Modern Plastics & Polymers - November 2011 by Infomedia18

EDITORIAL

Donning a new avatar ulti-hundred billion dollar rescue plans to prevent sovereign debt default, highly volatile energy costs and rising demand for financial inclusion among several strata of society across the globe, irrespective of the stage of a particular country’s economic prosperity. Are these mega challenges confronting the world today not exceedingly unprecedented and were these not almost unthinkable just a few years ago? The idea here is not to sound like a doomsday prophet, but to recognise the reality of a fast-changing global phenomenon and, more importantly, mitigate the risks effectively.

Change is not something new for an organisation of any size or industry. In fact, the progressive ones make that significant difference by managing change in a sustainable manner. Some of the real-life scenarios range from implementing new hardware and software to mergers and acquisitions, or relocation of facilities to adopting processes to do more with less resources. A few months ago, we also embarked on a similar journey to ‘change’ ourselves, more precisely, our brands, for better. In this exciting and challenging soul-searching sojourn, we revisited & thoroughly analysed every practical aspect of our motto of providing informative empowerment to our audience and not merely publishing content. Although we have put our best efforts towards perfecting the products and practices further, we would also submit that the best practices for managing change are still elusive. The result is there for you to decipher in this new avatar of ‘Modern Plastics & Polymers’. From the brand new sections to focussed features, emphasis has been laid on ensuring more analytical, in-depth and contemporary firsthand information. Of course, all these are presented in a lucid and elegant way, thanks to an optimum combination of applying mind over matter as well as some of the latest publishing software available.

Editorial Advisory Board A E Ladhabhoy Plastics Technologist

Dr Sushil K Verma Former Director General, CIPET

Rather than blowing our own trumpet, we will prefer your valuable feedback on these initiatives. Suffice to say, it will help us in our constant endeavour to help our audience in terms of receiving superior value on a sustained basis. Let there be more info-empowerment towards better decision making in business. Cheers!

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

Mohan K Jain MD, Indoplast & Past President, AIPMA

P P Kharas

Manas R Bastia manas@infomedia18.in

Chairman, Ecoplast

Raman M Patel Chairman, Industrial Products Mfg Co

Vijay Merchant President, Polycraft

November 2011 | Modern Plastics & Polymers

CONTENT S

SPECIAL FOCUS: Polymer Processing

Polymer processing ............... 50

63 Plastics in sports applications ..64

Insight & Outlook Sporting innovations ............ 68

Processing practices .............. 54

Interface - Anil Kumar ........ 72

Roundtable ........................... 58

Material corner..................... 74

Special Focus

Injection zone....................... 78 November 2011 | Modern Plastics & Polymers

Automation Trends

Technology index: Process optimisation for boosting efficiency

Energy Management

All-electric machines: Energy efficiency par excellence

Polymer pricing policy: Maintaining cost-quality equilibrium

Quantifying quality: Ensuring better business decisions

Policies & Regulations

Strategy

In Conversation With

M Hariharan, Director, Savoir Faire Management Consultancy Pvt Ltd

Atul Dave President, Baumuller India

Plastiblends India Ltd: Colouring the world of plastics

Tips & Tricks

100

Extrusion techniques: Effective methods for driving profits

114

Engineering Expo Pune 2011: Gateway to exuberant opportunities

116

Engineering Expo Rudrapur 2011: Optimising the Northern advantage

Event Preview

Event Report

Facility Visit

Details on pg no. 108

REGU L AR SEC T I ON S

Cover photo courtesy : Prasad Group of Companies

Editorial ............................... 11 Event List........................... 108

Highlights of Next Edition Special Focus: Plastics in Electronics / Electrical Appliances Insight & Outlook : Blow Moulding Note: ` stands for Indian rupee, $ stands for US dollar and ÂŁ stands for UK pound, unless mentioned otherwise

News, Views & Analysis ...... 28 Book Review ...................... 118 Technology & Innovation .... 40 Products.............................. 122 Technology Transfer ............ 42 List of Products.................. 137 Projects ............................... 106 List of Advertisers .............. 140

November 2011 | Modern Plastics & Polymers

Business Insights •Technologies•Opportunities

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November 2011 | Modern Plastics & Polymers

NEWS, VIEWS & ANALYSIS

DSM Engineering Plastics, RESINEX ink distribution agreement In line with its strategy to deliver value for existing and new customers worldwide, DSM Engineering Plastics has partnered with RESINEX for distribution in new markets. The move, which is effective from October 1, 2011, is designed to strengthen the position of DSM Engineering Plastics in the Swiss marketplace, where DSM already has an ongoing partnership with German supplier Ter Hell. According to the company, this agreement is important for extending the partnership of DSM and RESINEX. Swiss customers will benefit from

Shell restarts second CDU at a reduced rate of 75 per cent

Royal Dutch Shell Plc has restarted a second Crude Distillation Unit (CDU) at reduced rates at its fire-hit Singapore refinery, a week after the first was partially restarted. The 110,000 barrels per day (bpd) CDU will reach stable operating levels in 2-3 days, and is expected to run at a reduced rate of about 75 per cent. Restart of its distillate-making hydrocracker is planned at the 500,000

GW Plastics to expand silicones division GW Plastics, a global precision moulder and contract manufacturer, has announced the expansion of its Silicones Division in Royalton, Vermont, to support the increasing demand. With an initial investment of about $ 3 million, GW will commence work in October 2011 and is planning for full occupancy by the first quarter of 2012. 28

RESINEX’s local presence and technical structure. This joint approach will facilitate further growth of DSM Engineering Plastics in the key Swiss marketplace. This agreement will make DSM’s range of world-class products more easily available throughout Switzerland. All products will be fully supported by DSM’s outstanding technical support and application development programmes, where necessary. This distribution agreement is an important step for RESINEX as well, following the strategic expansion in engineering plastics and specialties product portfolio with well-known brands from prominent raw material producers.

SABIC gets country leaders in Europe

Michael Allen

bpd plant within the next 2-3 days. The CDU operations will facilitate restart of the 35,000 bpd hydrocracker, which was shut due to its proximity to the fire but was undamaged. With partial operations at the second CDU, the refinery is currently running at about 40 per cent, as its largest 210,000bpd capacity CDU has been functioning at about 50 per cent for nearly a week. A third CDU, of 110,000-bpd capacity, and some other smaller secondary units are still shut after the fire that lasted for more than 30 hours, largely crippling the capability to deliver clean oil products, such as gas oil, jet fuel, gasoline and naphtha. Shell is slowly trying to get the CDUs and the main secondary units back up at reduced rates, primarily to yield products with high margin, eg, base oils and lubricants, petrochemicals.

SABIC has appointed country leaders across Europe to ensure that customers benefit from its global assets as well as local expertise, and establish closer cooperation between SABIC’s business & sales operations in polyolefins, engineering thermoplastics and chemicals. Michael Allen was recently appointed as Country Leader in the UK. On his appointment, Michael Allen said, “We will have a unified team that can provide multi-product customers with complementary services, eg, referrals across product lines for materials, application development and integrated market intelligence.” The company has one integrated office with one Country Leader with his/her team responsible for the full product portfolio in Europe. By bringing everything under one roof, the company will be well positioned to provide customers with coordinated access to the company’s full portfolio of materials & services and align service practices to accelerate time to market.

The expansion will allow increased capacity by creating an additional 15,000 sq ft, scalable up to 25,000 sq ft, including a new ISO Class 8 clean room for silicone moulding and assembly. The initial expansion will be supporting up to 18 machines. Based on current projections, GW expects the expansion to add 25-50 jobs over the next 3-5 years. Mark Hammond, General Manager, GW Silicones, commented, “The

expansion of GW Silicones reflects our commitment to the business and growing manufacturing jobs in Vermont. It is encouraging to see that our customers recognise the value that GW Silicones is bringing to the market.” GW Silicones offers highly automated, precision moulding and contract assembly services for Liquid Silicone Rubber (LSR) applications, as well as internal mould design & build capabilities.

Modern Plastics & Polymers | November 2011

NEWS, VIEWS & ANALYSIS

New hydraulic technology machine by Negri Bossi

Negri Bossi has launched a new hydraulic technology machine EOS 80 SE. This machine sets a new record in terms of compactness, reducing from 5 to 3.5 m the floor space needed as compared to previous models. The extremely compact dimensions of the new EOS line are due to its meticulous design. It has two-platen clamping units and two cylinder injection units. The cantilevered clamping system design allows a free open area below the mould, enabling products to be transported in any direction and providing space for placing ancillary equipment. The injection unit slides on two prismatic guides with recirculating ball bearings and is equipped with two cylinders directly coupled hydraulically, pulling in tandem during the injection phase and a bi-metallic plasticising barrel, ensuring longer life when processing abrasive materials. The new machine will come in standard and ‘SE - Smart Energy’ configuration to minimise energy consumption. V Ramesh, Chief Executive Officer, Negri Bossi SACMI Engineering (India) Pvt Ltd, said, “The usage of two-platen clamping unit as against the traditional three-platen clamping unit is its uniqueness.” This provides an excellent parallelism between the platens and ensures cleanliness in the moulding area due to the absence of lubrication oil, making the machine ideal for use in the pharmaceutical, biomedical and ffood industry.

BASF to invest in SAP plants in Brazil, China and Malaysia BASF SE, the German-based polymer manufacturing company, plans to build Super-Absorbent Polymer (SAP) plants in Brazil and China, and is considering the possibility of setting up a similar plant in Malaysia. SAPs can absorb

Braskem acquires Dow Chemical’s PP business The leading resin producer, Braskem has acquired the Polypropylene (PP) business from the Dow Chemical Company, which is an important milestone in the company’s global expansion. The deal was announced in July 2011 and received the approval of the European Commission, Federal Trade Commission and Antitrust Division of the Justice Department of the US. The deal is expected to deliver about $ 140 million in synergies through a diversified portfolio, leveraged fixed cost base & working capital, logistics and supply optimisation. The assets involved in the deal include two manufacturing plants in the US and two in Germany,

with a total annual PP production capacity of 1.05 million tonne. The two US manufacturing plants in Freeport and Seadrift, Texas, will be fully integrated into Braskem America Inc. The two German plants in Wesseling and Schkopau will operate under Braskem Europe GmbH. Along with the acquisition, Braskem has made some new appointments. Mark Nikolich, formerly Vice President of Commercial and Supply Chain for Braskem America, has been named Chief Executive Officer of the new business. Also, Robert Nadin, General Manager of Braskem Europe GmbH, formerly Vice President of Innovation & Technology for Braskem America, has been appointed Vice President of Commercial & Supply Chain for PP in North America.

MachinePoint, Plasgrom SA partner to meet local demand MachinePoint Used Machiner y has entered into the Mexican market by way of partnership with Plasgrom SA to work more closely with the customers and meet the local demand. MachinePoint Used Machinery is the subsidiary of MachinePoint group, headquartered in Spain, with offices across all continents. Cesar Rodriguez, Chief Executive Office, MachinePoint, said, “Since our inception, Mexico has been a strategic market for us by the volume of sales. This local presence is important to expand our range of services in this market, including engineering services & local assemblies, complete plants and lines.” According to the company, the purchase of used machinery remains a complex process, and it is important to have a reputable company to ensure service quality and safety of the operation. This partnership will

help the company in closely advising local buyers in the purchase and sale of machinery used primarily for the beverage sector. Rohan Shrikant Shahane, Regional Director - South East Asia, Machine Point Consultants SL, informed, “We not only sell used machines but also buy them. The Mexican market offers numerous opportunities for us. Moreover, we are taking this step since MachinePoint believes in having a local language speaker of a country deal with customers there.”

and hold up to 500 times their own weight of liquid, or up to 50 times their own weight of salty fluids, eg, urine. The major uses of SAPs are diapers and adult incontinence & feminine hygiene products. The planned facility in Camaçari, Brazil, will have an annual

capacity of 60,000 Tonne Per Annum (TPA), and production will likely begin in late 2014. BASF-YPC Co Ltd, a 50:50 joint venture between BASF and Sinopec Ltd will set up a 60,000-TPA plant in Nanjing, China, to begin commercial production in early 2014.

Modern Plastics & Polymers | November 2011

L-R: Cesar Rodriguez, CEO, MachinePoint Consultants SL & David Felix Troche, Founder, Plasgrom SA

NEWS, VIEWS & ANALYSIS

PTT Chemical invests $ 150 million in NatureWorks

Emmbi Polyarns bags SME Excellence Award Emmbi Polyarns Ltd, one of the established players in the field of woven polyethylene and polypropylene product manufacturing industry, has recently bagged the SME Excellence Award at India SME Leadership Summit. The Summit was held on August 26 in Mumbai, organised by SME Chamber of India, and supported by Government of India. Many prominent personalities present at the Summit, including Virbhadra Singh, Union Minister for Micro, Small & Medium Enterprises; Dr Subhir Gokarn, Deputy Governor, Reserve Bank of India (RBI); Dr Sam Pitroda, Advisor to Prime Minister on Public Information, Infrastructure & Innovation, India. Eminent speakers from various industries, banks, financial institutions, government departments, trade promotion organisations and management leaders, policy & decision

Makrand Appalwar

makers, experts, consultants and other professionals were invited to share their thoughts to create leadership qualities among Small and Medium Enterprises (SMEs) and young entrepreneurs to compete in the global market. Makrand Appalwar, Managing Director, Emmbi Polyarns Ltd, after receiving the award, stated, “The award is an acknowledgement of our endeavour to excel in this industry, which is still at a nascent stage in India. It indicates that our efforts are well directed. It is also a strong motivator for us to pursue our goal to be pioneers in this sector.”

PTT Chemical Public Company Ltd (PTT Chemical) is investing $ 150 million in NatureWorks LLC. By attracting probably the most advanced biopolymer processing plant in the world to Thailand, PTT Chemical has made a significant step in achieving Thailand’s strategic aim of becoming a regional hub for green technologies and solutions. PTT Chemical’s investment supports NatureWorks’ intent to globalise its Ingeo manufacturing capability by building a new production facility in Thailand, to support the Asian customer base and deliver its commitment to renewable feedstock diversification. Ingeo offers the performance of conventional plastics and fibres with a fraction of greenhouse gas emissions and lower non-renewable energy requirements. Being made from renewable plant material, Ingeo has inherently more stable pricing, in contrast to massive price swings observed in fossilbased polymers.

Rusnano invests in basalt nanocomposites

Delhi government plans to ban the use of plastic bags

The global composites industry holds special significance for the specialty chemicals and polymers industry. Moscow-based Rusnano and UK-based Galen have jointly invested for setting up production of composite nanostructured polymer based on basalt fibre. The project has a budget of 500 million rouble, of which c o - i nve s t Rusnano will 200 million rouble. Project planners expect production to reach 2,500-3,000 tonne by 2016. Products include shaft lining for the mining industry; armature, flexible connectors & rawl plugs for the construction industry; composite alluvial drill rods for oil production; and poles for street lighting & power transmission lines. Alexander K o n d r a s h o v, Managing Director, Rusnano, said, “Galen is experienced in

Delhi government has decided to ban the usage and production of plastic bags in the next two months. Manufacturers and retailers found selling plastic bags will be subjected to imprisonment of nearly five years or a fine of up to ` 1 lakh or both as part of the initiative towards environment conservation. According to a draft notification issued by the centre, “No individual shall be allowed to manufacture, store, import, sell or transport any type of plastic carry bags (including that of Polypropylene, nonwoven fabric-type carry bags) in the National Capital Territory of Delhi, except for export purposes.” The Environment Protection Act 1986 has deemed the storage and sale of plastic bags an offence. “The plastic packaging industry will be affected by the ban imposed by the Supreme Court on plastic packaging. Many packaging companies in this line of business were forced to close their business operations after the verdict,” said Sandeep Jain, Director, Hi Tech Polyflex Private Ltd. While manufacturers have taken up alternative methods of packaging, this ban has not penetrated many states. This requires monitoring of manufacturing facilities and selling outlets in the 2 and 3 tier cities where laws are flouted easily. Only then, will the ban have a positive impact.

developing unique technological solutions. For example, its armature for construction of a single-span bridge in Northern Ireland or its flexible connectors for the Passive House in England. The strict British requirements for fire resistance of materials prompted the company’s engineers to experiment with nanomodifiers for polymer connectors.” Basalt plastic armature is as strong as steel and more durable. The basalt fibre-based composite material does not corrode. This is important for structures that must operate in high-moisture or high-salt conditions, particularly bridge supports. The material is considerably lighter than steel (average 70 per cent), simplifying transportation and saving cost.

Modern Plastics & Polymers | November 2011

NEWS, VIEWS & ANALYSIS

Italy’s Serioplast invests € 8 million in Poland plant Italian plastics packaging blow moulder – Serioplast – is investing more than € 8 million to construct a new plant near Lodz, Poland. The group, based in Dalmine, Italy, recently won a planning consent to occupy a 4.5-hectare site in the Kutno area of the Lodz special economic zone. The new facility will be operated by the group’s national subsidiary Serioplast Poland. In Poland, Serioplast intends to produce a range of packaging for the food, pharmaceutical, detergents and cosmetics industries. The group runs 16 plants in European countries, including Hungary, Slovakia, Germany, France

LANXESS adds capacity in Brazil

(L-R) Jens Hendrik Fischer, GM - Americas SCPBU; Guenther Weymans, Head - Technical Rubber Products-BU; Axel C Heitman, Chairman, LANXESS; Anno Borkowsky, Head - Rhein Chemie; Marcelo Lacerda, Country Representative, Brazil

Brazil being the world’s fifth largest car maker, with nearly 13 per cent growth in the nation’s automotive industry, LANXESS could not have chosen a more ideal destination for this investment. LANXESS is strengthening its commitment to Brazil with three major

Kabra Gloucester showcases first five-layer film plant KAGE is the brand name for film plants manufactured by Kolsite Group, utilising the engineering designs and technology of Gloucester Engineering Co. KAGE lines are specifically engineered to meet diverse challenges of the film plant industry, and the first five-layer fully loaded line is all set to be delivered to Prropyl Packs Ltd, Kerala. KAGE plants are designed to produce barrier film at rates and quality levels that not only meet the markets requirements, but also 36

and Italy. Serioplast Poland has agreed to meet a deadline for December 2017 and will employ a workforce of more than 66 at the new site. In late 2009, the Italian group, which blow-moulds bottles and injectionmoulds bottle performs, strengthened its position in France by taking over Graham Emballage Plastique of Meaux. The business changed its name to Serioplast Meaux and moved the company base to Langeais, France. It was at the end of 2008 that Serioplast launched 6,000-m² production hall at its Hungarian blow moulding plant at Nyirbator in the country’s North East. It has expanded this facility since then. new investments totaling € 30 million ($ 75 million), creating over 100 jobs. The three investments include construction of two new plants at LANXESS’ Porto Feliz site in São Paulo. One is for production of high-tech engineering plastics Durethan and Pocan – used primarily by the automotive industry to make cars lighter and more fuel-efficient. The new plant will be run by the Semi-Crystalline Products Business Unit (SCP-BU), and will have an initial capacity of 20,000 metric tonne per year. The plant will go on stream by mid-2013. The other new Porto Feliz plant will produce rubber additives, eg, Rhenogran and Rhenoshape curing bladders. Axel C Heitmann, Chairman, LANXESS, commented, “We are making major investments that will ensure that we participate in the current and future success of the Brazilian economy. ” result in enhanced operational efficiency and higher flexibility for plastics manufacturers. The five-layer 2,200-mm film line has an installed capacity of 4,000 tonne/year and output up to 600 kg/hr. This five-layer film plant can be used to pack oil, and in other barrier applications; it is also used for production of high-quality lamination films. Prropyl Packs will introduce the barrier film mainly for oil packaging, vacuum packaging and packaging that needs enhanced shelf life. As India has mandated edible oil to be sold in packaged form only,

Modern Plastics & Polymers | November 2011

Bioplastics market sees rapid global growth The bioplastics market is growing rapidly, with a 41 per cent Compound Annual Growth Rate (CAGR) forecast for 2010-15. This raises the 2010 demand of 571,712 metric tonne to over 3 million tonne in 2015. Early adoption of bioplastics and subsequent interest in the technology was driven by rising concerns over environmental issues, particularly with regard to product disposal and global warming. Bioplastics includes recyclable polymers like Polylactic acid, thermoplastic starch, bio-polyamide (nylon), Polyhydroxyalkanoate (PHA), etc, which are synthesised from biomass and food crops like corn, soybeans and sugarcane. The high availability of these crops in the US has led to the country’s dominance in the market, despite the fact that in the early stages, European adoption of bioplastics was higher than that of the US. Key applications of bioplastics are automotive, building, construction, electrical/electronic, medical and packaging sectors. Andy Sweetman, Chairman, European Bioplastics, said, “It is essential that the issues affecting the bioplastics industry are recognised and understood by policymakers since bioeconomy is an important issue in the European Union (EU). Bioplastics offer two distinctive advantages, their renewability and availability. We must encourage greater awareness of the bioplastics industry, its products and their benefits.” barrier film packaging shall not only meet government standards, but also improve the shelf life of packaged oil by protecting it against oxygen & moisture and ensuring its cleanliness.

Five-layer film plant

NEWS, VIEWS & ANALYSIS

LANXESS to produce world’s first bio-based EPDM rubber LANXESS is strengthening its commitment to produce premium synthetic rubbers f rom biobased raw materials. The German specialty chemicals company aims to commercially produce EthylenePropylene-Diene Monomer (EPDM) from bio-based ethylene – a first in the world – by the year end. EPDM is conventionally produced using the petroleum-based raw materials ethylene and propylene. Alternatively, the company plans to use ethylene derived purely from the renewable resource sugarcane. This bio-based form of ethylene is produced by dehydrating ethanol from Brazilian sugarcane. Braskem S.A. supply the bio-based ethylene via pipeline to LANXESS’ existing EPDM plant in Triunfo, Brazil. All EPDM grades will be sold under the brand name

Keltan. “Our company’s ongoing search for alternatives to fossil fuels underlines its commitment to reducing CO2 emissions through sustainable production,” said Guenther Weymans, Head-Technical Rubber Products Business Unit, LANXESS. Elaborating on the same, Marcelo Nunes, Director-Renewable Chemicals, Braskem, said, “LANXESS will contribute to broaden our portfolio of renewable chemicals’ clients. This agreement will bring the benefits of green ethylene to other important applications and markets. LANXESS has extensive automotive experience and an excellent reputation in this market, which makes it an ideal partner.” The Triunfo plant currently produces 40,000 metric tonne per year of regular EPDM rubber. It is expected that the first batches of the product Keltan Eco will amount to several hundred metric tonnes.

