Modern Plastics & Polymers - March 2012 by Infomedia18

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EDITORIAL

Sustaining to succeed

he curtains came down on the largest plastics and rubber exhibition in the country after a hectic 6-day schedule amid a confluence of more than 1,800 exhibitors and nearly 100,000 trade visitors. Plastindia, perhaps set the tone of infinite opportunities for the industry for 2012 and how.

In a nutshell, apart from adding to its international stature, this edition of Plastindia clearly emerged as an oasis in the desert, especially for the overseas exhibitors and visitors, given the cloud of uncertainties over Europe’s business climate. At the same time, one should also note this mega show’s outstanding role in bringing together the domestic industry’s demand and supply sides ranging from raw material producers and equipment manufacturers to plastics processors. That said, if one were to wonder about any missing aspects in this show, focussing on maybe a few operational areas that need a little more fine-tuning, will take this jewel of India one step closer to the top of its international league. Hopefully, these will get sorted sooner than later well before the next edition. Moving on, the crystal clarity of sustainable solutions is ascertained. These will continue to drive the future of business in many sectors including plastics and polymers. With growing consumer awareness and forward-looking environmental regulations, sustainability is not a trendy word in companies’ annual reports any more. In fact, it has become a strategic imperative for future business success.

Editorial Advisory Board A E Ladhabhoy Plastics Technologist

Dr Sushil K Verma Former Director General, CIPET

Dr Swapan K Dhara

When it comes to plastics, sustainability gets a tad more complex in the technical sense. Hence, it was apt and timely to see the international conference on the sidelines of Plastindia 2012 focussing on this vital aspect. With diverse perspectives within and outside the industry on sustainability and given India’s rapid requirement of this wonder material to meet the needs of a fast-rising economy, there has to be a clear & comprehensive roadmap to tackle this critical challenge. This is where the dedicated session on plastics recycling and sustainability holds plenty of promises in demystifying most of the misgivings that still remain. Of course, our endeavour shall continue to bring you more analytical insights on this in the ensuing editions as the industry slowly but steadily graduates towards a sustainable tomorrow. Stay tuned.

Regional Technical Head, Basell Polyolefins India Pvt Ltd

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

March 2012 | Modern Plastics & Polymers

CONTENT S

53 Ancillary equipment ........................... 54

Precision tooling.............. 40

Special Focus

Function focus ................................ 56 Chiller technology .......................... 58

Tool design ...................... 42 Quality assessment .......... 46 Interface - Ajay Verma.... 48

Insight & Outlook

Interface - Varun Kapoor ............... 62 Roundtable ..................................... 64 Polyamide alloy .............................. 66 Mould cavity .................................. 70

February 2012 | Modern Plastics & Polymers

Post Plastindia 2012 Automation Trends

Extrusion insights: Propelling growth through process integration

Energy Management

Heat recovery system: Harvesting energy, expanding margins

Policies & Regulations

Plastics recycling: Mechanisms for safer plastics disposal

Strategy

Compression moulding: Cost reduction through innovative concepts

Tips & Tricks

In Conversation With

S V Kabra, Founder, Kolsite Group of Companies

Bright Autoplast Ltd: Shifting gears towards ‘bright’ opportunities

Ancillary equipment management: Measures to ensure smooth operations

Event Preview

Indian Medical Devices & Plastics Disposables Industry 2012: Infusing vigour to healthcare industry

Event Report

Plastindia 2012: Investing in the India advantage

Highlights of Next Edition Special Focus: Injection Moulding Insight & Outlook: Engineering Plastics

REGU L AR SEC T I ON S Editorial ............................... 11

Event List............................. 92

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

Book Review ........................ 98

Technology & Innovation .... 30

Products.............................. 100

Technology Transfer ............. 32

List of Products.................. 118

Projects ................................. 90

List of Advertisers .............. 122

Facility Visit

Cover photo (Coordinate Measuring Machine): Carl Zeiss India Photography: Mexy Xavier Note: ` stands for Indian rupee, $ stands for US dollar and £ stands for UK pound, unless mentioned otherwise

March 2012 | Modern Plastics & Polymers

Business Insights •Technologies•Opportunities

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March 2012 | Modern Plastics & Polymers

NEWS, VIEWS & ANALYSIS

LANXESS begins high-tech plastics production at Jhagadia To serve the growing markets of India as well as Asia, LANXESS continues to expand its production site at Jhagadia (Gujarat). The specialty chemicals group has invested nearly ` 490 crore and created about 300 new jobs at the site. The Semi-Crystalline Products (SCP) business unit of LANXESS has started production of its flagship high-tech

Production begins with the symbolic press of a button (L-R) Dr Stassburger; Dr Michael Zobel, Head, SCP Business Unit; Dr Leopold-Theodor Heldman, General Konsul of Germany in India; Dr Breuers; and Dr Dattaprasad Talekar, Site Head, Jhagadia

Advanced dry-air generators introduced by Motan Colortronic Motan-Colortronic Plastics Machinery (India) Pvt Ltd has introduced an extended range of ‘LUXOR A’ dry-air generators, which are available in sizes of 80, 120 and 160 m³/hr. Earlier, the company had dryair generators in the range of 250-2400 m³/hr. With these additions, the range now includes 10 models suited for centralised drying of all types of plastic granulates, particularly of highend materials and engineering plastics in frequently changing batch sizes. “Interactive menu navigation is available via the clearly arranged TFT touchscreen colour monitor, considerably easing operation. Users are able to select all essential parameters for their chosen material from a pre-loaded databank. In addition, in-house formulae can be stored in a separate 20

plastics brands Durethan (polyamide) and Pocan (polybutylene terephthalate) at the new plant in Jhagadia. These products represent lighter-weight plastic alternatives to metals and enable carmakers & car parts suppliers to realise considerable savings by providing less costly production methods and easier assembly. These are used by leading car manufacturers including Tata Motors, Volkswagen and Ford. This underlines LANXESS’ commitment to the Indian subcontinent. In the words of Dr Axel C Heitmann, Chairman, Board of Management, LANXESS, “By concentrating many of our assets in Jhagadia, we are creating a specialty chemicals hub catering to the booming local market and the Asia region, and there is potentially further room for expansion at the site.” Added Dr Werner Breuers, Board Member, LANXESS, “Amid

databank,” informed Srikanth Padmanabhan, Managing Director, Motan-Colortronic Plastics Machinery (India) Pvt Ltd.

The company has added new functions to these products, such as conveying to up to 16 drying bins and 24 machine material loaders. Up to three conveyor blowers can be employed and any of these advanced versions can easily be incorporated into all available drying bin systems from Motan. The drying bins in the 100-2400 litre series have been expanded by the LBA system bins with a capacity of 15, 30 and 60 litre. Anwesh Koley

Modern Plastics & Polymers | March 2012

megatrends such as need for sustainable mobility, the future of LANXESS lies in its specialisation to develop proactive technologies, eg, green mobility through high-performance plastics and rubber products,” during the grand inauguration ceremony. Further, Dr Joerg Strassburger, Managing Director and Country Representative, LANXESS India, observed, “We see a promising future for India ahead, with our customer industries showing healthy growth rates. This justifies our investments in India, making it a manufacturing base for world-class products.” Jhagadia is LANXESS’ second largest production site in India after its site in Nagda in Madhya Pradesh. Jhagadia is a state-of-the-art, 18-hectare site with a fully automatic compounding line of 20,000-metric tonne capacity for the SCP Business Unit. Manas R Bastia

Die & Mould India-2012 sets the stage for highend technology In its eighth edition, the Die & Mould India international exhibition promises to provide a veritable platform for India’s burgeoning die & mould industry to show its ability to compete on an international level and a unique opportunity to interact with various segments from the supply chain that are integral to this industry. It is scheduled during April 19-22, 2012, at Bombay Exhibition Centre, Goregaon, Mumbai. While the manufacturing sector surges ahead, it must focus on the die and mould industry considering its pivotal role across manufacturing segments. As the industrial growth of the country hinges greatly on the strength of the manufacturing sector, the role of the die & mould industry should be highlighted so as to ensure greater cognisance among the government and trade circles. In view of the upcoming fiscal budget, the exhibition is well timed with an aim to further the prospects of this industry. About organising the event, P N Surendranath, Executive Director, TAGMA, said, “Die and mould forms a highend technology used in the manufacturing segment. It is the starting point for manufacturing and also because it covers the entire manufacturing sector from the largest to the smallest. From development of product and prototype to large-scale production, the impact of the die & mould industry is felt throughout.” Lionel Alva

NEWS, VIEWS & ANALYSIS

Honeywell opens new technology centre in India

(L-R) Rajeev Gautam; Jaipal Reddy, Union Minister for Petroleum & Natural Gas; with Jim Bujold, President, Honeywell India; and Mark Turowicz, Country Head, Honeywell

Honeywell has opened a new technology centre in Gurgaon to expand its technology development capabilities in key areas such as refining, petrochemical, low-global-warming and nylon technologies & applications. Besides, the centre will develop technology for Aclar films for packaging, which has special moisture barrier properties and colour masterbatches. The facility has pilot plants for developing and demonstrating refining & petrochemical process technology by UOP, part of Honeywell’s Performance Materials & Technologies (PMT) strategic business group. “The new facility will allow Honeywell to work with some of the brightest engineering minds in India. It brings the development of key technologies closer to our customers in the region and complements our other technology centres around the world,” said Rajeev Gautam, President and Chief Executive Officer, Honeywell UOP. The inauguration ceremony was attended by Jaipal Reddy, Minister of Petroleum & Natural Gas, and other dignitaries. The new technology centre will support Honeywell UOP in developing and licensing process technologies used in refining & production of petrochemicals & renewable fuels. Anwesh Koley

Husky announces sale of Injectoplast to Alpla Husky Injection Molding Systems Ltd has recently signed an agreement for the sales of Injectoplast, the former closure injection moulding operation of KTW, to Alpla. Injectoplast was a division of KTW, a closure mould maker that Husky acquired in early 2011. 22

Modern Plastics & Polymers | March 2012

Alok Masterbatches introduces pioneering products

KREYENBORG Group to debut advancements in backflush filtration at NPE 2012

Alok Masterbatches has introduced its latest range of masterbatches for varied plastics processing requirements. Amit Puri, Director, Alok Masterbatches, commented, “We have introduced Gold standard in black masterbatches, which are essentially premium quality black masterbatch with fine dispersion for injection moulding, extrusion and thin film application.” The company also introduced antimicrobial additive masterbatch, which inhibits microbial growth, thereby increasing the life of the plastic product. For the Fast Moving Consumer Good (FMCG) industry, the company has introduced two-tone colour masterbatches, which offer a wide range of colour options to customers. Other products from the company displayed at Plastindia 2012 include outdoor colours (for external product application with high light fastness) and Magna Fil Ext, an additive filler for woven sack application, which increases elongation & strength of tapes, drastically reduces dust formation on looms and is to be used in conjunction with our filler masterbatches. “These products will offer high flexibility to plastics processors in terms of their application and enable them to distinguish their products in the market,” added Puri. Anwesh Koley

As the global market leader for screen changers, KREYENBORG offers the appropriate machine for each filtration application. The portfolio ranges from discontinuous and continuous systems to fully automatic backflush screen changers. Screen changers with process, pressure and volume flow constant method of operation are unique in the market. These allow for successful processing of highly contaminated material to high-quality products in sensitive applications. The underwater pelletising systems of BKG Bruckmann and Kreyenborg Granuliertechnik GmbH have proved their excellence all over the world. These systems are supplied with pelletiser, centrifugal drying, water system and are ready-to-use. PLC control is suited for all thermoplastic materials, including production of micro-pellets. Process throughput ranges are available from 2-80 kg/hr (Labline 100) to systems capable of 35,000 kg/hr. For economical processing of PET, BKG has developed CrystallCut®, the Inline Crystallization System. With this system, pelletising and crystallisation are executed in one process step without the need for additional energy. At NPE 2012, the KREYENBORG Group will present a diverse range of screen changers and melt pumps, a discontinuous infrared dryer IR-batch, as well as a BKG CrystallCut® system for capacities up to 1,000 kg/hr.

During acquisition of KTW, Husky had announced divestment of Injectoplast due to potential conflicts with its existing injection moulding customers. After completing a thorough process, a deal was signed with Alpla Holding GmbH. The deal is anticipated to close before the end of the first quarter of 2012.

Husky Injection Molding Systems Ltd is a leading global supplier of injection moulding equipment and services to the plastics industry. Alpla holding GmbH, Austria, is part of Alpla Group of Companies, Austria. Specialising in plastics bottle designing and moulding, Alpla now has a global presence in over 34 countries with 128 manufacturing plants.

NEWS, VIEWS & ANALYSIS

Petainer’s ‘greenest ever’ refillable bottle

Manufacturing Summit for empowerment of SMEs

Plastics packaging technology specialist Petainer has developed a Polyethylene Terephthalate (PET) refillable bottle, claiming to further improve sustainability of one of the most environment-friendly forms of beverage packaging. Nigel Pritchard, Group Chief Executive Officer, Petainer, said, “The bottles are ‘eco-friendly’ because these use up to 90 per cent less virgin material per filling. Introducing post-consumer recyclate means that the bottles now require less energy and other resources to manufacture. These are economical in the conventional sense, as environmental benefits translate into lower costs. As the cost of PET resins inexorably rises, the economics of refillable bottles using recycled material become even more compelling.” Petainer has recently developed manufacturing technologies, which allow more than 25 per cent of post-consumer waste from used PET bottles to be included in refillable bottles. The company is now working on further improving the use of post-consumer recyclate. Petainer is working with bottled water companies, carbonated drinks producers and brewers across Europe to urge them to adopt refillable bottles. The bottles are returned to the retailer by the consumer after use, and sent to the beverage manufacturer for washing & refilling. Avani Jain

The contribution of Indian Small and Medium Enterprises (SMEs) in the economic development of the country cannot be overemphasised. In a fitting tribute to this, SME Chamber of India recently organised its national level annual flagship event titled ‘SME Manufacturing Summit 2012: Strategies and Initiatives for Sustainable Growth’ in Mumbai. The one-day summit was spread over three plenary sessions: Challenges and opportunities for SMEs, Strategies for better growth and Support services for better growth. While speaking on the occasion, the Chief Guest, M Narendra, Chairman & Managing Director, Indian Overseas Bank, highlighted the importance of Indian SMEs for the Indian economy and the challenges faced by this segment. Ajay S h a n k a r, Member Secretary, National Manufacturing Competitiveness Council (NMCC), Government of India, was the keynote speaker. In his address to the audience, he gave an overview of National Manufacturing Policy (NMP) that aims to take the growth of manufacturing sector to 12-14 per cent, create 100

HPMC unveils innovative extruders

mould. A highly efficient machine, it considerably reduces the production cost. It has independently controlled vacuum unit, haul-off and cutting unit for each pipe, enabling smooth production of four pipes of different sizes and weight simultaneously. Amit Kalra, Director, Hindustan Plastics and Machine Corporation, said, “The twin-screw extruder offers a range

At the recently held Plastindia 2012, HPMC displayed its latest machinery for the first time in India. The conical twinscrew extruder for four pipes, a 24-m long PVC pipe production line operating continuously, silently and smoothly was the major attraction. The machine can produce four pipes of different weights and diameters simultaneously from one 24

Modern Plastics & Polymers | March 2012

Ashland expands Plasdone™ PVP production Due to strong demand for Plasdone™ Polyvinyl Pyrrolidone (PVP), Ashland Inc will add new low-viscosity, pharma-grade PVP capacity at its manufacturing facility in the US.The new capacity will strengthen Ashland’s position in the market and enable it to support the growing needs of its pharma customers. Jeff Wolff, Group

M Narendra inaugurating the summit by lighting the lamp. (L-R) R K Dubey, Chandrakant Salunkhe and Ajay Shankar

million jobs and increase the share of the sector in India’s GDP to 25 per cent by 2022, from the current 16 per cent. “For this, it is necessary to have a regulatory environment that supports high birth rate of new enterprises and also helps SMEs to scale up and grow fast,” he added. Other dignitaries present at this interactive forum of policy makers, bankers and SMEs included Kewal Handa, Managing Director, Pfizer Ltd; R K Dubey, Executive Director, Central Bank of India; Prashant Nagre, Chief Operating Officer, Fermenta Biotech Ltd; Jayesh Rambhia, President, The All India Plastic Manufacturers’ Association; Dr Rajendra Abhyankar, Former Secretary, Ministry of Foreign Affairs; and Chandrakant Salunkhe, President, SME Chamber of India. Manas R Bastia

Vice President, Pharmaceutical and Nutritional Specialties, Ashland Specialty Ingredients, said, “Over the next few years, Ashland expects steady growth in PVP driven by an industry need for formulation ingredients to improve the quality of finished drug products. We see strong growth in emerging markets, resulting from high demand for generic drugs and consumer demographics.” of benefits to our customers, eg, efficient energy transfer, high performance backing, strength resistance to fatigue, increased screw and barrel life and higher process control.” In this extruder, all four pipes are produced independently, reducing wastage. It saves on labour and space, making it a preferred choice of machine for conduit pipe makers. Anwesh Koley

POST PLASTINDIA 201 2

ExxonMobil Chemical showcases ‘Technology Leadership for Innovation’ theme

ExxonMobil Chemical offers a portfolio of products for automotive applications

ExxonMobil Chemical, one of the world’s premier petrochemical companies, showcased its industry-leading polymer solutions at PlastIndia 2012. These solutions – Enable™ and Exceed™ metallocene polyethylene resins, Vistamaxx™ propylenebased elastomers, Santoprene™ thermoplastic vulcanisates, Vistalon™ Ethylene Propylene Diene (EPDM) rubber, ExxonMobil™ polypropylene resins, Exxtral™ polyolefins and Achieve™ polymer resins – enable innovation in packaging, automotive & non-woven applications. Aided by the technology leadership and application expertise of ExxonMobil Chemical, this product portfolio helps customers meet changing market needs and create higher value for end-use applications. Enable™ resins offer a good combination of film processing and higher alpha olefin performance benefits in a single resin. Exceed™ resins, besides offering outstanding film performance, help create value across the supply chain. Vistamaxx™ elastomers inspire new possibilities of wide ranging flexible films, extrusion coatings and lamination applications by delivering enhanced levels of performance, processing efficiencies & lower formulation costs. ExxonMobil Chemical also demonstrated its products in the processing halls on machines from leading manufacturers, where visitors could view benefits such as downgauging in packaging and lightweighting in automotive applications. Present on this occasion, Jeffrey S Beck, Global Marketing Manager, Polyethylene, ExxonMobil Chemical, emphasised on the company’s efforts in developing and delivering sustainable plastics packaging. Manas R Bastia 26

Modern Plastics & Polymers | March 2012

Toshiba optimistic about growth of all-electric machines Plastindia 2012 provided an opportunity for plastics machinery manufacturers to increase their ambit of operations, as well as meet prospective clients, as opined by Takashi Kamiyama, Managing Director, Toshiba Machine (India) Pvt Ltd. He added, “We have a range of injection moulding and die-casting machines on display with specific features to attract customers who value quality.” Kamiyama was pleased to see the buoyant automotive industry in India, presenting enormous opportunities

to the injection moulding industry. “Major Japanese Original Equipment Manufacturers (OEMs) are coming to India due to the rising demand here, and machinery manufacturers must be prepared to cater to their needs,” said Kamiyama. Toshiba displayed allelectric machines at the event. Kamiyama commented that all-electric machines are more expensive than the conventional ones, as environment-friendly characteristics of such machines make them a better choice in the long run. Anwesh Koley

High performance and sustainability go hand in hand at LANXESS LANXESS showcased its high-tech plastic products and innovative technologies at a 300-sq m-booth at Plastindia 2012. The range of products included its SemiCrystalline Products (SCP), Inorganic Pigments (IP) and Functional Chemicals (FC) business units. While Durethan® and Pocan® are from the SCP business unit, Bayferrox® and Colortherm® represent its IP business unit along with Macrolex®, Mesamoll® and Ultramoll® from the FC business unit. These products are used in industries such as automotive, electronics, paints and coatings, construction & textile. Dr Joerg Strassburger, Managing Director and Country Representative, LANXESS India, said, “We are exhibiting at Plastindia 2012 a range of LANXESS products and their end-applications for the plastics industry. Since the fair is attended by our manufacturers, customers and raw material suppliers, it is an ideal platform to engage with them while

Clariant promotes sustainability and high-performance Keeping pace with the myriad ideas and innovations afloat at Plastindia 2012, Clariant announced the addition of anti-microbial masterbatches based on MedX anti-microbial agents from SANITIZED® AG to its dedicated Mevopur® range. This is a cutting-edge solution to enhance the functionality and minimise risk in product development for pharmaceutical and medical

(L-R) Dr Michael Zobel, Head, SCP business unit; Dr Werner Breuers, Board Member; Dr Axel C Heitmann, Chairman, Board of Management; and Dr Strassburger

showing them our products through their applications.” Further, Dr Christof Krogmann, Vice President, SCP Business Unit, Asia Pacific, LANXESS, added, “There are many nations present at the exhibition and it will further grow. It is quite interesting and the right thing to do in India is to represent our industry.” LANXESS works closely with automakers and automotive suppliers towards green mobility by finding out new applications of its high-performance products. Manas R Bastia applications. Sahadeo Patil, HeadMasterbatches, Clariant Chemicals (India) Ltd, said, “Clariant’s masterbatch solutions are supported by a controlled, consistent and compliant approach towards processing. This combines the assurance of advanced performance with cost-saving processing efficiency and product safety to support the trend towards high quality and sustainability across all markets in the region.” Annabel Dsouza

