 27
Monofilament line ........................................................... 12
Priming valves .................................................................. 50
Swing-arm robot ............................................................ 110
Monolayer blown film line....................................BC, 8, 19
Printing and cutting/rewinding machines ....................... 12
Motor ............................................................................... 27
Printing presses ................................................................ 73
Mould temperature controller .................................. 21, 125
Process controllers ............................................................ 10
Moulding compound injection moulding machine ....... 111
Profile controller............................................................... 77
Moulds ....................................................................... 37, 87
Pulverise ..................................................................... 37, 87
Mould-temperature controller and chiller ..................... 114
Pulverise discs .................................................................. 71
Multi-component moulds ................................................ 35
Pump .......................................................................... 31, 50
Multilayer cast film line ................................................... 12
PVC.................................................................................. 25
Multilayer blown film line ..............................8, 12, 19, BC Multilayer co-extrusion sheet line.................................... 16 Napkin dies ...............................................................71 Optic sheet extrusion line ..........................................16 Optical brightners ............................................................ 51 Panel meters ............................................................121 Paperless recorder ............................................................. 10 Parallel & right angle axes gearboxes ................................ 5 Pelletiser parts .................................................................. 71 Pelletisers .................................................................. 71, 126 Perform injection moulding machine ............................ 111 PET bottle testing equipment ......................................... 81 PET perform dedicated machine..................................... 65 PET sheet extrusion......................................................... 16 PET/PE washing line ...................................................... 12 Pharmaceuticals/cosmetics ............................................... 25 Phase failure relays ......................................................... 121 Plastic board production system ...................................... 73 Plastic brighteners/shiners and whiteners ...................... 114 Plastic conveyor belt......................................................... 37 Plastic flap-loaded foot valve ......................................... 115 Plastic injection moulding machineries ........... 23, 109, 114 Plastic masterbatches ....................................................... 67 Plastic milk cans............................................................. 112 Plastic moulding............................................................... 25 Plastic planters ............................................................... 116 Plastic processing machinery ancillaries and spare .......... 97 Plastic processing machines ............................................. 12
PVC compounds .............................................................. 49 PVC foam core pipes ................................................... 8, 19 PVC mixer cooler......................................................... 8, 19
System solution ................................................................ 91 Tank truck equipment................................................50 Tape stretching line with inverter-driven cheese winders 12 Technical moulds ............................................................. 35 Temperature controller ....................................... 10, 77, 121 Temperature controller and waterflow regulator............ 114 Temperature indicator .................................................... 121 Testing instruments .......................................................... 81 Thermic fluid heater ...................................................... 116 Thermoformers .............................................................. BC Thermoforming & PS foam .......................................... BC Thermoplastic polyurethane............................................. 89