Innovations awarded in plastics extrusion With the aim to promote open innovations in the global plastics industry, Reifenhäuser had launched the Extrusioneers Innovation Contest in April this year. The company announced the winners from among over 101 ideas, and almost 1,000 commentaries have been collected during the competition in three categories – product, process and machinery. A jury of external experts and experts from the Reifenhäuser Group selected the best ideas, the most unconventional idea and the most valuable participant. The first prize was awarded to the idea Energy Recovery, which demonstrates a solution for energy recovery to exploit the great temperature differences in extrusion and is thus relevant in many areas of extrusion. The second prize went to the idea Exow Street – a drainage system for streets made of extruded tiles that can help reduce street damages and improve safety on the streets. The idea of using nonwoven material in layering artificial turf received the third prize; it is concerned with construction of artificial turf using nonwoven material as substrate, which could make artificial turf resemble closely to the natural ones. Dr Bernd Kunze, member of Reifenhäuser’s corporate leadership and responsible for innovation management, said, “We are surprised to see how much time the participants have invested in the competition and how open and intensively the ideas were discussed. The occasional unconventional approaches true to the competition motto ‘Thinking outside the box’ have stimulated us to reflect and discuss.”

Modern Plastics & Polymers | November 2011

Plastics firms in Southeast Asia face new challenges Buoyed by the economic growth in China and India, Southeast Asia’s plastics industries successfully emerged from the 2009 global recession. But there are major challenges looming, including inflation, a slowing world economy and rapidly rising wages that threaten to prise some of the former Asian economies out of the ranks of low-wage countries. Krianglit Sukcharoensin, President, Thai Plastics Industries Association, said, “Plastics firms in Thailand are facing up to 45 per cent wage increases, both from government plans to boost minimum salaries and from market factors like rising incomes in rural areas. To address the acute labour shortage, Southeast Asia’s largest plastics industries, Malaysia and Thailand, are investing in education & upgrading efforts. Labour shortages coupled with energy costs, capacity constraints, rising commodity & food prices, are threatening to push inflation beyond control.”

Unnati Speciality Films goes green Unnati Speciality Films (USF) has launched its first biodegradable stretch film, in an attempt to reduce the impact of waste films dumped & storage of the leftovers in the warehouse. The Ahmedabad-based USF manufactures flexible packaging films apart from Speciality Packaging Films has manufactured BioWrap, which is biodegradable & compostable during 2-4 months under pre-specified Ultraviolet (UV ) conditions. In contrast, a standard stretch film takes many decades to fully compost. Green consumers will no longer have to separate out the stretch film from other items being sent for recycling. More than 1.5 billion metre of stretch film wrapping could be used in industries alone every year. BioWrap contains an additive that initiates chemical breakdown more quickly and completely in the presence of oxygen, heat or UV light. These films shall be available in clear or tinted green. However, USF believes that choosing BioWrap with a green tint will help communicate the positive environmental impact of plastics. This will also help USF’s clients to differentiate their organisation by being recognised as a market leader.

MPP Nov 2011 Ad Name: Alok Pg No. 33

MPP Nov 2011 Ad Name: Loxim Pg No. 34

TECHNOLOGY & INNOVATION

Capillary Rheology study for injection moulding processes Malvern Instruments has developed Rosand Capillary Rheometer, which can measure Pressure–Volume– Temperature (PVT) characteristics of compounds and predict their suitability for use, or help predict optimum injection moulder settings. While injection moulding of samples, it is important to know about PVT properties of the melt, as some melts may be more compressible than others. Generally, a compressible melt is likely to require higher volume to fill the mould, but can bleed from the injection point after moulding, thus causing the die ‘drool’. Variations in melt compressibility can result in convex or concave surfaces of parts instead of flat surface. This can cause problems when parts are to be fitted together. By using the Rosand Capillary Rheometer, the density of the hot polymer melt can be used as an indication to processability when formulating new injection moulding compounds. This rheometer can be used in conjunction with laboratory and pilot-scale injection moulders to formulate high-quality polymer compounds. PVT testing can show how to optimise injection moulding settings, while high-shear rheometry can simulate the actual injection process.

Novopearls micro-granulate to colour thermoplastics Novosystems has introduced a new micro-granulate. Marketed under the name Novopearls, the granulate combines the best features of liquid colours and

High-performance UV absorber Tinuvin® 1600 Tinuvin® 1600 is a new Ultraviolet (UV) absorber that provides extremely longlasting UV protection to high-performance thermoplastics. It exhibits an outstanding UV absorption capacity, resulting in minimal loss of optical properties for stringent weathering requirements. The product is developed specifically for long-lasting protection of thin-layer applications for exteriors and allows plastic sheets, films & fibres to retain their mechanical properties, colour and transparency for extended durations. It belongs to the class of triazines and exhibits low volatility, excellent thermal stability and good substrate compatibility in various polymeric resins, which allow easy processing. It imparts superior durability than conventional UV absorbers of other

chromophores. It extends the durability and life expectancy of products under intense UV exposure. It is suited for longterm outdoor use for up to 20 years. Tinuvin® 1600 is recommended for monolithic and multi-wall Polycarbonate sheets for ultra-highdurability architectural and automotive glazing applications; biaxially oriented Polyethylene Terephthalate (PET) films for photovoltaics, window films, displays, protective films & other long-term applications; Poly(Methyl Methacrylate) (PMMA) laminations for durable specialty applications like window profiles, photovoltaics and demanding construction applications; PET and polyamide fibres; styrene acrylonitrile, acrylonitrile styrene acrylate high-performance plastics applications, eg, building & construction, automotive applications, etc.

REIfill technology saves raw material costs New thermoforming sheet line from Reifenhäuser Extrusion, equipped with a REItruder, reduces raw material costs by more than 40 per cent. The REIfill technology allows processors to replace up to 40 per cent of Polypropylene (PP) and Polystyrene (PS) with mineral fillers, eg, calcium carbonate, talc, etc. Besides cost-related aspects, addition of mineral fillers, according to application of the end product is also of interest in terms of product properties, ie, filled PP and PS films have a greater stiffness than pure PP and PS films with identical wall thickness. This is an ideal prerequisite

for manufacture of disposable dishes. Manufacturers whose products do not require such enhanced stiffness may reduce the film thickness, resulting in further raw material and costs-savings. Furthermore, filled thermoforming sheets can be produced in many cases depending on the end product at increased cycle rates. The suggested applications include disposable dishes.

conventional granulate batch material. It is a solid material with characteristics of liquid colours, making a higher degree of colouration possible and offering costsavings as compared to conventional colour batches. Novopearls micro-granulate fills the gap between liquid colours and conventional batch granulate. The spherical micro-granulate (average diameter, 450 μm) is a special wax mixture that can be homogenised with numerous thermoplastics.

Novopearlss is highly pigmented, can be mixed together, is dust-free and has low viscosity. But the real highlight is its melting point of 85°C. It melts in the screw faster than the basic plastic material to be coloured. This ensures rapid, streakfree homogenisation of the colour and the plastics. Due to optimally dispersed pigments in the wax-based granulate, small amounts of additives (0.1-0.9 per cent) are needed. Time-savings gained through quick colour changes gives a high degree of flexibility to the user.

Modern Plastics & Polymers | November 2011

TECHNOLOGY TRANSFER

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

Polyester chip plant

Rotational moulding of plastics

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 company from China offers polyester production plant, polycondensation plant, polymerisation line, hot melt adhesive plant (500-5,000 tpa), polyester chip plant (2,000-1,50,000 tpa) and film grade polyester plant (2,000-1,50,000 tpa).

A manufacturer of rotational moulding machines from India offers plant and machinery for constructing water storage tanks and other hollow plastic parts.

Areas of application

Chemical fibre and plastics

Polymerisation and fibre lines

Forms of transfer

Chemical storage tanks, water storage tanks, material handling trolleys, pallets, containers, etc

Turnkey

Technology licensing and turnkey

Forms of transfer

Plastic recycling technologies using organic and inorganic compounds

Pilot plants for small-scale production

Areas of application

Others

An Iranian company offers plastics 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.

Areas of application Plastics recycling

C P plant like polyester plant, polyester chip or direct spinning.

Recycling of PET wastes into polyester polyols

Areas of application

A Czech Republican company is offering the technology for recycling of PET wastes (plastic PET bottles, X-ray films, etc) to produce polyester polyols. The process consists of the following steps: Collection of PET wastes, sorting out & shredding of collected PET wastes, simple chemical process of glycolysis & esterification, and production of polyester polyols.

Chemical fibre and plastics

Forms of transfer Turnkey

Conversion of batch-poly plant to C P plant

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

An Indian company offers pilot plants for laboratory or small-scale production purpose. The plant consists of a spinneret, metering pump, spinning beam, candle filter, extruder unit, godet unit, PP multifilament plant manufacturer, singlescrew extruder machine or melt flow index tester machine for masterbatch industries.

Areas of application

Plastics recycling

Plastics, textiles, etc

Chemicals industry: Polyester polyol is a base material for the chemistry of polyurethanes, especially the production of polyurethane foams, which are primarily transferred into energy saving and insulating materials

Forms of transfer

Technology licensing

Sub-contracting, turnkey, etc

Technology licensing, others

Forms of transfer Others

Plastics recycling technologies

Areas of application

Share Your Technology Propositions The mission of Modern Plastics and Polymers is to spread the technology culture. We offer you an opportunity to participate in this endeavour by publishing the best technology ideas. Technology developers/sellers are invited to furnish the techno-commercial details (with environmental beneﬁts, if any) for publication in the Technology Transfer column of Modern Plastics and Polymers. R&D organisations, technical consultancy organisations and individuals assisting small and medium enterprises send the relevant literature, indicating the scope & services and the areas of speciﬁcation. Contact: Modern Plastics and Polymers Infomedia 18 Ltd, ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W), Mumbai 400 028. Tel: 022-3024 5000 l Fax: 022-3003 4499 l Email: spedit@infomedia18.in

Modern Plastics & Polymers | November 2011

TECHNOLOGY TRANSFER

Technology Requested Disposal and recycling of plastics waste 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

Forms of transfer Others

Polyacetal resins A Gulf-based organisation wants to promote projects in the chemicals and petrochemicals sectors in GCC countries. It is looking for technology suppliers for the manufacture of polyacetal resins.

Areas of application Chemicals/petrochemicals industry

Forms of transfer Feasibility study, know-how, equipment, turnkey plant, joint venture

PP/PET strap processing

Plastics industry, waste recycling, waste management

An Indian company is seeking the technology for PP and PET strap processing.

Forms of transfer

Areas of application

Others

Packaging industry

Forms of transfer Lab-scale non-woven and monofilament plant

Others

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

Recycled PET polyester polyols plant

Areas of application Plastics

Forms of transfer Others

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

A Poland-based company specialising in recycled PET polyester polyols manufacturing, is looking for an alternative proposal of design and engineering of bigger (approximately 25 ktpa) production plant. It plans to start with proper quality recycled PET flakes being delivered in big bags. Hence, the company needs a complete package offer for this service.

Areas of application Plastics and polymers industry

Areas of application

Forms of transfer

Plastics recycling

Others

Information courtesy: Information courtesy: Dr Krishnan S Raghavan, In-Charge, Technology Transfer Services Group, United Nations - Asian and PaciďŹ c 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.

November 2011 | Modern Plastics & Polymers

An invite that rewards as well...

Dear Reader, ‘Modern Plastics & Polymers’ solicits original, well-written, application-oriented, unpublished articles that reflect your valuable experience and expertise in the plastics & polymers industry. You can send us Technical Articles, Case Studies and Product Write-ups. The length of the article should not exceed 3000 words, while that of a product write-up should not exceed 200 words. The articles should preferably reach us in soft copy (either E-mail or a CD). The text should be in MS Word format and images in 300 DPI resolution & JPG format. The final decision regarding the selection and publication of the articles shall rest solely with ‘Modern Plastics & Polymers’. Authors whose articles are published will receive a complimentary copy of that particular issue and an honorarium cheque. Published by Infomedia 18 Ltd, ‘Modern Plastics & Polymers’ is the leading monthly magazine exclusively meant for producers and user fraternities of the plastics industry. Well supported by a national readership of over 80,000 and our strong network of 26 branch offices across India, this magazine reaches out to key decision makers among the Indian manufacturers of plastics products, machinery and allied sectors. Brought out in association with Hong Kong-based Ringier Trade Media Ltd (one of the world’s largest trade publishing houses with more than 200 special interest titles and offices in every major country), it ensures that advertisers are able to promote their products and services across the globe at no extra cost. So get going and rush your articles, write-ups, etc… Thanking you, Yours sincerely,

Manas R Bastia Senior Editor Infomedia 18 Limited ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W) Mumbai 400 028 India

D +91 22 3003 4669 T +91 22 3024 5000 F +91 22 3003 4499 E manas@infomedia18.in W www.infomedia18.in

“If energy is utilised to its fullest, the cost per piece will decrease steadily” …opines Atul Dave, President, Baumuller India Pvt Ltd. In an exclusive conversation with Vishakha Avachat-Naware, he underlines the importance of the use of plastics in various fields like food processing, retail and automobile. He believes that the use of latest technology & good-quality components in a machine ensures energy efficiency, better uptime and minimal rejections, thereby adding to the cost-efficiency.

Highlight the current market trends in the plastics and polymers industry. The plastics and polymers industry is growing at a fast pace. Baumuller as a company concentrates on three processes – injection moulding, blow moulding and blown films – since a major portion of our business comes from these areas. Based on these basic categories, this industry has been growing at the rate of 20 per cent over the last 2-3 years. The plastic processing machinery industry is expected to continue growing in a similar fashion for the next 4-5 years.

Following are the reasons for this growth: Investment in food processing: Food processing also comprises other agricultural practices, such as irrigation. Among all food items like fruits, vegetables, grains, etc that are produced in India, less than 50 per cent reaches the population. The remaining go waste and perish due to 46

lack of proper infrastructure in food processing segment across India. Realising this phenomenon, the government is now offering subsidiaries to ensure that at least 70 per cent of the foodstuffs produced reaches the population. We expect growth in the use of plastics in food processing. This growth would be not only in food processing, but also in packaging. Generally, packaged food comes packed in plastic pouches, bags or containers. This will result in increased demand for plastics in this segment. Another area where plastics are and will be used in large quantities is irrigation. For example, Polyvinyl Chloride (PVC) pipes, rubber pipes and plastic components are used in drip irrigation. Retail sector: The growing spending power of the Indian middle class has led to an increase in the packed food culture, and this will continue growing in future. This will provide an opportunity for further consumption of plastics in the

Modern Plastics & Polymers | November 2011

form of containers, bottles or films. The latest trend in plastic packaging in the retail sector is thermoforming. In this process, plastic granules are converted to a film. Thermoformed trays are used to pack products such as biscuits and chocolates. Automobile sector: Car making utilises various plastic components. These plastic components are now manufactured in India for export to developed countries.

What are the latest developments and innovations in this area? Three areas have seen a number of developments – energy efficiency, uptime of machine and quality of product. In energy, the processes, mainly injection moulding and, to some extent, blow moulding, are witnessing new developments. Energy is an important cost factor in manufacturing. It constitutes the second highest cost that a manufacturer incurs in production. The highest cost

Atul Dave

is incurred on raw materials. Processes like melting, blowing and injecting require huge amounts of energy. The biggest concern for those using injection moulding process is to make optimal use of the available energy. If technology is utilised to its fullest, the cost per piece will steadily decrease. The second development is the higher uptime of machine or greater reliability of the machine. A manufacturer loses out on man-hours when a machine requires frequent repairs or in case of shutdown and maintenance activities. The reliability of components used machines depends on the quality of components used. A well functioning machine can be achieved using good quality critical components like valves, controls, motor, sensors, etc. When the final product is made as per specifications, it ensures minimum rejections and optimum consumption of raw materials. Automation is a rising trend in this field.

Tell us about Baumullerâ&#x20AC;&#x2122;s stint in India. In India, Baumuller has recently opened a facility in Pune. We are greatly dependent on the plastics sector, so the growth in this industry has compelled us to expand our facilities. As Baumuller is a global company, our shareholders expect us to provide more services in the Southeast Asian region. When our customers provide their products to the Southeast Asian market, they expect our support in the form of customer visits, commissioning and troubleshooting. We provide services to companies in Southeast Asia and sales in India.

How has been your journey in this field? After graduating from College of Engineering, Pune, I wanted to do something different. In my first job at Godrej, I opted for the production department, as I wanted to work on the shop-floor. Later, in companies like Philips and Festo, I worked in the field of industrial automation. Here, I got an opportunity to work like an entrepreneur and develop my industry skills. I learnt how to start a

business and got an opportunity to work with machine manufacturers from the fields of plastics, packaging & printing. By the time I joined Baumuller, I had an in-depth understanding of this field and its nuances.

What has been the biggest challenge pertaining to business decisions for you? I have worked in up-market companies but not in a price-sensitive market. As the quality, reliability and after-sales service are good, the price of products is also high. Our strong technological support ensures long-term success. The biggest challenge for me has been to convince buyers about return on investment, even though the price of the products is high. I want to give this matter a thought and develop a new scheme of effective sales training for employees.

Who has been the greatest motivational force in your life? To whom would you attribute your success? I am a keen learner and like to learn from every person I meet and every new thing I see. The seniors in my previous workplaces were very helpful and taught me a lot. Their teachings at the beginning of my career have been of great value.

Any new technologies at Baumuller? Some of the new technologies at Baumuller are as follows: Servo pumps: Servo pump comes as a package that can be fitted into existing injection moulding machines, and this will bring down energy consumption by 50-60 per cent. The manufacturers using our machines need not buy a new machine. They can buy this package and fit it in their existing machines. The return on investment can be expected in 6-12 months. Our aim is to introduce these packages to our existing injection moulding customers. Special motors or high-torque motors: These are highly energy-efficient motors, which require less maintenance, are compact and reliable. These motors are unique and only 2-3 manufacturers produce them across the world. These motors are widely used in the plastics machinery industry in developed countries â&#x20AC;&#x201C; in injection moulding machines, extruders and blown film lines. In addition, we are working on automation solutions like remote diagnosis through EtherCAT. This will help in machine support and maintenance from a remote location without actually visiting the site and, in the process,, saving production man-hours.

What are your expansion and future plans in India?

Key demand drivers influencing the Indian plastics industry. The per capita consumption of plastics in India is about 5 kg. This figure is quite low when compared to countries such as China and Brazil, where the consumption stands at 30 kg and 90 kg, respectively. Hence, we can confidently say that the plastics industry will flourish in India in the coming decade.

How do you see your companyâ&#x20AC;&#x2122;s growth potential in the Indian market? The future of our company seems bright. We envision a 300 per cent growth in the next 5 years, as 40 per cent of our business comes from the plastics industry.

We are planning to start facilities for sales and application support in different regions of the country. By the year end, we will start operating in New Delhi, Ahmedabad and Chennai. Apart from this, we will start some manufacturing facilities in Asia.

What would be your advice to aspiring and upcoming entrepreneurs in this domain? The aspiring and upcoming entrepreneurs must work on improving their skills through learning, unlearning and re-learning. With technological upgradation, one needs to keep pace with new trends & benefits derived, and must be able to adopt changes as quickly as possible.

November 2011 | Modern Plastics & Polymers

SPECIAL FOCUS: Polymer SPECIAL Processing FOCUS

Courtesy: Georgia Tech Research

Polymer Processing Polymer processing: Riding high on innovative methods .................................................................. 50

Processing practices: Overcoming the bottlenecks.............................................................................. 54

Roundtable: What are the implications of fluctuating crude oil prices on polymer processing? ............................................................ 58

November 2011 | Modern Plastics & Polymers

SPECIAL FOCUS: Polymer processing

Courtesy: Georgia Tech Research

Riding high on innovative methods The Indian plastics industry is witnessing growth in all verticals. This, besides the increasing awareness about the importance of recycling such products, has ensured that not only consumers receive a better finished product, but the environment also breathes a sigh of relief. Anwesh Koley explores the phenomenal changes that have been shaping the Indian plastics processing industry. hen it comes to preparation of packaging material or containers, automotives & construction, trays and boxes, raw materials like Polypropylene (PP) and Polystyrene (PS) are fast gaining ground in terms of applications in the polymer processing industry in India. The rising demand, both domestic and global, has ensured that manufacturers have their order books full. Plastic products are fast replacing metal as the preferred choice in various industries. This has led to a flurry of innovations for the polymer processing industry, as it has to keep pace with the design and quality requirements of plastics manufacturers.

Banking on Research and Development (R&D) With increasing R&D undertaken in European countries like Germany and Asian countries like Korea and China, engineering polymers have promising growth prospects in the years to come. High-performance polymer products, which can replace metal and offer weight & cost reductions to customers, while also meeting the functional requirements of the application, have excellent growth prospects. The socio-economic trend of increasing younger-age working population has created new avenues for industrial polymers. Today, lifestyles are more hectic, dual incomes are encouraging the emergence of

Modern Plastics & Polymers | November 2011

organised retail, all of which are opening new application avenues in packaging. Demand is growing for safe & hygienic packaging for food, beverages and medicines. International companies are approaching these opportunities with their unique and high-performance offerings through engineering polymers. In the medium- to long-term, companies are looking at opportunities in the field of defence, renewable energy & materials (photovoltaics, bioethanol, bio-butanol, etc) and renewably sourced materials for different applications. India is witnessing heavy investments in these areas, as there is abundance of human talent â&#x20AC;&#x201C; both skilled and unskilled.

Polymer processing

The government should encourage the use of alternatives to plastics in noncore areas, as the instability in global crude oil prices impacts our business. Rajeev Bhatia Chief Executive Ofﬁcer, Premier Pigments & Chemicals

With advancements in machinery, raw material suppliers have increased their production with lesser number of people. Better and consistent material is available at much competitive prices than before. Sumit Dhingra Director, Dhingra Polymers

Current industry scenario

Areas of improvement

Currently, the polymer processing industry is witnessing a steady increase in the number of players driven by growth and profitability of the sector. “The Indian plastics industry is growing at the rate of 12-15 per cent per annum since the last few years. This means demand of raw material is growing simultaneously at the same rate. With regard to the Indian clientele, people are improving with technological advancements and have access to international standards. But this improvement happens at a much higher pace for a company that exports than the one that manufactures and sells in India,” feels Rajeev Bhatia, Chief Executive Officer, Premier Pigments & Chemicals. “With advancements in machinery, raw material suppliers have increased their production with lesser number of people. Better and consistent material is available at much competitive prices than before,” says Sumit Dhingra, Director, Dhingra Polymers. By 2012, India is projected to be the third largest consumer market for plastics, with a consumption of 12.75 million Metric Tonne (MT) per annum. Polymer consumption in India has historically grown at twice the Gross Domestic Product (GDP). This growth is driven by all consuming segments like automotive, housing, packaging, agriculture, etc. An increasing need is felt in the construction industry to replace conventional materials with plastics. “Earlier, wood was the preferred choice for construction equipment and internal requirements. Having evolved in their applications, plastics are fast gaining ground in this segment as well,” observes Bhatia. Masterbatch consumption is projected to increase from 182,000 MT in 2010 to approximately 255,000 MT in 2012. This growth can be attributed to the rise in competition both in the domestic and international market, as manufacturers now have access to global technology and are aware of the changing demand patterns.