POST PLASTINDIA 201 2

Unique collaboration between BASF and Hyundai for one-of-a-kind concept car

BASF officials posing with the i-flow during its exclusive preview in India

BASF ’s booth at Plastindia 2012 was abuzz with waves of visitors. The centre of attraction was the i-flow, the one-of-a-kind concept car, based on a unique collaboration between BASF and Hyundai Motor Group. The spectacular design of the i-flow has a wide range of innovative features beneficial to the environment as well as eye-opening to many carmakers and car lovers. According to BASF, its contributions to the i-flow allow greater fuel efficiency, reduced environmental impact, freedom of design and greater comfort & safety. As a result, the concept car offers vital new approaches to sustainable mobility. Further, due to these energy-efficient contributions in the i-flow project, BASF has been granted the ÖkoGlobe award, an international environmental award in the area of mobility, sponsored by the University of Duisburg-Essen and spearheaded by automotive expert Prof Ferdinand Dudenhöffer. Some of the key constituents of this concept car include Ultramid® Balance, a polyamide; Luquafleece®, a moisture-absorbing material; Elastollan®, a thermoplastic polyurethane elastomer; BASF polyurethane material Elastoskin®; a new catalyst from BASF that combines four technologies to cut emissions in just two components; pigments from BASF’s Sicotan®, Sicopal® & Lumogen® ranges; and Steron®, an innovative soft-touch coating technology; among others. Manas R Bastia 28

Modern Plastics & Polymers | March 2012

France emphasises on innovation

Rajoo unveils state-of-the-art technology

The French Pavilion at Plastindia 2012 served as an ideal point of confluence for Indian demand to leverage European technology. The French Pavilion, set up by Ubifrance and the French Trade Commission in India, saw 11 French companies exhibiting their solutions for the plastics industry. Corelco, a leading French manufacturer of corrugated pipes and netting extrusion lines, displayed its latest production lines for pre-wired electrical components. The netting extrusion process uses a knife and as anvil head for rotary die-cutting, allowing production of various netting materials, which can be used in the burgeoning manufacturing sectors of India, eg, construction, agriculture, etc. Joseph Vitello, Sales Director, Corelco, said, “The process of stretching the strands is known as mono- and biorientation. These processes enhance the mechanical properties of the endproduct. At Plastindia 2012, we aim to boost international expansion and meet local partners in the Indian market.” Plastpolis, France’s leading plastics innovation cluster, exhibited a range of ideas and innovations at Plastindia 2012. With leading companies, R&D centres, training institutions and investors, Plastpolis facilitated its expertise and solutions to India’s small- & medium-sized businesses to intensify trade between the two countries in plastics engineering and technology. Annabel Dsouza

Rajoo Engineers showcased its latest blown film lines at Plastindia 2012. The primary attraction was a 14.5-m tall five-layer blown film line. It was the only blown film line on the show running barrier films, among other films, with trimless winding, a feature that results in high material savings. This film line had an output ranging from 400 kg per hour for an 80-micron barrier film with gauge variation of ±3 per cent, to 600 kg per hour for a 70-micron collation shrink film with gauge variation of ≤3 per cent. The extrusion giant welcomed visitors at its booth, which sprawled over 730-sq m area with engaging graphics, well-depicted instruments and live demonstrations of their barrier film production. It displayed the biggest and the world’s smallest multilayer plant. “For Rajoo, this show is not a destination, but a journey to further our commitment to the extrusion industry and continue to serve this industry while being recognised as a quality and reliable supplier in the world market,” said Sunil Jain, President, Rajoo Engineers Ltd. Anwesh Koley

Manjushree stresses on increased automation in production One of the world’s largest events on plastics, Plastindia exhibited a high level of automation with high-speed and high-production machines. Vimal Kedia, Managing Director, Manjushree Technopack Ltd, said, “Automation is the need of the hour, as availability of land is decreasing, which hampers the potential to build new capacities. Factors such as land

constraints, labour unavailability and higher industry requirements have made companies move towards faster and more efficient machines.” Automation helps make machines that generate less waste, less carbon footprint and consume less energy. it is the demand of the day, driven by government regulations and increased consumer awareness, and events like Plastindia help generate and sustain this awareness. Anwesh Koley

TECHNOLOGY & INNOVATION

STEER launches compounding pelletising system

Super Production Line (SPL 40) launched by STEER is a compounding pelletising system comprising a corotating twin-screw extruder with a feeder, strand die head, water trough, air knife, pelletiser and classifier. Built with emphasis on reliability and safety to cater to dynamic needs of the industry arising of unscheduled/unplanned requirements for small quantities, control over Work-In-Progress (WIP) during grade change and power failures, the lean operation feature of the system allows effective testing of new formulations with minimum wastage. SPL 40 is precision manufactured using CAD/CAM technology. The line is designed through the Six Sigma process to ensure zero defects in product quality. It finds applications in colour and performance masterbatches, pre-coloured compounds for auto & appliance parts, modified polypropylene and high-impact polystyrene. Super production lines exemplify engineering excellence in EPZ products with STEER’s expertise in metallurgy, and focus on minimising wear & tear and corrosion in processing and ensuring higher conformity to quality & production efficiency.

New resins to reinforce thermoplastics portfolio for healthcare SABIC has launched new grades including High-Density Polyethylene (HDPE) resin featuring high flow properties, which can significantly reduce injection moulding cycle times for a number of healthcare products. 30

Modern Plastics & Polymers | March 2012

Extrusion blow moulding with special air management Extrusion mould specialist fhw-moulds GmbH has developed a special solution for removing air from extrusion moulds and proves its innovative strength. This brand new, optimised product is perfectly adapted to blow moulders’ requirements for improved cycle time. The new extrusion mould for a 20litre jerry can is vented in all four corners, and vacuum can be used to increase the ventilation effect. The vent is cut across the entire height of the mould corner to eliminate the occurrence of marks on the finished part. In this way,

entrapped air can be removed quickly and effectively. During extrusion blow moulding, cycle times are completely dependent on mould cooling times. The new mould design with corner venting allows significant cuts in cycle times. Due to the optimised cycle times, the additional costs for this special mould have a short payback time. An additional benefit of this solution is that exchangeable corners can accommodate different designs of hollow plastic products, which translates into more versatility and cost-efficiency for blow moulders.

New flexible packaging films by LINPAC Packaging LINPAC Packaging has launched two new Polypropylene (PP) film solutions for packaging fresh meat, poultry and fish. The two solutions – LINtop PP HB Lock Seal and LINtop PP HB Peelable – meet the best shelf-life targets in the PP market. Both product solutions are formulated to seal various PP trays, run smoothly in machines and seal through contamination to ensure a safe and secure pack. The lock-seal film option is available in two gauges, 35 μ and 42 μ; of these, 35 μ is the lowest gauge available on the market, ensures cost savings and a low carbon footprint in line with retailers’ sustainability strategies. LINtop PP HB Lock Seal outperforms other films’ anti-fog qualities and has excellent transparency for good on-shelf presentation. LINtop PP HB Peelable film offers safe and easy peelability, as it peels away in one piece from the tray. It is in line with the best market

offerings for anti-fog efficiency and oxygen barrier and outperforms most films for transparency qualities. These are engineered to perform to a high standard and have a low gauge to minimise their environmental footprint. LINtop film solutions are easy to handle and complement a wide range of PP trays, driving efficiency on the factory floor, thus providing long shelf-life to food products, helping retailers reduce their waste and keeping food fresh for longer.

With a melt flow rate of 30 g/10 min, SABIC® HDPE PCG300054 provides significant processing advantages that yield lower system costs for healthcare product manufacturers. SABIC® HDPE PCG300054 resin is typically suitable for injection moulding thin-walled, long-flow parts such as disposable syringe pistons, as well as caps

and closures for medical and pharmaceutical packaging. High-flow facilitates complete mould filling and enables the use of thinwall geometries that cool rapidly in order to reduce the cycle time. This translucent resin balances stiffness with good levels of environmental stress cracking resistance to ensure durability under a variety of usage conditions.

TECHNOLOGY TRANSFER

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

Technology Requested

Technology Offered Conversion of batch-poly plant to C P plant

Disposal and recycling of plastic waste

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

A Polish firm seeks the technology for dry processing of all kinds of plastic waste or a magnetic processing method in the electrostatic field. The technology should allow sorting of all kinds of plastic materials, hay-silage foils, PET, HDPE, PVC, etc, by excluding dangerous waste. Specific technical requirements include initial cleaning without the use of water, sorting of all kinds of plastic materials after cleaning in a closed system, and a maximum processing capacity of 10,000 tonne of waste per annum.

Areas of application Chemical fibre and plastics

Forms of transfer Turnkey

Areas of application

Plastic recycling technologies using organic and inorganic compounds

Plastics industry, waste recycling, waste management

An Iranian company offers plastic recycling technologies using organic and inorganic compounds. This idea is based on the principle of water electrolysis in which sodium chloride is kept in proximity of turpentine/pine oil and plastics.

Others

Areas of application

Forms of transfer

Lab-scale non-woven and monofilament plant An Indian company is looking for a lab-scale, non-woven and monofilament plant in a single station.

Plastics recycling

Plastics

Forms of transfer

Others

Plastic recycling technologies

An Iranian company is willing to provide plastic recycling technologies using urea and ammonium carbonate and synthetic ammonia.

A Sri Lankan company is seeking the latest plastic recycling technologies, especially for automatic sorting, washing, metal detection, granulation process system, washing plants, crushers, extruders, etc.

Areas of application

Plastics recycling

Forms of transfer

Technology licensing

Others

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

Contact: Modern Plastics and Polymers Infomedia 18 Ltd, ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W) Mumbai 400 028. Tel: 022-3003 4671 • Fax: 022-3003 4499 Email: spedit@infomedia18.in

Modern Plastics & Polymers | March 2012

Information courtesy: Information courtesy: Dr Krishnan S Raghavan, In-Charge, Technology Transfer Services Group, United Nations - Asian and Paciﬁc Centre for Transfer of Technology (APCTT), APCTT Building, C-2, Qutab Institutional Area, New Delhi 110 016, Tel: 011 - 2696 6509, Fax: 011 - 2685 6274, Email: krishnan@apctt.org, Website: www.apctt.org For more information on technology offers and requests, please log on to www.technology4sme.net and register with your contact details. This is a free of cost platform provided by APCTT for facilitating interaction between buyers and seekers of technologies across the globe. After submitting technology offer or request to this website, you are requested to wait for at least two weeks for receiving a response from a prospective buyer / seeker through this website, before contacting APCTT for further assistance.

MPP Tab 1 Mar 2012 Ad Name: Alok Pg No. 33

MPP Tab 1 Mar 2012 Ad Name: Loxim Pg No. 34

IN CONVERSATION WITH: S V Kabra

“In future, more responsible use of plastics will grow and fuel industry growth” …believes S V Kabra, Chairman & Managing Director, Kabra Extrusion Technik and Plastiblends India Ltd and Founder, Kolsite Group of Companies. With over five decades of experience and excellence in the plastics materials and machinery industry, he shares his views and visions on the role of plastics industry in the nation’s surging economy, in an exclusive interaction with Annabel Dsouza.

Modern Plastics & Polymers | March 2012

S V Kabra

What are the opportunities for engineering industry in Indiaâ&#x20AC;&#x2122;s growing economy? Industry sources state that the Indian manufacturing industry in terms of resin processing needs to invest $ 10 billion in plant and equipment (excluding buildings) by 2016 to accommodate overall demand from construction and infrastructure segments. This works out to processors investing $ 3-4 million per day for the next six years. Key focus areas are machines for all types of pipes used in agriculture, including water management and drip irrigation as well as in the infrastructure, housing, gas and telecommunication segment.

In an uncertain global investment climate, how can the Indian plastics industry expand further? Indian plastics industry is mainly driven by the domestic demand. This has its own merits and demerits. We are mostly insulated from global economic shocks but, at the same time, are taking measures to cool down the inflation and enhance capital accessibility for new projects. Use of plastics in the agricultural sector is expanding rapidly. Micro-Irrigation Projects (MIP) and the pipe industry are growing at a rapid pace. Food demand is growing as a result of population growth and expanding middle class due to increasing prosperity in the economy. As land is becoming scarcer, the focus will be on advanced farming to meet increasing food demand. This will increase the use of plastics in greenhouses, shade nets, pipes, drip irrigation sectors. As per the 11th plan estimates, an additional area of 10,58,000 hectare needs to be brought under drip irrigation, increasing the total land covered to 28,50,000 hectare. These steps will increase the market demand for drip irrigation pipes.

How can Indian entrepreneurs introduce international standards of innovations in the domestic market? Introducing international standards in the domestic market is a challenging task. This year, Kabra Extrusion Technik

(KET) acquired 15 per cent stakes in the US-based Gloucester Engineering Company Inc (GEC), which will help KET to attain technology and expertise in high-end blown film plants. We have also been associated with the US-based Drip Research Technology Services (DRTS), which provides drip irrigation machinery and technology to independent drip irrigation manufacturers across the globe. For Chlorinated Polyvinyl Chloride (CPVC) twin downstream line is being manufactured as per design specifications of our joint venture partner American Maplan Corporation USA â&#x20AC;&#x201C; pioneers in CPVC technology. These collaborations will enable us to provide our customers with the Indian machinery meeting international standards.

What are the challenges confronting the industry today? Higher interest rates and availability of funds result in immense pressure on the industry as it competes with players from developed countries, as well as with China. The government must devise mechanisms to find a way out of this situation, as increasing interest rates and Cash Reserve Ratio (CRR) changes hurt the industry in the global context even though these are proven effective tools for controlling inflation. As tax structure anomalies hurt the organised sector, Goods and Services Tax (GST) implementation will bring level playing fields. MIPs are suffering due to delays in reimbursement of subsidies from the government, particularly in the southern region such as Karnataka, Andhra Pradesh and Tamil Nadu, which results from of political instability. Sharp fluctuations in exchange rates deeply hurt raw material imports and finished goods exports.

How important is environmental conservation and community welfare for the growth of a company? Plastics have earned notoriety as being harmful to the environment. The actual

problem lies with waste management systems. To sustain the growing needs of an exponentially expanding population, we need to use plastics that are a versatile alternative to metal and paper products. Plastics is a useful material across a majority of industry sectors; moreover, responsible waste management is an important factor. The rise in population results in increased waste; hence, disposal of waste in a proper way is required. Plastics helps save fuel and energy as it helps make lighter weight components for various machines, vehicles and aircrafts. In future, more responsible use of plastics will grow and fuel industry growth.

How has your journey been as an entrepreneur in the plastics industry? Kolsite Group has completed 50 years of its journey, which has had a humble beginning. We had started with minimum resources as a small-scale unit working under various restraints, controls, licences and permit laws. Although it was impossible to have access to technology from Europe or the US, we were determined to face the challenges. We were dependent on our in-house developmental activities, which yielded success and good dividends later on. The hardships we faced made us more determined to succeed. After liberalisation, the process of getting access to technology and global markets became easier and we were able to accelerate our growth.

Where do you see Kolsite group in the next decade? With our leadership position in the industry, we will continue to excel in the fields we are present in. The growing influence of India in global markets will provide more opportunities for us to develop and grow as a global player. We will continue to invest heavily to shape a better future for our industry and will seize all opportunities made available to us by a vibrant Indian economy. Email: annabel.dsouza@infomedia18.in March 2012 | Modern Plastics & Polymers

SPECIAL FOCUS

Dies & Moulds Precision tooling: Combining accuracy with speed ..............................................................................................40

Tool design: Leveraging technolgy for cost benefit ......................................................................................42

Quality assessment: Analysing performance, optimising throughput Courtesy: Carl Zeiss India ..........................................................................................................46

Interface: Ajay Verma, VP - Value Solutions, Dassault SystĂ¨mes .............................................................48

February March 2012 | Modern Plastics & Polymers

SPECIAL FOCUS: Precision tooling

Combining accuracy with speed Machining of precision dies and moulds requires adopting highly sophisticated technology with a high degree of accuracy. Intense global competition in a high-stakes market provides a veritable challenge for the industry to live up to. Lionel Alva highlights the dynamics of the precision tooling industry today while providing insights into future trends.

he global arena has become extremely competitive with increased emphasis on reducing lead times, cutting down costs and wastage while ensuring a qualitatively high output to stay afloat. Owing to an increasing focus on reliability and accuracy, the need for precision equipment has also risen to a considerable extent. Therefore, the quality of precision dies and moulds as well as the time taken to design these leave an impressive insignia on the production process. The nature of success in the die and mould industry begins with selection of the right tool, but that would only be the beginning. The intricacies of 40

Modern Plastics & Polymers | March 2012

designing complex machine parts entail a difficult and arduous task that can only be accomplished with technological sophistication. Notably, the culture of die making has changed because, parallelly, there are many people working on several processes related to the production. Also, the nature of designing precision machinery and tools has undergone a paradigm shift as has that of the tool maker since success in die and mould machining begins with choosing the right tool. However, this does not end there, as now one must also have a complete understanding of the entire production process and how to use equipment effectively to improve productivity & profitability.

Role of software Machining problems are complex and designing of complex machine parts & tools requires maintaining a fine balance of software as well as hardware so as to acquire a harmony of manufacturing principles. With the advent of computer and information technology, manufacturing process is moving towards the realisation of a more automated approach and an ideal design process with a highly integrated approach that utilises software to a great extent. Today, a variety of Computer Aided Design or Computer Aided Manufacturing (CAD/CAM) software are available, which have become an integral part of the plastics industry. This software has allowed product

Precision tooling

designers and mould makers to work more efficiently. Complete enterprise solutions are available today that allow manufacturers to work more efficiently. The aim of an effective CAD/CAM solution is that tooling operations commence prior to completion of the design process, allowing considerable reduction in the lead time for new product development while cutting down on development costs. Thus, with the application of computer technology and information technology, the moulding process is moving towards realisation of computer-integrated manufacturing. Gopal Krishna Varier, General Manager Operations, Vasantha Tool Crafts Pvt Ltd, avers, “Software play a major role in the mould manufacturing industry, right from the concept level to marketing of the product. Some of the widely used software include ProEngineers, Unigraphics, AutoCAD, mould flow analysis, etc. With these software, one can visualise the product in totality before proceeding to the next step.” He continues, “One can make rapid prototypes by using these software and present these moulds to the decision makers. By using the simulation software, one can check for assembly among various parts and remove the bugs, if present. These software are helpful at every stage to preview the product/application and take necessary corrective actions.”

Current trends and demand drivers With optimistic forecasts, the mould manufacturing industry envisages a healthy high growth with the rising demand for high-quality plastics. This is further led on by a surge in demand for high surface finish and precision moulds with shorter moulding cycles to achieve optimum productivity and quality. The key considerations for moulding machines are tonnage, clearance between platen, injection pressure, distance between tie bars, height of closed mould, height of fully open mould, etc. The final mould design cannot be created until the final product design is complete.

Processing complexity include filling, cooling, shrinkage, warpage, etc. The cooling system must be capable of meeting the requirements of the application. The injection mould manufacturing process includes machining of steel plates, converting flats and rounds to core/cavity inserts and other critical parts with Computer Numerical Control (CNC) milling, CNC Electrical Discharge Machining (EDM), CNC Wirecut, etc. Reducing the amount of metal used, minimising the wall thickness of plastic products and improving the efficiency of the final product are also challenging and require continued effort through research. The current trend indicates the demand for injection moulds in the following categories: High-cavitation moulds with reduced cycle time increase productivity Fully hot runner system eliminate wastage of plastic raw material and increase cycle time Valve gate system for fast fill rate or lower clamp tonnage requirements In-mould closing system for high cavitation, caps and closures and FTP caps increases productivity and reduces the process cost Bi-colour moulds, moulding two polymer with multi-colours with aesthetic appearance and flexibility Multi-cavity stack mould for increasing productivity Quality assurance is imperative for any mould manufacturing operations and quality begins at the start of each project right from the raw material and ends with successful mould qualification to the satisfaction of customer. The design review and manufacturability is performed to ensure complete success of the project. Varier elaborates, “Drip irrigation, automobile manifolds (intake/ out-take), micro-motors, medical, pharmaceutical, fast-moving consumer goods, thin-walled packaging, electrical and many more sectors are emerging as new areas for creating more demand for plastics & moulds. In general, in many

Some of the widely used software include ProEngineers, Unigraphics, AutoCAD, mould ﬂow analysis, etc. With these software, one can visualise the product in totality before proceeding to the next step. Gopal Krishna Varier General Manager Operations, Vasantha Tool Crafts Pvt Ltd

sectors, several metal parts are being replaced by plastic parts due to the versatility in processing/manufacturing and also various other advantages offered by plastics.”

Reliable productivity Over the years, the demand for precision equipment has risen across all segments owing to the inherent advantages these offer. These are more reliable, accurate, productive and require less manpower. Although investments are high, the advantages offered by these equipment are enormous. However, care must be taken to justify the nature of such equipment and their role in reducing wastage as well as keenly scrutinising the cost of production. Areas of improvement could be gauged through a pre- and post-production analysis, and the need for such equipment could be assessed. Today, moulding machines, extrusion machines, tool room machines have become more accurate and offer all the advantages mentioned earlier, thus leading to faster delivery of the product. Email: lionel.alva@infomedia18.in March 2012 | Modern Plastics & Polymers

SPECIAL FOCUS: Tool design

The cost of a specific machine part hinges greatly on its design before it is produced. Here, a pivotal step is to have a clear idea of end-user requirements and also consider the working environment so that the design befits the scenario. Lionel Alva assesses the effects of tool design on the overall cost of plastics processing.

ool design in contemporary times depends greatly upon a keen understanding of the overall manufacturing process as well as the properties that a specific part would need to imbibe within itself depending on the operating environment besides other design implications. Thus, it is imperative that tool designers are aware of the intricacies of the production process, including a clear knowledge of the mould and die making process. Tool designers must also acquire laboratory reports of physical tests run for plastic materials. In view of the great degree of skill required in tool making, it is difficult to find a toolmaker that possesses the necessary know-how.

