Also available in Sri Lanka, Malaysia, Singapore, Thailand, Taiwan, China & Hong Kong
EDITORIAL
The seventh sense! hy seventh sense? In the ever-changing world of seven seas, seven musical notes and seven heavens, we need much more than what the common five or six can provide! Who could have imagined only a few years ago that the then ‘developing’ economies will one day drive and define the growth engine of the world? With that becoming a reality today, the global economic order seems to have come a long way from the Brazil, Russia, India, China and South Africa (BRICS) buoyancy to the Portugal, Ireland, Greece and Spain (PIGS) spin. As the cloud of political and economic uncertainty still looms large over Greece, and hence the European Union, followed by its anticipated ripple effect on the entire world, perhaps, the moment has arrived to apply the seventh sense and make some tough strategic decisions that will hold the business in good stead in the future.
W
Here is a quick overview of some of the mega trends that have significantly impacted the plastics industry over the recent months. While the demand patterns have been distinctly region-specific across the globe, tremendous progress has been made in the development of new materials as well as products, thereby driving the formulations. Apart from high volatility in raw material prices and availability of some products, greenfield capacity additions for both resins & finished plastic products have been the other recent industry trends amid significant shifts in technology for resin transformation. So, what is the way forward? As the Asia-Pacific region, particularly India and China, clearly emerge to boost the plastics industry in the mid- to long-term space, the next phase of growth will shape up a wider range of new-age plastics, novel end-use applications and, last but not the least, further emphasis on clean processes in line with eco-legislations.
Editorial Advisory Board A E Ladhabhoy
With such a dynamically evolving ecosystem, welcome to the 7th Anniversary Edition of Modern Plastics & Polymers! This edition extraordinaire delves deeper into the above and more such emerging avenues. Turn to Anniversary Special section (with seven sub-sections, each representing a crucial end-use segment) to discern what the experts have to opine, not just on the underlying trends and technologies, but also on the future prospects & pitfalls.
Plastics Technologist
Dr Sushil K Verma Former Director General, CIPET
Dr Swapan K Dhara Regional Technical Head, Basell Polyolefins India Pvt Ltd
We believe that you will benefit from exploring this special edition with the same zeal with which we have enjoyed chronicling these highly informative pieces of actionable knowledge and much more. Have a good read and looking forward to your valuable feedback!
Mohan K Jain MD, Indoplast & Past President, AIPMA
P P Kharas Chairman, Ecoplast
Manas R Bastia manas@infomedia18.in
Raman M Patel Chairman, Industrial Products Mfg Co
Vijay Merchant President, Polycraft
June 2012 | Modern Plastics & Polymers
9
CONTENT S
Anniversary Special 7 Pulsating prospects driving progressive performance
44 56 64 76 90 96 102
Agriculture Construction Electronics Energy Healthcare Packaging Transport
Insight & Outlook
114
Visual control methods in project management: Keeping an eye on project cost concerns
In Conversation With
38
Mahendra N Patel, President, Gujarat Chamber of Commerce & Industry, and Chairman, Mamata Group
112
STEER Engineering (P) Ltd: Steering progress through compounding innovations
Policies & Regulations
118
RoHS and REACH: Keeping pace with global trade standards
Strategy
122
Raw material cost stabilisation: Reducing dependence on imports
Event Report 134 Chinaplas 2012: Saluting the surging demands of Asia 1 36 Plastivision Arabia 2012: Indian expertise, global opportunities 1 38 Die & Mould India 2012: India Inc embraces global tooling solutions
Highlights of Next Edition Special Focus: Thermoforming
Facility Visit
Insight & Outlook: Plastics in Electronic / Electrical Appliances
REGUL AR SEC T ION S Editorial ................................. 9 News, Views & Analysis ...... 22 Technology & Innovation .... 30 Projects ............................... 126
Event List........................... 128 List of Products.................. 158 List of Advertisers .............. 161
Details on page no.128 Cover illustration and design: Sachin Pandit and Sharad Bharekar Note: ` stands for Indian rupee, $ stands for US dollar and ÂŁ stands for UK pound, unless mentioned otherwise
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
June 2012 | Modern Plastics & Polymers
11
FOUNDER & EDITOR, NETWORK 18 Raghav Bahl PRESIDENT & EDITORIAL DIRECTOR, TV 18 Senthil Chengalvarayan SENIOR EDITOR Manas R Bastia EDITORIAL TEAM Annabel Dsouza, Swati Sharma, Lionel Alva, Abha Mishra, Paskaline Sebastian, Anwesh Koley (Delhi), Avani Jain (Ahmedabad) ASSISTANT ART DIRECTOR Varuna Naik DESIGN Sharad Bharekar CHIEF PHOTOGRAPHER Mexy Xavier PHOTOGRAPHY Neha Mithbawkar, Joshua Navalkar BUSINESS CONTROLLERS Lovey Fernandes, Akshata Rane, Surekha Karmarkar, Deepak Bhatia, Shwetha ME, Jayashree N, Sugandha Kulkarni, Shefali Mahant
PRINTING
EXECUTIVE VICE PRESIDENT Ananth R Iyer ASSISTANT GENERAL MANAGER - PPC Shekhar Khot
PRODUCTION TEAM Dnyaneshwar Goythale, Surekha Karmarkar, Ravikumar Potdar, Ravi Salian, Sanjay Shelar
OVERSEAS CONTACT
CHINA 1001 Tower 3, Donghai Plaza, 1486 Nanjing Road, West, Shanghai 200040, China Tel: +86-21 6289 – 5533 Ext. 368, Fax: +86-21 6247 – 4855 (Craig Shibinsky) Email: craig@ringier.com.hk Ringier Trade Media Ltd HONG KONG 9/F, Cheong Sun Tower, 118 Wing Lok Street, Sheung Wan, Hong Kong Tel: +852 2369 – 8788 Ext. 21, Fax: +852 2869 – 5919 (Octavia Au-Yeung) Email: octavia@ringier.com.hk Ringier Trade Media Ltd TAIWAN Room 3, Fl. 12, No. 303, Chung Ming S. Rd., Taichung, Taiwan Tel: +886-4 2329 – 7318 Ext. 16, Fax: +886-4 2310 – 7167 (Sydney La) Email: sydneylai@ringier.com.hk Ringier Trade Media Ltd GERMANY, AUSTRIA, SWITZERLAND Tel: +41-44 734 0472, Fax: +41 44 734 0680 Email: info@islerannoncen.ch USA Tel: (513) 527-8800 Fax: (513) 527-8801 Email: dhight@gardnerweb.com USA Alfredo Domador, 6505 Blue Lagoon Drive, Suite 430 Miami, FL. 33126, USA Tel: (305) 448-6875, Fax: (305) 448-9942 Ringier Trade Media Ltd
GROUP CEO, NETWORK 18 B Sai Kumar CEO-PUBLISHING, INFOMEDIA 18 Sandeep Khosla EVP-HUMAN RESOURCES Sanjeev Kumar Singh ASSOCIATE VICE PRESIDENT Sudhanva Jategaonkar ADVERTISING SALES Shashin Bhagat (Ahmedabad) shashin.bhagat@infomedia18.in Mahadev B (Bengaluru) mahadev.b@infomedia18.in Hari Hara Subramaniam (Chennai) hari.s@infomedia18.in Prakash N (Coimbatore) prakash.n@infomedia18.in Kalyan Chakravarthy (Hyderabad) kalyan.chakravarthy@infomedia18.in Ameya Gokhale (Indore) ameya.gokhale@infomedia18.in Aayush Bidawat (Jaipur) aayush.bidawat@infomedia18.in Inder Dhingra (Ludhiana) inder.dhingra@infomedia18.in Surendra Kumar Agrawal (New Delhi) surendra.a@infomedia18.in Rohit Dass (Pune) rohit.dass@infomedia18.in Chirag Pathak (Vadodara) chirag.pathak@infomedia18.in MARKETING TEAM Ganesh Mahale, Prachi Mutha
NEWSSTAND AND SUBSCRIPTIONS DISTRIBUTION HEAD Sunil Nair
DEPUTY GENERAL MANAGER Manoj Palsay SENIOR MANAGER - SUBSCRIPTIONS Sheetal Kotawdekar CO-ORDINATORS Rahul Mankar, Anant Shirke, Sarita Quadros, Chaitali Parkar, Kamlesh Mathkar, Vaibhav Ghavale
SERVICES
SUBSCRIPTION SERVICES For subscription queries, write to chaitali.parkar@infomedia18.in or call +91 22 30034631-34 or toll free 1800 200 1021 PERMISSIONS For subscription to copy or reuse material from Modern Plastics & Polymers, Write to spedit@infomedia18.in Monthly Issue Price: ` 100 ` 799
Views and opinions expressed in this magazine are not necessarily those of Infomedia 18 Ltd, its publisher and/or editors. We at Infomedia 18 Ltd do our best to verify the information published but do not take any responsibility for the absolute accuracy of the information. Infomedia 18 Ltd does not accept the responsibility for any investment or other decision taken by readers on the basis of information provided herein. Infomedia 18 Ltd does not take responsibility for returning unsolicited material sent without due postal stamps for return postage. No part of this magazine can be reproduced without the prior written permission of the publisher. Infomedia 18 Ltd reserves the right to use the information published herein in any manner whatsoever.
Infomedia 18 Ltd is the publishing arm of Network 18.
Printed by Mohan Gajria and published by Lakshmi Narasimhan on behalf of Infomedia 18 Ltd. Senior Editor: Manas R Bastia Printed at Infomedia 18 Ltd, Plot no.3, Sector 7, off Sion-Panvel Road, Nerul, Navi Mumbai 400 706, and published at Infomedia 18 Ltd, ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W), Mumbai - 400 028. Modern Plastics & Polymers is registered with the Registrar of Newspapers of India under No. MAHENG / 2008 / 25265. Infomedia 18 Ltd does not take any responsibility for loss or damage incurred or suffered by any subscriber of this magazine as a result of his/her accepting any invitation/offer published in this edition.
June 2012 | Modern Plastics & Polymers
13
MPP Tab 1 June 2012 Ad Name: Alok Pg No. 15
MPP Tab 1 June 2012 Ad Name: Kalra Pg No. 16
NEWS, VIEWS & ANALYSIS
Metso strengthens its capabilities in India
Metso has opened India Supply Centre (ISC) in Vadodara, Gujarat, India. The new ISC supports the company’s strategy to grow its valve business globally and strengthens Metso’s service capabilities in India for major petrochemical, energy and oil & gas companies such as Reliance Industries Ltd, Indian Oil Corporation, Technip, Praxair India Pvt Ltd and PRAJ Industries Ltd. Housed in Gujarat Industrial Development Corporation (GIDC) Por, about 40 km from Vadodara, the ISC at Metso spans an area of over 22,000 sq ft. The new supply centre has the capacity of assembling 1,200 pieces per annum and this can be scaled up to 1,800 pieces per annum in future. “The market in India is growing. We already have a huge installment base in Reliance Jamnagar. We are now looking for more opportunities in the country. Thus, establishing a supply centre in India is a step forward to widen our manufacturing and service capabilities in India,” noted Alok Kishore, Country Manager-Flow Control, Metso Automation (India) Pvt Ltd. Avani Jain
BKG CrystallCut process awarded for innovative technology The spherical Polyethylene Terephthalate (PET) pellet offers double the energy savings. A plant with production capacity of 600 tonne per day may achieve an almost unbelievable energy savings of 25 Gigawatt hour of energy in one year of operation using the CrystallCut technology developed by BKG, Bruckmann & Kreyenborg Granuliertechnik (BKG). Acknowledging this, the Plastic Technology China in cooperation with
Borouge to aid China’s infrastructure vision Borouge, a leading provider of innovative, value-creating plastics solutions, is moving forward and on track with its new manufacturing & innovation facilities in Abu Dhabi, UAE. The investment of about $ 4.5 billion for expanding its petrochemicals complex and an innovation centre has enabled Borouge to further support China’s infrastructure growth in pipe systems, energy and communication networks, as well as the rapidly growing automotive & advanced packaging industries. The expansion will take the plants’ total manufacturing capacity of polyethylene and polypropylene to 4.5 million tonne by mid-2014. In 2010, Borouge had invested about $ 5 billion to expand the plant’s annual capacity to 2 million tonne to serve global markets, including China. The company has also invested in a compounding manufacturing plant with application research and development facilities, besides
IPPA launch to spark infrastructure revolution Vinyl India Conference 2012 was recently held in Mumbai. This was the second International Vinyl conference organised by the Chemicals and Petrochemicals Manufacturers’ Association (CPMA). The conference brought out clearly that the pipe sector will undergo structural changes in the next 3-4 years, with preference for quality pipes over low cost. On
22
the Vogel Media Advertising Co Ltd, nominated BKG for the award of the most innovative, energy-saving plastics processing equipment of the last decade (2002-12). The award was conferred to BKG in Shanghai. CrystallCut helps achieve an energy savings of around 20 per cent, with the conventional extrusion equipment for manufacture of PET pellets. A further energy cost savings of around 5 per cent is realised during the subsequent processing of the pellets in the injection moulding machine.
Modern Plastics & Polymers | June 2012
this occasion, the Indian Plastic Pipe Academy (IPPA) was also launched. A new group representing the Polyvinyl Chloride (PVC) pipe sector was launched at the conference. The IPPA is a non-profit organisation that will represent member companies and work to improve the image of the industry. “The IPPA would strive for increasing the positive image and acceptance of plastic piping systems by promoting the high quality &
Rashed Saud Al Shamsi (centre), Chairman, Borouge’s Marketing and Sales Company, holding a piece of film made from Borouge’s products (at Chinaplas 2012). Noora Juma (right), Consul General of the UAE in Shanghai, China, looks on
logistics hubs in Shanghai, Guangzhou and Singapore to enhance its service to its customers throughout the region. “O ur robust business growth momentum represents strong customer recognition of our innovative solutions and the differentiated value we create for their businesses and the entire value chain,” said Wim Roels, Chief Executive Officer, Sales and Marketing Company, Borouge. sustainability levels of these products,” said Rishav Aggarwal, Director, Kisan Moulding Ltd, one of the five ad hoc members. He added further, “Plastics has been stigmatised in the Indian society by various interest groups and, in the last few years, it is being overtly propagated as detrimental for the environment.” The group will also develop training programmes for plastic pipe system producers, installers and end-users for raising awareness for the same.
NEWS, VIEWS & ANALYSIS
KREYENBORG Plant Technology GmbH & Co KG gets new Managing Director
Andreas Holt
Andreas Holt has been appointed as Managing Director of KREYENBORG Plant Technology GmbH & Co KG. He will be responsible for the operational business of the company. JanUdo Kreyenborg, Managing Director, KREYENBORG Group, said, “We are delighted to have found an expert like Andreas Holt, who will further promote the infrared technology for drying and crystallisation, and the expansion of the mixing & conveying equipment.” Holt had studied mechanical engineering in Paderborn with a focus on plastics and process engineering. Throughout his career, he has held various positions in the field of plastic extrusion and automation technology. Since 2011, Holt has been controlling the expansion of the plant construction business of KREYENBORG. Since early this year, he has been a Member of the Board. Founded in 2008, KREYENBORG offers a wide range of infrared technology solution for the thermal treatment of bulk goods. These include heating, drying and crystallising operations that are less timeconsuming and energy-efficient.
Dr Werner Wittmann awarded Silver Commander’s Cross Dr Werner Wittmann, Managing Partner, Wittmann Group Holding Gmbh, was conferred Silver Commander’s Cross by Governor Dr Erwin Pröll in honour of his merits for the Province of Lower Austria. The award ceremony was held in the assembly hall of the Lower Austrian Parliament House in St Pölten. In his official address at
24
Modern Plastics & Polymers | June 2012
ECO Plastics and Coca-Cola open recycling joint venture
Global automotive plastics revenue to reach $ 42,135 million by 2016
Coca-Cola Enterprises (CCE) and ECO Plastics have entered into an innovative partnership to open the £ 15-million Hemswell, Lincolnshire-based Continuum Recycling plant. The plant is world’s largest and most sophisticated plastics recycling facility and will be capable of processing 150,000 tonne of mixed plastics a year, including 40,000 tonne of bottle-grade Recycled Polyethylene Terephthalate (rPET). Simon Baldry, Managing Director, CCE, said, “The new plant would ensure that the company fulfills its commitment to incorporate 25 per cent of rPET in all its plastic-made drinks bottles by the end of this year. Further, our (£ 5 million) investment in Continuum Recycling shows that we are serious about setting the industry standard for sustainable packaging.” Plastic flake produced at the Continuum plant will be used to make new Coca-Cola drinks bottles, some of which could find their way back onto retailers’ shelves, after being reprocessed, within six weeks of the first use. The joint venture claims that the decade-long programme will save about 33,500 tonne of CO2 annually, while the partnership will lead to creation of 30 new skilled jobs for the local area.
The global automotive plastics revenue will grow from $ 22,155 million in 2011 to $ 42,135 million by 2016 at an estimated Compounded Annual Growth Rate (CAGR) of 13.7 per cent between 2011 and 2016. The consumption of automotive plastics worldwide is expected to increase from the last year’s value of 6.7 million tonne to 10.2 million tonne by 2016 at a projected CAGR of 8.5 per cent for the same period. Among all automotive plastics, polypropylene leads consumption by 36 per cent, followed by polyurethane (17 per cent), Acrylonitrile-ButadieneStyrene (ABS) (12 per cent), composites (11 per cent), High-Density Polyethylene (HDPE) (10 per cent), polycarbonate (7 per cent) and Polymethyl Methacrylate (PMMA) (7 per cent) owing to their easy forming properties and cheaper price as compared to other materials. New opportunities are cited in new materials such as reinforced composites and PMMA. Canon Patel, Managing Director, Loxim Industries Ltd, opined, “The drivers of automotive plastics utilisation are their potential for weight reduction, greater fuel economy and carbon emission reduction potential as well as system cost reduction.” Avani Jain
the Governor’s reception, following presentation of Silver Commander’s Cross, the Governor honoured Dr Werner Wittmann’s achievements on behalf of Wittmann Battenfeld GmbH in Kottingbrunn, and also on behalf of the Province of Lower Austria. With Dr Wittmann’s courageous entrepreneurial move in taking over Battenfeld GmbH in 2008, more than 200 jobs were preserved in
Kottingbrunn. The company’s positive development during the following years has enabled it to increase the workforce to about 400 employees today. In his words of thanks, Dr Wittmann, expressed optimism for the future of Europe as an industrial location and pointed to the opportunities that the Asian market has in store for innovative companies such as the Wittmann Group.
NEWS, VIEWS & ANALYSIS
Highest LEED Platinum rating for Bayer’s ECB in Greater Noida Bayer’s EcoCommercial Building (ECB) in Greater Noida, India, has received the highest score in the category ‘New Construction’ (NC) of the international rating system Leadership in Energy and Environmental Design (LEED). The building was awarded 64 points out of a total possible score of 69 points. Bayer’s ECB achieved the maximum number of points in three out of six categories, namely, ‘ Water Efficiency ’, ‘Indoor Environmental Quality’ and ‘Innovation & Design’. The Bayer ECB at Greater Noida now has the highest score in the LEED NC rating worldwide. “We are pleased to have received the Platinum ranking with highest points in the prestigious LEED rating system. This is a clear signal that
the concept of ecologically sustainable buildings can be achieved with the right materials. This is independent of
whether the building is located in the developed world or an emerging market,” said Thomas Roemer, Vice PresidentIndustry Platform Construction & Building, Bayer MaterialScience AG. Bayer had opened its first emissionsneutral office building in Asia as part of its Group-wide sustainability
programme in Leverkusen, Germany. The new building in Greater Noida draws 100 per cent of its electricity f rom a Photovoltaic (PV ) plant, needs about 50 per cent less power than comparable buildings in the area. Bayer’s ECB has added a wide range of individual energy conservation measures such as Envelope (thermal insulation for roofs), Windows (type of windows), Lighting and Central plant to the budget case in order to optimise the performance of the proposed building. Also, the energy used by the ECB on an annual basis will be obtained from PV cells installed on the roof-top, which can significantly reduce the environmental impact by preventing greenhouse gas emission and air pollution. Anwesh Koley
BASF expansion to strengthen market ties
Astounding performance at CHINAPLAS 2012
BASF, headquartered in Florham Park, New Jersey, has planned to construct a new formic acid manufacturing plant in Geismar, Louisiana. The plant, an annual production capacity of over 50,000 tonne, will be located at the company’s integrated Verbund site. It will enable BASF to better serve strategic markets in both North America and South America for a wide range of applications. The formic acid production facility is anticipated to commence operation in the second quarter of 2014. Formic acid is used as an eco-friendly product by BASF’s customers in various applications. Formic acid salt, potassium formate, is an efficient de-icing agent used on airport runways and roads. It is a biodegradable formic acid solution used to protect marine wildlife in watersheds and rivers. Soeren Hildebrandt, Senior Vice President, Chemical Intermediates Division, BASF, remarked that this latest investment will enable BASF to better serve its clients with higher supply reliability and shorter lead times. It strengthens the company’s global position in the formic acid sector with production operations in Asia, North America and Europe. Currently, the company owns two formic acid facilities at Verbund.
The curtains closed on the 26th edition of Chinaplas at the Shanghai New International Expo Centre, PR China. The scale of the show expanded 16.67 per cent to 210,000 sq m as compared to that in 2011, and it recorded 40 per cent growth in comparison with that held in Shanghai in 2010. In terms of visitors, the turnout increased to 109,858 with a growth rate of 16.77 per cent. Stanley Chu, Chairman, Adsale Exhibition Services Ltd, Organiser of Chinaplas, commented, “Chinaplas has enjoyed the benefits from the
26
Modern Plastics & Polymers | June 2012
continuous economic recovery since last year, especially in Asia. The growing reputation along with a strengthening economy in the Asian region has boosted the confidence of our exhibitors, leading to an upsurge in the number of exhibitors. Thanks to the global trend of green manufacturing and China’s 12th FiveYear plan, we along with the exhibitors bring many new developments, technology and materials featuring low carbon emission, eco-friendliness, energy saving, etc.” It is worth mentioning that two new pavilions from Korea and Thailand joined Chinaplas this year, boosting the number of pavilions to 13. The organiser had announced that Chinaplas 2013, with an expected exhibition area of 220,000 sq m, will be staged at China Impor t & Export Fair Pazhou Complex, Guangzhou, PR China, during May 20-23, 2013.
NEWS, VIEWS & ANALYSIS
Capacity expansion for Hinds Machineries
In order to meet the growing demand of consumers, Hinds Machineries has recently inaugurated its new mega plant in the National Capital Region (NCR). The new manufacturing plant situated in Manesar, spread over an area of about 12,000 sq ft, will commence production soon. With five machines per month in the first phase of the setup, the production capacity of this mega plant will be nearly doubled to 10 machines per month within a short span. “The new facility will cater mainly to the India and South East markets and will provide high-quality and advanced machines with short lead times. The new factory is equipped with the latest tools and CNC machines,” said Praveen Sharma, Managing Director, Hinds Machineries. At present, the company manufactures the injection moulding machines with 25-400 tonne clamping force in hydraulic clamping and toggle clamping with the brand name Euro Series. The company works on providing the best solutions and cost-effective machines. These machines are energy-efficient and highly productive. The company’s current range includes PLCcontrolled injection moulding machines, press brakes, punching presses, hydraulic cylinders, insert moulding machines, hot runner temperature controllers, granulators, hydraulic press brakes and imported seals. 28
Jain Irrigations’ NaanDanJain acquisition highlights growing ambition Since signing the first agreement in 2007, NaanDanJain has increased its sales turnover by over 25 per cent. In the past five years, more than ` 1,250 million have been invested in the company on its innovative drip irrigation and sprinklers equipment, both in Israel and NaanDanJain subsidiaries worldwide. Investments in research and development have also increased. The agreement was signed in the presence of senior board members and executives of Jain’s representatives of the Israeli company. The agreement ensures that the scope of the company’s activity will continue in Israel until 2020.
Sweden’s Frohe to open new plant Swedish injection moulder Frohe Group has planned to move from its Polish plant in Wrocław to a new production facility in Nowa Wieś, Poland. The total area of the plant will be 3,500 sq m. Production at the new factory is scheduled to begin in October 2012. The factory is ISO 9001 and 13485 certified. The new facility will have a 200-sq m cleanroom certified according to ISO 14644 standards. It will allow the
SPE ANTEC makes India debut
The Society of Plastics Engineers (SPE) is organising its flagship technical conference SPE ANTEC in Mumbai on December 6-7, 2012, at The Renaissance Mumbai Convention Centre Hotel. SPE ANTEC Mumbai will be the first of its kind event to be conducted outside the US. SPE is the premier source of peerreviewed technical information for plastics professionals. The ANTEC annual conference is a recognised medium for communication among scientists, engineers and technical personnel. It offers plastics professionals multiple original
Modern Plastics & Polymers | June 2012
Anil B Jain, Managing Director, Jain Irrigation Systems, declared, “This is a significant step in strengthening of the ties between Israel and India. This is a great opportunity to expand our activities in the world in areas that provide solutions to the growing global climate change, water, food & energy crises. Jain’s response to this challenge in the fields of agriculture and irrigation will be expressed upon the conclusion of the agreement, and we foresee new possibilities for the growth of our company in these areas. NaanDanJain provides added value to Jain, and we are proud and excited with this opportunity to preserve & develop it for the benefit of our clients across the world. Together, we expect to become the world’s leading agro-industrial concern.” Lionel Alva Swedish manufacturer to significantly improve its transportation system. The company supplies its plastic products to a wide range of companies from the medical, agricultural, electronics, automotive and food processing industry. The product range at Frohe includes polystyrene, polypropene, p o l ye t hy l e n e, p o l yox y m e t hy l e n e, Acrylonitrile-Butadiene-Styrene (ABS), thermoplastic elastomers, Polyamide (PA) 6, PA11 and PA12. peer-reviewed technical papers. SPE will continue its commitment towards the development, conversion and application of plastics in India. Over 100 technical papers will be presented in the two-day conference. A New Technology forum will concentrate on the areas associated with carbonaceous nanomaterials, including graphemes and carbon nanotubes. Advancements in materials for various applications; processing technolog y ; processing methodology such as design innovation, engineering properties and structure, polymer modifiers & additives will be presented. There will also be papers on developments in machinery such as mixing equipment, downstream equipment, hydraulic, control systems and robotics; as well as rheology, modeling & simulation solutions.
TECHNOLOGY & INNOVATION
New DuPont™ ECCtreme™ ECA 3000 perfluoropolymer helps raise performance bar
The DuPont™ ECCtreme™ ECA 3000 perfluoropolymer resin is a new material that offers groundbreaking capability for high performance under extreme temperatures and conditions. The ECCtreme™ ECA 3000 resin insulation for wire and cable applications has the potential to operate at 300°C with the same high-temperature properties of perfluoropolymers typically used in these applications. This surpasses the 260°C temperature limit inherent in the conventional perfluoropolymer insulating materials. This resin is unique due to the way it responds to extremely high temperatures. When the polymer is heat-treated at temperatures greater than 280°C, the result is Epitaxial Co-Crystallisation (ECC), which actually improves the functionality of the polymer. This new capability offers options for high temperature tolerance in geothermal applications, Electric Submersible Pumps (ESP), data logging cables, other oil and gas applications, aerospace uses, automotive uses, heater cables & appliance wires.
MULTIVAC’s new thermoforming packaging machine
The R 515 machine from MULTIVAC is designed for addressing specific requirements of the fresh meat industry. The R 515 machine offers standard dies 30
Modern Plastics & Polymers | June 2012
Next-generation HyCAP systems to improve productivity Husky Injection Molding Systems has introduced next-generation HyCAP™ systems for high-output beverage closure manufacturing. The product line features two performance levels, each of which delivers industryleading cycle times for its target applications, besides the highest levels of reliability, repeatability and part quality. Advantages of the new HyCAP system include direct drive technology, which provides improved plasticising speed and control resulting in improved shot-toshot repeatability and better quality parts.
To maximise performance, elements of the system such as the plasticising screw and check valve have been specifically adapted to suit the characteristics of the direct drive technology. Enhancements on the clamp include electrification of the clamp lock function to improve efficiency & cycle potential. It also features a single interface for central control of the entire system, including hot runner temperature control and auxiliary equipment. With the latest generation of Polaris™ Control, the new HyCAP systems offer the highest level of precision and repeatability, enabling greater fine-tuning, which particularly benefits faster cycling light-weight applications.
PolyOne specialty solutions to address key challenges for automotive engineers PolyOne Corporation has launched three new grades of Therma-Tech™ specialty engineering materials for automotive lighting systems and new OnColor™ SmartBatch™ concentrates for automotive interior parts. With their outstanding heat dissipation functionality, the three new Therma-Tech™ formulations offer automotive Original Equipment Manufacturer (OEM) lighting engineers more design options. In addition to expanded design freedom, light-weighting potential and efficient manufacturability, these formulations help manage hot spots and enable designers to implement High-Brightness Light-Emitting Diodes (HB-LEDs) in lighting systems for new cars & trucks. The new materials
offer customers varying degrees of heat stability, enabling them to select the most appropriate solution for their application. The new offering of OnColor™ SmartBatch™ concentrates for automotive interior parts not only fulfils carmakers’ requirements for colour, but also prevents dust from collecting on finished parts in the automobile. OnColor™ SmartBatch™ concentrates are available as drop-in solutions for injection moulding and also for use in compounding lines.
and format sets, which are specifically tailored to requirements of the fresh meat industry. The new machine model is designed for running flexible films, such as for polyamide/polyethylene multi-layer films. The R 515 is also equipped with register mark control for running printed upper webs. In addition to vacuum packs, the machine can produce packs with Modified Atmosphere Packaging (MAP). The machine cycle output is
about 10 cycles per minute. Thanks to the Human-Machine Interface (HMI) 2.0 user interface, even less technically proficient or trained operators can easily operate the complete functioning of the machine or line with the touch of a finger. The R 515 can be equipped with an optional jumbo film unwind for lower webs. This reduces machine downtime caused by roll changes. R 515 also offers an optional quick-change system for forming and sealing dies.
MPP Jun_2012 Ad Name: Disha Tab-2, Pg No. 33
MPP Jun_2012 Ad Name: Boge Tab-2, Pg No. 34
TECHNOLOGY & INNOVATION
New engineered Lexan PC film grades from SABIC
SABIC’s Innovative Plastics business has launched three new engineered Lexan Polycarbonate (PC) film grades. This development is to help customers meet the growing demand for cost reduction, greater design flexibility, higher performance and compliance with global environmental regulations in the electronics & automotive sectors. The new grades – Lexan HP92TTY, Lexan 6060 and Lexan OQ8DA films – provide outstanding optical quality. These films provide new design options for In-Mould Decoration (IMD) overlays and lenses, and are suitable for embossing and printing. Lexan HP92TTY-coated film for 2.5-dimensional formed parts gives good chemical and abrasion resistance, is embossable and does not require post-curing step. Target applications include IMD overlays for consumer electronics and automotive parts. Lexan 6060 film for IMD overlays on three-dimensional parts is printable and provides high gloss, light transmission and increased surface hardness. It is used in housings for portable electronics. Lexan OQ8DA dual-coated sheeted film is printable and provides excellent impact performance. It is used for lenses & keypads in electronic devices.
