Modern Plastics & Polymers - june 2013

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EDITORIAL

Eight winning moves… lastics and polymers is an industrial sector that has been surging ahead at a phenomenal pace over the recent years in tandem with the country’s economic prosperity. This sector actually has a higher growth rate than the country’s GDP growth. Truly reflecting an emerging India and promising prospects of its techno-commercial prowess, the turnover of the plastics processing industry is almost reaching the milestone of ` 100,000 crore, with a demand potential of over 12 million metric tonne.

As the number of processing units impressively increases to exceed 50,000, this industry is expected to employ close to 7 million people, directly or indirectly, by 2015.

So much so, it is no exaggeration to state here that the plastic components industry is likely to become larger than the auto components industry by 2020.

Although the Indian plastics industry has come a long way with a healthy growth rate year on year, the current per capita consumption of plastics in the country vis-à-vis the global average indicates large growth opportunities that will only continue in the near future. It is also time for the industry to step up investment and efforts towards capacity building, skill enhancement and application development. A greater focus on green manufacturing practices, technology upgradation and optimisation of operations will take this industry to a higher level of international competitiveness.

The recent government policy of establishing plastic parks in various states across the country will further facilitate the growth momentum and can be the right time for the industry to reinvent itself to cater to the surging global demand.

Against this backdrop, welcome to the 8th Anniversary Edition of Modern Plastics & Polymers, which not only reflects on saving in the fast-evolving Indian plastics scenario but also takes forward this discussion to the next level of engagement among various stakeholders.

Themed ‘The game changers: 8 winning moves to shape success in the plastics industry’, this Anniversary Special brings forth eight important areas that promise strategic impact in enabling the sector to leap into the next orbit. Here’s a quick glance of the spectrum – saving energy, saving material, saving time, manpower management, saving capital, saving water, saving environment and space management. All of these eight sections provide focussed information on emerging challenges and opportunities that we believe will empower you to successfully make the impending transition and add miles to your success journey. After all, eight furlongs make a mile! Have a good read and share with us your valuable feedback.

With a toast to this special edition, we thank all our internal and external stakeholders who have inspired us for the last 8 years. Cheers!

P

Editorial Advisory Board A E Ladhabhoy Plastics Technologist

Dr Sushil K Verma Former Director General, CIPET

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

Mohan K Jain MD, Indoplast & Past President, AIPMA

P P Kharas Chairman, Ecoplast

Raman M Patel Chairman, Industrial Products Mfg Co

Vijay Merchant

Manas R Bastia manas@network18publishing.com

President, Polycraft

June 2013 | Modern Plastics & Polymers

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CONTENT S

In Conversation With

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Dr Asutosh Gor, President, The All India Plastics Manufacturers’ Association (AIPMA)

Anniversary Special 8 winning moves to shape success in the plastics industry 42 Energy savings 54 Saving material 64 Saving time 70 Manpower management 80 Saving capital 90 Saving water 96 Saving environment 104 Space management Facility Visit

Highlights of Next Edition

112

Jain Irrigation Systems Ltd: Fortifying water management systems in India

Special Focus: Thermoforming Insight & Outlook: Plastics in Electronic / Electrical Appliances

REGU L AR SEC T ION S Editorial ................................. 9

Tenders ............................... 116

News, Views & Analysis ...... 22

Event List........................... 118

Technology & Innovation .... 30

Book Review ...................... 120

Technology Transfer ............. 34

List of Products.................. 132

Projects ............................... 114

List of Advertisers .............. 135

Details on page no. 118

Cover illustration and design: Chaitanya Surpur and Sharad Bharekar

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

June 2013 | Modern Plastics & Polymers

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Business Insights •Technologies•Opportunities

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June 2013 | Modern Plastics & Polymers

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NEWS, VIEWS & ANALYSIS

Plastindia 2015 to be held in Gandhinagar, Gujarat, for the first time For the first time, Plastindia Foundation has chosen Gandhinagar, Gujarat, as against New Delhi, as its venue for the country’s largest plastics trade show Plastindia 2015. The forthcoming 9th Plastindia Exhibition & Conference will be held on February 5–10, 2015.

The international standard arena in Gandhinagar is spread over a large area of 1,00,000 sq m, which is 23 per cent more exhibition space.

Bipin Shah, President, Plastindia Foundation, said, “Plastindia 2015 is set to break all past records in terms of number of exhibitors as the visitors are from various leading countries of the world. Nearly 40 nations and 1,25,000 visitors are expected to be a part of this event. The strategic location, requisite infrastructure, industry-friendly environment and vibrancy of the state make it conducive for such an event.

Further, the Gujarat government has been very supportive and has promised significant support with infrastructure and transportation in the future as well.”

Plastindia 2015 will offer a global platform for buyers and sellers from the plastics industry to enhance their business prospects, to establish strategic alliances, technology transfer etc. Showcasing a platform of international standard, Plastindia 2015 will pave the way for intra-industry cooperation and will ensure bridging the gap between international community and Indian enterprises to explore bigger business avenues.

Avani Jain

HPCL board approves JV for ` 37,000 crore refinery and petrochemical complex in Rajasthan State-owned Hindustan Petroleum Corp Ltd (HPCL) has approved the incorporation of a joint venture company to set up a ` 37,320 crore oil refinery and petrochemical complex in Rajasthan.

HPCL will hold 74 per cent stake in the

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Modern Plastics & Polymers | June 2013

Innovations to dominate at the upcoming K 2013

place for viewing innovative technology and trend scouting. The event organised in Mumbai discussed the upcoming edition that is scheduled to take place on October 16–23, 2013, in Düsseldorf, Germany.

In Rugenstein’s address to the audience during her presentation, she spoke about innovative applications that the plastics and rubber industry can

Discussing the developments taking place in the global plastics and rubber industry was the underlining theme at a recent presentation event about K 2013. Organised by Messe Düsseldorf India Pvt Ltd, the event was held in Mumbai and chaired by Eva Rugenstein, Director of Press Department, Messe Düsseldorf GmbH and Dr Rainer Bueschl, Member of K 2013 Exhibitor Council along with other eminent dignitaries such as Bipin Shah, President, Plastindia Foundation; Ajay Desai, Former President, The All Dignitaries on the dais (L–R): Ajay Desai, Bipin Shah, India Plastics Manufacturers’ Eva Rugenstein, Dr Rainer Bueschl and Xavier Rebello Association and Xavier Rebello, Messe Düsseldorf India Pvt Ltd. provide. Elaborating on the upcoming At the event, Dr Bueschl spoke edition, she said, “Surpassing all other about the opening of new markets and trade fairs for the plastics and rubber the increasing competitive pressure. He industry, K offers the biggest and densest stated, “Almost all members of the plastics spectrum of ideas and products. At K industry agree that they want to explore 2013, some 3,000 companies from all existing resources to the fullest while over the world will be showing the trade also increasing production efficiency. public their products and processes in the Maximising output with minimum input categories of machinery & equipment, is the common objective. This can only be raw materials & auxiliaries and semiachieved with a material-oriented product finished products, technical parts & design that focusses on minimum material reinforced plastics. The exhibiting consumption, waste-free production companies are already working flat whenever possible and strategic recycling out to present themselves in the best of the used product whenever viable.” possible light, ie with inspirational Established in 1952, the innovations. The manufacturers of K International Trade Fair for Plastics plastics and rubber products as well as and Rubber, organised by the German their industrial end users will be able plastics industry under the supervision to witness the pinnacle of developments of Plastics Europe Deutschland e.V. and in machine, process and materials Messe Düsseldorf, has become an ideal technology at K 2013.”

9 million TPA refinery and Government of Rajasthan will hold 26 per cent. The unit is planned to go on stream in four years. Besides stake acquisition, the state has given in-principle approval for providing an interest-free loan of ` 3,736 crore per annum for 15 years from the date of commercial production.

The state government has also assured continuous supply of 28 MGD of water

for the project from Indira Gandhi canal and about 3,500 acre of land for refinery, terminal and township near Leelala, Barmer.

The refinery will run on crude oil from neighbouring oilfields of Cairn India. Half of the crude oil requirement at the proposed refinery will come from the Barmer oilfields of Cairn and the rest will be imported.

NEWS, VIEWS & ANALYSIS

Bosch Rexroth inaugurates new plant in Sanand to strengthen presence in India Bosch Rexroth has inaugurated its new plant in Sanand, near Ahmedabad, replacing the previous facility in Vatva, Ahmedabad, thereby increasing the overall square footage at this new location. In order to be able to address the specific regional product and system requirements, the company is not only expanding production but also stepping up sales and development. Overall, the company has invested about ` 280 crore into the expansion of its presence in the region. Going beyond production, the company has plans to develop the Sanand plant into a technology centre. Further, based on the product platforms, the company will develop regional product variations that meet the specific requirements of Indian customers.

WITTMANN BATTENFELD wins medal at Plastpol WITTMANN BATTENFELD, Austria, a leading manufacturer of injection moulding machines for the plastics industry has won a medal at Plastpol in Kielce for the second time. This year, the company won the first prize in the category of machine and process technology for its newly presented In-Mould Internal Welding (IMIW) process.

The IMIW process has made it possible to overmould inserts with gas and watertight sealing. The connection is made directly between the contact surfaces by joining two injection-moulded plastic halves from the inside, using the same plastic material the parts are made of. The finished parts show neither a ridge nor a welding bead, the weld seam has a high load capacity. Barkley, UK, has developed the mould technology and the equipment is marketed by WITTMANN BATTENFELD. At Plastpol, this process was demonstrated by overmoulding an electronic part on an EcoPower 110/350, an allelectric machine from WITTMANN BATTENFELD’s PowerSeries.

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Modern Plastics & Polymers | June 2013

New Bosch Rexroth plant in Sanand The new plant has a total area of about 37,000 sq m, and the production capacity is nearly two and a half times more than the previous one. Bosch Rexroth offers hydraulics, electric drives & controls, pneumatics, linear motion and assembly technology. This expansion will definitely benefit the plastics industry in the state as well as

the country. According to the company, “This step will help us in serving the plastics industry better as our drives & controls find major usage in the plastics industry. These products and solutions help the plastics industry to increase its efficiency in terms of energy savings and maximising output.”

Avani Jain

Star Thermoplastic opens TPR lab

handle large and small orders. The new laboratory gives the company the ability to analyse from a chemist’s perspective any given formulation and either precisely match it or dissect it to determine individual elements in the TPE formulation, tweak it to make it perform better, and in many cases, come up with a better price. The laboratory measures the rheological properties over a full range, including shear and elongation. Thomas A Dieschbourg, Star President, said, “The net result is that we can offer more depth with new or existing formulations, or determine the precise ingredients to make a given grade work for a customer and his application the very first time.”

A division of Star Thermoplastic Alloys & Rubbers Inc has opened a TPR rheology/analytical laboratory at the firm’s Broadview headquarters. The company’s Thermoplastic Division built the laboratory on two floors of the firm’s headquarters facility in Broadview. It invested in the fully equipped, multi-functional laboratory to further increase the level of customer focus, satisfaction and applications support.

Dozens of instruments are included in its additions that cost well into the six figure range. The company has a production line dedicated to producing and testing samples and finished goods.

Star is a provider of thermoplastic elastomers with production lines to

New polyethylene capacity from Chevron Philips in Texas Chevron Phillips Chemical Co LP is forging ahead with a project that will add two PE plants with total annual capacity of 2.2 billion pound. The plants will be located either at the firm’s Cedar Bayou complex in Baytown, Texas, or at its Sweeny facility in Old Ocean, Texas. The total cost of the project is estimated at $ 5 billion. The PE plants are part of a larger project that will install a new ethylene

feedstock cracker – using natural gas-based ethane – with annual capacity of 3.3 billion pound in Baytown.

The project is expected to create 400 permanent jobs and about 10,000 temporary engineering & construction jobs. Chevron Phillips ranks as North America’s largest maker of HDPE with a market share of 20 per cent of annual capacity.

It also ranks fourth in LDPE with an 8 per cent share and sixth in linear LDPE with a 4 per cent share.

NEWS, VIEWS & ANALYSIS

Heubach Colour and Toyo Ink sign JV pact for organic pigments

in the international market, especially Southeast Asia. The commencement of the construction of the JV’s factory is expected to be finished by May 2014, after which commercial production would start

use the most sustainable and eco-friendly process which is a declared philosophy Gujarat-based Heubach Colour Pvt Ltd of both the companies. Heubach’s (HCPL) and Japan-headquartered Toyo global philosophy of sustainable growth Ink SC Holdings signed an agreement to complements well with Toyo’s strategy of establish a Joint Venture ( JV) utilising the synergy between company – Heubach Toyo Colour different products within Pvt Ltd for setting up an azo its group.” pigment manufacturing plant at Soon after commissioning Ankleshwar. The new JV company of the production plant in will cater to their individual needs May 2014, the JV company as well as work closely towards will manufacture, sell and common business objectives of export disazo pigments for new product development and different applications in the leveraging capabilities of global ink industry, primarily printing marketing & sales of organic inks, resin colouring etc. The pigments. The JV will have new management team of the advantage of synergising the JV company, comprising the technological expertise and Katsumi Kitagawa, President, Toyo Ink, and Ravi Kapoor, MD, Heubach Colour members of both companies, experience of Toyo with Heubach’s is constituted, and the sixefficient and sustainable production model with annual capacity of 2,000 tonne. Ravi member team of the new JV company strategically located in India.

Kapoor, Managing Director, Heubach will comprise three members each from The new JV company will facilitate Colour Pvt Ltd, said, “The pigments, Heubach Colour and Toyo Ink. and strengthen Heubach’s presence manufactured by the new JV company, will Avani Jain

ELPIE Engineers bags ‘Certificate of Commendation’ for PP non-woven fabric making machine

Certificate of Commendation In the 3rd National Awards for Technology Innovation in Petrochemicals & Downstream Plastics Processing Industry (2012–2013), a ‘Certificate of Commendation’ was awarded to ELPIE Engineers Pvt Ltd in recognition of the contribution to technology innovation in the category of ‘Innovation of Polymer Processing Machinery & Equipments’ 26

Modern Plastics & Polymers | June 2013

for ‘PP Non-Woven Fabric Making Machine’. This award ceremony was organised by Ministry of Chemicals & Fertilizers, Department of Chemicals & Petrochemicals, Government of India, to promote innovation in the industry.

ELPIE’s PP non-woven spunbond lines offer various customised sizes ranging from 1.6 to 3.2 m fabric width with 12–150 GSM. India’s first indigenous, high-tech and high output PP non-woven spunbond line with 3.2 m fabric width and 450 kg/hr capacity was commissioned successfully in India in 2012 by the company. This machine produces zero wastage as whatever wastage is there is fed to the recycle extruder to make new fabric with allowable variation of ±5 per cent only. Further, the PP nonwoven fabric making machine has energy efficiency of 0.65–0.7 unit/kg, no noise pollution, is environment-friendly and easy to operate with the help of a single touch console. ELPIE dedicates this award to J P Aghera, Technical Director, who is the brain behind the machine and the real achiever.

Avani Jain

WACKER starts new production plant for dispersions in China Wacker Chemie AG officially ramped up its new production plant for Vinyl Acetate Ethylene ( VAE) Copolymer dispersions at its Nanjing site ( Jiangsu Province, China). With the additional 60,000 metric tonne from the second reactor line, the local VAE dispersion capacity doubles to a total of 1,20,000 metric tonne per year. The plant complex is thus one of the largest of its kind in China. At the same time, the Group is currently building a new plant at Nanjing to produce Polyvinyl Acetate (PVAc) solid resins with an annual capacity of 20,000 metric tonne. It is scheduled to come on stream in late 2013. Capital expenditures for both projects will amount to about € 40 million.

The dispersion plant expansion is WACKER’s response to the rising demand for high-quality VAE dispersions, especially in China and Southeast Asia’s emerging markets. The project goal is to ensure sufficient capacities for the strong demand for VINNAPAS® VAE dispersions now and in the years ahead.

NEWS, VIEWS & ANALYSIS

WACKER expands its technical centre in Brazil

ACADEMY training facility, which is also being expanded, is furnished with

and WACKER specialists. With the expansion, the Brazil technical centre Wacker Chemie AG is is increasing its local expertise strengthening its presence in applications technology, in South America and has know-how transfer and service, inaugurated its expanded thereby serving the strongly technical centre, including growing markets for high-quality a training centre near São silicone and polymer products in Paulo, Brazil. The new regional South America. competence centre combines WACKER’s own education research & development, and training centre, the applications technology and WACKER ACADEMY, has also a basic and advanced-training been expanded locally. Training facility for silicone and polymer participants now have access to applications under one roof. a new larger training laboratory Larger training laboratory with state-of-the-art equipment The expansion focusses on the with state-of-the-art equipment, laboratories for polymer binders that are a new practice room and offers an ideal allowing them not only to learn the primarily used in construction chemical platform for industry-specific networking theory but also to perform comprehensive applications. The integrated WACKER among customers, distribution partners practical exercises.

Evco invests $ 4 million in Oshkosh Evco Plastics is planning to spend more than $ 4 million to expand its Oshkosh facility by 30,000 sq ft and add more machinery. “We have several existing customers that have given us new projects and we getting ready for that,” said Dale Evans, President, Evco Plastics.

He said the expansion will boost the size of the facility to 100,000 sq ft and is designed to strengthen and increase the infrastructure so that it can handle larger moulds and bigger equipment and will include a 100 tonne crane.

Evco has had operations in Oshkosh since 1976. It built the current plant

Ravago buys Amco Plastic Materials Resin distribution major Ravago Americas has expanded its presence by acquiring distributor and compounder Amco Plastic Materials Inc of Farmingdale, NY. Amco co-owner and President Gary Metzger will remain with the 57-year-old firm, which will operate under the name Amco Distribution as a division of Ravago Holdings America (RHA) Inc. “Amco will remain as a unique and separate channel to market for distribution,” said Jim Duffy, President, RHA, during his announcement. Amco represents more than a dozen resin 28

Modern Plastics & Polymers | June 2013

in 2003, and the company expects to add as many as 20 employees within the next two years. Overall, Evco has 800 employees in 10 manufacturing plants that span from Deforest and Oshkosh in Wisconsin, to Calhoun in Georgia, Monterrey and Juarez in Mexico and Shenzhen in China.

It has three plants in Deforest, including its headquarters. “The initial stage is $ 2 million, but we expect to spend twice that much when it is all done,” said Evans. The company said that the construction is being handled by general contractor Cardinal Construction Co Inc. suppliers and has annual sales of about $ 150 million. The firm has added at least three sales representatives in the last year and now has more than 90 employees.

Amco also operates 14 compounding lines at an 80,000 sq ft plant in Farmingdale.

Its compounding specialties include compounds for anti-counterfeiting and antimicrobial uses.

For Orlando-based Ravago Americas, it is the firm’s first deal since it acquired resin distributor Performance Polymers Inc of Leominster, Massachusetts, in 2009. Ravago Americas is a unit of the Ravago Group based in Brussels.

Amcor launches lightweight 64-ounce PET bottle Amcor Rigid Plastics has created the lightest 64-ounce hot-fill PET container of its kind, weighing only 59 g. The company developed Powerblock 3.0 technology to make the bottle, which comes with a 38 mm finish, 13.2 per cent lighter than the typical 68-g bottle.

“The Powerblock 3.0 container is a major breakthrough because we achieved a highly sustainable packaging solution without compromising performance.

Our unique lightweight design retained line/stack handling performance and maintained ergonomic features for consumer handling,” said Michael Lane, an Amcor engineer.

Advantages of the Powerblock technology include optimised footprint (width and depth) for improved pallet pattern and corrugate savings. The bottles are also easy for the consumer to handle, the company claims. The firm is currently only using the technology for 64-ounce hot-fill containers but says it will adapt it to other bottles in the future. The stock bottle is currently commercially available in the US. The Valox iQ recycled resins, which are based on PBT incorporating post-consumer PET feedstock, can be used for cosmetics, particularly airless covers.

TECHNOLOGY & INNOVATION

KREYENBORG V-type screen changer for long-term quality In a recycling plant with strand pelletising, the patented KREYENBORG V-type screen changer with integrated self-cleaning function of the screens displays its value on a daily basis. The system was installed over three years ago and continues to perform without error. Despite the high mechanical demands on the system technology, there are no signs of fatigue after more than 51,000 backflush cycles. One cycle comprises the flushing of all four screen cavities, of which there are always at least three in production. The screen changer makes more than one hundred backflush cycles with the same screen pack. Then the screens are changed for security reasons in order to avoid fatigue of the mesh. The purpose of these preventive measures is to prevent the bypass of dirt particles around the boundary edge of the screen packs. If and when the screens need to be changed, the replacement of the screen packs is very simple.

The V-type easily proves its process stability in a strand pelletising line. Strand breaks are a thing of the past when using the V-type because the constant pressure of this machine type offers unequalled opportunities. In recycling applications for medium to high viscosity materials in which economic filtration is required, the KREYENBORG V-type technology provides a robust and durable solution. Furthermore, it provides for an extremely short payback time.

New hot runner for PC glazing from HRSFlow HRSFlow, based in Italy, has developed the Diamond Lux hot runner system for polycarbonate glazing parts, such as headlamp components, quarter windows and sunroofs. The system helps injection moulders meet the optical and aesthetic demands of these automotive applications through a combination of features. The company has achieved thermal optimisation by insulating the mould plates using spacers with low thermal conductivity and addressing power loss in the thermal bridges. All contacts with the mould have been geometrically optimised to reduce thermal power dissipation.

Heater positioning and nozzle tip contact have also been optimised.

Brass sleeve heaters help towards nozzle thermal control. Each heater is dedicated to the thermal control of the gate zone that ensures a more precise and steady process control. These technical solutions ensure a more constant temperature, with a tolerance in the region of 10°C across the entire system. All internal hot runner channels have been engineered to avoid stagnation spots that could cause unacceptable defects in crystal clear lenses.

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Modern Plastics & Polymers | June 2013

Quinn Plastics presents extended range of lenticular products Germany-based Quinn Plastics has extended its range of lenticular products – polyethylene terephthalate glycol sheets for lenticular technology. This dynamic technology leads to unique opportunities to create striking multi-imaging visual printing effects such as Real 3D, animation, zoom, flip and morphing.