Tool design considerations In general, most plastics designers have a 42

Modern Plastics & Polymers | March 2012

good understanding of the manufacturing process used in plastics despite its varied and complex nature. While a decade ago, design and engineering consisted of about 10 per cent of the cost of a generic mould, in recent times, the cost of a mould is higher. Apparently, the changing dynamics of tool design has resulted in the need for an overhaul of the conventional approach, where there is a renewed focus on engineering, depicting a more pragmatic approach. A tool designer should consider various aspects that can have a strong impact on the functional and design properties of the plastic parts. These may include the plastic material, shrinkage and the process equipment. The various cost factors would be as follows: Complexity of the shape of part Features in the part Overall size of the part

Undercuts in the part Surface finish required Tolerances on dimensions of parts The aim of an effective tool design is to minimise or eliminate the possibility of a poor initial design considering its significant impact in terms of affecting production cycles, reducing expenses and the possibility of product failure as well as overall impact on marketshare. This helps in achieving the objective of functional part design in the shortest possible time frame, thus enhancing the overall production and reducing costs. Moreover, intense competition is a key factor that has significantly changed the approach towards tool design. Sambit Pradan, Manager-Business Development, Asia Pacific, Geometric Ltd, notes, â&#x20AC;&#x153;The life of a tool is one of the prime considerations and is based

Tool design

The life of a tool is one of the prime considerations and is based on the number of parts to be produced. Different techniques are adopted for tool design depending on the number of parts to be produced within the expected cycle time. Sambit Pradan Manager Business Development, Asia Paciﬁc, Geometric Ltd

Automation of design is pivotal to ensure the desired output. However, the intricacies of tool design require that several iterations are made to create optimum design and also to allow for part changes. Avinash Shah Engineer, Finetech Engineers

Modern Plastics & Polymers | March 2012

on the number of parts to be produced. Different techniques are adopted for tool design depending on the number of parts to be produced within the expected cycle time. Another critical aspect is the dimensional accuracy within a multicavity design, and this has a strong impact on the overall life of the tool.”

Computer-aided tool design and automation In recent times, sophisticated technology has helped reduce manual labour and also the complexity of tool design to an extent. It is the development of ComputerAided Design (CAD) systems that is filling the void of the exquisite nature of tooling designers who are fast reducing in number. The reason for this change is that various techniques have evolved that use computer design systems, enabling the following: Parametric modeling techniques and the use of standard library components help create ThreeDimensional (3D) models faster Design rules being embedded at the design stage instead of utilising the conventional labour-intensive design guidelines approach The use of CAM technology directly on 3D models for tool manufacturing Complete enterprise solutions with customisations in CAD/ComputerAided Manufacturing (CAM) to address specific needs Furthermore, plastics manufacturers use numerically controlled machining centres – Computer–based Numerically Controlled (CNC) machining centres – besides CAD systems. “Automation of design is pivotal to ensure the desired output. However, the intricacies of tool design require that several iterations are made to create optimum design and also to allow for part changes. It thus makes for an arduous task that requires a great degree of scrutiny,” avers Avinash Shah, Engineer, Finetech Engineers. The development of such technologies has provided immense

help for manufacturing the tool, thus making the process more consistent and productive. This makes it easier for younger entrants in the profession to manage the trade since the quality of tool components today is looked at as a function of the equipment rather than being a process that is skill intensive.

Building effective prototypes While the cost of a mould varies greatly since its cost ranges anywhere from less than $ 1000 for a low-production prototype to more than $ 500,000 for a high-production mould. Considering these high costs, there is little room for trial and error since it could deviate the entire production process. Therefore, prototyping is generally used to test the efficacy of smaller part designs depending on the circumstances; however, this may be quite expensive in the long run. Some of the alternatives to manual prototypes: CAD system: It includes engineering that allows a tool designer to work with a 3D computer model of the tool being designed. Finite element analysis: This system uses computer-aided techniques to evaluate the worthiness of a tool. Rapid prototyping: Producing rapid prototype models for evaluation and testing is a topic of great interest in many manufacturing industries and is fast gaining prominence. This system uses a 3D computer drawing.

Cost-effective design A highly competitive environment has led to a paradigm shift in a crucial cost-effective process such as tool design. The focus of manufacturing is to reduce lead times by as much as possible, which has paved the way for the use of innovative techniques that are time-saving while also ensuring quality output. This marks a new era in the field of automation and also allows for a streamlined production process. Email: lionel.alva@infomedia18.in

SPECIAL FOCUS: Quality assessment

Analysing performance, optimising throughput The quality of plastic parts needs to be thoroughly verified so that these yield optimum performance. Assessment of part quality manufactured requires the use of appropriate measuring systems for ensuring the exact quality demands and that the best of products reach the end customer.

oday, high-precision parts are made of plastics or composite materials to reduce cost and weight and increase productivity. These components are used in almost all fields â&#x20AC;&#x201C; automotive, telecommunications and medical. Thus, to meet quality demands, the products must be meticulously verified, for which a suitable measuring system is required to measure and assure quality of not only the final product, but also before bulk production of the same.

Measure of efficiency Tooling and mould can be measured using the conventional Coordinate Measuring Machine (CMM). This machine can measure almost all dimensional features including the intricate features. Throughput of manufacturing plastics during the injection moulding procedure has increased considerably, particularly through the use of multiple cavities. These are often an ideal solution when high production volume has to be achieved at low cost. With such high throughput, proper alignment and insertion of the tools is vital. The tool is approved for serial production after process reliability is achieved; thus, quality assurance demands measuring equipment that can flexibly and quickly deliver informative results. Contact sensors can measure many dimensional features, but not small profiles. For small features, a camerabased system is an ideal solution. A combination of contact and optical sensor (multi-sensor system) increases efficiency in inspection of small, complex parts as well as small tools & cavities of a mould. Operators can alternate between optical 46

Modern Plastics & Polymers | March 2012

Courtesy: Carl Zeiss India

Coordinate measuring machine

and contact measurements without interrupting the CNC run. Multi-sensor systems are especially used for quality assurance and initial sampling of small, complex parts in the plastics industry. The CMM can be optimised for better productivity to reduce downtime of tool manufacturing and mould making by automating the measurement process with Computer Numerical Control (CNC) measurement run and fixturing. The software with direct Computer-Aided Design (CAD) (plan versus actual) comparison will help

the quality assurance unit to provide quick feedback.

Unveiling the interiors As a supplement to conventional technologies in testing and measurement, Industrial Computed Tomography (CT) creates the possibility of completely capturing a part, assessing the interior & exterior. This provides the user with all evaluation possibilities at a glance, in a short time and without harming the component. CT helps to non-destructively measure and make visible features and

Quality assessment

structures from the interior of materials & parts, such as material defects (crack, bubbles, gas, porosities, inclusions, etc) and internal workpiece features or geometries that cannot be probed. Existing measuring technology permits optical, contact and, occasionally, laser measurements. Currently, parts are ground to expose different layers and a two-dimensional section is measured. Generally, it takes up to 40 hour for the initial sample test report of a part. Use of CT for the same significantly reduces time to 40 minute. The evaluation can be done offline with measurement software. Thus, under optimal conditions, initial sample test reports with several cavities can be compiled in one day.

Performance testing Due to shrinkage, parts correspond exactly to the negative of their models. The tools are made using an iterative process that often consists of up to 10 steps. CT enables a clear reduction in the number of these cycles by using direct ‘Tool Correction’ function of the measurement software. Thus, deviations from the nominal geometry are not only recognised, but also reflected on the nominal surface. This represents the level of shrinkage in the model, and integrates the measurement immediately into the tool correction process. The reduction in the number of tool correction leads directly to faster availability of the parts on the market, and hence shorter innovation cycles. Besides metrology, nondestructive testing and defect analysis – assembly checks – can be done; the production process can be optimised & monitored; and products can be quickly & easily checked for defects. Small plastic and electronic devices have to meet increasingly higher design and quality requirements. Shorter product lifecycles place high demands on development and production process. The aesthetically shaped prototypes must be repeatedly checked for compliance with design specifications, which is practically impossible with the conventional measuring technology. Here, CT helps develop high-quality products in a short time for volume production. CT measurement is not only faster, but the quality of the measuring results also improves considerably because the parts no longer need to be destroyed. Till date, quality inspectors had to dissect or cast the parts to check their internal features, which often caused distortion of the final parts. CT generates a threedimensional image that displays all internal and external features in a short time.

Assurance of quality Most measurement software provide interfaces to statistics software. These software can be utilised for order-related archiving of all measurement data captured. This data can be easily accessed years later and utilised for statistical evaluation. Hence, each process is fully monitored and traceable, which is the key to quality assurance. Courtesy: Carl Zeiss India – Industrial Measuring Technology Division

March 2012 | Modern Plastics & Polymers

SPECIAL FOCUS: Inter face - Ajay Verma

“The industry has occupied a unique position in meeting the growing material needs of consumers” …opines Ajay Verma, VP – Value Solutions, Dassault Systèmes. He shares how plastics has emerged as a strategic commodity and finds applications in virtually every aspect of the industrial and household environment. In a conversation with Annabel Dsouza, he stresses how rapid technological development in materials, machinery, processes and products offers new opportunities for this industry in India.

What are the recent trends in die & mould technology for plastics processing? The plastics industry has grown and touched every facet of our lives – from packaging of daily use items to products with enhanced functionalities in agriculture, housing, healthcare, automotives, consumer durables and infrastructure. The industry has occupied a unique position in meeting the growing material needs of consumers. It has the ability to compete on a global scale by absorption of new technology and lean manufacturing practices. There is immense scope to boost production of machines, moulds, auxiliary equipment and dies, as Indian manufacturers strive to be cost-effective and focus on better quality & technology.

In which applications of plastics do you see emerging demand for precision moulds? As the moulding industry moves towards high-precision and multi-functional component moulding, the demand is 48

Modern Plastics & Polymers | March 2012

increasing for use of Computer-Aided Engineering (CAE) technologies to shorten product development cycle and improve product quality. Mould flow analysis technologies can be used as valuable tools for solving product design, mould design and process-related problems to enhance product quality & productivity in the moulding industry.

What are your R&D initiatives towards die & mould design? At Dassault Systèmes (DS), Research and Development (R&D) is a fundamental function to have a perpetual edge over its competitors. DS invests 23 per cent of its revenues in R&D. Over 25 per cent of the R&D staff is in India and is consistently growing. Today, the plastics industry is interwoven with some other key markets that we operate in, eg, use of moulded plastics in the automotive or aerospace industry. DS engages in extensive work of this nature to ensure that the complete product for these businesses adheres to precision engineering standards demanded by the market.

How does DS keep pace with tooling solutions for high-speed plastics moulding machinery? Our success in the Indian market lies in the combination of significant Product Lifecycle Management (PLM) implementations, the competitive advantages of our brands, the performance of our distribution channels and the investments we make to enhance our performance and long-term opportunities. We have created solutions to address different stages of product development in not only core industries, but also in the plastics industry. For instance, CATIA Mechanical products and solutions help create any type of Three-Dimensional (3D) assemblies for a wide range of mechanical engineering processes, eg, casting and forging, plastic injection & other moulding operations, composites part design and manufacturing, machined and sheetmetal part design as well as advanced welding & fastening operations. Email: annabel.dsouza@infomedia18.in

FACILIT Y VISIT: Bright Autoplast Ltd

Shifting gears

towards ‘bright’

opportunities In the technology-driven world of automotive plastics, Bright Autoplast Ltd has established itself as a system solutions supplier for India’s burgeoning automotive industry. Annabel Dsouza and Lionel Alva analyse how the company, with an integrated manufacturing facility and pan-India presence, has emerged as a pioneer in automotive plastics application and innovation.

ndia is not far behind in the global race for enhanced plastics application in automotives. The automotive industry in India is currently growing at a Compounded Annual Growth Rate (CAGR) of about 8 per cent, while the automotives plastics industry is surging ahead at a CAGR of about 13 per cent, clearly reflecting the promises and potential within this sector. Among the prominent players in the Indian automotive space, Bright Autoplast Ltd has emerged as a system solutions provider through integrated technology and an extensive product portfolio. With an industry presence of over 40 years as Bright Brothers, the company was incorporated as Bright AutoPlast Ltd in 2007 as a fully owned subsidiary of Sintex Holding. While keeping pace with increasing demand, the company is currently working towards improving its manufacturing capabilities, thereby setting an industrial paradigm. With strategic manufacturing units in Pune and Nashik, Bright Autoplast has effectively leveraged the automotive boom across the nation. Today, the company boasts of a pan-Indian presence in cities such as Sohna (Haryana), Pithampur (Madhya Pradesh) and Chennai (Tamil Nadu). 50

Modern Plastics & Polymers | March 2012

Spanning an area of 6,782 sq m, the Pune facility caters to some of the

leading automotive OEMs in India such as Mahindra & Mahindra, Tata Motors and General Motors (GM). Bright Autoplast also caters to some of the leading tier I suppliers, eg, Visteon and Plastic Omnium Varroc. The facility is equipped with 15 injection moulding machines with tonnage range of 802,700 tonne with a combined capacity of 2,000 metric tonne per annum. Advani highlights, “Bright Autoplast is reputed in the industry as a supplier of highquality large components at optimum cost. Along with interiors and exteriors, we manufacture a large number of underthe-hood components, which require high precision, fuctionality and heat stability. Our commitment to manufacturing excellence is evident in the fact that we collaborate with our machinery suppliers to design efficient solutions through customisation and reverse engineering.”

Assembly process

Thorough quality check

Indru Advani, President & Chief Executive Officer, Bright Autoplast Ltd, says, “One of the core strengths of our company is the capability of complete product development from designing and manufacturing to testing & validation. We have an integrated manufacturing unit that includes not only central processes such as injection moulding, blow moulding and assembling, but also value-added services such as paint shop, vacuum forming and state-of-the-art part joining techniques like vibration & ultrasonic welding. More than a product supplier, Bright Autoplast Ltd today is a solutions provider for automotive Original Equipment Manufacturers (OEMs) in India.”

Infrastructure edge

Bright Autoplast Ltd

Some of the main processes at the facility include injection moulding with gas-assisted technology, single/twin sheet thermoforming, PU foaming (RIM) etc. Bright Autoplast’s expertise in design and development has resulted in a vast product offering such as door trims & pillars, instrument panels, bumpers, radiator grills, exterior grills, exterior claddings, and many more. Some of the recent, innovative products of the company include soft touch dashboards, air induction systems, plastics fuel tank, fuel filler system and Heating, Ventilation & Air Conditioning (HVAC) ducts. Bright Autoplast extends its quality standards not only to its product portfolio, but also on all designing and manufacturing operations. The stringent quality checks involve tried and tested methods for analysing physical, mechanical and thermal properties of the moulded component. Many of the staff are engaged in assessing the overall health and efficiency of the machinery. By measuring the tonnage of material moulded and power consumed, the company maintains a robust manufacturing culture.

Illustrious clientele Bright Autoplast has an illustrious clientele that includes some of the foremost brands in Indian automotives such as Maruti Suzuki, Hyundai, TVS Motors and Honda. With a combination of manufacturing excellence and strategic business alignment, the company clocked an impressive turnover of ` 2,740 million in the previous fiscal. Advani asserts, “With an aim towards becoming a one-stop shop for plastics automotive components, we try to

Final finishing of the component

understand the application and design the product accordingly. For instance, we have supplied 66 components to the latest Mahindra XUV 500. We also supply a large number of components to different vehicle models.” Apart from the SUV segment, the company is well established in the commercial vehicle segment with Tata 207 and 407. Advani continues, “We are planning to increase our revenue share from the commercial vehicle segment owing to its strong growth prospects. In an uncertain global economy, the heavy automobile sector is relatively less impacted by fuel price hikes. This is in keeping with our efforts to boost the company’s top line while keeping bottom lines steady.” In order to further enhance product design and development capabilities, Bright Autoplast has project-based alliances with several global players such as HIVEC ( Japan), Daeji Metal Corp (Korea) and Kautex (Germany). Through its sister concerns Wausaukee Composites and NIEF Plastics, the company also synergises with the technical advancements in Europe’s developed automotive markets. This enables Bright Autoplast not only to deliver world-class solutions to its customers, but also to raise the technology standards of automotive tier I suppliers across India.

Future focus The story of Bright Autoplast is in many ways symbolic of the burgeoning Indian economy. With replacement of metal by plastics being a profitable and sustainable move, the demands by automotive OEMs for plastics

Paint shop

In an uncertain global economy, the heavy automobile sector is relatively less impacted by fuel price hikes. This is in keeping with our efforts to boost the company’s top line while keeping bottom lines steady. Indru Advani President & Chief Executive Ofﬁcer

has increased, both in properties and volumes. In a competitive, pricesensitive and exponentially surging automotive industry, Bright Autoplast is playing a catalytic role of merging global innovations at Indian costs. The company is expanding proactively not only in terms of volume production, but also Research and Development (R&D) capabilities. Along with the new facility in Nashik, likely to be operational by July 2012, Bright Autoplast is actively investing in R&D facilities for innovative product and process designing. “Growth and expansion are a continuous process for Bright Autoplast. In order to further consolidate our business, we will continue expanding our operations through joint ventures, technical & service collaborations, mergers & acquisitions, business alliances and strategic forward integration. We are seeking new investment avenues in the domestic automotive space, while also watching out for opportunities in other emerging markets such as Africa and East Europe,” concludes Advani. Email: annabel.dsouza@infomedia18.in, lionel.alva@infomedia18.in

Photo: Joshua Navalkar

March 2012 | Modern Plastics & Polymers

INSIGHT & OUTLOOK

Ancillary Equipment Ancillary equipment: Keeping pace with global standards ..................................................................... 54

Function focus: Intelligent solutions for boosting productivity ..................................................... 56

Chiller technology: Cool ideas for profitable performance Vijay Bali, Vice President, Reynold India Pvt Ltd .................................................. 58

Interface: Varun Kapoor, Director, Sarvasv Machinery & Equipments Pvt Ltd .............. 62

Roundtable: Where does the Indian ancillary equipment industry stand globally? ................ 64

Polyamide alloy: Imparting high performance with design flexibility Mandar Amrute, Market Development Manager, Arkema India ............................. 66

Mould cavity: Monitoring temperature for better quality Y R Anand, Partner, Unimark ............................................................................... 70

March 2012 | Modern Plastics & Polymers

INSIGHT & OUTLOOK: Ancillar y equipment

Keeping pace with

global standards

Manufacturers of auxiliary equipment are responding to plastics processors’ demands for machinery that can help reduce costs, improve efficiency and quality of parts and also stay competitive in the global marketplace. Anwesh Koley gauges the significance of various equipment used in the plastics processing industry.

uxiliary equipment in the plastics industry include granulators, gravimetric and volumetric blenders, vacuum & pressure loaders, railcar unloaders, metal separators, dryers, chillers, recycling systems and reclaim equipment. Material handling equipment and systems for pneumatic conveying of plastic resins, polymers and other pellet or powdered products are also included. Higherperformance dryers use less energy and provide cost savings. “Increased efficiencies are seen across the entire range of auxiliaries, contributing to profitability in plastics processing. Energy savers for granulators are the latest development this industry has witnessed,” opines Dhaval Bhatt, Chief Executive Officer, Sri Sai Plasto Tech. In terms of volume production, efficiency plays the central role. Efficient injection moulding machines require an energy-efficient design. However, efficiency is not only dependent on the energy consumption of the machines. Efficient operation concerns the productivity of the system as a whole and aspects such as machine availability, speed, precision and reproducibility must also be taken into consideration. Some of the latest technologies that can help increase efficiency are described here. 54

Modern Plastics & Polymers | March 2012

High-torque direct drives Distributed electric drives, which are used in all-electric or hybrid injection moulding machines, are usually synchronous servo motors. There are distinct differences among these types of motor, which affect the energy consumption or productivity of injection moulding machines. In contrast to conventional synchronous servo motors, high-torque direct drives provide high torque even at lower speeds. These do not use transmission systems that reduce efficiency, and therefore, do not have a negative effect on energy

Material mixer with integrated conveyor Courtesy: Motan Colortronic

consumption, drive dynamics, precision and reproducibility of the machines. Their minimal inertia, in combination with direct power transmission, provides high levels of dynamics (short and steep acceleration and breaking ramps) and zero backlash. The absence of transmission means that the drive requires virtually no maintenance and is highly reliable. The benefit of high-torque direct drives in terms of energy efficiency becomes obvious considering the dosing drive. “Usually, the dosing drive is the component in the injection moulding machine that consumes the maximum energy. Increasing the efficiency of this axis will have a significant effect on the efficiency of the overall machine. If high-torque direct drives are used here, no reduction or increase in the speed or torque via belt drives or planetary gearing will be required and, as opposed to standard synchronous servo motors, no energy loss will be caused by these components,” adds Bhatt. Thus, the efficiency of the dosing drive in the injection moulding machine will be as high as 90 per cent. The benefit derived f rom the optimised drive is more obvious when hydraulic dosing drives are considered. Hydraulically driven dosing axes usually comprise a number of components.

Ancillar y equipment

Courtesy: KYOUNGIL MACHINERY CO.LTD.

A motor drives a pump that delivers oil through hose lines. The oil is fed to the hydraulic motor via a valve and the motor generates the required rotational movement. Every component in a standard drive loses efficiency and when these losses are multiplied, their overall efficiency is rarely higher than 50 per cent when used in injection moulding machines. High-torque direct drives also have advantages when employed in other axes such as injection or mould movement or the ejector, which require linear movements. Again, no reduction or increase in speed or torque is needed here because the required performance will be provided directly by the drive. Belt drives, planetary gearings or other mechanical transmission systems are not required, as this will have a negative effect on the inertia of the drive. The dynamics, rigidity and reproducibility of the axes will also be enhanced, which, in turn, will bring about a reduction in the cycle time and will, therefore, increase the efficiency of the machine.

Use of toggle systems The toggle system is a good example of a technology that contributes to reducing energy consumption and increasing productivity, and it has a positive effect on input and output. The optimal force–speed characteristic will facilitate fast movements. Moreover, dynamic locking and unlocking reduces the dry cycling times of the injection moulding machine. Mechanical locking applies a constant clamping

force, without further input of energy. Because locking is purely mechanical and there is no hydraulic cylinder in the force path, a toggle clamping unit will be extremely robust. The toggle system technology is currently experiencing a revival through its use in all-electric injection moulding machines. However, when used on all-hydraulic clamping units, this system helps boost efficiency and provides high levels of reliability and low maintenance costs. In order to increase system availability in the production of plastics processing parts, it is vital to take care of the mould by reducing its wear and tear. Appropriate methods to do this include linear guidance systems to ensure perfect platen alignment and reduce machine frame deflection. Correct design of the overall machine will facilitate platen parallelisms so as to reduce wear on the mould. Moreover, reduced frictional resistance in the guides will lead to fewer losses, and thus an increase in energy efficiency.