New grades for pipe and advanced packaging by Borealis Borealis has launched new materials for the pipe and advanced packaging industry. A range of innovative Polyethylene (PE) and Polypropylene (PP) materials through its BorSafe™ and BorECO™ product ranges are developed for the infrastructure pipe industry. 36
Modern Plastics & Polymers | June 2012
Zero-defect plastic injection moulding systems Kistler North America has announced various zero-defect plastic injection moulding sensors, software and systems. New STASA QC software is expressly designed to optimise the machinery parameters most critical to zero-defect medical, automotive, electrical component, optical and Liquid Silicone Rubber (LSR) plastic injection moulding operations. Other benefits include faster production startup, fewer required experiments and safer injection moulding processes. Type 2869B CoMo Injection process monitoring system version 2.3, a firmware upgrade allows for automatic mould identification, costeffective cavity pressure monitoring and 100 per cent zero-defect part quality. Type 9211BE miniature quartz force sensor is used for highreliability dynamic and quasi-static
mould cavity measurements of up to 3,000 bar (43,511 psi), over a range of 0-2,500 N. It is ideal for use in moulds with small cavities or a large number of ejectors. Type 5155A multi-channel temperature and pressure charge amplifier converts the signal from all types of piezoelectric sensors and Type K thermocouples into a proportional voltage output signal, for effective monitoring, control and optimisation of injection moulding processes. Type 4021B industrial melt pressure measuring chain is designed for simultaneous recording of shortduration pressure peaks to 3,000 bar (29,000 psi) and temperatures to +350°C. It is ideal for use in demanding short cycle process monitoring environments, such as those typically found within nozzle sensing or hot-runner sensing systems.
New CFR cuts take-out time DB Automation offers its new Compact Flexible Robot (CFR) to the injection moulding industry as ‘the next generation of high-performance robotic take-out technology.’ It claims take-out times as short as 200 millisecond. The side-entry CFR uses an articulated motion to enter the mould area while the tool is still opening. Once inside the tool area, a further servo-controlled axis follows the continuing opening movement
The company has also introduced a new outer layer solution – BorPEX™ ME2578 – for Multi-Layer Composite Pipes (MLCP). It is available as the quality outer layer PEX-b solution for MLCP. The new PE-based material cross-links automatically at ambient temperatures, which avoids the need for a post-treatment stage, offering considerable savings for pipe producers. The stability of the material
and removes the moulded product. This configuration is designed to minimise delay to the moulding cycle by demoulding. Traditional Cartesian demoulding can prolong the cycle by up to 1.5 second, which claims nearly 25 per cent increase with the CFR. ensures a smooth production process and an excellent surface finish. Two new peelable compounds – Borpeel™ WD955CF and Steripeel™ WE950CF – have been launched for transparent lidding film and peel-against-itself applications. These provide superior optics, high transparency and a broad processing window and can be used in medical applications & antifogging films.
IN CONVERSATION WITH: Mahendra N Patel
“The quality of our machines is close to the standards followed in Europe” …opines Mahendra N Patel, President, Gujarat Chamber of Commerce & Industry, and Chairman, Mamata Group. In an exclusive interaction with Avani Jain, he underlines some of the constant efforts towards improving energy efficiency of machinery. He also highlights the industry’s grow prospects in India, particularly in Gujarat due to easy availability of raw materials. Photo: Sharan Goel
38
Modern Plastics & Polymers | June 2012
Mahendra N Patel
How is the plastics processing industry faring in Gujarat? The industry is performing well in India, and Gujarat has always been the hub for plastics processing machinery manufacturers. A majority of plastics processors are located around Ahmedabad and Rajkot. Almost all leading plastics processing machinery manufacturers in the state are offering technologies that can face the competition from foreign companies. The exports have also improved to a great extent in the State.
Which factors have made Gujarat a hub for commerce, particularly in the plastics industry? The people of Gujarat are entrepreneurs by nature and are continuously involved in a variety of businesses. With regard to the plastics industry in particular, the availability of raw materials in the State has helped the plastics industry to develop faster in this region. Further, the availability of machinery has provided a boost to the processing industry. The State has a receptive and proactive bureaucracy and the policies formulated by the Government for boosting the industrial development are very progressive. Issues such as red tapism, even if they exist, are resolved quickly.
What are the key drivers for growth of this industry? The major driver for the growth of the plastics industry in the State is the easy availability of raw materials, and this has resulted in price stability. The favourable exchange rates have also helped the industry prosper.
What are the leading innovations driving the plastics processing machinery sector? At present, due to the high energy cost, all technical advancements are oriented towards reducing energy consumption in the plastics processing sector. Thus, many changes are directed towards improving energy efficiency and speed. Companies are constantly striving to make machines
energy-efficient through the use of allelectric drives, servo drives, AC variable drives, improved temperature controls, insulation, etc. All-electric machines can be seen as the latest development in the plastics processing machinery sector. Further, new processing techniques that reduce energy consumption and moulding time are being developed. These days, improved raw materials, compounds and additives with unique characteristics are being developed.
What is your take on the cost-quality ratio of Indian machines vis-Ă -vis China? China is ahead of India in terms of quantity of machines, but is behind us in terms of quality and technology. The quality of our machines is close to the standards followed in Europe while the pricing is similar to that prevalent in the Far East.
What are the challenges faced by machinery manufacturers? Due to lack of proper industrial policy, the infrastructure is not sufficient. This impacts the development of the plastics processing industry. No steps have been taken for the development of the industry in the country. As a result, the industry is divided into pockets. Today, if someone wants to buy good casting, which is a major input for machinery manufacturing, the choices are limited. There are only few places from where one can source and purchase it.
How do you assess the growth prospects of the machinery sector? Companies already established in India will grow at a constant pace. However, new entrants may not invest in India. This is because of the surplus machines in the global market in comparison with the demand and consumption. The industry is moving towards good quality machines with improved technology. This has reduced the number of machines needed to perform certain tasks. Thus, we need to understand that when we are enhancing and improving our machines, we are
also affecting our own growth prospects. Further, machinery making business is quite challenging. It requires a lot of dedication.Today, when there are many simpler ways of making money, very few want to venture into plastics processing machinery manufacturing business. Thus, no new companies are emerging in this segment, and expansion of the existing companies is a viable option for the future. The new companies in this segment are only a few foreign players coming to India with their own manufacturing infrastructure or as joint ventures.
How do you perceive the future of plastics processing industry in India and Gujarat? The future of the plastics processing industry in India, especially in Gujarat is bright due to the easy availability of raw materials. Although, the growth might be slow, but that will not make much difference.
What are your growth plans for Mamata Group? We have been engaged in the manufacturing of plastics processing machinery. We have been growing at a constant rate. Presently, as a group, we are focussing more on energy-efficient technology and innovations.
What are the things that you consider while signing a deal? Most decisions are made with emotions and people rationalise it afterwards. As an entrepreneur, I always go by my instincts when it comes to collaborations and partnerships. Thus far, all of them have progressed well and have been rewarding for both sides.
Your message to aspiring and upcoming entrepreneur‌ Always follow your heart and do what you enjoy. If you like something, then do it and you will always find it rewarding. Further, money should never be your only goal. The moment you make money as your goal, you will become miserable. Email: avani.jain@infomedia18.in June 2012 | Modern Plastics & Polymers
39
ANNIVERSARY SPECIAL
7 Pulsating prospects driving progressive performance
Agriculture Mulch films: Investing in innovation, harvesting profits .......................................................44 Plastic irrigation equipment: Boosting productivity drop-by-drop ........................................46 Interface - R Swaminathan, Director–Manufacturing, Jain Irrigation Systems ....................54
Construction Plastic pipes: Conveying cost-effective solutions ....................................................................56 Polymeric geotextiles: Key to India’s infrastructure vision .....................................................58 Interface - Timothy Earl Madden, MD-South Asia Region, Lubrizol Advanced Materials India Pvt Ltd ...........................................................................62
Electronics OLED technology: Lighting up application avenues .............................................................64 Carbon fibre: Small ideas, big impact .....................................................................................66 Interface - Ramesh Dumbre, VP-Marketing, Plastiblends India Ltd.....................................72
Energy Wind power generation: Giving wings to performance plastics ..............................................76 Solar technology: Em‘power’ing the future of India................................................................78 Interface - Ajay Prakash Shrivastava, President, Solar Energy Society of India ....................82 Roundtable - Is India ready for large-scale investement in alternative energy solutions? .......84
40
Modern Plastics & Polymers | June 2012
ANNIVERSARY SPECIAL
Healthcare Machinery marvels: ‘Inject’ing innovations in medical grade plastics.....................................90 Imaging and diagnostics: Visualising exciting opportunities...................................................92 Interface - Dr Subhas Chandra Shit, Deputy Director, CIPET, Ahmedabad .......................94 Roundtable - Is plastics the answer to a competitive Indian healthcare industry? .................95
Packaging Bioplastics: Emphasising on the green factor...........................................................................96 High barrier films: Riding on the retail wave .........................................................................98 Interface - Dan Sawyer, Leader–New Business Segment, NatureWorks Llc .......................100
Transport Automotives: Accelerating ahead with composite solutions .................................................102 Aerospace: Light-weighting takes to the skies .......................................................................104 Interface - Ayush Lohia, CEO, Lohia Auto Industries ........................................................ 110 Roundtable - How can plastics boost safety and efficiency in aviation? ............................... 111
June 2012 | Modern Plastics & Polymers
41
AGRICULTURE: Mulch films
Investing in innovation, harvesting profits The rising population is putting pressure on water and food supplies. This has led to increased usage of agricultural plastics, especially mulch films, in the country owing to its various advantages. Avani Jain notes the benefits offered by mulch films and how these can help in increasing the agricultural productivity.
T
he usage of plastics is crucial to Indian agriculture in view of the changing technologic al scenar io for boosting crop yields and productivity. Particularly, plastic films have extended the growing season substantially and enhanced the yield, which is critical as the population grows but the area being farmed is fixed. Plastic films have three major applications in the agricultural sector, ie, mulching, greenhouse and silage. Introduction of mulch films has brought about a revolution in agricultural water management and soil conservation. Bhavin Patel, Director, Unnati Speciality Films (USF), avers, “Mulching is mainly employed for moisture conservation in rainfed areas, reduction in irrigation frequency and saving water in irrigated areas, soil temperature moderation in greenhouse cultivation, soil solarisation for control of soil-borne diseases, prevention of soil erosion & maintenance of soil structures.” 44
Modern Plastics & Polymers | June 2012
Mulching process Mulching is the process or practice of covering the soil/ground to enable more favourable conditions for plant growth, development and efficient crop production. Mulching reduces overflow, increases penetration of rainwater, controls erosion, corrects the chemical stability of the soil and decreases damage caused by pests & insects. While natural mulches such as straws, dead leaves and compost have been used for centuries, the advent of synthetic materials such as plastic mulch films have modified the methods & benefits of mulching. Plastic mulches are completely impermeable to water, prevent direct evaporation of moisture from the soil and curtail water loss and soil erosion over the surface. Further, the modified environment, allows plants to grow faster and to a superior size and quality. Patel avers, “Mulch films serve many different purposes. Transparent mulch films are used to encourage early season plant growth and early cropping, whereas black mulch films are used to
control weed growth; further, white films provide reflected sunlight for plants. In all cases, a more effective use of the available water is achieved.” He adds, “Mulch films are air proof and do not permit any moisture/vapour to escape, thermal proof for preservation of temperature & prevention of evaporation and durable at least for one crop season.”
Types of mulch films A wide range of plastic films based on different types of polymers are available in the market. Polyethylene (PE) is a preferred material owing to its greater permeability to long-wave radiation, which can increase the temperature around plants during the night. Today, the vast majority of plastic mulch is based on Linear Low-Density PE (LLDPE) as it is more economic to use.
Productivity booster Agricultural mulch film has been around for many years and as technology has progressed, so have the applications for
Mulch films
this specialty poly film. Some of the benefits include the following: Earlier planting dates: Plastic mulch films change the soil temperature and allow for earlier planting dates. Patel notes, “Dark or clear mulch films provide a warming effect to the soil, while white film reflects sunlight, thereby cooling the soil.” Reducing of soil moisture loss: Especially in dry or hot areas, agricultural mulch films help reduce soil dehydration, while also preventing fertiliser leaching. Cleaner produce: As the agricultural mulch films closely cover the soil, there is little contact between fruits, vegetables or other produce and the soil. This results in cleaner produce and has less likelihood of fruit decay. In addition, weed growth and root damage. are reduced. Soil protection: Agricultural mulch films are often used as a barrier to keep harmful fumigants away from the soil. These help protect the soil and its produce from being contamination with these harmful substances.
The downside Use of plastic agricultural mulch films also has few disadvantages. Patel says, “Not only the material is an added cost, but one must consider the equipment and labour needed to install and later remove this form of PE film.” Second, using plastic agricultural mulch film means that one has to use a unique application process for proper placement of the poly film on crops and soil. Special machines are needed to place the row of plastic film over the planting bed. Patel says, “Special machines called transplanters are required to continuously and evenly distribute the crops onto the film.” Finally, although biodegradable plastic films exist, non-biodegradable plastic films are more commonly used
today. “Because of this the agricultural mulch film must be removed and disposed of properly. This means taking them to a processing or recycling plant that specialises in disposing of this specific type of PE film,” avers Patel.
Present scenario The usage of plastics in agriculture in the country is currently very low. It is less as compared to that in the western nations. Hence, it has immense scope for growth. Patel says, “In 2012, India has an ambitious growth target of 4.1 per cent in agriculture, which means an increase of ` 1,50,000 crore in agriculture Gross Domestic Product (GDP). This can only be achieved with greater utilisation of plastics in this sector.”
Green prospects Ideally, looking at the kind of agricultural growth of the country and government schemes, India will witness a steep growth in the use of plastic films, especially mulch films, in the agricultural sector, but the onus lies on the processor. Patel notes, “Processors need to educate the farmers and join hands with the Government to ensure that farmers can avail the benefits of otherwise expensive mulch films and increase their productivity. Not only the companies need to do their bit, but the Government should also come forward and take all possible steps to produce these film on a mass scale and make it available to farmers at a reasonable price. Subsidy may also be given through banks to encourage the farmer to use mulch films. Further, low-cost machines should be developed for spreading and rolling down the films in the field. All these factors will go a long way in increasing the use of plastic mulch films in agriculture. Email: avani.jain@infomedia18.in
Mulching is mainly employed for moisture conservation, reduction in irrigation frequency & saving water in irrigated areas, soil temperature moderation in greenhouse cultivation, soil solarisation, prevention of soil erosion and maintenance of soil structures. Bhavin Patel Director, Unnati Speciality Films (USF)
Courtesy: Unnati Speciality Films
Ju une 2012 2 | Modern Plastics & Polymers June
45
AGRICULTURE: Plastic irrigation equipment
Boosting productivity drop-by-drop
The demands for low-cost, precision equipment in agriculture applications are driving plastics consumption across the country. Drip irrigation, also known as microirrigation, is an effective solution for enhancing farm output while conserving water. Annabel Dsouza takes a closer look at the latest developments in injection moulding that are addressing agricultural challenges.
F
or an agrarian economy like India, it comes as no surprise that agriculture is fast emerging as one of the key demand drivers for the plastics industry. With agriculture contributing about 18 per cent to the Gross Domestic Product (GDP), this sector offers immense potential for plastics applications. Apart from engaging more than 60 per cent of the workforce, India relies entirely on agricultural production to feed the growing population. As traditional farm practices are improvised to keep pace with global competition, there is a need to exploit available resources to their optimum potential. This is where the versatility and flexibility of plastics play an important role. As demonstrated by the Plastindia Plasticulture Project, the Indian plastics industry is contributing immensely towards water transportation and micro-irrigation. With a mature pipe manufacturing segment having millions of tonnes of installed capacity, Indian plastics processors play an important role in enhancing crop production while conserving water resources. Jigish Doshi, Chairman & Managing Director, Vishakha Polyfab, says, 46
Modern Plastics & Polymers | June 2012
“Emerging application areas such as agriculture offer tremendous growth potential to plastics consumption and the injection moulding industry. Microlevel perfection is essential in irrigation components for water flow control and motor compatibility. Precision in mould as well as machine is the unique advantage of injection moulding as compared to blow moulding and rotomoulding. The Indian industry is fast realising the advantages of agricultural applications, and hence many processing and moulding units are being established in traditional farming belts in North and East India. By catering to specific areas, these processing units are trying to understand the local needs and concerns through low capital investment and technology transfer.�
Key to precision Micro-irrigation is an important agricultural technique that ensures required water supply to the crops without over-supply and wastage. Micro-irrigation refers to lowpressure irrigation systems that spray, mist, sprinkle or drip. The water discharge patterns differ because emission devices are designed for specific applications due to agronomic
or horticultural requirements. Microirrigation components include pipes, tubes, water-emitting devices, flow control equipment, installation tools, fittings and accessories. Most of the components in a typical low-cost microirrigation system are manufactured from Polyvinyl Chloride (PVC) and various types of Polyethylene (PE) & Polypropylene (PP). The manufacturing technology is based on a simple extrusion or injection moulding process for precision, faster turnover and cost-efficiency. Drip irrigation systems mainly consist of plastics emission devices serviced by a water distribution network that ideally includes control zone equipment. At the water source, water is controlled with automatic valves, sometimes amended with fertilisers or chemicals, filtered and regulated at levels suitable for the emission devices chosen and crops being cultivated. From there, water is delivered to each of the emission devices through a network of PVC and PE pipes. The emission device, whether it is drip tape, a drip emitter, jet or micro-sprinkler, then delivers water & nutrients to the soil where plant roots can nourish the plant.
Plastic irrigation equipment
Micro-level perfection is essential in irrigation components for water compatibility. The Indian industry is realising the advantages of agricultural applications. Hence many processing and moulding units are being established in traditional farming belts. Jigish Doshi Chairman & Managing Director, Vishakha Polyfab
Doshi adds, “Low-cost drip irrigation lines are traditionally made by moulding a drip emitter with an elongated labyrinthine channel formed in the depth of the emitter body. A plastic film is extruded and passed through a film die with an air-injection tube at one end forming a plastic film bubble. These are durable and built to withstand outdoor conditions for reasonable lengths of time. In many cases, the environmental conditions will dictate the choice of emission device for any given application.”
Advantages of injection moulding Given the pivotal role of precision moulding for irrigation components, injection moulding has emerged as a crucial process for this industry. One of the most important developments 48
Modern Plastics & Polymers | June 2012
in injection moulding is the use of technologies, such as gas-assisted and multi-component injection moulding. These technologies help reduce the amount of material used and also the use of downstream assembly processes, respectively. Despite the advantages, all-electric injection moulding machines cost much more than conventional hydraulic systems. All-electric machines are making inroads to the Indian market with a 4-5 per cent share of total injection moulding machinery sales. With growth in auto, medical and electrical & electronics sectors, the investment in all-electric machines is expected to increase. This growth will be further fuelled by productivity improvement initiatives due to manpower shortage, wage inflation and higher power cost. W ith the advancements in technolog y, the demand for plastics and its products has increased. Evolved over the years, the plastics injection moulding industry has been delivering an array of products for agriculture and micro-irrigation applications. Plastics injection moulding is one of the various moulding methods available in the market today. Injection moulding can is a technique in which viscous molten thermoplastics, liquid, etc are injected under high pressure, held across a force greater than that exerted during injection and allowed to cure to a predetermined temperature. The ongoing developments in this technology are headed towards functional integration where emphasis is on switching elements. Doshi states, “The Indian injection moulding machinery industry is incessantly setting up new highs year over year due to the increased ability of Indian machinery suppliers to accommodate better technologies in their machines. Also, the influence of global brands on the Indian
machinery landscape has raised the quality bar in terms of technology collaborations and service & support facilities. Besides establishing sales offices across the country, these manufacturers are engaged with Indian players through Joint Ventures ( JVs) or technology transfer or traders/ distributors.”
Adding value through irrigation Owing to the positive response from cultivators and agriculturists, plastics is moving beyond irrigation functions. For instance, in the arid terrains of Israel and California, drip irrigation systems are being modified with individual hydraulic resistors & biosensors to deliver a constant flow of water at a given waterline pressure. Common PE and PVC pipes are being injection moulded with electrically powered solenoid valves, which control soil moisture by routinely regulating the water supply. At present, these advanced solutions are required only in arid regions of India. Also, such advanced technology is beyond the reach of common farmers due to complexity and cost factors. In principle, these self-regulating, moisturesensitive plastic valves could replace the emitters in a drip-system to provide the required plant-by-plant control on marginal lands, which have varying temperature and soil conditions. Despite initial cost concerns, intelligent irrigation solutions spell unlimited opportunities for the Indian plastics industry. Email: annabel.dsouza@infomedia18.in
MPP JUNE _2012_TAB 3_EVEREST PG_51
ELECTRONICA
MPP JUNE _2012_TAB 3_ELECTRONICS PG_52
AGRICULTURE: Inter SInterface face- -R RSwaminathan Swaminathan
“Plastics have become a necessity in current agricultural practices for enhancing output” …avers R Swaminathan, Director-Manufacturing, Jain Irrigation Systems. In a tete-à-tete with Avani Jain, he states how the increased use of plastics in agriculture has helped farmers to raise crop yields, improve food quality and reduce their ecological footprint. What is the current demand for plastics in the agricultural sector? The growing use of plastics in agriculture has enabled farmers to grow amny varieties of fruits and vegetables in all seasons and improve their quality, increase crop production and reduce ecological footprint of their activity. Thus, the demand for plastics is healthy, as it has become a necessity for current agricultural practices to raise the agricultural output.
What are the major applications of plastics in the agricultural sector? Plastic piping system is the backbone of water transportation and sub-surface drainage for the agricultural sector. One also finds extensive use of plastics in micro-irrigation/sprinkler irrigation, filtration systems, green house films, mulching and protection films, nursery bags, canal, pond & reservoir linings, packaging, etc.
What are the current trends in the segment? Current trends of plastics use in agriculture: Precision farming: Awareness about the significance of micro-irrigation has given a boost to the agricultural sector. The ability to supply water and nutrients at the required place, at required time and in required quantity has motivated the rice & wheat growers to adopt this method. 54
Modern Plastics & Polymers | June 2012
Soil reclamation: For harnessing the success of precision farming, agricultural lands must be reclaimed from the ill-effects of flood-irrigation. Drainage network using subsurface plastic pipes have proved to be the most viable technique. Protected cultivation: Success stories from extreme climatic zones (eg, subHimalayan states) have projected polyhouse cultivation as an effective solution for growing high-value vegetable crops throughout the year. Water storage structures: Rainfed farmers are adopting irrigated farming system, through water storage structures using external sources. These structures are either plastic tanks or plastic film–lined ponds. Grain storage structures: Plastic films are used to store silage effectively, to avoid spoilage of farm produce.
What are the recent R&D initiatives of your company? Some R&D initiatives in our company: Solar-powered drip irrigation: To overcome the problem of erratic power supply faced by farmers, we are working on solar-powered drip irrigation system. The concept of solar pumps is not new, but integrating it with the drip irrigation system needs a specially designed system and proper selection of pumps to fulfill the crop’s water requirement in different growth stages and different seasons.
High clog-resistant dripline: Clogging is an inevitable issue of drip irrigation technology. Thus, we are developing novel design of labyrinth of the emitter to prevent impurities from settling inside the flow path to avoid clogging. Integral pipe joint for shiftable sprinkler system: Shiftable sprinkler systems are conventionally used in India for sprinkler irrigation. These systems use easily detachable pipes to conveniently shift these from one place to another. We have developed sprinkler pipes with weldless integral coupler.
How will be the demand for plastics in the agricultural sector in future? There exists a vast potential for growth and enhancing productivity in agriculture to meet the growing demand for food and achieving food security for the population. Also, schemes like National Mission on Micro Irrigation and National Horticulture Mission, implemented by the Ministry of Agriculture will ensure the rise in demand for plastics. Availability of plastic products, grassroots-level distribution network and information dissemination programmes, technical know-how and extensive testing and standardisation facilities for plastics used in agriculture & irrigation applications will surely boost the use of plastics in agriculture. Email: avani.jain@infomedia18.in
CONSTRUCTION: Plastic pipes
Conveying cost-effective solutions While pipe technology using HDPE or PVC pipes have been used in construction since long time, only recently steps have been taken to improve their material properties and core mechanisms. Lionel Alva observes various trends and impact of plastic pipe technology on construction applications.
T
hermoplastic pipes such as unplasticised Polyvinyl Chloride (PVC-U) and Polyethylene (PE) have been used since long, with their properties and design criteria being well understood. Remarkably, only in recent times, efforts have been made to improve upon their mechanical and chemical properties while achieving significant material savings. The impetus has mainly been in developing countries, given the critical requirement for potable water and the incentive for water authorities & engineers to accept new pipe technologies. Standards for pipes were virtually being written even as pipelines were being commissioned. The acceptance of more cost-effective pipe systems is motivated by the fact that no single measure can do more to reduce poverty and disease and to save lives, than the provision of safe water & adequate sanitation. Continuous product developments enhance the performance, competitiveness and environmental impact of plastic pipe options. Plastic pipes are used for 56
Modern Plastics & Polymers | June 2012
infrastructure pipelines as well as pipes within properties and buildings used for water & gas applications. Both PVC and High-Density Polyethylene (HDPE) pipes have become the materials of choice in construction applications owing to their high tensile strength and material & mechanical properties. This has led to dynamic growth opportunities in India’s burgeoning construction industry and impelled the need for further Research and Development (R&D) efforts.
Demand drivers Some of the key factors influencing the growing use of plastic pipes in construction are high resistance to corrosion and abrasion. Plastic pipes have a high level of joint integrity. It is perhaps the elimination of corrosion as being a major factor that has led to the premature loss of conventional piping infrastructure that was the driving force behind plastic pipes asserting their supremacy in the construction market. To a lesser extent, it was the quality of joints in plastic pipes and innovative installation options that
enabled reduction in the overall time of construction. “Both PVC and HDPE pipes have witnessed a steady growth rate in the past decade. Currently, HDPE is more prominent in transportation under high pressure through large canalised underground piping systems, while PVC is usually used for drainage applications. While PVC pipes were mechanically weaker than conventional metal pipes, the use of compounds and plasticisers have overcome most of these shortcomings, and PVC pipes now offer better utility. Both PVC and PE pipes are most widely accepted. HDPE pipes are mechanically much stronger than PVC pipes, but PVC pipes allow for flexibility in applications and the usage of both depends on how it befits a specific scenario,� avers Rajeev Gupta, Director, Tirupati Pipes.
Material and chemical properties In their core state, mechanical properties of polymers include stiffness and breaking. However, plasticisers greatly influence the mechanical properties of
Plastic pipes
a given polymer depending on the type or amount used to impart certain desired properties to a polymer. Fillers affect the physical properties to a lesser degree. The physical state and morphology of a polymer have a strong influence on its mechanical properties. A simple measure of the differences produced in mechanical behaviour is the elongation that occurs when a plastics is loaded (stressed) in tension. Almost all plastics exhibit some elongation when under stress, which is not recovered when the stress is removed. In terms of usage in plastic pipes, HDPE is considered to be a much stronger material than PVC. It is also more tolerant of poor manufacturing processes and requires fewer additives while being more recyclable as compared to PVC. HDPE offers better durability, leak-free performance under stringent conditions, corrosion resistance and ductility. However, its cost is a major prohibiting factor that prevents it from being used extensively in construction applications. While there might be a degree of variance in regions, the cost of HDPE laterals is about 25 per cent higher than PVC laterals. However, HDPE resin and pipe have superior resistance to failure and Rapid Crack Propagation (RCP). These are essential properties for applications where scratching and gouging of the pipe are usual. HDPE pipes can be gouged up to 10 per cent (even 20 per cent according to some studies) of the wall thickness, with no detrimental effects on the long-term performance of the pipe. Resistance to RCP means that the monolithic piping system of heat-fused HDPE pipe will not be susceptible to rapid cracking that can run for hundreds or even thousands of feet with catastrophic results. The focus of current R&D efforts is to minimise the cost of materials used in HDPE, making it a more viable proposition. “In India, HDPE is mainly used to transport water through high-pressure
pipes. While both PVC and HDPE are excellent materials for piping, HDPE has a better ultraviolet resistance than PVC, which cannot withstand prolonged exposure to sunlight, making the material in PVC pipes crack. HDPE does not crack under duress, but gets compressed and has a long life span. It also offers better impact resistance, which makes it the ideal material for use in high-pressure piping applications. Compared to metals, both HDPE and PVC have greatly improved on their core piping mechanisms in the past few years,” observes Ravi G Iyer Research Analyst, Jogeetha Plastic Pipes.
Innovations in piping technology From a materials point of view, the most recent innovation has been the introduction and recognition of high-performance HDPE resins for pressure pipe allocations, specifically PE 4710. These resins are not the same old materials with a new name. These are new-technology HDPE materials – third or even fourth generation – with performance capabilities surpassing previous grades. Even though the previous grades of PE materials have an excellent performance history in gas & water service, the HDPE industry continues to challenge itself. The same is not readily noticeable with other base materials and pipes. These new resins take performance to another level, allowing them to be used with higher design stresses without sacrificing safety or design life. Continued improvements in pipe design, specifically in the corrugated drainage pipe industry (storm water management), has allowed for greater burial depths and improved joint performance. The modern-day HDPE corrugated pipe is significantly better than the original product that was introduced in the mid-1960s. As technologies in the petrochemical market continue to develop, the construction industry can expect continuing improvement. Email: lionel.alva@infomedia18.in
While PVC pipes were mechanically weaker than conventional metal pipes, the use of compounds and plasticisers have overcome most of these shortcomings, and PVC pipes now offer better utility. Rajeev Gupta Director, Tirupati Pipes
HDPE does not crack under duress, but gets compressed and has a long life span. It also offers better impact resistance, which makes it the ideal material for use in high-pressure piping applications. Ravi G Iyer Research Analyst, Jogeetha Plastic Pipes
June 2012 | Modern Plastics & Polymers
57
CONSTRUCTION: Polymeric geotextiles
Key to India’s infrastructure vision The global economic slowdown has had little impact on the remarkable growth story of India. For achieving a double-digit growth, the country will require adequate development in infrastructure. Lionel Alva assesses how polymeric geotextiles can help in paving the road towards sustainable growth.
I
ndia is well known as one of the fastest growing economies in world. But, the economic gains would be for naught were it not supplemented by the requisite inf rastructure support. The recent economic slowdown has impacted India as well. In order to attain doubledigit growth, the country needs to take pragmatic steps to upgrade the substandard and poor infrastructural approach currently in practice.
Rough roads ahead An estimated investment of $ 1.6 trillion is required to improve road and bridge conditions. Pavements are constructed over different types of water-sensitive subgrade soil including silt, clay and loess. These soil types react with moisture and gradually result in deterioration of the pavement. Potholes, ruts, uneven pavements are not only a safety concern, but also affect the movement of goods & services that depend on a reliable surface transportation system. This adds to the maintenance cost of vehicles, while also increasing fuel requirements to a great extent. In this context, geotextiles act as a panacea of sorts owing to the key benefits these offer to reduce overall construction 58
Modern Plastics & Polymers | June 2012
costs, deeply affecting the financial viability of the proposed development. Especially, in the Indian context, it bears great relevance since it plays the dual role of reducing costs while reinforcing a structure.
Key applications The key applications of geotextiles in inf rastructure include highways, railways, dams, connecting roads, footpaths and pavements and landfilling. “Jute and synthetic geotexiles are predominantly used in road applications. Geotextiles have four other functions – reinforcement, separation, drainage and filtration. Reinforcement increases the strength of sub-layers. The geotextiles used for road applications have low permeability to water; further, highstrength, high-tenacity fibres are used to make jute textiles. For reinforcement purpose, only non-woven geotextiles are used,” avers Vilas Patil, Senior Science Officer, Geotextiles, Bombay Textile Research Association. The salient features determining the effectiveness of geotextiles are the thickness and roughness of fibres & yarns, their orientation across the slope & installation procedures that do not disturb the site, with percentage cover
and water-holding capacity being another key facet. However, these parameters may vary depending on the application of geotextiles. Thus, geotextiles are essentially characterised by high puncture resistance, large elongation before break, excellent filter characteristics at all strains, especially chosen fibres for enhanced Ultraviolet (UV ) protection.