Quinn Plastics already offered a 75 LPI grade; this is now supplemented by 60 & 100 LPI grades, as well as a 60 LPI-3D grade. The extended range is suitable for all kinds of standard and special format applications.

The biggest applications for Quinn Lenticular are in advertising and marketing communications, on items such as displays, postcards, posters, POS material, magazine covers, DVD boxes, promotional gifts etc. Features of Quinn Lenticular that make it so attractive for these applications include its brilliant clarity, excellent ink adhesion, high impact strength, good chemical resistance and recyclability. It is also environmentally safe and meets current food contact legislation.

BASF adds variants to compostable plastic ecovio® BASF has once again added variants to its range of the compostable and partially bio-based plastic ecovio®. The ecovio T2308 is now available for the processing method of thermoforming.

For injection moulding, the company offers the new ecovio IS1335 grade. Because the packaging sector is displaying a growing interest in certified compostable plastics, BASF has now augmented its product line by new grades intended for two other significant processing technologies. Both of these products are now available in commercial quantities. They consist predominantly of renewable raw materials and lend themselves well for being dyed.

Thermoformed trays and cups can now be made with ecovio T2308. This plastic exhibits similar mechanical properties to those of amorphous PET, but it differs from this conventional thermoforming material by virtue of its compostability and its high content of renewable resources (polylactic acid). The second novelty in the ecovio product line, viz the injection moulding grade ecovio IS1335, also offers good stiffness. It can be processed using single or multi-cavity moulds that are equipped with or without hot runners. This material exhibits moderate flowing characteristics and is dimensionally stable under heat up to 55°C [131°F]. This variant lends itself for thin-walled, complex and high-quality packaging, which should preferably be manufactured by injection moulding and should be compostable.

TECHNOLOGY & INNOVATION

New anti-microbial masterbatch for moulding

Toray Plastics introduces Torayfan® MWX6

PolyFusion, the Utah, US-based masterbatch maker, has announced an anti-microbial masterbatch that remains permanently active throughout the life of the plastic, PF100. The anti-microbial masterbatch, which can be added in quantities as little as 0.25 per cent, is compatible with polyethylene, polyvinyl chloride, linear low density polyethylene, polycarbonate, polyethylene terephthalate, polyethylene terephthalate glycol, acrylonitrile butadiene styrene and polypropylene.

The active ingredient is a silane functional quaternary ammonium salt which is EPA registered. The material kills microbes by physically rupturing the cell wall. Because the active ingredient is not absorbed into the organism, it will not cause mutations.

The rate of kill is very fast compared with biocides that work by disrupting metabolic pathways after absorption. The material works without leaching silver, chlorinated phenolics or arsenic-based materials.

Further, the anti-microbial agent can withstand temperatures of up to 315°C, and it has been successfully used for adding to injection moulded and extruded materials.

100 per cent recyclable, carbon positive material by Polythene UK

Toray Plastics has launched Torayfan® MWX6 metallised white cavitated Biaxially Oriented Polypropylene (BOPP) film. This new BOPP film is designed with a proprietary, ‘ultra-barrier’ layer on one side for superior moisture and oxygen barrier functionality. The other side of MWX6 film is a hermetic, heat-sealable layer.

MWX6 film can be used as a monoweb or a lamination. It runs on horizontal and vertical form fill seal machines. End users will appreciate the film’s white, glossy appearance that enhances a package’s attractiveness inside and outside.

Besides appealing to consumers, it can contribute to a brand’s success. Available in 100 and 110 gauges (1–1.1 mil), MWX6 film is the ideal choice for packaging salty crisp snacks, baked goods, confectionery items, pet food and frozen foods. Torayfan MWX6 film can also be used for agricultural and chemical packaging.

Polythene UK has unveiled a new 100 per cent recyclable, carbon positive material called Polyair.

The new Polyair material is bio-based. Made from sugarcane, it is the process of photosynthesis that makes this product carbon positive.

Sugarcane actively captures CO2 from the atmosphere while at the same time releasing oxygen, making this material not just green but proactively green.

Polyair can be used across the full product range of bags, covers, tubes, films, wraps and stretch film, giving customers a significantly greener, environment-friendly option. Using a bio-based material, such as Polyair, at a percentage of 60 per cent in film reduces CO2 emissions to 0 per cent even when considering the energy used for manufacturing and shipping.

Further, Polylite can reduce the weight of polythene consumption by 20 per cent, leading to less polythene waste going to landfill, thereby significantly reducing the user’s carbon footprint. When integrated with Polyair, it provides a fantastic solution to tackling the problem of polythene waste.

Smart launches new DS Series Smart Machineries and Moulds Pvt Ltd has come up with the new DS Series Double Station Blow Moulding Machine. The DS Series blow moulding machine has five main variants based on the capacity of bottles/cans (250 & 500 ml and 1, 2 and 5 litre). Similar to the single station machines, these machines can be used to produce a wide variety of polymers such as high-density polyethylene, polypropylene, low-density polyethylene etc. The larger platen area helps accommodate bigger size moulds. The machine is flexible with centre distances of 80, 90, 110 and 150 mm with 2/3/4 parison die heads. The DS Series machines with faster dry cycles (capability of 15 dry cycles/min) result in higher outputs.

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The fully automatic machines are equipped with freely programmable machine controls.

The SMART DS-5 and DS-10 litre machines have proportional hydraulics for optimum energy consumption.

The DS Series machines are user-friendly and have two stations with larger platen area, freely programmable microprocessor controls, heavy duty helical gear box, superior quality mixing screws, continuous single or multi-parison die heads, AC drive, fast dry cycle and power saver hydraulics. The new SMART DS Series is getting excellent response because it enhances the production capacity by 50–60 per cent as compared to the single station machine while also saving energy.

TECHNOLOGY TRANSFER

Technology Offered As part of our endeavour to spread the technology culture, this section provides a means to promote and facilitate exchange of select technologies.

We strive to bring together suppliers of such technologies with suitable users for negotiations and industrial collaboration.

Biodegradable polymers

Forms of transfer

Forms of transfer

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

Equipment supply and turnkey

Technology licensing and turnkey

Pilot plants for small-scale production

Rotational moulding of plastics

Areas of application

Chemical fibres and plastics

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

Forms of transfer

Plastic lightguide fibres

Areas of application

Forms of transfer

A Chinese R&D institute offers to supply the technology of plastic lightguide fibres and handicraft articles made from it. Plastic lightguide fibres are cylindrical fibres with core-clad structure made of two highly transparent polymers, the advantages of which are excellent light transmission, good toughness, lightweight and easy to process and use.

Water storage tanks, material handling trolleys, pallets, containers, chemical storage tanks etc

Technology licensing

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

Areas of application Chemical fibres and plastics

Forms of transfer Turnkey

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

It employs the most cost-effective and efficient washing and drying units for plastic scrap.

Areas of application Plastics manufacturing and plastic waste recycling units 34

Modern Plastics & Polymers | June 2013

A Chinese company is interested in offering small capacity technology for a wide variety of plants such as polyester plant, polyester chip or direct spinning.

Areas of application

Turnkey

Areas of application Photoelectric switches, photosensitive elements, linear accommodation networks, short-distance optical communications and medical & dental devices

Forms of transfer Technology licensing and equipment supply

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

Areas of application Polymerisation and fibre lines

An India-based company, a leading manufacturer of rotational moulding machines, offers plant and machinery for manufacture of water storage tanks and other hollow plastic parts. Rotational moulding is low-cost technology to manufacture large-sized plastic items. It can be used to manufacture water storage tanks of capacity 500–30,000 litre.

Forms of transfer Supply of equipment

Waste plastics conversion A company offers plant technology for converting non-recyclable waste plastics into industrial fuel, which is more sustainable as compared to conventional industrial fuels such as furnace oil or light diesel oil. The company supplies technology to serious clients, who would like to get their waste plastics tested at a demo plant. The plant can be customised for specific requirements.

Municipal bodies, industries involved in generation of non-recyclable plastic scrap, plastic scrap dealers who have access to non-recyclable cheap plastic scrap and entrepreneurs are encouraged.

Areas of application Plastics scrap recycling for industrial fuel generation

Forms of transfer Consultancy, joint venture, technology licensing, turnkey

TECHNOLOGY TRANSFER

Technology Requested Disposal and recycling of plastic waste

Plastic recycling technologies

Areas of application

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

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

Plastics and polymers industry

Areas of application

Areas of application

Forms of transfer

Plastics industry, waste recycling, waste management

Others

Forms of transfer

Polyacetal resins

Others

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

A Vietnam-based company requires technology for recycling plastics.

Diameter of recycled plastic granules is 120–200 mm. Production capacity is 150–300 kg/hr. The technology is to be used for manufacturing plastic products in an eco-friendly manner, with a lowered cost by allowing optimum use of waste.

Plastics recycling

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

Forms of transfer Others

Recycled plastic-making technology

Areas of application Raw materials for making plastic products

Forms of transfer Others

Areas of application

Areas of application

Chemicals/petrochemicals industry

Plastics

Forms of transfer

Forms of transfer Others

Feasibility study, know-how, equipment, turnkey plant, joint venture

PET polyester polyols

Recycled PET polyester polyols plant

An Indian trading-based company is planning a small-scale project for PET polyester polyols manufacturing. The company will procure recycled PET flakes locally, and it already has available land of 28,000 sq ft for manufacturing.

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

Areas of application Polyols

Forms of transfer Others

Utilisation of natural rubber in asphalt A Pakistan-based company requires know-how on utilisation of natural rubber in modified asphalt covering. It requires standards and specifications guiding the use of natural rubber in modified asphalt, appropriate proportion of natural rubber in mixture, handling of the operation, additives needed and details on improvement in asphalt properties by using natural rubber.

Areas of application Rubber industry

Forms of transfer Others

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

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

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

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IN CONVERSATION WITH: Dr Asutosh Gor

“THE INDIAN PLASTICS INDUSTRY HAS ARRIVED ON THE

WORLD STAGE”

Photo: Nachiket Gujar

…confirms Dr Asutosh Gor, President, The All India Plastics Manufacturers’ Association (AIPMA). In a conversation with Sweta M Nair, he speaks optimistically about the future of the Indian plastics industry.

He attributes the projected growth of Micro, Small and Medium Enterprises (MSMEs) to environmentfriendly production capacities, use of automation and formation of favourable government policies.

What is India’s current position in the global plastics industry?

Plastics is a sunrise industry in India.

The demand is only set to increase here.

Currently, the per capita consumption is 8 kg in India, whereas it is about 60 kg in the US and about 45 kg 38

Modern Plastics & Polymers | June 2013

in China. At AIPMA, our focus is on increasing this 8 kg figure to 20 kg per capita in the next five to ten years. This statistic shows immense potential of growth and opportunities for all the entities related to the Indian plastics industry. The raw materials

consumption today is about 8 million tonne; this too is set to double by 2020.

Thanks to globalisation, adoption of homegrown technologies is gaining momentum. It would be safe to say that the Indian plastics industry has arrived on the world stage.

Dr Asutosh Gor

How important is governmental intervention to make India a mass volume player of quality products?

Plastics have become an inevitable part of everyone’s lives. Be it in automotives, consumer durables or medical applications, plastics are driving other industries. I believe it is high time we give plastics its deserved core sector industry status.

We at AIPMA have been vehemently supporting this. Once the core sector status is accorded, the industry can avail various incentives and schemes that are introduced in Union Budgets.

We require governmental support to be a leading player in the global market.

The government needs to monitor and incentivise investments in the Indian plastics industry. Taking a leaf out of the textiles sector, the government could provide technology upgradation funds and schemes for this sector too.

Rising costs of raw materials and energy put constraints on processors.

How does one tackle these issues in a competitive eco-system?

A small entrepreneur has four basic requirements – land, finance, technology and market. Recognising these needs, we have taken the initiative of setting up plastics parks in consultation with various state governments. We are setting up parks in Gujarat, Karnataka, Uttar Pradesh and Madhya Pradesh. Through this initiative, we are offering land at a good price. Due to a tie-up with Small Industries Development Bank of India (SIDBI), companies can get access to finance faster with a lower rate of interest.

Consultants from United Nations Industrial Development Organization (UNIDO) are helping processing units upgrade technology with reasonable capital investment. Trade shows also help in developing the market for all the entities related to the plastics industry.

Cluster development will help individual companies gain a strong foothold.

In this industry, the major costs are associated with raw materials, power and labour. Rising costs are definitely a concern for MSMEs. Indian moulders explore

avenues of improving productivity by reducing in-house waste and increasing energy efficiency. Awareness has brought about these changes. For instance, moulders are now switching over to servo motors to reduce consumption of energy and increase productivity. To survive the competition, moulders will have to apply these techniques.

Doubts have been raised on environmental sustainability of plastics processing units. What is your take on this issue?

Plastics processing units have often been questioned on their environmental sustainability quotient. Operational and feasible models also help the cause of the environment. Even small manufacturers have woken up to this cause. This is where our tie-up with UNIDO comes into play. The process begins with a UNIDO consultant visiting the facility of a particular plastics moulder. After studying the processes in the facility, the consultant presents a gap analysis and points out areas that have scope for improvement in productivity. Many companies have benefitted from the application of suggested techniques within their existing parameters without investing much. Plastics processors should take advantage of these initiatives.

When talking about disposal of plastics, everyone has to share the responsibility, including the end users.

Littering is bad, plastics are not bad per se. Segregation of waste at home is one of the simplest primary ways of initiating a cleaner disposal system. For instance, companies in developed countries are obligated to collect part of their produce to recycle it. Bottle crushers present in most malls in developed countries encourage consumers to recycle; this is a fantastic mechanism against plastic bottles that end up in landfills. We could use such techniques in India too.

What programmes are being conducted by the Association to address the evolving needs of this segment?

AIPMA recently conducted a job fair in Mumbai, the first of its kind by

any polymer association in India. The objective was to provide the industry in the manpower arena with a non-commercial, service-oriented and cost-effective model. Fourteen visiting employer companies, ranging from segments such as raw materials, compounds/additives, injection moulding, blow moulding, rotomoulding, extrusion (pipe & blown film) and machinery manufacturers, participated in the fair. The fair floated about 80 job openings, of which 90 per cent job openings demanded 2–15 years of experience. AIPMA addressed the job requirements and matched befitting candidates with employers. Following the overwhelming response of this event, we aim to make it regional. So far, Bengaluru, Chennai and Delhi are on our radar. The next fair in Bengaluru might be held in a couple of months. Further, trade shows are another avenue for gaining overall development. Organised by AIPMA, Plastivision is a renowned exhibition for the plastics industry in India. In the last edition, the trade fair witnessed visitor footfalls of close to a lakh. Last year, this trade show went global when we organised the first Plastivision Arabia at Sharjah Expo Centre. These initiatives help Indian MSMEs evolve with the changing times.

As President of a premier plastics association in India, what areas are included in your agenda?

Based on AIPMA’s commitment to the plastics industry, we continue to work on several projects. At a personal level, I would like to see the industry upgrade itself technologically. Manufacturers need to have a holistic approach as far as the environment is concerned. International markets and new applications are areas of much potential. Building new ‘waste to wealth’ models is part of my agenda.

However, this segment will receive a push only when capital investment in waste management is exempt from all types of taxes. Based on suggestions made by the Association, we expect to receive support from the government.

Email: sweta.nair@network18publishing.com

June 2013 | Modern Plastics & Polymers

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ANNIVERSARY SPECIAL

8 winning moves to shape success in the plastics industry

Saving Energy Motors & drives: Reducing energy consumption in injection moulding .....................................................................42 Hot runner systems: Moulding in an energy-efficient manner....................................................................................44 Interface - Rajiv Trivedi, Vice President (Marketing), Prasad Group and Chairman, Indian Plastics Institute - Ahmedabad Chapter ........................................................................................48 Khushboo Doshi, Executive Director, Rajoo Engineers Ltd .....................................................................50 Roundtable - How efficient are Indian processors in adopting global energy-saving techniques? .............................52

Saving Material Polymer processing: Minimising imports to maximise profits.....................................................................................54 Innovation and quality: Widening the scope for efficient plastics ...............................................................................56 Interface – Surinder Minocha, Managing Director, Minocha Enterprises Pvt Ltd ...................................................60 Roundtable - Does the Indian polymer industry have the potential to benchmark international standards? .................................................................................................................................................62

Saving Time Silent time savers: Right tooling for faster performance ..............................................................................................64 Sustainable processes: Need for industry–government collaboration ...........................................................................66 Interface – Manish Pathania, Sales Director, Greendiamz Biotech Ltd ....................................................................68

Manpower Management Managing workforce: Of man and machine .................................................................................................................70 Skill development: Fostering talent to meet requirements ...........................................................................................72 Interface – Amit Kalra, Director, Hindustan Plastic & Machine Corporation ..........................................................76 Roundtable - Do plastics processors have access to effective skill management techniques and programmes? .........................................................................................................................................78

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Modern Plastics & Polymers | June 2013

ANNIVERSARY SPECIAL

Saving Capital Cost-effective processing technology: Saving time, improving output ..........................................................................80 Cost efficiency: Integrating international techniques ....................................................................................................82 Interface – Jayesh Khimji Rambhia, Chairman, Plastic Parks & Projects, The All India Plastics Manufacturers’ Association (AIPMA) ....................................................................86 Herbert Kraibühler, Managing Director – Technology & Engineering, ARBURG GmbH + Co KG .....88

Saving Water Effective water management: An eye towards recycling ................................................................................................90 Interface – Umakant Sharma, Head – Sales & Marketing, Matsui Technologies India Ltd.......................................92 Vishal Jasrapuria, Director, Shree Sadguru Plastic Industries .....................................................................94

Saving Environment Waste management: Addressing environmental concerns .............................................................................................96 Plastics recycling: Mapping the challenges and opportunities ......................................................................................98 Interface – Pramthesh Pandya, Head - Unit & Business Development, Parikh Packaging Pvt Ltd ........................100 Apurva Kane, Senior Vice President, Mamata Machinery Pvt Ltd ......................................................... 101 Roundtable - How proactive are government policies towards environment-friendly plastics processing? ................103

Space Management Compact machinery: Less is more! .............................................................................................................................104 Minimalism in manufacturing: Managing space and machinery ................................................................................106 Interface – Raj Singh Rathee, Managing Director, KUKA Robotics (India) Pvt Ltd ..............................................108 Parag N Dave, CEO, Dave Technical Services .........................................................................................109 Roundtable - How does the engineering prowess of compact machines translate to manufacturing benefits? ................................................................................................................................................ 111

June 2013 | Modern Plastics & Polymers

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SAVING ENERGY: Motors & drives

Reducing energy consumption in injection moulding A rise in the price of energy is a crucial issue in plastics processing, including the injection moulding industry. This has drawn the attention of processors to the motors and drives used in the machines that consume the maximum energy. Avani Jain analyses ways of reducing energy consumption in the injection moulding process through the use of energy-efficient motors and drives.

A

pproximately twothirds of the energy costs in plastics processing, including injection moulding, is the result of energy consumed by motors. The motors in the main processing equipment such as compounders, moulders and extruders are obvious, but the majority of motors are hidden in other equipment such as compressors, pumps and fans. Thus, in order to ensure energy efficiency, the selection of motor and drives is important. Unlike the old motors that consumed much energy, the High-efficiency Motors (HEMs), Variable Speed Drives (VSDs), digital displacement pumps and servo motors greatly help in increasing cycle times and reducing energy usage.

Praveen Sharma, Managing Director, Hinds Plastic Machines Pvt Ltd, notes, “At present, there are an umpteen number of innovations happening in the injection moulding machinery segment for improving the quality of machines. In fact, we were one of the first manufacturers in North India who introduced the

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servo-controlled ram type injection moulding machine in 2009, which saves energy up to 40 per cent.�

Motor management policy When the running costs increase over the initial purchase price, it means that companies need to change the way they look at motors that consume the maximum energy. Thus, in order to reduce costs, companies must develop and implement a motor management policy for the purchase and operation of motors. This policy should include guidelines on purchase, repair and replacement based on lifetime costing of the motor. Repairing a failed motor may be a cost-effective action in the short run but can reduce energy efficiency by up to 1 per cent. It may also not be the most economical long-term action. Thus, an efficient motor management policy is the need of the hour.

Motor sizing Motor sizing assumes importance as a correctly sized motor also helps in

Courtesy: Kone Corp

reducing energy consumption.

Motors run most efficiently close to their design output. Motors are most efficient when their load equals, or is slightly greater than, the rated capacity. If machines larger than needed are purchased or used, then the motor will not reach the design load and will never run at optimum efficiency.

Oversized motors are inefficient, and equipment needs to be carefully matched with the demand. The size of motors depends on various factors. You decide on the size of the motor well in advance, ie during the design stage. Any error in selecting the correct size of the motor may result in heavy wastage of energy.

Motors & drives

High-efficiency motors HEMs consume approximately half of the energy used by conventional motors. In addition to energy savings, better designs and improved construction of HEMs can lead to various other benefits. Initially, these motors were highly priced, but now the cost has reduced and can easily be forgone for the fact that they help in saving on the energy cost. HEMs can achieve efficiency levels of up to 3 per cent more than conventional motors and have a peak efficiency at 75 per cent of load, thus reducing both energy costs and oversizing problems. A HEM is not very different from the normal motor, but manufacturers have developed it in such a way that it consumes much less energy than the conventional motor.

Variable speed drives The speed of an AC motor is fixed by the number of poles and the supply frequency. As a result, the hydraulic pumps in many processing machines are driven at a constant speed, even though the demand varies considerably during the cycle. Flow demand changes from the hydraulic pump are controlled by a relief valve and recirculation of the hydraulic fluid. Another way of meeting the varying demands is to fit a VSD to the motor. The VSD can serve as a good option for energy efficiency, as it allows the speed of an AC motor to be varied and the pump output can be matched to the variable demand.

Because VSDs enable the manufacturer to increase or decrease the speed as per requirement, energy consumption is bound to reduce remarkably during the injection moulding process.

In addition, a reduced demand on the hydraulic system means that the hydraulic oil runs at a lower temperature and requires less cooling, which can serve as an additional cost-saving measure.

Further, VSDs require less maintenance cost. A VSD can also be applied to fans, water pumps and air compressors where the load varies considerably.