Cooling and filtration technology Along with reduced energy consumption, an increase in productivity is the second result of enhanced machine efficiency. When developing new products, the goals are to avoid downtimes and reduce reject rates. A novel concept of cooling and filtration of the hydraulic oil of injection moulding machines is geared towards those objectives. With this system, another hydraulic circuit is operated by a small, energy-efficient rotary vane pump in the low-pressure circuit, which is designed to exclusively supply the oil filter and oil cooler. This additional hydraulic circuit operates independently from other main pressure circuits, which facilitate the use of a micro oil filter. A laminar oil flow without pulsation, even during the pause times inherent in the cycle, increases oil service life by 40,000 hour. In addition, the service life of the pumps, valves, cylinders and gaskets will increase because of

Modern auxiliary equipment help in scientiﬁc recycling of plastics and prevention of environmental pollution. Presently, most of the latest auxiliary equipment designed help save power and increase productivity. Dhaval Bhatt Chief Executive Ofﬁcer, Sri Sai Plasto Tech

the clean oil. This will help reduce downtime for maintenance or routine servicing and increase production hours per year. Continuous cooling with optimal heat transfer facilitates higher oil cooler flow temperatures, which means that complex cooling systems are not required anymore.

Challenges The basic problems faced by the industry include shortage of power and skilled manpower. The cost of power and skilled manpower has also risen, but has not resulted in any change on prices. The equipment industry has witnessed advancements in technology related to power savings, material handling and automation. “Modern auxiliary equipment help in scientific recycling of plastics and prevention of environmental pollution. Presently, most of the latest auxiliary equipment designed help save power and increase productivity. The manufacturing output has almost doubled with the latest auxiliary equipment that lower power consumption, and this helps reduce carbon footprint,” concludes Bhatt. Email: anwesh.koley@infomedia18.in March 2012 | Modern Plastics & Polymers

INSIGHT & OUTLOOK: Function focus

Intelligent solutions for boosting productivity

Courtesy: Motan Colortronic

The numerous machines used in the plastics industry necessitate a host of ancillaries, which depend on the application and requirement of the final product. Anwesh Koley finds out how all functions, with support from reliable and cost-effective solutions as well as an intelligent control network, help optimise plastics processing.

he global trend towards faster processing equipment and better accuracy in terms of productivity has led manufacturers across the country to adopt technologies that help achieve higher levels of innovation and end-user satisfaction. The major processing techniques such as injection moulding, blow moulding and extrusion warrant the use of complex end-toend systems of individual units for the automotives, electronics, household goods as well as medical devices industries. Each process requires reliable conveying as well as dosing and mixing systems for high-volume production. Individual extrusion systems require high-precision structures that deliver consistency for continuous production of films, cables, pipes and profiles. Raw materials and masterbatches require 56

Modern Plastics & Polymers | March 2012

accurate dosing and mixing systems for continuous production.

Mould protection Manufacturers have developed systems to protect injection moulds, which record the force path on mould closing. A control curve can be applied to this saved master curve at a freely adjustable axial distance. For example, if the force path as currently measured intersects the control curve during the closing movement because a part is caught in the parting line, the machine will stop the closing movement. As compared to conventional mould protection systems, these systems are reliable even at maximum mould closing speeds; thus, the shortest mould movement times will be achieved. These systems not only provide positive protection for the injection moulds, but also reduce cycle time, which results in increased production efficiency.

Smart solutions The current market for plastic ancillary equipment offers features for optimising and automating the production around plastics processing machines. Dosing and mixing units need to offer excellent mixing quality with highest repeatability. â&#x20AC;&#x153;Dosing additives help in regrinding directly on the processing machine. Innovative designs, high-quality engineering and technical specifications guarantee optimum performance & reliability of processing units. It is important for processors to understand how to precisely dose and mix granulate, flakes, powders and liquids volumetrically as well as gravimetrically,â&#x20AC;? says Srikanth Padmanabhan, Managing Director, Motan-Colortronic Plastics Machinery (India) Pvt Ltd. Consistent mixing ensures higher quality, which ensures a strong competitive edge in the market.

Function focus

A steady documentation process ensures a simple operation through colour graphic display and an added advantage would be a touchscreen panel, which does not require programming. An integrated network connection guarantees recipe integrity and lowest possible additive consumption. Higher productivity and consistent product quality along with low space requirement can also be achieved. An efficient regrinding management prevents overdosing of other components.

Switchable non-return valves In the past few years, considerable progress has been made with all-electric injection moulding machines in terms of precision and reproducibility. However, with highly precise parts, a weak point has been the non-return valve the systems used still do not lend themselves to active selection or activation. With conventional non-return valves, ring or ball-type, the closing behaviour is dependent on various process parameters such as back pressure, decompression, homogeneity of the melt or injection movement. It is only the melt pressure generated by injection that pushes the sliding ring or ball of the valve backwards to provide sealing. Up to that point, a part of the plasticised melt will flow back through the non-return valve. The closing behaviour of the non-return valve, and thus the amount of material flowing back will vary with process or material fluctuations. This will cause fluctuations in the remaining cushion or shot weight, which may result in quality fluctuations of the injection moulded part or even cause a reject. This is where the switchable nonreturn valve design finds use. The active closing of the non-return valve at the end of the dosing cycle will provide enhanced process consistency. Closing the nonreturn valve at the end of dosing by reversing the direction of screw rotation will guarantee constant and actively controlled closing behaviour. “Process consistency will be increased, fluctuations in the remaining cushion and the shot weight will be reduced, while the risk of rejects will be minimised through this,”

says Padmanabhan. This new technology can be used on all-electric machines for applications that demand the highest level of precision.

Conveying Efficient conveying systems optimise material flow, reduce waste and boost productivity of the production line. In the plastics compounding and manufacturing process, there are many powders with different flow properties that require handling. For vacuum conveying of both free-flowing and non–free-flowing powders, hopper loader with specific characteristics loader should be designed such that these can be easily integrated into the conveying systems. From the material source, through to the point of processing, powder handling requirements must be effectively addressed. In order to cope with different material conveying throughputs, hopper loaders are available in sizes of 10, 25 or 50 litre. System loaders are an integral part of a centralised material conveying system. Each system should be designed to suit the customer. Factors such as throughput, material types and plant layout should be individually taken into account. In addition to different loading sizes, a wide variety of conveying options, controls, blowers and filter techniques allow creation of the optimum structure for customer facility.

Dosing additives help in regrinding directly on the processing machine. It is important for processors to understand how to precisely dose and mix granulate, ﬂakes, powders and liquids volumetrically as well as gravimetrically. Srikanth Padmanabhan Managing Director, Motan-Colortronic Plastics Machinery (India) Pvt Ltd

the best quality finished products. “Drying systems are designed to operate at maximum efficiency and minimal maintenance. The integration of dry air conveying, line purging and manual & automatic manifold stations provide maximum flexibility & productivity,” adds Padmanabhan. This ensures maximum production time for the processor by mimimising the downtime caused during material changes.

Energy-efficient drying systems Modern drying systems must be able to do more than just function reliably when operating in accordance with demanding specifications. They must be economical, energy-efficient in operation and meet the high requirements demanded for

Courtesy: Yakohl

The way ahead From reliability of individual equipment to engineering of complex integrated systems, the plastics processing sector needs to take into account a number of factors. Optimising material usage and increasing efficiency & consistency across the entire process chain are important factors for delivering sustainable solutions. Over the years, equipment manufacturers and solution providers have modified their services according to domestic and global requirements, thereby staying committed to seamless plastics processing. Email: anwesh.koley@infomedia18.in March 2012 | Modern Plastics & Polymers

INSIGHT & OUTLOOK: Chiller technology

Cool ideas for profitable

performance Chillers are used across the entire ambit of plastics processing â&#x20AC;&#x201C; injection and blow moulding, extrusion, vacuum forming, laminating, embossing, calendaring, plating and high-intensity mixers, die casting, and many more. Since a large part of industrial chillers are supplied to the plastics, rubber and process industries, companies today are concentrating on specific process temperature-control applications.

Vijay Bali

he chiller market in India is divided between their applications in extrusion and the injection moulding applications. The size of chillers for extrusion machinery can vary from 10 Tonne of Refrigeration (TR) up to 200 TR, depending on the requirement. For injection moulding, the capacities are lower, ie, 2 TR to 40-50 TR. There are various other centralised chillers that can be used for multiple machineries. The size and configuration of the chiller will depend on the number of machines, capacity and the process. As far as manufacturing of chillers and their parts such as compressors and de-humidifiers are concerned, there has not been much change in technology. The scroll compressors have been in the industry for the last 15-20 years and screw compressors have been around for almost 30 years. The technology used in the operation of chillers has changed with 58

Modern Plastics & Polymers | March 2012

more focus on software than hardware. Today, machines are more electronically driven owing to the use of electric parts. Earlier, common chillers were used for all plastics processing requirements such as blow moulding, injection moulding and extrusion. However, with time, competition has increased and, currently, most companies use chillers for specific requirements for each technique.

Chiller speed Variable speed chillers are specific to injection moulding, and these do not carry any advantage for extrusion. These chillers have been designed for specific injection moulding needs, which helps users to produce results f rom the process while maintaining the lowest lifecycle cost of the equipment. In order to harvest the desirable benefits from the latest technology equipment and processes, chilled water, as an auxiliary supply, needs to be available at precise flow rates & pressures, besides maintaining temperature accuracy.

Different parameters of the equipment such as capacity output, power consumption, performance and electrical load conditions must be inspected for the right performance. Chiller manufacturers need to work within a range of capacities varying precisely as per changing process loads, enhancing process control and saving energy by up to 25 per cent. Chillers must have high-pressure multi-stage pumps with the flow rate varying precisely as per the process requirement. For specific process requirements, the water pressure must be adjustable along with rust-free chilled water supply for accurate process control and low equipment maintenance. This chilled water should be controlled via an automatic chilled water level controller with bypass arrangement. Air-cooled units must have high-efficiency aluminium condensers with high flow and low-noise fans. Installed equipment may be Courtesy: OPTI operating at their maximum efficiencies so they must be synchronised with

Chiller technology

other modern technologies to ensure higher levels of efficiency. Considering the multi-faceted requirements of these chillers, these should be manned by technically-trained operators who must be monitored according to the various requirements.

Chillers with dual temperature control Dual-temperature chillers with precise properties are designed for cooling requirements of the processes where the required temperature of the fluid is varied at different utility points. These include the features of two differently set chillers into one, which saves running costs and requires lesser footprint area. Another advantage is that these are able to maintain the total need through just one set of auxiliary equipment instead of many units. Such chillers offer two separate water circuits at varied temperatures set as per specific needs of the process. Semi-hermatic screw compressors with step-less capacity control maximise efficiency as these adjust automatically according to process load. It is important for chillers to be Chlorofluorocarbon (CFC) f ree in order to meet environmental standards. Efficiency can also be increased through

electronic expansion valves for precise temperature control. There should be wired as well as wireless connectivity for remote operation and data logging. As per the actual load, the step-less capacity should be controlled. The electronic expansion valves also help in precise refrigeration flow and increased operational efficiency. Air-cooled condensers should have a low Fin-Per-Inch (FPI) count, high-gauge coated fins pneumatically adjusted at high pressure, which will make them ready for operating at up to 52째C. For elevated efficiencies, economisers should be standard. During peak ambient conditions, it is important to save power; hence, the chillers should have low-noise, axial flow discharge fans.

Screw chillers The condensers and evaporators used in screw chillers should be designed for high fluid flow with due scope for higher fluid impurities. The air-cooled condensers should be designed and tested in extreme weather conditions, so that breakdowns are eliminated. Water-cooled condensers should also be designed on higher fouling factors to compensate for Total Dissolved Solids (TDS) in cooling water. The capacity of these chillers must vary exactly as per

Courtesy: Krane

Modern Plastics & Polymers | March 2012

Scroll chillers Scroll chillers must be efficient and easy to operate and maintain; also, breakdowns should be kept to the minimum even when the operating period continues throughout the year without halting. These machines should be robust in order to have a higher operational life and flexibility. The structure should be potent enough to withstand temperature fluctuations throughout the process.

Reciprocating chillers In conditions where scheduling of the machine for proper operation and maintenance is not possible, reciprocating chillers can be used. These chillers can operate within the largest range of ambient and operating temperatures. Although the operating parameters are the focus of such chillers, these should be designed on platforms where operating parameters are the primary focus, but the operating efficiencies are not compromised. Along with robust designs, reciprocating chillers should have data controlling features, which, when incorporated in them, will perform relentlessly. With advancements in technology and the numerous requirements from chillers, it has become important to combine features such as robust design, temperature control and faster cooling with energy efficiency. While the heat generated during plastics processing is managed through chillers, it is also important to ensure that these chillers themselves remain free of emission. Vijay Bali is Vice President of Reynold India Pvt Ltd. A mechanical engineer with an MBA in marketing, he has 19 years of experience in the plastic equipment industry. Email id: v.bali@reynoldindia.com

Energy-efficient material cooling technology

the fluctuating load conditions in order to ensure the best energy efficiency. Necessary chiller fittings provided as standard can go a long way in keeping installation costs to the minimum.

INSIGHT & OUTLOOK: Inter face - Varun Kapoor

“Higher levels of infrastructural development will immensely benefit the extrusion machinery sector” …asserts Varun Kapoor, Director, Sarvasv Machinery & Equipments Pvt Ltd. With the latest technology and equipment available to Indian manufacturers, the plastics industry is poised to deliver the best results. In an interaction with Anwesh Koley, he highlights the importance of plastics consumption in India and shares his views on industry trends. How is the plastics ancillary equipment industry growing in India? The plastics processing equipment industry is shaping up well in India. There is demand for extrusion sheathing lines in the cable industry, with greater rural connectivity and electrification programmes. We provide equipment for machinery used in production of insulating cables. We have been contributing well to overall growth of the extrusion sector. Currently, the industry is going through an unfavourable phase as the infrastructure sector has not seen much activity. The infrastructure industry is heavily dependent on the Government, and the policy makers are not doing enough. This has had a direct impact on the cable industry, and hence, on the plastics machinery industry. This industry produces domestic cables and power cables, where the latter is completely dependent on infrastructural developments. Thus, immediate inf rastructure investments are required for benefit of the extrusion sector.

What are the latest technologies used in this industry? We manufacture high-speed extrusion and sheathing lines and the technology employed here is at par with that in Europe. We have 30 years of experience in this industry. The technology has undergone vast improvements over the years, as customers have become more demanding of the products, and global trends are keeping domestic manufacturers on their toes. We have witnessed constant upgradations, especially in the electronic and electrical aspects of extrusion machinery. 62

Modern Plastics & Polymers | March 2012

advantages while using barrier/mixing screws in single-screw extruders. The combination of grooved barrel conveying, barrier melting mechanism and multiplezone mixing can substantially enhance the performance of single-screw extruders. The latest technology in screw and barrels is the introduction of bimetals. Bimetallic construction provides a protective wear surface fused into highstrength backing material. The design delivers efficient energy transfer between the bore and backing material. This feature allows for rapid detection of process condition changes, quick response to heat and cool commands, precise control and uniformity of barrel zone temperatures. An engineered lining improves component compatibility between the screw and barrel wear surfaces, minimises the wear gap and prolongs product life. The efficiency and speed of sheathing lines have increased and companies are focussing more on waste management. About 70-75 per cent of our production is exported. We export to Europe, Australia and various African countries. Indian machinery has a big market in South Asia – Nepal, Bangladesh and Sri Lanka.

How important is energy efficiency in the plastics industry? Improving efficiency is a priority for extrusion companies and is a major development objective for machine manufactures. The use of high-technology extruder screw/barrel units and extrusion dies is a key factor here. Maximum melt throughput with good melt quality and the ability to process a broad range of raw materials with the same screw are major

What are the challenges faced by the industry? Competition is a healthy challenge as it encourages higher productivity with an eye on innovations. Better infrastructural facilities are required to make products more competitive and provide a crucial edge over manufacturers from other countries. The machinery industry in India comes under Small & Medium Enterprises (SME), and thus having individual research and development centres is not feasible for manufacturers in the short run. The Government should initiate research activities and provide them to machinery manufacturers. Such initiatives will ensure a bright future for the industry. Email: anwesh.koley@infomedia18.in

INSIGHT & OUTLOOK: Roundtable

Where does the

Indian ancillary equipment industry

stand globally? The requirements of the global plastics processing industry are on the rise and the Indian ancillary equipment sector has responded well by integrating the mechanical aspects of equipment with electronic elements. Anwesh Koley speaks to industry experts on the current position of the Indian equipment industry vis-Ă -vis global standards. Amit Takkar Partner, Takkar Industries

Ashwini Aggarwal

Ancillaries to the plastics processing industry were originally supplied by companies that supplied these to other industries, ie, suppliers of agricultural equipment provided silos, bins, auger feeders, etc. This required special manufacturing skills that were initially missing in Indian companies. But, the specialised nature of the plastics processing industry meant extensive modification of off-the-shelf equipment to do the job. This set the trend of companies being formed solely to address the specific needs of plastics processors. Globally, ancillary equipment manufacturers already had technologies to support higher production requirements with a focus on sustainability. Over the years, Indian manufacturers also grew, gained knowledge and experience. Today, these manufacturers have evolved into strong engineering companies, dedicated to solve the problems of this unique industry.

President, Brose India Automotive Systems Pvt Ltd

Editorial take:

The Indian ancillary industry has become the source of processing solutions not only for its customer base, but also for equipment providers. Advancements in plastics manufacturing processes often come from the expertise that has evolved in the ancillary equipment companies. This is because we are in a unique position from where we can observe all processes and problems of the entire industry. This helps processing companies to bring continuous improvements to the entire industry. Existing customers globally depend on these innovations and benefit from it. International plastics companies are gearing up to advantages offered by Indian ancillary equipment suppliers. Manufacturers try to understand the problems of their customers and often find underlying problems that the customer may not have observed. Thus, they try to solve these problems with innovative ideas, which benefits the customers.

Umakant Sharma Marketing Manager, Matsui Technologies India Ltd

Constant quality improvements in ancillaries such as loaders, feeders, dryers, water and robotics by Indian ancillary equipment manufacturers are evident in the high-quality processors and finished products available in the market. The plastics industry in India has matured, and only those who supply consistent quality remain formidable competitors. Companies that lose sight of continuous product improvement lose ground in the marketplace, as their product lines become outdated. It takes a lot of learning and innovative ideas to succeed and only a few companies are willing to work on a project for the required extended period of time. New ideas and concepts take time and resources to triumph in the market. Besides, there is always the risk of failure. Thus, it is easier to take a successful product and modify it slightly. Indian equipment suppliers have successfully taken all these factors into account and are leading the way in terms of technology. Email: anwesh.koley@infomedia18.in

As new ideas often take a long time to develop fully, manufacturers find it easier to modify and sell an existing equipment or technology. However, to create a leadership position in the global arena, companies must enhance their expertise and aim to solve the problems of the industry and those of the customers. 64

Modern Plastics & Polymers | March 2012

INSIGHT & OUTLOOK: Polyamide alloy

Imparting high performance with design flexibility Polyamide (PA) alloy offers numerous features such as low density, low moisture pick-up, ease of processing and insensitivity to hydrolysis, which are important for various consumer electronics applications. Here is an introduction of polyamide alloy, its properties, processing techniques and some of the key applications in various sectors, particularly in automotive, electrical and electronics. Understanding polyamide alloys

Mandar Amrute

olyamides are well recognised for their outstanding mechanical properties and good chemical resistance. However, these materials also absorb moisture, and this property noticeably affects their mechanical and electrical properties as well as dimensional stability. The Polyamide (PA) alloy is a unique patented polyamide-based alloy that offers best properties of polyamide (excellent mechanical properties) while compensating on its drawbacks such as moisture pick-up and sensitivity to hydrolysis. One such polyamide alloy under the brand name Orgalloy® is marketed by Arkema.

Polyamides are incompatible with polyolefins. Polyamide alloy is a PA6based alloy with polyolefin and offers the benefits of combined properties of both polyamides and polyolefins. Polyamide alloy is based on a patented technology, which enables homogenous mixing of polyamides and polyolefins. Compatibilisers used are based on proven morphology, and therefore it ensures a consistent performance. Key advantages of polyamide alloys: Low moisture sensitivity (retention of mechanical and electrical properties) Good dimensional stability Easy to process Good chemical resistance Low density

Table 1: Comparison of moisture impact in PA6 and polyamide alloy

Moisture pick-up in equilibrium Air - 23°C - 50%RM Water - 23°C

PA6 2.80% 8.50%

Polyamide alloy 1% 3.30%

Table 2: General properties of polyamide alloy

Property Density Melting point

g/cm3

Polyamide alloy A 1.03

Polyamide alloy B 1.04 255

°C 220 Tensile strength@break 50 50 MPa % Tensile elongation@break 220 >100 Hardness SHORE D 76 77 Flexural modulus MPa 2,000 2,100 These properties are of general purpose polyamide alloy injection moulding grade only.

Modern Plastics & Polymers | March 2012

Recyclability (eg, polypropylene, polyethylene, PA, etc) Light in weight than PA6 and PA 6/6 High barrier properties against polar liquids, gases and aromatics Polyamide alloys feature high performance properties such as high temperature resistance, low density and mechanical fatigue resistance, which are required in the automotive market. Moreover, the elastomer part of these alloys provides several benefits in terms of processing and productivity.

Electrical properties The low moisture pick-up of polyamide alloys guarantees the stability of their electrical properties over time. Moreover, due to their easy injection mouldability, the possibility of overmoulding on polyolefins and their dimensional stability, this material is well suited for electrical applications. Dielectric rigidity is one of the parameters, which needs to be determined while designing a part for electrical or electro-technical applications. Although theoretical definition of this parameter is the upper value of an electrical field causing the material to brake at a given thickness, it is difficult to find a practical definition for the same. In theory, dielectric rigidity is expressed in kilo Volt per millimetre

Polyamide alloy

Table 3: Electrical properties of polyamide alloy

Property

Unit

Surface resistivity Dielectric rigidity

Ohm kV/mm

Resistance to tracking

Volt

Standard

Polyamide alloy A

Polyamide alloy B 2.5 E18 18

ASTM D257 4.8 E15 ASTM D149 19 NFC 26220 >600 >600 Note: Sample of 2 mm tested at 50% RM and 23°C

PA6 and Polyolefin incompatibles blend

Orgalloy® PA6-based allloy

Figure 1: Microscopic view of compatibility of polyamide alloy

(kV/mm) and is independent of thickness of the material. Generally, it has been observed after the internal study that dielectric rigidity decreases with thickness. Another factor affecting dielectric rigidity is moisture pick-up. Moisture pick-up in the polyamide 6 family causes considerable decline in dielectric rigidity.

such as injection moulding, blow moulding, extrusion and coextrusion. This material can be processed on standard extrusion or injection moulding machines with screw designed for polyolefins. The glass-filled range of polyamide alloys is also available.