Factors affecting design life Geotextiles are generally manufactured by woven or non-woven techniques. The polymers used are thermoplastic materials, which contain variations in both amorphous and semi-crystalline regions. Various factors affect fibre selection, which must be considered in relation to end-product durability, the basic polymer from which the product is made, any additives compounded with it as well as fibre morphology. Fibre morphology in materials science relates to the science of form and is linked to all physical aspects of the polymer structure. Thus, the selection of the right polymer type for the manufacture of textiles for use in civil engineering applications is essential. Geosynthetic products can be exposed to weathering and the effect
Polymeric geotextiles
Jute and synthetic geotexiles are predominantly used in road applications. The geotextiles used for road applications have low permeability to water; further, used to make jute textiles. Vilas Patil Bombay Textile Research Association
on the performance of products is important. The ageing of geotextiles is predominantly set in motion by the climate effects such as solar radiation, heat, wetting and moisture. Geosynthetics are generally exposed to weathering for a relatively short but slightly varying period during construction work. The properties of unprotected polymers are such that even one week of outdoor exposure can seriously damage geotextiles. The mechanism of degradation in most polymers is photochemical in nature; the absorption of UV light by the polymer provides the energy to break key molecular bonds near the surface of the exposed plastics. The resultant free radicals then react with oxygen to form peroxy radicals that then attack other polymer molecules, or even other points within the same polymer chain. More free radicals are then formed resulting in a chain reaction along the length of the polymer chain. Therefore, polymers used in geosynthetics must be protected by appropriate additives to minimise the detrimental effects of exposure to UV light energy. “The design life considerations assessed for geotextiles include the value of the ground, California bearing ratio and temperature. For instance, the temperature in Mumbai is about 40°C, while it is above 40°C in Gujarat; thus, the influence on wear and tear will be greater in Gujarat. Another June 2012 | Modern Plastics & Polymers
59
Polymeric geotextiles
The design life considerations assessed for geotextiles include the value of the ground, California bearing ratio and temperature. Another consideration is the soil geology, ie, the nature of soil. Venkat Ramanan Consultant, Shri Ambica Polymers Pvt Ltd
consideration is the soil geology, ie, the nature of soil; since goetextiles are seldom used in rocky terrain, plain alluvial or sandy soil is considered to be ideal for geotextiles. These could be used effectively in coastal roads. In India, geotextiles could greatly reduce maintenance costs for roads and help contractors in achieving better profitability,” avers Venkat Ramanan, Consultant, Shri Ambica Polymers Pvt Ltd.
Shifting focus The market for geosynthetics in general and geotextiles in particular has shifted towards developing and fast emerging regions such as Middle East and Asia. In the Middle East, with most of the European and US companies winning infrastructure development contracts, the use of geotextiles had already become widespread. The fastest growing consumer of geotextiles today is China. In recent years, China has invested as much as $ 86.70 billion in infrastructure construction, including improving road-rail networks, building new airports and water conservation projects. In 2001-02, China’s actual consumption of geosynthetics stood at $ 250 million, as compared with India’s market potential of $ 22 million in the same year. According to Business Co-ordination House (BCH), the consumption of geotextiles in India in 2006-07 stood at 6,000 tonne (30 million sq m), which is projected to go up to 18,311 tonne (92 million sq m) in 2011-12. In India, the market for geotextiles is expected to grow in excess of 25 per cent per year. The post-quota macro trend is witnessing a shift in focus from low to medium ends of the market to high value-added and technical products in the textile industry in Asian countries. In this backdrop, the need is realised to create and foster the market of geotextiles in the country. Email: lionel.alva@infomedia18.in June 2012 | Modern Plastics & Polymers
61
CONSTRUCTION: Timothy Inter faceEarl - Timothy Earl Madden Madden
“Infrastructure spending is an excellent opportunity for engineering plastics” …informs Timothy Earl Madden, Managing Director-South Asia Region, Lubrizol Advanced Materials India Pvt Ltd. He has established Lubrizol as among the pioneers for polymer technology with a strong presence in the Asian market. In a conversation with Lionel Alva, he highlights various opportunities existing for the chemical additives market in India. What are the major construction applications driving the growth of engineering plastics in India? We will certainly witness good growth in consumption-related items such as plastics packaging, transportation and telecommunication. Inf rastructure spending is another excellent opportunity for engineering plastics in building materials, with cable jacketing and piping being areas where engineering thermoplastics can play a larger role.
What are the additives used in plastics for construction? Plastics additives are important to the performance of plastics used in construction, providing durability at the time of installation as well as resistance to the elements once installed. Environmental regulation as well as consumer awareness will shape the future choices of additives used.
What are the major market drivers for engineering plastics in India? Fundamental understanding of the value of engineering plastics is the primary driver for growth. Conventionally, the market has looked at price as being the key differentiator, but as more demanding 62
Modern Plastics & Polymers | June 2012
applications arise, the understanding of properties and performance versus price will be the key deciding factor.
What are the significant innovations in this industry? Lubrizol had introduced FlowGaurd® Chlorinated Polyvinyl Chloride (CPVC) for hot and cold plumbing application only 10 years back. Since then, this has become the fastest growing and the most desired product in the Indian plumbing industry. The product is well suited for the market because it is highly durable and impact resistant, capable of use in hot & cold water application and can be easily installed. Lubrizol uses imported finished compounds based on our proprietary raw materials. Also, we work with licensed manufactures in the country to ensure that the finished pipe is of the highest quality.
What challenges are faced by the Indian engineering plastics market? There are thousands of plastics processors across the country, with many of them being small talented entrepreneurs who require process and applications technology as well as easy availability of products. This is both an asset and a disadvantage for the domestic industry
which is seeking to expand with global quality competence.
What is your approach towards understanding end-user requirements in the South East Asian market? The best approach is meeting with end users directly to discuss their requirements. We do this through trade show participation, direct customer visits by our sales people and also through a programme that we call ‘Lubrizol Earn and Learn’. There is a significant need in India for fresh graduates to gain practical experience in the marketplace. These fresh graduates have enormous enthusiasm and drive, but lack the opportunity to apply themselves to real life business challenges. In our Lubrizol Earn and Learn programme, we design market research programmes for such young talent in defined market spaces. Thus far, our experience has been encouraging, as these young graduates are able to explore new business opportunities, gather and analyse collected data and then make recommendations on how to proceed in the required applications. Through this programme, we have been able to make nearly 7,500 face-to-face visits in the first three months of this year. Email: lionel.alva@infomedia18.in
ELECTRONICS: OLED technology
Lighting up application avenues Courtesy: GE
I
n keeping with today’s consumer demands for impressive designs and features f rom electronic devices, plastics is playing a crucial role in product manufacturing for high performance, functionality and competitive pricing. The fabrication processes for polymer electronics often provide high production volumes, extremely low fabrication costs and largely free-of-assembly steps. Polymerbased electronics, or polytronics, are likely to form the basis for a completely new range of applications across a broad set of markets including electronic consumer goods, automotive, aerospace, energy, retailing, food packaging, imaging and healthcare. These applications are creating a market for extremely cost-effective, ubiquitous electronics, which is inaccessible for conventional silicon-based electronic devices because of the high costs of assembly and interconnection. These are primarily driven by flexible displays, Three-Dimensional (3D) circuit boards 64
Modern Plastics & Polymers | June 2012
With the advent of custom-made engineering polymers and corresponding innovations in designing & moulding technology, plastics has revolutionised modern devices such as smartphones and tablets. Annabel Dsouza traces the ideas and innovations that are shaping consumers’ experience of electronic products.
and injection-moulded interconnect devices, among others. With a demand share of about 18 per cent, the electrical and electronics industr y is the second-largest consumer of engineering plastics globally. Driven by rapid demand for innovative electronic gadgets, especially in developing economies, the growth of plastics application in electrical consumer durables is expected to grow at a Compounded Annual Growth Rate (CAGR) of about 10 per cent. Apart from pioneering features and design aesthetics to the end-user, plastics offers unique processing advantages along the consumer electronics value chain.
Bright ideas for the industry With the growing popularity of smartphones and tablets, polymers are making a breakthrough in cellular electronic technology owing to their significant advantages of aesthetics, light weight and energy-efficiency. The optical sharpness of flat panel displays
is now improved by a polymer coating. The Organic Light-Emitting Diode (OLED) technology is one of the many fields witnessing a breakthrough in polymer usage. OLEDs are flat, thin, luminous construction elements made from organic semiconductor materials, and these form an important part of the polytronic technology. These are likely to find use not only as substitutes for conventional Light-Emitting Diode (LEDs) in lighting systems, but also in completely new types of displays. Often based on polymers, these are also referred to as P-OLED or PLED. Their benefits include brighter, clearer displays; simpler construction offering the potential for cheaper and robust display modules; and ultra-fast response time. Anil Duggal, Advanced Technology Leader, Electronic Material Systems & Chief Scientist, GE Global Research, says, “P-OLEDs are engineered f rom conductive polymers, such as Polyphenylene V inylene (PPV ). These emit yellow-green light
OLED technology
when sandwiched between a pair of electrodes. PPV is a rigid-rod polymer, and is considered one of a kind that has been successfully processed into a highly ordered crystalline thin film. Rigid-rod polymers are generally extremely difficult to melt-process.� At present, the P-OLED technology is widely applied in flexible active-matrix displays. Duggal continues, “GE has developed a solution-coating technique that enables OLED fabrication on a plastic film substrate. P-OLEDs have two key advantages. First, these are mechanically flexible, allowing larger scope for application. Second, roll-to-roll processing of P-OLEDs can make devices available at a lower cost point than batch-processed glassbased OLED devices. The will enable manufacturers to fabricate active-matrix backplanes on plastic substrates, which will be used to create display modules that are thin, light and robust.�
Machining marvels In order to provide commercially viable solutions for plastic electronics, researchers are combining electronic circuitry into plastic injection-moulded parts. Existing Moulded-Interconnect-Device (MID) technology has failed to live up to the current demand scenario, especially in India. An MID is injection moulded with integrated conductors, combining mechanical and electronic functions. The automotive industry, witnessing a huge increase in electronic devices, provides enormous potential for the technology. The MID market currently shows an annual growth rate of 20 per cent per annum, and the drivers are the trend towards miniaturisation and higher functional integration, together with shorter product lifecycles & time-to-market requirements. A successful solution lies in the use of 3D Injection-Moulded Plastic Interconnect Devices (3D-MID). Not only do these offer a high level of design
freedom, but can even be used to create sophisticated mechatronic systems that combine electric and mechanical functions. Laser Direct Structuring (LDS) is an innovative technology used to manufacture precisionmoulded electronic components. It allows conductive tracks and electronic components to be attached directly to the plastic interconnect device in a simple, environment-friendly process (without the use of etching or caustic chemicals). The process offers an extremely high level of layout flexibility. It was recently shown that the miniaturisation potential of the process has still not come even close to exhaustion. In contrast, conventional processes are already reaching their limits in this respect with many electronic components. LDS is one of the crucial methods that are empowering mould designers and manufacturers to keep pace with constant innovations in the electronic plastics space. By combining the versatility of the two-shot moulding process for MID with the speed and precision of LDS capability, electronic component moulders can incorporate durability & versatility into miniature electronic gadgets.
Future scope Electronic applications offer significant potential for capacity building and product portfolio enhancement for the plastics processors & machinery manufacturers. The major advantages in production dynamics of plastics electronics include: Savings over product life cycle: Plastics is durable, hardwearing and easy to maintain. This increases the overall life cycle of electronic products. Finish: Plastics can deliver design flexibility of any colour – transparent, translucent or opaque; any texture – matte, smooth and non-slip textures. Less processing time: Plastic components consume less material and energy during production. This
P-OLEDs have two key advantages. First, these are
larger scope for application. Second, roll-to-roll processing of P-OLEDs can make devices available at lower cost than batch-processed glassbased OLED devices. Anil Duggal Advanced Technology Leader, Electronic Material Systems & Chief Scientist, GE Global Research
makes them cheaper and enables resource conservation. Strength: Plastics can be modified to offer superb mechanical strength, comparable to conventional materials like steel. Improving cost economics: Engineering innovations are constantly focussing on reducing volume consumption. Plastics offers considerable cost dynamics, which, in turn, can be transferred to the customer. As plastics promotes further advancements in the electrical & electronics industry, manufacturers in this sector have enormous opportunities ahead. The plastics industry is aiming at combining efficiency with new applications that will give a boost to the polymer industry in the domestic market as well as on a global scale in the years to come. Email: annabel.dsouza@infomedia18.in June 2012 | Modern Plastics & Polymers
65
.................................. ELECTRONICS: Carbon fibre
Small ideas, big impact Today’s electronic gadgets have moved beyond functionality and are seeking innovative solutions for challenges such as energy conservation and manufacturability. In keeping with these demands, plastics application in electronics is no longer merely about insulation, but also about conductivity. Annabel Dsouza finds out the role of carbon fibre in electrical-grade plastics compounding.
T
he key decisive factor for plastics use in electrical applications is mechanical and electrical properties. On account of its outstanding performance as insulators, plastics find application in a wide range of electrical and electronic devices. Plastics is also foraying into electrical circuitry where it offers more versatile applications beyond insulation. These unparalleled properties together with design and processing methods provide economical solutions that explain the popularity of plastics in the Electrical and Electronics (E&E) sector. Engineering thermoplastics and other high-performance polymers continue to progressively play a critical role in the production of electrical & electronic components and microelectronic devices. New polymer grades, additives and fillers have been developed to meet thin-wall and high-temperature requirements for moulded parts in E&E applications. Georg Steinbichler, Senior Vice President, ENGEL Teletronics Business Unit, says, “Plastic material and processing development is contributing to lower costs and performance enhancement of consumer and industrial electronics manufacturing technologies. Demands for 66
Modern Plastics & Polymers | June 2012
higher circuit density and high-speed data processing have resulted in an intensified search for new polymeric materials to use in microelectronics. Carbon nanotubes are among the latest innovations for electrical conductivity for plastic components. These are highly isotropic materials, which impart quality to parts by maintaining physical properties and minimal effect on neat resin properties, particularly low-temperature impact strength and ductility.”
Carbon fibre revolution While a variety of additives can be used to impart conductive and static dissipative properties to polymers, carbon nanotubes offer conducting and semiconducting properties, which play an indispensible role in the new generation of plastic electronic displays for cellular phones and other portable devices. Following are some of the key advantages of carbon fibre in electrical-grade plastics: Uniform electrical conductivity throughout the part owing to the small size and curvilinear shape of nanotubes ensure complete & random distribution Minimal increase in base resin viscosity, which is important in extrusion of
thermoformable sheet used to make static exteriors of electronic gadgets Greater retention of the base resin’s toughness without the use of impact modifiers, thereby reducing overall costs Carbon nanotubes can be compounded into five resin families of commercial quantity using thermoplastic masterbatches with fibril multi-walled carbon nanotubes. This high aspect ratio, curvilinear form of graphitic carbon confers electrical conductivity at lower loadings than other conductive additives when compounded with otherwise insulating materials such as thermoplastics. In order to optimise the conductivity level of a moulded plastic part to meet its end-use application, processors use a variety of combinations of the following five resins: Polyetheretherketone (PEEK) Polyetherimide (PEI) Polyphenylene Sulphide (PPS) Polystyrene (PS) Nylon [Polyamide (PA)12] Engineering thermoplastics (PEEK) and other high-performance polymers continue to progressively play a critical role in the production of Electrical and Electronic (E&E) components and microelectronic devices. New polymer
Carbon fibre
Product know-how is a key factor for success in CNTs. Most recently, producers have increasingly focussed on the production of MWCNT, with significant efforts being directed towards purity and yields as well as lowering the costs. Georg Steinbichler Senior Vice President, ENGEL Teletronics Business Unit
grades, additives and fillers have been developed to meet thin-wall and hightemperature requirements for moulded parts. Plastic material and processing developments are contributing to lower costs and performance enhancement of consumer & industrial electronics manufacturing technologies. A high dielectric constant Liquid Crystal Polymer (LCP) and Polyphenylene Sulphide (PPS) resin compound series has been developed to enable plastics processors to replace ceramics in high-performance electronic components used in highfrequency (microwave and millimeter wave) applications and are currently being used in moulded interconnect devices.
Market outlook Carbon Nanotube (CNT) has emerged as one of the most important classes of additives in compounding technology with enormous potential to drive the global plastics demand. CNTs 68
Modern Plastics & Polymers | June 2012
have extraordinary properties of extremely high electrical and thermal conductivities, very small diameters (less than 100 nm), outstanding mechanical properties and an excellent priceperformance ratio. Apart from plastics in electronic devices, CNTs are increasingly being used in chemical/electrochemical sensors, transistors, electron field emitters, lithium-ion batteries, white light sources, hydrogen storage cells and cathode ray tubes, among others. In fact, several products enabled by CNTs are already in the market, such as racquets, golf clubs, surfboards, ice hockey sticks, mass transportation fuel system components and battery electrodes. CNT-enabled engineering and specialty thermoplastics such as Polycarbonate (PC), PEI and PEEK have been used in cleanrooms for the production of computer chips & hard drives because these dissipate static electricity and, therefore, will not attract airborne contaminants. The global CNT market is highly consolidated and dominated by a few large suppliers/producers operating in multiple industry segments. The global CNT industry had a turnover of about $ 700 million in 2011, with Multi-Walled CNT (MWCNT) production value of approximately $ 600 million and SingleWalled CNT (SWCNT) production value of about $ 40 million; this is forecast to grow further at a Compounded Annual Growth Rate (CAGR) of 10.5 per cent to nearly 1.5 billion by 2016. Asia-Pacific has the largest installed capacity of CNTs, mainly due to the significant presence of the E&E market, which is dominated by Japan, South Korea, Taiwan, China and Singapore. The largest share of global CNTs is accounted for by plastics and composites, representing 69 per cent of global demand. Plastics application in electronics and data storage market is likely to witness the biggest penetration by 2016, with
the performance-enhancing properties of CNTs allowing electronics manufacturers to meet demanding market needs across a variety of applications, including interconnects, displays, memory, storage and others. Further, the energy sector will witness rapid growth, with enhanced performance requirements for batteries, wind turbine blades, photovoltaic cells and other applications in the next 5-10 years.
Rising above competition There are over a hundred companies around the world in the CNTs market, making it extremely competitive. Very few of these manufacturers have a footprint in India, and hence building commercial capacities will help bring down prices significantly. A number of issues, including high costs, inconsistent quality across the supply chain, dispersion and compatibility with matrix materials as well as toxicology still need to be addressed to ensure large-scale usage of CNTs in plastics compounding. Established manufactures may have excellent market and cost advantages due to their proprietary product technology, favourable access to raw materials, government subsidies, favourable locations and learning or experience curve efficiencies. Steinbichler concludes, “Product know-how is a key factor for success in CNTs. Most recently, producers have increasingly focussed on the production of MWCNT, with significant efforts being directed towards purity and yields as well as lowering the costs. The major markets at present are plastics and composites, electrical & electronics and energy.� Email: annabel.dsouza@infomedia18.in
MPP Jun_2012 Ad Name: Joyti Tab-4, Pg No. 69 MPP Jun_2012 Ad Name: Joyti Tab-4, Pg No. 69
AEROMAC
MPP Jun_2012 Ad Name: Aromac Tab-4, Pg No. 70
MPP Jun_2012 Ad Name: Aromac Tab-4, Pg No. 70
ELECTRONICS: Ramesh Inter faceDumbre - Ramesh Dumbre
“Masterbatches make electrical plastics safe, sustainable and easy to process” …says Ramesh Dumbre, Vice President-Marketing, Plastiblends India Ltd. In an exclusive interaction with Annabel Dsouza, he highlights the significant contribution of innovations such as flame retardants and antioxidants towards enhancing plastics consumption in electrical applications. What are the current dynamics of the plastics additives industry? Additives cost money, but by reducing production costs and making products last longer, these help save money and conserve the world’s precious raw materials. In fact, the world today would be a lot less safe, a lot more expensive and too dull without additives that cconvert basic polymers into useful plastics. Plastics additives encompass a wide variety of materials added to plastic resins in order to enhance the quality of these resins. Additive materials can be classified as property modifiers, property extenders and processing aids. Globally, the masterbatches industry volume is about 3.9 Million Metric Tonne (MMT), of which 0.86 MMT is the share of additive masterbatches. Per capita polymer consumption in India is very low as compared to advanced and other developing countries. With rapid growth in industries such as electronics, agriculture, infrastructure and packaging, the demand for plastics is constantly increasing, thereby ensuring rapid growth of Indian masterbatches industry.
What are the latest innovations in plastics masterbatches for electrical applications? The focus of the masterbatches industry for electrical applications is on making these materials and electrical goods safe, 72
Modern Plastics & Polymers | June 2012
sustainable and easy to process. The major areas of innovations include (1) Flame retardant masterbatches for wires and cables; (2) Anti-oxidants for process stabilising and recycling; (3) Antistatic masterbatches for electrical housings & casings to prevent dust build up; (4) Metal deactivators to prevent polymer degradation caused by prolonged exposure to copper metal; and (5) Anti-rodent masterbatches to prevent rodent attacks on cable to prevent short circuits & fires.
In a price-sensitive market like India, how do Indian processors deliver world-class solutions? The industry is constantly looking for new materials and sources of these raw materials. We extensively test these materials to validate them for Indian applications. We are also working on to improve customer awareness. The sustained demand helps us to constantly raise productivity levels. This, in turn, brings economic scales of operations.
What are export opportunities for Indian plastics industry? The next two decades are expected to offer unprecedented opportunities for the plastics industry in India. A report by Credit Rating and Information Services of India Ltd (CRISIL) states that the world trade in plastics is expected to reach 140 MMT in 2012, thus providing
a lucrative opportunity for India. Hhowever, with only a 1.5 per cent share in world export volumes, India is unable to capture this opportunity. The Indian plastics industry needs to consolidate and enhance capacity, upgrade facilities and improve productivity. As main competition is from key global masterbatches producers from Europe and the US, the Indian masterbatches industry has a clear opportunity to compete in high-end products due to low cost of production and easy access to technology.
How can additives/masterbatches contribute towards a more sustainable plastics industry? The additives and masterbatches help improve sustainability of the polymer industry by contributing in various areas – making polymers easy to process and reducing cost of utilities; improving longevity of polymers; helping in polymer recyclability, eg, chain extenders for Polyethylene Terephthalate (PET) strapping tapes that are made from 100 per cent recycled water & soft drink bottles; bringing desired functional properties in polymers; making plastics safe & environment-friendly; and preventing formation of toxic material in Polyvinyl Chloride (PVC), PET and Polybutylene Terephthalate (PBT) processing. Email: annabel.dsouza@infomedia18.in
ENERGY: Wind power generation
Giving wings to performance plastics Courtesy: Quadrant EPP Surlon India Ltd
O
ver the past few years, both the government and the wind power industry have succeeded in infusing stability into the Indian renewable energy market. This has encouraged larger private and public sector companies to invest in wind and stimulated the domestic manufacturing sector. The current annual level of 3,000-3,500 MW includes turbines for the domestic as well as export markets. However, the actual number of turbines produced is driven by market forces, and high interest rates often do not allow for accumulation of inventory. Thanks to new market entrants, the annual production capacity is expected to rise to 5,000 MW per year by 2015.
Wind power through engineering plastics Alternative energy sources account for a significant part of the total global energy production today and their significance is constantly increasing. Engineers are using engineering plastics worldwide to improve product quality and increase 76
Modern Plastics & Polymers | June 2012
Power generation through wind is one of the most environment-friendly methods. Hence, wind turbine manufacturers are constantly on their toes as the demand for components are on the rise. Anwesh Koley explores how all materials used for this purpose must comply with the highest requirements and also be easy to maintain.
profitability of manufacturing processes & equipment. Parts and components made from high-quality materials support the technical development in all major sectors of alternative energy generation. Preserving and maximising energy is the key requirement of energy generation and the top priority for the Government and power generation companies today. However, certain natural cautionary measures that must be observed while generating energy with wind turbines. Satendra Kumar, Chairman & Managing Director, Quadrant EPP Surlon India Ltd, says, “Abrasion, erosion and wear of critical parts in a facility and the equipment within the production chain cause immense costs. Related maintenance services and production downtime can impact significantly the financial performance of a project and business.” Valves, bearings, seals, guiders and rolls all require regular maintenance. High-grade engineering plastics solutions can increase equipment life, improve the mean time between repairs, reduce waste and limit replacement needs. Thus, it is
important for plastics used in the turbine technology to meet the highest challenges concerning temperatures, chemical resistance, corrosion, wear and stability.
Component development trends New component developments are underway that will significantly change the materials usage patterns. The general trend is towards lighter-weight materials, but as long as the life cycle cost is low. Most rotor blades in use today are built from Glass Fibre-Reinforced Plastics (GRP). Other materials that have been used include steel, various composites and Carbon Fibre-Reinforced Plastic (CFRP). As the rotor size increases on larger machines, the trend will be towards high-strength, fatigue-resistant materials. “As the turbine designs continually evolve, composites involving steel, GRP, CFRP and, possibly, other materials will likely come into use. Rotor blades are either GRP, wood-epoxy or injection-moulded plastics with carbon fibres,” adds Kumar. The step-up gearbox used on large turbines today is expected to be replaced
Wind power generation
in many future machines. Most small turbines designed for battery charging use a variable speed, permanent magnet, variable frequency generator connected to a rectifier. As high-power solid state electronics are improved, larger machines are likely to use AC-DC-AC cycloconverters. This trend will increase the use of magnetic materials in future turbines. Large epicyclic gearboxes used in large ships may continue to be the drive system for some large turbines.
Rotor blades The rotor blades are fundamental, essential components of a wind turbine. For this reason, there are optimised for maximum efficiency. The blades of today’s typical turbines are 40-90 metre long. Manufacturing rotor blades for wind turbines is a demanding business; the largest and most modern blades are made from bonded glass & carbon fibre mats into which epoxy resin is injected under vacuum. Composite materials on this basis have become the industry standard. Companies across the globe are developing products that are specifically suited for this process. The blades are built according to the sandwich construction principle and are stabilised with reinforcing spars & bars on the inside. This high-tech construction technique also provides exceptional stability and flexibility. The finish consists of multi-layer polyurethanebased coats, with different erosion and Ultraviolet (UV ) resistance depending on requirements. “The excellent adhesion properties of the coatings minimise the risk of stress cracking. In addition, their flexible behaviour prevents them from flaking off despite rotor tip vibrations that cause them to bend by several metres. Thus, the products are required to provide lasting protection for operating times of several years,� adds Kumar. Innovative resin systems for highly resilient, fibre-reinforced components as
well as specialised coatings materials for rotor blades require plastics. Polyurethane (PU) foams, basic materials for formulating Polyvinyl Chloride (PVC) foams and special PU-based adhesives complete the portfolio for production of high-performance blades.
Coating of wind turbines At present, the most widely used coating process is vacuum infusion. In this process, two half-shells are charged with a release agent. The shells are lined with glass fibre mats and other reinforcing materials. A plastic film is then used to seal the moulds airtight. Afterwards, a vacuum pump sucks an epoxy resin and hardener mixture into the mould and into the glass fibre mats. The blades are then hardened at 70°C, and the two blade halves are bonded together. In the next step, the rotor blade can be protected from environmental factors such as moisture and light applying by a gel coat. Small irregularities on the surface are smoothed with the putty. A coating that protects the edges against wear is applied, followed by application of a topcoat in the final step.
Abrasion, erosion and wear of critical parts in a facility and the equipment within the production chain cause immense costs. Related maintenance services and production downtime performance of a project and business. Satendra Kumar Chairman & Managing Director, Quadrant EPP Surlon India Ltd
Rising significance of wind energy Considering the central role of renewable energy solutions, wind energy has taken on a new significance. Intensive efforts are underway to boost its competitiveness with respect to other sources of energy, with turbines becoming ever bigger and more powerful. The trend is for wind energy plants to move from land (onshore) to the sea (offshore), where wind blows more strongly and steadily, thereby generating higher energy yields. Onshore turbines feature the classic use of wind energy on land and have proven themselves as efficient and reliable energy solutions. In the long run, companies will be expected to offer individual product solutions to address any regional challenge. Email: anwesh.koley@infomedia18.in Courtesy: Quadrant EPP Surlon India Ltd
June 2012 | Modern Plastics & Polymers
77
ENERGY: Solar technology
Em‘power’ the future of India Polymer solar cells are flexible, light-weight and inexpensive, but their performance lags behind that of conventional cells made from inorganic materials such as silicon. Anwesh Koley underlines how industry players are working to make polymer solar cells that can compete with thin-film silicon cells for mass power generation programmes. Courtesy: Maharishi Solar Technology (P) Ltd
T
he development of solar energy in India has gone through a phase where it has generated a lot of buzz in the industry. It is ultra clean, natural and a sustainable source of energy that can be utilised for producing solar electricity and making solar heating, solar cooling as well as solar lighting appliances. Pradeep Khanna, Chief Executive Officer, Maharishi Solar Technology (P) Ltd, opines, “The awareness is high, but so is the ignorance. Not many users are aware of the potential of solar energy in India. The capital costs are higher than those for conventional sources of energy. However, at present, costs have reduced drastically. There is a level of uncertainty on whether these cost reductions are sustainable. Some time back, there was a shortage of silicon; thus, the demand grew more than the supply. Due to this, many players jumped in the scene assuming they could meet the growing demand. This resulted in more production than demand eventually.”
Photovoltaic (PV) solar cells The best inorganic solar cells are also multilayer devices, but making multilayer 78
Modern Plastics & Polymers | June 2012
organic solar cells has been a rather difficult task. Polymers can be printed with a solution, similar to printing with ink on paper, which is both a primary advantage of the technology and a liability. There are no high temperatures involved, and manufacturing is also simple; however, finding the right solvents to print each layer in a cell without bleeding into the one below is tricky. The more the layers, the more complex is the problem. Matching the electrical properties of each layer is also a challenge, as is connecting them together. The efficiency of a polymer solar cell typically drop by about one-third when solar cells are taken out of the laboratory and sold in working modules. A polymer solar cell that tests at 15 per cent efficiency in the laboratory is likely to make a module with 10 per cent efficiency, which the industry believes is sufficient to compete with thin-film silicon solar.
from conductive polymers and organic nano-engineered materials offer high quality benchmarks. Aesthetically beautiful, silent and powerful, plastics outperforms all other materials in total energy collected over the course of a day. Its low light sensitivity enables to generate energy faster and for longer duration than other materials, in full or partial sunlight. Thin, flexible and semi-transparent, plastics conforms to a variety of shapes and contours and offers design freedom like never before. PV is an open technology and ample information about crystalline silicon is available in the market. Ethylene Vinyl Acetate (EVA) which is used to bind the wafers together, which is rarely available in India. “One area for plastics application is the back cover of the PV cells, which is required in every solar module. In the process of making silicon, we are growing and hoping to become self-dependent,” says Khanna.