The rate of growth witnessed by the Indian polymer processing industry does not match up to standards maintained by China. “The level of R&D undertaken by China is higher than India. Also, the government of China is more friendly towards manufacturers as well as exporters,” says Dhingra. While the Indian government has been taking regular measures towards making things easier for the polymer industry, the fluctuating crude oil prices have had a negative impact on this sector. “The government should encourage the use of alternatives to plastics in noncore areas, as the instability in global crude oil prices impacts our business,” says Bhatia. With increased demand, masterbatch manufacturers will strive to use up their present capacities. If the present capacity remains constant, there is a possibility of imports as well, which may result in price hike. The price of masterbatches depends not only on the polymer prices, but also on the pigment prices, and this has been increasing steadily. However, with the increase in demand for masterbatches, the probability of more manufacturers jumping into the foray is high. This will result in equilibrium price where the quantity demanded by consumers (at current price) will equal the quantity supplied by manufacturers.

Modern Plastics & Polymers | November 2011

Creating a vibrant future The pace of innovations in the polymer industry is commendable; however, it requires support from the government as well as international policies and prices. Also, the increase in applications for polymers has encouraged R&D by manufacturers, thereby increasing competence globally. However, the Indian polymer industry has shown enthusiasm towards adoption of latest technologies; moreover, exposure to international standards & quality has ensured that plastics find applications in more and more areas, which were earlier dominated by metal & wood.

SPECIAL FOCUS: Processing practices

Overcoming the bottlenecks The Indian polymer processing industry has well adapted to changes in the global market. It is now moving towards evolving as a major global player, as the international plastics fraternity is noticing the high quality standards followed in India. But, the enthusiastic expansion plans of companies in the polymer industry are replete with challenges that hinder smooth working for manufacturers. Anwesh Koley analyses some of these obstacles and how to prevent these.

Quality issues

Illustration: Sharad Bharekar

The primary requirement for the industry is availability of high-grade polymers. The final plastic product depends heavily on the quality of raw materials available with manufacturers. Amit Puri, Director, Alok Masterbatches, says, “We face an acute problem of low-quality polymers for the industry. The Indian quality is not up to global standards; hence, we have to import from Europe, particularly, Germany.” Dependence on imported polymers has not changed in the past years, with manufacturers having difficulty in finding options in the domestic market. The industry requires imports for specific materials such as Polyvinyl Chloride (PVC), which is in short supply. This is because India has a net shortage of PVC and only few large-scale players manufacture this raw material.

Space constraints he consumption of Indian polymer products is on the rise. “Polymer consumption is expected to double in the next three years, as products by Indian manufacturers are well priced as compared to those by European manufacturers,” says R K Aggarwal, Managing Director, Prayag Polytech (Pvt) Ltd. While earlier, manufacturers were skeptical towards using the latest technology, this trend has given way to

T 54

extensive Research and Development (R&D) in the field of polymers, resulting in the advent of the latest machinery in the country. The industry is now gearing up towards reducing the pollution caused by the plastics industry. A number of machines have been developed, which produce less wastage and help in reprocessing of the waste. Manufacturers now ensure that the waste they produce is either disposed properly or can be recycled.

Modern Plastics & Polymers | November 2011

Another constraint for manufacturers is availability of land. At times, expansion plans of companies get stalled due to lack of infrastructure and land availability. Most manufacturers operate in small areas and often do not have adequate space to implement any measures towards achieving green productivity norms. “Even after going ahead with our expansion plans, we are unable to achieve the desired levels of efficiency as we are handicapped for space of operation. Acquiring land

Processing practices

is often a cumbersome procedure,” informs Aggarwal. European polymer manufacturers operate on a much larger scale than their Indian counterparts.

scenario and reduction in margins. The volume growth should help sustain most players but, as in most industries, efficiency and innovation will be required.

Need for more power

As compared to the conventional single-screw machine, twin-screw extruders and gravimetric feeders have taken a lead with higher output, better quality and less involvement of people. R K Aggarwal Managing Director, Prayag Polytech (Pvt) Ltd

The government needs to have a clear understanding of polymers and their applications. This will help manufacturers, as the customer will better understand the quality of the product. Amit Puri Director, Alok Masterbatches

Inf rastructure problems remain persistent for the sector, as power availability is scarce in many areas, affecting the timeliness for manufacturers. “In terms of energy conservation in plastics production, the availability of power is a major concern for plastics producers. The steps required for implementation of green manufacturing and renewal of energy have not been seriously implemented in the industry till date. A major reason for this is that this implementation is costly and if it does not yield adequate returns, it is not worth carrying out,” says Aggarwal. Fluctuations in power supply hamper the regular operations of a polymer company, as a number of high-end equipment depend on the steady flow of electricity. While manufacturers have done their part in ensuring continuous flow of power in production units, there are larger problems that need to be addressed in the long run. “In India, the Transmission and Distribution (T&D) losses are high; hence, the final power reaching our manufacturing units is low as compared to the stipulated power on the grid,” says Aggarwal.

Pricing it right Price is an important factor determining growth of the polymer industry and in the long run determines the competence of a country. “The prices of masterbatches have been on an upsurge for the last few years due to a sharp rise in raw material prices and consolidation of international raw material suppliers. Sourcing quality raw material f rom consistent and reliable suppliers will be the key in the coming years,” says Puri. New masterbatch players, both domestic & international, will need to keep the selling prices competitive, thereby presenting a challenging market

Modern Plastics & Polymers | November 2011

Role of the government The government does not have specific policies for the polymer industry and, while this has not hindered manufacturers form reaping profits, a policy support in some areas could make a difference. “The government needs to have a clear understanding of polymers and their applications. This will help manufacturers, as the customer will better understand the quality of the product,” feels Puri. Even for polymer machinery manufacturers, advancements in plastics technology provide scope to adopt internationally accepted standards and higher consumer satisfaction. “New resins, additives and fillers are entering the market, which can enhance the material properties without causing much change in the price. As compared to the conventional single-screw machine, twinscrew extruders and gravimetric feeders have taken a lead with higher output, better quality and less involvement of people,” says Aggarwal. The latest technology in plastics helps in better detection of the material according to specific requirements. Most companies have their own R&D facilities and those that do not, generally outsource research activities to achieve a more customer-centric final output. The latest technology used in the raw material production machinery ensures that more customisation can be achieved along with higher rigidity.

Rising above the challenge The latest technology in polymer processing needs to be supported well with adequate infrastructure. Manufacturers are willing to innovate and bring quality up to international standards, but without adequate power and land availability, it is difficult to take the expansion plans forward.

SPECIAL FOCUS: Roundtable

What are the implications of fluctuating crude oil prices on polymer processing? The plastics industry depends heavily on the supply of crude oil for manufacturing polymers, which serve as raw materials. However, fluctuations in global crude oil prices have not gone down well with the industry, with a direct impact on the prices of polymers, and thereby the final plastic product. Anwesh Koley gauges the opinion of some of the industry experts about the impact of this price fluctuation on the plastics industry. Neeraj Garg, Partner, Suruchi Industries

Sumit Kumar,

While the Indian market saw price reduction by major producers, the Polypropylene (PP) price across Asia has fallen persistently, as most end-users and distributors bought raw materials on a short-term basis fearing that prices would fall amid weak demand in future. Concerns of further tightening of credit measures in China have dampened the buying interest for petrochemical raw materials in the country, and a sluggish buyer sentiment has spread in the Southeast Asian market. Domestic demand is slowing, with buyers deferring purchase decisions in anticipation of further fall in crude prices, further lowering polymer prices. Most players had suffered during global slowdown. The price protection scheme had helped buyers make a purchase decision and offered a sense of security towards a further price decline. Manufacturers expect stability in the near future, or else polymer manufacturers will have difficulty sustaining businesses.

Marketing Head, H K Industries

Vir Singh,

The domestic polymer industry has shown resilience in the face of global fluctuations and Indian polymer manufacturers have slashed prices of Linear Low Density Polyethylene (LLDPE) by ` 1.50-2 per kg across variants. This price decrease is only for LLDPE and not other polymers. LLDPE is a popular variant of polyethylene, produced at low temperature and used to make plastic bags & sheets, plastic & stretch wraps, toys, lids, pipes, containers, covering of cables, etc. It finds application in regular items, and hence price reduction may result in a lower-priced final product. Fluctuations across the polymers range have been a regular phenomenon, as domestic players do not have a role in determining crude oil prices. Price stability remains a key factor for the future of the polymer industry and has a direct impact on the price of plastic products. Gradually, manufacturers should move towards alternatives, as crude oil is a non-renewable source and its supply is limited.

Proprietor, Sai Thermoformers

Polymer grades may differ as per usage, but plastics manufacturers have to deal with price fluctuations, which often cannot be passed on to the end consumer. Currently, the crude oil prices have plummeted, leading to a drastic decline in naphtha prices globally. While crude oil prices have come down to $ 86-88 a barrel, naphtha prices are at $ 860-870 per tonne. This is as against a high of $ 110-115 per barrel for crude, which had propelled naphtha prices to touch $ 1,000 per tonne some time earlier. As people become aware of hazardous chemicals, the plastics industry is using products that are lead- & benzene-free and chemically friendly. Although not many manufacturers produce such products, people today are willing to spend extra for the same. Rcently, the demand for eco-friendly plastic products has risen 85-90 per cent. This is a comforting factor for the polymer industry, as otherwise global fluctuations in crude oil prices would have resulted in closure of many manufacturing units.

Editorial take: Regulating crude oil prices is an immense challenge given the demand-supply mismatch across the globe. While polymer manufacturers need to effectively deal with price volatility, broadbasing of raw material alternatives will considerably mitigate the risks.

Modern Plastics & Polymers | November 2011

FACILIT Y VISIT: Plastiblends India Ltd

Colouring the world of plastics Masterbatches are the secret ingredients that make all the difference to the processability and functionality of a polymer. In this regard, Plastiblends India has created a niche for itself through value-added services and a diversified product portfolio. Annabel Dsouza traces the company’s growth ambitions through an in-depth look at its best-in-class manufacturing practices. he growth of India’s plastics industry is closely linked with the phenomenal rise in applications and products across various sectors of the economy. The resultant increase in demographic dynamics and disposable incomes has driven the Fast Moving Consumer Goods (FMCG) sector to new heights. Consequently, packaging has emerged as one of the chief applications of the plastics processing industry. In keeping with today’s high-end specifications for retail packaging, the Indian convertor relies heavily on specialty masterbatches and additives to enhance performance and profitability of common plastics.

Masterbatch industry The masterbatch market in India has been growing at a rate of 15 per cent in the last few years, driven by demand f rom end-user segments, primarily

plastic packaging, plastic products and cables & pipes. Among the market leaders in the masterbatches and additives segment, Plastiblends India Ltd has created a niche for itself through value-added services and a diversified product portfolio in the Indian plastics scenario. Founded in 1991 as a brainwave of the Kolsite Group, Plastiblends India Ltd has evolved as one of India’s largest manufacturers and exporters of plastics masterbatches & additive compounds. By closely aligning its business model to the demands and developments of the nation’s plastics industry, Plastiblends has emerged as a leading player, with a 60 per cent marketshare in the organised masterbatch segment and an overall marketshare of 12 per cent. The company has been registering a Compound Annual Growth Rate (CAGR) of nearly 30 per cent for the last two years.

Manufacturing might The Indian masterbatches industry has a total capacity of 350,000 Tonne Per Annum (TPA), comprising organised (25 per cent of capacity) and unorganised (75 per cent) players. Since the process of manufacturing masterbatches is less capital- and technology-intensive, there are more players in the unorganised segment. In a highly competitive industry such as this, Plastiblends sets comparatively high standards of product quality and price competitiveness. Located about 200 km away from Mumbai, the company’s Daman facility has a capacity of about 50,000 TPA. Spread over an area of 45,000 sq m, this facility processes bulk of Plastiblends’ product offerings in the market, eg, varieties & grades of white, black, colour and additive masterbatches. Besides processing 4,000 tonne of material per month, the company maintains an inventory of more than 7,000 tonne at any given time. These figures indicate a manufacturing might that is tough to compete with in the masterbatch

White masterbatch processing Photo: JJoshua Ph h N Navalkar lk

Impressive product portfolio

Modern Plastics & Polymers | November 2011

Plastiblends India Ltd

segment. Ramesh Dumbre, Vice President - Marketing, Plastiblends India Ltd, says, “After fine-tuning our production and commercial operations for more than a decade, Plastiblends can today boast of a quick turnaround time and high levels of efficiency without compromising on product quality and consistency. ” With 24 dedicated compounding lines operating at an average capacity of 10-15 tonne, the company has clearly segregated its products as a precaution against crosscontamination. Plastiblends’ production system includes twin-screw extruder lines, high-speed continuous mixer lines, computerised gravimetric feeding systems and process control systems. Plastiblends attributes much of its success to its close association with the machinery excellence of Kabra Extrusiontechnik (KET), part of the Kolsite Group. Dumbre explains, “In order to provide tailor-made solutions to the market, we have to design our machinery accordingly. As KET is our partner for in-house machinery, it is easier for us to launch new processing lines and upgrade the existing ones. This ensures faster delivery to customers and has helped us to gain the higher market share.”

Quality control Being an ISO 9001:2008 certified company, Plastiblends ensures that all its production batches are subjected to processability tests for a wide range of critical performance properties. One of

the crucial advantages of Plastiblends’ masterbatches is the high dispersion and pigment loading properties that result in significant cost savings and process efficiency. The company conducts stringent simulated tests for specific functions like weatherability and stress tests important for performance of the plastics product in actual use. The facility is well equipped with an extensive and accurate inventory management system to closely monitor the company ’s shop-floor to market production cycle. These best-in-class manufacturing practices have given the company an edge not only for domestic demand, but also in an expanding export market. Plastiblends exports over 30 per cent of its capacity to 45 countries, mainly in Latin America, Africa and Europe. Hence, quality assurance is integral to the company’s production operations. Dumbre highlights, “Over the years, we have designed our in-house quality checks and practices to ensure that all our products meet the properties specified by customers. We understand the product’s process and application requirements and run our products in small batches before scaling-up operations, thereby ensuring 100 per cent results.”

Research and Development (R&D) The company’s commitment to product quality and consistency is reflected in its R&D operations for which Plastiblends has a Department of Scientific and Industrial Research (DSIR)-approved

Masterbatch processing is not a globally standardised procedure and every supplier has to deﬁne its own standards. Ramesh Dumbre Vice President - Marketing

in-house R&D unit. The R&D centre undertakes independent as well as customer-specific projects. In the moulding segment, the company is developing additives for automotive interiors and other such applications.

Sustainability, efficiency and growth Process sustainability and efficiency is crucial to Plastiblends’ functions and growth as a dominant player in the Indian plastics industry. The company has made conscious efforts to reduce utilities and enhance machinery output. The company is on an accelerated growth drive, with a recently established facility at Roorkee, which has a capacity of 10,000 tonne. Dumbre concludes, “With increased efficiency and business integration, we hope to raise the bar for additive and masterbatch processing in India.”

Dies for injection moulding Operator-friendly technology

Photo: Ph t JJoshua h N Navalkar lk

High output compounding lines November 2011 | Modern Plastics & Polymers

INSIGHT & OUTLOOK

Plastics in Sports & Entertainment Plastics in sports applications: Outmanoeuvring the competition .....................................................................64

Sporting innovations: Packing a punch for profitability ...................................................................... 68

Interface - Anil Kumar: Managing Director, Great Sports Infra ............................................................ 72

Material corner: Transparent polyamide with a clear advantage ................................................. 74

Injection zone: Performance monitoring in real time ................................................................ 78

November 2011 | Modern Plastics & Polymers

INSIGHT & OUTLOOK: Plastics in spor ts applications

Outmanoeuvring the competition Indiaâ&#x20AC;&#x2122;s emergence as an important player in the high-performance polymer market accurately corresponds with the growing investments in the world of competitive sport. From football to Formula One, analyses the challenges and opportunities in plastics application in sports equipment industry.

Plastics in spor ts applications

With the ability to offer weight reduction, excellent strength & stiffness, corrosion resistance and excellent fatigue properties, carbon ﬁbres are increasingly becoming the material of choice for ﬁbre-reinforced plastics. Akhil Hebbar Country Manager, Zoltek Corporation

Expanding application portfolio Thanks to plastics, athletic equipment can be literally ‘tailor-made’ to meet the most diverse requirements. As desired, such applications can offer thermal insulation for winter sports or can be breathable for track and field events. When used in specialised swimwear today, performance polymers create smooth flowing surfaces. It would be not an exaggeration to say that the top sports performances of today would not have been possible without plastics. High-strength polymers are ideal materials for high-performance athletic shoes and equipment. Exceptional compression and fatigue resistance make these polymers the best choice for outsoles where high strength and support are needed at low density. A wide variety of polymers offer excellent performance at low density. Ideal for outsoles, these block copolymer resins offer resilience to repeated stress, besides unmatched resistance to distortion and deformation. Polyamides also offer superior protection from scratches and scrapes caused by aggressive use of highperformance sports equipment. Their UV resistance maintains transparency & colour 66

clarity, and being resistant to salt, salt water & a host of chemicals, these polyamides keep equipment glossy and looking new season after season. Properties like shock absorbance in sports equipment improve control and increase vigour in sports. Resins have the capability to absorb shocks and vibrations normally experienced in applications like tennis racquets. As polymeric resins do not stiffen at low temperatures, snow shoe deckings made with such resins retain their mechanical properties and resilience under frigid conditions (-40°C). Premium golf balls also exploit polymeric resin capabilities like excellent compressive strength and high resistance to deformation. In various core technologies, these resins offer excellent resistance to permanent deformation, which can improve distance & ball flight.

Innovation index One comes across various grades of thermoplastics just about everywhere in sports applications. These materials give an impressive demonstration of their fitness in the world of sports shoes. These resins are particularly used in manufacturing of soles and heel taps by injection moulding. The unique selling points of these resins are their high abrasion resistance and elasticity as well as good resilience & flexural strength. Due to their rigidity and toughness, these resins are especially suitable for the shells of ski boots & inline skates. Soles and studs of football shoes – and also other sport shoes – have one thing in common; they have to undergo rigorous use everyday. We have, therefore, developed a range of new grades of Thermoplastic Polyurethane (TPU) with a 30 per cent lower abrasion loss than standard TPU grades. The parts manufactured from these can be readily de-moulded even at high wall thicknesses, enabling economical production with short cycle times.

On the right track An ideal track surface can help athletes to achieve ungained heights, while also preventing injuries. Having the right surface can easily make a difference of

Modern Plastics & Polymers | November 2011

tenths of a second while running and a difference of centimetres when jumping. Innovative sports surfaces provide safe & productive conditions for training and competition. Modern athletic track surfaces made of PU are installed by pouring in situ onto a level asphalt substrate. Installing an athletic track with these resins is a stepwise procedure and result in a three-layered finished system having a total thickness of about 14 mm. First, qualified application experts apply a specially designed PU levelling coating onto the absolutely level asphalt substrate and sprinkle it while still fluid along with an excess of synthetic rubber granules [Ethylene Propylene Diene Monomer (EPDM)]. The coating sets overnight and binds the rubber granules in direct contact with the substrate. This process is repeated to create a second layer. These two lower layers of the system are designed to minimise the risks of injury for athletes. Minute air chambers both in the PU and granules provide the most stress-free conditions for athletes’ joints and have shock-absorbing properties. The hardness and elasticity of PU can be precisely adjusted by modifying the individual component formulation, thereby imparting aesthetic and safety features to the surface.

The India advantage Currently, India is witnessing a boost in terms of ideas and opportunities for high-end applications of sports-grade polymers. Hebbar concludes, “Globally, there seems to be a resurgence in the reinforced plastics industry. India has never been a strong contender in this area due to a lack of investment in research & development for composite design, engineering and processing technology. However, as the competitive and professional parameters have risen in the world of sports, there is a significant opportunity to move into the higher valueadded and higher margin-driven composite sporting goods industry. The availability situation with fibres and resins is also set to improve, and this will provide a fillip to the Indian industry.”

Packing a punch for profitability In a challenging application like sports equipment, properties such as strength, toughness and weight ratio go a long way in building brand equity and profitability for processors and manufacturers. Annabel Dsouza identifies the accurate moulding and tooling strategies for some of the daunting applications in the sports equipment industry. lastics has long been known for its impressive mechanical, optical, electrical and thermal properties. Features such as strength, toughness and weight ratios have led to polymers successfully replacing conventional materials in sports. Highperformance polymers form an integral part of equipment used today. Polymeric materials, fibres and coatings contribute directly to improvements in performance and are vital in safety applications.

Innovations in action In recent times, polymer science and technology have improved effectiveness and performance of winter sports gear. It can also help protect participants from sports injuries, assist in repairing damage in both participants & equipment. With advancements in polymer science, the sports equipment industry is also demanding efficient moulding, tooling and machinery

standards in order to implement material innovations. In a challenging application like sports equipment, these properties go a long way in building brand equity and profitability for the processors and manufacturers.Todayâ&#x20AC;&#x2122;s sports merchandise industry manufactures specific products for dedicated applications (eg, running, skiing, snowboarding, etc), which has led to introduction of products with integrated functions by using innovative plastics grades. There have also been developments in unique manufacturing practices through innovative tooling and machining technology. Today, the tool and die fabrication technology in plastic injection moulding is one of the fastest growing industries in the world. Plastics is now used in almost all applications, ranging from household articles to space travel, transportation to packing, medicine to toys and from bridge building to sports. The injection

Precision moulding for sports helmets 68

Modern Plastics & Polymers | November 2011

Courtesy: Callaway

INSIGHT & OUTLOOK: Spor ting innovations

moulding moulding material i forcing it mould cavity. The desired shape of the plastics is achieved by cooling in thermoplastic or by chemical reaction for thermosetting.

Accuracy of design Mould design and fabrication is a costly and high-technology process, as it uses science-based ComputerAided Engineering (CAE) software to analyse and simulate the plastic parts and Computer-Aided Design (CAD) software to design the complicated plastic product. It also uses ComputerAided Manufacturing (CAM) to perform programming fabrication to run a Computer Numeric Control (CNC) machine for milling or latch. This design module provides the designer with necessary information to allow

Spor ting innovations

The main advantages of using nanotechnology in sports are improved mechanical and damping properties. Enormous investments have thus been made to utilise the potential of nanomaterials for sporting excellence. Philippe Michaud Global Technology & Innovation Director, Huntsman Advanced Materials

for environmental process, design and end-use effects to achieve an efficient, functional part design in the shortest possible time. Advancements in computer technology have led to an increasingly favourable power-to-cost ratio for computers. Hence, this advantageous and costly technology will improve productivity & process consistency. Thus, for this fast-growing industry, new technologies are vital to ensure that this technology reaches perfection. CAE is the assistant for processing and calculation of the plastic material flow inside the injection mould. The most important first step in designing a plastic part is to define properly and completely the environment in which the part will operate. Properties of plastic materials are substantially altered by temperature changes, chemicals and applied stress. These environmental effects must be defined on the basis of both short and long term, depending on the application. Considering the high stress and rough environment in which sports equipment are used, it is important

to determine the extent to which properties, and thereby the performance, of the part will be affected. If a part is to be subjected to temperature changes in the end-use, it is not enough to define the maximum temperature to which the part will be exposed. The total time for which the part will be at that temperature during the design life of the device must also be calculated. The same applies to stress resulting from the applied load. If the stress is applied intermittently, the time when it is applied and frequency of occurrence are crucial.