Applications of polyamide alloys Product range and processing Polyamide alloys offer rigidity in the range of 200-2000 MPa. Its product range is available in rigid, flexible and pliable series and can be processed by techniques

Polyamide alloy is widely used in the automotive sector for applications such as under bonnet tubes, air and oil ducts and many other blow moulded parts. Its high barrier properties make it an

Density in gm/cm3

1.14

PA-6/66

Polyamide alloy

1.14

1.01

9% Reduction

1.12 1.1 1.08 1.06

ideal candidate for food and cosmetics packaging. It has been an appropriate material for many engineering and agricultural films used for soil fumigation. This alloy also finds applications in electrical and electronics. Properties of polyamide alloy, such as thermal resistance and low sensitivity to moisture, make it suitable for electrical and household electronics applications: Solenoid valves (resistance to hydrolysis) Coil support (dimensional stability and dielectric resistance) Engine mountings Overmoulding of connectors Protective housing for electrical equipment and tools Actuators, spindles and fastenings Protective housings for electric ovens and instruments

Material of choice Polyamide alloy is a dynamic product suitable for electrical and electronics applications. In addition to mechanical properties, low moisture pick-up and dimensional stability, this alloy has a lot to offer in packaging and films where low permeation properties are a prerequisite. It is the material of choice for blow moulding applications such as air and oil ducts in the automotive industry. The ease of processing on standard extrusion and injection machines designed for polyolefins is an added advantage offered by this product range. Mandar Amrute is Market Development Manager with Arkema India Branch office. Email: mandar.amrute@ arkema.com

1.04 1.02 1 0.98 PA-6/66

Polyamide alloy

Figure 2: Density comparison between polyamide alloy and PA6/6,6

Modern Plastics & Polymers | March 2012

Arkema is a French chemical company mainly operating in industrial chemicals and specialty polymers such as Polyamide– 11/12 and PVDF. Polyamide alloy is marketed by Arkema under the brand name of Orgalloy®. In this article, polyamide alloy is referred to as Orgalloy®.

INSIGHT & OUTLOOK: Mould cavity

Monitoring temperature for better quality In the previous edition (January 2012), the author looked at various methods to eliminate the vagaries of external conditions influencing part quality and the ability to control part quality by monitoring cavity pressure in the injection moulding process. This article explores the significance of temperature monitoring in regulating quality of the parts produced. machine settings and natural variations in melt viscosity, which may occur due to batch variations, processing of regrind or effect of humidity. That is, every process variation in injection moulding alters melt flow behaviour and, at permanently set switchover thresholds, leads to greater or lesser deviations. Extreme variations lead to unfilled cavities or overfilled parts.

Y R Anand

cost-effective method of monitoring the cavity activity is temperature monitoring. If carried out alone, this method can be more accurate and less expensive than cavity pressure monitoring. A word of caution here is that in many applications, pressure monitoring is essential, while in more critical cases, both pressure and temperature must be monitored. In both cases, this is done by using sensors effectively and intelligently, putting their feedback to control part quality and reduce variations between shots and cavities.

Automatic switchover to holding pressure In contrast to cavity pressure sensors, cavity temperature sensors can detect sudden temperature increases within milliseconds, ie, arrival of the melt at the position of the sensor. For automatic switchover to holding pressure, these sensors are located ahead of the end of the flow path.

Cavity activities There is an association between constant

11 mm

Cooling Open loop Short shot

Overmoulded 120 bar

Cavity pressure Open loop (Fix level) Short shot

Overmoulded

Cavity temperature Volume fill

Automatic Closed loop

Typical choices for good quality injection moulding Source: Unimark

Modern Plastics & Polymers | March 2012

A method patented by Priamus System Technologies AG of Schaffhausen, Switzerland, is used to immediately generate a switch signal. This switch signal is used by the injection moulding machine to automatically switch over to holding pressure. This method eliminates the need for optimisation with filling tests, since the melt front is always recorded independent of machine settings. It even compensates changes in the machine settings, eg, injection speed, and the resulting changes in the melt volume. Thus, mould setups and process optimisation are considerably more robust, less susceptible to problems and easier to handle than by the classical procedure. Natural variations in the melt and ambient conditions are automatically compensated, thus clearly reducing the range of variation in the weight & dimensions of moulded parts. Two practical examples can illustrate this point. In the first, a Swiss company had compared various switchover techniques over long periods, with the following result: In cases where a cavity temperature sensor cannot be located at the most favourable position, the switch signals can be optimised with the aid of delay times. Dimensional variations in the injection moulded parts are considerably smaller during mould setup, in terms of deviation as well as variety when the Priamus switchover method is used rather than conventional methods. In the second example, an electric plug manufacturer in Belgium was having difficulty in processing glass

Mould cavity

fibre-reinforced materials (eg, PPA-GF33), especially with variations in dampness content and, consequently, viscosity. Since automatic switchover compensates viscosity variations, it eliminates hand sorting of parts. With the conventional method, 510 per cent was the usual percentage of rejects, whereas with automatic switchover, over 600,000 parts were produced without even a single reject. Noticeable variation in screw positions at the point of switchover was observed as a logical consequence of this method.

Opening and closing of shut-off nozzles In injection moulding, detection of the melt front in real time is of great significance, not only for automatic switchover to holding pressure, but also for many other applications. Only after the melt position is actually known can it be utilised for regulation and control functions. This is difficult to do by measuring only the cavity pressure, since certain pressure must be built before the switchover point is reached, ie, before sending a signal for opening or closing of the shut-off nozzle. Since pressure does not build up uniformly during production, but varies according to the actual ambient conditions and variations in melt viscosity, the opening or closing of shut-off nozzles always occurs at different melt positions when linked to this pressure level. A cavity temperature sensor automatically detects the melt front. When the melt reaches the sensor, the temperature rises quickly; therefore, the position of the melt is always known regardless of ambient influences or alterations in viscosity. Thus, the opening and closing of the shut-off nozzle can be regulated and, automatically, by a switchover signal generated when the sensor position is reached or by using delay times. This method can have practical applications, such as to detect, move and regulate weld line positions; automatically open shut-off nozzles in sequential injection moulding; or automatically ventilate cavities via an automatically triggered venting core.

No feedback

Constant machine settings set values vs. actual values

No feedback Constant machine settings Reaction on viscosity changes set values vs. actual values

Open loop

Closed loop

An illustration of cavity monitoring Source: Unimark

In many cases, it is not possible to predict the exact melt position or the end of the flow path due to complex parts geometry. It is also possible for the melt position to shift due to various machine settings. In family moulds, for example, it is often impossible to fill all cavities simultaneously. For such cases, there are solutions to release a switchover action on either the first or the last signal. Depending on the application, this enables preventing the parts from overfilling (first signal) or ensures that all parts or zones are completely filled (last signal).

Hot runner balancing Hot runner moulds with one or more cavities are subject to natural variations caused by changes in ambient influences as well as differences in mould temperature or melt viscosity. That is why injection moulded parts differ in consistency, weight and dimensions. In the absence of active hot runner control, there are natural limits to the precision of any process. The hot runner can be controlled by automatic detection of the melt position in the cavity and adapted via nozzle temperature in it. If nozzle temperature is too low at a particular cavity or zone of a broad surface part, the melt flow path shortens. In contrast, the flow path extends at extremely high temperatures. Both errors can be systematically detected and automatically corrected. Earlier, only cavity pressure was used instead of cavity temperature

sensing. Therefore, the functionality of the method could be demonstrated in the simple case of a multi-cavity mould with identical cavities. This principle had clear limitations: hot runner balancing was based on pressure increase, which in contrast with cavity temperature, is not transformed into a signal prior to the compression phase, ie, long after filling and switching over to holding pressure. Therefore, control based on melt position is impossible when cavity pressure sensors are used. Further, many applications, such as melt flow control in car bumpers or while processing fluid silicon, cannot be implemented without the knowledge of the actual melt position.

Beyond the convention Quality control through temperature sensing can be a cost-effective method in the part quality improvement, and this does not always have to depend on cavity pressure. Y R Anand holds a bachelorâ&#x20AC;&#x2122;s degree in Mechanical Engineering from University of Mysore and a masterâ&#x20AC;&#x2122;s degree in Production Engineering from IIT, Kharagpur. He worked for a little over nine years in manufacturing industries in Mumbai. Since 1980, he has been a partner in UNIMARK. The company sells and services machines in plastics processing, tooling industry, microelectronics and wire mesh welding industry. Email: anand@unimark.in

March 2012 | Modern Plastics & Polymers

AUTOMATION TRENDS: Extrusion insights

Propelling growth through process integration With plastics consumption growing in terms of volume and applications, today’s extrusion machinery require efficient control systems and die-changing options. Annabel Dsouza takes a closer look at the innovative automation solutions that allow processors to enhance throughput and operator safety while reducing material consumption and production cycle time.

mong the most versatile technologies in plastics processing, extrusion machinery plays an integral role in various plastic applications. As a larger number of Indian processors adopt futuristic extrusion solutions to keep pace with the exponentially growing demand, automation technology is making headway in the extrusion machinery

Modern Plastics & Polymers | March 2012

sector. The primary goal of automation and robotics is to enhance output and operator safety, while reducing power & material consumption as well as labour costs. A typical plastics extrusion plant performs the following three functions to run its production – material handling, blending/dosing and, finally, extrusion. With constant focus on enhancing productivity, the major contribution of

automation solutions has been towards complete process integration through accurate material delivery and faster die-changeover.

Extrusion yield control An extrusion yield control system maintains a constant material mass flow (throughput) in the extruders to maintain consistent properties of the final product. Yield control systems use gravimetric measurements to determine extruder throughput. Werner Gropp, Marketing Manager, B&R Automation, informs, “The control system determines the extruder throughput by analysing how fast each batch is consumed and gives operators a detailed & practical view into the extrusion process by using a large user-configurable material database in its memory, which provides enough information about each material to calculate the estimated volumerelated process parameters such as film thickness for blown film process.” The system also calculates blowup ratio, draw-down ratio and other useful process parameters. The control system can handle any extrusion line configuration – from simple mono-layer installations to complex multi-layer coextrusion lines – including temperature control of all extruder and die zones. This option is cost-effective and useful on larger extrusion lines with 30-50 temperature zones to control.

Extrusion insights

Batch blending control Another innovation in material dosing for the extrusion process is the use of control systems that rely heavily on the stability and quality of the ‘actual weight’ feedback coming from load cells on which the batch blender scale is suspended. The systems use special strain gauge analog inputs to process load cell signals. It is important to note that the fullbridge measuring scheme used in strain gauge modules provides sufficient stability in measurement to virtually eliminate digital filtering that would normally be used. The batch blending algorithm increases the load cell signal processing speed, translating into large gain in throughput. Gropp adds, “Our test results indicate that this blending control system implementation may result in 10-50 per cent of throughput increase on batch blenders with pinch valve or slide gate dosing mechanisms without any

Key advantages of automatic control system for extrusion machines Easily scalable extrusion process – for gravimetric measurement and melt pumps Simple operation using clear user interfaces and a large touch panel (application-specific) Simplified input of extrusion machine parameters Cost-savings through a complete solution for extrusion machines from largely pre-assembled software package and modular hardware Flexibility and upgradability based on global industry standards through fully integrated automation

changes to their mechanical designs. The system has been tested with a wide range of materials on blenders that use different physical principles of material dispensing. The control system consistently achieves superior throughput and accuracy working with either rubber pinch valves or steel slide gates as actuators.”

High-performance control systems for extrusion machine – including systems specially designed for pipe and profile extrusion – offer software advantages for controlling & operating all extruder-related components. Processors can operate followup equipment, sensors for product testing, melt pumps and measuring equipment with single control systems. However, the key concern of automation extrusion control system lies in its effectiveness for smaller capacity machines as well as larger ones. The control system should be customised as per individual production requirements.

Automation in die-changeover The process for removing extrusion dies prior to disassembly is conventionally an expensive and inefficient process. The standard method has four primary limitations: Safety: Workers often load dies into hot open tanks of caustic. Hot caustic vapours present potential hazards, such as fumes and splash, to workers. Tanks are sometimes open and not well ventilated. Additionally, because caustic corrodes metal, escaping fumes can negatively impact nearby metal structures. Time: A slow process, it can take 8-12 hour of soaking to get enough aluminium out of dies to permit disassembly. This increases machine downtime and reduces productivity. Cost: Temperature and pH are often not well controlled in cleaning tanks. Technicians may not understand the effects of temperature on the speed of the cleaning process or necessary items to control temperature may not be available. pH is important in the cleaning process, and a lack of understanding of the non-linear nature of pH may result in inefficient use of chemicals. Waste: Regulations regarding waste vary geographically. pH reduction requires controlled addition of acid. The standard operating procedure is to neutralise the waste and extract the solids through a filter press. Solids are disposed off in a landfill and liquids are generally of sufficient quality to enter the city sewer system.

The control system determines the extruder throughput by analysing how fast each batch is consumed and gives operators a detailed & practical view into the extrusion process by using a large userconﬁgurable material database in its memory. Werner Gropp Marketing Manager, B&R Automation

New improved system With increasing pressure on enhancing output and reducing cycle times, automation is a sought-after solution for quick and efficient mould changes. Automatic mould handling and loading significantly reduces mould changing times, gaining more productivity and flexibility in frequent production turnarounds. This boosts shopfloor safety and labour optimisation. Extrusion machinery operators can work efficiently without the equipment and tooling running the risk of damage from loading operations. Therefore, contrary to reducing labour investment, automation solutions actually allow processors to make their processing lines more efficient and safe. In the pursuit of designing automatic extrusion control and die changing system, standard industry practices have been challenged and a new improved system has been shown to provide safety and cost benefits that are valuable in the plastics extrusion process. Email: annabel.dsouza@infomedia18.in March 2012 | Modern Plastics & Polymers

ENERGY MANAGEMENT: Heat recover y system

Harvesting energy, expanding margins Moulding and manufacturing of plastic parts require transferring considerable amounts of heat. Heat is added to the plastic material to mould it into the desired shape. After this, the heat must be extracted from the formed part to handle it and make it ready to sell. Anwesh Koley explores ways by which waste heat can be harvested during the manufacturing process.

he efficiency with which heat is extracted f rom various processes can have a tremendous impact on maximising productivity and remaining competitive. One method of recovering energy in a plastic pipe manufacturing process can be by utilising a sealing gasket compression moulding process. In this process, a gasket moulding material is placed in a cavity with a predetermined shape, where the cavity is formed between a fixed and a movable mould member; subsequently, pressure is applied between the respective fixed and movable mould members to cause the gasket moulding material to conform to the shape of the mould cavity. A compression or injection moulding operation is used to form a sealing gasket, which is used in the subsequent manufacturing operation as part of the energy recovery system. â&#x20AC;&#x153;A Stirling engine cycle is used to recover heat during gasket manufacturing. The Stirling engine is driven by waste heat from the mould members or other associated parts of the injection or compression moulding apparatus,â&#x20AC;? informs Mangesh Manjrekar, 76

Modern Plastics & Polymers | March 2012

Director, Raj Engineering Works. The recovered waste heat is subsequently used to heat the female pipe end, which is belled in the pipe manufacturing process.

Managing heat with chillers The most common method of accomplishing heat extraction is by using a portable chiller. The capacity of portable chillers is generally measured in tonne. In this use, a tonne is defined as the capability to extract or reject 12,000 British Thermal Units (BTUs) per hour. A 5-tonne chiller can reject 60,000 BTUs per hour. If a chiller is needed for an injection-moulding machine that processes 120 lb of highdensity polyethylene per hour, a 4-tonne chiller should be selected for the job. Generally, portable chillers are available in sizes ranging from fractional tonnage up to 30-40 tonne. Beyond that, the units are too large and cumbersome to be considered portable. For the most part, portable chillers are available in two varieties: air-condensed and water-condensed. Air-condensed units utilise a radiator-type coil and fans

or a squirrel-cage blower to condense the refrigerant. This implies the need for a constant supply of relatively cool and fresh air. In contrast, water-condensed units incorporate a shell-and-tube heat exchanger to accomplish the same task, thus requiring condensing water from a cooling tower. In process cooling, a chiller is used to extract or reject heat from a process. However, the chiller does not absorb the heat â&#x20AC;&#x201C; it transfers it. The compressor, which is the heart of the refrigeration system, draws low-pressure, lowtemperature gas from the evaporator through the suction, or low pressure, side of the refrigerant circuit. Inside the compressor, the gas is compressed, increasing its temperature and pressure. The compressor then discharges the compressed gas to the high-pressure side of the system. Subsequently, the gas flows through the condenser, where the heat from the gas is transferred to the condensing medium. If the chiller is air-condensed, the heat is transferred to the ambient air. And, if it is watercondensed, the heat is transferred to the cooling tower water to be released

Heat recover y system

Components and features provided in today’s portable chillers are drastically different from those offered a few years ago. Probably, the most important change has been the introduction of scroll compressors and brazed plate evaporators. Mangesh Manjrekar Director, Raj Engineering Works into the air elsewhere. As the heat is transferred, the temperature of the gas reduces, condensing the gas into liquid. After passing through a filter and a sight glass, the now-liquid refrigerant reaches the thermostatic expansion valve. This valve creates a pressure drop in the system as the liquid is injected into the evaporator. Once inside the evaporator, which is essentially a heat exchanger, the refrigerant boils off and becomes a gas again as the heat from the process fluid is transferred into it. The lowtemperature vapour is then drawn out of the evaporator into the compressor to complete the cycle. This cycle continues while the compressor is operating.

Selecting the best system The choice between an air-condensed or water-condensed chiller requires careful consideration. Because portable chillers transfer the heat from the process to its surroundings in one form or another, the environment in which the chiller will be used must be appropriate. Air-condensed chillers must be located in an open, wellventilated space to avoid overheating. If the chiller has a blower rather than

Modern Plastics & Polymers | March 2012

fans, the heated air may be carried away via ductwork as long as adequate makeup air is provided. In addition, aircondensed chillers should not be used in areas where the ambient air temperature exceeds 35°C. Water-condensed chillers can be operated in hot, closed areas as long as they are supplied with a cooling tower water to carry away the heat. The amount of water needed will vary according to the capacity of the chiller. “Components and features provided in today’s portable chillers are drastically different from those offered a few years ago. Probably, the most important change has been the introduction of scroll compressors and brazed plate evaporators,” opines Manjrekar. Scroll-type compressors, which use a mating pair of orbiting scroll plates to compress the refrigerant, have fewer parts than their reciprocating pistontype counterparts. The efficiency of brazed plate evaporators permits transfer of significant amounts of heat in a compact size. This change has allowed chillers to be more space-efficient than in the past, thus better utilising valuable plant floor space. Other features that are more prevalent today are nonferrous construction to minimise corrosion and water contamination and also features such as microprocessor controls with special communication capabilities. A portable chiller can be incorporated into a temperature control system for an injection moulding operation. “The chiller can be used to remove heat from the hydraulic heat exchanger, mould temperature controller (thermolator) and feed throat of the injection moulding machine. Although some of these cooling loads could be cooled by other means, a chiller offers certain distinct advantages,” adds Manjrekar. Because the chiller contains a precisely controlled ref rigeration circuit, it is capable of supplying a consistent, accurate temperature to the process. This could result in more efficient moulding with less scrap. In addition, the chilled water

loop is a completely closed arrangement, which will provide the best water quality. This may result in better heat transfer, less maintenance and decreased downtime. The final advantage is that the chiller can produce much colder water than any other mentioned options, which may be important under some circumstances.

Waste heat recovery boilers Generally, waste heat boilers are water tube boilers in which hot exhaust gases from gas turbines and incinerators pass over several parallel tubes containing water. The water vaporises in the tubes and is collected in a steam drum from which it is drawn out for use as heating or processing steam. Because the exhaust gases are usually in the medium temperature range and to conserve space, a more compact boiler can be produced if the water tubes are finned so as to increase the effective heat transfer area on the gas side. The pressure at which steam is generated and the rate at which steam is produced depend on the temperature of waste heat. The pressure of a pure vapour in the presence of its liquid is a function of the temperature of the liquid from which it is evaporated. If the waste heat in the exhaust gases is insufficient to generate the required amount of process steam, auxiliary burners, which burn fuel in the waste heat boiler, or an after-burner in which the exhaust gases flue need to be added.

The way ahead The recovery of waste heat during plastics processing plays an important part not only in improving energy efficiency, but also in increasing productivity. The array of portable chillers available today is wide and vastly different from those offered a few years ago. Most of these can be modified easily to accommodate the specific needs of nearly any plastics processor and, with routine maintenance and water quality management, will provide years of service. Email: anwesh.koley@infomedia18.in

POLICIES & REGULATIONS: Plastics recycling

Mechanisms for safer

plastics disposal Plastics is a convenient commodity since it is less costly and easy to mould into different designs. But, when improperly disposed off, it can lead to environmental hazards. Recycling is a good method to avoid problems arising from poor disposal of plastics. Anwesh Koley underlines the importance of plastics recycling under different categories.

ecycling is a broad term that is generally associated with postconsumer scrap. However, scrap generally falls within two categories: post-industrial and postconsumer. Processors of all kinds try to avoid generating scrap; moreover, when generated, it is re-used by putting it back into the process. Industrial scrap includes off-specification parts, sprues, etc and is its size is usually reduced by devices such as granulators, shredders and pulverisers and re-fed into the machine. In postconsumer operations, recyclers collect bags, bottles and other end products. These products are washed, pelletised and sold by a recycler to processors or reprocessed into parts.