Plastics and PV technology
Solar technology policy in India
Plastics is a light-weight material and for thin films organic solar material, is more versatile than conventional solar panels. Photo-reactive materials made
During the financial meltdown in the US and the UK, demand for solar technology was at an all time low, which resulted in mounting inventories and
Solar technology
Not many users are aware of the potential of solar energy. The capital costs are higher than those for conventional sources of energy. However, at present, costs have reduced drastically. There is a level of uncertainty on whether these cost reductions are sustainable. Pradeep Khanna Maharishi Solar Technology (P) Ltd
the dipping price. Therefore, in the long term, there can be a situation when the cost of producing solar energy will be lower than conventional methods. However, in the short term, it is difficult since there is lower demand and higher production. “The government policies in terms of imports are not that conducive. This puts us at a disadvantage vis-a-vis one of our neighbours – China – who is far more competitive in terms of their pricing. Of late, the Government has woken up and has decided that the solar modules for large megawatt power plants cannot be imported. This is a welcome move, as the capacity shortfall will have to be met by domestic manufacturers. This will also attract Foreign Direct Investment (FDI) into the country for this sector, and everyone will be on a level playing field. However, the wafers will continue to be imported. 80
Modern Plastics & Polymers | June 2012
Thin-film PV cells are of two types – cadmium telluride and amorphous silicon. The original amorphous silicon was not appreciated in the industry, so a better version was invented with tandem junction, which had twin layers. “Cadmium telluride currently dominates the thin-film market by a large margin. The major difference between the two forms of PV cells is that thin-film cells are less efficient, but that does not mean they will produce lower power. If the efficiency is more, the Balance of Structure (BOS) cost of the land required to construct the megawatt plant will be lower, but the cost involved in invertors will be the same. Thus, crystalline silicon will help in lowering the BOS cost,� adds Khanna. When the temperatures increases, the performance of the solar modules go down, and the total output goes down. If PV crystalline has a thermal coefficient of 0.45, thin-film crystalline silicon will have a thermal coefficient of about 0.15. It also produces more power as these cells require lesser sunlight to send out more power, which is a boon for areas where the frequency of sunlight varies dramatically. Thus, a significant portion of the megawatt power plants in India has gone to thin-films. Currently, the prices of crystalline silicon are reducing, so it might give competition to thinfilms. However, it all boils down to the constraint of either space or cost. The market for PV cells for rooftop applications is a key area for growth in India, as new players are entering the scene. India has thousands of villages that still do not have access to electricity. This is one area where solar energy scores over other forms of conventional as well as renewable sources of energy generation.
Stumbling blocks Storage of solar power is currently the
Courtesy: Maharishi Solar Technology (P) Ltd
biggest challenge. Batteries are used to store solar power on a small level, but on the megawatt scale, no device has been made yet to store solar energy. Hybridisation is possible where thermal energy can be stored during the day for use during the night. Globally, the solar energy generation segment is facing challenging situations, as production has not reached a critical mass stage yet. PV cells are easy to install, but there are cost hindrances. A major area that has huge potential, but is not currently in vogue is the use of solar thermal energy in industries. This implies the use of solar power for manufacturing activities where fossil fuels are predominantly being used. For example, if a factory requires steam for its activity, it can be generated through solar power instead of burning diesel. It also results in lower power losses, as most of the generated power can be used for the required application. “The goal should be to minimise the use of conventional energy. Renewable energy must be integrated with thermal energy to produce optimum results in power generation. This transformation will be gradual, but technology will have to gradually replace fossil fuel– propelled energy,� asserts Khanna. The Government of India has planned 20 million sq m of reflective surface for solar thermal power generation across the country by 2020. If more research is encouraged, solar technology will soon be considered as a viable alternative for conventional sources. Email: anwesh.koley@infomedia18.in
ENERGY: Inter face - Ajay Prakash Shrivastava
“Increased efficiency and cost reduction can push the use of solar technology” …believes Ajay Prakash Shrivastava, President, Solar Energy Society of India. In an exclusive interaction with Anwesh Koley, he speaks about the future of solar photovoltaic cell technology in India and how the use of plastics can bring us closer to achieving the goal of ‘Power for all’. What is your outlook on the current state of solar power in India?
In which areas of PV technology are plastics used?
India has a huge potential for solar power and an even greater need for it. Almost 30 per cent of the Indian population does not have access to electricity, and there is a peak demand shortage, which can either be met through the use of fossil fuels, which are always facing shortage or from hydro power. We are reaching a limit on the power generated from coal, and oil prices are going up due to global economic crises. These concerns call for alternatives such as solar, wind and small hydro projects for power generation. The advantage of solar energy is that it can be generated at any location unlike wind, which requires the area to have abundant wind flow. From villages to cosmopolitan cities, India is blessed with long hours of sunshine, which can be successfully tapped. This energy can be generated and used immediately or saved for future use, thereby avoiding Transmission and Distribution (T&D) losses. In areas where grid connectivity is not possible due to geographical limitations, solar power can solve many problems.
The solar module uses a lot of plastic materials. One of the materials commonly used is Ethylene Vinyl Acetate (EVA). The back sheet of the PV cell uses polyester Tedlar, which helps in the process of module making; this requires joining 36 PV cells according to the amount of energy to be produced. Another important use of plastics is cost reduction. The total thickness of the silicon wafer is 180-200 micron, of which only the above 20 micron is used to generate electricity; the remaining part provides support. As silicon is an expensive material, research has sought to reduce its usage in areas where it is not required. Scientists have come up with the idea to use plastic substrates for support instead of silicon itself. These are called thin-film silicon and provide the same result as can be achieved if the entire unit is made with silicon. However, PV cell manufacturers often use both plastics and glass for this purpose as glass is sturdier. This resulted in plastics being used in another area of application where flexible PV cells are required to be mounted on curved surfaces.
82
Modern Plastics & Polymers | June 2012
An important breakthrough in plastics application for PV cells was achieved when jackets were made for the Indian army with thin-filmed solar cells to generate energy. These jackets came fitted with PV cells, which produced electricity to meet the daily requirements of army men on the site.
What can we expect from solar energy generation in the future? An area that needs improvement is to increase efficiency and reduce cost in order to make solar energy a more viable alternative for regular power generation. The key requirement for solar power generation is the battery, which stores the energy for future usage. An argument against solar electricity is the high cost associated with it. However, considering the non-renewable sources of energy and the associated environmental hazards, solar power comes as a cheaper and healthier option. Also, over the years, the cost of solar power generation has come down by almost 50 per cent. In the coming years, we will see even more use of solar power in areas where electricity is still a dream. Email: anwesh.koley@infomedia18.in
ENERGY: Roundtable
India ready for large-scale investments in alternative energy solutions? Is
The development of alternative energy in recent years has gathered steam due to various factors going against conventional sources of energy. Anwesh Koley finds out why there is a need for immediate investment to generate power through methods that not only reduce dependence on fossil fuels, but also have an environmental advantage.
Avi Bedi Chief Executive Officer, Geo cooling Technology Pvt Ltd
A key investment driver for renewable energy in India is the heavy dependence on fossil fuels, which may aggravate the power crisis. Over 65 per cent of installed capacities are in thermal mode followed by hydro, renewable and nuclear energy. Hence, state governments must reduce power distribution losses and explore other possible sources such as nuclear energy & hydro power. More than one-fourth of power produced in the country is lost in transmission and distribution. This has an important bearing on cost and quality of power. The Government should give incentives not only to encourage investments from the private sector, but also for improving operational efficiencies and exploring alternative energy sources. Annual losses in the power sector total ` 70,000 crore due to faulty distribution utilities. This can be recovered to a large extent through systematic investments in alternative energy.
Editorial take:
Avinash Brahmbhatt Chairman and Managing Director, Avin Energy Systems Pvt Ltd
Availability of regular power supply is a key determining factor for investment flows into various states. Some re-thinking is required on the tariff front as well so that private and Government-owned utilities can recover their running costs. Power companies should also be encouraged to improve their operational efficiencies through innovative means. The Government should encourage proper enforcement of laws while regulating greenhouse gas emission, enhancing energy efficiencies, exploring renewable sources of energy and reducing pollution levels. Rapid industrialisation and infrastructure development coupled with population growth and urbanisation have exerted tremendous pressures on the environment. The alarming pollution levels and threat of global warming may bring disastrous results in future by natural calamities such as the one witnessed recently in Japan. This will encourage competitiveness in grid-connected solar projects.
M V Suresh Divisional Engineer-Planning, Andhra Pradesh Power Generation Corporation Ltd
Renewable energy is still regarded as a modest-sized niche by some investors, media commentators and politicians. This perception has been out-of-date for many years and more so since 2010. There is also burgeoning investment in the parallel area of smart energy technologies, including smart grid, electric vehicles and energy-efficient devices & systems. In terms of investment, a total of $ 187 billion for asset finance and small-scale distributed projects for renewable energy in 2010 can be compared with the amount of capital spending worldwide on new fossil fuel plants. This shows that renewable energy, excluding large hydro power projects, is growing fast in investment, but is still in some way short of matching the rising number in fossilfuel capacity investment. In numbers, total investment in fossil fuel power plants was $ 219 billion, which is about $ 31 billion more than that in renewable solutions, excluding large hydro projects. Email: anwesh.koley@infomedia18.in
The Government’s target to achieve ‘Power for all’ by 2012 seems ambitious without reliance on alternative sources of energy. While initial investments are high, the long-term benefits of renewable energy justify the expenditure to ensure a cleaner tomorrow.
84
Modern Plastics & Polymers | June 2012
MPP Jun_2012 Ad Name: SCJ Tab-5, Pg No. 87
SCJ
MPP Jun_2012 Ad Name: SCJ Tab-5, Pg No. 87
MPP Jun_2012 Ad Name: Toshiba Tab-5, Pg No. 88
TOSHIBA
MPP Jun_2012 Ad Name: Toshiba Tab-5, Pg No. 88
HEALTHCARE: Machiner y mar vels
‘Inject’ing innovations in medical grade plastics Courtesy: Bayer Material Science AG
T
he growing population of India is playing a pivotal role in the growth of the medical devices industry and healthcare sector at large. Contributing about 6 per cent to India’s Gross Domestic Product (GDP), the demands in this sector are huge. This has resulted in a considerable growth in the industry’s manufacturing segment. The growth in the healthcare sector has given a boost to the Indian plastics industry. The global medical plastics market is estimated to reach nearly $ 10 billion by 2015. Most of this growth is expected to come from the Pacific region and Asia, including India. These days, there is increased usage of plastics in medical devices and healthcare products, which has led to development of new technologies of manufacturing medical-grade plastics. The plastics processors including the injection moulding solutions providers are continuously involved in finding out innovative ways for catering to the market needs. 90
Modern Plastics & Polymers | June 2012
The changing global healthcare landscape has resulted in increased use of plastics in the medical devices industry, prompting manufacturers to continually develop new injection moulding solutions for better results. Avani Jain highlights various injection moulding solutions and their role in manufacturing of high-quality medical grade plastics.
Amit Mahant, Director, PK Plastic International Pvt Ltd, notes, “The demand for injection moulding machines in the Indian medical industry has been mainly for lower- and medium-tonnage machines. Since 2007, the requirement started increasing for medium-tonnage machines. This shows good demands for injection moulding machines in the medical industry due to increase in requirement, multi-cavitisation, faster production, etc. At present, the demand for medium-tonnage machine is 70 per cent and for small tonnage, it is 30 per cent.”
Injection moulding solutions Most commonly used injection moulding solutions for manufacturing of medical-grade plastics include four to five types of injection moulding machines. Major are all-electric type, micro-injection moulding machines, multi-component injection moulding machines and liquid injection moulding machines. There are some variances of injection moulding solutions, which are
based on the medical plastics products. Mahant notes, “Injection moulded plastic parts are quickly replacing conventional materials in medical devices not only because of their wideranging material advantages such as sterility and design flexibility, but also because of the cost & speed with which they can be manufactured.” He adds, “Micro-injection moulding machines are used where the plastic part weight and total shot weight are just a few grams, ie, from below 1 gm to 10 gm. It helps reduce the cost of part per piece. Multi-component injection moulding machines are mainly used where large a number of rotating parts require elaborate moulds with the corresponding space requirements, such as toothbrushes with two to four colours. All-electric injection moulding machines are also increasingly used in the medical sector for making medical grade plastics, as these provide greater efficiency, cost savings, reliability, cycletime savings, cleanroom compatibility, among others benefits.”
Machiner y mar vels Medical grade plastics
Changing trends A lot of changes and improvements are being made in the injection moulding machines to make good quality of medical-grade plastics. “Hot runner systems offer high rates of efficiency and productivity. Most notably, they cut production costs dramatically. The elimination of cold runners makes hot runners the preferred solution for cleanroom production. Simply put, the moulding cell remains clean because the mould produces only parts and no waste is generated,� avers Mahant. In the injection moulding world, cycletime is money. It stands to reason that one of the most effective ways to improve productivity is to increase production speed. “This can be done by increasing the number of cavities, either in a single mould or through additional moulding cells. The other option is to run the injection moulding machine faster. This may not be a possibility as there are physical limitations to how fast a part can be made. Thus, having an optimised part mould and hot runner design is the only way to achieve better, more competitive results in the healthcare sector,� notes Mahant. With regard to micromoulding, there is a trend to develop new techniques to provide tighter tolerances and better quality control and surface finishes. These days, the demand for all- electric machines is also increasing manifold due to the benefits they offer to the customers, ie, energy efficiency, greater cleanliness, quick start-up, better repeatability and noise-less operations. These machines also offer shot-to-shot consistency and repeatability. These have fewer complex parts than hydraulic machines, making them relatively more reliable. Mahant says, “With aggressive growth in medical, pharmaceutical and medical packaging industries, investment in all-electric machines
is expected to increase. This growth will be further fuelled by productivity improvement initiatives due to manpower shortage, wage inflation and higher power cost. Clearly, all-electric injection moulding machines can provide numerous advantages to today’s medical moulders and medical-grade plastics manufacturers.�
Growth opportunities The medical industry presents huge growth opportunities for the injection moulding solutions providers. Mahant says, “With surging demand in injection moulding segment in recent times, during 2012-13, the medical industry is expected to need 500 injection moulding machines, be it all-electric, micro or vertical. It would be about 10 per cent of total demand of injection moulding machines in all sectors.� He elaborates, “Every year, the requirement is increasing by 9-10 per cent, as many of the medical components manufacturers understand the importance of quality machines and good manufacturing practices.�
Injection moulded plastic parts in general, and hot runner systems in particular, healthcare sector. In the future, the trend would be increased usage of microinjection and all-electric injection moulding machines. Amit Mahant Director, PK Plastic International Pvt Ltd
Future trends Medical devices are among the most challenging products for injection moulders to work with. Besides the constant pressure to reduce cycle times and cost, medical moulders must meet stringent Food and Drug Administration (FDA) specifications, tight tolerances and sterilisation requirements for many of the parts they produce. Mahant concludes, “Injection moulded plastic parts in general, and hot runner systems in particular, can offer flexibility and cost-efficiency to the booming healthcare industry. In the future, the trend would be increased usage of micro-injection and all-electric injection moulding machines.� Email: avani.jain@infomedia18. Ju une 2012 2 | Mod June Modern Plastics & Polymers
91
HEALTHCARE: Imaging and diagnostics
Visualising exciting opportunities Advancements in engineering plastics have enhanced the opportunities for plastics usage in the medical devices industry, making diagnosis and treatment easy & efficient. Avani Jain highlights the role and benefits of using engineering plastics in medical devices industry, especially in high-tech medical imaging and diagnostics systems.
T
he medical devices market in India has been experiencing a double-digit growth. The market for medical devices in the country is estimated at ` 5,750 crore, with a predicted annual double-digit growth rate of 23 per cent or higher for the coming years. The key factors responsible for this growth are increased affordability by patients, greater awareness of healthcare, improving hospital infrastructure, etc. Advancements in polymer technology and engineering plastics and their increased application have further broadened the horizon of the medical device industry in India. The use of plastics in medical applications is continuously growing, as new polymers have edged out metals, ceramics and other conventional materials. Engineering plastics are increasingly used in healthcare applications that demand high consistency, performance, precision and compliance with regulations. Dr Harindu Vyas, President (Technical & Development), Signet Industries Ltd, notes, “The use of plastics in the medical industry has steadily increased in the last decade. 92
Modern Plastics & Polymers | June 2012
In fact, where previously glass was used in the medical industry, it is now replaced by general-purpose and engineering plastics. It is used for a variety of applications ranging f rom simple glucose bottles and injection syringe, etc to complex medical devices such as medical imaging & diagnostic systems. Plastics has entered into the medical sector in such a manner that, today one cannot even imagine avoiding it, and all this is the result of its excellent properties & userfriendly features.�
Engineering plastics in medical devices High purchasing power of the Indian population will help make advanced medical treatment more affordable. This will facilitate the healthcare segment to provide further growth opportunities for plastics, especially high-performance plastics or engineering plastics, eg, Polytetrafluoroethylene plastic (PTFE; also called Teflon), Polyether BlockAmide (PEBA), Polyetheretherketone (PEEK), Ultra-high-Molecular-weight Polyethylene (UHMWPE), etc. Globally, about 750,000 tonne of plastics are used in healthcare
applications. Of this, about 7,500 tonne comprises engineering plastics (eg, polycarbonate) and highperformance plastics (eg, PEEK). These materials are chosen for the high-performance properties such as clarity, impact and chemical resistance, sterilisability, lubricity and kink resistance. PEEK and PEBA are some of the ideal materials for making catheter tubing due to their enhanced flexibility. PTFE are mainly used in high-lubricity, heat-shrink medical tubing. Acrylic compounds [Polymethyl Methacrylate (PMMA)] have various applications in the medical device segment. Typical applications include diagnostic devices due to its properties such as high Ultraviolet (UV ) transmittance capabilities and good resistance to gamma. Further, the advent of modified acrylics has broadened the scope in the medical device industry. Up to 90 per cent of acrylic applications in the medical device industry are for the disposable segment.
Monitoring and imaging systems Monitoring and imaging devices comprise a diverse range of applications
Imaging Engineering and diagnostics plastics
f rom hand-held and small devices such as pulse oximeters, blood pressure and other patient monitors, to larger transportable devices such as anesthesia delivery & ultrasound, to very large stationary equipment such as X-ray, Computed Tomography (CT), Magnetic Resonance Imaging (MRI) and Positron Emission Tomography (PET) imaging machines. Vyas avers, “Today, all hightech diagnostic and medical imaging systems are mainly made up of engineering thermoplastics. It is mainly because they are non-metallic and not affected by magnetic & electricity fields. For example, the MRI machine is a huge magnet that can attract any metal objects located in its range. This can be very dangerous. Thus, to avoid this problem, all tools and casing of the MRI machine are made from plastics.� He adds, “The advent of engineering plastics has made it easy to replace the metal used for manufacturing of any medical imaging system. This way, one can save the metal cost and reduce the weight of the instrument without compromising the performance.� Some other reasons for using engineering plastics in these systems include durable and impact resistance, light weight, chemical resistance to cleaners & disinfectants, flame retardance & Electromagnetic Interference (EMI) or Radio Frequency Interference (RFI) shielding and indoor Ultraviolet (UV ) stability. Further, engineering plastics offers significant design edge that make these expensive healthcare equipment such as MRI and CT scanners more affordable to emerging economics like India. The ability to mould complex shapes and consolidate parts are important in creating eye-catching ergonomic designs.
Medical diagnostic systems Medical diagnostic systems include instruments and accessories used for the analysis and diagnosis of patient samples. These include disposable vials and containers for sample collection, hand-held instruments such as pipettors (for sample preparation), clinical diagnostic equipment for rapid processing/evaluation of many samples. High-performance plastics is important in manufacturing of these medical devices, as these devices require materials that are biocompatible, light in weight, chemically resistant, enable gamma or autoclave sterilisation, etc. Vyas avers, “Thus, due to extraordinary characteristics of engineering plastics, such as good strength to weight ratio, easy processability, malleability, anticorrosiveness to body acids and its secretion and biodegradability (some polymers), these are used practically in every area of the healthcare sector.�
Moving beyond convention As the medical devices industry gears up to increased application of engineering polymers, features such as clarity, durability and ability to withstand large temperature gradients (40°C-121°C) will be the primary differentiating factor. Plastics medical equipment have to endure extreme sterilisation conditions such as steam, ethylene oxide and gamma radiation. A bewildering array of engineering plastics is available for manufacturers today, and the choices are still expanding as material developers find innovative ways to deliver greater strength, flexibility, resistance to sterilisation or bodily materials or, simply, the aesthetic appeal. In the foreseeable future, countries such as China and India will have greatest growth potential due to
In India, the demand for engineering plastics in the medical industry is set to increase, considering the ongoing research not only in the manufacturing of various medical devices and surgical instruments, but also for body implants. Dr Harindu Vyas President (Technical & Development), Signet Industries Ltd
their large populations and developing healthcare system. Vyas concludes, “In India, the demand for engineering plastics in the medical industry is set to increase, considering the ongoing research not only in the manufacturing of various medical devices and surgical instruments, but also for drug delivery and artificial body implants. Thus, advancements in medical technology will propel the consumption of engineering plastics and high-performance plastics in the healthcare sector.� Email: avani.jain@infomedia18.in June 2012 | Modern Plastics & Polymers
93
HEALTHCARE: Inter face - Dr Subhas Chandra Shit PACKAGING: xxxx
“Biomedical applications demand a lot of research and development activitiesâ€? ‌emphasises Dr Subhas Chandra Shit, Deputy Director, Central Institute of Plastics Engineering & Technology (CIPET), Ahmedabad. In conversation with Avani Jain, he discusses the growing demand for medical plastics and the leading innovations in this application. What are the current trends for plastics usage in the healthcare sector? Plastics finds application in all industry segments and the healthcare industry is no exception. However, many medical products and devices are manufactured outside India, which sometimes limits the usage of plastics in the domestic market, but this scenario is changing gradually. Companies are increasingly manufacturing high-grade medical plastics in the country. Thus, there is definitely good potential for plastics in the healthcare sector. A lot of innovations are happening in the plastics processing technologies and materials, such as engineering plastics and polymers, which can further increase the usage of plastics in this sector.
What makes plastics the preferred material for medical applications? The major benefit of using plastics in the healthcare sector is that it does not react with the body. When used during implantation, it does not damage the bones or tissues. The processing of plastics is also easy, and it is an extremely versatile material, ie, it can be moulded into any shape or size.
What are the major applications of plastics in the healthcare sector? Commodity as well as engineering plastics find extensive application in the 94
Modern Plastics & Polymers | June 2012
healthcare industry. Materials such as polycarbonate, nylon and polyurethane are majorly used in manufacturing healthcare products. Similarly, Polyethylene (PE) and Polypropylene (PP) are increasingly being used in the healthcare industry. Linear Low-Density Polyethylene (LLDPE) material is also used in the medical sector, eg, for making contraceptive devices, etc. Polymers are used for making drug delivery systems and even contact lenses. Today, plastics is also extensively used to make baby care products, eg, diapers, and baby bottles. Plastics is also used for packaging of medical products such as tablets and syrups. It is even used as an external fixator to immobilise the position of bones throughout the healing process. It is used in short-term joint implant test devices to determine the correct sizes for long-term joint implants.
What are some of the leading innovations in the segment? Numerous innovations are happening in plastic injection moulding and thermoforming technologies to manufacture high-grade medical plastics. These processes are being customised to deliver accurate results. New polymers such as Ultra-High-Molecular-Weight Polyethylene (UHMWPE) are being developed to cater to the needs of the
medical sector. It is a smooth material and used in bone implantation. Hydrogel polymer is an example of UHMWPE, which is injected into the body to regulate blood flow, ie, for expansion and contraction of blood vessels.
What is the status of biodegradable plastics market? The biodegradable plastics market is also growing. There is increasing demand for biodegradable thermoplastic elastomer, though it is difficult to manufacture. Thus, the use of plastics in biomedical field demands lot of research and development activities.
How do you perceive the demand in future? The demand is ever expanding owing to the high population growth. Even awareness is increasing and this has resulted in people demanding quality products. But, the usage and choice of material will depend on the properties desired for specific applications. In the future, many innovations in plastics will be made to increase their consumption in the healthcare sector. Hydrogels, polyurethane, biodegradable plastics are already used in the healthcare sector, and many new useful materials will be developed in future. Email: avani.jain@infomedia18.in
HEALTHCARE: Roundtable
Is
plastics the answer to
Indian healthcare industry? a competitive
Advancements made in plastics for the medical device industry promise to transform the healthcare sector in India. Avani Jain speaks to some industry experts to gauge the reason for increasing demand for plastics in the healthcare sector and how it can give a boost to the industry. Ajay Pitre Chairman–Medical Equipment Division, Confederation of Indian Industry, and Managing Director, Sushrut Surgicals
There is a genuine requirement for plastics in the medical industry, as it is used for making various types of medical equipment. In fact, plastics is one of the largest segments of the medical devices industry. Currently, the demand for plastics in manufacturing medical devices is not as much as in other nations. This is mainly because most of the machines are imported in order to meet the global standards. There is not sufficient healthcare infrastructure development in many parts of the country. All these factors have led to low consumption of plastics in the medical sector. However, as the medical device industry is catching up and seeing an upward growth, the plastics industry also seeing positive impact and the demand is set to increase. In fact, in future, the medical devices industry can become one of the major users of plastics in the country.
Sachin Unde Segment & Product Marketing Leader, SABIC Innovative Plastics India Pvt Ltd
The demand for engineering plastics in the medical devices industry in India is about 10 per cent ($ 2.5 billion) of the total demand for engineering plastics and the demand is growing at six per cent per annum, though hardly at one per cent of the total global demand. Thus, the demand is comparatively lower than that in other countries. Moreover, there is enormous demand for Polyvinyl Chloride (PVC)-based medical polymers in the medical devices industry, but not for engineering plastics. This is because engineering plastics is costly and not everyone is willing to pay the higher prices. Since the demand is low, there is a good scope in the future for engineering plastics in the medical devices industry. As the medical devices industry gears up to increased application of engineered plastics, features such as clarity and durability would be the primary differentiating factors.
Sohil Kalva Managing Director, Angel Products
Today, most of the medical equipment, components and products are made from engineering plastics. The innovations in the engineering plastics segment are driving this demand. Of late, not only engineering plastics, but also various types of elastomers, polymer compounds, alloys and blends are finding use in manufacturing of medical devices. These materials are chosen for their high-performance properties such as clarity and impact & chemical resistance. Advancements in polymer technology have enabled the use of plastics in healthcare applications that demand high consistency, performance, precision and regulatory compliance. Also, the machines have been modified to make good-quality medical-grade plastics. Some of the major new technologies such as micromoulding, thin-wall extrusion and moulding are being developed for medical plastics processing. The usage of allelectric machines is also increasing. Likewise, many other developments are underway to increase the usage of plastics in the healthcare sector.
Editorial take: Email: avani.jain@infomedia18.in Although the Indian medical plastics industry is still in a nascent stage, the opportunities for plastics in the medical devices industry are soaring. The use of plastics for manufacturing disposables and light-weight, portable & user-friendly devices are the growth triggers for demand in the healthcare sector. June 2012 | Modern Plastics & Polymers
95
PACKAGING: Bioplastics
Emphasising on the green factor Courtesy: BASF
T
he t e c h n o l o g y - d r i ve n packaging industry presents a potentially lucrative market for bio-based plastics. In recent times, several breakthroughs with bioplastics have opened avenues for analysing various possibilities for their use in numerous applications, providing tremendous benefits and have also given a new lease of life to Research and Development (R&D) efforts for bioplastics. There is an increased interest in Asian markets, and India has witnessed the entry of bioplastics manufacturers who are exploring the potential in the Indian market owing to its booming retail sector. Development efforts in bioplastics have focussed predominantly on starch, which is a highly renewable and widely available raw material. Starch is economically competitive with petroleum and used in several methods for preparing compostable plastics. Corn is the primary source of starch for bioplastics, although more recent global research is evaluating the potential 96
Modern Plastics & Polymers | June 2012
Globally, there has been an increasing emphasis on environmental sustainability. This has led to an interest in bioplastics technology as being a suitable alternative to conventional plastics. Lionel Alva analyses some of these trends and assesses how recent developments in bioplastics technology are set to capture the imagination of the packaging industry.
use of starch from potato, wheat, rice, barley, oat and soy sources in making bioplastics. The most promising application of bioplastics so far is seen in the food packaging industry.
Key market drivers Petroleum-based resins (thermoplastics) are used in many food packaging applications. However, the recent concern of oil shortage regarding the formation of greenhouse gases, and the saturation of landfill sites with thermoplastic waste has steered research towards development of ‘green’ polymeric materials, such as Polyhydroxybutyrate (PHB). This high-molecular-weight polyester is produced by a broad spectrum of microorganisms and has characteristics similar to those of conventional thermoplastics. But, the commercial use of PHB is limited by availability and cost. Furthermore, PHB homopolymer has a narrow processing temperature range since it degrades and becomes brittle at room temperature. Therefore, initial material characterisation, such
as flexibility at desired temperatures, gas and water permeability and thermoforming capability, is required to assess the feasibility of using PHBbased bioplastics for food packaging applications. In recent times, with fuel becoming scarcer and more expensive, the conventional petroleum-based resins are impacted, as these are ubiquitously used in food packaging. In this scenario, PHB is being looked upon as a possible contender. Starch-based thermoplastic materials have been commercialised over the last several years and currently dominate the market of bio-based, compostable materials. Other foodrelated applications include films for food wrapping and thermoplastics for food packaging and other food containers such as bowls, plates, cups and egg trays. Thermoplastic starch has been shown to demonstrate good oxygen-barrier properties, but the hygroscopic nature of starch dictates that this material is unsuitable for highmoisture and liquid food products.
Bioplastics Bioplastics packaging
The weak links Despite all its advantages, as a packaging material, starch-based bioplastics is extremely brittle. Starch alone cannot form films with satisfactory mechanical properties (high percentage elongation, tensile and flexural strength) unless it is plasticised, blended with other materials, chemically modified or modified with a combination of these treatments. Common plasticisers used include glycerol and other low-molecular-weight polyhydroxy compounds, polyethers and urea. Cellulose, on the other hand, is the most abundantly occurring natural polymer on earth, similar to starch that is composed of glucose monomer units. Cellulose is found in all plant material and is thus an inexpensive natural resource. However, it is difficult to use in packaging because of its hydrophilic nature, poor solubility characteristics and highly crystalline structure. The alternating hydroxyl side chains along the cellulose backbone are responsible for the poor moisture-barrier properties of cellulose-based packaging materials. They also contribute to the highly crystalline structure of cellulose, which, in turn, results in a packaging material that is brittle and demonstrates poor flexibility and tensile strength. “While there are several types of bioplastics available in the market today, a somewhat latent interest is witnessed in the Indian market. Mass production is a key challenge that needs to be addressed along with further R&D efforts. Bioplastics have good potential in food packaging applications, as the shelf-life of bioplastics packaging is the same as that with conventional packaging material. However, bioplastics are not actually completely biodegradable since they merely break down to smaller particles and remain present in the environment. Thus, they could actually pose a serious threat for the environment. With adequate
regulations in place, it is possible to find out the exact percentage of the packaging that is actually biodegradable. This is vital to preserve the integrity of bioplastics applications,� observes Saurabh Gokhale, Managing Director, Polygreen Agents and Distributors.
Recognising market potential The challenges surmounting the use of bioplastics in several applications are being addressed to R&D. The nature of these challenges is multi-faceted and complex. However, recent developments have depicted that bioplastics could soon become the material of choice for food packaging applications. It is now possible to find bio-packaging materials that exhibit properties such as high sealability, soft-touch, good breathability, good thermal stability, good puncture resistance, clarity, toughness, high tear resistance as well as water, oil & fat protection that can be bio-based and/or biodegradable. While there is still room for much improvement, these developments show that bioplastics have enormous promise for future applications. This has been achieved only through a culmination of efforts in recent times. By combining the disciplines of agricultural biology, food packaging and microbiology, new biodegradable packaging solutions made from renewable plant resources are helping to address this environmental concern of rampant worldwide growth in plastics waste. Therefore, continued research in this field is clearly needed if economically viable development and sustainable production processes are to be widely implemented across the world. While this may be the case with any emerging technology, bioplastics are already beginning to show their promise and will soon dominate India’s burgeoning retail space. Email: lionel.alva@infomedia18.in
Mass production is a key challenge that needs to be addressed along with further R&D efforts. Bioplastics have good potential in food packaging applications, as the shelf-life of bioplastics packaging is the same as that with conventional packaging material. Saurabh Gokhale Managing Director, Polygreen Agents and Distributors
Courtesy: BASF
June 2012 | Modern Plastics & Polymers
97
PACKAGING: High barrier films
Riding on the retail wave With India being among the fastest growing retail markets in the world, the focus has increased on high-barrier packaging in the food and pharma industry. Lionel Alva observes how innovations in barrier films are providing a healthy impetus to the country’s retail sector that is all set to grow at a swift pace.