Digital displacement pumps These also help in attaining energy efficiency. A digital displacement pump is a

hybrid device that combines reciprocating hydraulics with micro-processor control, creating a highly integrated machine capable of producing variable flow and power. The advantages of this pump/ motor over conventional techniques lie on the response speed and the inherent energy efficiency.

Servo motors Companies are increasingly using servo motors for energy efficiency. The servo motor only drives the shaft required for the moulding process, creating a direct exchange of energy and ensuring reduced energy consumption. Sharma avers, “The existing normal electric/fuel-driven motors transmit power to various points of movements through gears, chains, belts and pulleys, which are heavier and bigger. On the other hand, in the servo motors, all movements in the machine are powered by appropriate size of motors controlled by drives and sensors, which are smaller, lighter and convenient.”

These are better than VSDs, as in case of a VSD, the motor is continuously working, but in a servo motor, the motor stops when there is an idle cycle, ie the whole motor will stop automatically, so there is no energy consumption during that time. Moreover, the response time for reducing or increasing the desired levels is higher in VSDs as compared to servo motors, where the desired levels are achieved in a matter of five seconds. Thus, servo motors give more accurate results than VSDs. Further, these motors help in reducing cycle times, thereby increasing the speed. Thus, the servo drive facilitates high-energy efficiency, accuracy, precision and good control.

Hitesh R Shah, Business Head – Injection Moulding Machines, Windsor Machines Ltd, notes, “These days, servo motor-driven geared pump machines are increasingly used as the geared pump offers highest efficiency of transmission. This, when used with servo motor feedback and drive, offers the best response level of actuators resulting in high repeatability and highest power cost savings.”

Email: avani.jain@network18publishing.com

At present, there are an umpteen number of innovations happening in the injection moulding machinery segment for improving the quality of machines.

Praveen Sharma Managing Director, Hinds Plastic Machines Pvt Ltd

Servo motor-driven geared pump machines are increasingly used as the geared pump offers highest efficiency of transmission.

This, when used with servo motor feedback and drive, offers the best response level of actuators resulting in high repeatability and highest power cost savings.

Hitesh R Shah Business Head – Injection Moulding Machines, Windsor Machines Ltd

June 2013 | Modern Plastics & Polymers

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Courtesy: Husky Injection Molding Systems Ltd

SAVING ENERGY: Hot runner systems

Moulding in an energy-efficient manner With intensifying global competition for moulding plastic parts, the pressure is rising on reducing per piece moulding cost and energy consumption in the injection moulding process. This has increased the demand for hot runner systems. Avani Jain analyses the benefits of hot runner systems for reducing energy consumption during the plastics injection moulding process.

K

eeping in mind the energy concerns at present, the demand for hot runner systems is growing by the day.

A hot runner system is one of the important enhancements that manufacturers can incorporate into their mould to improve moulded part quality, reduce production times & energy usage and remain price competitive.

Rajendran Kasi, Regional Manager – SAARC Nations, Husky Injection Molding Systems Pvt Ltd, says, “Demand for direct gating of plastic parts is increasing. Hot runners are replacing cold runner technology, thus allowing customers to run faster cycles and achieve more efficient production.

In fact, the hot runner industry is growing faster in comparison to the overall plastics industry.”

Functioning of hot runners A hot runner system is an assembly of heated components used in plastics injection moulds that inject molten plastics into the mould cavities. It usually includes a heated manifold and several heated nozzles. The main task of the manifold is to distribute the plastic 44

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material entering the mould to various nozzles, which then meter it precisely to the injection points in the cavities.

Hot runners are one of the most sophisticated components of an injection mould – a key technology in achieving an efficient injection moulding process that has a direct impact on profitability and part quality.

Kasi notes, “Decreased energy consumption can be achieved through two ways. First, better insulation, which enhances energy efficiency by using appropriate materials with low thermal conductivities in places where hot steel touches the cold plate. Second, more efficient heaters and the use of electrical actuated valve stems versus pneumatic or hydraulic actuation systems.

This can be achieved through the use of hot runner systems.”

Hot runners are fairly complicated systems. These runners have to ensure that the plastic material inside is heated uniformly, while the remaining part of the injection mould is cooled in order to solidify the product quickly.

Types of hot runner systems Hot runner systems are of two main types – insulated and heated.

Insulated runner moulds have oversized passages formed in the mould plate. The passages are of sufficient size through which, under conditions of operation, the insulated effect of the plastic (frozen on the runner wall) combined with the heat applied with each shot maintains an open, molten flow path.

For heated runner systems, there are two designs – internally heated and externally heated. In the internally heated system, the plastic material flows directly over slender heaters inside oversized runners. This system takes advantage of the insulating effect of the plastic melt to reduce heat transfer (loss) to the rest of the mould.

On the other hand, the externally heated system consists of a cartridgeheated manifold with interior flow passages. The manifold is designed with various insulating features to separate it from the rest of the mould, thus reducing heat transfer (loss).

Husky has made many changes in their hot runner systems to help moulders achieve maximum energy efficiency. Kasi notes, “Two of our recent developments help reduce overall energy consumption

Hot runner systems

Hot runners are replacing cold runner technology, thus allowing customers to run faster cycles and achieve more efficient production.

In fact, the hot runner industry is growing faster in comparison to the overall plastics industry.

Rajendran Kasi Regional Manager – SAARC Nations, Husky Injection Molding Systems Pvt Ltd

Hot runner systems offer high rates of efficiency and productivity. Most notably, these cut production costs dramatically. The elimination of cold runners makes hot runners the preferred solution for clean room production and for achieving energy efficiency.

Amit Mahant Director, PK Plastic International Pvt Ltd

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to a large extent in the injection moulding process. The electric actuated valve gates consume more than 70 per cent less energy as compared to a similar pneumatic or hydraulic actuation system.

Further, our new side-gating technology allows customers to direct gate plastic parts that previously would have to be gated with a cold runner.”

Amit Mahant, Director, PK Plastic International Pvt Ltd, says, “Hot runner systems offer high rates of efficiency and productivity. Most notably, these cut production costs dramatically. The elimination of cold runners makes hot runners the preferred solution for clean room production and for achieving energy efficiency.”

Shorter cycle time, reduced energy usage

Hot versus cold runner systems

The cycle time of any mould is largely influenced by the cooling cycle – how fast the resin can be sufficiently cooled so that the part can be ejected without permanent deformation. The usage of hot runners systems help in reducing the overall moulding cycle by individual time reductions of the various processes involved, thereby contributing to increased output per unit time. The shorter cycle time also results in less energy consumption.

Thus, although there is a more expensive capital investment upfront, a hot runner system is a significantly more cost-effective means to keep production costs to a minimum over the long run and reduce the energy consumption to a large extent.

Hot runner systems help in better energy savings as compared to cold runners. Kasi avers, “With cold runner tools, a significant amount of resin needs to be melted just for the purpose of filling the cold runner to reach the cavity. Even if re-used, this resin serves no other purpose than to transport the resin to the cavity. In contrast, with a hot runner mould, the amount of resin required for filling the cavity is prepared in the injection unit and leads to reduced shot volume. Further, cold runners often have a higher pressure drop compared to hot runner moulds.

The extra energy (higher machine pressure) required to fill the cavity with a cold runner is wasted as the pressure drops. This is not the case with the hot runner system.”

Additional advantages

Future outlook

Because there is no cold runner to discard or recycle, resin consumption is reduced.

Hot runner systems also help reduce the labour cost. Secondary operations, such as manual part de-gating and trimming, are eliminated with a hot runner system.

Further, they help in mould cost savings, as a smaller cavitation hot runner-equipped mould may be able to satisfy production quotas using a smaller number of cavities because it runs at a faster cycle. Hot runners allow reduced injection pressures during packing, as the system does not have to deal with injecting resin through a cooled runner.

Thus, the use of hot runner systems not only improves the energy efficiency to a large extent but also offers other benefits.

Despite the high initial cost, the long-term benefits of equipping a mould with a hot runner system can be easily justified. In fact, in the future, plastics moulders will focus on maximising productivity and efficiency through the use of hot runner systems.

Kasi concludes, “When compared to cold runner technology, hot runner technology helps customers achieve this goal by allowing parts to be produced at faster cycle times and with less resin.

In addition, increasing labour costs are driving the need for more automation and precision. Therefore, hot runner systems are a key technology to achieve a higher degree of automation, productivity and precision.”

Email: avani.jain@network18publishing.com

SAVING ENERGY: Inter face - Rajiv Trivedi

“Electricity cost is among the highest cost incurred in the plastics processing segmentâ€? ‌opines Rajiv Trivedi, Vice President (Marketing), Prasad Group and Chairman, Indian Plastics Institute Ahmedabad Chapter. In a conversation with Avani Jain, he underlines the strategies that can be adopted by plastics processors for achieving energy efficiency. He also underlines how ancillary equipment can help in this regard.

How important is it for plastics processors to adopt energy efficiency measures?

At present, energy efficiency is the main concern of customers and manufacturers.

In fact, customers would not mind paying a high price for an energy-efficient machine. This is because today electricity cost is among the highest cost incurred in the plastics processing segment, and in order to survive, they need to deal with this issue at the earliest.

What are the energy saving methods adopted by plastics machines manufacturers?

There are various ways and means for saving energy. These days, manufacturers are adopting latest technologies such as servo-based systems, programmable logic controllers and variable drives for energy efficiency. Further, proper screw and die design can help in saving energy. Manufacturers are using these technologies in machines irrespective of the high cost as they greatly help in saving energy.

How is the demand for ancillary equipment in the plastics processing machinery segment?

The demand for ancillary equipment is high in the plastics processing machinery segment. Earlier, ancillary equipment 48

Modern Plastics & Polymers | June 2013

was considered a luxury; however, they are now a necessity and a very important part of machines because they help in achieving energy efficiency to a very large extent. Even the rising demand for automation in the machinery segment has provided a boost to the ancillary equipment sector.

can control the entire process. Robotics has also helped increase productivity.

We have developed the SCADA system and are working towards decreasing the energy consumption of machines.

How does ancillary equipment help in increasing energy efficiency and overall productivity?

The plastics industry is growing at a very fast pace. The consumption of plastics is increasing in the flexible packaging, cosmetics and white goods industries. Further, major cement plants and fertiliser producers in India are expanding their production capacity at a faster rate. This is creating a good demand for raffia bags, carry bags etc. Also, the pharmaceutical sector is growing at a fast pace in India. All this is leading to an increasing demand for plastics. The future also seems bright with the automotive segment growing at a very fast pace. Thus, if the plastics industry in India needs to compete with its global counterparts, then it needs to fight against anti-plastics lobbies by creating awareness and emphasising on recycling and energy efficiency. If the concerns related to energy efficiency are resolved at the earliest, then surely the Indian plastics industry can touch new heights in the times to come.

Email: avani.jain@network18publishing.com

These days, it is required of all plastics processing machines to generate higher output with less consumption of resources and energy. In order to do so, ancillary equipment is a must. Various processes are involved in converting raw material to finished products, such as storage, handling, drying, conveying, colouring, cooling, heating, counting, grinding and recycling. For performing these functions, ancillary equipment, such as chilling plants, mould temperature controllers and drying systems, assume much importance as these help in enhancing productivity and improving quality.

Further, the advent of automation has led to the popularity of ancillary equipment, which in turn has helped in decreasing the dependence on manpower. The development of Supervisory Control and Data Acquisition (SCADA) systems is one of the ways, as now an individual

How is the plastics industry fairing in the country, and what would be the future trends?

SAVING ENERGY: Inter face - Khushboo Doshi

“For energy efficiency, economy of scale coupled with automation is the need of the hourâ€? ‌opines Khushboo Doshi, Executive Director, Rajoo Engineers Ltd. In a conversation with Avani Jain, she underlines the need for automation technology to improve energy efficiency. She also talks about the steps that can be taken by the industry for energy efficiency.

In the present times, how important is it to save energy and how much importance is given to this issue by the plastics industry?

Becoming more energy efficient is an important first step to reduce our impact on the environment. Energy efficiency is also a non-controversial issue and improving efficiency means encouraging innovation and technology, creating jobs, reducing our dependence on non-renewable resources and saving money. If we talk about the plastics industry, then in the present scenario of rising environmental concerns, it is very important for the industry to develop energy-efficient machinery to conserve resources.

What are the recent trends related to energy efficiency in the plastics processing machinery manufacturing segment?

When it comes to energy efficiency, economy of scale coupled with automation is the need of the hour.

Currently, the level of automation in the Indian plastics machinery industry is quite low due to high investment levels required in such automation.

However, in the global market, plant capacities are high, thus justifying high investment in automation technologies.

Slowly and gradually, the situation is 50

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changing even in India and the benefits of automation are being understood and appreciated by processors. There are several benefits offered by automation such as lower wastage levels, consistency in product quality, lower labour cost and easier process control. Basically, it helps in reducing consumption of polymers at the source itself by reducing wastage levels. This also helps in reducing the need for recycling activities that are energy intensive. In addition, if we talk about thermoforming segment, then trends in automation include temperature control, multiple axis servo control and automatic stacking.

What are the leading innovations making headway in the segment?

Increasing the efficiency by design improvement of hot parts such as die and screw, keeping in view the polymer rheology, is the way ahead in the machinery segment. In fact, we can get more output with same size of the screw and same motor rating by just improving the screw geometry as compared to the conventional design.

How does your company address the issue of saving energy?

As a machiner y manufacturer, technology upgradation is the only way

for us. We are well known for bringing world-class technology at the door step of the Indian industry. We have introduced latest automation techniques such as material conveying, multicomponent gravimetric blending, gravimetric dosing for GSM control, temperature control, history logging, recipe and process parameter recall, thickness control and integrated supervisory process control for saving energy in terms of power consumption and manpower cost. In fact, we were the first company to introduce automation in blown film extrusion in India 15 years ago. We have also been successful in marrying our indigenous hardware with automation technology sourced from Europe. Since then, we have supplied machines with advanced automation both in India and overseas.

Other machinery manufacturers have followed suit, and thus, the demand and understanding of this technology among processors have also increased. Further, the unit plant capacities have increased, thus justifying high investment for energy-efficient machinery.

What will be the future trends in the segment?

The technology will further evolve in reducing start-up wastage, reducing thickness tolerances in high output lines, more efficient use of melt capacity to increase finished product outputs, quality and, most importantly, there would be an increase in energy efficiency measures taken by companies in the segment.

Email: avani.jain@network18publishing.com

SAVING ENERGY: Roundtable

HOW EFFICIENT ARE

INDIAN PROCESSORS IN ADOPTING GLOBAL

ENERGY-SAVING TECHNIQUES? With rising concerns on energy efficiency, the industry is realising the need of adopting measures for saving energy. Avani Jain speaks to industry experts to find out the efficiency of Indian processors in adopting global energy-saving techniques.

Mahendra N Patel Chairman, Mamata Group

Due to the high cost of energy, technical advancements are oriented towards reducing energy consumption in the plastics processing sector. Thus, many changes are made to machinery for improving the energy efficiency and speed. There are constant efforts to make machines energy efficient through all-electric drives, servo drives, AC variable drives, improved temperature controls, insulation etc. All-electric machines are the latest development in the plastics processing machinery sector.

Further, new processing techniques that reduce energy consumption and moulding time are being developed.

Thus, almost all the leading plastics processing machinery manufacturers in the country are offering technologies that can stand the competition faced from foreign companies. Presently, as a Group, we are focussing more on energyefficient technologies, with my company Mamata Energy dealing in this area.

Thus, Indian processors are continuously working towards adopting global energy-saving techniques.

Editorial take:

Shirish V Divgi Managing Director, Ferromatik Milacron India Pvt Ltd

If we talk about efficiency of Indian processors in adopting global energysaving techniques, then I would rate them six out of ten, which means that there is a long way to go. However, slowly and gradually, the industry is realising the importance of energy efficiency, and everybody is working towards it. Almost all the customers, whom I meet ask just one question – “How to save energy?”. So, changes are being made in machines to ensure energy efficiency to a very high level.

At an operational level, we need to employ all possible steps to reduce energy such as using solar energy, day light, water conservation etc. We also have to provide solutions to customers with products consuming optimum energy. Ferromatik Milacron India has been following this principle for many years not only in many operational areas but also through our products.

Thus, we are continuously making machines that can save energy for our customers, and our new machine series can save nearly 30–40 per cent energy.

Anand Panchal Marketing Director, N A Corporation (NAROTO)

The plastics processing segment, including rotomoulding, is growing at a fast pace. With this growth, the need for energy efficiency is also increasing, keeping in mind the high rates of power and fuel. Thus, companies in the segment are adopting steps to increase energy efficiency. They are gradually adopting global energyefficient techniques. In rotomoulding, the future trend will focus on minimising the production cost in energy consumed by using better cooling media/programmable logic controller systems, improving oven thermal insulation to reduce heat loss, improving air circulation to reduce resin sintering time, reducing mould cooling time to increase production and using clamping devices rather than conventional nuts & bolts for quicker demoulding. Thus, as plastics processors strive to achieve economies of scale, efficient technology, energysaving measures and green innovations will go a long way in deciding the industry’s future.

Email: avani.jain@network18publishing.com

High energy costs and the demand from customers have forced the plastics industry to adopt energy-efficient measures. This has lead to development of servo motors, all-electric injection moulding machines, programmable logic controller-based systems and more. Although the steps taken by the Indian plastics industry towards energy efficiency are remarkable, there is a long way to go when it comes to adopting global energy-saving techniques.

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SAVING MATERIAL: Polymer processing

Minimising imports to maximise profits Polymer manufacturers across the country have geared up to meet international standards in terms of quality at affordable prices. The polymer processing industry, however, needs to complement these efforts with more research initiatives in order to create a global brand appeal for the Indian plastics industry and keep imports to the minimum. Anwesh Koley looks into the various aspects of the polymer industry in India and the way forward.

Plastics in packaging Plastics for the packaging industry have greatly evolved in the past decade. “We have witnessed a shift from the traditional materials of

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Courtesy: BASF

T

he polymer processing industry has grown favourably well in the last 8–10 years. The annual growth rate has always been in double digits except for the last few months where external influences had taken a toll on this trajectory. The best thing about the Indian plastics industry is that it is more domestic demand driven rather than relying heavily on exports like China. Growth is taking place across all sectors in the polymer industry, and many investments for plastics have occurred in the automotive industry.

India is now seen as a hub for the automotive industry, and the plastics industry has complemented this sector appropriately. Ravi Kumar, Director, Shiv Pooja Plastics, says, “The current trend is to use more of plastics in automobiles as it substantially increases the powerto-weight ratio. The increased usage of plastics not only helps in reducing the overall weight of the car, and thereby increasing the fuel efficiency but also provides more flexible design options to the manufacturer.”

paper, wood and metal used for packaging to plastics. This has been across all packaging forms ranging from rigid, semi-rigid and flexible,” adds Kumar. The growing awareness among consumers regarding international designs and user-friendliness offered by plastics go a long way in expanding the market for plastics in packaging.

The flexibility offered by plastic packaging and the low costs involved have allured customers, and manufacturers have been quick to adapt to the changing requirements. Also, India is a price-sensitive market, and usually high-end products use metals, glass and other heavy materials for packaging. The low and middle end products generally have plastic

packaging as they are economical to produce and affordable to buy.

Although there are certain environmental issues related to the use of plastics, the key issue is to educate the end-user regarding the proper methods of plastic waste disposal. Various industry bodies and the government have come up with education programmes as plastics serve more purposes than other materials used for similar applications. The debate continues, but no one can do away with the use of plastics.

In terms of biodegradable plastics, India is still in the nascent stage, but companies are witnessing fast adoption of such plastics by customers. “Gradually, as the market evolves and the income

Polymer processing

levels increase, we can expect a rise in the use of bioplastics on a more regular basis. Another propelling factor for bioplastics is the fact that multinationals are entering the country rapidly, and many of them are into the use of biodegradables. So we can expect them to carry out research initiatives in order to make bioplastics more affordable,” avers Kumar.

Compared to the global average consumption of plastics that is about 25–30 kg per person, India has a low plastic consumption of about 6 kg per person. Hence, there is much scope for companies, both domestic and international, to capitalise on the opportunities that are yet to be tapped.

“The temporary blips like currency fluctuations and volatility of crude oil prices will continue, but as the current trend suggests, investments will continue to increase and so will consumption levels.

We do need support from the government in terms of creating a more favourable platform for the industry to thrive and also provide manufacturers with the required infrastructure,” feels Kumar.

New varieties of fillers and additives are now being used to ensure that the polymer is of a premium quality.

Compounding technology The industry still prefers the traditional compounding methods for polypropylene and talc-filled compounding, but processors are seeing an increase in the usage of composites such as wood and plastic composites. In countries such as the US and UK, this trend is quite prevalent. India is also expected to follow this trend as there is a lot of wood waste available in the country that can be

used. Such composites present a better finishing of the product and offer good value for money.

Another trend is more of engineering plastics being compounded. Till the last decade, not many companies were into the use of engineering plastics such as the mobile phone and laptop companies.

However, the recent years have seen many domestic manufacturers using engineering plastics. “The compounding for commodity polymers is seeing an organic growth, but the inorganic growth will come from engineering plastics.

Processors import a lot of high and medium grade compounds for wires and cables, which are required to withstand flow of high voltage current. However, with evolving customers’ demands, it can be expected that domestic companies will start manufacturing products that are currently imported,” says Kumar.

The traditional compounds of calcium carbonate cannot fulfil all the design and feature-based requirements of companies; hence, these are now evolving.

New varieties of fillers and additives are now being used to ensure that the polymer is of a premium quality. Apart from aesthetics, another requirement is that paints should be volatile organic compound-free. They should have less odour and less fumes.

Safety concerns The latest additives are those which reduce volatile emissions and make the final product more user-friendly.

In addition, for the people inside the processing units, compounding activities should emit less fumes and not have an adverse impact on health. In India, regulations regarding safety standards are not stringent, and manufacturers are also casual regarding these health issues, which are taken up seriously in other countries. The awareness and intent are strong in those countries. However, with the advent of multinationals, such concerns are expected to be addressed.

Research initiatives In terms of Research and Development

The current trend is to use more of plastics in automobiles as it substantially increases the power-to-weight ratio. The increased usage of plastics not only helps in reducing the overall weight of the car, and thereby increasing the fuel-efficiency but also provides more flexible design options to the manufacturer.