Recycling plastics A big problem with plastics recycling is that it is difficult to automate sorting of plastic waste, and hence is labourintensive. “While containers are usually made from a single type and colour of plastics, making them relatively easy to sort out, a consumer product such as a cellular phone may be made of many small parts consisting of different types and colours of plastics,” says Amit Kalra, Director, Hindustan Plastics and Machine Corporation. It is difficult to recycle such an item. However, there are several plastics that can be recycled easily. 80

Modern Plastics & Polymers | March 2012

To identify and sort recyclable plastics internationally, Society of the Plastics Industry (SPI) developed a standard code in the late 1980s. This code identifies the type of plastics used to make a particular object; however, it does not indicate whether recyclable plastics was used to make that piece, nor does it indicate whether that type of plastics can be recycled. Generally located at the bottom of the plastic container, the code consists of three arrows that cycle clockwise and create a triangle with rounded corners. Inside each triangle is a number that identifies that plastic’s type, and below each triangle is a combination of letters that correspond to the scientific name of the type of plastics. Types of plastic recognised by SPI: Polyethylene Terephthalate (PET or PETE): This is one of the most frequently recycled plastics by consumers. Containers marked with a ‘1’ and ‘PET’ or ‘PETE’ include some soft drink bottles, water bottles, plastic jars, plastic wrap, etc. High-Density Polyethylene (HDPE): This plastics is marked with a ‘2’ and ‘HDPE’, it is frequently recycled. Some examples of this plastics is some milk cartons, juice bottles, shampoo bottles, liquid detergent containers made of plastics. Polyvinyl Chloride (PVC): This type

of plastics is marked by a ‘3’ and ‘PVC’, and is less commonly accepted at local recycling centres as it is more difficult to recycle. Common examples include clear food packages, liquid detergent containers, many construction applications, such as some traffic cones. Low-Density Polyethylene (LDPE): This is marked with a ‘4’ and LDPE, this plastics is used in some bags for packing bread and frozen food, trash cans, garbage can liners, etc. Polypropylene (PP): This type of plastics is commonly used in the automobile and construction industries; this plastics is marked with a ‘5’ and ‘PP’. Some examples include car battery casings, oil funnels, plastic drinking straws, etc. Polystyrene (PS): It is uncommonly used by consumers. Marked by a ‘6’ and ‘PS’, this plastics is used in some packing foam, plastic cutlery and protective packaging for electronic goods & toys. Others: Plastics marked as ‘other’, ‘O’ or with a ‘7’ cannot be recycled since these are commonly made of a combination of the previous six types of plastics, or with a type of plastics other than those listed here, and cannot be broken down for recycling. While there are many different types

Plastics recycling

of plastics, not all can be recycled, and some that are recyclable may not be eligible for curbside pick-up or accepted at the local recycling location. “Of the types of plastics that can be recycled, it is critical that they be recycled with their own type because even a small amount of the wrong type of plastics can damage the melt. Hence, sorting of plastics is a critical part of the recycling process, and many cities offer bins to help residents sort recyclables properly,” adds Kalra.

Plastics recycling process The process of plastics recycling is performed in five stages: Plastics collection: This is done by roadside collections, special recycling bins and directly from industries that use large amounts of plastics. Manual sorting: At this stage, nails and stones are removed, and the plastics is sorted into three types, eg, PET, HDPE and other. Chipping: The sorted plastics is cut into small pieces ready to be melted. Washing: At this stage, contaminants are removed, eg, paper labels, dirt and remnants of the product originally contained in the plastics. Pelleting: In this stage, plastics is melted and extruded into small pellets ready for reuse. However, after washing, much of moisture remain in the material. Hence, many polymers emit vapours and gases during melting, and these must be removed so as to prevent bubbles in the product. Therefore, degassing or devolitisation of polymers is often crucial to manufacture acceptable pellet quality. This can be accomplished in several ways. Pre-drying is often not sufficient; hence, venting during extrusion is an important solution.

Function of vented screw The primary advantage of a vented screw is that it reduces the melt pressure to atmospheric pressure, so the polymer does not pump out of the vent opening. This is accomplished by increasing the channel volume so that the output of the extruder only partially fills the flights under the vent. A vented or two-stage screw is essentially a dual-design screw

on the same shaft. The first part works as a conventional screw by feeding, melting and conveying the polymer forward. The second part of the screw does the same, except that it is melt-fed by the first part of the screw. The first part of the screw operates with no head pressure, while the second part has to overcome any head pressure from the die and other downstream components. Proper design of the screw requires knowledge of the polymer viscosity, output capacity of both stages and head pressure. Adequate venting with no leakage or vent flow does not depend solely on the design of the screw. The barrel vent opening needs to be fitted with a contoured plug called a diverter. The diverter deflects polymer away from the opening or else it will quickly get filled with the melt. The design is more of an art than a science but many variations work here, all using the same principles. Several companies specialise in a range of reprocessing machinery. Some of the materials that can be processed in the vented type extruder include PP, LDPE, HDPE, High-Impact Polystyrene (HIPS), PS, AcrylonitrileButadiene-Styrene (ABS), Polymethyl Methacrylate (PMMA), Polycarbonate (PC), Polyamide (PA) and all types of engineering plastics. Another useful technology in recent times for reprocessing is the co-rotating twin-screw extruder. In the plastics recycling industry, the use of co-rotating extruders is increasingly becoming a winning solution. “Co-rotating twin-screw extruder is capable of yielding high mixing quality. It promotes distributive mixing. Distributive mixing aims at obtaining a final uniform composition of the extruded products,” adds Kalra.

material and quickly absorbs air moisture. During the extrusion process, it is necessary to limit the stress transferred by the screws (mechanical degradation); however, the humidity must be extracted from the material before the hydrolytic degradation process begins. PET dehumidification is generally carried out separately, and this requires a previous material crystallisation to avoid its softening inside the dryer (Tg = 75°C). A corotating twin-screw extruder can be used for carrying out in-line dehumidification inside the extruder.

Recycling PET

Recycling requirements

PET is one of the most recycled polymers. While recycling PET, it is necessary to cope with its different degradation possibilities (eg, mechanical, thermal, oxidative, hydrolytic, etc). Hydrolytic oxidation is the most hazardous degradation process and can result in a severe reduction in molecular weight, viscosity and, thereby, mechanical properties of the material. PET is an extremely hygroscopic

Besides technological advancements, several other steps should be undertaken to promote recycling of plastics. Financial incentives for recycled products and businesses involved in recycling represent an important step in allowing these industries to develop and compete on an equal footing with those using resin or other non-recycled products. Email: anwesh.koley@infomedia18.in

Of the types of plastics that can be recycled, it is critical that they be recycled with their own type because even a small amount of the wrong type of plastics can damage the melt. Hence, sorting of plastics is a critical part of the recycling process, and many cities offer bins to help residents sort recyclables properly. Amit Kalra Director, Hindustan Plastics and Machine Corporation

March 2012 | Modern Plastics & Polymers

STRATEGY: Compression moulding

Cost reduction through innovative concepts Compression moulding is a plastic moulding method specifically used to mould complex, high-strength plastic components. It is fast gaining acceptance, especially in engineering applications, such as automobile plastics, owing to its short lead times and a higher production rate. Lionel Alva finds how recent innovations in compression moulding processes have helped reduce processing costs.

ompression moulding is a high-volume, high-pressure plastic moulding method suitable for moulding complex, high-strength objects. Also, with its short cycle time and high production rate, many organisations in the automotive industry have chosen compression moulding for production of parts. Compression moulding is a plastics moulding technique originally developed during the inception of the commercial plastics industry. This technique fell out of favour in the latter part of the century, while other thermoplastics methods were increasingly being accepted in the plastics industry. However, at the turn of the century, when compression moulding was ‘rediscovered’ as a highly cost-effective production process with low-cost moulds and low-maintenance machinery. This was a revolution of sorts driven mainly by 82

Modern Plastics & Polymers | March 2012

a number of domestic and global factors, especially due to the rising cost of raw material and an increasing need to cut down on energy consumption. Compression moulding methods were adopted mainly by automobile manufacturers owing to its ability to produce lightweight materials for production of exterior, interior and under-the-hood parts, with an aim to enhance vehicle fuel efficiency. Further, the electronic equipment industry regards the compression moulding technique as a critical part of their operations. The most widespread application of compression moulding is in manufacturing thermoset parts.

Innovations abound In the 1990s, a new process came into light for compression moulding of automotives and other structural

composites made from long-glass– reinforced thermoplastics; this process offered inherent advantages in processing, quality of parts and overall processing using Glass-Mate or Thermoplastic (GMT) sheets. This technique involved compression moulding by using an extruded ‘hot log’ of reinforced compound. This compound was produced directly from glass and resin in a onestep process, eliminating the need to buy pre-moulded material. This is called the CPI technique and has numerous advantages over GMT sheet and even allows moulding of highly sophisticated parts. Superior flow inside the mould resulted in more uniform distribution of fibres and eliminated resin-rich areas in complex parts. The process can help reduce substantial scrap and enable reuse of scrap material, much like in injection moulding. The inherent cost advantages

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Compression moulding

A signiﬁcant challenge with compression moulding is its labour intensiveness as compared to other production techniques. Also, the rejected material is not always recyclable, so this problem must be looked at seriously by industry pioneers in an otherwise robust production process. Nilkant Raut Director, Raut Engineers over GMT, resulting from scrap reduction and elimination of the value-added step of sheet preparation, are the drivers for future applications and licensees. The compounding system needed a single-screw extruder built to proprietary specifications, while the preform accumulator was custom designed. More recently in 2003, a significant innovation in the compression moulding process – Composite Flow Moulding (CFM) – delivered net-shaped thermoplastic composites with strength per unit weight reportedly competitive with those of machined steel, aluminium and titanium. This process transferred up to 62 per cent by volume of carbon fibre into a thermoplastic, yielding highstrength and abrasion-resistant screws, bolts, inserts, studs, anchor nuts and other fasteners. The CFM process starts with a pultruded carbon fibre rod, whic is made by one of the German suppliers who employed a proprietary method of incorporating high levels of carbonfibre tow with virtually no damage to the integrity of the reinforcements. The rod is then cut into a blank whose 86

Modern Plastics & Polymers | March 2012

volume is equal to that of the final part. The blank is transferred by robot to a heating chamber where it is melted and wets out the continuous fibres, thus minimising voids. The blank is then transferred to a compression mould cavity where it is pressed at precise speed, temperature and pressure to form a part with a predictable fibre orientation to enhance part strength. The vibrationresistance of CFM fasteners has immense appeal for marine applications such as rig fittings and the like. The company has worked on to broaden the capability of CFM processing with additional resins, such as Nylon 6 and Polybutylene Terephthalate (PBT), to permit fibres other than carbon for use, particularly ceramic, glass and tantalum.

Relevance in the Indian scenario Considering that the plastics industry in India is largely fragmented and driven mainly by Small and Medium Enterprises (SMEs), the compression moulding technique offers a unique opportunity for entrepreneurs. It is ideal for smalland medium-scale enterprises in India, as it has low initial setup costs and is capable of manufacturing large-sized parts beyond the capacity of current extrusion techniques. Moreover, it is an effective technique to mould parts that carry intricate details with good surface finish. It produces relatively less wastes since raw material is consumed in an optimal fashion. Automotive parts as well as a wide range of components used in electrical equipment, plumbing and hydraulic applications can be produced by the compression moulding process. Most of the items used everyday in kitchens and restaurants, such as handles for cooking

Downside of compression moulding process Production speed is not up to standards of injection moulding Limited largely to flat or moderately curved parts with no undercuts Less-than-ideal product consistency

pots, cafeteria trays, kitchen utensils and dinnerware, can also be manufactured with this technique. Compression moulding has proved to be an integral part of the contemporary plastics processing environment.

Challenges to overcome While determining the production method, the product engineer should take into consideration that compression moulding may not be suitable for delicate joints or more fragile shapes. If the finished part is small, the deflashing process may require special techniques such as cryogenic deflashing. While, conventionally, compression moulding has faced numerous disadvantages such as production not being of injection moulding standards, leading to slower production cycles with less than ideal product consistency. However, most of these disadvantages have been eliminated with recent innovations, as these have led to enormous improvement in quality, high performance consistency, faster moulding cycles and significant cost reduction at a higher output with low energy consumption. These factors have heralded a new era where this process is gaining ground again. “A significant challenge with compression moulding is its labour intensiveness as compared to other production techniques. Also, the rejected material is not always recyclable, so this problem must be looked at seriously by industry pioneers in an otherwise robust production process,” avers Nilkant Raut, Director, Raut engineers.

Cost-effective solution Compression moulding is an advanced manufacturing process that is highly suited for the mass production of practically any moulded rubber shape from the most simple to the highly intricate, and from small ‘micro’ parts to relatively large parts. Rubber compression moulding is a manufacturing technique, which has proven to be the most cost-effective manufacturing solution for many types of moulded rubber parts used in numerous applications in many industries. Email: lionel.alva@infomedia18.in

TIPS & TRICKS: Ancillar y equipment management

Measures to ensure smooth operations Ancillary equipment serve as the basic ingredients for an efficient operational set-up for any plastics processor. Anwesh Koley looks into various measures that should be taken into consideration by manufacturers to ensure seamless plastics processing operations. Anwesh Koley

lastics manufacturers across the globe maintain a host of plastics extrusion processing and provide custom-made products for businesses or individual consumers. Plastics ancillary equipment

vary greatly in how much and what they can do, although their chief function is to break down plastics, usually into small pellets, and mould these into different shapes for making a wide assortment of goods. There is a need to ensure a homogeneous integration of all equipment in order to achieve

the desired production levels. Also, since heavy automation is involved in processing, manufacturers must ensure a harmony between the hydraulic and electronic components. Email: anwesh.koley@infomedia18.in (With inputs from Motan-Colortronic Plastics Machinery (India) Pvt Ltd)

The following essential checks should be made to ensure safety in operations:

Dryers: Optimal and constant production conditions are essential for high product quality and efficient production. The current range of hot air dryers used in plastics machinery offers an effective method of processing plastic granules and removing surface moisture. With pre-heated material, the important production parameters are under control.

Conveyers: Automatic vacuum conveying protects the integrity of the material, eliminates waste and improves the costeffectiveness of the factory. Central conveying systems provide the customer substantial operational cost benefits from automatic coupling station. These eliminate spillage and make more productive use of factory floor space, and improve health & safety.

Modular design: The manufacture of flat sheet film involves mixing of three or more components in a single or twin extruder. Multilayer extrusion heads are used when different raw materials are made into composite-layer film. This reduces downtimes at material changing points. High-grade digital load cell technology secures better recipe integrity due to throughput changes.

Temperature control: Dryers can be mounted directly on the throat of the processing machine or a support frame beside the machine. Advanced models have a microprocessor-controlled temperature regulator and are equipped with a safety thermostat to prevent overheating of materials. Use of corrosion-resistant materials ensures a long life and avoids contamination of plastic granules.

Maintenance: Maintenance costs can be reduced by reliable, easy-to-maintain central vacuum pump and filter systems. Centralised material storage in one silo serving multiple machines with consequent reduction of bins maximises material usage with closed loop recycling. Faster and more efficient loading of materials in the machine ensures better safety standards in the facility.

Acquiring consumption data: Precise control of the process during start-up, recipe change, fast and continuous adjustment of production capacities creates a detailed database. During orientation of machine direction, the cooled and stabilised film is heated to optimal temperature & stretched by passing through a series of closely located rollers. Stretching can be varied by adjusting speed settings.

Modern Plastics & Polymers | March 2012

PROJECT S

New projects and expansion activities are the barometers of industrial growth. These also present business opportunities to service providers like consultants, contractors, plant & equipment suppliers and others down the value chain. This feature will keep you updated with vital information regarding new projects and capacity expansions being planned by companies in the plastics, polymers and allied industries.

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

proximity to potential customers like Lockheed, Boeing, Proterra and BMW. Processes will include hand layup, resin transfer moulding and automated tape layup. Construction of the facility will begin shortly, and Carbures plans to have the facility online in the second quarter of 2012. It will employ 50 people. Project location Greenville, USA Project cost $ 6.5 million (â&#x201A;Ź 4.9 million) Implementation stage Planning

Project location Dahej, Gujarat

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

Project cost ` 1,175 crore ($ 245 million)

Multiple plastics applications

Implementation stage Proposed Contact details: Aant Pant Lubrizol India Pvt Ltd 9/3, Thane Belapur Road Turbhe Navi Mumbai-400705 Tel: +91-22-27672568-74 Fax: +91-22-27632407 Email: apan@lubrizol.com

Composites Processing Carbures Project type New facility Project news Spain-based Carbures plans to invest $ 6.5 million to build a composites manufacturing plant in Greenville, USA. The company selected the location in part due to its

Modern Plastics & Polymers | March 2012

Supreme Industries Project type New facility Project news Leading manufacturers of plastics products, Supreme Industries has drawn up plans to invest ` 200 crore in the current fiscal year. An investment of ` 58 crore is being pumped into the unit for producing LPG composite gas cylinders at Halol in Gujarat as well as another ` 56 crore to start up a new unit for manufacturing cross laminated plastic products in Vadodara. Besides, it is investing ` 28 crore in a new unit at Hosur, Tamil Nadu to manufacture protective packaging products and also invest in expansion of other value-added products. The expansion will be completed by September 2013. Project location Gujarat, Tamil Nadu

Project cost ` 200 crore Implementation stage Planning Contact details: Pallavi Shah 1161, 1162 6th Floor, Solitaire Corporate Park, 167, Guru Hargovindji Marg, Andheri-Ghatkopar Link Road, Chakala Andheri (East) Mumbai-400093 Tel: +91-22-67710000, 30840000 Email: pallavi_shah@supreme.co.in

Nylon-6 processing Gujarat State Fertilizers & Chemicals Ltd (GSFC) Project type Capacity expansion Project news GSFC has decided to enhance the existing production capacity of its nylon-6 engineering plastic to meet with the requirement of engineering and film grade plastics. The project for additional 15,000 MTPA capacity will be undertaken by M/s Lurgi GmbH, who will be providing technology, knowhow, basic design, supply of proprietary items and technical advisory services to GSFC. Project location Vadodara, Gujarat Project cost ` 125 crore Implementation stage Planning Contact details: GSFC Fertilizernagar Vadodara-391 750 Tel: +91-265 2242051, 2242451 Email: vishvesh@gsfcltd.com

EVENT LIST

National Conference on Indian Medical Devices & Plastics Disposables Industry 2012

Diemould India 2012

Ind plast

This event will focus on the growing range of applications and opportunities in the Indian medical devices industry. The conference will highlight the scope for plastics application in disposable medical devices manufacturing; March 23-24, 2012; at Ahmedabad Management Association (AMA) Complex, Ahmedabad

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

This is an initiative to promote India as a leading producer of plastics and specialty polymers on the global platform. It will facilitate interaction and international investments in the domestic market. This will be an ideal platform for sourcing equipment, raw materials, products and engineering & consultancy services; October 5-8, 2012; at Science City Ground, Kolkata

For details contact: D L Pandya B-4, Mandir Apt Satellite Road Ahmedabad - 380 015 Tel: 079 26740611 Fax: 079 26754867 Mob: 09825457563 Email: dlpandya gmail.com Website: www.imdiconferences.com

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

For details contact: Vishal Ganju FICCI Mumbai 33/B, Krisnamai Building Pochakanwala Road, Worli Mumbai – 400030 Tel: 022-2496 8000, 2496 6633 - 39 Fax: 022-2496 6631/32 Email: vishal.ganju@f icci.com Website: www.indiachemgujarat.com

International JEC Europe 2012 JEC is a composite industry organisation dedicated to developing products and services for its customers and for the composite industry. This conference will address the booming composites market’s requirements of raw materials and automation solutions. It will be a meeting ground for the scientific community, R&D professionals across Europe; March 27-29, 2012; at Porte de Versailles, Paris, France For details contact: Guillaume Vouioux Journals and Exhibitions 25 boulevard de l’Amiral Bruix Paris-75116, France Tel: +33 1 58 36 15 07 Fax: +33 1 58 36 15 19 Website: www.jeccomposites.com

NPE 2012 A leading international plastics technology 92

Modern Plastics & Polymers | March 2012

trade fair held in the US will showcase a broad range of polymer technologies for the packaging industry. It will present innovative polymer technologies to advance the medical devices industry as well as automotive manufacturers; April 1-5, 2012; at Orange County Convention Center (OCCC), Orlando, Florida, USA For details contact: Hemah Saxena Comnet Exhibitions Pvt Ltd # 217 B, 2nd Floor Okhla Industrial Estate Phase III, New Delhi - 110 020, India 011 - 42795055/42795000 Email: hemasaxena@eigroup.in Website: www.npe.org

Chinaplas 2012 This edition of Chinaplas will continue the legacy of bringing solutions to the global plastics industry while

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

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

EVENT PREVIEW: Indian Medical Devices & Plastics Disposables Industr y 2012

Infusing vigour to healthcare industry

The 9th national conference of the Indian Medical Devices & Plastics Disposables Industry promises to provide an ostentatious spectacle of an impressive assortment of technological innovation and groundbreaking ideas that will revolutionise the industry. Here is a chronicle of some of the expectations of this landmark event. Lionel Alva

he $ 300-billion strong global medical devices market is growing at a Compounded Annual Growth Rate (CAGR) of 10 per cent and is undaunted by the recent economic downturn. The prognosis is healthy with demand set to rise across all regions. This bears special significance for developing countries such as China and India who are to establish themselves as major stakeholders. While the US continues to be the biggest contributor, other nations are fast catching up. The 9th edition of Indian Medical Devices & Plastics Disposable Industry 2012, is scheduled to be held from March 23-24, 2012, at Ahmedabad Management Association (AMA) Complex, Ahmedabad. The event will provide a strong platform to find new avenues for growth, bring together the best minds in the Indian medical devices industry and provide a unique opportunity for direct interaction with experts. 94

Modern Plastics & Polymers | March 2012

Setting the stage The conference will allow industry leaders, experts and authorities to plan a course of action to further boost the countryâ&#x20AC;&#x2122;s prospects in an increasingly competitive global arena. It will examine in detail factors including key trends, drivers and challenges that impact the growth of this market, providing a complete outlook over 25 best practices presentations from some of the leading professionals from the government, research, industry and academic institutions. Compliance to requirements and standards set by the regulatory framework is integral to success in development & marketing of medical devices. This is particularly important since the Indian medical devices industry has been growing sturdily despite the economic crunch, prompting multinationals to set up companies in India to tap into the prospering domestic market. But, to establish themselves effectively, they must be aware of the safety regulations for medical devices in India. Pradeep Rao, Managing Director, Pradeep

Surgipack, says, â&#x20AC;&#x153;High import duty on raw material import is a major constraint. While the duty structure is same for raw materials and finished goods, it would be ideal if import duty on raw materials is reduced as compared to finished goods, giving the local manufacturing industry easy access to quality inputs, while restricting import of finished goods at lower prices. Adherence to quality standards and certifications should be mandatory for all manufacturers and preferably come under the purview of the Drugs Controller General of India.â&#x20AC;?