Emphasis on innovation Todayâ&#x20AC;&#x2122;s moulding technology needs to consider the growing range of composites that are making waves in the world of sports equipment manufacturing. Nanocomposite materials are being used in squash and badminton racquets, baseball bats, hockey sticks, snowboards, skis, fishing rods & poles, golf balls & clubs, etc. Philippe Michaud, Global Technology & Innovation Director, Huntsman Advanced Materials, emphasises, â&#x20AC;&#x153;The main advantages of using nanotechnology in sports are improved mechanical and damping properties. Enormous investments have thus been made to utilise the potential of nanomaterials for sporting excellence. Today, nanotechnology represents a small, but fast growing, part of the composites market for sports goods.â&#x20AC;? Smart solutions in the consumer sports segment reflect general trends in engineering plastics manufacture. Besides strength and flexibility of the polymer, manufacturers are enhancing user-friendly electronic features digital clocks and pulse monitors as training aids for professional & amateur athletes. The moulding and tooling methodology has been designed such that plastics is not merely the material used in a helmet, but also compatible with other value-added products.

Research focus The conceptual design of plastic parts is based on the need of the plastic processor.

Modern Plastics & Polymers | November 2011

For sports equipment, part is designed in a changeable insert mould base. The use of one mould base will reduce the cost and time taken for manufacturing. In the mould-making industry, accuracy and tolerance are important issues; thus, the use of CAD/CAM will enhance quality of work in mould design and reduce number of errors in manufacturing. From the analysis simulation, it is important to obtain information results such as fill time, injection pressure and pressure drop. With this result, users can avoid defects of plastics in actual injection, eg, sink mark, hesitation, air traps and overpacking. The analysis will also help mould designers to design a perfect mould with minimum modifications and reduce mould setup time.

Sporting excellence Since long, sports goods manufacturers have been using system integrators for developing products that combine microelectronics, plastics and ceramics in new smart functional applications. In order to develop value-added products and applications for the sporting community, manufacturers have developed virtual tools and applications that offer consumers entirely new experiences. All these will provide engineers and designers with direct feedback on how consumers use their products.

INSIGHT & OUTLOOK: Inter face - Anil Kumar

â&#x20AC;&#x153;There is an evolving sports culture in the countryâ&#x20AC;? â&#x20AC;Śbelieves Anil Kumar, Managing Director, Great Sports Infra. Unlimited possibilities of plastics application in sports along with an increasing interest in sports in India have spurred investments in sports infrastructure. He elaborates on the evolving sports equipment market and the future scope of plastics use in various sports equipment in an interaction with Annabel Dsouza.

What are the key performance requirements from polymer sports surfaces? Synthetic turf is a unique application of common plastics such as Polyethylene (PE) and Polypropylene (PP). The overall material design & usage is such that it replicates the properties and visual aesthetics of natural grass field. However, polymer surfaces have several advantages over natural grass. This is significant in the context of sports as artificial (polymer) turf does not require watering or any other kind of intensive maintenance. It offers unlimited usage and all-weather playability. The key parameters for artificial turf are softness and flexibility, low f riction, high resilience, Ultraviolet (UV ) resistance and fire-retardance. Apart from these basic properties, there are other applications of polymer surfaces in modular (interlocking) sports tiles. These exhibit other important performance criteria such as grip on the surface, sports load-bearing and shock absorption of the underlay.

How is this market evolving in India? What are the demand drivers? The last 10-15 years have witnessed a complete paradigm shift. There has 72

been a dramatic increase in the number of sports infrastructure projects, and this is primarily due to the increased awareness in the general population. Unlike a few years ago, it is not uncommon for every new residential project, school, corporate campus, large hotel or a facility to have at least some basic sports infrastructure. One of the key drivers is also that the sports surfaces should ideally be maintenancefree. In order to meet the high standards set by international governing bodies like the International Federation of Association Football (FIFA) and International Basketball Federation (FIBA), plastics score high on this factor. Overall, there is definitely an evolving sports culture in the country, but this definition does not include cricket fans watching matches on their television screens.

What are the safety and performance standards used to formulate plastics for sports applications? Different sports bodies have evolved standards that define performance & safety standards in sports surfaces, irrespective of whether they are natural or plastic based. Some examples include American Society for Testing and Materials (ASTM) in the US

Modern Plastics & Polymers | November 2011

and other European standards. These parameters broadly measure various performance aspects, eg, friction, shock absorption, breaking strength, melting temperature, human & environmental hazards, etc.

Where do you see the scope for research and innovation in the coming years? Tracing the path of polymer surfaces, AstroTurff introduced this innovation almost 40 years ago. FieldTurf continued to expand the application portfolio almost 20 years ago. From the perspective of sports, research should focus on all other types of sports that can benefit from the use of plastics. Apart f rom maintenance advantages, plastics considerably reduces the use of natural resources involved in sports (eg, reducing water consumption for watering natural sports turf ). Polymer surfaces can also be used to convert any unutilised areas into productive areas. Any reduction in the cost is always welcome, and this encourages widespread acceptance of new innovations. From an environmental perspective, utilisation of every discarded plastic wrapper, cover, bag, bottle, etc, can be recycled and used to create new products.

INSIGHT & OUTLOOK: Material corner

Transparent polyamide with a clear advantage Several transparent engineering polymers are available in the market today, most of which fall in the amorphous family and offer desired characteristics for standard end-use applications. Polyamide-12â&#x20AC;&#x201C;based transparent Nylon is one such material, which is more dynamic and offers many advantages over existing conventional transparent plastics for demanding applications. Here we explore some of the key properties of transparent Polyamide-12, its application, processing and advantages. Mandar Amrute ccording to the history of polymers, Poly(Methyl Methacrylate) (PMMA) is considered as one of the oldest polymers, developed in the late 1920s. Polycarbonate was commercialised by General Electric in 1950. Various other specialised

transparent materials were developed later and, today, this process still continues. Polyamide - 12 is one such transparent material discussed here and, for simplicity, it will hereafter be referred to as clear polyamide.

Polymers and properties Most transparent materials belong to

Table 1: Polymer properties and morphology relationship

Property Light transmission Solvent resistance Lubricity Dimensional stability Mould shrinkage Resistance to dynamic fatigue Facility to form high-strength fibres Thermal expansion coefficient Melting temperature Dependence of properties on temperature

Crystalline High High High High High High High High Sharp High

Modern Plastics & Polymers | November 2011

Amorphous None to low Low Low Low Low Low None Low Absent Low

the amorphous family of thermoplastics. Polymers can either be amorphous or partially crystalline, depending on their molecular structure and conditions of formation of solid phase. A polymer is considered semi-crystalline when it develops a detectable crystalline phase in its structure. Crystalline and amorphous polymers are distinguished by different properties, most evident of which is light transmission: crystalline polymers are opaque, whereas amorphous polymers are transparent. This thumb rule is applicable in general, though there are exceptions, eg, Polyethylene Terephthalate (PET). Table 1 presents the key properties of amorphous and semicrystalline materials.

Clear polyamide The polyamide family offers various mechanical properties. These properties

Material corner

Table 2: General mechanical and physical properties of clear polyamide

Density HDT under the load of 0.45 MPa Glass transition temperature

Standard

Unit

Clear polyamide

ISO R1183D

g/cm3

0.99

ISO 75

°C

125

ISO 11357

°C

145

Hardness

ISO 868

Shore D

Water absorption at equilibrium

ISO 62

1.1

AT 23°C and 50% RH Charpy impact

ISO 179 / 1eU

Unnotched at 23°C

ISO 179 / 1eU

kJ/m2

ISO 179 / 1eU

kJ/m2

Tensile strength modulus

ISO 527

MPa

1420

Flexural modulus

ISO 178

MPa

1360

Unnotched at -40°C

are further enhanced in Polyamide - 12/11, in terms of robustness and excellent chemical resistance. Capitalising on these properties, clear polyamide was developed to offer properties offered by the Polyamide 12 family, with an additional benefit in the form of transparency. Today, clear polyamide is available in various forms, some of which are semi-aromatic and cycloaliphatic amorphous polyamide. The second-generation (cycloaliphatic) clear polyamide offers better transparency over the first-generation (semi-aromatic) clear polyamide. Key properties of clear polyamide are as follows: 1. Excellent flexibility, which provides design of freedom 2. Outstanding optical properties and transparency 3. Good chemical resistance 4. Good ultraviolet resistance 5. Excellent processability 6. Light in weight 7. Good mechanical properties Table 2 presents general mechanical and physical properties of clear polyamide.

Advantages Razor sharp clarity: Clear polyamide is more transparent than any general glass and polycarbonate at any thickness. This increases the possibility of its varied applications where high transparency is a critical criterion. 76

Ultra light-weight: When compared with glass, clear polyamide is definitely lighter; moreover, it is the lightest transparent polymer. It is lighter than polycarbonate by approximately 20 per cent. This helps in reducing the weight of end product, faster processing and energy savings. Maximum flexibility: Clear polyamide is the most flexible material in the transparent materials family. This property gives long-lasting endurance, excellent shape recovery and vibration dampening characteristics to the end product. Easy processing: Clear polyamide has a broader processing window, which makes its processing easier and reduces probability of material degradation. Its excellent thermal resistance helps in processing even if the material is left in the barrel at 280-290°C for 1-2 hour, and will not get oxidised. Its improved flow helps in processing, especially in the packing stage. This reduces shrinkage bubbles. Overall, faster processing is achieved with a reduction in cycle time of up to 20 per cent, as well as energy savings.

Processing of clear polyamide Clear polyamide is easy to process on conventional polyamide injection moulding machines as well as extrusion and blow moulding machines.

Modern Plastics & Polymers | November 2011

Similar to most of the polyamide family members, clear polyamide must be pre-dried before using on the machine. Generally, a sealed bag can be used directly; however, if it is open and remains open for more than 2 hour, it should be vacuum dried in a dehumidifier. The recommended drying conditions are 70-90°C for 4-6 hour. Care must be taken with purging for this material before running it on the machine, since if a barrel is not purged thoroughly, the transparency of the end product may be affected. Standard purging compounds available in the market can be used with High-Density Polyethylene (HDPE).

Applications Clear polyamide is used in optical lenses, sunglasses, safety lenses (3D) and Three-Dimensional glasses due to its excellent flexibility and transparency. It is the preferred choice of material for optical fibre cable due to its anti-termite property. Owing to its mechanical properties and chemical resistance, clear polyamide is used in diesel water separators, air separation filters and hydraulic filters. Also, due to its light weight and excellent transparency, it is used in many other industrial applications, eg, electronic housing & covers, consumer goods and automotive applications. Mandar Amrute is Market Development Manager with Arkema India Branch office. Email: mandar.amrute@ arkema.com

Courtesy: Arkema & Biobased edge: Clear Polyamide is sold by Arkema under the brand name Rilsan Clear®. Arkema is a French Chemical Company offering products like vinyl compounds, industrial chemicals and specialty chemicals. Arkema is a leader in bio-based Polyamide - 11, with an experience of over 50 years.

INSIGHT & OUTLOOK: Injection zone

Performance monitoring in real time With injection moulding shops adding machines, the need to monitor their performance has become increasingly important. The use of conventional methods like manual tracking and Kanban are slated to soon reach their limits. Thus, here are some other options that can be used for online performance tracking in real time. Y R Anand ver the past decade, many injection moulding and general manufacturing shops have rapidly increased in their capacity and number of machines on the shop-floor. To an extent, it is easy to manually track machine performance, material planning, maintenance schedule, inventory management and many other functions. Beyond a point (eg, when number of machines cross 20), this process becomes more complex. Typically, most of these shops will have several auxiliary items like dryers, colouring devices and mould temperature controllers. Often there will be other processes also, eg, ultrasonic welding, extrusion, blow moulding and

painting. All these require a complex management system to produce parts in the most cost-effective manner. Most companies implement ERP systems to manage an enterprise. As ERP systems generally do not relate to actual machine performance or behaviour, it is important to seek solutions for managing complex injection machine-oriented manufacturing units to merge the two. An online management system can be a Manufacturing Execution System (MES). Some of its critical objectives are: Reduced machine stops (long & short stops) Reduced cycle time, increased speed Reduced scrap by real-time quality control Optimised scheduling, machine and mould maintenance

Figure 1: Concept of a complete MES Courtesy: BarcoVision

Modern Plastics & Polymers | November 2011

Improved decision support Reduced human resource paperwork Improved logistics Management reports

Management solutions in real-time The major function of such a system is to record machine behaviour directly online and transfer the data to a central database. This should allow manipulation of data to satisfy various functions within the company. It should provide a link to the company-wide planning system for direct information flow. Consequently, a complete vertical integration â&#x20AC;&#x201C; from machines to material planning, purchasing and sales â&#x20AC;&#x201C; can be achieved seamlessly. In todayâ&#x20AC;&#x2122;s globalised world, production is distributed, and it is almost essential to have worldwide access to production data from any site. There should be a central management of part, mould and material master data, with real-time production planning (without waste) by online acquisition of: Order progress Machine status Process parameters Alarms Manual data entries could resultt in multiple errors. This is completely eliminated by online data acquisition. Many injection moulding machine manufacturers offer their own systems to cater to these needs. Such a system does not require additional external hardware for collecting and transferring data to a server. Another advantage of using such systems from a machine supplier is the ability to optimise the production process through a central server.

Injection zone

Planning machine & mould maintenance Calculation of required operators Tool change forecast report with machine mould conflict resolution Support for family moulding Support for frames & inserts (Option) They system should auto flag for: Low efficiency Stop time & number of stops Remaining time (quantity) till job ends

For a good monitoring system

Figure 2: A typical server view Courtesy: BarcoVision

But, manufacturers will face limitations if multiple brands of machines are present in a shop and also while integrating other manufacturing machines to same systems. Currently, several vendors can supply complete solutions with external data collection modules to integrate a complete injection machineoriented manufacturing plant.

Data management Figure 1 shows a typical layout with different types of plastics production machines with data collection modules and their routing to different aspects of production management. Through these programmes, a database is built for the following elements: Calendar (working days, shift times) Products (technical data) Moulds Machine operators (direct personnel) Machine data & production counters Machine groups (work centres, machine types) Production orders Stop cause reasons (table per machine type) Reject causes (table per machine type) Maintenance counter definitions Such systems should generate real-time information with a graphical overview of the plant layout displayed. Each pictogram on the screen represents a machine and contains information concerning speed, production, efficiency, etc. Exceptions have been colour 80

coded to attract instantly the users’ attention. From the filter window, a specific filter set can be selected, which will display only machines that correspond with that filter, eg, all stopped and slow-running machines. A mouse click on a specific machine opens a window with required details for the selected machine. This window can be configured as per user specifications and includes textual & graphical information. A typical system such as this offers users a broad range of information: Efficiency of machine, quality, cavity efficiency, speed, cycle time Overall Equipment Effectiveness (OEE), Mean Time Between Failures (MTBF), Mean Time To Repair (MTTR) calculations Run time and downtime analysis (eg, Pareto Analysis) Production counts Reject or defect analysis Automatically detected stop analysis Manual stop declaration analysis Problem machine detection Maintenance status for mould & machine Such systems can help schedule the shopfloor with the following: Real-time graphical plan board Drag & drop to assign orders to machines and re-schedule orders Order splitting options Automatic check for mould availability and resolve conflicts

Modern Plastics & Polymers | November 2011

Besides machines and moulds, auxiliary resources like robots, chillers, regrinders and packers may be needed to make a product. Thus, a good system must be able to support management and scheduling of these resources by availability and assign resource needs per product or production counters per resource & maintenance counters. Generally, they will check resource availability in real-time when planning a job and should warn the planner in case of possible problems. Such systems must be able to communicate with different types of ERP systems, which will be running or planned for general management. More advanced systems can incorporate quality systems and preventive maintenance systems. Here, a system by a machine manufacturer would offer greater access to the machine control system. Thus, organised moulding shops should invest in a good MES to attain benefits from their shop-floors, minimise scrap and maximise efficiencies. Y R Anand holds a bachelor’s degree in Mechanical Engineering from University of Mysore and a master’s degree in Production Engineering from IIT, Kharagpur. He worked for a little over 9 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

AUTOMA ATION TRENDS: Technology index

Cou

y: rtes

Sie

men

Process optimisation for boosting efficiency As the Indian plastic processing industry battles higher operating costs while delivering cutting-edge solutions, automation technology offers a wide range of benefits like reduced material consumption and energy management. Annabel Dsouza takes a closer look at automation solutions that drive performance and profitability for the plastics industry. he plastics compounding industry is facing an escalating need to supply an ever wider variety of specialty products within the shortest possible time. This results in an increasing demand for frequent formula changes in masterbatches and additive mix manufacturing. Today’s compounding plants focus on single polymer production in large volumes, and in a continuous mode. With the growing need for variety, the demand for customised, rather than universal masterbatches, has increased and given rise to higher degrees of automation throughout the plastics supply chain. Sunil Chaudhari, President & Chief Executive Officer, Zylog Plastalloys Pvt Ltd, says, “Improving the process through automation helps an organisation perform better on customer delivery reliability, productivity, machine utilisation and improvement of machine uptime. This helps optimise manpower across the manufacturing direct processes, thus minimising waste across processes such as nonvalue-added activities, sequential process operations, time & motion study of process, work in progress inventory, waiting time, over production and defects.”

T olutions

ndling s

l ha Materia

Role in compounding industry Besides increasing process efficiency and product consistency, automation technology is empowering today’s plastics processor by bringing down labour costs and utilities investment. Specialist compounding companies are faced with increasing quality challenges, driven by users who issue tighter specifications. New medical applications, high-end car coatings and bulletproof polycarbonates are only a few examples of the high demands in specialty compounding. At the same time, the quantity per process unit reduces. This presents a significant burden

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Technology index

Process automation equipment manufacturers must provide low-cost excellent automation solutions with innovative ideas to Indian manufacturers currently operating at competitive pricing with thinner margins. Sunil Chaudhari President & Chief Executive Ofﬁcer, Zylog Plastalloys Pvt Ltd

on a manually operated plant where the human factor must be constantly managed to minimise risk of errors. Increasing the automation levels of existing machinery enables instant changeover times of operators by way of applying the Single Minute Exchange of Dies (SMED). These smart manufacturing methods, when correctly applied, bring benefits that far outweigh the apparent savings of manual tasks or outsourcing operations. In today’s dynamic and volatile business environment, a company’s focus has shifted from ‘quality’ to ‘competitive quality’. With ever-changing customer requirements, quality is no more a competitive weapon and processors strive to deliver top quality at competitive pricing. What separates an organisation from others is in how better it is from its competitors. The need of the hour is to constantly challenge the status quo to improve the present performance. The ultimate key to success in any business enterprise is customer satisfaction. Business process automation makes an organisation successful in the long term, not only by meeting customer expectations but also by exceeding them, and hence beating competition by increasing marketshare. 86

Chaudhari says, “Automation of production processes helps the organisation to minimise activities in terms of on-line inspection, monitoring, proper utilisation of resources, infrastructure, minimising spillage, startup and process scrap, improving process accuracy and product quality. It enables plant utilisation by way of addition of quality software to monitor & control statistical process control, measurement system analysis, effective quality management system tools in place, eg, Kaizen, continual improvements, Poka-Yoke, lean manufacturing quality tools/software, etc.” Taking one step beyond process automation, most players in the compounding industry have automatic material handling systems at the inbound stage, whereas outbound logistical activities are manual in the Indian scenario. Adding material handling equipment improves personnel productivity, housekeeping, response time to customer and easier handling of emergency activities in terms of customer delivery reliability.

Material wastage reduction With operating costs escalating globally, waste reduction is another important advantage of automation systems. Following are some of the immediate benefits of automation technology with regard to waste minimisation in plastics processing plants: Overproduction: Mixing additives in large quantities than ordered, as cleaning is a challenge Waiting: Operators and expensive machinery standing idle, eg, due to cleaning activity or awaiting quality check analysis results Inventory: Customer requirements for rapid and next-day delivery resulting in huge finished goods and intermediate goods storage Defects: Rework for human error or pigment colour problems discovered after value is added (extrusion) Transporting: Additional transporting to & from inventor storage and between processes to meet variations in client demands

Modern Plastics & Polymers | November 2011

Over processing: Technology selected on worst case scenarios and applied to the whole, as opposed to applying sufficient technology for the application Motion: Unnecessary movement of people and product between processes due to poor process flow or additional motion caused by poor plant layout The actual and potential cost associated with waste is enormous, leading to higher prices and reduced profitability. Moving the wasteful process to a low-cost practice is not a long-term solution. Smarter manufacturing without generating waste is the key to sustainable profitability.

Indian automation standards The Indian plastics industry is highly fragmented with large numbers of smallscale manufacturers. Thus, the overall automation standards in Indian processors are at the first basic level as compared to global standards followed in the plastics industry. Hence, acceptability of high-end automation solutions to increase profitability depends on improving financial resource capabilities and building awareness on lean manufacturing. Chaudhari says, “Currently, a high standard of automation is restricted to medium- or large-scale industries, especially with industries having joint ventures or collaborations with multinational companies. Implementation of automatic machinery is on an accelerated pace with medium- and large-scale processing industries.”

Continuing the success story With conscious efforts to keep pace with global competition through a booming export market, the automation story in India is set to continue. International competition and quality awareness, coupled with customer involvement and increasing supplier capabilities, will go a long way in bringing automation solutions to Indian shores. But, Chaudhari suggests, “The need of the hour is that process automation equipment manufacturers must provide lowcost excellent automation solutions with innovative ideas to Indian manufacturers currently operating at competitive pricing with thinner margins.”

ENERGY MANAGEMENT: All-electric machines

Energy

efficiency par

excellence

Rising energy prices is a crucial issue with the plastic processing industry. As a result, the need to monitor and reduce energy consumption has become more important than ever. This has given rise to new developments in the injection moulding industry, like all-electric injection moulding machines. Avani Jain analyses the effectiveness of these machines in achieving energy efficiency.

he cost of energy has conventionally been between 4 and 5 per cent of the cost of a moulding, but this is increasing rapidly with rising energy prices. To remain competitive, a business must have an effective energy management process. Thus, the focus is more on energy efficiency, which has led to popularisation of electric injection moulding machines. Earlier, hydraulic injection moulding machines ruled the market, but with the advancements in technology, various new developments are now taking place. Currently, all-electric machines are making inroads into the Indian market, with a 4-5 per cent share of total injection moulding machinery sales. Their demand is expected to increase in the near future due to their energy efficiency, greater cleanliness, quick start-up, better repeatability and noiseless operations.

Hydraulic versus versu electric injection moulding machines The basic difference between the two is the use of servo motors in electric injection moulding machines as against the use of pumps in hydraulic injection moulding machines. Rohan Shrikant Shahane, Regional Director - South East Asia, Machine Point Consultants SL, says, â&#x20AC;&#x153;Energy consumption in different injection moulding machines depends on how the drives are powered. The product type, size and material can be a large contributor to the difference in energy consumption. A conventional hydraulic machine uses one or more pumps as a central unit to drive the machine. Two of the most wasteful aspects of a hydraulic machine are the architecture of the system and the wasted pump power when there is no demand. In contrast, all-electric machines reduce losses by using high-speed servo motors to drive injection moulding processes.â&#x20AC;? All-electric

Modern Plastics & Polymers | November 2011

injection moulding machines are said to have the potential to reduce energy costs for moulding by 30-60 per cent, depending on the moulding and the machine.