Ravi Kumar Director, Shiv Pooja Plastics

(R&D), wise Indian players are lagging behind as many unorganised players cannot afford huge investments.

However, the organised players need to invest more in R&D. The government must create conditions where manufacturers are encouraged to come up with ideas and techniques that can benchmark international standards. “Indian polymer manufacturers have not disappointed the market in terms of quality and availability of polymers, but the processors should also be encouraged to undertake research efforts which would complement polymer manufacturers. This will help in bringing down the cost of the product and create a high brand value for Indian polymers. The vast expanse of the Indian market will ensure that the country remains a value-for-money oriented one and such a market requires a harmonious blend of quality at affordable prices,” believes Kumar.

Email: anwesh.koley@network18publishing.com

June 2013 | Modern Plastics & Polymers

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SAVING MATERIAL: Innovation and quality

Widening the scope for efficient plastics

Courtesy: Wilh. Willumsen

The Indian plastics industry is witnessing growth from all verticals. This, coupled with the increasing awareness about the importance of recycling such products, has ensured that not only do consumers get a better finished product but the environment also breathes a sigh of relief.

Anwesh Koley analyses the numerous roles played by polymers in improving final product quality.

W

hen it comes to packaging material or containers, trays & boxes, automotives & construction, raw materials such as polypropylene and polystyrene are fast gaining ground in terms of usage in the polymer processing industry in India.

The rising demand, both domestic as well as 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 lead to a flurry of innovations for the polymer processing industry, and it has to keep up with the design and quality requirements of plastics manufacturers.

Why research and development With increasing Research and Development (R&D) being undertaken in European countries such as Germany and Asian countries such as Korea and China, engineering polymers have bright growth prospects in the years to come. High-performance polymer products, which can replace metal and offer weight & cost reductions to customers at the same time meeting the functional needs of the application, have excellent growth prospects.

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The socio-economic trend of increasing younger-age working population (including more women) has created new avenues for industrial polymers as well. Lifestyles are more hectic, dual incomes are also encouraging the emergence of organised retail, so new application avenues in the area of packaging are coming up. Demand for safe and hygienic packaging for food, beverages and medicines is growing.

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 defence, renewable energy and materials (eg photovoltiacs, bio-ethanol & bio-butanol) and renewably sourced materials for different applications.

India is witnessing heavy investments in these areas as the country provides abundance of human talent – both skilled and unskilled.

Where the industry stands Currently, the polymer processing industry is witnessing a steady increase in the number of players who are driven by the growth and profitability of the sector. Rajeev Bhatia, Chief Executive Officer, Premier Pigments & Chemicals, says, “The Indian plastics industry is growing at the rate of 12–15 per cent per annum since the last few years. This means the demand of the raw material is also growing at the same rate simultaneously. With regard to the Indian clientele, people are improving with technological advancements and have access to international standards.

However, this improvement happens at a much higher pace for a company that exports than for the one that manufactures and sells in India.”

By 2012, India is projected to be the third largest consumer market for plastics, with a consumption of 12.75 million MT per annum. Polymer consumption in India has historically

Innovation and quality

The Indian plastics industry is growing at the rate of 12–15 per cent per annum since the last few years.

This means the demand of the raw material is also growing at the same rate simultaneously.

Rajeev Bhatia Chief Executive Officer, Premier Pigments & Chemicals

grown at twice the gross domestic product rate. This growth is driven by all consuming segments such as automotive, housing, packaging, agriculture etc. “With the advancement and developments of machinery, raw material suppliers have increased their production with lesser number of people.

Better consistent material is available at much competitive prices than before,” says Sumit Dhingra, Director, Dhingra Polymers.

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, plastics, having evolved in their applications, are fast gaining ground in this segment as well,” says Bhatia. Masterbatch consumption increased from 182 thousand MT in 2010 to approximately 255 thousand MT in 2012. This growth is attributed to the rise in competition both domestically as well as internationally as manufacturers now have access to global technology and are aware of the changing demand patterns.

Improvement areas

With the advancement and developments of machinery, raw material suppliers have increased their production with lesser number of people.

Better consistent material is available at much competitive prices than before.

Sumit Dhingra Director, Dhingra Polymers

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However, 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 more than India. Also, the government there is friendlier towards manufacturers as well as exporters,” feels Dhingra. While the government has been taking regular measures towards easing things 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 non-core areas, as our business gets impacted with the global crude oil prices,” says Bhatia.

Masterbatch manufacturers will strive to exhaust their present capacities with increased demand. If the present capacity remains constant, there is a possibility of imports as well; this

may result in higher prices. Prices of masterbatches depend not only on the polymer prices but also on the pigment prices, and these have been increasing steadily. However, with increase in demand of masterbatches, probability of more manufacturers jumping into the foray is great. This will result in an equilibrium price where the quantity demanded by consumers (at current price) will equal the quantity supplied by manufacturers.

The rate of innovations witnessed by the polymer industry is commendable, but R&D needs support from the government. Also, the increase in applications for polymers has resulted in more R&D by manufacturers, thereby increasing competence globally.

However, the Indian polymer industry is enthusiastic in the adoption of latest technologies. Exposure to international standards and quality has ensured that more areas find plastics application, which was earlier the forte of metals and wood.

The polymer manufacturing sector seems to grow and adapt according to the changing needs of the market.

However, there are issues concerning the sector. “As polymers use a petroleum base, their prices have gone up drastically. Energy and labour costs have also increased substantially. The challenge before the plastics processing industry has been to manage these steep cost increases without the same degree of increase in sales prices and sharp decline in margins,” laments Dhingra.

The measures taken by the industry to cope with these shortcomings include lowering input resources such as energy and space. Manufacturers are coming up with equipment that have higher productivity and consume lesser space within the plant. Another important measure is to reduce all forms of waste, which result from operational rejections, waste heat and spillage.

Apart from technical requirements, a major problem is the availability of skilled workforce.

Email: anwesh.koley@network18publishing.com

SAVING MATERIAL: Inter face - Surinder Minocha

“The colouring of plastics has evolved with the use of technology”

…opines Surinder Minocha, Managing Director, Minocha Enterprises Pvt Ltd. In a conversation with Anwesh Koley, he explains the need for adapting to global techniques as manufacturers want international standards. He also highlights the need for robust technology at affordable prices to stay competitive.

What are the latest innovations witnessed by the polymer compounding sector?

Compounding is a continuous process.

With time, people realised the importance of compounds. When the industry was in its nascent stage, people were not aware of its applications. Gradually, with the advent of multinational companies, domestic manufacturers understood the need for effective compounding, and accordingly, the market saw a flurry of machines that catered to the compounding process. The need was felt for more advanced machines that could furnish the growing needs of the market.

The market is currently growing at 10 per cent per annum. With the growth of polymers, masterbatches will also grow.

There is a direct correlation between the growth of polymers and masterbatches as the demand for innovative colour options will only increase in the future.

What are the latest machines used in this sector?

Mainly twin screw extruders are used for regular compounding of polymers. Earlier, these were expensive to buy, but now extruders are manufactured in India. They are still imported, but there are many domestic manufacturers. This has resulted in extruders becoming cheaper over the years. For plastic compounding, twin screw extruders are very important. Chinese, 60

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German and Japanese manufacturers are also into manufacturing extruders that are accepted globally. While Germany is the biggest exporter of extruders to India, a host of domestic manufacturers have come up with machines with international standards.

How has compounding evolved over the years?

Compounding was earlier complemented with manual colouring. Masterbatches have recently emerged as an efficient method of giving colour to plastics. A couple of decades ago, the only materials available were polystyrene and Lowdensity Polyethylene (LDPE). Initially, people used hand-moulding machines to colour these materials. Companies used the manual approach for colouring before the advent of masterbatches. As the market grew, it was not considered feasible to outsource all the colouring requirements; hence, they adopted the use of masterbatches. Then came the single screw process of colouring plastics, which was faster and a more convenient technique in the plastics processing industry. Thus, compounding was always a technical process, but the colouring of plastics has evolved with the use of technology.

Most of the compounds that are made in India are tailor-made compounds.

Whenever global players enter the

country, they want materials according to their specific requirements. There are different minerals available, and companies indicate to us their choice.

In the automotive industry, before the arrival of Japanese manufacturers, most body parts were made of metal. With the advent of Japanese players, metals paved the way for plastics. Along with these changes, plastics compounding also evolved as different components required plastics with different properties, and engineering plastics offered this versatility.

The additional requirement for talc, glass, calcium and other minerals was best fulfilled with the use of plastics.

What are the various research and development initiatives in compounding?

Domestic companies find it better to work with the existing techniques as this helps them to save on cost – the primary concern for the entire industry.

The masterbatch segment has witnessed a lot of activity as the end consumer now wants a variety of colour combinations for the plastics they use. More companies are exploring different combinations of colours that can effectively supplement the compounded polymers. Compounds have largely remained the same, but the efforts towards improving their external appeal have increased.

Email: anwesh.koley@network18publishing.com

SAVING MATERIAL: Roundtable

DOES THE

INDIAN POLYMER INDUSTRY HAVE THE POTENTIAL TO BENCHMARK

INTERNATIONAL STANDARDS?

The Indian plastics industry is growing at a rapid pace in the last few years. This means the demand of raw material is also growing at the same rate. At present, processors are conscious about the quality of products and high efficiency of production. Anwesh Koley speaks to industry experts to gauge the way forward for the polymer and masterbatch industry.

Girish Dhawan Proprietor, Perfect Polymers

V Vikram Proprietor, Sealers India Agencies

The plastics industry in India has a big market potentiality and is gradually prospering. This market potentiality has been constantly encouraging entrepreneurs to invest in this industry.

Entrepreneurs are trying to provide high-quality plastic products so that it becomes a booming industry. The masterbatches business in India is slated to benefit the most from the rise in plastics consumption. Masterbatches form about 75–80 per cent of the plastics industry, and hence will witness a parallel rise in demand as India becomes the third largest plastics consumer by 2013.

More processors are turning to masterbatches on account of enhanced consistency in performance and elimination of pollution problems.

New found opportunities for silicon masterbatches are in applications for PE duct for optical fibres. This could generate additional business of almost 1,500–2,000 tonne per year. Growth of polymers and masterbatches is also expected to be high as polymer manufacturers are resorting more to the use of the masterbatch system.

Editorial take:

Vijay Vora Director, Roshma Pet Plast Pvt Ltd

The plastics industry is already witnessing steady growth in consumption. With India set to become the third largest consumer of plastics, prices in the market will surely go down. The domestic market is expected to witness a boost as many plastics manufacturers are resorting to locally made materials. Also, logistics is expected to become more efficient as demand and supply will need to be better matched. The development of high productive machines has opened up a new horizon of masterbatch application. Not only this, but plastic 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 plastics industries.

The plastics industry has shown a 20 per cent increase in volumes over the previous year, and growth is driven by all the segments where plastics find applications. Another important factor that will complement the consumption is the gradual movement from metal packaging to flexible packaging.

Masterbatch manufacturers across the country are witnessing a strong rise in demand as the market is growing strongly due to sufficient supply and availability of materials. The next year will be challenging for polymer producers and the entire polymer market. Further growth will happen because many large players are developing a number of capacities near their plant. With India emerging as the third largest consumer of plastics in the world, the north region is particularly expected to witness considerable developments in the polymer industry. Also, polymers like polypropylene have always been in excess supply in the country, and this being one of the major materials being used in manufacturing plastics will witness an even higher demand.

Growth in the plastics sector has always exceeded the GDP growth rate in the country, and with the increase in demand, both globally and domestically, manufacturers will have to increase their production capacities.

Email: anwesh.koley@network18publishing.com

The polymer industry in India is currently on the path towards achieving international standards. Domestic manufacturers and processors are keen on providing global quality to their consumers. With an increase in growth, the industry also has an eye towards cost efficiency.

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SAVING TIME: Silent time savers

Right tooling for faster performance Precision and accuracy are the most important characteristics that ancillary equipment must have in order to ascertain accurate processing and ensure timely production. It is also important to reduce energy consumption while ensuring seamless processing of high-quality raw materials. Anwesh Koley explores the latest technologies that go into making a perfectly processed plastic product without any delay.

Precision feeders for higher accuracy The latest additive feeders operate under a gravimetric dosing principle where material flow is continuously monitored and controlled on a loss-in-weight basis. This is said to increase dosing accuracy and consistency, thanks largely to the disk-based metering technology that releases a precise volume of additives.

The closed loop system monitors and compensates for changes in flow behaviour and bulk weight.

Further, precision is derived from shears at the dosing disk that cut granules to ensure that the dosing chambers are consistently filled.

A smart calibration feature on the feeder means no component

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weighing procedures have to be undertaken during material changes. Instead, the additives are dosed in a synchronised manner according to the plasticating time of the moulding machine or the screw speed of the extruder.

Processors using liquid colours and additives can now benefit from the accuracy and simplicity of gravimetric (lossin-weight) metering technology.

Varun Kapoor, Director, Sarvasv Machinery & Equipments Pvt Ltd, says, “The liquid feeders eliminate the need for timeconsuming colour calibration and

adjust automatically for changes in material and processing conditions.

This, in turn, results in easier set up and greater processing up-time for increased productivity.�

The current equipment in feeders use the same clean, simple peristaltic pumping technology as conventional volumetric dosers.

However, the liquid container is supported on a load cell that constantly measures the loss-inweight as material is pumped into the processing machine.

Programming is easy and in injection-moulding applications, the operator simply enters

Courtesy: Stimul Brain

E

fficient moulding machines require an energy-efficient design.

However, efficiency does not depend only on the energy consumption of machines.

Efficient operation concerns the productivity of the system as a whole, and aspects such as machine availability, speed, precision and reproducibility must also be considered.

Silent time savers

the part weight and the colour and additive percentage.

High-quality feeding systems Drying, conveying, metering and mixing equipment make up a complete set of feeding system for plastics processing.

Drying equipment is applicable to pre-treat hygroscopic materials such as acrylonitrile butadiene styrene, polyoxymethylene, polycarbonate, polyamide and poly methyl methacrylate before moulding. During the processing of polyolefin plastics, drying is generally adopted to guarantee product quality. For instance, in the injection moulding of random polypropylene and polyethylene material for crosslinked polyethylene, the material needs to be dried to the extent of moisture content.

Based on the material moisture content of products, various drying fashions and equipment are also under application. For the material loading of polyvinyl chloride granules, an oven dryer is the optimal equipment. For plastics with strong thermo-sensitivity, a rotary double-cone vacuum dryer is mostly used.

However, for successive drying, direct-type hopper dryer is the first choice. “The central feeding system is mostly applied on large-scale and automated production. Equipment in the processing units are controlled via computers with material entering mixers after passing metering devices by proportion,” says Kapoor.

Each hopper is equipped with a level sensor to detect material quantity, which will control opening or closing of the material tank in conveying pipes.

The critical technique in the central feeding system is the accurate metering of electronic scale, which will influence whether the feeding material quantity by proportion is right or not.

Enhancing efficiency For extrusion, the feeder can run on an open loop or precisely control the metering rate against extruder screw

speed. Once set up, the digital control takes over, adjusting the pump speed to meter exactly the right amount every time, regardless of changes in production rate, variations in viscosity, pump/hose condition or environmental changes.

Dhaval Bhatt, Chief Executive Officer, Sri Sai Plasto Tech, says, “Loaders and blenders provide more accuracy and efficiency for reduced waste and improved quality of parts. Higherperformance dryers use less energy and provide cost savings. Increased efficiencies are being seen across the whole range of auxiliaries, contributing to profitability in plastics processing.

Energy savers for granulators are the latest development the industry has seen till date.”

In plastics processing industries such as extrusion, injection moulding, calendaring, hollow moulding, film blowing and spinning, host machines require plenty of auxiliary equipment, which are indispensable components.

Therefore, product quality and corporate viability depend to some extent on the automation and rationalisation of plastics process auxiliary equipment. “According to the functions, there are three types of plastics auxiliary equipment, including feeding equipment, temperature control equipment and granulating & recycling equipment of rim leftover. These devices perform various functions in plastics processing,” adds Kapoor.

Temperature control to reduce time Heating equipment during plastics processing include the cylinder moulds used for extruder, injection moulding and rolling machines, as well as heating controllers for forming rolls.

The heating method currently in use is the electric heating of heat transfer oil but not the complicated steam heating.

Heating equipment in plastics processing mainly refers to the temperature heating controller applicable to the cylinder mould and stack of extrusion, injection and calendaring production.

Email: anwesh.koley@network18publishing.com

The liquid feeders eliminate the need for time-consuming colour calibration and adjust automatically for changes in material and processing conditions. This, in turn, results in easier set up and greater processing up-time for increased productivity.

Varun Kapoor Director, Sarvasv Machinery & Equipments Pvt Ltd

Loaders and blenders provide more accuracy and efficiency for reduced waste and improved quality of parts.

Higher-performance dryers use less energy and provide cost savings. Increased efficiencies are being seen across the whole range of auxiliaries.

Dhaval Bhatt Chief Executive Officer, Sri Sai Plasto Tech

June 2013 | Modern Plastics & Polymers

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SAVING TIME: Sustainable processes

Need for industry–government collaboration The increasing use of plastics in industrial and consumer applications, growing consumer awareness on solid waste recycling and lower cost of recycled goods have led to an increased demand for recycled plastic resin and products. However, recycling of plastics must be timely and not harm the environment. Anwesh Koley stresses on guidelines that can be implemented to achieve the desired results in the shortest possible time.

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o understand the requirements for recycling plastics, it is important to look into the chemical structure of plastics, whereby it can be successfully reused without resulting in any environmental damage. The government has constantly come out with measures to ensure efficient recyclability of plastic bottles and the industry has also started contributing towards this measure.

India recycles approximately 3.6 million tonne of plastics every year.

There are about 3,500 organised and 5,000 unorganised recycling units employing 6 lakh people directly and 10 lakh indirectly.

The major types of plastics recycled are polyethylene, polypropylene, Polyethylene Terephthalate (PET), polyvinyl chloride, acrylonitrile butadiene styrene, polystyrene, nylon, polycarbonate, high-impact polystyrene, poly methyl methacrylate and other engineering plastics.

Nature of plastics in PET PET is a common plastic material used as an ingredient to make beverage bottles.

Like most plastics, PET bottles are nonbiodegradable and will just sit in landfills if not recycled on time. PET is made of petroleum, so a more efficient recycling of used PET bottles would also help reduce dependence on oil.

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Industry–government efforts Nearly all types of plastics can be recycled; however, the extent to which they are recycled depends on technical, economic and logistic factors.

Innovations in plastics separation, sorting, washing and de-contamination technologies equipment have made it possible to efficiently collect, separate and recycle mixed rigid packaging plastics. Tej Ram Singhal, Director, Courtesy: Under30CEO Suraj Plastic Industries, says, “The National Recycling is an efficient concept, Plastics Waste Management Task Force of but often the recycling process ends up the Ministry of Environment and Forests, wasting more energy in reprocessing the Government of India, has recommended recyclables rather than gaining it. Besides, a strategy and action programme of the industry is yet to find a cost-effective plastics waste management in India. Also, means of recycling food containers into the Bureau of Indian Standards (BIS), new food containers.

New Delhi, has issued guidelines on Although there is a demand recycling of plastic waste. All responsible for recycled bottle-grade PET, manufacturers of plastic recycled products the high cost of cleaning post-consumer adhere to the safety rules and regulations beverage bottles, strict Food and laid out by the government.”

Drug Administration (FDA) requirements and outmoded technology have Modern technology for quick recycling favoured the use of virgin PET Most bottles are made of PET.PET containers over recycled PET in manufacturing are identified by a resin identification code of beverage bottles. This has resulted imprinted on the side or bottom of the in most beverage bottles collected container. After collection, the bottles are for recycling being reprocessed into forwarded to recycling locations where they non-food products such as fibre are run through grinders that reduce them to the flake form. The flakes then proceed and strapping.

Sustainable processes

The latest PET washing/grinding/drying systems incorporate heated pre-wash stage to remove labels from whole bottles before grinding, a wet grinder/crusher to reduce bottles to flake, followed by a succession of small wet-washing units – hot and cold – that use intensive friction.

Tej Ram Singhal Director, Suraj Plastic Industries

through a separation and cleaning process that removes all foreign particles such as paper, metal and other plastic materials. Among the recently developed technologies, the automatic PET washing system that requires less capital and energy cost is useful for the Indian market.

“The latest PET washing/grinding/drying systems incorporate heated pre-wash stage to remove labels from whole bottles before grinding, a wet grinder/crusher to reduce bottles to flake, followed by a succession of small wet-washing units – hot and cold – that use intensive friction,” adds Singhal.

Each washer is followed by a friction dryer to strip off dirty water. It also uses density separators and metal detectors both before and after washing. Density separation is followed by two friction dryers, one for the polyolefin that ‘floats’ and second for PET ‘sinks’. The PET is air-classified for removing fines, labels and nylon barrier material from bottles. The last stage is the drying stage, where flakes are thoroughly dried by friction dryers. After being cleaned according to market specifications, the recovered PET is converted into a variety of useful products such as carpet fibre, strapping, moulding compounds and non-food containers.

An eye on the future The need for an effective means to recycle PET bottles has urged both the industry and policy makers to look into the problem, with particular focus on energy efficiency and reusability of PET. With more companies becoming involved in research to develop better means of recycling PET, the condition is expected to improve both globally and in India.

Till then, a better understanding of the chemical structure of PET would only help speed up its recycling.

Email: anwesh.koley@network18publishing.com June 2013 | Modern Plastics & Polymers

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SAVING TIME: Inter face - Manish Pathania

“Biopolymers can be decomposed by microorganisms and assimilated in the soil again” …believes Manish Pathania, Sales Director, Greendiamz Biotech Ltd. In an interaction with Anwesh Koley, he talks about the various developments in the bioplastics sector and the key areas that need to be addressed with urgency.

How relevant are bioplastics in today’s world?

In an age where sustainability is one of the biggest issues facing the packaging industry, the use of bioplastics seems the most feasible option considering the rapid increase in pollution levels caused by petroleum-based plastic materials. The major difference between biopolymers and hydrocarbon polymers is that due to their physical and chemical structures, biopolymers can be decomposed by microorganisms and assimilated in the soil again.

This property of biodegradable plastics has made them popular across the globe.