I
n the modern consumerist lifestyle, the nature of packaging both through its forms and functions has shaped the retail shopping experience. The myriad forms of packaging impact the psyche of a consumer. The packaging industry is driven by innovations with consumer tastes and needs acting as a dogma. The focus of these innovations from a functional perspective is to preserve the quality of its contents from the time of manufacture to consumer use. The most common quality losses are associated with water vapour and oxygen transfer. This is why multi-layer barrier films play such an important role and the research on barrier films is the crux of what is driving packaging technology today. The manufacturing demands are restrictive for polymer packaging films with defined barrier against gases, moisture and flavours.
Materials research High-barrier plastic packaging films are fast replacing conventional materials such as aluminium foils owing to their flexible nature and the uncompromised 98
Modern Plastics & Polymers | June 2012
degree of protection they offer. With five-layer multi-barrier packaging technology prevalent in the market, it is paving the way for even higher multi-barrier packaging technology so that packaged goods can be stored for longer durations. High-barrier packaging consists of several different layers and various types of resins, which provide advanced properties for an extended shelf-life and the ability to let in certain gases to change product colouring. The interaction of water with a polymer depends on the polarity of its functional groups and influences the mechanism of diffusion transport in macromolecular compounds. Moreover, the strength and stiffness of films increase as density goes up, while permeability goes down. “Gas permeability is a highly critical factor in case of multilayer high-barrier packaging films for food and pharma. Especially in food packaging, as in case of pickles where the pungent smell needs to be preserved, oxygen permeability is necessary to maintain freshness.. Nylon, metallocene and polyester are some of the major materials used to make
Courtesy: Avery Dennison
barrier packaging,” avers Mallikarjun Jamdar, Marketing Head, Synthetic Packers Pvt Ltd. On the environmental f ront, aluminium metallising meets source reduction requirements. Since the aluminium coatings are a molecular layer, metallised substrates are considered as mono-materials. Besides providing an effective barrier to atmospheric gases and aroma constituents, metallising also prevents light penetration.
Understanding market trends In the pharma industry, the regulations are already too stringent and in the food industry, the fastest growing segment is ‘pre-cut’ or ‘fresh-cut’ produce. This includes ready-to-eat food items, coleslaw and other food items delivered to the consumer in eye-catching, highbarrier packaging films where the impact on the shelf-life of such products is dramatic. Properly formulated freshcut packages reduce spoilage waste and provide a wide variety of pre-washed, pre-cut produce with long shelf-life. Long product shelf-life depends to a great degree on production of a film that
High barrier films
can match exact oxygen transmission rate (OTR) of the specified product. Barrier films developed for the Indian market predominantly uses metallocene technology. These films include packaging for products in meat, cheese, industrial and medical applications. Metallocene is used in the sealing layers and combinations of various additional resins are used in the interior layers. Several benefits are seen in this form of packaging that provides hermetic seals, great optical clarity for appealing product display and high strength, tensile & puncture resistance. Moreover, the cost of developing such barrier films despite these attributes is not very high. “In the Indian market, preserving the rich smell of certain products such as that in oil and ghee packaging is important. Conventionally, such products are packed in three-layer barrier films of thickness 110 micron each; but in the new five-layer barrier films of 90-micron thickness, each layer utilises metallocene as the sealing layer, significantly improving on the core
characteristics of the packaging material while extending considerably the shelflife as compared to three-layer barrier films. They are also more economical in the long term, considering the inventory in retail shelves,� observes Jamdar.
High-barrier solutions The high-performing, low-weight packaging solutions are taking the retail market by storm. This has only served to reinvigorate the prospects of perishable commodities such as food and pharma since they are moving towards a more ideal form of packaging. With highbarrier packaging films, the inventory woes will become a thing of the past, and the manufacturers can also afford to focus on quality as well as research & development as a tenable measure to create appealing designs at a minimum cost. Considering that new films are constantly being developed, it is possible to reach an ideal price-point ratio for packaging designs in the future. Email: lionel.alva@infomedia18.in
Gas permeability is a highly critical factor in case of multilayer high-barrier pharma. Especially in food packaging, as in case of pickles where the pungent smell needs to be preserved, oxygen permeability is necessary to maintain freshness. Mallikarjun Jamdar Marketing Head, Synthetic Packers Pvt Ltd
June 2012 | Modern Plastics & Polymers
99
PACKAGING: Inter face - Dan Sawyer
“In an emerging market, you can build the business from ground up” …asserts Dan Sawyer, Leader–New Business Segment, NatureWorks Llc. In an e-interview with Annabel Dsouza, he shares the challenges and opportunities for bioplastics packaging for an emerging market like India.
What are the current market dynamics of bioplastics processing and packaging industry? One of the key concerns while introducing a new material into the supply chain is controlling costs. The economies of scale and years of process optimisation of conventional materials are difficult to compete with during the initial phases of commercialisation. Converters are recognising that in order to compete against established commodity polymers with a new polymer, they need to reassess their processing mindset. For example, higher costs associated with smaller campaign sizes can sometimes be neutralised by savings in other areas. With the application space for bioplastics expanding into new durable applications that require compounded blends, elimination of processing steps can ensure savings and improve properties.
the product design stage to package development, there is no additional inherent cost associated with bioplastics application. This become just a material of choice to build converting equipment, rather than trying to fit them into infrastructure or processing equipment designed for another material. The biggest challenge for some entrepreneurs in India is the lack of experience with plastics processing or packaging production. We are working to align ourselves with partners who can build or modify plastics processing infrastructure for use in applications where NatureWorks’ Ingeo best fits. With our recently announced high-performance Ingeo grades and inroads into Ingeo blends with compounded grades resulting from our BioAmber joint venture, we are confident that we can address a wide range of applications.
What is the potential for bioplastics packaging in emerging markets like India?
What technology and skills are required for bioplastics packaging and converting?
India is an interesting market. Much of this interest stems f rom the Government’s concerns about careless consumption by an emerging middle class. In an emerging market like India, one can build the business from ground up. There are no ingrained incumbent materials or mature, optimised supply chains. If bioplastics are used from
A majority of our customer base uses Ingeo in processing equipment designed for conventional plastics such as Polyethylene Terephthalate (PET) or Polystyrene (PS). Often, customers take some time to learn to operate at the optimum processing conditions for Ingeo. Typically, a basic understanding among converters about different
100 Modern Plastics & Polymers | June 2012
grades of packaging polymers reduces the learning process. Through the stereochemistry of the polymer, we can control its structure to produce a family of grades, ranging from completely amorphous polymers to those that crystallise rapidly, with the use of right formulation and processing conditions. When converters start from the ground up and build equipment specifically designed to implement Ingeo, they often modify equipment designs originally meant for other polymers, to leverage on Ingeo’s properties in their applications. For instance, thermoformers and injection moulders have modified their processes to allow the polymer to be crystallised or annealed in the process.
What are Nature Works’ R&D initiatives in bioplastics packaging? Recently, we have developed new highperformance grades, which will be available commercially in the first quarter of 2013. The manufacture of these products requires a capital investment, but we believe that bioplastics grades will allow for production of crystalline parts at a much more competitive cost. By tailoring the crystallisation rate of our grades, converters can address a wider application range of temperature performance requirements more cost effectively. Email: annabel.dsouza@infomedia18.in
TRANSPORT: Automotives
Accelerating ahead with composite solutions Courtesy: Lohia Auto Industries
W
hile designing the cars, today, automotive companies look for some key attributes in addition to attractive looks and functionality. These are fuel efficiency and safety. Plastics wins over metals in both these attributes. Carbon fibre– reinforced plastics and other innovative plastics are strong & light-weight and can be moulded into virtually any shape. Being light-weight, these increase fuel efficiency as well as range of the vehicles. The toughness of carbon fibre increases the safety of these vehicles.
Plastics for lighter vehicles Light-weight vehicles represent an important market for plastic resins and composites, one that has grown significantly during the last five decades. The average light vehicle now contains 378 pound of plastics and composites, which is 9.4 per cent by weight. This is up from 286 pound in 2000 and 194 pound in 1990. In 1960, less than 20 pound of plastics was used. 102 Modern Plastics & Polymers | June 2012
Plastics encompass a wide variety of functional polymeric compounds that exhibit a vast range of desirable properties. Anwesh Koley explores the various reasons why plastics is the preferred choice for the automotive industry and is being adopted for all categories of vehicles.
Rajiv Arora, Vice President and Business Head, Shriram Polytech, says, “The automobile industry share in the last decade in the Indian economy was about 5 per cent of Gross Domestic Product (GDP). Economic progress is indicated by the amount of goods and services produced, which gives boosts the transportation and sales of vehicles. Increase in automobile production has a catalyst effect by indirectly increasing the demand for plastics.” Composites are any combination of polymer matrix and fibrous reinforcement. Glass, carbon and other fibres provide strength and stiffness while the polymer matrix (or resin) of polyester, Polyurethane (PU), epoxy, Polypropylene (PP), nylon or another resin protects and transfers loads between fibres. This creates a material with attributes superior to either component alone. Across the industry spectrum, automakers are using materials that are more lightweight, ie, plastics-based components. These are replacing conventional
materials because they are fuel efficient. “The top priority for the automotive industry at present is designing and manufacturing of a commercially viable light-weight vehicle while maintaining structural performance. There are significant cost implications while using the advanced light-weight materials from procurement and manufacturing processes to end-of-life recycling,” adds Arora. Future competitiveness will depend on the ability of the automotive industry to be truly innovative and to effectively leverage the full potential of plastics & polymer composites. Substantial weight reduction is possible as composites are typically up to 40 per cent lighter than steel parts of equal strength. In addition to lightweighting to improve fuel efficiency and reduce emissions, plastics and composites enhance design flexibility, allow exceptional aerodynamic modeling, enhance safety and provide unparalleled corrosion and damage. Ashwani Aggarwal, President, Brose India Automotive Systems Pvt Ltd,
Automotives Automotive plastics
says, “The main objective is reduction of vehicle weight and cost optimisation. Eliminating the use of certain number of components and using alternative materials results in weight reduction. This results in an increase in efficiency and performance of the vehicle. Alternative materials are also used to provide comfort and safety factors to the customers.”
Areas of application It is well known that plastics is widely used in the exterior of automobiles. Today’s plastics have revolutionised the design of auto body exteriors. From bumpers to door panels, light-weight plastics gives cars better gas mileage and allows designers and engineers the freedom to create innovative concepts that otherwise would never be possible. Opting for plastics for auto body exterior parts allows manufacturers to implement modular assembly practices, lower production costs, improve energy management and use advanced styling techniques for sleeker, more aerodynamic exteriors. Conventionally, metal alloys were synonymous with auto body exterior design and manufacturing. However, metal alloys are susceptible to dents, dings, stone chips and corrosion. These are also heavier and more expensive than plastics. “Safety in automobiles requires the use of robust plastic composites, which can be designed accordingly and, at the same time, withstand the impact of a crash. Various grades of plastics are used, particularly PP, across the length of a vehicle. Different applications within an automobile require different grades of plastics, which require expertise,” adds Aggarwal. Many of today’s car engine components are made of plastics. From air-intake systems to cooling systems to actual engine parts, plastics helps make engine systems both easier to design and
assemble as well as lighter in weight. The versatility offered by plastics has provided numerous breakthroughs in car engine component designing.
Automotive powertrain The term ‘powertrain’ refers to the system of bearings, shafts, and gears that transmit the engine’s power to the axle. Plastics helps reduce the number of parts needed to assemble these complex components. Plastics also helps reduce vehicle weight, which helps lower assembly costs while increasing fuel efficiency. Plastics can also be used to manufacture transmission oil screens and other components requiring exposure to hot transmission oil. As with fuel tanks, plastics helps free designers from the space constraints that arise with the use of sheetmetals. The ability to design a transmission with few design limitations allows design engineers to place transmission components in tight-fitting spaces. This is especially important in front-wheel drive vehicles where several components compete for a limited amount of space. “The use of plastics in front-wheel drive transmissions also helps lessen the weight in the front of the vehicle, thus improving vehicle handling. Polyetherimide resins are used extensively in transmission sensors and solenoid valve applications because of their resistance to high temperatures and creeping,” adds Aggarwal.
The winning solutions provider With the ever increasing demand for power, efficiency and safety in the world of automobiles, manufacturers are hardpressed for design and functionality. Plastics has provided solutions for most of these challenges. Being lightweight, it enhances fuel economy and being rigid, it improves the dynamics of a vehicle, thus providing a win-win situation for both manufacturers and consumers. Email: anwesh.koley@infomedia18.in
The top priority for the automotive industry at present is designing and manufacturing a commercially viable, light-weight vehicle while maintaining structural performance. Rajiv Arora Vice President and Business Head, Shriram Polytech
The use of plastics in frontwheel drive transmissions also helps lessen the weight in front of the vehicle, thus improving vehicle handling. Polyetherimide resins are used extensively in transmission sensors and solenoid valve applications. Ashwani Aggarwal President, Brose India Automotive Systems Pvt Ltd
June 2012 | Modern Plastics & Polymers 103
TRANSPORT: Aerospace
Light-weighting takes to the skies Aircraft have traditionally been made from metal, usually aluminium alloys, but engineers are now increasingly using carbon fibre composites to enhance the quality and functionality of aircraft: a welcome move towards lightweight aviation. Anwesh Koley outlines various applications of plastics in the aviation industry and the reasons behind its steady acceptance.
M
achinable engineering plastic materials have been used in aerospace applications for over 40 years. Materials such as nylon and acetal have routinely been used as wear surfaces, rub strips, brackets, grommets and fasteners in areas where environmental & performance issues meet the capability of the polymer. Some of these applications have been injection moulded, while many are machined from stock shapes with proven applications. Today, aircraft engineers are looking at engineering plastics to reduce the dry weight of aircraft without sacrificing physical performance of the metal parts they are replacing. Engineering plastics are finding their way into applications as resin systems for advanced composites or as parts, injection moulded or machined from stock shapes. A K Kanth, Senior Deputy General Manger, Heavy Engineering Corporation Ltd, says, “In the 1980s, the top global aircraft manufacturers turned to lighter weight materials in order to increase payload and fuel efficiency while reducing maintenance costs. Much of the internal research and development centred on the use of ceramics & advanced composites.” 104 Modern Plastics & Polymers | June 2012
Benefits and applications While nylon and acetal are still utilised, more advanced materials are finding their way into applications due to their increased chemical resistance, higher modulus, low coefficient of thermal expansion and high temperature resistance. Those basic benefits and the ability to add fillers to these polymers offer engineers the ability to increase strength and decrease wear while lowering weight. Also, due the lowvolume nature of aircraft production, stock shapes of these materials offer a cost-effective option by machining the parts rather than moulding them. Fibrous composite materials were originally used in small quantities in military aircraft in the 1960s, and within civil aviation from the 1970s. “Initially, composites were being used by civil aircraft manufacturers for several secondary wing and tail components such as rudder & wing trailing edge panels. However, with the advent of the latest generation of airliners of which few are world’s largest passenger aircrafts, these materials have been deployed extensively in primary load carrying structure,” informs Kanth. For example, Airbus A380 uses composite
Courtesy: Eurocopter Deutschland GmbH
materials in its wings, which enables 17 per cent lower fuel use per passenger than a comparable aircraft.
Lower weight, higher strength Polyamide-Imide (PAI) is a meltprocessable, amorphous engineering plastics that offers excellent stiffness and comprehensive strength at extreme temperatures. The material can endure harsh thermal, chemical and stress conditions. PAI is an excellent choice for wear applications. For example, a spacer used in an aircraft’s reverser assembly is an application where PAI is used due to its dimensional stability and heat resistance. With just two reversers on a typical aircraft, only a handful of parts are used on a single airplane. This is an ideal application for parts machined from stock shapes. Other plastic materials such as Polyphenylene Sulphide (PPS) and Polyetheretherketone (PEEK) offer excellent physical properties as compared to metals, as well as chemical resistance to aircraft fuels and hydraulic fluids. High-end materials such as PAI, Polyimide (PI) and Polybenzimidazole (PBI) offer similar resistance to fluids with good strength and even higher temperature resistance.
MPP Jun_2012 Ad Name: Prayag Tab-6, Pg No. 105 MPP Jun_2012 Ad Name: Prayag Tab-6, Pg No. 105
MPP Jun_2012 Ad Name: Adroit Tab-6, Pg No. 106
ADROIT
MPP Jun_2012 Ad Name: Adroit Tab-6, Pg No. 106
Aerospace
In the 1980s, the top global aircraft manufacturers turned to lighter weight materials in order to increase payload and maintenance costs. Much of the internal research and development centred on the use of ceramics & advanced composites. A K Kanth Senior Deputy General Manger, Heavy Engineering Corporation Ltd
Another application example is a pivot bushing. Advanced materials such as PAI and PBI have various fillers added to the base polymer to reduce wear and increase load bearing capability. Hinge bushings in cabin and exit doors, aircraft flaps, handles & video arms can benefit from the self-lubrication & impact resistance, and in case of interior systems, flame resistance of machinable plastics. In each of these applications, the close tolerances required for proper function make machined parts an ideal solution.
The composite advantage Composite materials for aerospace application can provide a better strength-to-weight ratio than metals, sometimes by as much as 20 per cent. The lower weight results in lower fuel consumption and emissions and, as plastic structures require fewer riveted 108 Modern Plastics & Polymers | June 2012
joints, enhanced aerodynamic efficiencies and lower manufacturing costs. The aviation industry was attracted by such benefits when composites first made an appearance, but it was the manufacturers of military aircraft who initially seized the opportunity to exploit the use of these materials to improve the speed and manoeuvrability of their products. Civil aircraft manufacturers have been slower to implement these materials in their airframes for two reasons: stringent civil airworthiness requirements deterred the wholesale adoption of relatively unproven materials, and the flat price of fuel in the late 1980s reduced the need for increased fuel efficiency in emerging airliner designs. However, with extensive experience in the use of composites within the industry and against the backdrop of worldwide targets to reduce emissions from aircraft, the value of realising the full potential of this important technology is clear.
Airframe usage In order to derive maximum benefit from the use of carbon composites, it is essential to direct the fibres towards the main stress. For example, the wing of an aircraft bends during take-off, landing and flight, which means that it is subject to stress across its span. To support this, engineers orient up to 60 per cent of the fibres along the wing skins and the span-wise internal stiffeners. In addition, wing skins are subject to parallel stresses known as shear stresses – to combat this, plies are directed at 45°. Components inside the wing, such as spars and ribs that are designed to bear stresses, are made of about 80 per cent of plies. In this way, the direction in which the plies are laid ensures that material volume, and hence weight, is kept to a minimum and consistent with adequate strength.
Courtesy: Danube Wings
The impact on the work of structural engineers caused by the advent of Carbon-Fibre-Reinforced Polymer (CFRP) has been considerable, as the engineers can now effectively choose the stiffness characteristics of the material they use. Taking this a step further, engineers are collaborating with aerodynamicists to explore ‘aero-elastic tailoring’. Aircraft wings are designed in the knowledge that their shape impacts on their lift and load distribution, but also that lift and load distribution will alter their shape. “By employing aeroelastic tailoring, structural engineers can generate wing designs that deflect under increased loading in order to moderate the internal load increase. CFRP is peculiarly amenable to this type of design because, by orienting fibres in specific directions, the stiffness characteristics of a laminate can be modified to give precisely the response to increased load required,� adds Kanth.
Flying higher Machinable engineering plastics in the form of rods, sheets and heavy-wall tubes offer unique solutions for the aerospace industry. Their use is ideal for small-volume applications where their unique benefits of weight savings and easy processing outshine their metallic counterparts. The design flexibility, material strength and enhanced aerodynamics offered by engineering plastics used in aerospace applications ensure that this industry is slated to grow with the rapid development of aviation technology. Email: anwesh.koley@infomedia18.in
TRANSPORT: Inter face - Ayush Lohia PACKAGING: xxxx
“Electric vehicles will become the primary vehicle in every homeâ€? ‌opines Ayush Lohia, Chief Executive Officer, Lohia Auto Industries. In a conversation with Anwesh Koley, he explains the reasons for the fast growth of the electric scooters in India and also highlights the areas of improvement.
What is the state of the electric scooter segment in India? The electric scooter segment in India is in its nascent stage, since manufactures began showing interest in this area only since 2005 for developing environment-friendly scooters for the masses. Hence, it has a great future with enormous opportunities and scope for improvement. Electric scooters cannot be directly considered as competition to scooters running on gasoline and no data is currently available to substantiate it. They are still treated as secondary vehicles, which are essentially bought for children or housewives for short-distance commuting at a lower cost. In terms of technology, the products available in India are comparable to international products, as transfer of technology takes place rapidly between manufacturers. However, domestic companies are constrained due to price concerns, which must be economical from a purchase point of view while also running costs. A predominant market for electric vehicles is in the the Asian region, namely Malaysia, Indonesia, China and now India. Currently, the share of electric vehicles in the developed countries is negligible. This is because of the rapid development of technology in the fourwheeler segment in these countries. 110 Modern Plastics & Polymers | June 2012
However, with the rising oil prices, we can soon expect extensive Research and Development (R&D) in electric technology for transport solutions.
What is the extent of plastics application in electric scooters? Increasing efficiency is the most important aspect in electric vehicles for increasing the range of vehicles. In order to run for longer distances in a single charge, manufacturers must make efforts to reduce considerably the mass of the product. They should be specific while considering the plastic materials to be used in each vehicle. Almost the entire vehicle is made from plastic composites. From the technology required to fit the products together to body panels, plastics is an integral part of electric vehicles. It is considered as the material of choice to gain substantial weight reduction advantages, as it finds use in the speedometer, body frame, under-seat storage area, side panels, etc. As there is no combustible fuel involved in these vehicles, plastic parts can be conveniently used across the external and internal lines of the vehicle.
Which types of polymers are used in these vehicles? We primarily use Polypropylene (PP) and Acrylonitrile-Butadiene-Styrene
(ABS) as raw materials for our vehicles. These are light in weight and can be moulded as per the individual product specifications. In addition, PP offers excellent cold weather flexibility and in case of mechanical damage, it can be easily repaired by using simple field tools or tape. The body parts made from these polymers can withstand the varied weather conditions during the year and also provide sturdiness to the vehicle.
How do you perceive the future of electric vehicles in India? Electric vehicles are the need of the hour in the country. From low running costs to environmental benefits, they fit the bill for many across the globe. Also, with the ever-increasing prices and ecological drawbacks of fuel, it is time to make electric vehicles the primary mode of transport. The Government has been facing difficulty due to rising fuel prices, but they cannot do much about this issue. Instead, they should make efforts to promote electric vehicles across the country, which will lessen the burden of fuel costs on the nation. Increased interest of the consumer in electric vehicles will also encourage manufacturers to develop better technology at competitive costs and make electric vehicle manufacturing a highly profitable industry in India. Email: anwesh.koley@infomedia18.in
TRANSPORT: Roundtable
boost safety efficiency aviation? How can plastics and in
High-performance plastics materials have special properties that render them useful in the aviation and aerospace industry for specific applications. Anwesh Koley delves into the various reasons why plastics has become the preferred material for the aviation industry across the world. Jai Singh President, SKIL Infrastructure Ltd
Without the use of plastics, it would be difficult to imagine the recent developments in aircraft design and functionality. The use of plastics makes planes lighter, safer and more economical. Advantages of plastic components are not restricted to the interiors, but also spread to sophisticated technical parts, structural elements and propulsion components among others. Recently, the significance of technical plastics and composites in aviation & aerospace applications has grown rapidly. Plastics has high thermal and mechanical stability, which allows it to score over other materials, especially glass. It is inherently flame retardant and has a low degree of thermal expansion. It also has a high chemical resistance even at raised temperatures and a low level of outgassing in vacuum. Many plastic composites provide good electrical insulation, which is required to keep the mechanical parts moving.
Editorial take:
Sushen Gupta Director, Indian Avitronics Ltd
Vinay Kumar Director, Sherman International Pvt Ltd
Engineering plastics in aerospace has numerous benefits attached. Every extra kilogram that an aircraft carries, costs energy, fuel and money. The use of modern polymers and reinforcing fibres allows for achieving light-weight construction. Normally, plastic components can be fabricated economically and these offer flexibility to the overall structure of the aircraft. Plastics is about 50 per cent lighter than aluminium and does not corrode like metals. It also provides a high degree of freedom in design, which is often not possible with many of its metal counterparts. Plastics with modified sliding properties is best suited for use in dry operation under extreme conditions. Transparent plastics serves as a lighter and more impact-resistant alternative to glass. The varieties of plastic composites available today offer a high degree of precision in terms of the exact requirement of the aircraft, which in the current scenario is increasingly becoming prevalent.
Plastics can be flexible enough to withstand vibrations from an aircraft, and rigid enough to ensure safety during the flight. They can be transparent for easy observation, shatter resistant and offer ballistic protection. The need for more efficient engines, improved aerodynamics and weight reduction has brought plastics to the forefront, and its uses continue to grow. The heavier the vehicle, the more fuel it requires to travel a given distance. The weight-to-fuel impact for jetliners is quite high. A one-pound weight reduction means tens and even hundreds of thousands of dollars in lifetime fuel savings, which results in large savings for international aviation companies. Due to their combination of properties, plastics can be less expensive to manufacture, more resistant to wear, need less upkeep and are easier to repair than other heavier materials. Plastic materials continue finding new uses in aerospace, and new plastic materials continue to be created, further expanding the range of possibilities. Email: anwesh.koley@infomedia18.in
The versatility offered by plastics in terms of design, functionality and safety has ensured that it finds increased application in the aviation industry. Combined with the aesthetic advantages over metal and glass, this property has made plastics a worthy replacement in this sector.
June 2012 | Modern Plastics & Polymers 111
FACILIT Y VISIT: STEER Engineering (P) Ltd
Steering progress through compounding innovations
In order to keep pace with the latest trends in plastics application, STEER Engineering (P) Ltd has evolved from manufacturing extruder processing zone parts to complete co-rotating twin-screw extrusion machinery. Annabel Dsouza identifies the ideas and innovations that are paving its way forward. ggere R
Sa Photo:
a dhakr
ishna
T
he surging growth rates of end-user industries are driving the Indian plastics compounding industry at a Compounded Annual Growth Rate (CAGR) of 10-12 per cent. This is, in turn, churning the wheels of innovation for the technology and machinery manufacturing sector. STEER Engineering (P) Ltd is among the leading manufacturers of Extruder Processing Zone (EPZ) elements and complete production lines for the plastics, pharmaceutical, powder coating & food processing industries. Established in 1993 to manufacture screw elements for twin-screw extruders, today, STEER has a global presence and marketshare of about 15 per cent. The company has transformed the methods of conventional twin-screw compounding through constant innovation and lean manufacturing technology. Dr Babu Padmanabhan, Founder and Managing Director, STEER 112 Modern Plastics & Polymers | June 2012
Engineering, says, “Our journey has been meaningful and we have moved beyond parts manufacturing to machinery manufacturing. We recognised early on that being a parts supplier alone will not help us achieve the progress we were aiming for. Although EPZ manufacturing is the core of our business even today, we have developed a more consolidated approach towards material compounding and processing. Also, with a focus on the complete production line, we adopted twinscrew extruder manufacture to utilise our EPZs in the most efficient and effective method.”
Integrated manufacturing STEER manufacturing expertise lies at the ‘heart’ of co-rotating twin-screw extrusion. These elements, namely, screws, shafts and barrels, result in the desired quality of compounded material. Spread over 1.5 acre, the STEER facility in
Bengaluru’s Peenya Industrial Estate has a capacity to manufacture about 50,000 individual screw elements of varying sizes, properties and applications. STEER can manufacture segments with diameter ranging from 10 mm to 320 mm and up to 400 mm in length. The company has a process capability of over 2.5, making it a Six Sigma company. In 2003, STEER forayed into complete extrusion machinery manufacturing and is world renowned for some of its flagship brands, namely, OMEGA, MEGA and ALPHA. STEER’s compounding lines are built with a greater emphasis on reliability and safety to cater to the dynamic needs of the industry, which arise from unscheduled/ unplanned requirements for small quantities, control over Work-In-Progress (WIP). Further, during grade change and power failures, the lean operation feature of the system allows effective testing of new formulations with minimum wastage.
STEER Engineering (P) Ltd
Compounding line assembly Following are some of the special facilities at the STEER shop-floor: Foundry: Located in Coimbatore, STEER has its own state-of-theart foundry to manufacture specialty tool steels. Acrolloy 10 is a product of microgenic technology developed by STEER. Its unique properties make it appropriate for applications in various areas, including EPZ components, cutting tools, wear plates and dies. Polymer Science and Diagnostic Centre: This offers various specialist services such as polymer testing and characterisation service, certification programs for Original Equipment Manufacturers (OEMs), plastics compounding solutions & new formulation development, material & process technology development. Application Development Centre: This provides technology solutions and support, compounding tests, contract manufacturing, compounding trials, library creations and Research & Development (R&D). Technical services group: STEER is committed to maintain and increase the quality of customer service & support and provides dedicated technical teams for annual extruder maintenance at client locations.
Manufacturing shop floor
Software solutions for extrusion lines: The screw configuration software OUTLINE is a powerful tool for visualising, designing, comparing and sharing extruder screw configurations. Its easy-to-use features and extruder database make the preferred screw configuration software.
The best way to combat cost-quality pressures is to understand customer one’s process capability accordingly. Thus, STEER implements Six Sigma methodology with complete control over the entire process.
Culture of quality STEER follows the ISO 9001 quality system certified by Det Norske Veritas. The company is currently planning to deploy Total Productive Maintenance (TPM) within the organisation. With the advantage of sourcing from its own foundry, the products are traceable from the raw material stage. All products are inspected individually prior to dispatch. The elements are wrapped and packed in styrofoam or expanded polyethylene boxes and then placed in corrugated boxes to avoid damage during transportation. STEER uses an approach that fills the gap in the quality system documentation. It rewards team members for contributing to solutions and their implementation. Moreover, it looks at the quality system document as a living entity that needs to be constantly improved and rewritten through all continuous improvement projects or corrective actions to problems. This allows monitoring and auditing of the implementation. Padmanabhan says, “In a competitive global plastics industry, the best way to combat cost-quality pressures is to understand customer specifications and optimise one’s process capability accordingly. High product costs can often be attributed to rejection, rework and wastage. Thus, STEER implements Six Sigma
Dr Babu Padmanabhan Founder and Managing Director
methodology with complete control over the entire process.�
Future focus Driven by a passion to provide generation-next performance extruders for modern needs and challenges, STEER has steadily cultivated application efficiency and process capability through close synergy with market demands & requirements. This approach has earned it a coveted position in the plastics extrusion segment among the world’s established and emerging markets alike. With its headquarters in Bengaluru, STEER has expanded its products and services in the US, Japan, China, Europe and the Middle East. The company is currently working towards enhancing its expertise in hot-melt extrusion for pharma compounding applications by establishing an application development centre on the lines of its polymer diagnostic capabilities. Padmanabhan concludes, “We want to provide the industry with futuristic solutions to process the most complex, new-generation materials. Our latest innovation in this regard is to improve the extruder melt engine.� Email: annabel.dsouza@infomedia18.in June 2012 | Modern Plastics & Polymers 113
INSIGHT & OUTLOOK: Visual control methods in project management
Keeping an eye on project cost concerns The previous (April 2012) edition detailed the four-step QRST approach for management of project cost. This edition introduces the concept of Earned Value Management (EVM) and also investigates two methods – S Curve and Savoir faire 4D Project Management GridŠ – for addressing the project cost & schedule concerns.