The plus points All-electric machines have several advantages over hydraulic machines. â&#x20AC;&#x153;The servo motor used in an electric machine only drives the shaft required for the moulding process, creating a direct exchange of energy and ensuring less energy consumption. Also, a substantial reduction is seen in maintenance cost, as the electric machine eliminates the need for hydraulic oil, obviating the need to store, dispose, maintain and cool the oil. All-electric machines eliminate the need for cooling the hydraulic system, besides the associated equipment requirements and energy use. A shorter product cycle makes these more productive than the hydraulic machines. All-electric machines

All-electric machines

All-electric machines eliminate the need for cooling the hydraulic system, besides the associated equipment requirements and energy use. A shorter product cycle makes these more productive than the hydraulic machines. Rohan Shrikant Shahane Regional Director - South East Asia, Machine Point Consultants SL

produce less noise as it does not have pumps. The plumbing piping to the plant can be greatly reduced for new construction. Moreover, these machines are more precise and good for repetitive operations,” notes Shahane. All-electric machines allow machine movements to be integrated directly with the control system. This greatly improves machine set-up, adjustment and process control. These machines use less water, and, depending on the product, water consumption can be reduced by up to 65 per cent. Generally, all-electric machines require less maintenance as compared to hydraulic machines. Overall, all-electric machines have a relatively lower risk of failure and are easy to maintain than conventional machines. Thus, all-electric machines can significantly reduce energy consumption and production cost for many mouldings. These machines are used in applications that require high precision, eg, engineering and pharmaceutical applications.

Demerits

As compared to India, the demand for all-electric injection moulding machine is high in other countries like Japan where 90 per cent of the machines are injection moulding machines. V Ramesh Chief Executive Ofﬁcer, Negri Bossi SACMI Engineering (India) Pvt Ltd

Despite the many advantages of allelectric machines, these do have certain disadvantages, which might hamper their demand. Shahane observes, “The market barrier of accepting all-electric machines is the cost differential between hydraulic and all-electric machines, which is almost 40 per cent. However, of late, this price has declined by 10-20 per cent. Although all-electric injection mouldings exhibit superior efficiency in the plastics manufacturing process, these cannot be used in applications that require high speed and high clamping forces.”

Demand scenario The higher cost of electric injection moulding machines than the conventional hydraulic systems limits their usage. V Ramesh, Chief Executive Officer, Negri Bossi SACMI Engineering (India) Pvt Ltd, says, “Of the total injection moulding machinery market in India, electric injection moulding machine constitutes only a small percentage. As compared to India, the demand for all-electric injection

Modern Plastics & Polymers | November 2011

moulding machine is high in other countries like Japan where 90 per cent of the machines are injection moulding machines. As a result, the governments in these countries have subsidised the price of these machines for end-users.” Adding to this, Shahane says, “In India, people prefer to buy machines that are less costly and bear the high maintenance cost throughout the year. Although the capital investment in electric injection moulding machine appear to be huge in the beginning, there are no further costs involved with them. Thus, despite being energy efficient, the scope of these machines in the Indian market seems limited at present.” he continues, “But with the growth in auto, medical and electric & electronic sectors, the investment in all-electric machines is expected to increase. This growth will be fuelled by productivity improvement initiatives due to manpower shortage, wage inflation and higher power availability.”

New technologies for greater efficiencies With the rising focus on energy management, companies are looking beyond electric injection moulding machines. “For this purpose, new machines like the Canbio VS series with electrohydraulic system comprising servo-driven motor and variable displacement pump are produced by Negri Bossi,” says Ramesh. Through complete digital control, Canbio VS provides high moulding accuracy and improved repeatability of the moulded parts. The use of digital variable displacement pumps with integrated electronic control of pressure and speed permits higher energy savings. “These machines are close to electric injection moulding machines and can save more energy & other costs. This gives them an advantage over electric injection moulding machines, which are expensive and have certain limitations,” details Ramesh. Thus, in future, energy management concerns are expected to rise further and machines with higher output and lower power consumption per unit will lure customers worldwide.

POLICIES & REGULATIONS: Polymer pricing policy

Maintaining cost-quality

equilibrium

The growing consumption of plastics in India is putting a pressure on raw material supplies, thus increasing the possibility of raw material imports. This will, in turn, result in price hike of raw materials, which would trickle down to the end product. Anwesh Koley finds out how government could play a significant role by regulating price rise and helping companies maintain product quality. olymers constitute an integral part of the plastics industry. Over the years, the market for plastic polymers has grown and so have the numbers of players in this arena. Demand for raw materials is on the rise and producers have stood up to the challenge.

Where we stand By 2012, India is projected to be the third largest consumer market for plastics, with consumption of 12.75 million Metric

Tonne (MT) per annum. Rajiv Arora, Vice President & Business Head - Shriram PolyTech, says, “Polymer consumption in India has historically grown at twice the Gross Domestic Product (GDP) rate. This growth is driven by all consuming segments such as automotive, housing, packaging and even agriculture.” In addition to polymers, masterbatch consumption is projected to increase from 182,000 MT (2010) to approximately 255,000 MT (2012). This growth can be attributed to the rise in competition,

Modern Plastics & Polymers | November 2011

both domestically and internationally, as manufacturers now have access to global technology and are aware of the changing demand patterns. This rise in production and consumption has helped existing players to expand and new manufacturers to establish themselves.

Future avenues Polymer manufacturers will strive to exhaust their present capacities with increased demand. If the present trend continues, there is a possibility of imports as well, and this may result in higher prices. “Prices of masterbatches are dependent not only on polymer prices, but also on pigment prices, and these have been increasing steadily. However, with an increase in demand for masterbatches, there is a high probability of more manufacturers jumping into the foray,” says Parag Parikh, Partner, Universal Colorant Company. This will result in an equilibrium price where the quantity demanded by consumers (at current price) will equal the quantity supplied by manufacturers (at current price). Overall, with the rise in consumption of plastics in India, many new avenues will open for manufacturers and an increase in competition will only result in better quality of final products. The Indian plastics industry is growing at the rate of 12-15 per cent per annum since the last few years. With this growth, the demand for the raw material is growing simultaneously at the same rate. “At present, a manufacturer is well aware of the quality of his product, cleanliness

Polymer pricing policy

Growth of masterbatches is also expected to be higher, as polymer manufacturers are resorting more to the use of the masterbatch system instead of direct addition of additives. Rajiv Arora Vice President & Business Head, Shriram PolyTech

Prices of masterbatches are dependent not only on polymer prices, but also on pigment prices, and these have been increasing steadily. However, with an increase in demand for masterbatches, there is a high probability of more manufacturers jumping into the foray. Parag Parikh Partner, Universal Colorant Company

of his production area as well as need for developing a new look for his end products,” adds Parikh. People in India are improving with technological advancements and have access to international standards. But, this improvement happens at a higher pace for a company that exports than the one that manufactures and sells in India. The prices of masterbatches have seen an upward trend for the last few years due to soaring raw material prices and consolidation of international raw material suppliers. Sourcing quality raw material from consistent and reliable suppliers will be the key in the coming years.

Policy changes required The polymer fraternity has been seeking government support on various issues. “We have requested the government to fix customs duty on polymers to a level equal to the customs duty imposed on inputs of major producers of crude & naphtha. This would force indigenous producers to maintain stable domestic prices and also keep the price levels in parallel with the international levels,” says Parikh. As a result of continuous follow-up, the customs duty on polymer imports has been steadily reduced from the earlier high level of 25 per cent to the current level of 5 per cent. “Manufacturers seek elimination of this protection from the government; major producers do not need it, as they operate through world-class plants equipped with the latest technology,” says Bhatia.

What is in store for masterbatches? Along with conventional masterbatches, the future of additive masterbatch is equally bright. The development of highly productive machines has opened up new horizons for masterbatch application. Moreover, plastics is widely used as a first immediate replacement of metal, paper, etc. This has created a compulsion for development of new blends (composite plastics) for the plastics industry. The market for masterbatches is showing robust growth, as there is sufficient supply and availability of materials. The next year will be challenging for polymer producers and the entire polymer market; further growth will happen as

Modern Plastics & Polymers | November 2011

many large-scale players are developing a number of capacities near their plants. New players, both domestic & international, will keep the selling prices competitive; hence, a challenging market scenario and reduction in margins is likely. The volume growth should help sustain most players, but as in most industries, efficiency and innovation is and will be required.

Looking forward The Indian plastics industry has a huge market potential and is gradually on its way to prosperity. This potentiality of the market has been constantly encouraging entrepreneurs to invest in this industry. Entrepreneurs are making all efforts to provide high-quality plastic products, to make it a booming industry. The masterbatch business in India is slated to benefit the most from the rise in plastics consumption. Masterbatch, which is an advanced polymer, forms 75-80 per cent of the raw materials used in the plastics industry, and hence will witness a parallel rise in demand as India becomes the third largest consumer of plastics by 2012. This is mainly because more and more manufacturers are turning to advanced polymers on account of enhanced consistency in the performance and elimination of pollution problems. “Silicon masterbatches find applications in manufacture of Polyethylene (PE) ducts for optical fibres. This could generate additional business of almost 1,500-2,000 tonne per year. Growth of masterbatches is also expected to be higher, as polymer manufacturers are resorting more to the use of the masterbatch system instead of direct addition of additives,” believes Arora.

On the road to success The growth in the plastics sector has always exceeded the GDP growth rate in the country and, with the increase in demand, manufacturers on global as well as domestic levels need to increase their production capacities. However, as growth propels production, new avenues to meet additional demand will surface. Hence, with adequate government support, there is huge scope for manufacturers to grow further

Illustration: Sharad Bharekar

STRATEGY: Quantifying quality

The theory of constraints is a generally followed concept today, where improvements everywhere may not necessarily lead to overall improvement. Most organisations have taken initiatives such as Six Sigma, 5S, single minute exchange of die, autonomous maintenance, cycle time reduction, single piece flow, milk run and cross docking, to ensure long-term profits. Here we take a look at some of the basic tenets of quantification of performance to maximise quality. M Hariharan rganisations embark on myriad quality initiatives. Many of these initiatives have emerged from Japan – 5S, Kaizen, Quality Circles, Total Quality Management (TQM), Total Productive Maintenance (TPM), etc – and a few from the West, Six Sigma being the most popular one. It is often observed that ideas of improvement are rejected by financial controllers, as no perceptible improvement is visible in the bottom line; moreover, some times, the bottom line declines after an initiative. K Ramakrishna (adjunct Professor of SP Jain Institute Management and Research) – a renowned expert in Project Financing – has developed a modified version of DuPont chart. Using

this model as a base, and applying to it the principles of activity based costing, Savoir faire has created a model for quantifying the benefits of operations initiatives (quality initiatives or supply chain initiatives).

model, widely used and appropriate for understanding the overall performance of an enterprise. However, to further analyse the operations performance one needs to go into a micro level.

K Ramakrishna’s model DuPont chart DuPont chart of ratios is a popular and useful model for measuring profitability performance (Figure 1). This chart was developed by Frank Donaldson Brown (1885-1965), a financial executive and corporate director with DuPont and General Motors. This model is useful for analysing the performance on three parameters, viz, operating efficiency [Profit After Tax (PAT)/sales], efficiency of asset usage (sales/total assets) and efficiency of financial leverage (total assets/net worth). This is till date a popular

Modern Plastics & Polymers | November 2011

The model developed by K Ramakrishna is a modified version of DuPont chart (Figure 2). This model differentiates between the areas under the control of finance and operations. This model is extended to develop a methodology to address key impact areas of operations.

Factors affecting the three operations ratio Contribution/sales ratio: This is the popular profit-volume ratio and signifies the direct profitability of the product. Three factors impact this ratio, namely,

Quantifying quality

Goal of a business enterprise: Maximising investor’s wealth

Goal of a business enterprise: Maximising investor’s wealth PAT

PAT Net worth

PAT

CE NW

PBIT PAT

Total assets

Sales

Net worth

PBIT

PBIT Capital employed

PBT (1-T)

X Sales Sales Total assets (-) Cost of sales (variable cost, fixed cost incl depreciation) = Profit before interest and tax (-) Long-term interest = Profit before tax (-) Taxation = Profit after tax (PAT)

Fixed asset + Working capital = Capital employed Net worth (ie, capital plus reserves) + Long-term debt = Capital employed

Contribution Sales X (-) Variable cost = Contribution (-) Fixed cost incl depreciation = Profit Before Interest and Tax (PBIT) (-) Long-term interest = Profit Before Tax (PBT) (-) Taxation = Profit Before Tax (PAT)

Figure 1: DuPont chart

change in variable cost per unit, change in selling price per unit and change in product mix. Any action taken by an operation that impacts these three factors will affect this ratio. Profit Before Interest and Tax (PBIT)/contribution: This is the popular margin of safety and signifies two issues: (a) How safe is one's business? (b) How well is one utilising the fixed cost resource. Besides the three factors listed for the profit volume ratio, two more factors affect this ratio – change in fixed cost and change in sales volume. Any action taken by an operation that has an impact on these five factors will affect this ratio. Sales/Capital Employed (CE): This is the popular asset turnover ratio, which signifies how well one’s assets (fixed assets and working capital) are utilised. Of the five factors that affect the margin of safety, three factors impact this ratio, eg, sales volume, sales mix and sales price. Apart from these three, one’s decision on fixed asset and change in working capital will affect this ratio. Any action taken by an operation that affects these five factors will impact this ratio.

Operations triggers of the bottom line The seven triggers of the three ratios can be grouped under sales, expenses and investment. 98

Sales

(1 + D/E)

Capital employed Contribution

Sales

Finance

Operation

Figure 2: K Ramakrishna’s model

Sales triggers: Sales price, sales volume and sales mix are the three sales factors that trigger the bottom line. Cost triggers: Change in variable cost and change in fixed cost will affect the bottom line. In other words, any process improvement that releases fixed cost capacity will not result in shortterm cost reduction. Investment triggers: Change in working capital and decision on fixed asset are the two triggers. Any action that releases the capacity of fixed assets will help hold over the investment to a later date.

Savoir faire model for quantification of operations and quality measures Not all results of operations and quality will lead to cost reduction and asset reduction. It may result in reducing tomorrow’s cost and today’s investment. The Savoir faire model for quantification traces the actions of operations to these seven triggers of bottom line. This model uses an activity-based approach to understand the financial reaction of the actions. The model follows a four-stage approach: Stage 1: Identifying the activities pre- and post-implementation of the initiative Stage 2: Identifying the resources required pre- and post-implementation of the initiative

Modern Plastics & Polymers | November 2011

Stage 3: Comparing the resources required pre- and post-implementation of the initiative Stage 4: Tracing the impact of changes to the seven triggers of bottom line Stage 5: Quantification of benefits/ costs of initiatives

Quantifying quality measures Initiatives cannot be justified simply based on intellectual satisfaction levels attained. Initiatives should help organisations improve their profitability for a sustained period. At the same time, one cannot expect the initiatives to derive benefits within only a few months. Hence, a model to quantify today’s costs and tomorrow’s benefit is critical for a sustainable initiative. Ultimately, for every action, there is a financial reaction.

M Hariharan practises consultancy in the field of cost management, lean thinking, constraint management, management control system and business excellence as Founder Director at Savoir Faire Management Services. Savoir Faire develops cost information systems to support pricing, outsourcing and control decisions using the cost excellence (CE©) model. Email: sfgroup@vsnl.com

TIPS & TRICKS: Extrusion techniques

Effective for driving methods profits In the plastics industry, using the right technique to manufacture the desired end product is of prime importance. Plastic extrusion techniques have evolved with time and manufacturers are constantly figuring out ways to improve productivity and ensure seamless processing. Here are some tips on how to achieve quality products in an efficient way. Anwesh Koley

xtrusion is the process of forcing molten plastics under pressure through a shaped die

to produce a product with a specific cross-section. This method is used to manufacture a wide range of plastic products and can be applied to shorter products cut to length, such as piping, or continuous

length products, such as plastic sheeting. Plastic extrusion can be highly automated, resulting in nearly continuous and consistent production, and the level of automation depends on the quality of equipment.

There are a number of ways to achieve consistent quality in extruded products:

Blown film extrusion is one of the most common methods of film manufacture. The process involves extrusion of a plastic material through a circular die, followed by â&#x20AC;&#x2DC;bubble-likeâ&#x20AC;&#x2122; expansion. The advantages of making films with this process are ability to produce flat & gusseted tubing in a single operation and regulating the width & thickness of film by regulating volume of air in the bubble and output of the extruder.

Sheet extrusion method is used for making plastics sheets, where converts plastic pellets or powder are converted to plastic sheets by extrusion through a flat die. These sheets can then be made into rolls, cut into specific lengths or made directly into finished products via in-line thermoformers. The means of production is a sheet extrusion line.

Screw extrusion is the technique of manufacturing most thermoplastics. Screw extruders involve single or multiple screws. Currently, twin-screw applications are also used, depending on temperature requirements. A drawback to most extrusion operations is that dimensional tolerances are relatively high, ranging up to 10 per cent of the workpiece.

The oldest form of extruder used was the ram extruder, which is still in vogue. In a ram extruder, instead of extrusion screw, a ram or plunger is used. This is used to produce profiles, sleeves, rod, block, tubing, lining sheet bars, etc. It is effective for specific materials like polytetrafluoroethylene, which cannot be extruded successfully by using a screw extruder.

100 Modern Plastics & Polymers | November 2011

Jacketing extrusion is the process of extruding plastics as a coating over another product, particularly wires. This requires plastics to be flexible and able to withstand current flow & temperature fluctuations. Plastic insulation can be extruded over a single conductor or a bundle of wires. Different materials can be used for this purpose depending on the application.

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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 Africa. Considering the investor-friendly and transparent policies and best infrastructural facilities in Gujarat, the company has chosen the state for setting up this unit.

Project location Dahej, Gujarat

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

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

Polysilicon Punj Lloyd

Project type New contract

Project news Punj Lloyd has bagged an Engineering, Procurement and Construction (EPC) contract to set up Qatar’s first plant for manufacture of polysilicon, the raw material used to build solar cells. The contract has been awarded by Qatar Solar Technologies (QSTec) and is scheduled

to be commissioned by mid-2013. The EPC contract awarded to the Indian conglomerate involves the establishment of 4,000 tonnes per annum (TPA) of polysilicon manufacturing capacity. The total envisaged capacity of the plant is 8,000 TPA of high-purity solar grade polysilicon at an investment of $ 1 billion. The work under the contract involves residual basic engineering & design, detailed engineering, procurement, supply, manufacturing, construction and commissioning, among others.

Implementation stage

Project location

BASF

Ras Laffan Industrial City, Qatar

Project type

Project cost

New facility

$ 1 billion approx

Project news

Implementation stage

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

Planning Contact details: Punj Lloyd House 17-18 Nehru Place New Delhi - 110019 Tel: +91 11 2646 6105 Fax: +91 11 2642 7812 Email: info@punjlloyd.com

Composites Processing Carbures

Project type New facility

Project news Spain-based Carbures plans to invest $ 6.5 million to build a composites manufacturing plant in Greenville, USA. The company selected the location in part due to its proximity to potential customers like Lockheed, Boeing, Proterra and BMW. Processes will include hand layup, resin transfer 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 (€ 4.9 million)

106 Modern Plastics & Polymers | November 2011

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

Plastic additives

Project location Bahrain

Project cost Not known

Implementation stage Planning Contact details: Reinhold Lutz BASF Bahrain P.O. Box 18696 Al Seef, Bahrain Tel: +973 - 17585251 Fax: +973 - 17583400

EVENT LIST

National

Pune

Chennai

Indore

Aurangabad

Maharashtra Nov 18-21, 2011 Auto Cluster Exhibition Centre, Pimpri-Chinchwad

Tamil Nadu Dec 8-11, 2011 Chennai Trade Centre, Nandambakkam

Madhya Pradesh Jan 6-9, 2012 Poddar Plaza, Nr Gandhi Hall

Maharashtra Feb 17-20, 2012 Garware Stadium, Chikkalthana

India’s premier industrial trade fair on products and technologies related to Machine Tools, Hydraulics & Pneumatics, Process Machinery & Equipment, Automation Instrumentation, Packaging & Auxiliaries, IT Products, Electrical & Electronics, Material Handling and Safety Equipment.