However, the guidelines that regulate the usage of bioplastics are not well defined in India. In India, the ISO 17088 guidelines rule the use of bioplastics but have not been implemented properly. The journey towards starting a bioplastics initiative has been fraught with challenges and, above all, negative sentiments, from the plastics lobby and the government. They perceive the initiative as a threat to industry and livelihood. The sentiments of people today are completely different from the government’s perspective and are considered as proactive in their support for bioplastics.

What are the implications of the ISO guidelines?

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identification & labelling of plastics & plastic products that are suitable for recovery through aerobic composting.

This specification is intended to establish the requirements for labelling of plastic products & materials, including packaging made from plastics, as ‘compostable’, ‘compostable in municipal and industrial composting facilities’ or ‘biodegradable during composting’. The labelling will, in addition, have to conform to international, regional, national or local regulations. In February 2011, a Life Cycle Assessment (LCA) by the UK Environment Agency showed that oxo-biodegradable plastic bags have a better LCA than paper bags or compostable plastic bags.

The current market for bioplastics is restricted as compared to other countries where they have high utility. The government is clear in terms of guidelines issued for anti-solid waste management.

Identify the stumbling blocks hindering the growth of the bioplastics sector.

Oxo-biodegradable packaging is more expensive and requires continual exposure to microorganisms in an industrial composting environment; hence, this rules out the problem of littering of plastics. Composting is an artificial process with a shorter timescale than natural biodegradation, which results in rapid, unfavourable carbon release into the atmosphere. These cannot be recycled in the normal recycling process and

have to be segregated from the waste stream and treated separately, which considerably increases the cost. Furthermore, it is difficult for manufacturers to physically distinguish between hydro-biodegradable and normal plastics.

The government has made it mandatory that plastic bags of thickness less than 40 micron cannot be manufactured for packaging purposes. Similar standards are yet to be implemented for bioplastics.

Our customers are sceptical about the long-term viability of plastics, be it classical plastics or biodegradable ones.

If the government does not demarcate between classical plastics and bioplastics, a substantial share of consumers will not be able to achieve the full benefits of bioplastics.

How do you see the future of bioplastics in India?

Hydro-biodegradable and oxobiodegradable plastics have their own unique merits and should compete fairly in the market. Although oxo-biodegradable plastics do not decompose as much as conventional biodegradable plastics, it is a step forward to moving away from the use of classical plastics, which take hundreds of years to decompose. Government policies and guidelines are the most important factors determining market acceptability for biodegradable plastics.

Email: anwesh.koley@network18publishing.com

MANPOWER MANAGEMENT: Managing workforce

OF MAN AND MACHINE With the increase in consumption of plastics, polymer processing companies are expanding their horizons in every way. However, in doing so, they are faced with challenges such as manpower shortage and heavy power and energy costs. Anwesh Koley highlights strategies adopted by companies in the segment to deal with these challenges.

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he consumption of Indian polymer products is on the rise. Polymer consumption is expected to double in the next three years.

This has directly impacted the polymer processing industry and its scale of operation. Now, polymer processing companies are expanding in terms of capacity and production. However, they are faced with many issues such as manpower shortage and heavy power costs. So, companies need to take adequate steps to deal with these issues as these have a direct impact on the cost and quality of machines.

Saranjit Singh, Proprietor, Bamra Engineering Works, says, “Due to high labour and power costs and shortage of manpower, the polymer processing machinery manufacturers are pushed to develop machines facilitating higher output. This is the situation of the domestic and global polymer processing industries. Another trend is that when we talk about higher output machines, then automation has become an obvious need. Hence, polymer processing industries have reacted to this demand and have developed machines with complete automation facilities. These two factors have also led to increase in energy efficiency, thereby reducing the power cost.�

Increasing manpower efficiency through automation To ensure consistent quality and greater production efficiencies to offset high cost of raw materials, labour and power, customers are moving towards the use of automation and robotics.

Automation technologies have thus gained due attention from plastics processing companies.

These days, companies in the plastics processing segment are using Computer Numerical Control (CNC) machines for manufacturing of key components. These CNC

machines have revolutionised machining processes as now the parts need not be manufactured manually. This has helped in making highly precise machines, and the chances of mistakes are minimised.

Further, customers want highly automatic and synchronised systems in order to improve their product quality and efficiency. The controls in use at present make use of microprocessor-controlled high-speed Programmable Logic Controller (PLC) systems. The PLC systems help in reducing the labour costs to a very large extent

Managing workforce

as you need to have only one skilled person to set the parameter once and then repeatable operations can be carried out automatically. Thus, there is no need of manual labour.

Efforts of the plastics processing segment are in enhancing quality & efficiency of machines and reducing dependence on labour.

Another system that helps in reducing the dependence on manpower is the Supervisory Control and Data Acquisition (SCADA) based system, which usually refers to centralised systems, which monitor and control complex systems spread out over large areas. Machines in this system help in achieving zero rejection. It also makes the work of the manufacturer easy, as there is no need to set the parameters of a repeated process every time because the machine will do that automatically according to the commands given.

Neeraj Garg, Partner, Suruchi Industries, says, “The development of the SCADA system is one of the best ways through which one man can control the entire process, thus reducing the dependence on manual labour.”

Role of ancillary equipment Ancillary equipment play a major role in increasing energy efficiency and reducing the dependence on labour. Singh says, “Ancillary equipment can be seen as the answer to automation requirements of companies as they highly help in decreasing the dependence on manpower. Various processes are involved in converting raw material to finished products, and for performing these functions, companies need not hire labour, instead ancillary equipment such as chilling plants, mould

temperature controllers, drying systems etc can be used, thereby enhancing productivity and improving quality.” If the right type of ancillary equipment is used, then it will not only avoid wastage of the raw material but also save energy consumed during processing.

Servo motors for power and efficiency Not only have polymer processing companies taken novel steps for reducing dependence on labour but they have also developed technologies that have helped in reducing their energy consumption to a very large extent. The development and usage of servo motors and drives is a clear answer to this. These motors seem to be the buzzword in the plastics processing machinery segment. Almost every processor is talking about them and clearly think that they are the future of the industry.

The main reasons being that servo motors help in reducing the energy consumption by about 60 per cent, and the fact that they occupy less space.

The existing normal electric/fueldriven motors transmit power to various points of movements through gears, chains, belts and pulleys, which are heavier and bigger. On the other hand, in the servo motors, all movements in the machine are powered by appropriate size of motors controlled by drives and sensors, which are smaller, lighter and convenient.

Due to high labour and power costs and shortage of manpower, the polymer processing machinery manufacturers are pushed to develop machines facilitating higher output. This is the situation of the domestic and global polymer processing industries.

Saranjit Singh Proprietor, Bamra Engineering Works

The way forward In the future, the expectation from new machines would be more from less.

In the competitive world, machines with higher output and lower power consumption per unit of output will be the winners. Thus far, the efforts of the plastics processing segment are in enhancing quality & efficiency of machines and reducing dependence on labour. The innovations that have made headway in the sector at present will surely have a long-term impact on the industry and will form a basis for future advancements.

Email: anwesh.koley@network18publishing.com

The development of the SCADA system is one of best ways through which one man can control the entire process, thus reducing the dependence on manual labour.

Neeraj Garg Partner, Suruchi Industries

June 2013 | Modern Plastics & Polymers

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MANPOWER MANAGEMENT: Skill development

FOSTERING TALENT TO MEET REQUIREMENTS With the plastics industry expanding its horizon in the country, there is need of nurturing professionals and empowering workforce so as to meet global standards and provide a boost to the industry. Indian processors have realised this fact and have ensured this by setting up several educational institutions to develop a skilled workforce. Anwesh Koley highlights the needs of the industry in giving impetus to talent and in encouraging a healthy growth momentum.

Need for efficient skill development programmes To support this growth of the plastics industry in the state, several factors have to be kept in mind. One of the important 72

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ducating the workforce on how a machine operates is often a time- and costconsuming activity that hampers efficiency. Usually, this results in many functions of the machinery remaining unused. Thus, technical education is an urgent requirement for the people operating on the shop floor.

Currently, plastics processors are looking for compact machinery as they are starved in terms of space. The dimensions of equipment today have reduced largely from the ones used about 5 years ago.

Besides, they are more efficient and use less energy. Manufacturers are also opting for machines that use fewer components, and consequently, require less manpower.

Global companies manufacturing ancillary equipment are fast entering India as the cost of manufacturing is lower, availability of raw materials is higher and labour is far cheaper. The Indian ancillary equipment market has been witnessing rapid growth. Dipak Vyas, Chief Executive Officer, Neo Pack, says, “We hope to continue in the same vein, partner many new companies, bring in the latest technology as and when they are launched globally, invest more in research & development and ensure higher productivity coupled with efficiency to provide better products in the future.”

factors is nurturing professionals and empowering workforce in the segment as this is necessary to increase business and meet the global quality standards.

Technology upgradation, be it in the mechanical or electrical aspects of plastics processing, is continuously happening, and if you are not aware of these changes, then your end product may not be of global standards. Thus, in such a case, it is necessary to train the workforce and make them aware about such changes and thus enhance their productivity.

Skills and knowledge are the driving forces of economic and industrial growth of any state or country. Countries and states with higher and better levels of skills adjust more effectively to the challenges and opportunities faced by industries. As India moves progressively

towards becoming a ‘knowledge economy’ it becomes increasingly important that processors should focus on advancement of skills for the advancement of the plastics industry. Thus, the need to focus on developing the skilled manpower is extremely important, and it is for the same reason that institutes such as Indian Plastics Institute (IPI), Central Institute of Plastics Engineering & Technology (CIPET), Plastindia Academy of Technology and Management have been set up to nurture talent from across the country.

Skilled manpower is the demand of every industry and the plastics industry is no exception. Today, with the way companies are expanding and employing new technologies, the demand for skilled manpower is increasing. However, it is

Skill development

We hope to continue in the same vein, partner many new companies, bring in the latest technology as and when they are launched globally, invest more in research & development and ensure higher productivity coupled with efficiency to provide better products in the future.

Dipak Vyas Chief Executive Officer, Neo Pack

We find it very difficult to find students who have a diploma or a degree in plastics engineering. Even private educational institutes can work on this concept and introduce courses related to plastics engineering. There is a huge gap in demand and supply as far as employment is concerned.

D S Rawat Secretary General, ASSOCHAM

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a common fact that skilled manpower is a scarce resource. Thus, investing in human capital is an important step and an effective way to achieve this is through industry–academia collaboration.

In the plastics industry, all production processes require skilled engineers and high-grade machines require skilled operators. Also, companies need an efficient workforce for marketing. Thus, through training institutes, the industry can actually train students to meet these requirements.

Need for further government support Very few colleges offer courses on plastics engineering. D S Rawat, Secretary General, ASSOCHAM, says, “The government has to redesign its policies.

We find it very difficult to find students who have a diploma or a degree in plastics engineering. Even private educational institutes can work on this concept and introduce courses related to plastics engineering. There is a huge gap in demand and supply as far as employment is concerned. Due to the lack of proper courses, we do not get the right people for the job.”

“Every new recruit has to be trained for a certain period of time until deemed fit for the job. This process takes up a lot of time and hampers our productivity to a great extent. Students are opting for other attractive courses. Hence, we have fewer options for selection of candidates,” feels Vyas. Paucity of manpower in the sector has shot up the cost of construction labour by over 25 per cent due to inflationary pressures, leading to an upward spiral in the basic cost of living. Besides, leading players in this field are hiring skilled workers from overseas, and this has almost doubled the cost of labour.

“India’s plan for growth and development of physical infrastructure is in peril as the majority of projects are getting delayed or cancelled due to lack of skilled manpower. Besides, lack of technology has proved to be a bane for the growth of India’s plastics sector. As the domestic companies adopt automated construction machines big-

time, India is likely to be a hub and one-stop construction equipment shop serving domestic and overseas markets during the course of the next few years,” avers Rawat.

With the way companies are expanding and employing new technologies, the demand for skilled manpower is increasing.

Towards an optimistic future Despite economic slowdown, the plastics industry has not witnessed major dips in its projects. India has a substantial market of about 27 lakh tonne, and Maharashtra alone has a market of 6 lakh tonne. “Plastics is 100 per cent recyclable, and the use of plastic components in the auto industry, agriculture and many other industries will increase. The plastic component industry will become larger than the auto component industry by the year 2020. The central government has given a go ahead to the establishment of plastic parks in various states across the country. The industry can expect an inflow of ` 30,000 crore as investment. This is the right time for the Indian plastics industry to upgrade itself. Getting the right people in the industry would go a long way forward,” adds Vyas.

Domestic plastics processing companies need to invest heavily in technology to reduce operational costs, thereby providing additional benefits to customers and spurt demand. With the cost of production being almost 48 per cent cheap, this industry in India is attracting global equipment companies from China, Finland, Italy, Spain, South Korea, Turkey and others as it allows them to cater to the Indian market effectively and generate exports.

Email: anwesh.koley@network18publishing.com

MANPOWER MANAGEMENT: Inter face - Amit Kalra

“Efficient management of workforce has a direct impact on production quality� ...believes Amit Kalra, Director, Hindustan Plastic & Machine Corporation (HPMC). In an interaction with Anwesh Koley, he explains the importance of manpower management in achieving effective operational efficiency and the areas that need to be addressed in this regard.

How is the plastics industry placed in terms of manpower?

With the ongoing advancements in technology, demand for skilled labour has increased. Efficient management of workforce has a direct impact on production quality. However, there is a shortage of skilled labour especially in unorganised sectors such as thermoplastic recycling. Here, there is a definite need for incorporating technology so as to simplify the operation of machines.

This will only happen if there is a true sense of collaboration between the manufacturers of such machines not only with their buyers but also with the layman who is ultimately going to operate the machines. So, incorporating technology for simplifying extrusion operation is the need of today’s times. Extrusion has a wide range of applications, so in order to cash in on the advantages of this technology, one needs to have simplified operations and higher use of automation.

How crucial is it to understand manpower needs in everyday operations?

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find the right one. It then proceeds with the client and partner determining how the process will work, well in advance, so that all potential problems can be fixed early on. Mistakes can be made if the machine manufacturer develops complex extrusions in a short amount of time. The client and the supplier need to determine in advance what might be a realistic lead time that gives the project the best chance to meet quality demands and the marketing timetable. Also, downstream processes and equipment have significant impact on process quality and stability.

in the process must understand that extruded products are becoming less of an off-the-shelf commodity. Customers frequently want a specialised component that will interface with an application or product. This means cut-to-length sizes, co-extrusion and other special requirements, all of which have to be handled a little differently. Having state-of-the-art downstream equipment and skilled operators who know how to make adjustments to these processes is important.

What are the key areas of concern for labour in the plastics industry?

How does manpower efficiency affect the operational flexibility of a plastics processor?

The biggest problem in India is labour management and government formalities.

At every step, the legalities involved make work difficult. There are instances when more than half of the productive time goes into tackling various legal requirements. The availability of labour is another major concern as unskilled labour has become wary of coming to cities like Delhi as various government schemes have provided them the option to work in smaller cities. Many new industrial areas are coming up in states like Uttarakhand, where the cost of living is much lower than cities like Delhi. Hence, people end up saving more in such areas.

A lot of these issues can be overcome with proper planning. Everyone involved

The machine operator is critical in successfully running an extruder.

Sometimes, an operator is just not capable of running a process correctly.

Having properly trained, educated and experienced operators is very important, but they can be hard to find. Extrusion is not a process where one can just press a button and have everything turn out the same every time. The operator must be good at running an established process and at developing processes and knowing what inputs affect what output.

Reacting to differences in materials in the correct way is critical. Taking the time to find the right operators also makes a big difference.

Email: anwesh.koley@network18publishing.com

MANPOWER MANAGEMENT: Roundtable

Do plastics processors have access to effective skill management techniques and programmes?

The availability of a skilled workforce is imperative for any industry, and plastics processors have often emphasised the need to retain manpower – the biggest asset for any company. Anwesh Koley interacts with industry experts to gauge their responses on whether Indian processors are using right manpower management techniques.

Debdeep Kole Director, Koley Converting Machinery (P) Ltd

Ravi Kumar Director, Shiv Pooja Plastics

A major challenge for the sector is retaining manpower. The exodus of labour from key industrial areas like Delhi-NCR is a concern as various government employment initiatives like National Rural Employment Guarantee Act (NREGA) have resulted in an acute shortage of manpower in the city. It is important to change the mindset of people. Most plastics processing units are MSMEs. It is important to refer to such companies as emerging enterprises so that they do not remain tagged as ‘MSMEs’ forever. Greater emphasis should be put on skilled manpower development as it is one of the primary needs of the industry.

The plastics industry is not devoid of opportunities, but it is essential to lure professionals towards the bright future prospects of this sector. However, this is not a prevalent practice across the industry due to heavy government formalities and infrastructural bottlenecks. Government policies can go a long way in ensuring that these loopholes are effectively addressed.

Nilkant Raut Director, Raut Engineers

Intense competition from countries like China and South Korea producing cheap plastic products together with labour pangs are eroding the profit margins of the Indian plastics industry, which employs over 12 lakh men and women across the country. Besides, successful implementation of government programmes like Mahatma Gandhi National Rural Employment Guarantee Scheme (MGNREGS) and Jawaharlal Nehru National Urban Renewal Mission ( JNNURM) contribute to the deficient labour force for this sector as workers are keen on remaining within their local habitat rather than exploring the avenues present in industrial clusters.

Apart from rampant labour shortage, lack of promotion, volatility of exchange rates and usage of archaic technology are other serious issues hurting the industry. Managing the workforce remains one of the most crucial problems that the industry faces during its regular operations.

Availing the services of skilled manpower is an issue which the government has acknowledged over the years.

The initiation of various government programmes to generate employment and increase productivity highlights this fact.

Machines cannot replace humans, and we need to recognise this at the earliest. A key consideration in this regard is that the workforce today understands that they are part of the holistic development of a company and that their services are well sort after. Thus, if we require an efficient workforce, they need to be paid well which will provide them the sense of well-being and job security. A competent workforce will result in high-quality machines and better output for the company in the long run.

Training the workforce is a mutually benefitting exercise. However, this needs to be implemented within the company in order to provide hands-on experience to employees. Training workers is never a wasteful exercise.

Editorial take: Email: anwesh.koley@network18publishing.com The Indian plastics industry needs to have better training facilities and skill development programmes. In addition, suitable policies could help retain talent as well as ensure higher employee satisfaction and sustained interest in this growing sector.

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SAVING CAPITAL: Cost-ef fective processing technology

Saving time, improving output A thermoplastic material softens and shows plastic property when heated, but it does not set or get cured. Thermoplastics, generally available in the form of pellets, become liquid when exposed to high temperature. Finding a cost-effective option for processing has been an area of constant development and innovation. Sweta M Nair delves into this cause to see the available options.

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ising costs are a concern all around the world.

Standard processing models require a bit of tweaking to make them more cost effective. Despite a hefty economic stimulus package, banks are not lending money like they used to, especially to the manufacturing sector.

In times such as these, it is vital that processors use costeffective processing technology without degrading output quality.

With an average consumption level of about 150 tonne/unit, the Indian plastics processing industry is largely fragmented. To meet the growth potential of plastics, the Indian plastics industry needs to develop an increased capacity – the most economic production capacity with better efficiency to remain competitive in the face of global competition.

Effective initiatives For processors, simple techniques, such as using regrind when possible and adapting zero-defect production practices to reduce scrap and start-up waste material, can be implemented at even a small and medium enterprise level.

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Conserving electricity with efficient and well-maintained machines, monitoring scrap and setting goals ensure that everyone is on the same page at the production level.

Elaborating on the primary steps when implementing cost-effective processing technology, Herbert Kraibühler, Managing Director – Technology & Engineering, ARBURG GmbH + Co KG, says, “A huge amount of know-how is necessary to find the most efficient overall concept for the production of a particular moulded part from the multitude of available machine equipment, technologies and processes. Therefore, ARBURG has placed the main focus on the subject of production efficiency. Achieving

production efficiency – maximum quality at minimum unit cost – is a challenging task due to the numerous influencing factors along the entire value chain. That is why it is important to offer consulting, both during the planning stage in the case of new capital investments and during the production stage through optimisation of existing production facilities and processes.”

As with most industries, controlling cost is critical to sustainability and profitability.

However, costs can be controlled and often reduced by implementing measures that do not require significant investment. In many cases, improvements can be made for low or no cost by making

Cost-ef fective processing technology

slight changes to the way a process or equipment is operated to optimise its performance. Energy efficiency offers short- and long-term benefits, and by increasing the efficiency of a business, the bottom line can be strengthened. The ability of businesses to make rational and informed decisions about the use and deployment of capital on site will play an increasingly important role in helping to manage the new challenges in a changing business climate. Kraibühler adds, “In adopting a holistic view, we differentiate among the areas of product design, mould, machine & peripheral technology, configuration, process integration, process control and production planning. Each of these areas offers, to differing degrees, potential efficiency enhancements by shortening cycle times, reducing energy consumption and/or optimising production organisation. If companies also take into account the production environment, such as infrastructure and facility management at the production site, significant additional scope for savings can be identified in order to render production even more efficient and cost effective.”

Feasible options In an increasingly competitive environment, moulders are driven to reduce their costs per part by every available means. Many other operational elements need to be considered in achieving this and in optimising costs. When referring to costeffective processing technology that will save time without degradation in output quality, J N Bhat, Managing Director, Shini Plastics Technologies India Pvt Ltd, says, “Automation is a profit maximising tool because it eliminates space for errors and provides maximum utilisation of time and money. Robots are used at injection moulding machines for removing sprues & finished products and conveying them to further process. This saves labour, improves production efficiency and reduces accidents.

The continuity of process, fixed and shortened cycle-time, perfection in timely material handling etc improve productivity by providing a better control on costs.

The reduction in human interference by automation provides standard results with stable working surroundings and avoids rejection & wastage. Such efficient systems not only improve quality and build a positive corporate image but also avoid disorder and optimise utilisation of space.

Thus, fully automatic production ensures high efficiency with continuous workflow.

Moreover, the continuous communication with primary machinery optimises the time required in processing or moulding plastics.”

When referring to the processing or moulding stage, advantages of a centralised solution are quick to translate to cost efficiency as well. Flexible, quick and safe handling of polymers without any material wastage and risk of mistake is the main benefit of such a system. No material degradation or formation of dust occurs since pneumatic conveying of granules is carried out at controlled speed.