114 Modern Plastics & Polymers | June 2012
Progress (%)
Jun-97 Jul-97
Apr-97 May-97
Feb-97 Mar-97
Dec-96 Jan-97
Months
Progress Curve
Pt
Pt
Pt
Jun-97 Jul-97
200 0
CT
Apr-97 May-97
BCWP
100 90 80 70 60 50 40 30 20 10 0
Cost Curve
Feb-97 Mar-97
BCWS
1200 1000 800 600 400
Months Trends summary & recommended action: t 1SPEVDUJWJUZ TFFNT UP CF MFTT UIBO UIF OPSNT PS SFTPVSDFT not being utilised properly t #PUI CVEHFU BOE TDIFEVMF OFFE UP CF SF FYBNJOFE intensive monitoring advised
Scenario 2: Behind schedule and cost over-run
Progress (%)
Scenario 1: Project is behind schedule (Pt vs P2), while cost is under control (Ct vs C2)
Dec-96 Jan-97
The S curve is a powerful visual control methodology for a project manager; however, with multiple projects handled simultaneously, it is difficult for a top manager to have a bird’s eye view of all projects. Similarly, in case of a large project with multiple Work Breakdown
Pt
Pt
Trends summary & recommended action: t 1PTTJCMF MBDL PG SFTPVSDFT PO TPNF DSJUJDBM XPSL GSPOUT leading to less progress then planned t "EWJDF JEFOUJGJDBUJPO BOE BVHNFOUBJPO PG SFRVJSFE SFPVSDFT
ACW
Project management with 4D PCM Grid
200 0
Progress Curve
Pt
Sep-96
BCWP
CT
Oct-96 Nov-96
ACWP
100 90 80 70 60 50 40 30 20 10 0
Cost Curve
Sep-96
Many natural processes, including those of complex system learning curves, exhibit a progression from a small beginning that accelerates and approaches a climax over time. In the absence of a detailed description, a sigmoid function is often used. An S curve is a sigmoid function, which is a mathematical process or function that results in an S-shaped curve also called a Sigmoid Curve. The S curve is used in project management to represent the following: Expenditures of resources over the estimated time of the project Real-time expenditure of resources Estimated progress of the project schedule
BCWS
1200 1000 800 600 400
Oct-96 Nov-96
Project management with S curve
Structure (WBS) elements handled at the same time, it becomes voluminous for the top manager to comprehend the total project. The 4D PCM Grid facilitates this. The x-axis of the Grid Costs in ` (Lakh)
I
n the previous article, the QRST method for addressing project cost concerns was explained. This article presents the concept and measures of Earned Value Management (EVM). Two methodologies – S curve and Savoir faire 4D Project Management GridŠ (4D PCM Grid) – are explained for tracking and addressing project cost & schedule concerns.
Actual progress of the project schedule The S curve is a tool for quantitative risk analysis in project management, for determining the possible risks of a given course of action in terms of cost and schedule variances. It is a handy visual control chart used for tracking cost over-runs and schedule lags. To explain this, four scenarios of possible cost and schedule variances related to a Jetty project are depicted here: Scenario 1: Project is behind schedule (Pt vs P2), while cost is under control (Ct vs C2) Scenario 2: Behind schedule and cost over-run Scenario 3: Ahead of schedule and cost under control Scenario 4: Ahead of schedule but cost over-run
Costs in ` (Lakh)
M Hariharan
Progress Curve
Pt
Jun-97 Jul-97
Apr-97 May-97
Feb-97 Mar-97
Pt
Months Trends summary & recommended action: t .PTU EFTJSBCMF TDFOBSJP t .BJOUBJO USFOET UP UIF FYUFOU QPTTJCMF
CT
Progress Curve
P1
Jun-97 Jul-97
Apr-97 May-97
Feb-97 Mar-97
PT
Dec-96 Jan-97
200 0
C1
Sep-96
BCWS
100 90 80 70 60 50 40 30 20 10 0
Cost Curve
Oct-96 Nov-96
BCWP
Costs in ` (Lakh)
ACWP
1200 1000 800 600 400
Progress (%)
Scenario 3: Ahead of schedule and cost under control
Months Trends summary & recommended action: t $SBTIJOH PG QSPKFDU MFBEJOH UP BWPJEBCMF DPTU PWFS SVOT t "EWJTF EF IJSJOH PG SFTPVSDFT BOE BWPJEBODF PG PWFSUJNF
Scenario 4: Ahead of schedule but cost over-run
represents cost performance and y-axis represents schedule performance. The Schedule Performance Index (SPI) and Cost Performance Index (CPI) related to multiple projects (eg, a multi-project company) and SPI & CPI of various WBS elements (eg, a large project company) are calculated. The CPI and SPI combinations are plotted on the Grid. Scenario 1 of S curve (behind schedule and cost under control) (SPI<1 & CPI>1) will be plotted in the Deploy quadrant of the 4D Grid. Any project in this grid triggers deployment of resources. Scenario 2 of S curve (behind schedule and cost over-run) (SPI<1 & CPI<1) will be plotted in the Danger Zone quadrant of the 4D Grid. Any project in this grid calls for close monitoring by senior management to bring it back on track. Scenario 3 of S curve (ahead of schedule and cost under control) (SPI>1 & CPI>1) will be plotted in the Defend quadrant of the 4D Grid. Any project in this grid is in a 116 Modern Plastics & Polymers | June 2012
Types of performance SPI > 1
Schedule performance
Pt
Dec-96 Jan-97
200 0
CT
Sep-96
ACWP
100 90 80 70 60 50 40 30 20 10 0
Cost Curve
Oct-96 Nov-96
BCWS
Costs in ` (Lakh)
BCWP
1200 1000 800 600 400
Progress (%)
Visual control methods in project management
Deliberate (Likely crashing happening; check for over deployment; cost engineer)
Danger Zone (Both cost and schedule are slipping; address immediately)
Defend (Sustain this as far as possible)
Deploy (Starving of resources; check for constraints)
SPI < 1 CPI > 1
CPI < 1
Cost performance Sarvoir faire 4D project management gridŠ
favourable state, and efforts should be made to ensure that it remains in this quadrant. Scenario 4 of S curve (ahead of schedule but cost over-run) (SPI>1 and CPI<1) will be plotted in the Deliberate quadrant of the 4D Grid. The management has to apply their judgement on these projects. For example, a Build-Operate-Transfer project or a project with incentives for early completion may be allowed to go in the same vein; alternatively, if the project has cost as a critical driving factor, then the project may be slowed down to reduce the cost to the budget level. The management has to deliberate on the possible actions. The 4D Grid gives a macro-perspective to the top manager. This is a power visual control mechanism for project management. This is not a replacement of the S curve, but works well in conjunction with the S curve. S curves for the Danger Zone and Deliberate projects will be the focus areas for the top management.
Expanding the learning curve Any tool is as good as the user and the context of usage. S curves gives a specific focus on an individual project or a WBS of a larger project, whereas the 4D Grid gives a macroperspective of all projects or all WBS elements of a larger project. These can be used in conjunction. These are not mutually exclusive methodologies, but related to visual control methods to provide both macro- and microperspectives.
M Hariharan practises consultancy in the field of cost management, lean thinking, constraint management, management control system and business excellence as Founder Director at Savoir Faire Management Services. Savoir Faire helps organisations to improve their profitability by aligning their people and processes to customer value and articulate the bottomline impact using the cost excellence (CEŠ) model. Email: hari@sfccostmanagement.com
POLICIES & REGULATIONS: RoHS and REACH
Keeping pace with global trade standards Globally, concerns about the nature of health and human impacts from certain substances are steadily rising, leading to stringent legislations in the form of RoHS and REACH that regulate international trade. Lionel Alva assesses the implications of these regulations on the plastics industry in India and their effect on international trade.
C
hemical restrictions exist across jurisdictions globally. The two most recognised regulations are Restriction of Hazardous Substances (RoHS) and Registration, Evaluation, and Authorization of Chemicals (REACH), which have emerged from the European Union (EU). Today, similar regulations have been adopted around the world, including Proposition 65 in California, China RoHS, Korea RoHS and J-MOSS in Japan. The EU directive with an emphasis
on sustainability measures worldwide has put forth certain restrictions in its latest legislation formulated in November 2011. As is apparent, new iterations of RoHS as well as REACH regulations brings up new challenges for plastics processors with a strong overseas market. Considering the volatile nature of the Rupee in the current turbulent economic conditions, it is rather crucial to understand the long-term implications that the legislations have brought forth on
economic opportunities for the plastics industry abroad. From a broader perspective, it will allow for greater insights into trends in the international market, thus facilitating the need to espouse a rigid long-term strategy for plastic products, keeping in view the concerns of overseas markets with regard to toxic hazards posed by certain chemicals. The major aims of REACH are to ensure safety of human health and the environment from the risks posed by chemicals, promotion of alternative test methods, free circulation of substances on the internal market and enhancing competitiveness & innovation. It helps by creating awareness in the industry, ensuring that the industry makes effort to assess and manage the risks posed by chemicals as well as provide appropriate safety information to the users.
Broadening the knowledge base Plastics is a diverse material and widely used in several industries and for various types of products; hence, it is affected by many regulations across the world. Four regulatory areas especially important to plastics processors include air quality, end-of-life waste, toxic substances and fire safety. From the proscribed chemicals that are most relevant to the plastics industry are lead, cadmium and Polybrominated Diphenyl Ether (PBDE). The major types of PBDE are octa-bromine, penta-bromine and deca-bromine. Currently, the first two are restricted by both EU and China 118 Modern Plastics & Polymers | June 2012
RoHS and REACH
The RoHS and REACH regulations have had little impact on the polymer fraternity at large, and currently, compliance is not much of a concern for exporters. A slight impact will be felt on the vinyl industry since the companies will have to use lead-free formulations. Harish Rai Managing Director, Raj Enterprises
RoHS directives. In order to comply with this legislation, plastics and other materials containing these substances must be replaced with alternatives that do not contain these chemicals. As of September 2005, deca-bromine was exempted from the EU RoHS restrictions, but the ruling is currently under review. RoHS sets maximum allowable concentrations for ‘homogeneous materials’ of 0.01 per cent for cadmium and 0.1 per cent for other substances. This definition can become complex when considering circuit boards and other electronic components. But plastics themselves are considered as homogenous materials. REACH and RoHS are separate directives with different timelines, but their effect on the selection and use of plastics is intertwined. A number of technologies are available to assist processors to produce parts that comply with the REACH and RoHS directives.
120 Modern Plastics & Polymers | June 2012
Colorants: GE and other companies have reformulated their resins to achieve high-chroma red, orange and yellow colours without heavy metals. Flame retardants: The RoHS directive restricts the use of materials containing PBDEs, with the exception of deca-bromine. In order to simplify recovery and recycling at end of life, many Original Equipment Manufacturers (OEMs) are consolidating materials and limiting choices to plastic products that meet the performance requirements of the application without using brominated or chlorinated flame retardants. GE Plastics offers a number of these, including various grades of Cycolon Polycarbonate/AcrylonitrileButadiene-Styrene (PC/ABS), Lexan PC, Ultem polyetherimide, Noryl Polyphenylene Oxide (PPO) alloys and other specialty compounds. Flexible vinyl: Flexible Polyvinyl Chloride (PVC) wire coatings have conventionally used lead-based heat stabilisers. Although lead-free PVC wire formulations are available today, many electronics companies are interested in other alternatives that are both lead-free and do not contain other halogens – such as chlorine – an integral component of PVC resin. The electronics market is key for plastics processors, which is developing faster than the legislation requires. For example, many electronics companies have decided voluntarily to reduce the use of halogen-containing plastics in their products. Both the EU and China RoHS-type directives exempt deca-bromine from their restrictions and neither addresse chlorine. Despite this, many electronics OEMs have publicly declared their intention to reduce or eliminate PVC and other halogen-containing materials, such as deca-bromine, as part of their corporate environmental vision and commitment. The most significant impact of RoHS and REACH will be on the
raw material suppliers in India. This will affect the product design and also carries implications for the product life cycle. It may even restrict the use of certain materials in applications, thus leading to export opportunities lost.
Impact on exports The impact of RoHS and REACH regulations can be mitigated to a great degree if the stipulations and framework as well as long-term trends pertaining to certain materials used are well understood. Thus, for fullcomponent manufacturers, the Research and Development (R&D) team must make efforts to ensure compliance with REACH & RoHS to ensure that export opportunities are not lost. “The RoHS and REACH regulations have had little impact on the polymer fraternity at large, and currently, compliance is not much of a concern for exporters. A slight impact will be felt on the vinyl industry since the companies will have to use lead-free formulations. However, due to persistent R&D endeavours, this challenge has been mostly overcome. India’s plastics industry will continue to grow and find opportunities amid the burgeoning polymers industry abroad,” avers Harish Rai, Managing Director, Raj Enterprises.
The game booster Today, environmental sustainability is one of the key concerns of international trade. Exporters as well as the plastics industry must endeavour to acquire a greater understanding of chemical restrictions such as RoHS and REACH, as well as implications of their larger framework. This will enable the Indian plastics industry to have a fruitful journey and tap the enormous international trade opportunities available. Moreover, it will prepare India to step on the world stage as a producer of quality and environmentally safe products, thus strengthening the faith that investors put into the Indian plastics industry. This could prove to be a game booster for the players in the Indian plastics industry. Email: lionel.alva@infomedia18.in
Why Subscribe? Be the first to get the latest news, views & reviews relevant to your Industry. Door delivery of copies. Never miss an issue. Easy payment options.
Years
(36 issues)
You Pay `. 1999/Get 44% dis c ount on Cover Price `. 3600/-
http://eshop.infomedia18.in
Year (12 issues) You Pay `. 799/Get 33% dis c ount on Cover Price `. 1200/-
SSSSS UUUUU BBBBB SSSSS C CCC C RRRIRR I IBII BBEBB EE EE
STRATEGY: Raw material cost stabilisation
The Indian polymer industry is highly dependent on imports, which has posed a serious challenge to the domestic plastics processing industry. Avani Jain highlights the reasons behind the heavy imports and strategies that can be adopted to generate higher domestic production and reduce raw material imports.
T
he plastics industry in India has made remarkable achievements since its inception, with the production of polystyrene about five decades ago. The industry is growing at the rate of 12-15 per cent per annum since the last few years. This shows that the demand for raw material is growing at the same rate. This, along with few other reason, have resulted in heavy reliance on imports. Rajiv Vastupal, Chairman & Managing Director, Atlantis Products Pvt Ltd, notes, â&#x20AC;&#x153;Of the total raw material consumed in the country, about 30 per cent is imported. A major reason for this is low availability of raw material when the processors need it. Another reason is huge price fluctuations in the domestic market. Hence, processors feel safe to import at a fixed price.â&#x20AC;? 122 Modern Plastics & Polymers | June 2012
Polymer imports status Since 2006-07, there has been a surge in imports, with Polyvinyl Chloride (PVC), Polypropylene (PP) and Polyethylene (PE) dominating the scene. Accelerated reduction in import tariff on polymers has been the major factor for the increase in imports, and this has posed as a severe challenge for the domestic players. Also, the final plastic product depends heavily on the quality of raw materials available with manufacturers. Indian quality standards are not on par with global standards; hence, the plastics processing companies have to import from cost-intensive countries such as Germany and other players in Europe. Price is also a factor that determines the growth of the polymer industry. While the Government is taking regular measures towards making things easier for the polymer industry, the fluctuating
crude oil prices have negatively impacted this sector. This can result in companies buying raw materials from outside the country at fixed prices. Another constraint for polymer manufacturers in India is the availability of land. Mostly, the expansion plans of a company are stalled due to lack of infrastructure and land. Further, acquiring land is often a cumbersome and expensive process in India. In such a scenario, European polymer suppliers stand to benefit as they operate on a much larger scale than their Indian counterparts.
Strategies for import reduction Numerous steps can be taken for reducing the imports and generating higher domestic production. Vastupal notes, â&#x20AC;&#x153;New petrochemical complexes should be set up and more benefits be given. New industrial belts should be allotted by the
Raw material cost stabilisation
New petrochemical complexes should be set belts should be allotted by the Government, providing land at lower rates and passing in terms of partial/full waiver by the ! Rajiv Vastupal Chairman & Managing Director, Atlantis Products Pvt Ltd Government, providing land at lower rates and passing more benefits in the initial stage, ie, in terms of partial/full waiver by the Government for a fixed period. Also, new technologies should be adopted to increase production.â&#x20AC;? The latest innovations in plastics processing help in better detection of the material according to specific requirements. These also helps in achieving increased customisation in the raw material production machinery. This, in turn, increases the domestic production, as processors can then obtain quality raw materials from local suppliers.
Capacity growth in India Over the years, the major polymer production capacities have emerged in Gujarat and Maharashtra. Most of the capacity additions through commissioning of new plants and debottlenecking of existing facilities in India have been done to meet the rising demand and facilitate exports & reduce imports. In recent years, India has exported significant amount of PP. Going forward, India can export more than a million tonne of PP in the international markets, which will account for over 10 per cent of global trade of PP.
Government hand-holding The latest technology in polymer processing methods needs to be supported well with adequate infrastructure. Manufacturers are willing to innovate and improve quality at par with international standards, but without adequate power and land availability, it is difficult to take expansion plans forward. Thus, the Government should come forward to increase domestic production in order to reduce the dependence on raw material imports. The imports are high at present, but the situation is likely to improve with adequate collaboration between industry and Government to boost domestic production. This would be directly beneficial for the industry and the economy at large. Email: avani.jain@infomedia18.in June 2012 | Modern Plastics & Polymers 125
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.
Engineering resins compounding plant Intercontinental Polymers Pvt Ltd
Project type New facility
Project news Indian-American joint venture compounder Intercontinental Polymers Pvt Ltd is building a 44.1-million pound-per-year engineering resins compounding plant in Gujarat, aimed at providing opportunities to switch traditional metal products to plastics. The new facility in Dahag, Gujarat, will be a tenfold increase in capacity for the company, which is a joint venture of Intercontinental Export Import Inc, in Columbia, Maryland, and Indian injection moulder, toolmaker and design house Jyoti Plastic Works Pvt Ltd. The Dahag plant will have four twin-screw extrusion lines, with the equipment likely coming from Western machinery suppliers because the company wants to be able to supply global firms.
Project location
1.1 Million Metric Tonne (MMT)/ year and ethylene at 400,000 MMT/ year, will be the largest olefins unit in India. Opal’s downstream units will be designed to produce 350,000 MMT/ year of PP using the Ineos process and 350,000 MMT/year of HDPE, using Mitsui process. Two LLDPE lines, each designed to produce 360,000 MMT/ year using Ineos process, are being built as part of the Dahej investment. Opal’s complex is being built in a Special Economic Zone (SEZ).
Project location Dahej, Gujarat
Project cost ` 12,440 crore
Implementation stage Planning Contact details: ONGC Petro additions Ltd 1st Floor, Omkara Building, Near Sai Chowkdi, Manjalpur, Vadodara - 390011, Gujarat Tel: 0265-6192600 Email: info@opalindia.in
Dahag, Gujarat
Project cost
Polyolefin
Not known
BCPL
Implementation stage
Project type
Planning
New facility
Project news Contact details: 101, Advent Atria, Chincholi Bunder Road, Malad (West), Mumbai - 400 064 Tel: 022-28886767/68 Fax: 022-28820629 Email: info@intelpolymer.com
Polyethylene Manufacturing Facility Opal
Project type New facility
Project news Opal, a joint venture by ONGC, GAIL and Gujarat State Petroleum, is expected to complete its project in Dahej by 2014. Opal’s cracker, with Propylene (PP) production capacity of
126 Modern Plastics & Polymers | June 2012
BCPL’s project to build a plant at Lepetkata in Assam has been delayed, resulting in soaring construction costs. BCPL is a joint venture between GAIL, Oil India, Numaligarh Refinery and the Government of Assam. GAIL holds a 70 per cent stake in the project, which includes plants with capacity of 220,000 Million Metric Tonne (MMT)/year of ethylene; 60,000 MMT/year of propylene; 220,000 MMT/year of PE; and 60,000 MMT/year of PP. Commissioning of the complex, which was approved in 2006, is expected by the end of 2013.
Project location Lepetkata, Assam
Project cost Approx $ 1.75 billion
Implementation stage Planning Contact details: GAIL (India) Ltd, B35 & 36, Sector -1, Noida - 201301, Uttar Pradesh Tel: 0120-2549261, 2549310, 2549155-6 Email: d.roy@gail.co.in
PTA-PET-PSF Indorama Ventures Public Co Ltd
Project type New facility Project news Indorama Ventures Public Co Ltd (IVL), Thailand’s largest polyester producer, has announced construction of a world-class, integrated facility in India containing Purified Terephthalic Acid (PTA), Polyethylene Terephthalate (PET) and Polyester Staple Fibre (PSF) plants fully integrated with a third-party paraxylene producer. A Memorandum of Understanding was signed with Indorama Synthetics (India) Ltd to enter into a joint venture for constructing and utilising the offtake of the plant. Indorama Ventures plans to backward integrate into the paraxylene facility of a third party in order to ensure a captive supply of its essential raw material while providing low cost access.
Project location India
Project cost $ 700 million
Implementation stage Proposed Contact details: Ms Rawissara Indorama Ventures PCL 75/102 Ocean Tower 2, 37th Floor, Sukhumvit Soi 19, Bangkok - 10110, Thailand Tel: +662-6616661 Fax: +662-6616664 Email: rawissara@indorama.net
EVENT LIST
National
Ahmedabad
Pune
Chennai
Ludhiana
Indore
Aurangabad
z > '<
Gujarat
]X "
Maharastra ^ ] "
Tamil Nadu ^ ] "
Punjab _ "] "
Madhya Pradesh `' ""]" "
Maharastra % [ "] "
Uttarakhand % [ ] "
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: Infomedia 18 Ltd, Infomedia 18 Ltd, Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028. " # %' ** # +' ; < = + > '"XY # Z [ \\\Y ;;] < Y +
Packplus South 2012 This will be an opportunity to focus on the emerging opportunities in the fast industrialising markets of South India. This event will emphasise on plastic packaging applications through the latest trends and technologies, especially by SMEs; July 6-9, 2012; at Hyderabad International Trade Exposition Centre (HITEX), Hyderabad For details contact: Prateek Kaushik Print Packaging Pvt Ltd E-6, 1st Floor Lajpat Nagar 2, New Delhi Tel: 011-2981 2833/2981 2934/2981 2834 Mob: 09313011029 Fax: 011-4172 2130 Email: info@packplus.in Website: www.print-packaging.com
India Chem 2012 As the Indian industry is soaring in terms of commodity plastics and engineering polymers, this event will focus on 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 128 Modern Plastics & Polymers | June 2012
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 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: 022-2496 8000, 2496 6633-39 Fax: 022-2496 6631/32 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
For details contact: Brijesh Purohit Saurashtra Plastic Manufacturers Association, â&#x20AC;&#x153;Laxmanâ&#x20AC;?, 3rd Floor Paramount Hall Bhutkhana Chowk Rajkot â&#x20AC;&#x201C; 360 002, Gujarat Mob: 09426249072 Tel: 0281-2228802 Fax: 0281-2223798 Email: spma@plasticmanufacturer.org Website: www.plasticmanufacturer.org
PlastAsia 2013 The fourth edition of this exhibition will be among the highly anticipated launch pad for the plastics industry, and will take off amid an era of renewed optimism in Asia. This is an excellent platform to build business alliances and increase channels to expand opportunities in the dynamically expanding plastics industry; February 15-18, 2013; at Palace Grounds, Bengaluru For details contact: Vilma Pereira No 25, 3rd Floor 8th Main Road Vasanthnagar Bengaluru â&#x20AC;&#x201C; 560 052 Tel: 080 4330401 Mob: 09480944213 Fax: 080 22352772 Email: info@plastasia2013.com Website: www.plastasia2013.com
EVENT LIST
International ArgenplĂĄs 2012 While focussing on the latest in plastics technology and value-added innovations, this event will serve myriad business interests through a highly qualified segmented audience of OEMs and distributors. It will be a good opportunity to ideate and network with the best minds in the regionâ&#x20AC;&#x2122;s polymer industry; June 18-22, 2012; at Centro Costa Salguero, Buenos Aires, Argentina For details contact: Emma Fiorentino Argentine Chamber of the Plastics Industry J Salguero 1939, Buenos Aires 1425 Argentina Tel: +54-11482 19603 Fax: +54-11482 65480 Email: info@emmafiorentino.com.ar Website: www.argenplas.com.ar
Specialty Plastic Films 2012 Over the past 26 years, this event has established a reputation for its ability to attract the biggest names in materials processing technology and equipment from around the world. This show will highlight the latest developments in this vital continually developing field; June 19-21, 2012; at Inter Continental, Dusseldorf, Germany For details contact: HIS Chemical Events D-81241 Munchen MCT Munich City Tower Munich â&#x20AC;&#x201C; 80339, Germany Tel: +44-01963 450771 Fax: +44-01963 453330 Email: marketing.deustch@ihs.com Website: www.ihs.com
JEC Composites Asia 2012 JEC is a composite industry organisation dedicated to developing products and services for the global composite industry. This conference will address the booming composites marketâ&#x20AC;&#x2122;s requirements of raw materials and automation solutions. It will be a meeting ground for the scientific
130 Modern Plastics & Polymers | June 2012
community and R&D professionals across Asia; June 26-28, 2012; at Suntec City, Singapore For details contact: Jun Wang 25 boulevard de lâ&#x20AC;&#x2122;Amiral Bruix Paris â&#x20AC;&#x201C; 75116, France Tel: +33-15836 1507, Fax: +33-15836 1519 Email: info@jeccomposites.com Website: www.jeccomposites.com
PLASTEX 2012 This is an important international trade fair dedicated to the plastic 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 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
FAKUMA 2012 This international trade fair for plastics processing is celebrating its 30th anniversary. It will demonstrate plastics advantages for conservation of resources, lightweight design engineering and energy efficiency. The exhibition will provide the industry with enormous opportunities for futuristic 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
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 & furute 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 Tel: +44-01939 250383 Fax: +44-01939 251118 Email: info@rapra.net Website: www.smithersrapra.com
Plast Eurasia 2012 This trade show plays an important part in the expansion of plastics industry to new markets and influences machinery and technology investments. This event will witness some leading innovations in precision plastics moulding and recycling; November 29 â&#x20AC;&#x201C; 2 December 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 +' < [ > ' < > ' > [{ < ] ;' Y } ' { ' > < sent the views of
EVENT REPORT: Chinaplas 2012
Saluting the surging demands of Asia The recently concluded 26th edition of Chinaplas has revealed unlimited opportunities for the plastics industry, particularly in India. However, it remains to be seen how the Indian Government leverages this opportunity to further advance economic avenues. A reportâ&#x20AC;Ś Arvind M Mehta
W
ith an aim to strengthen the booming plastics market in the AsiaPacific region and tap the unlimited opportunities in this industry, Chinaplas 2012 was recently concluded in Shanghai, and the event proved to be a far bigger show as compared to the previous one. In its 26th edition, the exhibition witnessed participation of 2,600 exhibitors from 35 countries in 17 halls and 13 country pavilions, and a visitor count of nearly one lakh. It highlighted the key factors spurring the growth of the plastics industry. The show had 11 theme zones â&#x20AC;&#x201C; Injection Moulding, Extrusion Machinery, Blow Moulding, Die and Mould, Auxiliary & Testing Equipment, Raw Material, Plastics Packaging and Other Machinery & Equipment. A Future Zone was also created in order to demonstrate some of the futuristic
applications that are beyond imagination. The Future Zone consisted of a Premium Design Gallery, which is responsible for collaborating with top universities and design institutes for facilitating technology exchange between industry and academia, thereby drive future growth in new areas such as energy saving and new automobile design.
Opportunities unlimited Today, China uses 50 million tonne of polymer per year and converts it into plastic products, which also includes reprocessed materials. The per capita consumption of polymers in China is about 36 kg as against 12 kg in India (8 kg of prime and 4 kg of reprocessed polymers). This is because companies in China are supported by a massive plastics machinery manufacturing industry. Their machines are economical, with complete lines ensuring faster delivery and well within the reach of processors in developing countries today. China
Glimpses of Chinaplas 2012
134 Modern Plastics & Polymers | June 2012
is one of the worldâ&#x20AC;&#x2122;s top exporters of plastics machinery, surpassing Germany and Italy. Although managed by private chief executive offiers, many industries are public limited companies supported by government financing, which are quite similar to Public Sector Units (PSUs) in India. The companies here have created competition among those in the US and are focussed on doing business.
The growth triggers Massive exhibition centres in China are triggering the development of its economy today. Shanghai Exhibition Centre, built with 60 per cent of the cost from Shanghai Centre, a Government body, and 40 per cent from German Companies such as Messe Dusseldorf is a brilliant example of collaboration, which was built in less than a year. Even this fell short of the requirements for Chinaplas 2012, necessitating the construction of hangars. There
Chinaplas 2012
Inaug
ura
f Ch tion o
inapla
2 s 201
is a growth of 30 per cent every year in the sales of exhibition space. Guangzhou and Beijing exhibition centres are also huge in size. More than 20 exhibitions across different industry sectors are held every year, triggering growth opportunities for all. Understanding the business growth created by exhibitions, the Government of China has begun to build exhibition centres in two-tier cities of China. The technology required for building exhibition centres in India is not difficult since the expertise is available for planning and execution of large projects involving applications of civil, mechanical, electrical & electronic engineering conform to global standards. The key is that the Indian Government must understand the important role played by exhibition centres for triggering the growth of the countryâ&#x20AC;&#x2122;s economy. This has the potential to boost the Gross Domestic Product (GDP) growth from its present level of 7 per cent to 12 per cent, provided that it is understood and implemented in the appropriate manner.
Welcoming India At Chinaplas 2012, Indian visitors and exhibitors were well received. Although the business is in favour of China, Indian players must also realise and exhibit their strengths. It was encouraging to see nearly 10 Indian companies exhibiting at the fair, of which at least five were small and medium enterprises (SMEs). The All India Plastics Manufacturers Association (AIPMA) had also hosted an elaborate dinner for a large group of Indian and Chinese delegates. The event was presided over by Neelkamal Darbari, Joint Secretary, Department of Chemicals & Petrochemicals; M A Zhanfeng, Secretary General, Chinese Plastics Processing Industry Association, who was also the Chief Special Guest; and Stanley Chu, Chairman, Adsales, Organiser of Chinaplas exhibition. The get-together was a grand success, boosting the morale of all Indian delegates. Arvind M Mehta is Chairman at Welset Plast Extrusions Pvt Ltd. He is also the Past President of All India Plastics Manufacturers Association (AIPMA), and Immediate Past President of Plastindia Foundation. Email: arvindmehta@welset.com
June 2012 | Modern Plastics & Polymers 135
EVENT REPORT: Plastivision Arabia 2012
Indian expertise, global opportunities As the curtains came down on the first edition of Plastivision Arabia, it served as the ideal platform that brought together the expertise of Indian plastics processors and burgeoning demand in the Middle East market. Besides the technology exhibited, Plastivision Arabia 2012 addressed some of the key concerns of the global plastics fraternity. A report… Annabel Dsouza
T
he Middle East is known to be the world’s most competitive petrochemical industry owing to its feedstock reserves and central proximity to developed markets. Plastivision Arabia played an important role in making this market more accessible to the Indian plastics industry. The recently concluded edition of Plastivision Arabia 2012 in Sharjah served as a premier sourcing and networking platform for the region’s fast-growing plastics industry. Reflecting the combined robustness of the plastics industry in India and the Middle East, Jayesh Rambhia, President – All India Plastics Manufacturers’ Association (AIPMA), and Co-organiser, Plastivision Arabia, commented, “Countries in this region are focussing on value addition, from oil economy to polymers and plastic products, and India is willing to support this transition with its industry – the manpower, machines and moulds. We see opportunity for the Middle East and India, where we can cooperate with and supplement each other.”