PVC palletising lines.................................................... 8, 19
Thermoset ........................................................................ 25
PVC perforated cable tray ............................................ 116
Thick & wide plastic sheet extrusion line ....................... 16
PVC pipes .................................................................... 8, 19
Thin flim dryer .............................................................. 112
PVC profile lines.......................................................... 8, 19
Three arm biaxial rotomoulding machine.................. 37, 87
Quick mould change system .....................................115
TPU masterbatches .......................................................... 13
Recycling...................................................................69
Transmissions & ptos ....................................................... 50
Recycling lines.................................................................. 12
Twin-mill pulveriser ................................................... 37, 87
Reducer ............................................................................ 27
Twin-screw ..................................................................... 107
Relays ............................................................................. 121
Twin-screw extruder gearboxes .......................................... 5
Resin dehumidifier ........................................................... 83
Twin-screw element ....................................................... 107
Right-angled helical bevel geared motors/reducers ......... 40
Twin-screw extruder................................................. 61, 107
Right-angled helical worm geared motors/reducers ........ 40
Twin-screw extrusion line ............................................ 6, 14
Rigid injection moulding machine................................. 111
Two-layer blown film ................................................... 8, 19
Robot system .................................................................... 21 Robotic automation ...................................................... 115 Rock-n-roll machine .................................................. 37, 87 Roots blower .................................................................... 31 Rotary automatic hot colour marking machines.............. 93 Rotary cutters ................................................................... 71 Rotary dies ....................................................................... 71 Rotomoulding machine .................................................. 110 Round table carrousels ..................................................... 37 Safety access equipment .............................................50 Screws............................................................................... 97
Two-platen injection moulding machine ....................... 111 Ultrasonic flow meter .................................................10 Universal bag maker ........................................................... 3 Universal controller .......................................................... 77 UV stabilisers ................................................................... 51 Vacuum booster pump ................................................31 Vacuum dryer ................................................................... 85 Vacuum forming machine .............................................. BC Vacuum pumps & systems ............................................... 50 Vacuum system ................................................................. 31 Variable displacement pump energy-saving machine ...... 65 Vario speed variators ........................................................ 27
Sealants............................................................................. 25
Vertical machining centre .............................................. 111
Servo-driven pouch maker ................................................. 3
Vertical sachet packing machine ........................................ 3
Servo energy-saving machine........................................... 65
Vibro screens .............................................................. 37, 87
PLC.................................................................................. 77
Sheet calendaring line ...................................................... 73
Volumetric dosing unit..................................................... 83
Pneumatic-driven large beam robot ............................... 108
Shut-off nozzles ............................................................. 126