Additionally, rational and organised distribution ensures higher production rhythms and constant quality along with optimisation of energy consumption.

With regard to synchronising processes, Kraibühler adds, “Moulders can save time without degradation in output quality. To reduce unit costs and remain competitive, more upstream and downstream operations are being integrated into the injection moulding process, resulting in the use of increasingly complex production cells featuring peripherals and automation solutions. Turnkey solutions, comprising robotic systems and peripherals, will increasingly be used. This is because through integrated finishing of plastic parts, for example, injection moulding companies can increase their added value, exploit further potential for reducing unit costs and respond quickly to new requirements. Automated systems are available around the clock, operate fatigueand error-free, fast and at a consistently high quality. A machine operator simply cannot equal their performance. More customers, also in Asia, are therefore integrating our Integralpicker, linear robotic systems or six-axis robots into their production processes.”

Email: sweta.nair@network18publishing.com

In adopting a holistic view, we differentiate among the areas of product design, mould, machine & peripheral technology, configuration, process integration, process control and production planning.

Herbert Kraibühler Managing Director – Technology & Engineering, ARBURG GmbH + Co KG

Automation is a profit maximising tool because it eliminates space for errors and provides maximum utilisation of time and money.

Robots are used at injection moulding machines for removing sprues & finished products and conveying them to further process.

J N Bhat Managing Director, Shini Plastics Technologies India Pvt Ltd

June 2013 | Modern Plastics & Polymers

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SAVING CAPITAL: Cost ef ficiency

INTEGRATING INTERNATIONAL TECHNIQUES The cost to mould or process plastics has become a hot topic in the international plastics fraternity. Moulders are starting to take interest in the topic of integrating international techniques of cost efficiency to satiate domestic demand. Sweta M Nair assesses the international techniques of cost efficiency that can easily be integrated.

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usinesses are dealing with the high cost of processing plastics. Concerns about the environmental impact of the industry and the battle for limited natural resources are driving businesses to seek and implement techniques that will help save them money. However, no set definitions or criteria exist for businesses to integrate into their existing models in order to reap benefits. Most processors seem to know the positive terms in applying well known techniques, but perhaps the re l u c t a n c e to change is what keeps them from achieving cost-efficienc y in manufacturing.

When pondering on this topic, one cannot help but mention the term ‘lean manufacturing’. Having originated at Toyota Motor Corp in the 1960s, its roots arguably can be traced to Henry Ford’s assembly lines from 50 years earlier. The Toyota Production System (TPS) has an objective of eliminating all waste, be it wasted time, material, space or money.

Over the succeeding years, lean has taken off in a number of directions, and many consulting firms and management gurus 82

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sell lean as the ultimate key to effective business management to achieve cost efficiency. So much so, that it now

Efficient production means including all added value in analysis and optimisation - ARBURG

has been elevated to almost a virtue.

However, is it apt for all businesses? The answer is that lean certainly has benefits to offer all businesses, even in the service sector; however, the potential for gains varies widely based on the unique characteristics of the business.

Starting over ‘Cost efficiency’ is a vague business objective, but the abundance of concrete data on what has been accomplished until now by implementing manufacturing techniques is merely an indicator of its recent acceptance into the mainstream. Although there might not be any reliable data from any region or country on how the plastics manufacturing marketplace has changed, the willingness sensed in the domestic circle is substantial evidence.

At the onset, for better quality output, processors need better quality input which includes raw material, manpower, machinery and marketing. The need to constantly train manpower for retaining and improving efficiency and quality output is a continuous process from day one of setting up a manufacturing facility. In the scheme of things, quality of factory infrastructure also has a major impact on the consistent quality of output. Developing and documenting proper processes and systems may look time consuming and costly in the beginning, but it is one of the only ways to improve reliability

Cost ef ficiency

For Small and Medium Enterprises (SMEs), techniques of cost efficiency can be implemented by adopting new designs and making new moulds.

This makes it possible to reduce the cost of products.

Moreover, it is important to have a strong relationship with buyers to make sure that they will continue purchases from the same supplier.

Jayesh Khimji Rambhia Managing Director, Premsons Plastics Pvt Ltd

of products delivered that will match the buyer’s satisfaction. “Customers are willing to pay immediately or even in advance if the product or service mix is as per their needs. This can reduce capital needed for selling products on credit. Processors need to focus on increasing the speed of conversion from receiving plastic granules to dispatching finished products from the factory,” says Jayesh Khimji Rambhia, Managing Director, Premsons Plastics Pvt Ltd. Materials management is a key issue in the plastics industry. There is an ever-increasing pressure from original equipment manufacturer customers and even channel partners to get the price lower. Materials management plays a big role in determining the successful performance of the entire organisation.

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cost savings when virgin materials are not a primary requirement. To reduce costs, processors can leverage lightweighting and increase the recycled content. As markets mature, a globalised market brings competition from across the world. Entrepreneurs need to be aware of latest developments worldwide so that they are prepared to meet the customer’s future requirements. Talking about the developments in this field, Rambhia adds, “Polyethylene terephthalate bottles used for packing water, juice and soft drinks have reduced 40 per cent in weight in the last decade. To save the environment, legislations in the US have made it compulsory to use 20 per cent recycled material in packaging.

For Small and Medium Enterprises (SMEs), techniques of cost efficiency can be implemented by adopting new designs and making new moulds. This makes it possible to reduce the cost of products. Moreover, it is important to have a strong relationship with buyers to make sure that they will continue purchases from the same supplier.”

Getting the most Processors are looking to get the most value out of their investments by extending the life of existing equipment.

In the past, the cost of machinery was the deciding factor. Now, the total cost of ownership of machinery is emerging as a deal making factor because the total cost of ownership includes cost of machine, cost of operator, cost of electricity, cost of spares, cost of maintenance, cost of rejections, speed of production, life of machine, reliability etc. Processors have the option to retrofit their running machine with servo motors and controls to further save energy and subsequently costs.

Because most members in the industry are first generation manufacturers, they have learnt much regarding techniques of cost efficiency. With the internet, enough information is freely available to those who are willing to improve.

Talking about the relevant techniques, Rambhia adds, “By following Kaizen

(continuous improvement of processes in manufacturing) and learning & adopting new techniques from other industries, we can be more competitive. Some of the other techniques to improve overall equipment efficiency are maintaining JIT – just in time – which refers to reduced inventory cost, replacing ‘stock & sell’ with ‘make to order’ to further reduce inventory, standardising common parts & reducing colours offered, and adopting Single Minute Exchange of Dies (SMED), lean manufacturing, 5S, Kanban, balanced score card etc.

By sincerely following the International Organization for Standardization sy stem, processors c an be more process and system dependent rather than person dependent. This reduces errors and mistakes, thereby reducing rejections and helping in retaining customers. Furthermore, even enterprise resource planning systems, which are used by multinationals, are now available to SMEs on cloud computing in a very affordable pay per user model. Execution is the key to convert available knowledge to team work – this is the challenge SMEs need to overcome.”

In line with cost-efficient techniques, SMEs are also tweaking their working capital to minimise the impact of their business on the environment. As cost of utilities (eg power and water) is increasing and their availability is also under pressure, entrepreneurs are prudently using resources. Most plastics are being recycled, which is keeping the generation of waste under control.

Because plastics are hydrocarbons derived from petroleum oil, those plastics that cannot be recycled can be burned to produce energy. Integrating costefficiency techniques helps businesses to deal with global rather than purely local competition. However, before delving into any of the aforementioned techniques, one needs to bear in mind that cost efficiency cannot be achieved merely by resource minimisation but by resource effectiveness.

Email: sweta.nair@network18publishing.com

SAVING CAPITAL: Inter face - Jayesh Khimji Rambhia

“India is an amazing land where entrepreneurship thrives” …says Jayesh Khimji Rambhia, Chairman, Plastic Parks & Projects, The All India Plastics Manufacturers’ Association (AIPMA). In a conversation with Sweta M Nair, he talks about ways in which Indian processors can maintain cost effectiveness without compromising on output quality. Taking stock of the developments, he elaborates on simple techniques that can make a positive impact on a processor’s balance sheet.

What is your prediction for growth in the plastics industry beyond 2013?

For those who prepare well, the future is bigger and better. India is an amazing land where entrepreneurship thrives. The cost of a new start-up is probably one of the lowest in the world. Most plastics industries that started in India had no factories initially. They began with getting a mould made and engaging job workers who use their land, machines, manpower and material to produce goods. Only after a market was established, did companies set up their own manufacturing facility.

Companies that initially provided services gradually graduated to manufacturing and marketing their own products.

Considering domestic perspectives, Indian plastics consumption will approximately grow from its present figure, which is 12 kg per capita, to 25 kg per capita by 2020. The per capita income in India is also rising, and this will push consumption up. Moreover, young India is consuming a lot more these days, which is complementing the growth story. In the light of such developments, manufacturers will need to gear up their factories to deliver products as per international quality and that too at competitive prices, as clients are exposed to goods from across the world.

Only those who invest ahead of the curve will be able to reap the benefits of demand.

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products will be packaged and branded.

This will boost demand for plastics in packaging.

In other areas, due to the rising cost of fuel, automobiles are becoming more lightweight. This is ensuring a steady increase in the amount of plastics being used. Plastics are an affordable replacement to metal, glass, paper and wood, and with rising competition, this changeover will continue.

brand is also another option to add value to products. The introduction of new technology to the Indian market also allows you to add value.

However, these suggestions form part of a continuous process.

How can plastics moulders or processors safeguard themselves from potential increases in costs of raw material?

Electricity is the second highest input for plastics processors. India is energy deficit, and it would take a long time to match the growing demand for electrical power.

Modern servo-based machines consume about 60 per cent less power compared to traditional plastics processing machines. By upgrading their machines by retrofitting servo drives and controls, processors can save a considerable amount of energy.

By using capacitors and maintaining a power factor close to 1, the cost of energy reduces. By using natural light through transparent roofing, the use of light can be minimised. Also, by replacing tube lights with light-emitting diodes, significant savings can take place. Electrical audits in manufacturing facilities should be given priority to understand areas where energy can be saved. By balancing cooling water circulation and keeping minimum bends in water flow, pumping power can be saved.

Email: sweta.nair@network18publishing.com

It is extremely difficult to predict oil and forex fluctuations. Polymer hedging is available on MCX (Multi Commodity Exchange of India Ltd), but it still needs to evolve to be useful to most processors. In reality, profits of processors are squeezed between polymer producers and large buyers of plastic products. The processor fraternity is much smaller than the supplier and buyer fraternities.

Processors need to learn to add value to their production, so it is easier to absorb raw material fluctuations. They need to invest in research and development to own intellectual property rights.

When you own a product that nobody can copy, customers will pay you for its innovativeness, which hopefully will not be on per kg basis. Creation of a

How are moulders, processors or small and medium enterprises affected by fluctuating energy costs?

How can they protect themselves from spikes?

SAVING CAPITAL: Inter face - Herber t Kraibühler

“Servo-hydraulic drives offer a price advantage compared to electric ones”

What are the developments that have taken place at the machinery end?

…says Herbert Kraibühler, Managing Director – Technology & Engineering, ARBURG GmbH + Co KG. In an exclusive interaction with Sweta M Nair, he talks about the cost advantage that moulders or processors can leverage through injection moulding machines.

When developing and enhancing products for the machine sector, production efficiency always plays an important role because the machine has an enormous influence on the cycle time and energy consumption. Thanks to their energysaving drives, electric machines also score highly where energy consumption is examined in isolation. Electric drives enable fast, independent movements, resulting in short dry cycle times and simultaneous ejector movements. Our latest Edrive series makes cost-effective the use of electric injection moulding machines, even for standard products. In the high-end electric ALLDRIVE series, new machine sizes enable even more precise adaptation to the application, which offers benefits for cost-effective part production.

However, the energy consumption of hydraulic machines can also be reduced through the use of efficiency class IE2 motors, an electro-mechanical dosage drive or a servo-hydraulic drive system. To increase the efficiency of hydraulic machines, we offer a productivity package that comprises the ARBURG Energy-saving System (AES) with variable speed pump drive and watercooled drive motor. The speed of the pump motor is adjusted to requirements by means 88

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of a frequency converter. The advantages of the productivity package are up to 20 per cent lower energy requirement, shorter dry cycle times, reduced cooling requirement and lower noise level.

I see a further challenge in the development of practical, innovative solutions for new applications. I am thinking here about techniques for the processing of new materials, for instance, long-fibre reinforced plastics as substitutes for metals. In 2012, we presented for the first time a solution that enables long fibres with flexible length to be fed directly into the liquid melt. This opens up new possibilities for lightweight construction.

any movement, the pump motor also stops – in contrast to standard hydraulic machines, the pump of which continues to circulate oil when at standstill. The energy requirement of servo-hydraulic injection moulding machines is reduced by 50 per cent; efficiency in production increases accordingly.

Servo-hydraulic drives offer a price advantage compared to electric ones during procurement. These represent the most energy-efficient hydraulic solution and are particularly well suited to applications in which no machine movements are performed over a lengthy period, eg during cooling. However, only serial movements can be implemented using these machines. They cannot therefore be used for compression injection moulding.

For simultaneous movement sequences and short cycle times, hybrid or electric machines – available in various expansion stages – are the solution.

Since ‘servo-drives’ has become the buzzword, how much efficiency can be achieved by them?

When talking about peripheral equipment, what aspects should a moulder take into consideration to ensure its cost and performance efficacy?

The fact that energy efficiency is not only achievable with electric machines is clearly illustrated by our innovations in the hydraulic machine segment. For our large machines with clamping forces from 2,500 to 5,000 kN, we now offer a servohydraulic drive concept. They feature a servo motor with a constant pump, the output of which can be continuously adapted to the actual requirements.

No-load losses are virtually eliminated.

When the machine is not performing

In addition to the injection moulding machine, peripherals such as robotic systems, temperature control devices as well as material preparation and conveying impact on efficiency in production. With our machines, the robotic system and all the peripherals can be integrated and managed via the unique SELOGICA control system by ARBURG. This ensures minimum downtime, maximum flexibility during configuration and fast setup.

Email: sweta.nair@network18publishing.com

SAVING WATER: Ef fective water management

An eye towards recycling Expanding the recycling and process equipment service for the primary processing of plastic waste materials is the need of the hour. By offering process solutions to a wide range of difficult waste challenges in the plastics sector, recyclers need to reduce their disposal cost and increase yield and quality of their recovered materials for reuse in new products. In the light of such developments, Sweta M Nair focusses on the areas of recycling where the use of water can be optimised.

The wash down The wash solution consists of an alkaline detergent in water, which removes dirt and grease and degrades protein. The detergent used is an alkaline, cationic detergent (ie an alkaline solution containing a cationic surfactant).

During washing, the agitator in the wash tank acts as an abrasive, grinding off the glue of the labels and reducing any paper labels to fibres. The plastics are then separated from the glue, paper, dirt etc in a spinning tower in which this very fine material is forced out

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Courtesy: WRAP

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hile there are few industry standards, a typical recycling business collects used plastic products, and then sorts them according to the type and colour of the plastic. The sorted plastics are then shredded into small plastic chips or flakes that are then cleaned to remove any dirt, oil, food particles, labels, glue or other contaminants, which may be present. For instance, the polyethylene terephthalate stream is washed at about 90°C for a certain period of time, while highdensity polyethylene, which has a comparatively lower melting point, is washed below 40°C to prevent discolouration.

through small holes, while plastics remain inside. The plastics are then further rinsed and then separated on the basis of weight. This is done using a water cyclone, which is designed to separate out the given plastic from all the others.

The clean chips are then generally pelletised or somehow organised in a usable form for a plastics manufacturer. Elaborating on the above process, Vijay Merchant, Former President, Indian Plastics Institute, says, “Water is used in washing and removing all the contaminants such as the adhesives and the labels.

Basically, any other substance that is attached with the plastic scrap is

removed. This is a universal process.

Because water alone will not help remove the contaminants, there are chemicals that are added to water.

The chemicals are decided on the material you are trying to clean and the properties of the material itself. Primarily, recyclers use caustic soda with manual scrubbing. In the hills of Kalimpong and Siliguri, the entire plastic scrap in huge liquid tanks is stirred so that the labels and other impurities are separated from the plastic scrap. Depending on the grade of the plastic scrap, the temperature of the liquid is raised.

The temperature ensures that the particular adhesive or the food particles in the plastics is completely

Ef fective water management

cleaned. This is done to ensure that the quality of the plastics after recycling does not suffer. The same water is used again and again until it is full of all these impurities after which it is disposed.”

Beneficial edge Recycling plastics prevents damage to the environment via excessive landfilling and use of non-renewable resources. The process is also largely environmentally safe, with the only effluent being from the wash water. This is recycled in the plant as much as possible to minimise water use, and when it is finished with, it is still sufficiently clean to be dumped into sewers. However, in India, the absence of monitoring of the fluent discharge is leading to irresponsible disposal.

This polluted water seeps through the ground and affects the quality of groundwater. In some cases, this leads to blockages in waste water disposal canals. It also pollutes drinking water bodies. The western countries, however, have legislations in place to check these practices. The recycling units in developed economies have separate water treatment that separate solid impurities from the water and subsequently also remove the chemicals from the water. The fluent is thus no longer toxic. The treated water is not re-circulated in the recycling plant, but it is used in other non-manufacturing areas. For example, if the pH level of the water is good, then it can be used for maintaining the lush green lawns that surround the recycling unit.

Recycled plastics in end applications can displace virgin plastics and save an average of two tonne of CO2 for every tonne of plastics recycled. Moreover, for every 1 tonne of plastics that is recycled, reports estimate that 7 yards of landfill space is saved. By recycling, one can also help conserve an additional 80 per cent of energy that is typically used when making new plastic bottles, containers and other items instead of recycling. When referring to optimising use of water in recycling, Merchant adds, “From a plastics recycler’s perspective, if there are no incentives provided to optimise water, then why

would they make extra investments in this area? I have been talking to various plastics recycling groups based in different regions of the country, but they are indifferent to this. It would be more cost economical if these groups were to come together and set up centralised units of water treatment plants. In India, we have plastics recycling guidelines, but no enforcement or awareness programmes are conducted by the authorities.”

International examples The haphazard recycling segment in India is similar to that in China’s earlier times, when the country too had 50,000 odd plastics recyclers. Primitive recycling methods in the country transpired to irresponsible disposal of waste that affected the living conditions of regions where these recycling units were situated.

Having taken stock of the situation, the Chinese Government came down strongly on many recyclers and many of them shut shop. The scene in India could also be altered if effective government waste policies were to come into play.

Being futuristic, making comments about recycling techniques that use a dry clean approach may sound lame, but there is enough and more evidence to support this happening. Supported by the British Government, Axion Recycling Ltd working with the Waste & Resources Action Programme (WRAP) has championed dry cleaning technology as a highly effective and environmentally beneficial method for cleaning contaminants off mixed plastics. Having conducted trials using the German technology to dry cleaning system, the Manchester-based company claims that adoption of the technology could lead to significantly greater recycling in the UK because there is no need for a dirty water effluent treatment plant as there is with wet washing technology. The economical advantages of the technology are suitable for smaller companies that face many hindrances when it comes to optimising the use of water in recycling plastics. Perhaps a far-fetched dream for Indian recycling units, but its reality is

Water is used in washing and removing all the contaminants such as the adhesives and the labels. Basically, any other substance that is attached with the plastic scrap is removed. This is a universal process. Because water alone will not help remove the contaminants, there are chemicals that are added to water.

Vijay Merchant Former President, Indian Plastics Institute

hard hitting, astounding and definitely worth a shot!

In conclusion Since their creation, plastics have been an indispensable ingredient in people’s lifestyles. They have found their way into various household, medical and commercial products, such as water bottles, food containers, medical devices, gadgets, wire & cable insulation and packaging material. Plastic materials are convenient and inexpensive, but their disposal poses an environmental dilemma.

Although current recycling rates are not very efficient, perhaps new plastics recycling techniques will fine tune the entire process. Scientists and engineers are tackling the challenge of plastics recycling, and with increased consumer awareness, the upcoming technologies have the potential to create more sustainable lifestyles and a healthier planet.

Email: sweta.nair@network18publishing.com

June 2013 | Modern Plastics & Polymers

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SAVING WATER: Inter face – Umakant Sharma

“The industry uses the open type cooling tower for the centralised water cooling system” …points out Umakant Sharma, Head – Sales & Marketing, Matsui Technologies India Ltd, which in his viewpoint degrades the quality of water and affects the overall quality of production. In a conversation with Sweta M Nair, he discusses the importance of water in plastics moulding and outlines techniques that can bring in efficiency.

When referring to fast and repeatable plastics processing, how much importance is given to water? What is the role that water plays?

In the plastics industry, water is used in heat exchangers of injection moulding, blow moulding and extrusion machines, water baths for extruders, mould heating/ cooling in the injection machine process, water-cooled air compressors, water cooling chillers, water cooling towers, hydraulic oil coolers, extruder cooling rolls etc. Water plays a vital role in plastics processing, which requires water supply at a constant temperature to ensure quality moulding and to minimise rejections. Injection moulding is one of many technologies that use water as the primary cooling agent. For instance, to cool moulds, water can be fed through a channel providing quick cooling times. Colder moulds often work more efficiently as they allow for faster cycle times. Similarly, to heat up the mould, a mould temperature controller is used so that the water circulates in the mould channels.

What types of water cooling systems are used in plastics Small and Medium Enterprises (SMEs)? How and why do they end up wasting water during the moulding process?

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water cooling system, and air cooled/ water cooled chillers for process water in the case of chilled water requirements.

However, open type cooling towers are exposed to air, leading to contamination in process water due to dust and foreign particles. Process water in the open cooling tower is of low quality, contaminated with foreign materials, gases, algae and bacteria, accumulation of salt crystals, rusting etc. This contamination flows into the process line and results in scaling, clogging the process lines of water. Due to clogging, heat transfer does not take place efficiently, which is the main objective.

Coming back to the cooling towers, as these are exposed to the atmosphere, much water is evaporated.

For these SMEs, how can the cooling process be made more efficient?

To avoid water contamination, rusting or clogging and to minimise water evaporation losses, we recommend using the closed loop water circulation system as it is efficient for heat dissipation and provides good quality of water to the process.