For details contact: Infomedia 18 Ltd, Infomedia 18 Ltd, Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028. Tel: 022 3003 4651 • Fax: 022 3003 4499 • Email: engexpo@infomedia18.in • Web: www.engg-expo.com

POLY INDIA 2011

Industrial Automation-India

This international exhibition and conference will highlight the use of advanced plastics & polymers in automobile, aviation, telecommunication and other emerging areas; November 9-11, 2011; at Hyderabad International Trade Expositions Ltd (HITEX), Hyderabad

The event will bring latest trends and technology in automation, energy and power transmission closer to the Indian traders; December 6-9, 2011; at Bangalore International Exhibition Centre, Bengaluru

For details contact: Manoj Mehta FICCI Federation House, Tansen Marg New Delhi - 110001 Tel: 011 23738760-70, Fax: 011 23320714, 23721504, Mob: 09891098772 Email: ficci@ficci.com Website: www.ficci.com

For details contact: Hannover Milano Fairs India Pvt ltd 603/604, Samarpan Complex, New Link Road, Chakala, Next to Mirador Hotel Andheri (E), Mumabi - 400 099 Tel: 022 4005 0681-82 Fax: 022 4005 0683 Email: info@hmf-india.com Website: www.hmf-india.com

This exhibition will showcase the latest plastic films, packaging & printing machinery, tapes/plastic pallets, warehousing equipment, bag making machinery, material handling equipment, etc; November 23-27, 2011; at University Grounds, Ahmedabad For details contact: B Swaminathan Smart Expos T-6, Agarwal Court - K G Plaza 41-44, General Patters Road, Chennai Tel: 044 28603086, Fax: 044 28604261 Mob: 09789095247 Email: info@smartexpos.in Website: www.smartexpos.in

For details contact: 113, New Sonal Link Industrial Estate Building No 2, Link Road Malad (W) Mumbai - 400 064 Tel: 022 28803977/28803978 Fax: 022 28819008 Email: intelexpo@vsnl.net Website: www.intelexpo.com

Indian Medical Devices Conference 2011 Plastindia 2012

CONVEXPO

technology and converting applications for the future of plastics packaging. Visitors will find innovations & solutions to make their business more efficient and profitable; February 23-25, 2012; at Bombay Exhibition Centre, Mumbai

This is the premier exhibition of the Indian plastics industry. It will once again prove to be a strategic meeting point for all large and small players from the global arena; February 1-6, 2012; at Pragati Maidan, New Delhi For details contact: Plastindia Foundation 401, Landmark B, Suren Road, Off Andheri Kurla Road, Andheri (East), Mumbai - 400093 Tel: 022 26832911, Fax: 022 26845861 Email: info@plastindia.org Website: www.plastindia.org

Intelpack 2012 This exhibition will showcase various

108 Modern Plastics & Polymers | November 2011

This event will focus on the growing range of applications and oppotunities in the Indian medical manufacturing industry; March 23-24, 2012; at Ahmedabad Management Association (AMA) Complex, Ahmedabad For details contact: D L Pandya Classic Computer Services B-4, Mandir Apt Opp P & T Colony Jodhpur Char Rasta, Satellite Road Ahmedabad - 380 015 Tel: 079 26740611 Fax: 079 26754867 Mob: 09825457563 E-mail: mpds00@vsnl.com / dlpandya gmail.com Website: www.imdiconferences.com

EVENT LIST

International IPCC 2012 The International Paint, Coatings and Chemicals Exhibition has a special significance since the Middle East is the world’s fastest growing chemicals and petrochemicals market. The region’s booming construction sector is renewing the demand for raw materials and propelling business for the processing industries; Decermber 28-31, 2011; at Tehran Permanent Fairground, Tehran, Iran For details contact: Banian Omid Company Apt.7, 4th floor, No 2212, Near Park Saie Gas Station, Vali-e-Asr Avenue, Tehran, Iran Tel: +98 (21) 88720005-7 Fax: +98 (21) 88710252 Email: nfo@ ipcc.ir/nfo@banian.ir Website: www.ipcc.ir

exhitbited; February 17-20, 2012; at Athens Metropolitan Expo, Athens, Greece For details contact: 3EK Organization of Exhibitions L. Pentelis 28 152, 35 Vrilissia, Hellas, Greece Tel: +30 (210) 8056205/207/208 Fax: +30 (210) 8056209 Email: info3ek@otenet.gr Website: www.plastica-expo.gr

While serving as an international platform for the Indian plastics industry, this exhibition will facilitate business prospects for all major global players in the region. This event will promote opportunities and provide exposure to manufacturers of raw material & machinery, auxiliary equipment, pigments & additives, dies & moulds, etc; May 14-17, 2012; at Expo Centre Sharjah, United Arab Emirates

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

Polyester and PET Chain 2012

For details contact: AIPMA House A-52, Street No. 1, MIDC Marol, Andheri (E) Mumbai - 400 093 Tel: +91 22 28217324 / 25, 28352511 Fax +91 22 28216390 Email office@aipma.net Website: www.plastivisionarabia.org

Argenplás 2012

The 16th annual polyester world congress brings together industry leaders from around the world to focus on the new technology, product and application directions needed to sustain growth and maintain profitability as markets recover worldwide; February 1416, 2012; at Swissôtel, Zurich, Switzerland

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

For details contact: Nicole Morris MBS Polymer Events A unit of Chemical Business Media 110 William Street, 11th Floor New York, NY 10038 Tel: 1-212-621-4978, Fax: 1-212-621-4970 Email: events@mbspolymer.com Website: www.mbspolymer.com

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 in the coming future; April 18-21, 2012; at Shanghai New International Expo Centre, PR China

Plastica 2012 This is a biennial exhibition that aims at presenting the new developments, trends and technologies in plastics and rubber processing. Raw materials, petrochemicals, polymers, resins, mixtures, special chemicals, additives, masterbatches, semi-finished and finished polymers, processing machines, moulds, ancillary equipment, etc will be

Plastivision Arabia 2012

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

110 Modern Plastics & Polymers | November 2011

While focussing on the latest in plastics technology and value-added innovations, this event will serve myriad business interests through a highly qualified segmented audience of OEMs and distributors. It will be a good opportunity to ideate and network with the best minds in the region’s polymer industry; June 18-22, 2012; at Centro Costa Salguero, Buenos Aires, Argentina For details contact: Emma Fiorentino Argentine Chamber of the Plastics Industry J Salguero 1939 Buenos Aires 1425, Argentina Tel: 54-11-4821-9603 Fax: 54-11-4826-5480 Email: info@emmafiorentino.com.ar Website: www.argenplas.com.ar

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

PUNE

Nov 18-21, 2011 Auto Cluster Exhibition Centre

Gateway to exuberant opportunities The industrial hub of Pune is gearing up to witness the mélange of latest technologies and innovative products at the highly awaited engineering congregation, Engineering Expo Pune. To be held from November 18-21, 2011, at Auto Cluster Exhibition Centre, Pimpri, the event will reinforce itself as a leading platform for companies to reach out to the target audience and display their manufacturing prowess. It will also enable the business fraternity to collaborate with companies and find right partners and solutions.

ENGINEERING EXPO PUNE STATS 225+ Exhibitors 15,000+ Expected visitors 15,000+ Products on display Spread over more than

45,000 sq ft Expected business worth more than

` 55 crore

Swapnil Pillai estern India is the second-largest consumer goods market after the northern market. Various developmental policies and initiatives have resulted in the emergence of Pune as a preferred choice for manufacturing companies to establish their base in the region. The proximity to Nhava Sheva port and the presence of huge supplier base are some of the key investment drivers for this region. The bustling industrial hub of Pimpri-Chinchwad has seen many MNCs setting up their base here to leverage on the Small & Medium Enterprise (SME) advantage.

114 Modern Plastics & Polymers | November 2011

Pune occupies an important place in production as well as export of cutting-edge engineering solutions. Satish Joshi, Director, Micro Supreme Auto Industries (I) Pvt Ltd, says, “Pune offers good transportation and logistics support, and has comparatively less union troubles. These factors have resulted in the creation of a positive environment, suitable for high growth rate and capital investment.” As per the latest figures released by the Auto Component Manufacturers Association (ACMA), Pune has 53 large companies with a collective turnover of $ 1,400 million, and exports worth $ 235 million. Additionally, there are about 7,000 auto ancillary units in and around Pune.

Engineering Expo Pune 2011

According to S J Gijare, General Manager - Handling Equipment Division, CTR Manufacturing Industries Ltd, “Pune was home to many ‘startup’ SMEs in the 1960s and 1970s, with hi-tech products that met the requirements of defence establishments and some large private companies. The last decade has witnessed a high growth in the SME sector with thousands of such units coming up and adopting latest manufacturing and management techniques.” Engineering Expo Pune, being organised by Infomedia 18 Ltd, is a testimony to the rising significance of Pune in the Indian industrial landscape. Milan Supanekar, Proprietor, Welding Technologies India, observes, “Pune is a preferred manufacturing destination for automobile as well as engineering companies. This has a favourable impact on the development of the SME sector here. Thus, the business environment for SMEs is favourable.”

Leveraging the legacy Engineering Expo enjoys wide media coverage and leaves no stone unturned in consistently meeting the expectations of both exhibitors & visitors alike. The previous edition of the event generated business worth ` 47 crore and more than 6,038 business leads. This has reinforced the faith of exhibitors in the event, which is evident from the fact that this year’s

edition was fully booked two months in advance. Referring to the event as a gateway to Pune’s industrial opportunity, Prasanna Kulkarni, Business Manager Industrial Air, Atlas Copco (India) Ltd, says, “Engineering Expo provides an excellent platform to interact and touch base with the customers. It enables us to not only showcase our products but also provide live demonstrations. This interactive forum provides companies a chance to display their products and discuss the latest happenings in the industry. Western region is one of the important markets and companies will utilise the Engineering Expo as a platform to create a brand that comes first in the mind of the customer and is synonymous with quality.” Elaborating further on the crucial role played by Engineering Expo in enhancing business prospects, Prashant Wani, Proprietor, Shende Sales Corporation, states, “The Expo has carved a niche for itself among professionals, and thereby attracts quality visitors. This enables us to reach a wide base of customers and generate high amount of business.” S Chandra Sekar, Senior Manager - Western Region, S & T Engineers (P) Ltd, feels that the event enables exhibitors to forge new relations with decision makers from the SME sector and corporate houses, who are regular visitors at the event. “It helps us to connect with our existing customers as well as meet prospective clients, besides showcasing our new range of products. It gives us the opportunity to identify and interact with decision makers from various big & small companies,” he adds.

More in store The sixth edition of the event aims at empowering the visitors with latest technology. Companies can use this Expo to reinstall customers’ confidence and

loyalty in the brand & take advantage of new opportunities. As Engineering Expo Pune continues its success saga, an ebullient Sandeep Khosla, Chief Executive Officer - Publishing, Infomedia 18 Ltd, puts this in perspective, “Engineering Expo has come a long way today by becoming one of India’s largest multi-location (other places include Ahmedabad, Chennai, Indore, Rudrapur and Aurangabad) SME meeting points. Over the years, it has successfully achieved its goal of being a preferred destination for SMEs and manufacturing & engineering companies to connect, transact and leverage ideas to foster growth of individual organisations as well as that of the industry at large. As we look forward with further valueadditions for even better experience and reach to the target audience, we welcome large, medium & small industries in the manufacturing and servicing sector to be a part of the Expo in this exciting journey.” Gijare, who feels that Engineering Expo plays a vital role in bridging the gap between business stakeholders, says, “The event enables manufacturers and traders from Maharashtra and other states to showcase their products and services, thereby gaining brand recognition & additional customers. Also, many visitors to these exhibitions, particularly in the SME segment, have gained appropriate knowledge and solutions to meet their specific requirements.” With the Indian industry poised to maintain the high growth momentum in the coming years, expectations are high about an upbeat investment environment in Pune. This spells excellent business opportunities for the manufacturing sector to scale new heights, and Engineering Expo Pune would act as a catalyst towards this end.

November 2011 | Modern Plastics & Polymers 115

EVENT REPORT: Engineering Expo Rudrapur 2011

RUDRAPUR Sept 23-26, 2011 Gandhi Park

Optimising the northern advantage The ‘Think Global… Act Local’ anthem got another anecdote. With major multinational manufacturing and general engineering companies participating in & visiting the maiden edition of Engineering Expo Rudrapur, this northern stronghold got a befitting partner. With many promises delivered and many made, the Expo concluded with a promise to come back next year with more offerings and opportunities for the participating & visiting companies.

Arindam Ghosh ew-age realities spring some unwritten guiding principles. In the boundaryless market reality, it is critical for companies to establish a strong base in the local markets. This guiding principle take a different dimension when multinational corporations have to establish a local connect and client

base while keeping their gaze fixed on the global trend. To combat such critical needs, many skillfully crafted ‘meet your customers’ or ‘showcase your innovations’ platforms are created. But when it is a veteran brand like Engineering Expo and an opportune location like Rudrapur, the scope and extent of such platforms multiply manifold. The latest edition of the Engineering Expo, an established trade show brand

116 Modern Plastics & Polymers | November 2011

of Infomedia 18 Ltd, turned out to be a huge success in terms of its quest towards bringing out the message to the entire Indian manufacturing fraternity of a new and emerging manufacturing hub – Rudrapur – located in the state of Uttarakhand. With the aim of highlighting India’s new manufacturing hub situated in the northern belt, it indeed helped the fraternity to come together and created a conducive business environment for manufacturers to network, showcase and build brands & business, all under one enabling roof. Vikas G Patil, Incharge – Customer Care, Ratnaparkhi Electronics India, one of the exhibitors at the event, substantiated this fact. “We have been participating in Engineering Expo since the past 4-5 years and we are grateful that Infomedia 18 Ltd. has given us this opportunity to participate and display our machines at Engineering Expo Rudrapur. Engineering Expo takes place in areas where new industries are coming up and I hope that Infomedia 18 Ltd keeps searching for new & lucrative places so that we can also reach there and showcase our machines,” he added. The inaugural function of the Expo saw the attendance of Chief Guest Tilak Raj Behar, MLA, Rudrapur; along with the Guest of Honour, Darbara Singh, President, Kumaun Garhwal Chamber of Commerce and Industry (KGCCI) – Uttarakhand; Meena Sharma, Chairman, Rudrapur Municipality; and Anil Sharma, Lawyer; in the presence of Sudhanva Jategaonkar, Associate Vice President, Infomedia 18 Ltd. The guests highlighted the need to tap the potential of this region and offer a fillip to the industries here by providing them a conducive networking environment and state-of-the-art products & services. “Rudrapur has been emerging as an industrial destination for companies, and Uttarakhand is garnering benefits from this growth. I am sure that events such as Engineering Expo will further substantiate the importance of Rudrapur as a major industrial hub. The expanse of products & technologies on display at the event will offer a whole new gamut

Engineering Expo Rudrapur 2011

of opportunities for existing companies as well as pave the way for the growth of prospective companies in the region,” Behar pointed out.

Rudrapur shining The latest edition of Engineering Expo turned out to be an eye opener of sorts. It highlighted the potential that new manufacturer-f riendly regions like Rudrapur in northern India have to offer to manufacturers. Elaborating further on the same, Singh opined, “There are many reasons why big manufacturing companies are setting up their plants in Rudrapur. Apart from the fact that the region is highly adaptable, the state government is supportive and offers manufacturers a slew of industry-friendly policies. Companies wanting to set up base here can have access to skilled manpower and resources. In addition, proximity to Delhi is one of the biggest advantages that this region offers investors.” Commenting from the organiser’s perspective on the choice of a new location for organising Engineering Expo, Jategaonkar explained, “Going by the customers’feedback, we selected Rudrapur as our next destination. We are committed to work closely with the Government of Uttarakhand in furthering industrial growth of the state and that is the intent of launching the Rudrapur edition of Engineering Expo.” Setting up manufacturing facilities in the Tier II and Tier III cities is the new mantra for all big manufacturing companies in India. Cities like Pune, Nagpur and Indore are slowly and steadily finding space in the investment and expansion plans of

the big companies as they provide easy access to land, labour & logistics expertise, strategic geographical locations, etc. Led by manufacturing biggies, Rudrapur is fast emerging as a leading investment destination in the northern belt of the country.

ENGINEERING EXPO RUDRAPUR AT A GLANCE

223 Exhibitors 5,260 Visitors 15,000+ Products displayed

Exhibitors positive on the new edition Held during September 23-26, 2011, Engineering Expo Rudrapur boasted of profuse industry participation from diversified manufacturing spaces, which included machine tools & accessories, process machinery and equipment, material handling equipment, hydraulics & pneumatics, automation and instrumentation, electrical & electronics, light and medium engineering, safety & security, packaging machinery, etc, from all over the country. Substantiating this, Patil stated, “The business generated has been quite good. A lot of potential customers had visited our stall. Based on the enquiries I received, if things work out, about 30-40 per cent of my business will come from Rudrapur.” On how he plans to cash in on the lucrative opportunities that Rudrapur offers, T N Gopinath, Director – Technical & Marketing, Suyog Rubber India, one of the exhibitors at the event, explained, “There are a number of auto companies as well as engineering companies in Rudrapur. We are located in Haridwar, as we are suppliers to Mahindra, who are our primary customers in Uttarakhand. Having said that we would like to develop business in Rudrapur, as it offers a potentially bigger business opportunity in comparison to Hardwar.” Highlighting the healthy relationship, which Infomedia 18 Ltd shares with the exhibitors, Arun Nene, Manager – Channel Support, Jyoti CNC Automation, one of the exhibitors at the event, averred, “Our relationship with Infomedia 18 has brought us to Rudrapur.” Responding to the question as to whether Engineering Expo Rudrapur fulfilled its promises, Michael A Martyr,

` 11.25 crore Business generated 1,25,000 sq ft Exhibition area 77,000 kg Machinery moved 50 Cities participated Sr General Manager, Trident Precision International, said, “The event has certainly exceeded my expectations. I see a huge potential in Rudrapur.”

Satisfied visitors The responses from visitors were quite encouraging as well. They highlighted that such events should be organised more often in future. “The expo was highly informative. More events like these should be organised here,” opined Joginder Singh, Managing Partner, J K Industries, and further added,“The event met my expectations, and it has been able to meet some of my business requirements as well.” Another visitor, Papu Prasad Sharma, Manager – Electrical, Teracom, averred, “The event was well organised and the product spread was good.” Commenting on the potential that events like Engineering Expo hold, Martyr said, “Such exhibitions provide food for thought and opportunities to learn besides offering the opportunity to become a service provider to companies looking out for vendors or suppliers. I find a lot of potential in expos such as this.” Taking a step ahead and carrying this growth momentum forward, the next edition of the Engineering Expo will be organised in Ahmedabad this month.

November 2011 | Modern Plastics & Polymers 117

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PRODUCT S

This section provides information about the national and international products available in the market Extruders

Steer Engineering offers Mega series co-rotating twin-screw extruders that offer complete interchangeability of parts and high levels of compatibility with other extruder lines. The processing challenges are met by an optimal energy-saving screw geometry, appropriate use of special materials and specific treatments, a robust gearbox, modern drive systems and state-of-the-art automation. All of these are supported by user-friendly configuration management software. These extruders feature cycloidal spline profile with shafts, which are proof-tested at 125 per cent rated torque. Major applications are in fibre-grade polyesters, polyethylene masterbatches, polymer blends automotive compounds, short fibre-reinforced thermoplastic compounds and in many other specialised applications. The twinscrew extruders are available in laboratory, pilot-plant and production models in various sizes, capable of outputs in excess of several thousand kilograms per hour.

Injection moulding machines Allied Solutions offers injection moulding machines that are available in a wide range of 251,600 T clamping force. The injection and clamping force are controlled by linear transducer. These have a five-point toggle clamping system. The variable piston pump system enables 35-45 per cent energy savings. It comes with hydraulic motor and high torque control and low speed with six-stage injection speed and pressure control and four-stage holding pressure. The injection moulding machines are available with melt decompression, bi-metallic screw and barrels. The hydraulic components are sourced from Vickers, Rexroth, Yuken and Tokmias. Allied Solutions India Pvt Ltd Mumbai - Maharashtra Tel: 022-4221 0100 Fax: 022-2557 6234 Email: info@alliedsolutions.com

Granulators Steer Engineering Pvt Ltd Bengaluru - Karnataka Tel: 080-2372 3309, Fax: 080-2372 3307 Email: info@steerworld.com

Plastic raw materials AVI Additives offers various plastic raw materials. Necessary and inf rastructure equipment are provided to come up with suitable compounding solutions for the plastic and polymers industry. Other products consists of: plastic masterbatches, plastic compounds, calciumfilled polypropylene, tale-filled polyethylene, colour masterbatch, fluroscent masterbatch, afterglow masterbatch, performance additives, engineering compounds, flame retardants and alloy. AVI Additives Pvt Ltd Hyderabad - Andhra Pradesh Tel: 40-2355 0551/ 2/ 3 Email: info@aviadditives.com 122 Modern Plastics & Polymers | November 2011

Yudo Hot Runner India offers an efficient range of granulators for different types of materials and products. The capacity starts from 20 kg/h to 400 kg/h with low and high speed of crushing. These granulators are available with various options like titaniumcoated blade, strong 2-axis crushing blades. These are easy to move with a handle, easy to check blade through transparent window with CE certified controller. The granulators are compact in size and have elegant design. These are also easy to adjust the size of particles by changing a screen, crushed pieces of size 4-10 mm. Yudo Hot Runner India Pvt Ltd Thane -Maharashtra Tel: 0250-245 1155 / 56 Fax: 0250-245 1158 Email: sales@yudo.co.in

PRODUCT S

Hopper dryers Shini Plastics Technologies (India) offers Euro hopper dryers (SHD-U series) that adopt hot air down-blowing design and use stainless steel material hoppers to avoid contamination. With this design, these can be used with honeycomb dehumidifiers to dry engineering plastics. The capacities range from 20-8,000 litre with air-tight material cleaning doors. Features of these dryers include: innovative design with sleek appearance; hot air down-blowing pipe to ensure even distribution of hot air to maintain a steady temperature in the hopper & increase drying efficiency; all air & material contact surfaces are made from stainless steel; microprocessor used for accurate temperature control; double overheat protection ensure reliable operation; provided with digital PID temperature control with LED display; and equipped with main power switch & control switch. Shini Plastics Technologies (India) Pvt Ltd Mumbai - Maharashtra Tel: 0250-302 1125/36, Fax: 0250-302 1100 Email: sales@shiniindia.com

November 2011 | Modern Plastics & Polymers 123

PRODUCT S

Rotomoulding machines

Reclosable packing products

N A Corporation offers RockN-Roll model rotomoulding machines that are used to produce the smaller to large size hollow products of capacity up to 40,000 litre. These machines are made from heavy mild steel and tripodal supporting structure with all required accessories. Heavyduty gearboxes are provided for suitable drives. The machines are provided with AC variable motors for smooth working of major and minor axis. Features include: easy & comfortable machine operating function through digital control & display panel; operator can easily adjust the burners for effective flame control & low consumption of fuel; gas burner's constructions are robust & simple; trouble-free working; and flexibility to convert from gas-fired to diesel oil-fired system. The moulding processes are fully visual to the operator so the monitoring of the products during process leads lesser chances of product rejection.

SVP Packing Industry offers series of flexible packing reclosable products and solutions that are tailor-made as per customers' requirements. The product range consists of PP & PE ziplock bags, PP & PE zipper profiles, PP & PE slider bags and biodegradable ziplock bags. Various salient features of special low sealing temperature zippers are that these are manufactured from advanced polyolefin/specialty polymers; seal with laminates at a very low temperature; increase machine speed by 20 per cent; reduce wrinkles on films due to low temperature requirement; avoid delamination as temperature required is very low; and have good bonding between zipper and laminates. The latest development is soft seal zipper. It crushes at a very low temperature and pressure. Soft seal zipper does not leave gaps or pins-holes on side sealing pouches and is good for hydroscopic material, pharma products, etc.

N A Corporation Ahmedabad - Gujarat Tel: 079-2584 0374/1821, Fax: 079-2584 0809 Email: info@naroto.com

124 Modern Plastics & Polymers | November 2011

SVP Packing Industry Pvt Ltd Mumbai - Maharashtra Tel: 022-2494 5116 / 17 / 6635 1516 / 17 Fax: 022-2494 5118 Email: info@svpmagicseal.com

PRODUCT S

PVC pipe threading machines Vikrant Special Machines offers PVC pipe threading machines (model WPD2E & WPD4E) complete with tangential diehead and chaser holders, motors and DOL starter. These machines are used for cutting external thread on PVC pipes by chasing method. HSS Tangential chasers are used as cutters. BSP, Metric, BSPT, NPT, BSW, threads can be cut on this machine depending on the type of chasers. The PVC pipe threading machines are designed to give maximum efficiency and reliable performance under the most severe conditions of service with minimum maintenance cost. These machines range from Â˝" to 2.0" and 2Â˝" to 4.0" and are highly suitable & productive machines. This further ensures high durability and effective performance due to which these are high on demand in the national and international market. Vikrant Special Machines Pvt Ltd Kolkata - West Bengal Tel: 033-2551 3070 Fax: 033-2337 7053 Mob: 98307 06056 Email: vikrantspecial@rediffmail.com

November 2011 | Modern Plastics & Polymers 125

PRODUCT S

Liquid-ring vacuum pumps

Injection moulding machines

Acmevac Sales offers liquid ring vacuum pumps that find applications in vacuum distillation, drying, concentration, degassing, crystallisation, gas evacuation, gas conveying & compression, etc, in chemicals, drugs, food, beverage, sugar, fertiliser, paper, metallurgy and allied process industries. These vacuum pumps are available in both single and double stage with capacities ranging from 10 CFM to 4000 CFM and ultimate vacuum up to 720 mm Hg. The sophistically designed pumps are silent in operation with the result that the silencer is totally eliminated. Mechanical shaft seal design ensures adequate protection to the expensive shaft and provides ease of maintenance. This leads to minimal time required for servicing, thereby cutting down time to the barest minimum. The liquid ring vacuum pumps are rugged in design, reliable in performance and easy to maintain.