The four-day Plastivision Arabia witnessed more that 120 exhibitors and 6,000 visitors f rom Germany, Singapore, UK, Italy, Taiwan, China, Japan, Korea, Portugal, Turkey, Egypt, Russia and France. The resurgence in these fundamental growth drivers and the enthusiasm it has created in the industry were clearly evident at the launch of Plastivision Arabia, which was inaugurated by Sheikh Abdullah Bin Salim Bin Sultan Al Qassimi, Deputy Ruler of Sharjah; M K Lokesh, Indian Ambassador to UAE; Saif Mohammed Al Midfa, Director-General, Expo Centre Sharjah, among other dignitaries.
The India advantage As the Middle East invests in building a higher-value plastics sector, Indian entrepreneurs are playing a significant role in delivering higher return on investments, creating secondar y manufacturing industries and services, thereby throwing up a plethora of business opportunities for both countries. Nikhil Dhruva, President, Uniplas, said, “The emphasis on the upstream and downstream petrochemical sectors is a result of the regional governments’ focus
Sheikh Abdullah Bin Salim Bin Sultan Al Qassimi, Deputy Ruler of Sharjah, inaugurating Plastivision Arabia 2012 at Expo Centre Sharjah. To his right is M K Lokesh, Indian Ambassador to the UAE, and to his left is Saif Mohammed Al Midfa, Director General, Expo Centre Sharjah
136 Modern Plastics & Polymers | June 2012
on reducing their economic dependence on the production and export of crude oil & natural gas. The region’s strong basic petrochemical industry will continue to serve as a feedstock provider for the downstream industry.” Some of Indian multinationals at this show included STEER showcased its new line of compounding pelletising system dedicated to lean manufacturing, while Eco-Polymers introduced its range of degradable plastic additives. Gurucharan Industries launched a new high-output twin-die extrusion plant and Sparkonix India displayed its range of Electrical Discharge Machine (EDM) cutting solutions.
Futuristic solutions on display The biggest group participation at the show was an international technology centre organised by United Nations Industrial Development O rganiz ation – International Centre for the Advancement of Manufacturing Technology (UNIDO ICAMT). This centre demonstrated a comprehensive sourcing point for key segments such as plastics processing, injection moulding, thermoforming,
Guests exploring futuristic solutions at Plastivision Arabia 2012
Plastivision Arabia 2012
packaging, industrial users, construction, infrastructure, automobile and telecommunication. It also featured leading raw material suppliers, primary processing and auxiliary equipment suppliers from India and beyond. Some of the key attractions of the event were the Business Opportunity Pavilion, Expert Consultation Counter, Recruitment Counter and Green Pavilion. The event witnessed idea exchange presentations where a wide range of topics were presented, tailored specifically to the needs of Indian entrepreneurs. Some of the topics discussed were raw material supply chain, new trends and avenues in plastics applications, as well as issues like how to hedge & protect businesses from price fluctuations and become a productive & profitable processor. Ajay U Desai, Chairman, Plastivision Arabia 2012 opined, “Indian processing machinery suppliers are best placed to effectively tap into the fast-expanding plastics and petrochemicals sector in the UAE and neighbouring regions, owing to factors such as logistical advantage due to geographical proximity, excellent trade & cultural ties, and the unique demographic benefit of trading with a strong Indianorigin business community. Proximity of UAE to India will be a boon to the manufacturing sector of both regions. With just over three hours of flying time between Gulf countries and major cities of India, the cost of transportation and ease of travel for technicians to install and maintain machines is extremely cost-effective as compared to that in other any part of the world.”
Concurrent show While Plastivision Arabia 2012 featured leading raw material producers, primary processing and auxiliary equipment suppliers f rom around the world, ArabiaMold 2012, co-organised by DEMAT Fairs & Exhibitions-Germany, showcased moulding equipment and services such as mouldmaking tools, filtration instruments, welding equipment, cooling systems and other related industrial machines & accessories. ArabiaMold 2012 was held concurrent to Plastivision Arabia 2012 at Expo Centre Sharjah. The die and mould industry is one of the largest beneficiaries of industrial investments in the Middle East. UAE has raised the contribution of the industrial sector in the gross domestic product of the country from the current 14 per cent to 25per cent. Al Midfa said, “Plastivision Arabia 2012, together with ArabiaMold 2012, will enable global investors and manufacturers to effectively tap into the fast-expanding plastics and tooling industries in the UAE and surrounding regions. We have received encouraging response from the domestic industry and believe that the expanding economy and overall positive business climate have helped in generating considerable interest in the regional and global plastics industry.” Email: annabel.dsouza@infomedia18.in June 2012 | Modern Plastics & Polymers 137
EVENT REPORT: Die & Mould India 2012
India Inc embraces global tooling solutions As one of its kind in the country, Die & Mould India 2012 served as a platform for initiatives and opportunities to consolidate the future of the Indian tooling industry. Lionel Alva reports on the warm response generated by the 8th edition of the show and the active participation from the Indian manufacturing industry. Lionel Alva
I
n order to aid the progress as well as discuss the opportunities and challenges faced by the tooling industry, Die & Mould India 2012 was organised recently. The four-day Die & Mould India (DMI 2012) International Exhibition 2012 encouraged the growth prospects and highlighted the challenges prevailing in the surging tooling industry in India. Now in its 8th iteration, the DMI show was held at the Bombay Exhibition Centre, Mumbai, where participation was seen from both domestic and several key international players, thus depicting the industry’s growing prominence on the world stage. Spanning an area of 20,000 sq m, the exhibition witnessed active participation from several major players from the automotive,
medical equipment, aerospace and general engineering segments, highlighting the strategic importance of the tooling industry in India’s manufacturing scene. DMI 2012 was inaugrated by Dr Abhay Firodia, Chairman, Force Motors, and P G Deshmukh, Head, MiG Complex, Hindustan Aeronautics Ltd, Nashik. Dr Firodia said, “The best machine with weak tooling is not as good as a poor machine with excellent tooling. It is in this context that the effort to recognise and bring together various tooling solutions and players by the Tool & Gauge Manufacturers Association of India (TAGMA) is noteworthy. We must strive to get the best tooling solutions for further growth of the Indian manufacturing sector.”
Focus on technology As the global tooling industry focusses
(L-R) Dr Abhay Firodia , Chairman, Force Motors, and P G Deshmukh, Head, MiG Complex, Hindustan Aeronautics Ltd, Nashik, cutting the ribbon during the inaugration function
138 Modern Plastics & Polymers | June 2012
on new avenues for expansion and varied applications, Die & Mould India 2012 emphasised on modern manufacturing practices and the demands of high-end applications. “We are seeking greater participation from the private sector in areas as critical as control surfaces for aircraft and tooling,” said P G Deshmukh, MiG Complex, Hindustan Aeronautics Ltd (HAL), Nashik. He added that private players, both local and global, need to proactively assess the needs of the manufacturing sector and provide customised solutions for its growth. He highlighted the opportunities arising from the offset clause in the defence, and civilian aerospace segments may also open up major business for the tooling industry in India. Thus, the tooling suppliers need to stay updated with the latest innovations in the global tooling industry. In this regard, SC Kalyanpur, President, TAGMA, informed that the association is making efforts to widen the participation of the exhibitors. As the Indian tooling industry expands into novel applications, it has increased the emphasis on innovation and technology. DMI 2012 showcased the industry’s needs for low-volume, high-precision moulds rather than high-volume, low-precision moulds. With the growth of the automotive and aerospace sector, manufacturers & designers have realised the need for innovative tooling solutions. This is because the tooling business model has become multifaceted, and with a focus on diverse products & niche markets, it comes as an intrinsic need to adopt cutting-edge technologies. Huge investments are to be expected from Indian mould makers in CAD/CAM technology in the coming
Die & Mould India 2012
years. At present, it is important that Indian mould manufacturers develop designs that are more accurate and also increase profitability.
Event showcase One of the key attractions for the fourday exhibition was the opportunity to attend live demonstrations of tooling and metal-cutting technology for participants rendering an accurate simulation of factory or manufacturing conditions. This facilitated participants’ interaction with exhibitors in an effective manner. The event showcased products such as press tools, mould bases, standard parts, hot runner systems, heat treatment systems, texturing gauge, CAD/CAM, die spotting, machine tools and accessories, consumables for machine tools & moulds. The solutions were aimed at improving productivity and quality as well as reducing costs for customers. Nilesh Shah, Product Manager-Metal Cutting Machines, Electronica HiTech Machines Pvt Ltd, said, “We are satisfied with the way TAGMA has conducted the exhibition here. With this platform, our aim was to create business relationships here since our networking is already strong in India. DMI is an ideal platform for reaching new customers. It has helped us promote our brand image and build awareness regarding various possibilities for die & mould manufacturers like us, considering that manufacturers in this sector are constantly looking for new machining solutions.” It must be noted that the tooling industry has contributed a noteworthy
` 13,225 crore in 2010-11 to the Gross Domestic Product (GDP) and aided the manufacturing sectors in achieving consistent quality and productivity, thus contributing to the growth of the manufacturing sector. TAGMA has been striving to promote the tooling sector through DMI and other initiatives, which create opportunities for networking and awareness.
Tooling trends With the growing manufacturing sector and new application areas for moulds & dies, the Indian machine tools industry is manufacturing a range of metal-cutting and metal-forming tools. Customised in nature, Indian products comprise conventional machine tools as well as CNC machines. Moreover, Indian manufacturers offer other variants that espouse robotics, handling systems and operator-friendly machines. DMI 2012 highlighted the industry’s initiatives to improve features of CNC machines and provide further value additions at lower costs and meet specific end-user requirements. In keeping with the current trends and emerging demands, the CNC segment could be the growth driver for the machine tools industry in India. However, one must consider the increasing global competition, changing customer expectations and rapid model changes, which call for fast turnaround in manufacturing technology and their applications in mainstream operations. At present, Indian tool rooms are facing challenges such as shortage of capacities, which is met through imports by Original
Equipment Manufacturers (OEMs). This issue needs to be addressed through better liaisons and partnerships with OEMs, seeking their support in reinforcing their commitments to further enhance domestic production.
Future frontiers The Eleventh Five-Year plan estimates that the manufacturing sector will contribute more than 20 per cent to the national economy. This spells enormous opportunities for Indian tool rooms. The tooling demand in India is estimated to reach ` 23,620 crore by the end of 2015 and will witness a growth of 16 per cent over the next five years. Plastic mould and die-casting dies are expected to grow at a Compounded Annual Growth Rate (CAGR) of 17 per cent, whereas sheetmetal and forging dies anticipate a growth of 15 per cent CAGR. The advent of these opportunities puts the Indian industry in a favourable position, which can be leveraged to successfully harness the future potential. Being the flagship trade show for the tooling industry in India, DMI 2012 proved to be the ideal platform for industry professionals to connect, network and explore business prospects with leading players in the global market. June 2012 | Modern Plastics & Polymers 139
An invite that rewards as well...
Dear Reader, ‘Modern Plastics & Polymers’ solicits original, well-written, application-oriented, unpublished articles that reflect your valuable experience and expertise in the plastics & polymers industry. You can send us Technical Articles, Case Studies and Product Write-ups. The length of the article should not exceed 1500 words, while that of a product write-up should not exceed 100 words. The articles should preferably reach us in soft copy (either E-mail or a CD). The text should be in MS Word format and images in 300 DPI resolution & JPG format. The final decision regarding the selection and publication of the articles shall rest solely with ‘Modern Plastics & Polymers’. Authors whose articles are published will be sent a complimentary copy of that particular edition. Published by Infomedia 18 Ltd, ‘Modern Plastics & Polymers’ is one of the leading monthly magazines exclusively meant for producers and user fraternities of the plastics industry. Well supported by a national readership of over 80,000 and our strong network of 26 branch offices across India, this magazine reaches out to key decision makers among the Indian manufacturers of plastics products, machinery and allied sectors. Brought out in association with Hong Kong-based Ringier Trade Media Ltd (one of the world’s largest trade publishing houses with more than 200 special interest titles and offices in every major country), it ensures that advertisers are able to promote their products and services across the globe at no extra cost. So get going and rush your articles, write-ups, etc… Thanking you, Yours sincerely,
Manas R Bastia Senior Editor Infomedia 18 Limited ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W) Mumbai 400 028 India
D +91 22 3003 4669 T +91 22 3024 5000 F +91 22 3003 4499 E manas@infomedia18.in W www.infomedia18.in
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 Compact AC drives
Gravimetric auto-dosing and mixing system
The Vacon 10, available in the power range of 0.25-5.5 kW, has a re-designed user interface and more functionality. The Vacon 20, available from 0.25 to 18.5 kW, is a real workhorse that offers high performance and excellent tailorability. The Vacon 20 cold plate is available from 0.75 to 7.5 kW. It is designed to allow Original Equipment Manufacturers (OEMs) to create the optimum cooling solution for the drive. This series incorporates a built-in Programmable Logic Controller (PLC) functionality, which conforms to the IEC61131-3 standard.
This system measures precisely the powder resin, granule resin, masterbatch or additive in small amount to keep the product in the right colour with good quality. This also saves the energy, labour and material cost. To enter the required capacity per hour and the mixing percentage of each resin or masterbatch, the humanmachine interface system automatically calculates all required values. This is fit to mix for many materials, masterbatch and additives and applies to extruder, injection, blowing moulding machine, wire, brown bags & plastic woven bag manufacturers.
Vacon Drives & Controls Pvt Ltd Chennai - Tamil Nadu Tel: 044 - 24490024 Email: vacon.india@vacon.com Website: www.vacon.com
PVC wire and cable coating plants MERWC series PVC wire and cable coating units comprise one single-screw extruder fit with screw/barrel set, heaters, motor, crosshead & die-unit; one pay-off stand for conductor feed into extruder; one water cooling tank, Capstan type/ Caterpiller type take-off unit, Spool Winder with torque motor drive and control panel for complete machine. In operation, the bare conductor is fed into extruder. The machine is currently manufactured in screw sizes of 40 mm, 45 mm, 50 mm, 65 mm and 75 mm, with corresponding capacities of 8 mm, 13 mm, 15 mm, 30 mm, 50 mm and 65 mm being the maximum diameter of PVC. Malik Engineers Dist Thane - Maharashtra Tel: 0250 - 2390839 Email: info@malikengg.com Website: www.malikengg.com 142 Modern Plastics & Polymers | June 2012
Yann Bang Electrical Machinery Co Ltd Taichung - Taiwan Tel: 86-4-22716999 Email: yb@yannbang.com Website: www.yannbang.com
Cast PE breathable film line This breathable film is designed for baby diaper and mask. It is used as a unique ventilating outer cover with micro pores. It helps prevent stuffiness and rashes, & offers better air circulation. It also keeps baby's skin dry, comfortable and healthy. This machine uses a 2.6-m wide auto flat T-die from Extrusion Dies Industries (EDI) or Cloeren Co with an auto-thickness gauging system from NDC, USA. It is designed to be completely automatic and easy in operation. Chi Chang Machinery Enterprise Co Ltd Tainan - Taiwan Tel: 886-6-2612121 Email: Chichang2012@extrusion.com.tw Website: www.extrusion.com.tw
PRODUCT S
PP non-woven spunbond line The Texti-eLP series of PP non-woven spunbond lines offer various customised sizes in the range of 1.6-3.2 m fabric width with 12-150 GSM. This is differentiated by its enhanced spinning system, which includes optimised air process supply, optimised stretching and optimised lay down. Improved barrier property due to composite spunbond lines produce sandwich layer of improved spunlaid as support layer for melt blown layer. Elpie Engineers Pvt Ltd Rajkot – Gujarat Mob: 9712973716 Email: jjaghera@elpie.in
Portable water chillers The air- and water-cooled portable water chillers are ideal for cooling. The SIC-A & SIC-W series are equipped with compressor and pump overload protector, phase shortage and reversal alarm, anti-freezing thermostat, pressure gauge, etc. This is worked on the basic principle of heat exchange & is applicable to the industry that requires flow of
precisely controlled chilled water. The air-cooled portable water chillers use atmospheric air to cool the refrigerant. The water-cooled portable water chillers use water to cool the refrigerant. Shini Plastics Technologies (India) Pvt Ltd Dist Thane – Maharashtra Tel: 0250 - 3021132 Email:info@shiniindia.com Website: www.shini.com
Screw elements Steer’s Dynamic-Stir (DSE) screw elements are a new grooved mixing element multiple-geometry in a short length for twin-screw extrusion. The uniqueness is achieved through the speed-controlled dynamic stirring action designed to deliver effective and efficient homogenisation in the melting and metering zones. Steer Engineering Pvt Ltd Bengaluru – Karnataka Tel: 080-23723309 Email: info@steerworld.com Website: www.epz.steerworld.com
June 2012 | Modern Plastics & Polymers 143
PRODUCT S
PE stretch film blown film machine This machine is used for producing PE stretch film & PE cling film. It supplies the PIB injection system to inject liquid adhesive into the screw to mix resin in order to produce stretch film. The stickiness can be adjusted, thus saving resin cost. The machine is equipped with â&#x20AC;&#x2DC;edge film re-feed systemâ&#x20AC;&#x2122;; the edge of film can be fed to extruder. It can produce 10 rolls of film with width of 300 mm or 6 rolls of film with width of 500 mm at one time.
Essen offers placemats, drawer mats, shower curtains, print-laminated table mats, foamed PS take-away food containers, stationery sheets, signage board sheets, etc, processing various polymers to the tune of 3,500 TPA, with the major polymer being EVA. Various EVA grades with 8-28 per cent VA content are processed. Sheets are produced with thickness in the range of 0.05-2.8 mm. Also offered are polystyrene foam disposable products. Essen Speciality Films Pvt Ltd Rajkot - Gujarat Tel: 02827-252021 Email: info@essenspeciality.com Website: www.essenspeciality.com
Plastic injection moulding machine Chyi Yang Industrial Co Ltd Taoyuan County - Taiwan Tel: 886-3-3288686 Email: cymw@cymw.com.tw Website: www.cymw.com.tw
Single screw extruder These series of singlescrew extruder is used for producing EPE foam products from lowdensity polyethylene plastic material. The products produced from this machine include low-density foam packaging sheet, foam tube, rod, profile and also netting. These products are widely used in packaging of fragile and delicate items, cold insulation, etc. The machine is provided with accurate electronic controllers and circuits for precise control of the process parameters. EPE sheet can be produced in standard width of 1 metre and thickness 1-5 mm. Foam pipe and rod can be produced from 4-50 mm diameter. Malik Engineers Dist Thane - Maharashtra Tel: 0250 - 2390839 Email: info@malikengg.com Website: www.malikengg.com
Polymer products
This injection moulding machine provides complete plastics processing solutions. The machine is used to mould plastics into the desired shape. It is designed as per the current technical developments and is quality tested. The plastic injection moulding machine comes with an autocentralised lubrication system and a motorised mould height adjustment. Sarada Machinery Company Hyderabad - Andhra Pradesh Tel: 040-23076557, Mob: 09849546022 Email: info@saradamachinery.com Website: www.saradamachinery.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 its 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
144 Modern Plastics & Polymers | June 2012
PRODUCT S
GRP pipes These are manufactured by filament winding process with efficient engineering techniques. Standards followed are IS:12709-1994 for potable water application, IS:14402 sewerage water application and also followed by design standard AWWA-M45. The pipes are tested by efficient testing methods followed by specific standards. GRP pipes are technically advanced for all sewer application with continued benefits. EPP Composites Pvt Ltd Rajkot - Gujarat Tel: 02827-287059 Email: marketing@epp.co.in Website: www.atikagroup.com
Multilayer plants The KET multilayer plants are designed to give uniform or flat films at low power consumptions and are suited for high-end applications. These plants are available for film widths up to 2,500 mm and come in standard or with an internal bubble cooling system. Shrink films are made either of LDPE or a blend of LDPE/LLDPE and PVC. Kabra Extrusiontechnik Ltd Mumbai - Maharashtra Tel: 022-26734822 Email: sales@kolsitegroup.com Website: www.kolsite.com
Gravimetric additive feeders TrueFeed gravimetric feeders are simple to install and use, extremely accurate and economical. These colour and additive feeders deliver accurate feeding rates on the basis of continuous loss-in-weight metering technology with closed-loop control of the feeding speed. These can be used in injection moulding, extrusion and blow moulding processes. All operate with the same bilingual, user-friendly control. Nu Vu Conair Pvt Ltd Ahmedabad - Gujarat Mob: 09377483203 / 09376783206 Email: salesindia@conairgroup.com Website: www.conairgroup.com June 2012 | Modern Plastics & Polymers 145
PRODUCT S
Vacuum thermoforming lines These high-speed PSP vacuum thermoforming and tr imming machines are used for foam and unfoamed products. The machines allow users to run different materials such as PS, HIPS, PP, PVC, APET, OPS, PE and PLA, with thickness in the range of 2-3 mm for foam sheet and 0.2-2 mm for unfoamed sheet. These machines are equipped with fully automatic controllable touch system. Oshonic Enterprise Ahmedabad - Gujarat Tel: 09427143762 Email: oshonic.enterprise@gmail.com
Extrusion lamination machine Lamistar extrusion lamination machine is available in width from 1,000 mm to 6,000 mm. This machine has high production capacity and high line speeds of more than 200 metre per minute for LDPE/
PP lamination on woven sacks, PP non-woven fabrics, sandwich lamination of BOPP, paper, polyester, jumbo bags & FIBC fabrics, knitted bags, aluminium foil, jute, tarpaulins and many other customised applications. Gujarat Machinery Pvt Ltd Ahmedabad - Gujarat Tel: 079-29295988 Email: growth@gujaratmachinery.com Website: www.gujaratmachinery.com
Drying and conveying system Nomad series portable drying and conveying systems are mounted on a single, easy-to-position, portable cart. The Nomad PD integrates WD series dryer, while the Nomad II utilises the AD desiccant dryer. The Nomad II is available in four basic configurations with a process airflow from 25-100 m続/hr, and is compatible with 25-255 litre drying hoppers. ACS Auxiliaries India Pvt Ltd Pune - Maharashtra Tel: 020-40147575 Mob: 09371154045 Email: njain@corpemail.com
June 2012 | Modern Plastics & Polymers 147
PRODUCT S
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
Extrusion tape stretching plant The fully inverter duty extrusion tape stretching plant has high production capacity up to 900 kg/hr for PP/HDPE. The plant is developed for producing PP/HDPE tapes for many applications, such as woven sack bags for cement, fertiliser, sugar, wheat, rice, raffia tapes, FIBC/jumbo bags, carpet backing, tarpaulins, knitted bags, wrapping fabrics and many other customised applications. Gujarat Machinery Pvt Ltd Ahmedabad - Gujarat Tel: 079-29295988 Email: growth@gujaratmachinery.com Website: www.gujaratmachinery.com
Engineering thermoplastics Anulon-114 is a versatile engineering thermoplastics processed into machinable rods. The mechanical components machined out of the Anulon-114 rods are gear wheels, gear racks, sprockets, bearing bushes, feed screws, slipper pads, sliding bars, pulleys, castors, etc. Due to low co-efficient of friction against ferrous and non-ferrous metals, Anulon-114 bushes, gears, sprockets and bearings give trouble-free service with minimum maintenance and even without external lubrication. Plastic Abhiyanta Kolkata - West Bengal Tel: 033-2236 5371 Email: anulon@cal2.vsnl.net.in Website: www.plasticabhiyanta.com 150 Modern Plastics & Polymers | June 2012
PRODUCT S
Plastic tool pockets The plastic tool pockets are used for holding tools of different tapers such as BT30, 40 and 50. These ensure a systematic and vertical storage of tool holders for optimum performance and also help in easy identification of tools. The tool pockets can be mounted easily on any type of metal or wooden trolley with the help of Allen bolts. Kumbhojkar Plastics Pune - Maharashtra Tel: 020-24450055 Email: kpss@plamoulds.com Website: www.plamoulds.com
Reclosable packing products A series of flexible reclosable packing products and solutions are offered that are tailor-made as per customersâ&#x20AC;&#x2122; requirements. The product range consists of PP & PE ziplock bags, PP & PE zipper profiles, PP & PE slider bags and biodegradable ziplock bags. These products are manufactured from advanced polyolefin/ specialty polymers. SVP Packing Industry Pvt Ltd Mumbai - Maharashtra Tel: 022-24945116 Email: info@svpmagicseal.com
Compress moulding press machine Bekelite or rubber fully automatic compress moulding press machine is manufactured using high quality raw material. This is equipped with buzzer system for saving time. The machine is fully hydraulic and electronic controlled and consumes less power. This is a two-in-one machine as its motor automatically turns on and off while heating processing time. Amrut Brothers Ahmedabad - Gujarat Tel: 079-22928163 Mob: 09824093682 Email: exports@amrutbrothers.com Website: www.amrutbrothers.com June 2012 | Modern Plastics & Polymers 151
PRODUCT S
Additive masterbatches Various types of additive masterbatches having desired properties to end users are offered. The additive masterbatch range includes UV stabiliser, anti-static, conductive, slip, anti-block, Polymer Processing Aid (PPA), dessicant, flameretardant, purging compound, antimicrobial, antioxidants and foaming agents. Blend Colours Pvt Ltd Hyderabad - Andhra Pradesh Tel: 040-243614999 Email: xyz@blendcolours.com Website: www.blendcolours.com
PVC clear colour films The PVC clear colour films are offered in thickness ranging from 50 micron to 100 micron. These films are available in various colours such as blue, green, orange, red and yellow. The PVC clear colour films find applications in Polaroid glasses, 3D glasses, top covers for halogen lights, etc.