Warehouses ...............................................................73
Polyacetal copolymer ..................................................... BIC
Side-weld bag maker.......................................................... 3
Water chiller ..................................................................... 83
Polybutylene terepthalate .............................................. BIC
Single mill pulveriser.................................................. 37, 87
Water jetting .................................................................... 50
Polyester staple fibre......................................................... 61
Single-screw extruder gearboxes ........................................ 5
White masterbatches........................................................ 51
Plastic raw materials....................................................... 112 Plastic textile and machinery ........................................... 47 Plastics washing line ........................................................ 61
FGF - Front Gate Fold, FIC - Front Inside Cover, BIC - Back Inside Cover, BGF - Back Gate Fold, BC - Back Cover
122 Modern Plastics & Polymers | August 2012
LIST OF ADVERTISERS Advertiser’s Name & Contact Details
Pg No
Advertiser’s Name & Contact Details
Pg No
Advertiser’s Name & Contact Details
Pg No
ACS Auxiliaries India Pvt Ltd ...................... 28
Gelco Electronics Pvt Ltd............................121
Litel Infrared Systems Pvt Ltd ...................... 63
T: +91-02135 - 329112
T: +91-79-22200902
T: +91-020 - 66300633/636/637
E: acsindia@corpemail.com
E: info@gelco-world.com
E: sales@litelir.com
W: www.aecinternet.com
W: www.gelco-world.com
W: www.litelir.com
Aerodry Plastics Automation Pvt Ltd............ 69
Glaves Corporation ...................................... 71
Lohia Starlinger Ltd. .................................... 47
T: +91-120 4766777
T: +91-141-2460324,+91-9983330808
T: 011-30641770
E: info@aerodry.com
E: sales@glaves.biz, axj@glaves.biz
E: prom.lsl@lohiagroup.com
W: www.aerodry.com
W: www.glaves.biz
W: www.lohiagroup.com
Aeromec Marketing Co Pvt Ltd .................... 93
Hinds Machineries ....................................... 23
Lubrizol Advanced Materials India Pvt Ltd .. 89
T: +91-250-2454915
T: +91-0124-4368305
E: hvt@aeromec.in
E: hinds@rediffmail.com
W: www.aeromec.in
W: www.hindsmachine.com
Mamata Machinery Pvt Ltd ............................ 3
Alok Masterbatches Ltd ............................... 13
Hindustan Plastic And Machine
T: +91-79-66309800
T: +91-011-41612244
Corporation ..............................................6, 14
E: sales@mamata.com
E: sales@alokindustries.com
T: +91-011-25473361
W: www.alokmasterbatches.com
E: poonam@hindustanplastics.com
Ask Me .......................................................119
W: www.hindustanplastics.com
T: +91-3555 5555
Huarong Plastic Machinery Co Ltd .............111
E: twitter.com/AskMe_35555555
T: +91-9825739634
W: www.facebook.com/AskMe.infomedia18
E: j.v.papaiyawala@huarong.com.tw
Boge Compressed Air System ....................... 33
W: www.huarong.com.tw
T: +91-44-43009610
Husky Injection Molding Systems Pvt Ltd ..BGF
E: s.sriram@boge.com
T: +91-22-25706316
W: www.boge.in
E: snair@husky.ca
Eng Expo Hyderabad ...................................113
W: www.husky.ca
T: +91-09819552270
J P Extrusiontech Limited ............................ 12
E: engexpo@infomedia18.in
T: +91-2646-222163
W: www.engg-expo.com
E: info@jpextrusiontech.com
Everest Transmission .................................... 31
W: www.jpextrusiontech.com
T: +91-11-45457777
Kabra Extrusion Technik Ltd.....................8, 19
E: info@everestblowers.com
T: +91-22-2673 4822
W: www.everestblowers.com
E: sunil@kolsitegroup.com
Ferromatik Milacron India Pvt Ltd ............... 21
W: www.kolsite.com
W: www.naroto.com
T: +91-79-25890081
Landmark Extrusion & Engineering ............. 61
Neejtech India (Braun) ................................. 35
E: salesfmi@milacron.com
T: +91-9873252699
T: +91-79-26561312
W: www.milacronindia.com
E: info@landmarkextrusion.com
E: info@neejtech.com
Gardner Denver Engineered Product
W: www.landmarkextrusion.com
W: www.neejtech.com
India Pvt Ltd................................................ 50
Larsen & Toubro Ltd ................................... 53
Neejtech India (Niigata) ............................... 15
T: +91-79-40089312
T: +91-22-6752 5656
T: +91-9909974224
E: info.ahm@gardnerdenver.com
E: ss-ccd@lth.ltindia.com
E: contact@niigataindia.com
W: www.gardnerdenver.com
W: www.larsentoubro.com
W: www.niigataindia.com
Our consistent advertisers
T: +91-22-66027800 E: Estane-SA@lubrizol.com