Multiplas Enginery Co offers injection moulding machines for a wide range of applications. The vertical injection V-series of injection moulding machines feature up/down clamping for easy insertion and enhanced safety, while allowing for wider operation area on four sides of the machine. Lead frame device can be equipped to make insert moulding process automatic. Multi-mould option can be selected to improve productivity, for quality control and efficiency, while the vertical structure of the machine and its flexible arrangement of wires and pipes allow easy assembly, disassembly and maintenance. The injection moulding machines occupy less floor space. The 2/3-colour process saves time and improves efficiency.

Acmevac Sales Pvt Ltd Mumbai - Maharashtra Tel: 022-2837 5837 Fax: 022-2836 4977, Mob: 092233 88105 Email: acmevac@vsnl.com

Multiplas Enginery Co, Ltd Gueishan - Taiwan Tel: 886-3-3180090 Fax: 886-3-3974598 Email: sales@multiplas.com.tw

126 Modern Plastics & Polymers | November 2011

PRODUCT S

Grain effect masterbatches New Partic le Chemical Colors Corp offers grain effect masterbatches that have colourful flow patterns based on differences in melting temperature between masterbatches and plastic resins. These

masterbatches are applicable for ABS, PP, PS, HIPS, PE, PMMA materials. There is no need to change the injection or extrusion machines as these can be processed as normal with temperature and pressure setting control. Also offered are standard colours and customised formula for clients. New Particle Chemical Colors Corp Taoyuan County - Taiwan Tel: +886-2-8209 4051 Fax: +886-2-8209 4053 Email: npccolor@seed.net.tw

Injection moulding machines Neejtech India offers world-class all-electric horizontal injection moulding machines from Niigata Machine Techno Co Ltd, Japan. These injection moulding machines are available in the range of 50-1,000 tonne and vertical IMM in the range of 30-150 tonne. Shot size (PS) is in the range of 20-4,550 g. These all-electric machines are generally known as green machines because these save more than 60 per cent power consumption

than similar size Hydraulic/toggle machines. The machines are absolutely free from oil and therefore do not create pollution. Due to no oil use the machines reduce maintenance and repair costs of hydraulic system. These machines ensure enhanced accuracy and reliability, and also provide great cost-savings and contribute to the environmental preservation. The injection moulding machines are ideally suitable for medical, automotive, pharmaceutical, healthcare and packaging moulding segments of the industry. These machines run silent and without vibrations. These are precise as there is no deviation through oil viscosity, compressibility, through drifting hydraulic valve action time. By switching over from hydraulic to electric injection moulding machines, one can save greater cost on power consumption, cooling water consumption, hydraulic oil elimination, as well as housekeeping and maintenance cost. This will increase uptime and decrease material wastage. Neejtech India Ahmedabad - Gujarat Tel: 079-2656 1312, Mob: 098250 40231 Email: sales@neejtech.com November 2011 | Modern Plastics & Polymers 127

PRODUCT S

Humidity & temperature transmitters Katlax Enterprises offers RH and temperature transmitters that are available with X’Bee wireless connectivity. instruments These use ASIC chip as an RH & temperature measurement devices. X’bee is a low-cost, low-power, wireless mesh network standard. The low cost allows the technology to be widely deployed in wireless control and monitoring applications. The instruments have an accuracy of 0.6 per cent for temperature and 3 per cent for RH. Range of the devices is 0-100 per cent RH and 0-100°C. These units have a local 7-segment display and transmit 0-10 V DC/420 mA. They can control two temperature (lower & higher) and two humidity (%RH lower & higher) setpoints. The units are available with various supply voltage options, ie, 230 V AC/12 V DC/24 V DC, etc. These have a range of up to 50-60 metre indoor and 1 km for outdoor application. The humidity and temperature transmitters are widely used in cleanroom application. Katlax Enterprises Pvt Ltd Gandhinagar - Gujarat Tel: 02764-286 784 Fax: 02764–286 793 Mob: 097245 06614 Email: info@katlax.com

PVC clear colour films All India Plastics manufactures and offers PVC clear colour films in thickness ranging from 50 micron to 100 micron. These films are available in various colours, like blue, green, orange, red, yellow, etc. The PVC clear colour films find applications in Polaroid glasses, 3D glasses, top covers for halogen lights, etc. All India Plastics Mumbai - Maharastra Tel: 022-2342 8096 Fax: 022-2344 8151 Email: kompak@bom8.vsnl.net.in 128 Modern Plastics & Polymers | November 2011

PRODUCT S

Quick mould change systems Madhu Machines & Systems offers electromagnetic quick mould change (QMC) systems from EMT, Hong Kong, for injection moulding machines. These QMC systems can be supplied for machines up to 3000-tonne capacity. Major areas of applications are in the following: automotive, motorcycles, home appliances, electrical & electronics, packaging, consumer products, etc. Important features of the electromagnetic plate of QMC are: most efficient QMC to replace conventional hydraulic clamp; compatible with any machine & considerable mould; easy installation & setup for minimum machine downtime; permanent magnetic force: powerful, reliable & safety; uniform & flexible; and clean & power saving. QMC can be easily interfaced with main machine control and supplied for various special applications, like side loading & oversize mould, rotating system, large moulds for automotive, etc. The QMC systems help processors to introduce automation in mould change operation and increase mould-up time, while ensuring safety of operation and operators. Madhu Machines & Systems Pvt Ltd Vadodara - Gujarat Tel: 0265-235 3886/232 1104, Fax: 0265-233 4278 Email: machinery@madhu-group.com

November 2011 | Modern Plastics & Polymers 129

PRODUCT S

Colour marking machines Aeromec Marketing Co offers rotary automatic hot colour (hot embossing) sequential colour marking machines that are designed to mark in colour in all types of polyethylene pipes, rigid PVC pipes and sections during extrusion process. These machines require power only for heating. Model AMC-210 can mark from 10 mm to 315 mm outside diameter of pipes. The marking is done at every one metre on the pipes/sections by using pantorgraphed brass/SS stereos fixed on the heater body. Stereos are heated by using electronic percentage differential circuit, which adjusts the temperature. The machines are designed to colourmark by adjust using a coloured polyester tape placed between the stereos and the pipes/sections to be marked. Option of periodical marking can be given with special electronic equipment and an apparatus with pneumatic working. Periodical marking can be set up to three digits. Other models available are: automatic sequential counter with 3- or 4-digits and up to 7-digit coder (hand-operated) colour marking machines. Aeromec Marketing Co Pvt Ltd Thane - Maharashtra Tel: 0250 245 4915 / 3896, Fax: 0250-245 5579 Email: mail@aeromec.in

Gripper systems Neejtech India offers world-class gripper systems from Gimatic SPA, Italy. Gimatic manufactures pneumatic components for plastics and handling like grippers, rotary actuators, linear actuators and pick-&place for many industries. Dynamism, flexibility and fast reaction time are all factors that distinguish our company. The company regularly produces and implements innovative ideas of which it is rightly proud. All Gimatic products are covered with patents. Some of the features include: specifically developed profiles, high flexibility at a reasonable price, each point of the part is attainable, ready-to-use as per design, more than 200 patented products, customised applications, dynamic & flexible, etc. The grippers are used in robots as end arm in industries, eg, automotive, packaging, medical, etc. Neejtech India Ahmedabad - Gujarat Tel: 079-2656 1312, Mob: 098250 40231 Email: sales@neejtech.com 130 Modern Plastics & Polymers | November 2011

PRODUCT S

Crystallising systems With the increased use of PET in plastic processing, the efficient use of amorphous regrind material is critical. A Conair crystallising system allows one to convert amorphous PET to a crystalline state that then can be dried. The drying can occur at elevated temperatures to obtain low moisture levels without the fear of agglomeration. The Conair crystallising systems consist of a high-temperature heat source, an insulated hopper with an agitator and a rotary discharge valve. These can be easily integrated other material handling with equipment. Salient features include: continuous, automatic operation; configuration to meet users' needs; agitating hopper prevents agglomeration; and safe design, convenient clean out, etc. Nu-Vu Conair Pvt Ltd Ahmedabad - Gujarat Tel: 079-3298 5993, 2584 1181 Fax: 09377483203 / 204 / 205 Mob: 093767 83206 Email: sshah@conairgroup.com

November 2011 | Modern Plastics & Polymers 131

PRODUCT S

Additive masterbatches

PVC pipe extrusion units

Blend Colours offers various kinds of additive masterbatches that have desired properties for end users. Their additive masterbatch range includes: UV stabiliser, antistatic, conductive, slip, anti-block, Polymer Processing Aid (PPA), dessicant, flame-reardant, purging compound, antimicrobial, anti-oxidants and foaming agents.

Malik Engineers offer rigid Polyvinyl chloride (PVC) pipe extrusion units for producing pipes for water supply, irrigation and electrical conduits. The unit includes a single-screw extruder fitted with die for PVC pipe, vacuum tank fitted with sizer, water tank, caterpiller take-off, motorised cutting device and seperate control panel for complete machine. The extruder is fitted with nitrided and hard chrome-plated screw & barrel set, DC main drive, gearbox, pulleys, heaters, die, etc. In operation, the PVC dry blend compound is fed into the extruder, where it is heated, melted and forced out of the annular die in the form of hot hollow pipe. This passes through vacuum sizing chamber for proper size as per the OD of pipe desired, and then through the water tank where the pipe is cooled. The pipe thus produced is passed through caterpiller unit, which maintains the pipe straight as it passes through the line, and finally through the cutter where desired lengths are cut. The control panel is fitted with controls for the DC motors of extruder, caterpiller and precision electronic solid state controllers for accurate control of the process temperature and safety devices.These machines are manufactured in screw sizes of 40 mm, 45 mm, 50 mm, 65 mm, 75 mm and 90 mm.

Blend Colours Pvt Ltd Hyderabad - Andhra Pradesh Tel: 040 -2436 1499/ 2436 0887 Fax: 040-2436 0894

Bag making machines Plas Alliance offers PL42BFWFA-V+SL4 rollto-roll bag making machines. The Garbag bag on the roll machines (BFWFA-V+SL series) combines full automatic production to multi-tracks roll. There is no need to wait or to manually operate to change roller. The BFWFA-V+SL series bag making machines can supply side slitting seal to get multi-tracks roll to roll at the same time and good output condition. These machines use the heavy-duty unwind up to 1,000 mm diameter bobbin. The bag making machines take less space, cost less and have many more advantages. Plas Alliance Ltd Chia-Yi Hsien - Taiwan Tel: +886-5-221 7005, Fax: +886-5-221 1929 Email: plas@pal-plas.com

Cartridge heaters Pratik Heat Products offers cartridge heaters. The heating conductor grade NiCr 80:20 is uniformly wound over the supporting core that is located centrally in a SS-304 tube and the inner space is packed with particularly chosen high-purity magnesium oxide. The unit is compressed, thereby converting the core, powder and conductor into a homogenous mass. The base of the heater is welded with a disc washer to avoid contamination. These products are used in marking & sealing machinery, medical & laboratory apparatus, hot runner bushings, packaging industry and shoe making industry. These cartridge heaters are CE certified. Pratik Heat Products Pvt Ltd Mumbai - Maharashtra Tel: 022-2920 0183 Fax: 022-2925 4309 Mob: 09004388444 Email: sales@phpheat.com 132 Modern Plastics & Polymers | November 2011

Malik Engineers Thane - Maharashtra Tel: 0250-239 0839, Fax: 022-2883 0751 Email: info@malikengg.com

Gravure proofing machines Graphic (India) offers JM Heafordâ&#x20AC;&#x2122;s SCOF gravure proofing machine. The open fronted design ensures fast cylinder loading for greater productivity, with additional space around the cylinder for ease of operation. The moving rail and fixed drum design helps consistently print high quality, in register, proofs. The low open fronted rail with load platform and easy lift system ensures that smaller cylinders can be loaded by hand and the design of the load platform and register camera position allows for larger cylinder loading by crane. Processing times vary by user, but it can handle up to 10 cylinders per hour including one substrate change. It incorporates a larger drum, which gives longer proof length and the higher proofing speed improves ink transfer from fine cells. A range of smaller detailed modifications such as addition of a quick change doctor blade, have also been made. The machines are used by both printing companies and cylinder engraving service houses for checking cylinder quality, separations, text and register, producing production quality proofs for customer approval, in-house development work and staff training purposes. Graphic (India) Mumbai - Maharashtra Tel: 022-2261 3151/ 6147, Fax: 022-2262 5300 Email: trs.sanon@vsnl.com

PRODUCT S

Lab extruders Neoplast Engineering offers fully instrumented single-screw & twin-screw laboratory extruders with integrated data acquisition PLC. This machine can be attached to various downstream equipment for carrying out a variety of tests like extrudability of polymers, studying the problems occurring in R&D as well as in practical applications. It is provided with manifold screws, die heads and downstream equipment to fulfil all kinds of extrusion tasks. The sample material is plastified under practice-oriented conditions and extruded through die-head. All measuring values such as torque, melt pressure, and melt temperature are recorded continuously and represented in the form of tables & graphs parallel to the running test. The extruder frame is mounted on four caster wheels with level screw arrangement for fixing it rigidly on the floor. The main motor with AC variable frequency drive and detachable keyboard are fitted with this extruder. For attaching various tools, the barrel flange is provided with hinge-type arrangement for its quick opening, dismantling and screw cleaning. Since the maximum output is just 5 kg/hr, it prevents wastage of expensive material under testing. The maximum processing temperature is up to 40째C, which can be controlled by auto tune-type and dual-display PID temperature controllers. Neoplast Engineering Pvt Ltd Ahmedabad - Gujarat Tel: 079-2583 0602/1185, Fax: 079-2583 5298 Email: info@neoplastindia.com

Coders Process Instrumentation and Controls offers 'Sparsh' coder. It is used to print various statutory information like batch number, date of manufacturing, expiry date, prices and any other information on various packing like tins, container, cartons, lids, stickers, laminated flexible pouches & films, metal containers, etc. It is a small compact intermittent motion reciprocating contact coder with an ink cartridge enclosed in a sealed container to give a constant amount of PIC fast drying coding ink. It is specially used for high-speed coding application viz selfsticker labelling and multi-tracking line, FFS, blister pack and strip pack machine. Its compact design makes it easy to install where space is limited. It can be mounted in any angle, vertical, horizontal or side mounting. Due to separate ink cartridge, it avoids film contamination and keeps the printing area clean. It is a versatile controller, which consist of in-built cyclic timer and five different input modules to achieve or optimise printing speeds up to 180-200 impressions per minute with easy operation. It also runs through external inputs. Process Instrumentation & Controls Vadodara - Gujarat Tel: 0265-235 7228, 232 0756, Fax: 0265-235 5429 Email: batchprinting@yahoo.com November 2011 | Modern Plastics & Polymers 133

PRODUCT S

Desiccant dryers

Dispensing systems

Atlas Copco Compressor Sales offers energy-efficient 'CDX 120-1050' desiccant dryers. Features include low pressure drop and almost negligible power consumption. Reliable performance of the dryers is achieved by massive desiccant overfill, wide desiccant chambers, low air speed design and proper selection of the desiccant. Wide desiccant vessels and optimised flow have reduced the pressure drop to as little as 0.25 bar for smaller dryers. Routine maintenance has been made fast, clean and as simple as possible. Changing the desiccant takes just a few minutes, as the it can be removed and replaced without disconnecting the dryer from the compressor. Standard pressure dew point performance is -40ºC (with activated alumina as desiccant), for more demanding applications -70ºC pressure dew point is available as an option (with molecular sieves). Each dryer of the 'CDX 120-1050' range can operate in 4-16 bar working pressure. Each dryer is also suitable for both G and NPT connection.

AM Spa offers ‘Servo-Flo® 801-HV’ V positive-displacement, two-component meter-mix dispensing system manufactured by Sealant Equipment & Engineering. It is designed to apply small precision beads and small metered shots of precisely mixed resins and provides longer bead lengths and/or an increased quantity of metered shots. The servo-motor design provides consistent and repeatable bead profiles and a change of flow rate during the dispense cycle. The fixed-ratio design improves production rates, product quality and reduces manufacturing costs in micro-dispensing applications. This dispensing system is designed to provide a variety of preset material-dispensing profiles and dispense results ranging from 0.2 cc to 18 cc at 1:1 ratio. It can dispense precisely mixed materials for different part configurations in batch or random processes. It can be preset to vary the flow rate during dispensing in automated, indexing, XYZ-motion and robotic processes. The control accepts operator preset material profiles or electronic commands from the automation.

Atlas Copco Compressor Sales Pune - Maharashtra Tel: 020-3985 2316, 3985 2318, Fax: 020-2714 5948 Email: littlemaster@in.atlascopco.com

Laser displacement sensors

AM Spa Mumbai - Maharashtra Tel: 022-2648 9074, Mob: 98339 32265 Email: anjanitewari@amspa.org

Banner Engineering offers triangulation laser displacement sensors for noncontact height or thickness measurement of a wide variety of materials such as sheetmetal, wood, ceramic, paper, plastic, rubber, foam and baking dough. These sensors provide precise measurement of distance, web thickness and alignment. Applications include hot parts, machined parts, semiconductors & PCBs, shiny or reflective parts and soft or sticky parts. There are three models in the series, with measurement ranges of 25-35 mm, 60-100 mm and 100-200 mm. Thickness is measured by two sensors mounted at either side of the target that automatically synchronise with one another. Up to 32 sensors can be easily combined in a mixed measurement network of multi-track displacement or thickness sensors. The dedicated software application included with each sensor allows easy set up, configuration and software accommodates data logging and monitoring for statistical process control. Output communication is via simultaneous 4-20 mA (16 bit D/A) and RS485 serial connection.

Zambello riduttori Group offers gearboxes for electric injection moulding machines. Its MNP3 is upgraded series from MHP3, which is mainly shorter than the bell connected with motor, and becomes more compact overall. In addition, the new MNP3 series gearboxes are equipped with new cooling plate system up to size MNP3-280. The innovative cooling plate solution is entirely made of aluminium and provided with internal channels used for water circulation. The plate is fitted directly to the cast-iron housing of the gearbox, which offers excellent efficiency and long life. In order to provide a complete solution for customers, the company also supplies the high-performance motor made by Oemer SpA.

Banner Engineering India Pvt Ltd Pune - Maharashtra Tel: 020-6640 5624, Fax: 020-6640 5623, Mob: 93223 39208 Email: salesindia@bannerengineering.com

Zambello riduttori Group Milan - Italy Tel: +39-0331-307 616 Fax: +39-0331-309 577 Email: info@zambello.it

134 Modern Plastics & Polymers | November 2011

Gearboxes

PRODUCT S

Blow moulding machines

Injection moulding machines

Chen Way Machinery Co offers the ABL series blow moulding machines. These are particularly used for producing Jerry can/ drum tank/large articles. These machines can be combined with some accessory equipment to increase the efficiency and expand functions, such as after cooling unit/auto deflashing unit. The die head can stock the melting resin and purge the material for blowing, and its design includes twoheart flow channels. This can make welding line-free to increase the strength of production. The tie bar-less clamping unit consists of the stiff structure frame and guiding devices that ensure deflection-free advantage. Also, the device with precision rack gear of both sides enables synchronised movement of plates. The blow pin unit is designed for production calibrating that will be suited for different demand of customers.

Jon Wai Machinery Work offers Centre Force extra large-size toggletype injection moulding machine. This CF-series fits a centre force and external-acting five-point double toggle clamping to give long efficiency and reliable movement. These machines with large inner tie-rod distance and thickened platen can minimise toggle pressure, lower deformation and increase structure rigidity and reliability. To optimise the production need, the CF-series is used for different types of material and different design of screws. The CFseries are used in automotives, housewares, electronics, appliances and furniture, for any specific demand on production machinery.