152 Modern Plastics & Polymers | June 2012
All India Plastics Mumbai - Maharashtra Tel: 022-23428096 Email: kompak@bom8.vsnl.net.in Website: www.allindiaplastics.com
Plastic hose nipples The new range of plastic hose nipples is appreciated for its dimensional accuracy and its lowcost design. It gives good appearance with some distinguished features such as durability, a friction-free design, corrosion resistance, leak proof and better linear flow of water in suction lines. These hose nipples have a wide application in various fields like agricultural, engineering and industries. The hose nipples give good crimping of rubber pipe due to the dotted special design finesse. Arti Products Rajkot - Gujarat Tel: 0281-2388908 Mob: 09428155144 Email: arti_product@sify.com Website: www.artiproducts.in
PRODUCT S
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
Plastics injection moulding machine The range of plastics 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 plastics injection moulding machine is available in
June 2012 | Modern Plastics & Polymers 153
PRODUCT S
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 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 perfect substitute for aluminium cans. Cost-effective, lightweight and durable 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
Twin-screw extruder The MEGA series co-rotating twinscrew extruder offers complete interchangeability of parts and high levels of compatibility with other extruder lines. This extruder features cycloidal spline profile with shafts, which are proof tested at 125 per cent rated torque. The MEGA series extruder is available in laboratory, pilot-plant and production models in various sizes, capable of output in excess of several thousand kilogram per hour. Steer Engineering Pvt Ltd Bengaluru - Karnataka Tel: 080-23723309 Email: info@steerworld.com Website: www.steerworld.com
Torque rheometer The Brabender Plastograph EC plus is an economical tabletop version of the universal torque rheometer Plasti-Corder Lab-Station for application investigations or processing tasks in laboratories and simulation. With its digital 3.8 kW motor, a torque measuring range of 200 Nm 154 Modern Plastics & Polymers | June 2012
PRODUCT S
and a speed range of 0.2-150 per min, the Plastograph EC plus is the drive for practice-oriented measurements. Brabender GmbH & Co KG Duisburg - Germany Tel: +49-203-77880 Email: plastics-sales@brabender.com Website: www.brabender.com
Screw compressor Model CLD 15 screw compressor forms part of the established CL series range of screw compressors. The CL series is a popular choice with the smaller compressed air users such as workshops and garages where these small and quiet compressors are the ideal solution. Three new models are introduced that extend the power band on this range up to 15 kW. Boge Kompressoren Chennai - Tamil Nadu Tel: 044-43009610 Email: s.sriram@boge.com Website: www.boge.in
Plastic raw materials These are BioAdd range of biodegradable additives. Heat, oxygen and sunlight are used to cause degradation benefits. Flameretardant masterbatches are used for engineering and commodity plastics. Also offered are colour masterbatches 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
EPS cup making machine This machine ensures a highvolume production since it comprises a highly efficient pneumatic control. Equipped with 16-cavity moulds, it is designed to run at an optimised cycle time and comparatively offers a 60 per cent higher production rate. This
June 2012 | Modern Plastics & Polymers 155
PRODUCT S
machine is used for making drinking cups for hot and cold drinks and ice-cream cups. Besides, even disposable trays, plates, containers, etc, can easily be made by changing the mould. Neejtech India Ahmedabad - Gujarat Tel: 079-26561312, Mob: 09825040231 Email: info@neejtech.com Website: www.neejtech.com
Flat surface finish brushes These flat surface finish brushes are used for smooth and resplendent metal surfaces. The brushes are used in stainless steel fabrication industries. Valgro-Fynex metal surface finishing system is the most versatile solution for all applications where a linear scratch pattern is required. These ensure reduction in costs and find use in various mediums like stainless steel, aluminium, brass, copper and alloys. These systems consist of combi and plain brushes. Valgro Engineers Pvt Ltd Ahmedabad - Gujarat Tel: 079-22972603, Mob: 09374083443 Email: arvindpatel@valgroabrasives.com Website: www.valgroabrasives.com
Injection moulding machine This rubber injection moulding machine is ideal for moulding precision parts with accurate process control and high productivity. The VE series is a state-of-the-art vertical hydraulic PLC-controlled 4-post rubber screw injection moulding machine designed to maximise the accuracy of the shot size. The VEC series is a 25- and 50-tonne screw injection moulding machine designed with a C-frame type clamp for unobstructed loading of inserts or extrusions and ease of removing moulded parts. J R D Rubber & Plastic Technology Pvt Ltd New Delhi Tel: 011-27128281 Mob: 09810121208 Email: jrdrp@vsnl.com Website: www.jrdrubber.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 Â&#x2021;7HFKQRORJLHVÂ&#x2021;2SSRUWXQLWLHV
156 Modern Plastics & Polymers | June 2012
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
Acoustic enclosure .....................................................51 Additive masterbatch ..................................................... 152 Air audit blower ............................................................... 50 Air bubble sheet plant.................................................... 133 Air chiller ......................................................................... 27 Air-conditioner parts.................................................... FGF Air-cooled chiller ............................................................. 51 Air-cooled die face pelletiser............................................ 32 Aluminium extrusion ..................................................... 150 Ammonia liquid chiller .................................................... 79 ASTM plumbing pipe ................................................... 153 Auto dosing and mixing system..................................... 145 Auto vacuum loader ....................................................... 145 Automatic material handling system ............................... 32 Automation ..................................................................... 71 Automation panel........................................................... 106 Automation system ........................................................ 132 Automotion controller.................................................... 157 Baking system .......................................................... 143 Barrel .............................................................................. 164 Barrel screw ...................................................................... 29 Bed knive........................................................................ 121 Bi-axial plant .................................................................. 159 Biodegradable additive ............................................... 23, 34 Blender ............................................................................. 19 Blending unit ............................................................... FGF Blow moulding machine ................................. 20, 154, BIC Blower series .................................................................. 132 Blown film extrusion line .............................................BGF Bottle testing equipment .................................................. 81 Brine chiller...................................................................... 51 Bulk milk cooler ............................................................... 79 Butterfly valve .................................................................. 79 CAM follower.......................................................... 156 Cartridge heater ............................................................. 156 CASI .............................................................................. 119 Cast film line.................................................................. 133 Cast PE breathable film line.......................................... 142 Centre seal.......................................................................... 5 Central material conveying system ................................ 145 Centre/surface slitter ........................................................ 86 Chiller .................................................................... 117, 147 Chucks ................................................................... 129, 146 Circular weaving loom ................................................... 141 Circular weaving machine ................................................ 14 Clean room application .................................................... 17 Cleaning oven ................................................................ 164 Cluster facia ................................................................. FGF CNC machine .................................................................. 69 CNC vertical machining centre ....................................... 49 Co-extruded sheets and telecom cables ........................... 87 Cold room ...................................................................... 147 Colour mark sensor ........................................................ 106 Colour masterbatch .......................................................... 15 Colouring extrusion plant .............................................. 159 Compact AC drive ......................................................... 142 Compact chiller ........................................................ 27, 163 Compounding extrusion................................................. 159 Compounding mixer ...................................................... 159 Compress moulding press machine ............................... 151 Compressed air dryer ..................................................... 107 Compression moulding hydraulic press ......................... 154 Compressor ...................................................................... 50 Condensing unit............................................................. 147 Conical twin-screw extruder ................................ 16, 25, 32
Product
Pg No
Connector..................................................................... FGF Continuous screen changer ............................................ 164 Control panel ......................................................... 147, 154 Control system ............................................................... 106 Controller ........................................................................... 6 Convertor ....................................................................... 154 Conveying system............................................................. 71 Corrugated plastic pipe extrusion machinery .................. 59 Corrugator ........................................................................ 59 CPVC pipe................................................................. 10, 21 Crane control system ..................................................... 106 Crusher ........................................................................... 145 Crystalliser...................................................................... 107 Customised development scanner ...................................... 6 Cutting and stitching machine ........................................ 14 Dairy machinery ........................................................79 Data logger ......................................................................... 6 Datalogging software ..................................................... 154 Dehumidified air dryer .................... 27, 67, 145, 163, FGF Die changing system ........................................................ 33 Die face cutter ................................................................ 121 Die plates ....................................................................... 121 Digital panel meter .......................................................... 12 Digital temperature controller.......................................... 83 Doctoring and inspection machine ................................. 86 Door trim system ......................................................... FGF Dosing and blending equipment...................................... 71 Dosing and mixing system ............................................. 132 Double column vertical machining centre ....................... 69 Double-shaft gearbox ....................................................... 60 Drives ....................................................................... 83, 157 Dry vacuum pump ......................................................... 150 Dry vane pump ................................................................ 51 Dry-break coupling .......................................................... 50 Drying and conveying system ........................................ 147 Drying and dehumidfying system.................................. 132 Drying system .......................................................... 71, 143 Dual channel with modbus .............................................. 83 Dyestuff .......................................................................... 131 Dynamic controller .......................................................... 83 Ejector.......................................................................50 Elastomer refinery/petrochemical system ..................... 119 Electric injection moulding machine gearbox............ 7, 153 Electrical conduit ........................................................... 153 Electrical panel ............................................................... 106 Element shrink disc ....................................................... 156 Engineering plastic material .......................................... 150 Engineering thermoplastic ............................................. 150 EPS cup-making machine ............................................. 155 Evaporating unit ............................................................ 147 Expandable shaft .................................................... 129, 146 Exposing tube......................................................... 129, 146 Extruder .................................................................... 35, 73 Extruder screw ............................................................... 121 Extrusion coating lamination plant.......................... 133, 63 Extrusion coating lines ................................................... 14 Extrusion lamination machine ................................. 63, 147 Extrusion plant.............................................................BGF Extrusion tape stretching machine .......................... 63, 150 Feed roll .................................................................. 121 Feeding and conveying system ............................... 107, 132 Ferrous casting machine ................................................. 150 Film cutter ...................................................................... 121 Flame retardant masterbatch ......................................... 101 Flat surface finish brushes.............................................. 156
Product
Pg No
Fluorescent ..................................................................... 131 Forged component ......................................................... 150 Freewheel one-way clutches ........................................... 156 Fueling system .................................................................. 50 Fully automatic strapping plant ..................................... 133 Gear ..........................................................................60 Gear motor ....................................................................... 89 Gear pump ..................................................................... 164 Gearbox ............................................................................ 60 Granulating and recycling system .................................. 132 Granulator ........................................................ 27, 107, 163 Granulator blades ........................................................... 121 Gravimetric additive feeder ............................................ 145 Gravimetric auto-dosing and mixing system ................. 142 Gravimetric blender ............................................... 151, 163 Grinder ............................................................................. 27 GRP pipe ....................................................................... 145 HDPE..................................................................... 153 Head and tail lamp ...................................................... FGF Heart valve frame................................................. 74, 75, 99 Heat transfer roll ............................................................ 164 Heater cooler mixer.......................................................... 32 Heating and cooling system ..................................... 71, 132 Heating solution............................................................. 143 Helical speed reducer ....................................................... 60 High cavitation ................................................................ 17 High-performance screw................................................ 164 High-speed mixer ...................................................... 35, 73 high-speed precise injection moulding machine ............ 149 HM/ HDPE/ LDPE/ LLDPE..................................... 133 HMI ............................................................................... 157 Hopper dryer ............................................................ 27, 145 Hopper loader .......................................................... 27, 163 Hot air dryer ...................................................FGF, 67, 163 Hot runner system ......................................................... 132 Hot runner temperature controller ................................ 106 Hydraulic injection moulding machine.......................... 149 Hydraulic power packs and automatic voltage stabiliser . 33 Hydraullic press ................................................................ 32 IML techniqe ............................................................17 Inductin motor ............................................................... 157 Industrial chilling equipment ......................................... 147 Infrared heater ............................................................... 106 Injection blow moulding machine ................................... 33 Injection moulding machine ................................................. FGF, BFG, 31, 52, 88, 115, 127, 149, 154, 156 Inline drip irrigation plant ............................................... 61 Inline drip tubing ....................................................... 10, 21 In-mould labeling system............................................... 149 Insert moulding machine ........................................ 20, BIC Instrumentation and control system .............................. 106 Jumbo bag dumping station ........................................32 Jumbo bag manufacturing machine ................................. 63 Jumbo blown film plant ................................................. 141 Keyless transmisson element .................................... 156 Knobs and switches ...................................................... FGF Lab extruder ..............................................................32 Lab mixer ......................................................................... 32 Lamination plant .......................................................... 141 Large flow water heater ................................................. 132 Liquifier............................................................................ 51 Loading arms ................................................................... 50 Machined components ............................................. 150 Manual and hydraulic screen changer ............................ 164 Masterbatch.............................................................. 87, 119
FGF - Front Gate Fold, FIC - Front Inside Cover, BIC - Back Inside Cover, BGF - Back Gate Fold, BC - Back Cover
158 Modern Plastics & Polymers | June 2012
LIST OF PRODUCT S
Product
Pg No
Masterbatch feeder ....................................................... 145 Masterbatch mixer ........................................................... 32 Material dryer .................................................................. 19 Material storage sytem ................................................... 163 Material testing instrument ............................................. 81 Medical mould ................................................................. 17 Melt pressure transducer ................................................ 106 MFRS of injection moulding machine.................. 20, BIC Micro fine pulverising system ........................................ 159 Mono- and multi-layer sheet line .................................... 14 Monoblock high-vacuum pump .................................... 150 Monofilament line ........................................................... 14 Monofilament plant ...................................................... 141 Monolayer blown film ................................................ 10, 21 Monolayer blown film line...........................................BGF Mould ......................................................................... 35, 73 Mould protection system paint shop ............................... 33 Mould temperature controller ............................ 27, 67, 163 Moulding system .............................................................. 17 Multi-component mould.................................................. 17 Multilayer blown film ................................................ 10, 21 Multilayer blown film line .....................................14, BGF Multilayer blown film plant ........................................... 133 Multi-layer cast film line ................................................. 14 Multilayer co-extrusion sheet line.................................... 18 Multilayer plant .............................................................. 145 Napkin dies ............................................................. 121 Neat resin ....................................................................... 131 Non-ferrous casting machine ......................................... 150 Oil chiller ..................................................................51 Oil cooler ....................................................................... 117 Oil seal high-vacuum pump........................................... 150 Optic sheet extrusion line ................................................ 18 Panel cooler ............................................................. 117 Paper chemicals .............................................................. 131 Paper lamination plant ................................................... 141 Paperless recorder ............................................................. 12 Parallel and right angle axes gearbox ................................. 7 Parallel shaft helical gearbox ............................................ 60 Paramic band heater....................................................... 156 PE stretch film blown film machine.............................. 144 Pelletiser ........................................................... 32, 121, 164 Pelletiser parts ................................................................ 121 PET bottle testing equipment ......................................... 81 PET box strapping plant ............................................... 133 PET perform dedicated machine..................................... 55 PET sheet extrusion line ................................................. 18 PET/PE washing line ...................................................... 14 Pharmaceuticals and cosmetics ...................................... 119 PID controller ................................................................ 154 PID temperature controller................................................ 6 Planetary gearbox ............................................................. 60 plastic auxiliary equipment ............................................... 33 Plastic compounds.......................................................... 119 Plastic conveyor belt......................................................... 35 Plastic hose nipples ........................................................ 152 Plastic injection moulding machine ................. 42, 144, 153 Plastic masterbatch................................. 105, 125, 135, 137 Plastic milk can .............................................................. 154 Plastic moulding machine ...................................... 119, 154 Plastic processing machine ....................................... 14, 152 Plastic processing machinery ancillaries and spares ......... 29 Plastic raw material ........................................................ 155 Plastic sheet extrusion line ......................................... 18, 63 Plastic textile and machinery ......................................... 155 Plastic tool pocket .......................................................... 151 Plate heat exchanger ........................................................ 79 PLC ................................................................................ 83 PLC and Control ............................................................. 33 PLS and HMI based project ............................................. 6 Plug valve ......................................................................... 79 Pneumatic valve................................................................ 79 Polymer conveyer belt ...................................................... 27 Polymer products............................................................ 144 Polyolefin pipe............................................................ 10, 21 Portable water chiller ..................................................... 143 Pouch maker....................................................................... 5 Power distrubution system ............................................... 37 Power management software............................................ 37
Product
Pg No
PP mineral-filled compound .......................................... 101 PP non-woven spunbond line ........................................ 143 PP TQ Plant .................................................................. 133 PP woven sack manufacturing machine .......................... 63 PP/HDPE semi-automatic strapping plant .................. 133 PP/HDPE rafffia tape line ............................................ 133 PP-R pipe .................................................................. 10, 21 Precision moulding system ........................................... FGF Precision temperature control ........................................ 154 Preform injection moulding machine ............................ 149 Primary slitter rewinder ................................................... 86 Priming valves .................................................................. 50 Printing and cutting machine ......................................... 14 Process controller ..................................................... 12, 154 Process indicator ................................................................ 6 Process tank...................................................................... 79 Product assemblies ......................................................... 150 Profile controller............................................................... 83 Programmable counter and timer ...................................... 6 Pulveriser .................................................................... 35, 73 Pulveriser disc ................................................................ 121 Pump .................................................................. 51, 50, 150 PVC................................................................................ 119 PVC clear colour films ................................................... 152 PVC compound ............................................................... 87 PVC foam core pipe .................................................. 10, 21 PVC kisan pipe plant ..................................................... 141 PVC mixer cooler....................................................... 10, 21 PVC palletising line ................................................... 10, 21 PVC pipe.................................................................... 10, 21 PVC profile line .......................................................... 10,21 PVC wire and cable coating plant ................................. 142 Quick change sleeves ........................................129, 146 Rail tanker.................................................................79 Reclosable packing products .......................................... 151 Recycling line ................................................................... 14 Recycling machine ........................................................... 71 Refrigerant pump ............................................................. 79 Refrigeration system ........................................................ 79 Reprocessing plant ......................................................... 141 Resin dehumidifier ......................................................... 107 Rigid PVC...................................................................... 153 Robot system ............................................................ 27, 115 Rock-n-roll machine .................................................. 35, 73 Roots blower .................................................................... 51 Rotary automatic hot colour marking machine ............... 70 Rotary cutter .................................................................. 121 Rotary dies ..................................................................... 121 Rotary pump .................................................................. 150 Rotational mould ........................................................... 159 Rotational moulding machine ........................................ 159 Rotogravure printing press ............................................... 86 Rotomoulding machine .............................. 35, 73, 144, 159 Round table carrousel....................................................... 35 RTD ............................................................................... 154 Rubber roller .......................................................... 129, 146 Safety access equipment .............................................50 Sandwich BOPP lamination machine ............................. 63 Screw commpressor .................................................. 79, 155 Screw element ................................................................ 143 Screws............................................................................... 29 Seals................................................................................ 153 Secondary slitter rewinder................................................ 86 Sensor ............................................................................. 106 Servo drives .................................................................... 106 Servo energy-saving machine........................................... 55 Servo motor.................................................................... 157 Shaft mounted speed reducer........................................... 60 Shut off nozzels ............................................................. 164 Shuttle rotomoulding machine ...................................... 159 Shuttle series plant ......................................................... 159 Side weld bag maker .......................................................... 5 Single bag feeding system ................................................ 32 Single mill pulveriser.................................................. 35, 73 Single-screw extruder ............................................... 32, 144 Single-screw extruder gearbox ........................................... 7 Single-screw extruder plant........................................ 16, 25 Single-shaft extruder gearbox .......................................... 60 Software ........................................................................ 107
Product
Pg No
Solid granulator .............................................................. 159 Solid state relay .............................................................. 154 Sprocket............................................................................ 60 Stack moulds .................................................................... 17 Storage tank equipment ................................................... 50 Stretch blow moulding machine ............................. 20, BIC Switching devices ........................................................... 106 SWR pipes and fittings.................................................. 153 System solution .............................................................. 132 Tank truck equipment................................................50 Tanks and silos ................................................................. 79 Tape stretching line ........................................................ 14 Tarpaulin manufacturing machine ................................... 63 Technical moulds ............................................................. 17 Temperature controller ....................................... 12, 83, 154 Tensioner nut ................................................................. 156 Testing instrument ........................................................... 81 Thermocouple ................................................................ 154 Thermoformers ............................................................BGF Thermoforming ............................................................BGF Thermoforming and PS foam......................................BGF Thermoforming machine ............................................... 152 Thermoplastic alloy ........................................................ 131 Thermoplastic compound .............................................. 131 Thermoplastic polyurethane............................................. 47 Thermoset products ....................................................... 119 Thin film dryer .............................................................. 153 Thyristorised power controller ....................................... 154 Torque rheometer ........................................................... 154 TPE/TPU compound .................................................... 101 TPU masterbatches .......................................................... 15 Track roller ..................................................................... 156 Trade show organiser ......................................................... 8 Transmission and PTOS.................................................. 50 Tubular heater ................................................................ 156 Turned components........................................................ 150 Twin-mill pulveriser ................................................... 35, 73 Twin-roll mill ................................................................... 32 Twin-screw co-rotating extruder .......................... 74, 75, 99 Twin-screw element ............................................. 74, 75, 99 Twin-screw extruder..................................... 74, 75, 99, 154 Twin-screw extruder gearbox ..................................... 7, 153 Twin-screw extrusion line .......................................... 25, 16 Two-colour cane plant ................................................... 141 Two-layer blown film ................................................. 10, 21 Ultrasonic flow meter .................................................12 Underwater pelletiser ....................................................... 32 Universal bag maker ........................................................... 5 Universal controller .......................................................... 83 Universal input temperature scanner ............................. 154 Universal masterbatch .................................................... 101 UPS .................................................................................. 37 UV and PU masterbatch ................................................ 101 Vacuum booster pump ................................................51 Vacuum dryer ................................................................... 67 Vacuum forming machine ............................................BGF Vacuum loader .............................................................. FGF Vacuum pump ................................................................ 150 Vacuum pumps and systems ............................................ 50 Vacuum system ................................................................. 51 Vacuum thermoforming line .......................................... 147 Variable displacement pump energy-saving machine ...... 55 Vertical injection moulding machine ............................... 33 Vertical machining centre .......................................69 , 149 Vertical sachet packing machine ........................................ 5 Vibratory screening system ............................................ 159 Vibroscreen................................................................. 35, 73 Volumetric dosing unit................................................... 107 Water chiller ............................................................ 107 Water jetting system ........................................................ 50 Water-cooled chiller ......................................................... 51 Winder ........................................................................... 141 Wire EDM ...................................................................... 49 Worm reducer .................................................................. 60 Worm reducer gearbox ..................................................... 60 Woven sack manufacturing plant ..................................... 63 Wovensack tape plant ................................................... 141 Wrinkle remover .............................................. 34, 129, 146
FGF - Front Gate Fold, FIC - Front Inside Cover, BIC - Back Inside Cover, BGF - Back Gate Fold, BC - Back Cover
160 Modern Plastics & Polymers | June 2012
LIST OF ADVERTISERS Advertiser’s Name & Contact Details
Pg No
Adinath Controls Pvt Ltd ............................. 154 T: +91-2764-286573 E: info@adinathcontrols.com W: www.adinathcontrols.com Adroit Control Engineers ............................. 106 T: +91-011 47600700 E: sales@adroitcontrol.com W: www.adroitcontrol.com Aerodry Plastics Automation Pvt Ltd..............71 T: 120 4766777 E: info@aerodry.com W: www.aerodry.com Aeromec Marketing Co Pvt Ltd ......................70 T: +91-250-2454915E: hvt@aeromec.in W: www.aeromec.in Alok Masterbatches Ltd .................................15 T: +91-011-41612244 E: sales@alokindustries.com W: www.alokmasterbatches.com Arctic India Sales ......................................... 151 T: +91-011-23906777 E: bryairmarketing@pahwa.com W: www.bryair.com Ash Win Engineers ...................................... 159 T: +91-79-22811879 E: info@ashwinengineersindia.com W: www.ashwinengineersindia.com Ask Me ........................................................ 148 T: +91-3555 5555 E: twitter.com/AskMe_35555555 W: www.facebook.com/AskMe.infomedia18 Bharat Bijlee Ltd .......................................... 157 T: +91-22-2430 6237 E: vishwajyoti.vengurlekar@bharatbijlee.com W: www.bharatbijlee.com Blend Colours Pvt Ltd ................................. 101 T: +91-40-2436 1499 / 2436 0887 E: info@blendcolours.com W: www.blendcolours.com Boge Compressed Air System ........................34 T: +91-44-4300 9610 E: s.sriram@boge.comW: www.boge.in Bombay Hydraulic India ............................... 153 T: +91-161-2494216 E: bombayhydraulic@yahoo.co.in W: W: www.info@bombayhydraulic.com Bonfiglioli Transmissions (Pvt) Ltd ................23 T: +91-44-43009610 E: sales.buins@bonfiglioli.com W: www.bonfiglioli.com Disha Machinery and Projects Pvt Ltd ............33 T: 91-11-45635747 E: director@dishatech.co.in W: www.dmppl.co.in Eaton Power Quality Pvt Ltd..........................37 T: +91-011- 42232329 E: eatonpowerqualityindia@eaton.com W: www.eaton.com/powerquality/india Electronica Plastic Machiners Ltd .................52 T: +91-22-32531959 E: vkt@electronicapmd.com Our consistent advertisers
Advertiser’s Name & Contact Details
Pg No
Heaters and Controllers................................ 156 T: +91-044-22501713 E: sales@elmecheaters.com W: www.elmecheaters.com Elpie Engineers Pvt Ltd ............................... 152 T: +91-2827-294522 E: jjahera@elpie.in W: www.elpie.in Eng Expo ..................................................... 146 T: +91-09819552270 E: engexpo@infomedia18.in W: www.engg-expo.com Essential Power Transmission Pvt Ltd.............89 T: +91-022-28488742 E: jshah@esenpro.com W: www.esenpro.com Everest Blowers ..............................................51 T: +91-11-45457777 E: info@everestblowers.com W: www.everestblowers.com Ferromatik Milacron India Pvt Ltd .................27 T: +91-79-25890081 E: salesfmi@milacron.com W: www.milacronindia.com Flu Tech ...................................................... 154 T: +91-79-40084051 E: flutech@yahoo.com W: www.flutechindia.com Freeze Tech Equipments Pvt Ltd .................. 117 T: +91-44-42152387 E: info@freezetechequip.com W: www.freezetechequip.com Gardner Denver Engineered Pro. (I) ...............50 T: +91-79-40089312 E: info.ahm@gardnerdenver.com W: www.gardnerdenver.com Glaves Corporation ...................................... 121 T: +91-141-2460324, +91-9983330808 E: sales@glaves.biz, axj@glaves.biz W: W: www.glaves.biz Gujarat Machinery Pvt Ltd.............................63 T: +91-79-29295988 E: growth@gujaratmachinery.com W: www.gujaratmachinery.com Heattrans Equipments Pvt.Ltd. .................... 150 T: +91-79-25840105 E: info@heattrans.com W: www.heattrans.com Hinds Machineries .........................................42 T: +91-0124-4368305 E: hinds@rediffmail.com W: www.hindsmachine.com Hindustan Plastic and Machine Corporation ..16 T: +91-011-25473361 E: poonam@hindustanplastics.com W: www.hindustanplastics.com Hindustan Plastic and Machine Corporation ..25 T: +91-011-25473361 E: poonam@hindustanplastics.com W: www.hindustanplastics.com Huarong Plastic Machinery Co Ltd .............. 149 T: +91-9825739634 E: j.v.papaiyawala@huarong.com.tw W: www.huarong.com.tw
Advertiser’s Name & Contact Details
Pg No
Husky Injection Molding Systems Pvt Ltd ..BGF T: +91-22-25706316 E: snair@husky.ca W: www.husky.ca IC ICE Make Refrigeration Pvt Ltd ............. 147 T: +91-79-65426394 E: info@icemakeindia.com W: www.icemakeindia.com IDMC Limited ..............................................79 T: +91-2692-225399 E: idmc@idmc.coop W: www.idmc.coop Ingeco Gears Pvt Ltd......................................60 T: +91-2717-651551 E: info@ingecogears.com W: www.ingecogears.com J P Extrusiontech Limited ..............................14 T: +91-2646-222163 E: info@jpextrusiontech.com W: www.jpextrusiontech.com Joyam Engineers & Consultants Pvt Ltd....... 150 T: +91-79-26569533 E: joyam@joyamvactech.com W: www.joyamvactech.com Jyoti CNC Automation Pvt. Ltd......................69 T: +91-’011-47262000 E: info@jyoti.co.in W: www.jyoti.co.in Kabra Extrusion Technik Ltd..........................10 T: +91-22-2673 4822 E: sunil@kolsitegroup.com W: www.kolsite.com Kabra Extrusion Technik Ltd..........................21 T: +91-22-2673 4822 E: sunil@kolsitegroup.com W: www.kolsite.com Kody Equipments Pvt Ltd ..............................86 T: +91-79-65131345 E: export@kody.co.in W: www.kody.co.in Kody Rube Tech Pvt Ltd .............................. 129 T: +91-9825005991 E: subhash@kody.co.in W: www.kody.co.in Konark Plastomech Pvt Ltd .......................... 133 T: +91-79-22891670 E: sales@konarkplastomech.com W: www.konarkplastomech.com K-Tron Process Group ...................................85 T: (856) 589-0500 W: www.ktron.com L&T Plastics Machinery Ltd...................... FGF T: +91-44-26812000 E: handigolg@larsentoubro.com W: www.larsentoubro.com Larsen & Toubro Ltd .....................................43 T: +1-22-6752 5656 E: ss-ccd@lth.ltindia.com W: www.larsentoubro.com Litel Infrared Systems Pvt Ltd ...................... 143 T: +91-020-66300639 E: nmshah@litelir.com W: www.litelir.com Lohia Starlinger Ltd. .................................... 155 T: +91-011-30641770 E: prom.lsl@lohiagroup.com W: www.lohiagroup.com
COC - Cover on Cover, FGF - Front Gate Fold, FIC - Front Inside Cover, BIC - Back Inside Cover, BC - Back Cover
June 2012 | Modern Plastics & Polymers 161
LIST OF ADVERTISERS Advertiser’s Name & Contact Details
Pg No
Advertiser’s Name & Contact Details
Loxim Industries Limited ............................. 131 T: +91-2717-308000 E: info@loxim.com W: www.loxim.com Lubrizol Advanced Materials India Pvt Ltd ....47 T: +91-22-66027800 E: Estane-SA@lubrizol.com W: www.estane.com Mamta Machinery Pvt Ltd ...............................5 T: +91-79-66309800 E: sales@mamata.com W: www.mamata.com Matsui Technologies India Ltd. ......................67 T: +91-’0120-4243862 E: rahuldeep@mass.motherson.com: Mifa Systems..................................................83 T: +91-79-2687082 5E: info@mifasystems.com W: www.mifasystems.com Mold - Masters Technologies Pvt Ltd ........... 109 T: +91-422-4502171 E: mmiplinfo@moldmasters.com W: www.moldmasters.com Mona Chem Additives Pvt Ltd ..................... 119 T: +91-261-2894847 E: sales@monachem.com W: www.monachem.com N.A. Corporation ...........................................73 T: +91-79-25840374 E: info@naroto.com W: www.naroto.com Neejtech India ( Braun) ..................................17 T: +91-79-26561312 E: info@neejtech.com W: www.neejtech.com Neejtech India (Niigata) .................................31 T: +91-9909974224 E: contact@niigataindia.com W: www.niigataindia.com Neoplast Engineering Pvt Ltd ........................32 T: +91-79-25830602 E: info@neoplastindia.com W: www.neoplastindia.com NMTG Mechtrans Techniques Pvt Ltd. ....... 156 T: +91-79-22821527 E: nmtg@nmtgindia.com W: www.nmtgindia.com Nu-Vu Conair Pvt Ltd .................................. 163 T: +91-9376783206 E: salesindia@conairgroup.com W: www.conairgroup.com Piovan India Pvt Ltd .................................... 107 T: +91-22-28560450 E: amit.bajaj@piovnindia.com W: www.piovan.com Poly Mechplast Machines Ltd.........................20 T: +91-265-2631211 E: goldcoin@polymechplast.com W: www.polymachplast.com Polyplastics Marketing (India) Pvt Ltd.........BIC T: +91-22-67587668 E: tushar.birje@polyplastics.com W: www.polyplastics.com Our consistent advertisers
Pg No
Prasad Koch Technik Pvt. Ltd.........................35 T: +91-79-25830112 E: plastics@prasadgroup.com W: www.prasadgroup.com Prayag Polytech Pvt Ltd ............................... 105 T: +91-011-47262000 E: delhi@prayagmb.com W: www.prayagmb.com Prayag Polytech Pvt Ltd ............................... 125 T: +91-011-47262000 E: delhi@prayagmb.com W: www.prayagmb.com Prayag Polytech Pvt Ltd ............................... 135 T: +91-’011-47262000 E: delhi@prayagmb.com W: www.prayagmb.com Prayag Polytech Pvt Ltd ............................... 137 T: +91-011-47262000 E: delhi@prayagmb.com W: www.prayagmb.com Presto Stantest Pvt Ltd ...................................81 T: +91-0129-4085000 E: gaurav@prestogroup.com W: www.prestogroup.com Procon Technologies Pvt Ltd ..........................12 T: +91-79-27492566 E: info@procon.co.in W: www.procon.co.in R R Plast Extrusions Pvt Ltd ..........................18 T: +91-22-42461500 E: marketing@rrplast.com W: W: www.rrplast.com Radiant Controls and Automation Pvt .............6 T: +91-79-30126483 E: sales@radiantcontrols.in W: www.radiantcontrols.in Rajoo Engineers Ltd..................................... BC T: +91-2827-252701 E: kcdoshi@rajoo.com W: www.rajoo.com Remica Platics Machinery Manufactur ......... 141 T: +91-79-25712741 E: remicaplastic@dataone.in W: www.remicaplastics.com Reynold India Pvt Ltd ....................................53 T: +91-0120-4664000 E: v.bali@reynoldindia.com W: www.reynoldindia.com S&T Engineers ............................................ 49 T: +91-422-2590810 E: stycm@stengineers.com W: www.stengineers.com Sacmi Engineering India Pvt Ltd ................. 127 T: +91-7600003968 E: sales@negribossi.in W: www.negribossi.com Sanity International .......................................29 T: +91-79-65227458 E: info@sanityindia.com W: www.sanityindia.com SCJ Plastics Ltd .............................................87 T: +91-011-25439950 E: vball@scjgroup.net W: www.scjindia.com
Advertiser’s Name & Contact Details
Pg No
Seal Jet Seals ................................................ 153 T: +91-020-27121581 E: vswasu@satyam.net.in W: www.sealjetseals.com Shini Plastics Technologies I Pvt Ltd............ 132 T: +91-250-3021166 E: jnbhat@shiniindia.com W: www.shini.com Sri Sai Plasto Tech .........................................55 T: +91-44-42994365 E: sspt_plastics@live.in W: W: www.srisaiplastotech.com Steer Engineering Pvt Ltd ..............................99 T: +91-80-23723309 E: info@steerworld.com W: www.steerworld.com Streer Engineering ....................................74, 75 86+91-80-23723309 E: info@steerworld.com W: www.steerworld.com Suresh Engineering Works .............................61 T: +91-79-22821527 E: suresen@aittelmail.in W: www.sureshengg.com Taiwan External Trade Development Council (TAITRA)........................................................8 T: 886-2-2725-5200 E: taitra@taitra.org.tw W: www.taitra.org.tw Toshiba machine (india) pvt. Ltd.....................88 T: +91-011-43291111 E: dineshelija@toshiba-machine.co.in W: www.toshiba-machine.co.jp Unicor Gmbh .................................................59 T: 49-9521-956-196 E: nbendel@unicor.com W: www.unicor.com Unimark (Arburg) ........................................ 115 T: +91-11-45457777 E: infomum@unimark.in W: www.unimark.in Unimark ( Maguire) ........................................19 T: +91-22-25506712 E: infomum@unimark.in W: www.unimark.in Venna Pipes & Fittings Pvt Ltd .................... 153 T: +91-8308807829 E: venna201@gmail.com: Wittmann Battenfeld India Pvt Ltd ............. FIC T: +91-44-42077009 E: info@wittman-group.in W: info@wittman-group.in Xaloy Asia (Thailand) Ltd. ........................... 164 T: +91-79-40327380 E: m.sanghvi@th.xaloy.com W: www.xaloy.com Yann Bang Electrical Machinery Co.,Ltd. ..... 145 T: 886-4-2271-6999 E: yb@yannbang.com W: www.yannbang.com Zambello Riduttori Group ...............................7 T: 39-0331-307-616 E: info@zambello.it W: www.zambello.it
COC - Cover on Cover, FGF - Front Gate Fold, FIC - Front Inside Cover, BIC - Back Inside Cover, BC - Back Cover
162 Modern Plastics & Polymers | June 2012
Modern Plastics & Polymers
June 2012
Modern Plastics & Polymers
June 2012
Reg No: MH/MR/WEST/234/2012-2014 RNI No: MAHENG / 2008 / 25265 Licence to Post at Mumbai Patrika Channel Sorting OfďŹ ce, Mumbai GPO., Mumbai 400 001. Date Of Posting 1st & 2nd Of Every Month / English & Monthly. Date Of Publication: 28th Of Every Month.
168