How can moulders ensure good heat transfer from the plastic to the cooling water?

Effective heat transfer is the prime concern of mould analysis. This means that the heat transferred to the mould by

the plastic and any other sources must be removed quickly. Cooling is efficient if the heat removal is effected with the smallest possible expenditure of capital and energy. To facilitate quick heat removal in the mould itself, resistance depends on the heat conduction properties of the material of which the mould is made, size & design of cooling channels and the placement of cooling passages with respect to the part being moulded. This improvement consists of accelerating the rate of heat transfer and balancing heat transfer throughout the mould.

What are the next generation improvements in areas where water is used in the moulding process?

Matsui is always keen to provide the best technologies to industries. Matsui brings conformal cooling, rapid heating & cooling systems, Ecobrid systems, heating & chilling on a single platform to make sure energy, capital & water losses are minimised, weld lines avoided and good surface quality is maximised.

The mould temperature control technology by Matsui improves moulding cycle times (compared to conventional water heating & cooling systems with standard mould temperature controllers), adds value by improving welded part strength and reduces parts sticking in the mould, warpage and deformation of the part.

Email: sweta.nair@network18publishing.com

SAVING WATER: Inter face – Vishal Jasrapuria

“There is a need for creating awareness about water conservation in the industry” …states Vishal Jasrapuria, Director, Shree Sadguru Plastic Industries, as a step towards optimising water usage when recycling plastics. In a conversation with Sweta M Nair, he points out that the challenge is universal and needs to be dealt with an open mind.

What are the challenges involved when reducing consumption of water during recycling of plastics?

The biggest challenge is of mindset.

Most of us do not understand the need for judicial use of water and the role that we can play in conservation. It is deeply entrenched in our mind that water and air are unlimited and free resources. This thinking needs to change, and there is a need for creating awareness about water conservation in the industry. Having said that, there is always a cost attached with taking any environment-friendly initiative, and in a fiercely competitive industry such as ours, this incremental cost can render some players uncompetitive in the market place. Thus, the government should also try to provide some incentives to players who are trying to do the right thing. The incentive need not be purely monetary but can be preferences in the government procurement through entire supply chain report card system, something like the Black Economic Empowerment system in South Africa.

recycled plastics. The significant savings can come from the cleaning operations by ensuring that recyclable plastics are handled & collected properly at the procurement stage, and reusing or recycling the water used for cleaning in the cooling process.

What technology is available to help achieve this reduction?

Some of the commonly used techniques are physical chemical treatment, sand filtration, biological treatment and membrane systems. At some places, even ultraviolet and ozone are used; however, in plastics recycling, it is not very useful.

The two techniques used widely are sand filtration and membrane systems, where the physical impurities are removed from water, and the water is ready to be reused. At some stages, physical chemical treatment is also used to remove the chemical and other impurities from water.

Hence, by using such techniques, one can save up to 40–80 per cent of consumption of water.

What techniques are used to reduce consumption of water during the recycling process?

What is the capital involved in setting up this technology or technique?

The techniques depend on the nature of operations and the sources of raw material.

Water is mainly used in two processes – cleaning of inputs and for cooling of

The capital expenditure of the water treatment plants could vary from a few lakh to about two crore depending on the scale of operation. One of the key

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decision making points while deciding the size of the plant and the amount of recycled water to be used is striking a balance between the reduction in the cost of water consumption and the capital expenditure and operating expenditure of the plant over a reasonable period of time.

Is technology that reduces consumption of water during recycling readily available?

There are a host of companies offering a variety of solutions across technologies.

Apart from the larger players there are also a host of small and local players offering some good solutions at very competitive prices. However, one should wisely choose the solution provider based on the performance guarantee and the ability/commitment to offer after sales services.

What are the international advancements in this area?

Different countries are at different stages of implementing water conservation policies. One thing consistent across nations is that the emphasis on water recycling is increasing. An increasing number of industries are brought under the gambit of compulsory water recycling, eg the US government is talking about recycling and reusing water that comes up from hydraulic fracturing jobs. So, I think the Indian government should take up the issue seriously and start an initiative where recycling and reusing of waste water should be made compulsory across various industries such as ours, where the consumption of water is very high.

Email: sweta.nair@network18publishing.com

SAVING ENVIRONMENT: Waste management

Addressing environmental concerns The plastics processing industry often faces heavy criticism for causing environmental damage and industrial pollution. Processors are thus taking this issue seriously and ensuring that production techniques do not result in heavy wastage of raw materials, energy etc. Avani Jain notes pioneering environmentally safe processing techniques through effective waste management initiatives.

W

aste is any aspect of operations that fails to add value. It is a significant hidden cost for many plastics companies, and it includes the costs associated with energy & maintenance, solid wastes, inefficient use of water, hydraulic oil and emissions to the atmosphere.

With rising energy costs, soaring raw material prices and the impacts of climate change, the need to monitor energy consumption and reduce waste is more important than ever. To remain competitive, a business must adopt effective energy management processes and waste reduction methods. Thus, companies and organisations are

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increasingly taking an interest in waste reduction, which thereby results in optimising cost. There are many ways of reducing waste and optimising cost such as recycling of waste, employing strategies for reducing energy & water consumption, adoption of automation solutions and usage of energy-efficient motors.

Although the solutions are many, the main thing is the intention and motivation on the part of companies to do so, and here is where the change is coming.

Strategies by polymer processors From polymer processors to plastics processing machinery manufacturers,

it seems that the industry is aware of its responsibilities and is adopting various steps in reducing waste. M M Biswal, Business Head – Polymers, Loxim Industries Ltd, details, “In order to reduce waste, one has to have an appropriate system in place as it helps in improving the overall efficiency of the company.

In our company, whatever water is consumed during manufacturing of the engineering thermoplastic compounds is recycled and used for watering our plants in the garden.

Because we are located in a lowlying area and experience a lot of water accumulation, we also have a rainwater harvesting plant. We not only reduce waste but also consume it. For example, we have an eco range made of recycled products that we offer to our customers. Further, we believe that automation and training of people are important; if people are trained well, they could contribute more towards operating efficiencies.”

Reducing waste does not merely mean managing solid and liquid wastes, but it also means avoiding the excessive use of energy.

“Energy efficiency is only possible

Waste management

through a good set of machinery, which demands good investment. Cutting cost on infrastructure in turn would increase the cost of efficiency, so we believe that investing in right machinery is very important. Using the right machinery will result in cost & operating efficiency and waste reduction in the long run. At the same time, the product quality will also be good,” Biswal opines.

Machinery manufacturers’ initiatives Many companies have taken up the task of recycling plastic products and are also reusing them. Bharat Mistry, Partner, Ash Win Engineers, notes, “We make machines that recycle plastic wastes.

For example, entire plastic tanks are cut into small pieces by a scrap cutter; these pieces are then fed into a solid granulator where their size is further reduced to 10 mm. These are then put into a recycling extrude in which fine plastic granules are obtained; these granules are used to make entirely new products. Thus, we not only make machines but also reuse the plastic waste.”

He adds further, “This is profitable as we do not have to buy fresh plastic, and we are making products from the already available resources. However, customers are not showing much interest in such products, and hence their perception needs to be changed.”

Thus, plastics processing machinery manufacturers have also started adopting novel methods for waste reduction.

Due to high power and raw material costs, the polymer processing machinery manufacturers are pushed to develop machines facilitating higher output. For that matter, automation solutions have become an obvious need as they help in reducing waste to a very large extent. This has also led to increase in energy efficiency, thereby reducing the power cost. The return on investment is also high.

Automating for no wastage To ensure consistent quality, reduced wastage and greater production efficiencies to offset high costs of raw materials, labour and power, companies are moving

towards the use of automation and robotics. Thus, automation technologies have gained their due attention from plastics processing companies. As a result, companies in the plastics processing segment are using numerical control machine tools for manufacturing of their key components. These numerical control machine tools have highly revolutionised the machining process as the parts need not be manufactured manually. This has helped in making highly precise machines, and the chances of mistakes are minimised, thereby reducing wastage.

At present, customers want highly automatic and synchronised systems to improve their product quality and efficiency. They thus make use of microprocessor-controlled highspeed programmable logic controller systems. Another system that helps in increasing efficiency and minimising waste is the supervisory control and data acquisition system, which usually refers to a centralised system that monitors and controls complex systems spread out over large areas. The machines in this system help in achieving zero rejection.

In order to reduce waste, one has to have an appropriate system in place as it helps in improving the overall efficiency of the company.

Using the right machinery will result in cost and operating efficiency and waste reduction in the long run.

M M Biswal Business Head – Polymers, Loxim Industries Ltd

Role of ancillary equipment Ancillary equipment can be the answer to automation requirements of companies and can help reduce wastage to a very large extent. Various companies are developing new technologies that enable efficient recycling of plastic products.

Some companies make machines or auxiliary equipment that help processors in regrinding waste plastic materials; for instance, injection moulding and blow moulding screws can be ground by using granulators and reused further.

In a nutshell As waste is eliminated, the quality improves while production time and cost are reduced. With the ongoing efforts by various companies, the future of the plastics industry will be more environment-friendly. Energy efficiency and waste reduction will be other feats by this industry.

Email: avani.jain@network18publishing.com

We not only make machines but also reuse the plastic waste. This is profitable as we do not have to buy fresh plastic, and we are making products from the already available resources.

Bharat Mistry Partner, Ash Win Engineers

June 2013 | Modern Plastics & Polymers

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SAVING ENVIRONMENT: Plastics recycling

Mapping the challenges and opportunities With increasing focus on saving the environment, the plastics industry is making every effort to recycle plastics to move towards sustainability. Avani Jain notes the steps taken by the industry and government to address the concerns of the plastics recycling sector in India.

Courtesy: Moore Recycling Associates Inc

T

o understand the requirements for recycling plastics, it is important to look into the chemical structure of plastics, whereby they can be successfully reused without causing any environmental damage. In India, approximately 3.6 million tonne of plastics is recycled every year. There are about 3,500 organised and 5,000 unorganised recycling units. The major types of plastics recycled include polyethylene, polypropylene, polyethylene terephthalate, polyvinyl chloride, acrylonitrile butadiene styrene, polystyrene, nylon, polycarbonate, high-impact polystyrene, poly methyl methacrylate and other engineering plastics.

According to the EU Directive on Waste (2008/98/EC) (8), “Recycling means any recovery operation by which waste materials are reprocessed into products, materials or substances whether for the original or other purposes.”

Recycling benefits Recycling helps in reducing waste in 98

Modern Plastics & Polymers | June 2013

landfill and the consequent methane emissions. Recycling of plastic packaging waste, both post-consumer and waste at the time of manufacturing process, is beneficial. An efficient and real-time recycling and returnable process should be implemented to capture and bring back waste to recyclers or packing companies for recycling. Recycling uses less energy and produces less pollution than making the products from scratch. Making bags from recycled polythene takes one-third the sulphur dioxide and half the nitrous oxide than making them from scratch.

Challenges posed The market for sustainable development and awareness about recycling is increasing in India. However, the technology and machines needed for recycling are still not fully developed in India. Companies operating in the Indian market have to import machines and technology from abroad, which makes it a costly affair. Thus, recycling technology solution providers have to spread their

wings to help their customers in the best possible manner.

The main challenge is the correct separation of the waste to be recycled.

Cesar Rodriguez, Chief Executive Officer, MachinePoint Group, notes, “For this reason, industrial recycling, where waste separation has proved to be easier, is economical and environmentally more interesting than post-consumer recycling, where the challenge is the correct separation, cleaning and sorting of all materials.” Thus, the development of technologies for the separation process employed during recycling is one of the major challenges.

Government efforts Nearly all types of plastics can be recycled; however, the extent to which they are recycled depends on technical, economic and logistic factors. Innovations in plastics separation, sorting, washing and de-contamination technologies equipment have made it possible to efficiently collect, separate and recycle rigid packaging

Plastics recycling

plastics. The National Plastics Waste Management Task Force of the Ministry of Environment and Forests, Government of India, has recommended a strategy and action programme of plastics waste management in India. Also, the Bureau of Indian Standards (BIS), New Delhi, has issued guidelines on recycling of plastic waste. All responsible manufacturers of recycled plastic products adhere to the safety rules and regulations laid out by the government.

Further, the government has formulated several rules and regulations so as to cause minimum environmental damage. These rules fall under the Environment Protection Act 1986.

According to the Act, all recycling of plastics shall be undertaken strictly in accordance with the BIS specification IS 14534:1998, ‘The Guidelines for Recycling of Plastic Products’. Manufacturers of plastic products also have to incorporate markings and codings. These markings indicate the type of plastic and also whether it is virgin or recycled. Apart from regulations, The Plastics Industry Association through its member units undertakes self-regulatory measures to protect the environment.

consists of the leftovers of the process to input them back in the process, making this method of recycling the most efficient one,” notes Rodriguez.

Industry initiatives

Future trends

Not only the government but industries are also doing their bit to move towards saving the environment through efficient plastics recycling. Various strategies are adopted by companies for recycling plastics. Rodriguez notes, “Reducing plastic packaging wall sizes with multilayer products will make them lighter but stronger. Another way is to develop monopolymer products, where a bottle, cap and label are made from the same material.

The recycling of this plastic bottle is easier because no product separation will be required as the polymers used are not different.”

Further, various machines that are available in the market can enable easy recycling of plastics. “Size reduction machinery and re-pelletising machinery are mainly used in industrial recycling.

Further, the recycling process usually

The future trends will be to adopt more efficient recycling technologies, increase energy efficiency and further increase economies of scale. Rodriguez avers, “The new trends would include the development of mono products. At the same time, multi-layer products can go for a weight reduction as these are more difficult to recycle. However, the real challenge remains the development of technologies for separation process employed during recycling.”

Further, the integration of conventional waste management methods with commercial viability requires skills and technologies. One has to choose the right method with all the precautions and correct machinery for building profitability through efficient recycling of plastic products.

Email: avani.jain@network18publishing.com

Cost factor Noting the cost factor of plastics recycling, K M Shah, Managing Director, NU-VU Conair Pvt Ltd, says, “Recycling of plastics is a cost-effective solution, which needs to be developed in a proper manner. It gives convertors an edge in today’s competitive market. There are certain areas where recycled plastics in tolerable percentage can be used effectively, and this also makes the products cost effective.”

Growth scenario The need for effective plastics recycling has urged both the industry and policy makers to look into the problem, with particular focus on energy efficiency and recyclability of plastics. With more companies becoming involved in research to develop better means of recycling plastics, the condition is expected to improve both globally and in India.

Till then, a better understanding of the chemical structure of plastics would make their recycling easier.

Industrial recycling, where waste separation has proved to be easier, is economical and environmentally more interesting than post-consumer recycling, where the challenge is the correct separation, cleaning and sorting of all materials.

Cesar Rodriguez Chief Executive Officer, MachinePoint Group

Recycling of plastics is a cost-effective solution, which needs to be developed in a proper manner. There are certain areas where recycled plastics in tolerable percentage can be used effectively, and this also makes the products cost effective.

K M Shah Managing Director, NU-VU Conair Pvt Ltd

June 2013 | Modern Plastics & Polymers

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SAVING ENVIRONMENT: Inter face - Pramthesh Pandya

“One of the most visible trends driving sustainability involve focus on environment-friendly materials”

…opines Pramthesh Pandya, Head – Unit & Business Development, Parikh Packaging Pvt Ltd. In a conversation with Avani Jain, he talks about the various strategies that can be adopted by companies in the plastics segment to save the environment and attain sustainability.

Keeping in mind the environmental concerns, what are the leading innovations making headway in the plastics segment?

Many new concepts have been introduced in the market such as reduction in the usage of plastics at the source (yield improvement), biodegradable laminates etc. Further, the focus today is on sustainable development. At present, one of the most visible trends driving sustainability involves focus on environment-friendly materials.

‘Renewable, recyclable, compostable’ – these green terms are showing up on plastic packages everywhere, from grocery aisles to shoe stores, shipping containers to the retail shelf.

How can the use of biodegradable plastics help in saving the environment and in achieving sustainability?

The American Society for Testing of Materials (ASTM) and the International Organization for Standardization (ISO) define degradable plastics as plastics that undergo a significant change in chemical structure under specific environmental conditions. These changes result in a loss of physical and mechanical properties, as measured by standard methods. Biodegradable plastics also undergo degradation from the action of naturally occurring microorganisms such 100 Modern Plastics & Polymers | June 2013

as bacteria, fungi and algae. Plastics may also be designated as photodegradable, oxidatively degradable, hydrolytically degradable or those which may be composted. At present, there are many biodegradable synthetic resins available such as polyalkylene esters, polylactic acid polyamide esters, polyvinyl esters, polyvinyl acetate, polyvinyl alcohol and polyanhydrides. These materials exhibit degradation promoted by microorganisms, and the reaction is often coupled to a chemical or mechanical degradation step. Thus, biodegradable plastics can definitely help in saving the environment.

How can recycling plastics help in saving the environment?

Recycling should be adopted where it results in lower environmental impacts than alternative recovery options, and where other requirements, such as safety, are met. Some types of recovered material are also a valuable source of energy (eg incineration with energy recovery).

The optimal balance between recycling and energy recovery varies enormously with the composition of the waste. For example, the optimal balance for general waste lies at 70 per cent recycling or composting and 25 per cent energy recovery. By contrast, for lightweight plastics, the optimum balance lies at 15 per cent recycling with 85 per cent

energy recovery. Thus, undertaking recycling of plastics can help address the environmental concerns to a very large extent.

What are the problems associated with sustainable development?

Problems of sustainable development are rooted in issues of resource use and their pattern of distribution and ownership.

Thus, a policy towards sustainable development cannot be framed in isolation to politics and state regulations.

The world community is confronted by economic problems that have further led to resource crisis and environmental despoliation. This leads to constrained economic revival due to which nations find it more difficult to solve problems related to the unsustainable use of the environment.

What are the steps taken by your company in saving the environment?

We are constantly involved in reducing product waste and solvent usage across the manufacturing process, preventing over packaging, improving on energy efficiency through various methods and usage of biodegradable materials to offer sustainable solutions to our customers. Thus, through these steps, we help in saving the environment to a very large extent.

Email: avani.jain@network18publishing.com

SAVING ENVIRONMENT: Inter face - Apur va Kane

“Plastics serve as the cheapest, most lightweight and durable material” …opines Apurva Kane, Senior Vice President, Mamata Machinery Pvt Ltd. In a conversation with Avani Jain, he talks about the perception of people on plastics.

He also underlines the recent innovations and challenges faced by the industry.

The plastics industry is often blamed for polluting the environment. What is your take on this?

The plastics industry is unnecessarily blamed for polluting the environment. If anybody is to be blamed, then it is the poor civic sense of the people in terms of littering the place and civic authorities that are unable to take appropriate steps for solid waste management in urban areas.

Further, it is seen that nearly 22 per cent of agricultural output is wasted because it is not stored or packed properly.

Plastics serve as the cheapest, most lightweight and durable material that can be used to save this wastage. Thus, putting a ban on the usage of plastics is pointless, since till date, there is no alternative material that can take the place of plastics.

With growing environmental consciousness, what innovations are making headway in the segment?

What are your company’s initiatives?

Leading innovations include usage of biodegradable/ compostable films and recyclable & environmentally sustainable films. Many companies recycle plastics, which can reduce pollution to a very large extent.

We focus on developing machines that are versatile and able to process not only laminates but also more sustainable nonlaminated co-extruded films and biodegradable films used for making pouches and bags at high speeds. Even the horizontal form fill seal machine developed by our design team based in the US is able to run unlaminated bare films.

What are the challenges faced by the industry?

The biggest challenge faced by the plastics industry is the wrong perception of people that plastic is polluting. Further, companies need to realise their roles and responsibilities well and put the green foot forward without actually being forced by the government or other regulatory body.

Email: avani.jain@network18publishing.com

June 2013 | Modern Plastics & Polymers 101

SAVING ENVIRONMENT: Roundtable

HOW PROACTIVE ARE

GOVERNMENT POLICIES TOWARDS ENVIRONMENT-FRIENDLY

PLASTICS PROCESSING? Rising energy prices and environmental consciousness are driving the industry towards environmentfriendly plastics processing. Avani Jain speaks to industry experts to find out how proactive are government policies towards environment-friendly plastics processing.

Manish Pathania Sales Director, Greendiamz Biotech Ltd

The usage of environment-friendly plastics, such as bioplastics, is still a new concept in India. The raw materials required to produce bioplastics are not available in India and have to be imported from countries like France.

Because the sourcing of bioplastics resin is a costly affair, it makes these plastics expensive. Hence, not many companies take to manufacturing of bioplastics due to low awareness and high price of bioplastics resin. Further, at present, the technology is not cost-competitive with petroleum-derived plastics as the cost of raw materials required to manufacture bioplastics is very high. Also, the awareness about such plastics is less, and government support to companies in the segment is not up to the mark.

Thus, steps need to be taken by the government to promote bioplastics that are environment-friendly. So, with help from the government and industry, the environment-friendly plastics segment will surely grow in India.

Umesh Sharma Managing Director, Julison Packaging India Pvt Ltd

These days, the government is banning plastic packaging in many states with a view that it harms the environment, but this is a wrong notion as there is no environmental harm caused during plastics processing. In fact, it is practically impossible to ban plastics completely because it is used everywhere. No doubt that plastics discharge harmful toxics into the environment but that is only to a certain extent. Also, no good alternative to plastics is available in the market. So, plastics is the basis of any industry in the country. However, steps can be taken by the government to effectively manage plastic waste.

Instead of banning plastics usage, the government needs to formulate strict guidelines for plastics disposal. The cost of new plastics (bioplastics) could be reduced as otherwise their market would remain restricted as not every company would be able to afford to manufacture bioplastics.

Jigish Doshi Chairman & Managing Director, Vishakha Group

There is absolutely no pollution caused during plastics processing.

Also, companies are coming up with environment-friendly plastics so as to address environmental concerns. In such a scenario, blaming the industry for polluting the environment would be wrong. The industry is taking every step to save the environment.

In fact, the problem is with the waste management system in the country.

Moreover, it is the people who litter the streets and then put the blame on the plastics industry. Even the government is banning plastics. So, this attitude of the government and common man needs to be changed. However, by saying this, we cannot negate the efforts taken by the government. In a few months, the government will place two dustbins for different types of waste so that recycling could be easier. Undoubtedly, this could have been done earlier, but it is better late than never.