W: www.mamata.com Matsui Technologies India Ltd. .................... 85 T: +91-0120-4243862 E: rahuldeep@mass.motherson.com Mifa Systems................................................ 77 T: +91-79-26870825 E: info@mifasystems.com W: www.mifasystems.com Mold - Masters Technologies Pvt Ltd ........... 95 T: +91-422-4502171 E: mmiplinfo@moldmasters.com W: www.moldmasters.com Mona Chem Additives Pvt Ltd ..................... 25 T: +91-261-2894847 E: sales@monachem.com W: www.monachem.com N.A. Corporation ......................................... 87 T: +91-79-25840374 E: info@naroto.com
COC - Cover on Cover, FGF - Front Gate Fold, FIC - Front Inside Cover, BIC - Back Inside Cover, BC - Back Cover
August 2012 | Modern Plastics & Polymers 123
LIST OF ADVERTISERS Advertiser’s Name & Contact Details
Pg No
Advertiser’s Name & Contact Details
Pg No
Advertiser’s Name & Contact Details
Pg No
Nu-Vu Conair Pvt. Ltd ................................125
R R Plast Extrusions Pvt Ltd ........................ 16
Sri Sai Plasto Tech ....................................... 65
T: +91-9376783206
T: +91-22-42461500
T: +91-44-42994365
E: salesindia@conairgroup.com
E: marketing@rrplast.com
E: sspt_plastics@live.in
W: www.conairgroup.com
W: www.rrplast.com
W: www.srisaiplastotech.com
Piovan India Pvt Ltd .................................... 83
Rajoo Engineers Ltd....................................BC
Steer Engineering Pvt Ltd ...........................107
T: +91-22-27782367
T: +91-2827-252701
T: +91-80-23723309
E: amit.bajaj@piovnindia.com
E: kcdoshi@rajoo.com
E info@steerworld.com
W: www.piovan.com
W: www.rajoo.com
W: www.steerworld.com
Plastiblends India Ltd .................................. 51
Rotomotive Powerdrives India Ltd................ 27
Toshiba Machine (India) Pvt. Ltd. ................ 68
T: +91-022-67205200
T: +91-2692-230430
T: +91-011-43291111
E: rsd@koisitegroup.com
E: info@rotomotive.com
E: dineshelija@toshiba-machine.co.in
W: www.plastiblendsindia.com
W: www.rotomotive.com
W: www.toshiba-machine.co.jp
Poly Mechplast Machines Ltd....................... 18
Sacmi Engineering India Pvt Ltd .................. 56
Unimark (Maguire)....................................... 17
T: +91-265-2631211
T: +91-7600003968
T: +91-22-25506712
E: goldcoin@polymechplast.com
E: sales@negribossi.in
E: infomum@unimark.in
W: www..polymachplast.com
W: www.negribossi.com
W: www.unimark.in
Polyplastics Marketing (India) Pvt ............. BIC
Sanity International ..................................... 97
Unimark (Stahuli)......................................... 75
T: +91-22-67587668
T: +91-79-65227458
T: +91-22-25506712
E: tushar.birje@polyplastics.com
E: info@sanityindia.com
E: infomum@unimark.in
W: www.polyplastics.com
W: www.sanityindia.com
W: www.unimark.in
Power Build Ltd ........................................... 40
SCJ Plastics Ltd ........................................... 49
Vista Intergraded Pvt Ltd ............................... 4
T: +91-2692-231070
T: +91-011-25439950
T: +91-020-46781106
E: infopbl@elecon.com
E: vball@scjgroup.net
E: abhijit@vistaint.co.in
W: www.pbl.co.in
W: www.scjindia.com
W: www.liad.co.il
Prasad Koch Technik Pvt. Ltd....................... 37
Shanghai Forward Machinery Co., Ltd ......... 73
Witte Pumps & Technologie ........................ 32
T: +91-79-25830112
T: 86-21-5990-8899
T: +91-11-41613643
E: plastics@prasadgroup.com
E: forward_sale@exalt.com.tw
E: witte@goodiesons.com
W: www.prasadgroup.com
W: www.forwardsh.com
W: www.witte-pumps.de
Prayag Polytech Pvt Ltd ............................... 67
Shini Plastics Technologies I Pvt Ltd............ 91
Wittmann Battenfeld India Pvt Ltd ............FIC
T: +91-011-47262000
T: +91-250-3021166
T: +91-44-42077009
E: delhi@prayagmb.com
E: jnbhat@shiniindia.com
E: info@wittman-group.in
W: www.prayagmb.com
W: www.shini.com
W: info@wittman-group.in
Presto Stantest Pvt Ltd ................................. 81
Shri Gurukrupa Engineering Works ............101
Xaloy Asia (Thailand) Ltd. ..........................126
T: +91-129-4085000
T: ‘+91-265-3042371
T: +91-79-40327380
E: gaurav@prestogroup.com
E: shrigurukrupaengg@yahoo.com
E: m.sanghvi@th.xaloy.com
W: www.prestogroup.com
W: www.gurukrupaengg.com
W: www.xaloy.com
Procon Technologies Pvt Ltd ........................ 10
Som Shiva Impex Ltd ................................... 99
Zambello Riduttori Group ............................. 5
T: +91-79-27492566
T: +91-79-26763503
T: 39-0331-307-616
E: info@procon.co.in
E: info@simpexin.com
E: info@zambello.it
W: www.procon.co.in
W: www.simpexin.com
W: www.zambello.it
Our consistent advertisers
COC - Cover on Cover, FGF - Front Gate Fold, FIC - Front Inside Cover, BIC - Back Inside Cover, BC - Back Cover
124 Modern Plastics & Polymers | August 2012
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Modern Plastics & Polymers
August 2012
Modern Plastics & Polymers
August 2012