Incredible prospects The conference provides an opportunity to establish India as a research and development hub. In 2009, the Indian market for medical equipment was estimated at $ 1,908 million. Trends insinuate increasing investments at a steady rate into the private sector infrastructure along with increased healthcare funding from the Government will consolidate the robust growth of this market. Email: lionel.alva@infomedia18.in

EVENT REPORT: Plastindia 2012

Investing in the India advantage As Plastindia brought down the curtains on its eighth edition, the Indian plastics fraternity opened itself to a new world of opportunities. Along with large and small domestic companies, this show witnessed many global solution providers who want to collaborate with the $ 25-billion strong Indian plastics industry. Annabel Dsouza

uch has been said about the performance and potential of India’s status as an emerging market. However, Plastindia 2012 proved to be a pulsating testimony not only of the promising market scenario, but also of the buoyant spirit of the Indian entrepreneur. The eighth edition of the triennial Plastics Exhibition and Conference was held f rom February 1-6, 2012, at Pragati Maidan, New Delhi. Spread over 100,000 sq m, Plastindia 2012 hosted more than 1,800 exhibitors and 100,000 business visitors from 40 countries. Plastindia 2012 was inaugurated by Chief Guest K Jose Cyriac, 96

Modern Plastics & Polymers | March 2012

Secretary, Department of Chemicals and Petrochemicals, Government of India. Neel Kamal Darbari, Joint Secretary, Department of Chemicals and Petrochemicals, Government of India, was the Guest of Honour at the occasion. Speaking at the inauguration ceremony, Cyriac said, “The plastics industry has been growing at a fast pace and is expected to maintain a similar growth rate in the coming years. Plastindia exhibition has grown in terms of number of Indian & international exhibitors and visitors. It is a clear testimony to the fact that India now plays a pivotal role in the global plastics industry.” Ashok Goel, President, Plastindia Foundation, speaking on the occasion observed, “Over the years, Plastindia has grown to become the second largest fair in plastics in the world.

With plastics foraying into important sectors of Indian manufacturing such as infrastructure healthcare, agriculture, packaging and automobiles, we believe that Plastindia 2012 can play a big role here by providing a platform for alternative raw material/additives source and the latest technology.”

Business panorama Apart from knowledge sharing and technolog y exposure, Plastindia 2012 incited among the industry players great interest for international partnerships, especially in the areas of pipes and profiles, packaging and automotives. Being at the centre of Indian manufacturing, the plastics industry needs to keep pace with the global innovations making headway in India. This is particularly relevant for

Plastindia 2012

the consumer durables and automotive markets where the consumers’ appetite is changing f requently. This spells enormous opportunities for the entire value chain while also creating a need for inclusive technology facilitation. The optimistic stance of the exhibitors was reflected by Sunil Jain, President, Rajoo Engineers Ltd. He said, “For Rajoo, this exhibition is not a destination, but a journey to further our commitment to the extrusion industry and continue to serve this industry while being recognised as a quality, reliable and trusted supplier in the global markets.” With the global plastics industry pledging their faith in the Indian economy, Plastindia 2012 offered a glimpse into futuristic solutions that are making their way into Indian plastics processing. At the British Pavilion, Claudia Finamore, Marketing Manager, ColorMatrix, said, “Plastindia offers an invaluable opening into India’s growing market. For our company, the world’s largest plastics trade show, K Show Düsseldorf is predominantly a maintenance event where we get the opportunity to interact with existing customers. The major difference at Plastindia is that we can reach out to new customers by introducing our innovative solutions to their processes.”

Emphasis on sustainability Besides the exhibition, Plastindia 2012 conference witnessed a large gathering of experts and visionaries from the Indian & global plastics fraternity. They shared their views and visions on technology & trade besides offering extensive networking opportunities. This two-day conference proved to be a platform for sharing knowledge among scientists, technologists, business professionals and, more importantly, students & future leaders of the plastics industry. Among the various subjects impacting the plastics industry, sustainability was a key concern and the speakers highlighted the need for comprehensive solutions, inclusive of the plastics value chain as well as the end user. This edition of Plastindia featured an updated version of Proplast. Proplast was first started in 2006, dedicated to the finished goods segment of the plastics industry. This exclusive pavilion, served as a one-stop-shop for Original Equipment Manufacturers (OEMs), product packers, Fast-Moving Consumer Goods (FMCG) companies, retail chains, etc. The show also had a special pavilion for recycling and agricultural applications of commodity and engineering plastics. Through this pavilion, Plastindia Foundation introduced all the participants to its plasticulture

Inaugurating Plastindia 2012: (L-R) K K Seksaria, Treasurer, and Bipin Shah, Vice President, Plastindia Foundation; K Jose Cyriac, Secretary, and Neel Kamal Darbari, Joint Secretary, Department of Chemicals and Petrochemicals, Government of India

project. Plasticulture seeks to cover 17 million hectare of agricultural land in India under micro-irrigation schemes, which will further boost the prospects of plastics consumption across the country. Goel added, “India recycles 60 per cent of its used plastics, higher than the world average of 22 per cent. Contradictory to what most people believe, plastics and plastic bags account for only 3 per cent and 0.3 per cent of the municipal waste, respectively. For building plastics’ image as a green material, Plastindia Foundation is showcasing through various campaigns the recyclability of plastics and lower carbon footprint during its processing as compared to conventional materials. The problem lies in the handling and disposal of plastics and the real challenge is waste management. One needs to start waste segregation at source, ensuring easy and effective recycling, as has been successfully done in case of Polyethylene Terephthalate (PET) bottles.”

Investing in talent Keeping pace with the rapid expansion of the domestic plastics industry, Plastindia Foundation has decided to set up an integrated campus under the name of Plastindia International University. This university will be affiliated to Gujarat Government and is likely to start operations in 2013. It will cater to the training and development requirements of the plastics industry. The objective of Plastindia International University is to provide engineering and management education up to the postgraduate level coupled with industrial research, project management and entrepreneurship. It will ultimately incorporate doctorate level programmes at a later stage. With this activity, Plastindia Foundation is moving ahead with one more successful step, by collaborating with two foreign universities – University of Wisconsin Madison, USA, and University of Massachusetts, Lowell, USA. Email: annabel.dsouza@infomedia18.in

March 2012 | Modern Plastics & Polymers

BOOK REVIEW

Thermoplastic and Rubber Compounds Authors : James L White and Kwang-Jea Kim Price : ` 7,275

Hot Runner Technology Author : Peter Unger Price : ` 9,450

Compounding of polymers had started with the beginning of rubber industry 150 years back. Today, this industry has reached maturity. The book Thermoplastic and Rubber Compounds gives a description of the technology and physical chemistry of rubbers and plastics. It also explains the culture in both industries and concepts behind the complex and sophisticated recipes. The book highlights the mechanism of additives during compounding as well as their interactions with one another. Hence, this book is useful for both students and formulation chemists working in the industry. The book begins with a chapter on ‘Overview of Compounding Ingredients’ and describes the additives used by both plastics and rubber industries; it ends with a chapter on the mixing machinery used by the two industries. A good attempt has been made to explain 150 years of development span of compounding machinery used by the industry today. The purpose of this book is to describe the components and composition of major types of polymer compounds used by plastics and rubber industries along with the mechanism of their effectiveness, which it has successfully achieved.

The hot runner technology has reached a high level of technical knowhow today. Designers, mould makers, hot runner suppliers and raw materials producers across the world have collaborated and perfected this technology. The book Hot Runner Technology explains various topics, starting with basic concepts of heat technology and then explaining the hot runner components, manifold blocks and nozzles. The author has followed the old rule of ‘learning through experience’ by analysing past failures through hands-on experience and come up with new developments and inventions. At every stage, the author has narrowed down his observations and suggestions into pointers, which would be extremely helpful for the reader in absorbing the knowledge. Other topics covered in this book, which are related to hot runner technology, are the basic concepts of plastics technology, material behaviour under mechanical load, such as notch effects under static and dynamic load, corrosion and wear as well as design aspects of the special hot runner system. Therefore, this book is valuable for product and mould designers, tool room engineers, process engineers as well as students.

Reviewer: Dr Yatish B Vasudeo, President, BY INNOVATIONS Consultancy (I) Pvt Ltd Avaliable at: Wisdom Book Distributors, Hornby Building, 1st floor, 174, D N Road, Mumbai 400 001 Tel: 022-2207 4484/6631 8958 • Telefax: 022-2203 4058 • Email: thadam@vsnl.com

Modern Plastics & Polymers | March 2012

PRODUCT S

This section provides information about the national and international products available in the market Thin film dryer

High-pressure compressor

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 (pre-dominantly) and vertical configurations, with a variety of proprietary wiping and scraping arrangements, accompanied by solvent-recovery systems where required.

This highpressure compressor is used for PET blowing. Its features are valve piston and rider rings designed for annual one time maintenance, low RPM & rugged cast iron design ideal for heavyduty continues 24x7 operating year-after-year, forged crank shaft & connecting rod, precision main & crank pin bearings with force feed lubrication have very high load-bearing capacity. Two throw balance-opposed frames are designed to minimise unbalanced forces. Cylinders constructed with large cast-in-water jackets are specially designed intercoolers for dimensional stability and for better cooling under continue operation.

Alpha Process Engineers Chennai - Tamil Nadu Tel: 044-28111351 Email: apeepa@vsnl.com Website: www.alphaprocessengineers.com

Screen changer

Comp-Tech Equipment Ltd Ahmedabad - Gujarat Tel: 079-22201296, Mob: 09825039768 Email: comtecheqpltd@yahoo.co.in Website: www.comptechcompressor.com

Injection moulding machine

This machine is offered for each filtration application. The spectrum ranges from discontinuous and continuous systems to fully automatic backflush screen changers. Screen changer with process-, pressure- and volume-flow constant mode of operation is also offered. The screen changer is used for filtration application. Relating to throughput the scope ranges from 2-80 kg/hr to systems with 35,000 kg/hr. For economic processing of PET, inline crystallisation system CrystallCut is used. With this, pelletising and crystallisation is affected in one process step, without supplying additional energy. Kreyenborg GmbH Muenster - Germany Tel: +49-251-214050 Email: info@kreyenborg.de Website: www.kreyenborg-group.com 100 Modern Plastics & Polymers | March 2012

This rubber injection moulding machine is ideal for moulding precision parts with accurate process control and high productivity. The VE series is a state-ofthe-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

Product Inquiry Card

EASY STEPS TO GET PRODUCT INFO

Product Sourcing Just Got Simpler

1 See the index page in this issue. Every product carries a number. 2 Choose products of your choice from the list. 3 Write their serial numbers (as per the index page) of your chosen product/s one-by-one in the boxes. 4 Fill in your complete contact details. 5 Send it to us at the address printed overleaf.

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UR O L FIL TH PR OF YO D WI ER/S EN S ND MB NU OICE A CH

-2 TIP SE ENSUILRLEIN Name:___________________________________________________Designation:_________________________________________ Company:_______________________________________________________________________________________________

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Business Insights •Technologies•Opportunities

3/2012

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POSTAGE WILL BE PAID BY ADDRESSEE

Business Reply Inland Permit No. 555 Bhavani Shankar Post Office, Mumbai 400 028.

Special Projects INFOMEDIA 18 LIMITED Ruby House,1st Floor J K Sawant Marg Dadar (W), Mumbai 400 028 INDIA

NO POSTAGE STAMP NECESSARY IF POSTED IN INDIA

PRODUCT S

Temperature controller This is a microcontrollerbased temperature controller, which meets custom-built industrial process applications. The controller is available in double or single fourdigit display. It can be used for process and set value indication, output heater relay and alarm relay, supply of 230 V AC, 12 V DC, ON/OFF or TP action for heating control, etc. The temperature controller offers a password facility for configuration mode to avoid unauthentic entry. It is available in sizes of 96 x 96 mm, 72 x 72 mm, 96 x 48 mm and 48 x 96 mm. Analogue and digital base controller is also offered. Wavetronics Ahmedabad - Gujarat Tel: 079-22811329, Mob: 09327003425 Email: info@wavetronics.co.in Website: www.wavetronics.co.in

March 2012 | Modern Plastics & Polymers 103

PRODUCT S

Injection moulding machine The ABH series vertical plunger-type plastic injection moulding machine is equipped with hydraulic system for mould locking/opening and injection/rifling by lever operated valve. It comes with two-zone digital temperature controller and consumes less power. The locking and injection system is operated by digital timer. This machine is available in manual, semiautomatic and fully automatic. It is provided with adjustable automatic hydraulic hopper. The machine comes with digital shot counter and emergency stop push button.

Mechatronics Machinery & Tools (India) Delhi Tel: 011-27830809, Mob: 09810129642 Email: mcs109@yahoo.co.in Website: www.mechatronicsmachinery.com

Amrut Brothers Ahmedabad - Gujarat Tel: 079-22928163 Mob: 09824093682 Email: exports@amrutbrothers.com Website: www.amrutbrothers.com

Plastic injection moulding machine

The range of plastic injection moulding machine is suitable for manufacturers and engineering industries. Designed using latest technology, the range is known to perform better even in harsh conditions. This plastic injection moulding machine is available in various specifications to suit different requirements of engineering and manufacturing industries.

March 2012 | Modern Plastics & Polymers 105

PRODUCT S

Temperature controller and waterflow regulator This temperature controller controls the temperature of manifold block and the nozzle with correct circuit connection and parameters on the panel. It also maintains a constant temperature within the system as well. The water flow regulator is designed to work with mould heaters, water chillers and cooling towers, which can be connected to more than one mould connector. It has functions like temperature and flowrate display, flowrate control in order to meet the requirement of different working conditions. Modularised combination ensures installation and maintenance. It is a necessary equipment for modern plastics industry to improve its moulding efficiency. Shini Plastics Technologies (India) Pvt Ltd Thane - Maharashtra Tel: 0250-3021132 Email: info@shiniindia.com Website: www.shini.com

106 Modern Plastics & Polymers | March 2012

PRODUCT S

Digital printing technology The online digital printing technology attributes to the printers with highresolution piezo inkjet technology, thereby offering the packaging industry the most efficient and state-of-arttechnology in terms of hardware, software, accessories and consumables. In terms of application, it is cost-effective modern technology, used for marking, printing and helps in traceability. The simplified operation at each level of production process is versatility in application software to design, the logos, text, barcodes, variable and fixed data field, option for multi-colour printing, standalone or network printing. M & M Technologies Pvt Ltd Navi Mumbai - Maharashtra Tel: 022-27781580 Email: mp@mmtechnologiesindia.com Website: www.mmtechnologiesindia.com

CAM followers The stud-type CAM followers are available with standard and eccentric stud cage/ needles guided cylindrical/ crowned outer race, grease filled ready-to-use. Holes for grease nipple and plug fitting are provided. The CAM followers are used as full complement bearings and can take heavier loads at a lower speed. These are greaselubricated, maintenance-free and have slight gap adjustment by eccentric. The CAM followers are applicable in all medium and heavy industries. NMT Group Ahmedabad - Gujarat Tel: 079-22821527, Mob: 09328271660 Email: nmtg@nmtgindia.com Website: www.nmtgindia.com

110 Modern Plastics & Polymers | March 2012

PRODUCT S

Plastic brighteners/shiners and whiteners These plastic br ighteners, shiners and whiteners are used for natural transparent, colours and milky white end products. These are also used for adding clarity and gloss finish to natural transparent polymers. The products give shining and bright finish colours to end products. These remove yellowness and dullness from the end products and make them super milky white. The products are used in virgin, second, dull natural or milky white sutli, ropes, twine, reprocess granules, HDPE-LDPE-PVC pipes & profiles, etc. Plast Fine Polymers Ahmedabad - Gujarat Tel: 079-65242332, Mob: 09825587152 Email: plastfine@indiatimes.com

March 2012 | Modern Plastics & Polymers 113

PRODUCT S

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 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

114 Modern Plastics & Polymers | March 2012

PRODUCT S

FORM IV

Plastic injection moulding machine

Statement about ownership and other particulars about Modern Plastics & Polymers, as required to be published in the ﬁrst issue every year after the last day of February. 1. Place of Publication: Ruby House, ‘A’ Wing, JK Sawant Marg, Dadar (W), Mumbai-400028 2. Periodicity of Publication: Monthly 3. Printer’s Name: Mr Mohan Gajria Nationality: Indian Address: Infomedia 18 Ltd, Ruby House, ‘A’ Wing, JK Sawant Marg, Dadar (W), Mumbai-400028 4. Publisher’s Name: Mr Lakshmi Narasimhan Nationality: Indian Address: Infomedia 18 Ltd, Ruby House, ‘A’ Wing, JK Sawant Marg, Dadar (W), Mumbai-400028 5. Editor’s Name: Mr Manas Bastia Nationality: Indian Address: Infomedia 18 Ltd, Ruby House, ‘A’ Wing, JK Sawant Marg, Dadar (W), Mumbai-400028 6. Names and addresses of Individuals who own Modern Plastics & Polymers & partners or shareholder holding more than 1% of total capital: Infomedia 18 Limited (formerly known as Infomedia India Limited), Ruby House, ‘A’ Wing, JK Sawant Marg, Dadar (W), Mumbai-400028 is the owner of Modern Plastics & Polymers. Details of the shareholders of Infomedia 18 Limited who are holding more than 1% of the paid up equity share capital of the company as on 20-02-2012: 1. Network18 Media & Investments Limited, 503,504 & 507, 5th Floor, Mercantile House, 15 Kasturba Gandhi Marg, New Delhi - 110001 2. Acacia Conservation Fund LP, Citibank N A, Custody Services 3rd Flr, Trent House, G Block, Plot No. 60, BKC, Bandra (East), Mumbai - 400051 3. Pramod Premchand Shah, Kalpana Pramod Shah, Agra Building, 1st Floor, 121/4 M.G.Road, Mumbai - 400023 4. Acacia Institutional Partners, LP, Citibank N A, Custody Services 3rd Flr, Trent House, G Block, Plot No. 60, BKC, Bandra (East), Mumbai - 400051 5. SPS Capital & Money Management Services Pvt Ltd, 66,Tamarind Lane, 4/5,Haji Kasam Bldg, 1st Floor, Fort, Mumbai - 400023 6. Sanjiv Dhireshbhai Shah, 201-203, Sapphire Complex, Nr. Cargo Motors, C.G. Road, Ahmedabad - 380006 7. The Oriental Insurance Company Limited, Oriental House, P B 7037, A-25/27, Asaf Ali Road, New Delhi - 110002 8. Accurate Finstock Pvt Ltd, 9th Floor, Shikhar, Adani House, Nr. Mithakhali Six Road, Navrangpura, Ahmedabad - 380009 I, Lakshmi Narasimhan, hereby declare that all particulars given above are true to the best of my knowledge and belief. Dated: 20th February 2012 Lakshmi Narasimhan Signature of the publisher

116 Modern Plastics & Polymers | March 2012

The Optima series plastic injection moulding machine is characterised by the proven, reliable machine design with an attractive price to performance ratio. This machine has clamping force of 450-1750 kN. Features include: proven 5-point double toggle mechanism, selflubricating bushes for toggle mechanism, automatic mould height/ thickness adjustment, automatic centralised grease lubrication, choice of three injection units for each clamping force, twin cylinder injection unit, automatic barrel heating function, ceramic band heaters, etc. Electronica Plastic Machines Ltd Pune - Maharashtra Tel: 020-22922212 Email: epml@electronicapmd.com Website: www.elpml.com

Blown film extrusion line The mono-layer blown film extrusion line is used for HM-HDPE/LLDPE/ LDPE/PP. It comes in width of 90 mm to 1300 mm and has an output of 20 kg/hr to 70 kg/hr. The plant is available with stationery and rotating die. Applications are in plastic bags, vest bags, liners, garbage bags, packaging films, stretch films, shrink films, detergent bags, etc. Dura Exports Pvt Ltd Mumbai - Maharashtra Tel: 022-26744053, Mob: 09930476588 Email: info@duraexports.com Website: www.duraexport.com

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

LIST OF PRODUCT S To know more about the products featured in this magazine, fax us on 022-3003 4499 or tear and post to us the â&#x20AC;&#x2DC;Product Inquiry Cardâ&#x20AC;&#x2122; by following the 5 easy steps given there. Alternatively, you may also write to us at michael@infomedia18.in or call us on 022-3003 4684, and we will send your inquiries to the advertisers/companies directly to help you source better. Sl No Product