Chen Way Machinery Co Ltd Tainan Hsien - Taiwan Tel: +886-6-243-4077 Fax: +886-6-243-4071 Email: chenwaym@ms35.hinet.net

Servo driven robots Shini Plastics Technologies’ ST3 series are specially designed robots for small manufacturing plants. These can quickly and accurately remove finished products from the mould and place in desired location, and can be equipped with special jig for plug-in module assignments. It is suitable for large hot runner mould users. Based on the stoke of the arms, there are three models (STM1-900-1600DT, STM1-1100-1800DT, STM1-13002000DT) available for use with plastic injection moulding machine 200T, 300T, 450T and under 650T. The series has European style streamline, beam, crosswise and vertical arms. It uses servo motor, and with high-precision steel wire belts, cooperates with linear guides to achieve maximum stretching and faster running. Sucker and gripper work with gear rack and gear wheel, which are cylinder driven. External oleo-strut and proximity switch are present in the limit position of the arms that remove products, which has accuracy limit & sucker with a protection device. Customers can adjust the parameters according to their needs. Electrical support uses the enable move design, and is easy to install and maintain. The machine has an intelligent controller and is man-machine interface friendly, easy to operate, has self-diagnostic function as well as triggers alarm for trouble and its cause. Shini Plastics Technologies (Dongguan) Inc Taipei - Taiwan Tel: +86-769-8111 6600, Fax: +86-769-8111 6611 Email: shini@shini.com 136 Modern Plastics & Polymers | November 2011

Jon Wai Machinery Work Co Ltd Kunshan - Taiwan Tel: +86-512 5766 6123-7, Fax: +86-512 5793 2889 Email: jw_kun@163.com

TPE foaming materials Microcell Composite Company (MCC) offers TPE foaming materials. These are comfortable to touch, with conforming physical characteristics and do not involve vulcanisation, which results in excellent flexibility and anti-spreading. These contain electro-insulation compounds and have excellent durability for better acid & alkali resistance. These foaming materials are non-toxic, odourless and harmless to the environment and human body. These meet international environmental standards as well. The wastes generates are completely recyclable and reusable. These can meet individual demands for customers with their adjustable materials. These find usage in shoes, sports equipment, semiconductors, building construction, toys, medical treatment, stereos and products of anti-percussion in the information industry. Microcell Composite Company Tainan County - Taiwan Tel: +886-6-264 1352, Fax: +886-6-249 1692 Email: karen@microcell.com.tw

Business Insights •Technologies•Opportunities

LIST OF PRODUCT

To know more about the products in this magazine, refer to our â&#x20AC;&#x2DC;Product Indexâ&#x20AC;&#x2122; or write to us at spedit@infomedia18.in or call us at +91-22-3003 4684 or fax us at +91-22-3003 4499 and we will send your enquiries to the advertisers directly to help you source better. Sl No Product

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24

Pg No

AC motorr ..................................... 37 Additive.............................................55 Additive masterbatch ......10, 132,COC Air bubble sheet plantt ...................... 91 Air treatment system ........................77 Air-conditioner part...................... t FGF Ammonia liquid chiller..................... r 29 Auto dosing and mixing system .......43 Automotive gripper........................... r 45 Auto vacuum loader.......................... r 43 Automatic leak testing machine .......93 Auxiliary equipment..........................22 Axial flow fan..................................131 Bag making machine ...................132 Barrel..............................................BIC Barrel screw..................................... w 123 BBL/KEC flame proof motorr .......... 37 Bed knife...........................................73 Biodegradable additive......................55 Biodegradable masterbatch ..........COC Black masterbatch ............10, 55, COC Blender..................................... 25, FIC Blending unitt ................................ FGF Blow moulding machine ............93,136

Sl No Product

25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48

Pg No

Blower & fan ..................................131 Blown film extrusion system........... BC Boiler............................................... r 121 Brake motorr ...................................... 37 Brine chillerr .................................... 125 Bulk milk coolerr ............................... 29 Butterfly valve ...................................29 Caloriferr ..................................... 121 Cartridge heaterr .............................. 132 Cast film line ....................................91 Central material conveying system ...43 Centrifugal air blower..................... r 131 Circular weaving loom ......................48 Circular weaving machine.................14 Clean room application.....................31 Cleaning oven ................................BIC Cluster facia ..................................FGF CNC vertical machining centre ........81 Coderr .............................................. 133 Colour additive .................................55 Colour marking machine ................130 Colour masterbatch......10,33,55, COC Compound ........................................55 Compressed air dryer...................... r 107

Sl No Product

49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72

Pg No

Compressed air system .......................8 Compressorr ................................. 8, 131 Compressor air chiller................ r 18,143 Conductive compound .....................coc Conical twin-screw extruder............. r 53 Connectorr ..................................... FGF Continuous screen changer............ r BIC Conveying blowerr ........................... 131 Coolant pipe .....................................87 Cooling pad ....................................121 Cooling towerr ........................... 77, 121 Counter & power supplyy .................... 7 CPVC pipe .................................12; 19 Crane duty motorr ............................. 37 Crusherr ............................................. 43 Crystalliserr ...................................... 107 Crystallising system ........................131 Cutting and stitching machine .........14 Dairy machinery........................... y 29 DC motorr ......................................... 37 Dehumidified air dryerr ................. FGF Dehumidified dryer............ FIC, 39, 43 Desiccant dryerr ............................... 134 Digital panel meterr ........................... 16

November 2011 | Modern Plastics & Polymers 137

LIST OF PRODUCT

Sl No Product

73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127

Pg No

Digital temperature controllerr .......... 97 Dispensing system ..........................134 Door trim ......................................FGF Double shaft gearbox ................99, 124 Drive .................................................97 Drymax air-hot dryer..................... FIC Drymax dryer................................. r FIC Drymax pet-dehumidified dryer.... r FIC Dual channel with modbus...............97 Dust collector system......................131 Dyestuff............................................. f 34 Dynamic controllerr ........................... 97 Electric injection moulding machine 9 Electric solution ................................89 Encoder............................................... r 7 Exhibition Engineering Expo ............... 83,105,112 Exhibition - Imtex Forming 2012..104 Exhibition - Poly India 2011..........144 Extruderr .......................................... 122 Extruder machine .......................23, 35 Extrusion ......................................... BC Extrusion coating lamination plantt .. 91 Extrusion coating line ......................14 Extrusion machinery......................... y 69 Extrusion pump ..............................135 Extrusion system ............................. BC Feeding & conveying system ........107 Filler compound................................55 Finger gripperr ................................... 45 Flame retardant................................. t 55 Flame retardant masterbatch ............10 Flange mounting b5/b35 motor .......37 Fluid..................................................26 Fluorescent........................................ t 34 Fuel burner...................................... r 131 Fully automatic strapping plantt ........ 91 Gear................................. r 26, 99, 124 Gear motorr ........................... 26, 62, 65 Gear pump..............................135,BIC Gearbox.................. 26, 62, 99, 124,134 Geared & flexible coupling............... g 26 Geared motor.................................... r 37 Grain effect masterbatch ................127 Granulator....................... r 107,122, FIC Gravure proofing machine ..............132 Gripper system.......................... 45, 130 Head lamp & tail lamp ..............FGF Heart valve frame .............................27 Heat transfer roll ...........................BIC Helical gearbox .................................65 Helical inline geared motor/reducer... 62 Helical speed reducer................ r 99, 124 High cavitation .................................31 High-performance screw w ............... BIC High-pressure reciprocating air-compressors ...............................129

Sl No Product

128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144 145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176

138 Modern Plastics & Polymers | November 2011

Pg No

High-speed mixerr ............... 23, 35, 125 HM/HDPE/IDPE/IIDPE ..............91 Hopper dryerr ............................. 43,123 Hot air dryer........................... r 39, FGF Humidity & temperature transmitter....................................... r 128 IML technique ............................. 31 Industrial automation........................85 Industrial control & sensing device ....7 Industrial coolerr ................................ 77 Industrial cooling system ................125 Injection and blow moulding machine .....................18,143 Injection mould...............................123 Injection moulding machine ..17,71, 95, 121,122,126,127,133,136, FGF Injection moulding-general..... 123, 126 Injection moulding - multi-componentt ......... 123 Injection moulding - vertical ..........123 Inline drip irrigation plant.............. t 128 Inline drip tubing........................ g 12, 19 Inline shaft mounted helical geared motor.......................... r 62 Intuitive display-revolutionary user interface .....................................57 Invertor/variable frequency drive ........7 Jumbo blown film plantt ................ 48 Knob & switch ..........................FGF Lab extruder................................ r 133 Lamination plant for tarpaulin .........48 Laser displacement sensorr .............. 134 Level controllerr ................................... 7 Liquid ring vacuum pump ...... 126, 131 Loader............................................ r FIC Manual & hydraulic screen changer........................... r BIC Masterbatch ................................10, 55 Masterbatch feederr ........................... 43 Material dryerr ................................... 25 Measuring & monitoring relay for 1ph/3ph ................................7 Medical mould ..................................31 Metal detector & separator............. r 113 Mould sweat protector............... r 18,143 Mould temperature controller........... r 39 Mouldingg .......................................... 31 Mono and multilayer sheet line ........14 Monofilament line ............................14 Monofilament plant .........................48 Monolayer blown film .................12,19 Monolayer blown film line ............. BC Motion control....................................7 Motor................................................ r 37 Mould .........................................23, 35 Mould changing system ..................127 Mould clamp.....................................22

Sl No Product

177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193 194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229

Pg No

MTC .............................................. FIC Multi-component mould ..................31 Multilayer blown film ..................12,19 Multilayer blown film line ........ 14, BC Multilayer blown film plant.............. t 91 Multilayer co-extrusion sheet line ................................... 75, 141 Multistage centrifugal air blower.... r 131 Multi-station ...................................123 NPE 2012 .................................... 20 Oil/coolant coolerr ....................... 125 Oil/gas firing equipment.................131 Online B2B marketplace ...........51,139 Optic sheet extrusion line.........75, 141 Optical brightnerr ......................... COC Panel air-conditioner................... r 125 Paper chemical ..................................34 Paper lamination plant...................... t 48 Paperless recorder..............................16 Parallel & right angle axes gearbox ....9 Parallel shaft helical gearbox.............99 Patented diffusion bonded transducerr57 Pelletiserr ......................................... BIC Pelletiser - dry cut strand type .........73 PET bottling compressor................129 PET box strapping plantt .................. 91 PET masterbatch..............................10 PET perform dedicated machine .....41 PET sheet ................................ 75, 141 PET/PE washing line.......................14 Photoelectric sensorr ............................ 7 Pipeline ...........................................121 Pipe makingg .................................... 123 Planetary gearbox...................... 99, 124 Plastic compound..............................55 Plastic conveyor beltt ......................... 35 Plastic extrusion machineryy ............ 125 Plastic injection moulding machine .............. 21, 22, 131 Plastic processing machine ........14,123 Plastic raw material.........................122 Plastic scrap grinder........................ r 125 Plastic textile and machineryy ............ 59 Plastivision Arabia 2012 ...................24 Plate heat exchangerr ......................... 29 Plug valve ..........................................29 Pneumatic conveying system ..........131 Pneumatic valve ................................29 Polyolefin pipe .............................12,19 Portable loaderr ................................ 131 PP glass-filled compound .................10 PP mineral-filled compound ............10 PP/HDPE - semiautomatic strapping plantt ................. 91 Precision mouldingg ....................... FGF Pressure guage ...................................87

LIST OF PRODUCT

Sl No Product

Pg No

230 Printing and cutting/rewinding machine ...............14 231 Process controllerr .............................. 16 232 Process tankk ...................................... 29 233 Profile controllerr ............................... 97 234 Programmable logic controller....... r 7,97 235 Programmable terminal.......................7 236 Proximity sensor.................................. r 7 237 PU tube.............................................87 238 Pulveriser..................................... r 23, 35 239 Pump ...............................................131 240 Pumping filtering unit vacuum pump ..................................131 241 Push fittingg ....................................... 87 242 PVC clear colour film .....................128 243 PVC flexible braided hose ................87 244 PVC foam core pipes...................12,19 245 PVC mixer coolerr ....................... 12, 19 246 PVC palletising line .....................12,19 247 PVC pipe ............................ 12, 19, 121 248 PVC pipe extrusion unit................. t 132 249 PVC pipe plantt ................................. 48 250 PVC pipe threading machine .........125 251 PVC profile line ..........................12, 19 252 Quick connector.......................... r 103 253 Quick die change system ................127 254 Quick mould change system .................. 103, 127,129 255 Rail tankerr ................................... 29 256 Reclosable packing productt ............ 124 257 Recycled polymer.............................. r 55 258 Recycling line ....................................14 259 Redefining high-end disc performance ...............................57 260 Refrigerant pump..............................29 261 Refrigeration .....................................29 262 Reprocessing plantt ............................ 48 263 Resin .................................................34 264 Resin dehumidifier.......................... r 107 265 RFID...................................................7 266 Right-angled helical bevel-geared motorr ........................... 62 267 Right-angled helical worm-geared motorr .......................... 62 268 Robott ..................................... 130, FIC 269 Rock-n-roll machine...................23, 35 270 Rotary automatic hot colour marking machine .................111 271 Rotary cutterr ..................................... 73 272 Rotomoulding machine ..................124

Sl No Product

273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291 292 293 294 295 296 297 298 299 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319

Pg No

Round table carrousel .......................35 Safety light curtain ......................... 7 Screw............................................... w 123 Screw compressor.............................. r 29 Self-adhesive tape ...........................129 Servo driven robott .......................... 136 Servo energy saving machine ............41 Shaft mounted speed reducerr ... 99, 124 Shut off nozel ................................BIC Side channel blower........................ r 131 Single-/two-stage reciprocating air-compressor........... r 129 Single mill pulveriserr .................. 23, 35 Single-screw extruder gearbox ............9 Single-screw extruder plantt .............. 53 Single-shaft extruder gearbox ... 99, 124 Software for central monitoringg ..... 107 Solenoid valve ...................................87 Spare .................................................73 Spare twin-screw barrel set............. t 137 Special refrigeration equipment...... t 125 Spiral cum helical gearbox ................26 Sprinkler system..............................121 Sprockett .................................... 99, 124 Sprue pickerr ...................................... 45 Stack moulds .....................................31 Switching relay.................................... y 7 Tank & silo .................................. 29 Tape line ...........................................91 Tape stretching line with inverter ...14 Technical mould................................31 Temperature controller............ r 7, 16, 97 Thermoformerr ................................ BC Thermoforming & PS foam ........... BC Thermoplastic alloy........................... y 34 Thermoplastic compound .................34 Thick & wide plastic sheet extrusion line ................... 75, 141 Three-arm bi-axial rotomoulding machine ................23, 35 Timerr .................................................. 7 TPE foaming materials ..................136 TPE/TPU compound.......................10 TPU masterbatch..............................33 Trim handling system .....................131 Twin-screw co-rotating extruderr ...... 27 Twin-screw element.......................... t 27 Twin-screw extruderr ......................... 27 Twin-mill pulveriser.................... r 23, 35 Twin-screw extruder gearbox..............9

Sl No Product

Pg No

320 Twin-screw extrusion line .................53 321 Twin-screw extrusion plant machineryy .............................. 137 322 Two-colour cane plantt ...................... 48 323 Two-layer blown film..................12, 19 324 Two-stage reciprocating air-compressor................................. r 129 325 Ultrasonic flow meterr ................... 16 326 Universal controller........................... r 97 327 Universal masterbatch .......................10 328 UV stabiliserr ................................ COC 329 Vaccum cup .................................. 45 330 Vacuum dryer.................................... r 39 331 Vacuum forming machine............... BC 332 Vacuum loaderr .............................. FGF 333 Vane damperr ................................... 131 334 Variable displacement pump energy-saving machine ...........41 335 Ventilator.................................................... r 129 336 Vibro screen ...........................................23, 35 337 Vision sensorr ..................................................7 338 Volometric dosing unit............................... t 107 339 Walk-away automation ................. 57 340 Water chiller...............................................125 341 Water-cooled reciprocating air-compressorr ............................................129 342 Water ring vacuum pump ..........................131 343 Water chiller...............................................107 344 Welding gun ...............................................121 345 WFR R ......................................................... FIC 346 White masterbatch ......................10, 55, COC 347 Winderr .........................................................48 348 Wire EDM ..................................................81 349 Worm gear....................................................26 350 Worm reducerr ......................................99, 124 351 Worm reducer gearbox .........................99, 124 352 Wovensack tape plant for PP/HDPE..........48

Looking for a speciďŹ c product? We will ďŹ nd the product for you. Just type MPD (space) Name of the Product and send it to 51818 eg, MPD (space) xxxx and send it to 51818.

FIC - Front Inside Cover, BIC - Back Inside Cover, BC - Back Cover

November 2011 | Modern Plastics & Polymers 139

LIST OF ADVERTISERS Advertiser’s Name & Contact Details AB Diachem Systems y Pvt Ltd

Pg No 121

T: +91-11-25155456 E: sales@scalewatcher.in W: www.scalewatcher.in 111

T: +91-250-2454915 E: hvt@aeromec.in W: www.aeromec.in 33

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

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

137

T: +91-09832926696 E: bjsengg@yahoo.co.in W: www.bjsengg.com j gg Battenfeld-Cincinnati Austria Gmbh

T: +91-098207 01960 E: shah.d@battenfeld-cincinnati.com W: www.battenfeld-cincinnati.com Blend Colours Pvt Ltd

Exxonmobil Chemical Asia Pacific

67, 79

FICCI

144

T: +91-44-43009610 E: s.sriram@boge.com W: www.boge.in

Forwell Precision Machineryy Co Ltd

127

T: +91-44-42184295 E: dmeindia@gmail.com W: www.dmeindia.net

T: +886-4-834-5196 E: forwell@forwell.com W: www.forwell.com 126

T: +886-6-595-0688 E: fcsco@fcs.com.tw W: www.fcs.com.tw

T: +86-769-8318-0326 E: info@alfarobot.com W: www.alfarobot.com Elecon Engineering g g Company p y Limited

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

T: +91-2692-236469 E: infogear@elecon.com W: www.elecon.com 133

T: +91-22-32531959 E: vkt@electronicapmd.com p

131

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

T: +91-2717-651551 E: info@ingecogears.com W: www.ingecogears.com

Our consistent advertisers

T: +91-79-22891670 E: sales@konarkplastomech.com W: www.konarkplastomech.com 21

T: +91-9941342299 E: ryanrhee@gmail.com W: www.woojinselex.com FGF

T: +91-44-26812000 E: handigolg@larsentoubro.com W: www.larsentoubro.com 85

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

T: +91-11-30641770 E: prom.lsl@lohiagroup.com W: www.lohiagroup.com 34

T: +91-2717-308000 E: info@loxim.com W: www.loxim.com Madhu Machines & Systems y Pvt Ltd

51, 139

T: +1800-200-4444 / 91-120-3911000 E: pr@indiamart.com W: www.indiamart.com

Ingeco g Gears Pvt Ltd

12, 19

Loxim Industries Limited

IDMC Limited

18, 143

T: +91-265-2353886 E: info@madhu-group.com W: www.madhu-group.com Matsui Technologies g India Ltd

104

W: www.imtex.in 83, 105, 112

Kabra Extrusion Technik Ltd

Larsen & Toubro Ltd

T: +91-124-28124921 E: hinds@rediffmail.com

Indian Machine Tool Mfg. Association

123

L & T Plastics Machineryy Ltd

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

IndiaMART InterMESH Ltd

Jon Wai Machineryy Works Co Ltd

Kotra & Woojin j Selex Co Ltd

T: +91-11-25724865 E: poonam@hindustanplastics.com W: www.hindustanplastics.com 130

Konark Plastomech Pvt Ltd

Fu Chun Shin Machinery Manufacture Co Ltd

Hindustan Plastic And Machine Corporation p 53

Dongguan gg Alfa Automation Machinery Limited

Jagmohan g Pla-Mach Pvt Ltd

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

Hinds Machineries

D & M Enterprises p

T: +886-2-2595-4867 E: infor@jonwai.com.tw W: www.jonwai.com.tw

Glaves Corporation p

Boge g Compressed p Air System y

J.P. Extrusiontech Limited

Pg No

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

Gem Equipments q p Ltd

T: +91-40-24361499 E: info@blendcolours.com W: www.blendcolours.com

Advertiser’s Name & Contact Details

T: +91-2646-222163 E: Iinfo@jpextrusiontech.com W: www.jpextrusiontech.com

T: +91-11-23738760 E: manojmehta@ficci.com W: www.poly-india.in

Avi Additives Pvt Ltd

T: +91-09819552270 E: engexpo@infomedia18.in W: www.engg-expo.com

Expo Centre Sharjah

T: +86-10-5965-7385 E: bo.ding@exxonmobil.com W: www.exxonmobilchemical.com

Alok Masterbatches Ltd

Engineering Expo

Pg No

T: +91-22-67778849 E: sales@plastivisionarabia.org W: www.plastivisionarabia.org

Aeromec Marketingg Co Pvt Ltd

Electronica Plastic Machiners Ltd

Advertiser’s Name & Contact Details

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

T: +91-79-26870825 E: info@mifasystems.com W: www.mifasystems.com w FIC - Front Inside Cover, BIC - Back Inside Cover, BC - Back Cover

COMPLETE ENGINEERING UNDER ONE ROOF @ www.engg-expo.com

140 Modern Plastics & Polymers | November 2011

LIST OF ADVERTISERS Advertiser’s Name & Contact Details

Pg No

Mold - Masters Technologies g Pvt Ltd

T: +91-422-4502171 E: mmiplinfo@moldmasters.com W: www.moldmasters.com N.A. Corporation p

124

107

109

COC

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

113

129

Steer Engineering g g Pvt Ltd T: +91-80-23723309 E: info@steerworld.com W: www.s w teerworld.com

142 Modern Plastics & Polymers | November 2011

T: +91-20-24474303 E: icemktg@indianelectric.com W: www.indianelectric.com 71

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

Unimark (Staubli Faverges g Sca)

Vacunair Engineering Co Pvt Ltd

135

T: +91-11-41613643 E: witte@goodiesons.com W: www.witte-pumps.de FIC

T: +91-44-42077009 E: info@wittman-group.in W: www.wittmann-group.com Xaloyy Asia (Thailand) Ltd

129

125

T: +91-80-23289889 E: info@wernerfinley.com W: www.wernerfinley.com

Wittmann Battenfeld India Pvt Ltd

131

T: +91-79-22910771 E: info@vacunair.com W: www.vacunair.com

Witte Pumps p & Technologies g

123

103

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

Werner Finley Pvt Ltd

T: +91-44-24343343 E: sreelakshmitraders@gmail.com W: www.sreelakshmitraders.com T: +91-44-42994365 E: sspt_plastics@live.in W: www.srisaiplastotech.com

128

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

T: +91-79-65227458 E: info@sanityindia.com W: www.sanityindia.com y

The Indian Electric Co

Unimark (Maguire) g

T: +91-22-23436320 E: samson7@vsnl.com W: www.samson-grp.com

Sri Sai Plasto Tech

T: +91-20-66314100 W: www.premiumtransmission.com Procon Technologies g Pvt Ltd

T: +91-79-22870666 E: sales@saimona.com W: www.saimona.com

Sreelakshmi Traders

TA Instruments-Thermal Analysis

Toshiba Machine (India) Pvt Ltd

W: www.npe.org

T: +91-79-25830112 E: plastics@prasadgroup.com W: www.prasadgroup.com Premium Transmission Ltd

T: +91-7600003968 E: sales@negribossi.in W: www.negribossi.com

Society Of Plastics Industry - NPE2012

T: +91-2692-231070 E: infopbl@elecon.com W: www.pbl.co.in Prasad Gwk Cooltech Pvt Ltd

T: +91-20-26741012 E: makarand.mandke@se-so-tec.com W: www.se-so-tec.com

Sanityy International

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

S+S Separation p And Sortingg Technology Gmbh

Samson Extrusion Ind Pvt Ltd

T: +91-22-26832911 E: lalit@plstemart.com W: www.plastindia.org Plastiblends India Ltd

S&T Engineers g

Saimona Air-Mech Pvt Ltd

T: +91-22-28560450 E: amit.bajaj@piovnindia.com W: www.piovan.com p Plast India Foundation

Remica Plastics Machineryy Manufacture

Sacmi Engineering g g India Pvt Ltd

T: +91-79-25620953 E: info@panchalmachinery.in W: www.panchalmachinery.in Piovan India Pvt Ltd

Rajoo j Engineers g Ltd

Suresh Engi g neeringg Works

Pg No

T: +91-80-23194177 E: india@tainstruments.com W: www.tainstruments.com

T: +91-422-2590810 E: stycm@stengineers.com W: www.stengineers.com

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

125

T: +91-79-25712741 E: remicaplastic@dataone.in W: www.remicaplastics.com

T: +91-9909974224 E: contact@niigataindia.com W: www.niigataindia.com Omron Automation Pvt. Ltd.

Rajj Engineering g g Works

Advertiser’s Name & Contact Details

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

T: +91-2827-252701 E: kcdoshi@rajoo.com W: www.rajoo.com

T: +91-79-26561312 E: info@neejtech.com W: www.neejtech.com Neejtech j India (Niigata) g

75, 141

T: +91-20-65104541 E: raj.engg.wks@gmail.com W: www.rajengg.net

T: +91-79-26561312 E: info@neejtech.com W: www.braunform.com Neejtech j India (Gimatic)

R R Plast Extrusions Pvt Ltd

Pg No

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

T: +91-79-25840374 E: info@naroto.com W: www.naroto.com Neejtech j India (Braun)

Advertiser’s Name & Contact Details

BIC

T: +91-79-27541971 E: m.sanghvi@th.xaloy.com W: www.xaloy.com Yann Bangg Electrical Machineryy Co Ltd

T: +886-4-2271-6999 E: yb@yannbang.com W: www.yannbang.com 27

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

November 2011

146

Modern Plastics & Polymers

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