Pg No

Sl No Product

Pg No

Sl No Product

Pg No

ABS ..............................................................103

Connector ......................................................... FGF

108

Fluorescent ............................................................ 34

AC drive.............................................................. 110

Continuous screen changer ................................ BIC

109

Fuel burner .......................................................... 106

AC motor .............................................................. 49

Control system ...................................................... 95

110

Gear box ........................................................104

Additive masterbatches .............................. 10, COC

Conveying blower ............................................... 106

111

Gear motor.......................................................... 104

Air bellow ............................................................. 87

Conveying system ................................................. 35

112

Gear pump ................................................. 103, BIC

Air bubble sheet plant............................................. 8

Cooling tower ....................................................... 89

113

Granulating and recycling system ......................... 85

Air cooled chiller .................................................. 43

Counters and power supplies .................................. 7

114

Granulator .......................................................... FIC

Air treatment ........................................................ 89

CPVC pipe ..................................................... 12, 19

115

HALL/MR sensor ...........................................29

Air-conditioner parts ........................................ FGF

Crane control ........................................................ 95

116

HDPE caps and containers .................................. 65

Ammonia liquid chiller ....................................... 111

Cutting and stitching machine ............................. 99

117

HDPE woven sack manufacturing plant ............ 117

Automatic leak testing machine ......................... 107

Cyclic olefin copolymer ...................................... 119

118

HDPE................................................................. 103

Automation panel ................................................. 95

Dairy machinery ............................................111

119

Head lamp & tail lamp..................................... FGF

Automation system ............................................... 85

DC motor ............................................................. 49

120

Heart valve frame ........................................... 72, 73

Automation ........................................................... 35

Dehumidified air dryer ..................................... FGF

121

Heat transfer rolls .............................................. BIC

Axial flow fan...................................................... 106

Dehumidified dryer...................................... FIC, 63

122

Heating and cooling system............................ 35, 85

Bag making machine ........................................47

Differential pressure transmitter ........................... 29

123

Helical inline geared motor/reducer ................... 104

Barrel .................................................................. BIC

Digital panel meter ............................................... 14

124

Hi speed rotogravure printing machine ................ 47

Beryllium copper plastic mould materials .......... 121

Digital printing technology ................................ 110

125

High-cavitation mould.......................................... 17

Bi-axial plant ....................................................... 123

Door trim .......................................................... FGF

126

High-performance screws .................................. BIC

Bio-degradable masterbatches..........................COC

Dosing and blending system................................. 35

127

High-pressure compressor .................................. 100

Black masterbatches ................................... 10, COC

Dosing and mixing machine ................................. 85

128

High-pressure transducer ...................................... 29

Blender ......................................................... FIC, 91

DPT with LCD display ....................................... 29

129

High-speed mixer ............................................... 106

Blending unit .................................................... FGF

Drying and dehumidifying system ....................... 85

130

Hips..................................................................... 103

Blow moulding machine ............................... 18, 107

Drying system ....................................................... 35

131

HMHD............................................................... 103

Blower series ......................................................... 85

Drymax air-hot air dryer ................................... FIC

132

Hot air dryer ............................................... 63, FGF

Blowers and fans ................................................. 106

Drymax dryer ..................................................... FIC

133

Hot runner system ................................................ 85

Blown film extrusion line.................................... 116

Drymax pet-dehumidified dryer ........................ FIC

134

Hot runner temperature controller ....................... 95

Blown film extrusion systems ............................. BC

Dyestuff................................................................. 34

135

IML technique ................................................17

Bottle testing equipment....................................... 69

Electric injection moulding machine gearboxes .. 9

136

Inductive sensor .................................................... 29

Brake motor .......................................................... 49

Electrical panel...................................................... 95

137

Industrial automation .......................................... 109

Brine chiller .......................................................... 43

Encoder ................................................................... 7

138

Industrial control and sensing device...................... 7

Bulk milk cooler.................................................. 111

EPS cup making machine................................... 114

139

Industrial cooler .................................................... 89

Buschjost series ..................................................... 87

Exhaust valve ........................................................ 87

140

Infrared dryer ...................................................... 103

CAM followers ..............................................110

Exhibition - 8th Die & Mould

141

Infrared heater ...................................................... 95

Cast film line .......................................................... 8

India international exhibition ............................... 52

142

Centrifugal air blower ......................................... 106

Exhibition - Plastivision Arabia-2012 ................ 108

Chillers for batching plant .................................... 43

Extruder feeding system ..................................... 103

143

In-line drip irrigation plant ................................ 114

Circular weaving machine ..................................... 99

Extrusion coating lamination plant ........................ 8

144

Inline drip tubing ............................................ 12, 19

Clean room application......................................... 17

Extrusion coating line ........................................... 99

145

Cleaning oven .................................................... BIC

Extrusion dies ..................................................... 126

Cluster facia ...................................................... FGF

Extrusion lamination machine ............................ 117

146

Insert moulding machine ...................................... 18

CNC vertical machining centre ............................ 25

Extrusion lamination plant ................................. 117

147

Instrumentation and control ................................. 95

Co-extrusion blown film plant ............................... 8

Extrusion plant.................................................... 123

148

ISO star ..........................................................87

Co-extrusion dies .................................................... 8

Extrusion system ................................................. BC

149

Junction box wireless ............................................. 29

Color masterbatches................................... 33, COC

Extrusion tape stretching machine ..................... 117

150

Junction box .......................................................... 29

Colour mark sensor ............................................... 95

Extrusion tape stretching plant........................... 117

151

Knobs and switches......................................FGF

Colouring extrusion plant ................................... 123

100

Extrusion ............................................................. BC

152

Lamination machine ........................................47

Compounding extrusion plant ............................ 123

101

Feeding and conveying system ..........................85

153

Large flow water heater ........................................ 85

Compressed air system.......................................... 21

102

Flame retardant masterbatches ............................. 10

154

LDPE.................................................................. 103

Compressor ................................................... 21, 106

103

Flameproof motor ................................................. 49

155

Level controllers ...................................................... 7

Conductive compounds....................................COC

104

Flange mounting motor ........................................ 49

156

Lintra rodless cylinder ......................................... 87

Conference .......................................................... 112

105

Flat surface finish brushes .................................. 114

157

Liquid crystaline lymer ....................................... 119

Conical twin-screw extruder ........................... 59, 61

106

Flexo-printing machine ........................................ 47

158

Liquid ring vacuum pump .................................. 106

Connector and cable assembly .............................. 29

107

Flow regulator ....................................................... 87

159

Liquifier ................................................................ 43

Injection moulding machine ..........FGF, 18, 23, 31, 100, 105, 115, BGF

Inline shaft mounted helical geared motor/reducer ............................... 104

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

118 Modern Plastics & Polymers | March 2012

LIST OF PRODUCT S Sl No Product

Pg No

Sl No Product

Pg No

PP mineral filled compounds................................ 10

Sl No Product

Pg No

160

Loader ................................................................ FIC

218

276

Solid granulator................................................... 123

161

Manual and hydraulic screen changer ............BIC

219

PP woven sack manufacturing machines ............ 117

277

Special silo .......................................................... 103

162

Material dryer ....................................................... 91

220

PP/HDPE/PET ..................................................... 8

278

Spool valve ............................................................ 87

163

Material testing instrument .................................. 69

221

PPCP .................................................................. 103

279

Stack mould .......................................................... 17

164

Measuring and monitoring relay ............................ 7

222

PP-R pipe ....................................................... 12, 19

280

Stretch blow moulding machine ........................... 18

165

Medical mould ...................................................... 17

223

Precision moulding machine ............................. FGF

281

Switching device ................................................... 95

166

Melt pressure transducer ....................................... 95

224

Press ...................................................................... 38

282

Switching relay ........................................................ 7

167

Micro-fine pulverising systems ........................... 123

225

Printing and cutting/rewinding machine .............. 99

283

Synthetic string plant .............................................. 8

168

Modbus ................................................................. 29

226

Printing press ........................................................ 38

284

System solution ..................................................... 85

169

Monolayer blown film line ................................. BC

227

Process controller .................................................. 14

285

Tanks and silos ..............................................111

170

Monolayer blown film plant ....................... 8, 12, 19

228

Process tank ........................................................ 111

286

Tape stretching line............................................... 99

171

Motor .................................................................... 49

229

Products exporting ................................................ 65

287

Technical mould.................................................... 17

172

Mould changing system ...................................... 105

230

Proportional valve ................................................. 87

288

173

Mould temperature controller ............................... 63

231

Proximity sensor ...................................................... 7

174

Moulding machine ................................................ 17

232

Pump ................................................................... 106

289

Temperature controller .............................. 7, 14, 100

175

Multi-component mould ...................................... 17

233

PVC foam core pipe ....................................... 12, 19

290

Testing instrument ................................................ 69

176

Multi-layer blown film line............................99, BC

234

PVC mixer cooler ........................................... 12, 19

291

Thermoformer..................................................... BC

177

Multi-layer blown film plant .................................. 8

235

PVC palletising line ........................................ 12, 19

292

Thermoforming and PS foam ............................ BC

178

Multi-layer blown film.................................... 12, 19

236

PVC pipe ........................................................ 12, 19

293

Thermoplastic alloy ............................................... 34

179

Multi-stage centrifugal air blowers ..................... 106

237

PVC profile line .............................................. 12, 19

294

Thermoplastic compound ..................................... 34

180

Neat resin ........................................................34

238

Quick die change system ................................105

295

Thin film dryer ................................................... 100

181

Nylon................................................................... 103

239

Quick mould change system ............................... 105

296

Timer ...................................................................... 7

182

Oil chiller ........................................................43

240

Raffia tape line ................................................. 8

297

TPE/TPU compound ........................................... 10

183

Oil ....................................................................... 106

241

Rail tanker........................................................... 111

298

TPU masterbatches ............................................... 33

184

Optical brightener ............................................COC

242

Recycling machine ................................................ 47

299

Trade show organiser ............................................ 16

185

Packaging service provider .............................124

243

Recycling system ................................................... 35

300

Trim handling system ......................................... 106

186

Paper chemicals ..................................................... 34

244

Refrigerant pump................................................ 111

301

Twin-screw co-rotating extruder............. 72, 73, 125

187

Paperless recorder.................................................. 14

245

Refrigeration ....................................................... 111

302

Twin-screw element ................................ 72, 73, 125

188

Parallel and right-angle axes gearbox ..................... 9

246

Right-angled helical bevel geared motor/reducer104

303

Twin-screw extruder gearbox .................................. 9

189

PBEGL geared motor .......................................... 49

247

Right-angled helical worm geared motor/reducer104

304

Twin-screw extruder ............................... 72, 73, 125

190

PC ....................................................................... 103

248

Robot system......................................................... 23

305

Twin-screw extrusion line ............................... 59, 61

191

Pelletiser ............................................................. BIC

249

Robot ................................................................. FIC

306

Two-layer blown film ...................................... 12, 19

192

Pet bottle testing equipment ................................. 69

250

Robotics .............................................................. 113

307

Ultra sonic flow meter......................................14

193

Pet container ......................................................... 65

251

Rotary automatic hot-colour marking machine.... 93

308

Underwater pelletising system ............................ 103

194

Pet masterbatches.................................................. 10

252

Rotational mould ................................................ 123

309

Universal masterbatches ........................................ 10

195

Pet perform dedicated machine ............................ 67

253

Rotational moulding machine............................. 123

310

Universal quick mixer ......................................... 103

196

Photoelectric sensor ................................................ 7

254

Rotogravure printing machine .............................. 47

311

UV and PU masterbatches ................................... 10

197

Photosensor ........................................................... 29

255

Rotomoulding machine....................................... 123

312

UV stabiliser.....................................................COC

198

Plastic board production system ........................... 38

256

Roundline cylinder .............................................. 87

313

Vacuum dryer...................................................63

199

Plastic brighteners/shiners and whiteners........... 113

257

Safety light ....................................................... 7

314

Vacuum forming machine ................................... BC

200

Plastic extrusion machinery ................................ 106

258

Sandwich BOPP lamination............................... 117

315

Vacuum loader................................................... FGF

201

Plastic injection moulding machine ...... 27, 105, 116

259

Screen changer ............................................ 101, 103

316

Vane damper ....................................................... 106

202

Plastic masterbatches ............................................ 45

260

Screw compressor ................................................ 111

317

203

Plastic processing machine.................................... 99

261

Self-adhesive tape ............................................... 113

204

Plastic scrap grinder ............................................ 106

262

Sensor .................................................................... 95

318

VDMA cylinders ................................................. 87

205

Plastic sheet extrusion plant ............................... 117

263

Servo drive ............................................................ 95

319

Ventilator............................................................. 113

206

Plastic textile and machinery ................................ 77

264

Servo energy saving machine ................................ 67

320

Vertical machining centre ..................................... 79

207

Plate heat exchanger ........................................... 111

265

Sheet calendaring line ........................................... 38

321

Vibratory screening system ................................. 123

208

Plybutylene terepthalate ...................................... 119

266

Short-stroke cylinder ........................................... 87

322

Vision sensor ........................................................... 7

209

PMMA ............................................................... 103

267

Shut-off nozzle .................................................. BIC

323

Warehouse.......................................................38

210

Pneumatic valve .................................................. 111

268

Shuttle series plant .............................................. 123

324

Water-cooled chiller .............................................. 43

211

Polyacetal copolymer ........................................... 119

269

Side channel blower ............................................ 106

325

Water-ring vacuum pump ................................... 106

212

Polymer valve ...................................................... 103

270

Side sealing-bag making machine ........................ 47

326

White masterbatches ................................. 10, COC

213

Polyolefin pipe................................................. 12, 19

271

Single-screw extruder gearbox ................................ 9

327

Wire EDM ........................................................... 25

214

Polyphenylene sulfide .......................................... 119

272

Single-screw extruder plant ............................ 59, 61

328

Wired connection ................................................. 29

215

PP caps.................................................................. 65

273

Slipring crane-duty motor .................................... 49

329

Wireless receiver ................................................... 29

216

PP container.......................................................... 65

274

Slitting machine .................................................... 47

330

Wireless................................................................. 29

217

PP glass-filled compounds .................................... 10

275

Solenoid valve ....................................................... 87

Temperature controller and waterflow regulator ............................................. 106

Variable displacement pump energy-saving machine .......................................... 67

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

120 Modern Plastics & Polymers | March 2012

LIST OF ADVERTISERS Advertiser’s Name & Contact Details

Pg No

Advertiser’s Name & Contact Details

Pg No

Advertiser’s Name & Contact Details

Pg No

Adroit Control Engineers ............................. 95

Hindustan Plastic And Machine Corporation ...59,61

Loxim Industries Limited ............................. 34

T: +91-11-47600700 E: sales@adroitcontrol.com W: www.adroitcontrol.com

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

T: +91-2717-308000 E: info@loxim.com W: www.loxim.com

Aerodry Plastics Automation Pvt Ltd............ 35

Husky Injection Molding Systems P Ltd .. .BGF

Makino India Private Limited....................... 79

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

T: +91-22-25706316 E: snair@husky.ca W: www.husky.ca

T: +91-80-28419500 E: slim@makino.co.in W: www.makino.com

Aeromec Marketing Co Pvt Ltd .................... 93

IDMC Limited ...........................................111

Matsui Technologies India Ltd. .................... 63

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

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

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

Alok Masterbatches Ltd ............................... 33

IMI Norgren Herion Pvt Ltd........................ 87

T: +91-11-41612244 E: sales@alokindustries.com W: www.alokmasterbatches.com

T: +91-120-4089500 E: enquiry@norgren.co.in W: www.norgren.com

Ash Win Engineers .....................................123

Ishan International....................................... 47

T: +91-79-22811879 E: info@ashwinengineersindia.com W: www.ashwinengineersindia.com

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

Ask Enterprises ...........................................124

J.P. Extrusiontech Limited ............................ 99 T: +91-2646-222163 E: Iinfo@jpextrusiontech.com W: www.jpextrusiontech.com

T: +91-09860921110 E: ask.ent@sify.com W: www.asktechnopack.com

Jagmohan Pla-Mach Pvt Ltd .......................107

Blend Colours Pvt Ltd.................................. 10

T: +91-22-25955678 E: info@jagmohan.com W: www.jagmohan.com

T: +91-40-2436 1499 / 2436 0887 E: info@blendcolours.com W: www.blendcolours.com

Medical Plastics Data Service ......................112 T: +91-79-26740611 E: mpds00@vsnl.com W: www.imdiconferences.com Mipalloy .....................................................121 T: +91-44-24541068 E: mipalloy@md3.vsnl.net.in W: www.mipalloy.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

Jing Cheng Mold Machinery Co., Ltd..........126

Ocean Extrusions ........................................... 8

T: +86-576-8461-0001 E: jing-cheng_times@vip163.com W: www.jc-times.com

T: +91-79-22902200 E: oceanextrusions@gmail.com W: www.oceanextrusions.com

Kabra Extrusion Technik Ltd................... 12; 19

Omron Automation Pvt. Ltd. ......................... 7

T: +91-124-4367450 E: ajay.kapoor@dirco.in

T: +91-22-2673 4822 E: sunil@kolsitegroup.com W: www.kolsite.com

T: +91-80-40726400 E: in_enquiry@ap.omron.com W: www.omron-ap.com

Dongguan Alfa Automation Machinery Ltd.. 113

Katlax Enterprises Pvt Ltd............................ 29

Plastiblends India Ltd ..............................COC

T: +86-769-8318-0326 E: info@alfarobot.com W: www.alfarobot.com

T: +91-9328197614 E: info@katlax.com W: www.katlax.com

T: +91-22-67205200 E: rsd@kolsitegroup.com W: www.plastiblendsindia.com

Expo Centre Sharjah ...................................108

Kotra & Woojin Selex Co., Ltd ..................... 27

Poly Mechplast Machines Ltd....................... 18

T: +91-22-67778899 E: sales@plastivisionarabia.org W: www.plastivisionarabia.org

T: +91-09941342299 E: ryanrhee@gmail.com W: www.woojinselex.com

T: +91-265-2631211 E: goldcoin@polymechplast.com W: www..polymachplast.com

Forwell Precision Machinery Co., Ltd..........105

Kreyenborg Group.......................................103

Polyplastics Marketing (India) Pvt Ltd.........119

T: +886-4-834-5196 E: forwell@forwell.com W: www.forwell.com

T: +49-251-214-050 E: k.engelhardt@kreyenborg.de W: www.kreyenborg-group.com

T: +91-22-67587668 E: tushar.birje@polyplastics.com W: www.polyplastics.com

Gem Equipments Ltd ................................... 89

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

Power Build Ltd ..........................................104

T: +91-422-3267800 E: sales@gemindia.com W: www.gemindia.com

T: +91-44-26812000 E: handigolg@larsentoubro.com W: www.larsentoubro.com

T: +91-2692-231070 E: infopbl@elecon.com W: www.pbl.co.in

Gujarat Machinery Pvt Ltd..........................117

Larsen & Toubro .........................................109

Prayag Polytech Pvt Ltd ............................... 45

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

T: +91-22-6752 5656 E: ss-ccd@lth.ltindia.com W: www.larsentoubro.com

T: +91-11-47262000 E: delhi@prayagmb.com W: www.prayagmb.com

Himalayan Packaging Industries P Ltd ......... 65

Lohia Starlinger Ltd. .................................... 77

Presto Stantest Pvt Ltd ................................. 69

T: +91-120-4269355 E: info@himalayangroup.co.in W: www.himalayangroup.co.in

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

T: +91-129-4085000 E: gaurav@prestogroup.com W: www.prestogroup.com

Boge Compressed Air System ....................... 21 T: +91-44-43009610 E: s.sriram@boge.com W: www.boge.in Dirco Polymers Pvt Ltd ...............................103

Our consistent advertisers

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

122 Modern Plastics & Polymers | March 2012

LIST OF ADVERTISERS Advertiser’s Name & Contact Details

Pg No

Advertiser’s Name & Contact Details

Procon Technologies Pvt Ltd ........................ 14 T: +91-79-27492566 E: info@procon.co.in W: www.procon.co.in Raj Engineering Works ...............................106 T: +91-20-65104541 E: raj.engg.wks@gmail.com W: www.rajengg.net Rajoo Engineers Ltd....................................BC T: +91-2827-252701 E: kcdoshi@rajoo.com W: www.rajoo.com Reynold India Pvt Ltd .................................. 43 T: +91-120-4664000 E: v.bali@reynoldindia.com W: www.reynoldindia.com S&T Engineers ............................................ 25 T: +91-422-2590810 E: stycm@stengineers.com W: www.stengineers.com Shanghai Forward Machinery Co.,Ltd .......... 38 T: +86-21-5990-8899 E: forward_sale@exalt.com.tw W: www.forwardsh.com Shini Plastics Technologies I Pvt Ltd............ 85 T: +91-250-3021166 E: jnbhat@shiniindia.com W: www.shini.com Specific Engineering ...................................125 T: +91-265-2646871 E: info@specificgroup.com W: www.specificgroup.com Our consistent advertisers

Pg No

Sreelakshmi Traders ....................................113 T: +91-44-24343343 E: sreelakshmitraders@gmail.com W: www.sreelakshmitraders.com Sri Sai Plasto Tech ....................................... 67 T: +91-44-42994365 E: sspt_plastics@live.in W: www.srisaiplastotech.com Steer Engineering Pvt Ltd ........................72,73 T: +91-80-23723309 E: info@steerworld.com W: www.steerworld.com Suresh Engineering Works ..........................114 T: +91-731-2527872 E: suresen@aittelmail.in W: www.sureshengg.com Tagma .......................................................... 52 E: mumbai@tagmaindia.org W: www.tagmaindia.org Taiwan External Trade Development Council (Taitra) ...................... 16 T: +886-2-2725-5200 E: taitra@taitra.org.tw W: www.taitra.org.tw The Indian Electric Co................................. 49 T: +91-20-24474303 E: icemktg@indianelectric.com W: www.indianelectric.com Toshiba Machine (India) Pvt. Ltd. ...............115 T: +91-11-43291111 E: dineshelija@toshiba-machine.co.in W: www.toshiba-machine.co.jp

Advertiser’s Name & Contact Details

Pg No

Unimark (Maguire)....................................... 91 T: +91-22-25506712 E: infomum@unimark.in W: www.unimark.in Unimark (Stahuli)......................................... 23 T: +91-22-25506712 E: infomum@unimark.in W: www.unimark.in Vacon Drives ...............................................110 T: +91-44-24490024 E: bavani@vacon.com W: www.vacon.com Vacunair Engineering Co Pvt Ltd

106

T: +91-79-22910771 E: info@vacunair.com W: www.vacunair.com Wittmann Battenfeld India Pvt Ltd ............FIC T: +91-44-42077009 E: info@wittman-group.in W: www.wittmann-group.com Xaloy Asia (Thailand) Ltd. ........................ BIC T: +91-79-27541971 E: m.sanghvi@th.xaloy.com W: www.xaloy.com Zambello Riduttori Group ............................. 9 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

124 Modern Plastics & Polymers | March 2012

Modern Plastics & Polymers

March 2012

Modern Plastics & Polymers

March 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.

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