Editorial take: Email: avani.jain@network18publishing.com Sustainable development and reducing carbon footprint have become the main principles for the growth of any industry, including the plastics industry.

Plastics processors are increasingly adopting steps for environment-friendly plastics processing. However, government support is required to aid the process. The need of the hour is proactive government policies and industry initiatives for environment-friendly plastics processing.

June 2013 | Modern Plastics & Polymers 103

SPACE MANAGEMENT: Compact machiner y

Less is more!

When referring to the topic of the greening of plastics machinery, the advantages of seeking out energy efficiency in manufacturing equipment is becoming more evident. The plastics industry has become increasingly aware that investment in manufacturing equipment and processes holds the key to making the industry more energy efficient. In the light of such developments, Sweta M Nair tracks the global trends in developing compact machinery for the plastics industry.

P

lastics processing businesses are under competitive pressures and look for costeffective ways to increase profits and return on assets. The way companies manage their property, plant and equipment assets has a tremendous impact on their overall competitiveness and profitability.

Optimum utilisation and performance of these assets are not just desirable but absolutely essential. By optimally locating, sizing, engineering, delivering and maintaining facilities, plastics processing businesses can achieve a competitive advantage and increase profits. The way manufacturing businesses manage their facilities affects their ability to produce and compete in terms of quality, price, delivery, flexibility and customer relationship management.

Customers expect quality products to be delivered at competitive prices,

104 Modern Plastics & Polymers | June 2013

with shorter lead times and less waste than competitors. In an environment where competitors pay approximately the same price for resins, labour and equipment, the difference is the cost, location and performance of their buildings and real estate.

Word on the street By relocating, right-sizing and consolidating operations, plastics processors can become more efficient and cost effective. Improving space layout, workflow and process controls to support new compact technologies, management strategies and business plans may be the way ahead. With skyrocketing realty prices, it is essential for most plastics processors to have effective space utilisation of available shop floor space management for maximum performance in minimum space. On this topic, Sundaram Subramanian, Chief Executive

Officer, Karan Engineering Co (exclusive agent in India for Dr Boy GmbH & Co KG, Germany) says, “At Dr Boy, our slogan is ‘Great Machines - Compactly Designed’.

Owing to the small footprint, the compact design and easy accessibility of all components reduce the actual space requirement by almost onethird. Therefore, more machines can be placed in a specified area. Our Boy XS Ultra machine used for micro component moulding offers shot sizes that range from 0.1 g to 7.8 g and has a robust design and footprint of 0.8 sq m. Ideally suited for micro injection and sprueless moulding, this machine is economical and precise with good repeatability.”

Compact machinery is slowly becoming the predominant theme among the small and mediumsized entrepreneurs where areas are being explored as to how one

Compact machiner y

Owing to the small footprint, the compact design and easy accessibility of all components reduce the actual space requirement by almost one-third.

Sundaram Subramanian CEO, Karan Engineering Co (exclusive agent for Dr Boy GmbH & Co KG, Germany)

can decrease footprint through innovations in manufacturing processes. Another motivating factor in increasing the adoption of compact machinery is energy efficiency of manufacturing operations. On an average, manufacturing of plastic products consumes massive amounts of electricity. Energy costs alone can stunt a company’s competitiveness, especially small and mediumsized companies that cannot afford a sharp rise in operating expenses. This is one reason why small steps to increase energy efficiency have gained momentum in the move towards installing compact machinery.

Trending factors Globally, the market size of compact machinery is increasing by 20 per cent every year. For reasons such as reduced space requirement, low energy cost, low tool investment and highly precise moulding, compact machinery could have a significant impact on the Indian plastics industry. “With this type of machinery, since processors would be able to line up more machines, this would ultimately translate into better profit margins as well,” states Subramanian.

He adds, “From our series of machines, Boy XS 10, 22, 35 and 55 tonne are being adopted by Indian processors for micro component moulding for high precision consistency and repeatability. With a footprint of 0.8–4 sq m, we expect a 15 per cent growth of Boy machines in the Indian market. Less space requirement, reduced tool investment, high precision and consistent repeatability will be the main drivers of this machinery, which could also offer faster payback and high profitability. With a low running cost, which means energy saving up to 50 per cent, most compact machines of Boy have an energy consumption of 0.8–3 units/hr, even for the 55 tonne model. Moreover, with the Procan ALPHA® 2 control, the machines present the latest generation of machine controls.

Thus, the control combines innovative technology and long-term, practical experience and will continue the success story of the Procan control systems. The smart intuitive control system comes with a touch surface that has been protected against damage with stable single safety glass cover.”

Email: sweta.nair@network18publishing.com June 2013 | Modern Plastics & Polymers 105

SPACE MANAGEMENT: Minimalism in manufacturing

Managing space and machinery All available forecasts suggest a rising demand for plastics in the next few years. New technologies will allow Indian processors an unprecedented long-term boost in productivity, but their management skills with regard to space and machinery will also come into play. Sweta M Nair finds out how Indian processors can manage all of it without losing any productive efficiency.

W

ith few clouds on the horizon, strong growth is likely for most players in the plastics industry. There will be ups and downs, but overall, as far as the plastics industry is concerned, the ups will prevail. The next five years are going to be crucial, where players can look at solid growth.

In practical terms, this means that the massive capital investment of the past five years will not only pay off but is likely to continue. In the light of such promising growth how are the Indian processors or moulders prepping themselves to withstand the upcoming wave of demand?

In the books Continued increases in manufacturing productivity hold the key to maintaining overall growth in the Indian plastics industry. In the past few years, productive efficiency has been rising at a fast rate; this can be attributed to the processors’ management skills when it comes to space and machinery.

One of the simplest ways of achieving efficiency is to use visual management – where processors can implement a shop floor layout with clear and concise instructions at each employee’s workstation. By removing complexity from the shop floor and providing concrete visual and descriptive aids, companies can get a better control over the plant’s overall performance. This will utilise all personnel to develop a particular system that will eventually ease the load off from one’s quality control systems.

W hen implemented properly, manufacturing operation can become a profitable venture, the result of which 106 Modern Plastics & Polymers | June 2013

is reduced scrap rates. Productivity is increased through a well-designed approach and downtime becomes consistent due to the established approach, helping companies schedule their resources more efficiently.

Effective visual management uses colour coding to improve workplace performance, numbering tooling & tools, standardising overall operation and training & communication. Elaborating on the manufacturing layout in a facility so as to ensure increase in production efficiency, Ranadip Basu, Plant Manager, Trelleborg Industrial Products India Pvt Ltd, says, “The manufacturing layout has been designed to ensure there is maximum utilisation of available space while keeping the principles of lean manufacturing in mind. For instance, equipment is laid out in the sequence of process flow, cellular concepts have been adopted where possible, transportation of parts from warehouse to production floor & movement of parts between cells are minimised and emphasis on

efficient utilisation of vertical space have all been taken into consideration.

Layout optimisation, ergonomic design, minimum transportation, high level of 5S and efficient ventilation systems are prerequisites for efficient utilisation.

Automation may or may not have a role to play depending on the product and level of automation being used.”

Physical amendments Amid efficiency and improving techniques, there is a certain solution that can in reality open up space on the shop floor. The global connotation of compact machinery is finding its way to India as well. Talking about the development of compact machinery, Jignesh Bavishi, Director – Neejtech India (representing NIIGATA, Japan), says, “Couple of decades ago, the large amount of steel and castings used in the structural formation of machinery was considered to be sturdy designs.

Many a times, they were over-designed machines. Input costs of steel for these

Minimalism in manufacturing machines at that time were not much significant compared to other parts and equipment. Over a period of time, everywhere the slim-fit phenomenon took deeper root for manufacturers of machinery. Designers using computeraided design and finite element analysis focussed on optimised designs that resulted in lightweight machines with better efficiencies. This in turn had reduced the manufacturing cost of machines.�

Saturation of available space in existing factories and skyrocketing land & building prices are causing moulders to look for compact and efficient machinery.

Because Indian moulders, like the rest, want to be more productive and cost effective, the compact machines have opened an avenue for them to expand their business in given land and building by securing more machines in the given space. Saturation of available space in existing factories and skyrocketing land and building prices are causing moulders to look for compact and efficient machinery. For instance, in all-electric injection moulding machines, the utilisation of ball screws in place of hydraulic cylinders made the mechanisms more efficient and more compact due to no extension of clamp cylinder behind the end platens. Large oil tanks have been replaced by small electrical panels. Clumsy piping and hose pipes laid across unproductive spaces have been replaced by simple neat and clean electrical cables not protruding outside the machines.

Peripheral control Controlling activities on the shop floor in reality could translate to a whole lot of advantages for the company.

Understanding that each shift is an individual team, but keeping communications effective for the whole company is also crucial. Developing a solid approach for shift interaction ensures that communication on quality, scheduling or current status is crisp and clear. An engineered and wellplanned factory will keep every one on the same page as they will all know the status of a single process, product line, shipping dock and more. Thus, smooth functioning could be achieved without the use of oil – at least one area evades the occurrence of unwanted grease!

Email: sweta.nair@network18publishing.com June 2013 | Modern Plastics & Polymers 107

SPACE MANAGEMENT: Inter face - Raj Singh Rathee

“More companies are applying industrial automation” ...states Raj Singh Rathee, Managing Director, KUKA Robotics (India) Pvt Ltd, when referring to automation as an avenue to open up space on the shop floor. While talking to Sweta M Nair on the company’s latest offerings, he sheds light on the developments that are taking place in the automation side of the business.

What are your thoughts on the adoption of automation solutions in the Indian plastics industry?

Being easy to manufacture, plastics is the chief alternative to metal. As far as automation in this industry is concerned, we do not follow any machinery growth trends since that might mislead us because the tonnage of a machine is the deciding factor on the kind of automation that can be used. However, in the Indian scenario, we were the first ones in the robotic segment to take the lead. Due to this, we have grown considerably over the years. Initially, a lot of questions were asked about the benefits of industrial automation; some companies grasped this and standardised the use of robots in their facilities. At present, other than the automotive segment, because the use of plastics has been increasing, more companies are applying industrial automation.

To better utilise space on the shop floor, what role does industrial automation play globally?

Improving and maintaining consistency of production along with opening up space on the shop floor are advantages of using industrial automation. Moreover, robots come in handy when handling bigger plastic parts because the work can be done faster in comparison with manual labour.

The new generation of robots also involve secondary operations that further justify 108 Modern Plastics & Polymers | June 2013

its cost. Taking the plastic part out from the mould and clinching extra parts while it is on the way to its final destination can be considered as secondary operations.

This means the time in between cycles can be utilised to the fullest with the help of industrial automation. Ultrasonic welding is another area where robotics is used, but this is a relatively new concept.

Because the Indian plastics industry mainly uses shelf-mounted robots, we have launched QUANTEC K, which is new generation automation. Owing to its maximum flexibility in the system planning & design phase, reduced conception & design work and greater planning security, this series makes automation easier in the plastics industry. With the latest stateof-the-art drive technology and the new KR C4 controller, the QUANTEC K robots achieve up to 25 per cent shorter unloading times and up to 30 per cent less energy consumption. The QUANTEC K ultra line has a payload of 270 kg for a reach of 2,900 mm and a payload of 120 kg for a reach of 3,900 mm.

What is your company’s top technology development in the recent years for the plastics industry?

KUKA’s lightweight robot LBR iiwa (intelligent industrial work assistant) was launched at the Hanover Fair this year. With built-in sensitivity achieved by integrated sensors, the LWR iiwa is ideally suited to handling and assembly

tasks. Because of its low weight of 14 kg, the robot is energy efficient and portable, and it can thus be used for a wide range of different tasks.

The joints of this lightweight robot are connected using CRP structures, and its remaining components are also optimised for weight. Through the integration of this new-generation robot with the PC-based KUKA robot controller, a completely new type of robot is emerging. We have long been concerned with the topic of human– robot cooperation, and this intelligent robot supports the human operator with its high-quality work. The LWR iiwa is an important milestone on the road to service robotics.

Do you perceive indigenisation as a crucial area in terms of satisfying domestic demand?

This is not necessary as our robots are designed to work in harsh and more demanding conditions. Our robots are loaded with features that are not even fully utilised in some Indian facilities.

For instance, we have different kinds of safety norms embedded in our systems that are normally not used by our Indian customers. This exists because safety regulations in Europe are relatively more stringent. However, we have made a few changes to the shelf-mounted series, where we extended its base. This gives customers the benefit of a better reach.

Email: sweta.nair@network18publishing.com

SPACE MANAGEMENT: Inter face: Parag N Dave

“The need for compact machinery was being feltâ€? ‌says Parag N Dave, CEO, Dave Technical Services, as he narrates the rise of this profound type of machinery. Keeping in line with the changing times, he talks to Sweta M Nair about the universal amendments in compact machinery.

What has led to the development of compact machinery for the global plastics industry?

The plastics industry has come a long way with new ideas and concepts being put to work by manufacturers across the globe aiming for better quality and output with minimum resources involved. With rising demands for micro mouldings and specific parts developments that require machines built keeping the application in focus, conventional machines were a compromise on all fronts. It was then that the need for compact machinery was being felt. Space saving is of course the first visible benefit that anyone can predict, but compact machinery provides many more advantages and flexibilities.

What are the changes required to make compact machinery efficient?

Choosing a right injection moulding machine for the required product is in itself a versatile process. It is a wellknown fact that injection machines essentially have an injection and clamping unit. All the developments take place with these two units being upgraded and built to provide adequate injection pressure and clamping tonnage for getting the expected level of product quality and quantity. Earlier, the ranges of machines were limited, with more or less similar machines offered to

customers. At Dave Technical Services, the DTS Mini Hand Injection Machine is a vertical moulding machine for hand moulds and is also available for fixed (vertical), plunger (RAM) and lever operated moulds. It works on single and three phase operations.

How does one gauge the suitability of compact primary machinery?

In the injection moulding process, efficiency and profitability depend on whether the machine chosen for the particular product serves the purpose.

The machine has enough shot capacity to completely fill all the cavities with adequate pressure, while the clamping force is higher than this injection pressure to ensure positive mould clamping, avoiding its opening under pressure.

Each product is unique and requires different force to fill the cavity. Hence, an initial study of the product mould design with respect to requirement is very important, and then, based on the number of cavities in the mould, an adequate machine must be chosen for production.

With the availability of compact machinery in different shot and clamping options, flexibility is obtained for fast production at lower power

consumption rates, lesser rejections and better quality control. The ongoing developments in allied fields related to machine manufacturing such as providing upgraded and efficient parts and components to the machine manufacturers (eg pump motors, gear boxes, servo motors, automation and hydraulics) have changed the face of injection moulding machines across the globe.

Could you highlight the benefits of this type of machinery?

Mould designs have become flexible with the availability of a wide range of machines to choose from. This helps the designer to create faster production cycles. Micro to small and mediumsized products such as light-emitting diodes, watch parts, miniature moulding parts (eg gears, connectors, electronic parts, appliances and industrial parts), medical parts, packaging and many other applications are being produced with this technological innovation. In compact machinery, with regard to the control system, the option to choose from electrical panel to programmable logic controller and full microprocessor control system is available. Today, one can control and monitor processing variables (temperature and pressure) at each specific point in the manufacturing process, providing complete control over the moulding machine, mould and polymer processing. This eliminates costly errors and enhances overall productivity, quality and profitability of the organisation.

Email: sweta.nair@network18publishing.com

June 2012 | Modern Plastics & Polymers 109

An invite that rewards as well...

Dear Reader, ‘Modern Plastics & Polymers’ solicits original, well-written, application-oriented, unpublished articles that reflect your valuable experience and expertise in the plastics & polymers industry.

You can send us Technical Articles, Case Studies and Product Write-ups. The length of the article should not exceed 1500 words, while that of a product write-up should not exceed 100 words.

The articles should preferably reach us in soft copy (either E-mail or a CD). The text should be in MS Word format and images in 300 DPI resolution & JPG format.

The final decision regarding the selection and publication of the articles shall rest solely with ‘Modern Plastics & Polymers’. Authors whose articles are published will be sent a complimentary copy of that particular edition.

Published by Infomedia 18 Ltd, ‘Modern Plastics & Polymers’ is one of the leading monthly magazines exclusively meant for producers and user fraternities of the plastics industry. Well supported by a national readership of over 80,000 and our strong network of 26 branch offices across India, this magazine reaches out to key decision makers among the Indian manufacturers of plastics products, machinery and allied sectors.

Brought out in association with Hong Kong-based Ringier Trade Media Ltd (one of the world’s largest trade publishing houses with more than 200 special interest titles and offices in every major country), it ensures that advertisers are able to promote their products and services across the globe at no extra cost.

So get going and rush your articles, write-ups, etc…

Thanking you, Yours sincerely,

Manas R. Bastia Senior Editor Modern Plastics & Polymers Network18 Media & Investments 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@network18publishing.com W www.network18publishing.com

SPACE MANAGEMENT: Roundtable

HOW DOES THE

ENGINEERING PROWESS OF COMPACT MACHINES TRANSLATE TO MANUFACTURING

BENEFITS? As economic recovery has a large impact on the plastics industry, companies are starting to invest into their pipeline. As they put more equipment back into service, they are considering different options. For small and medium-sized enterprises, the developments in the field of compact machinery seem to attract a lot of attention. Sweta M Nair gets some fresh and thought-provoking comments on its engineering prowess.

Parag N Dave CEO, Dave Technical Services

Jignesh Bavishi Director, Neejtech India (representing NIIGATA, Japan)

Apart from offering conventional moulding machines, we have taken a step ahead by providing small investment projects in the form of small vertical injection moulding machines suitable for hand/fix moulds. The machines are simple to operate and are efficient because they have control over temperature and pressure, thus providing similar quality parts that one would get from conventional machines. Regarding the engineering prowess of compact machinery, at Dave Technical Services we offer vertical injection machines for hand moulds in 20 & 40 g shot capacity and machines for fix moulds plunger (Ram) type in 40/60 & 80 g. The fully automatic vertical screw type moulding machines are available in 60/80/100 g capacity. We are working on an ambitious project that will offer a very small automatic pneumatic injection machine working on a single phase. We aspire to generate industry development in rural areas and thereby increase employment.

Sundaram Subramanian CEO, Karan Engineering Co (exclusive agent for Dr Boy GmbH & Co KG, Germany)

Sky rocketing prices of real estate has made expansions of manufacturing facilities difficult. Effective utilisation of shop floor space by investing in compact machinery could be a real boon for plastics processors. Moulders can conserve capital investment in land and further accommodate more compact machines in the available space. Compact machinery can help reduce energy costs. Its application is suitable for producing high-precision components, and the benefits of its repeatability for maximum performance with minimum space requirement can be reaped. This leaves the processor with additional space that could be utilised for automation integration in the production environment. Also, after considering certain aspects, more machines could transpire to more profits. For product variants demanding factory machinery layout, changes can be done with relative ease and with less constraints using compact machinery.

With compact machinery, we are looking at benefits of maximum flexibility, small footprint, optimum production conditions etc. Dr Boy compact machines offer maximum flexibility; the two platen clamping system is suited for compact clean room applications, automation and integration into various production environments. The machine’s small footprint (ranges from 0.8 sq m for 10 tonne machines to 4.65 sq m for 90 tonne ones) reduces space requirement by one-third, thereby allowing more machines to be placed in a specified area. The machine also provides easy access to all machine components such as the mould area and peripheral equipment. Its intuitive control system has a touch screen where operating functions such as scrolling and page changes can be done by swiping.

Further, energy savings up to 50 per cent can be achieved with the help of a servo motor pump system.

Editorial take: Email: sweta.nair@network18publishing.com If space is a company’s most limiting factor, then compact machinery could be a blessing in disguise. However, size alone should not be the deciding factor here as volume of production is equally crucial. Nevertheless, for an industry experiencing an entrepreneurial wave, compact machinery could make a huge difference.

June 2013 | Modern Plastics & Polymers 111

FACILIT Y VISIT: Jain Irrigation Systems Ltd

A multinational company with a turnover in excess of ` 4,200 crore, Jain Irrigation Systems Ltd attributes its pan-India and global presence to its 27 manufacturing facilities that are spread across four continents.

Sweta M Nair visits the Jain Plastic Park at Jalgaon to experience manufacturing by the largest processor of thermoplastic piping in India.

B

eing one of the largest micro irrigation companies in the world, Jain Irrigation Systems Ltd’s businesses include a complete range of micro irrigation systems and components, Polyvinyl Chloride (PVC) & Polyethylene (PE) piping systems, PVC sheets, solar water heaters, lighting & pumping solutions, processed fruits & vegetables, tissue culture, green houses etc. With regard to the Group’s plastics business, the facility in Jalgaon is spread on approximately 325 acre of land and stands as an epitome of manufacturing exuberance. The Group commenced operation at the Jain Plastic Park in 1986–87 by manufacturing pipes and gradually expanded its portfolio. Prior to this, in the 80s, the company was a dealer of several plastics manufacturers.

However, it forayed into manufacturing to satisfy the rising demand.

Urban design The Jain Plastic Park is a systematically laid out production park that manufactures 112 Modern Plastics & Polymers | June 2013

An employee verifying the thickness of a polyethylene pipe

the inputs required for water extraction and management. The fully integrated plastics processing plant is equipped with state-of-the-art manufacturing and testing equipment. This facility, in particular, has quite a few distinctions to its credit. Other than being one of the largest processors of thermoplastic resins in India, it is capable of manufacturing PE piping in up to 1.6 m in diameter, including all types of fittings. Being the largest micro dripper manufacturing

facility in the world, it is also the only integrated fittings manufacturer with extensive in-house capability for mould design, manufacturing and injection moulding. Owing to its huge capacity of manufacturing Linear Low-density Polyethylene (LLDPE) drip tubes and tapes, this facility also produces most components required for micro irrigation systems such as PVC & High-density Polyethylene (HDPE) piping, LLDPE drip tubes & tapes, drippers, stakes,

Jain Irrigation Systems Ltd

couplers, fittings, valves, sprinklers of all types, filter elements & filters, venturi etc.

The park is divided into smaller facilities based on production and works 24/7. Due to the scorching temperatures that are prevalent in Jalgaon in the summers, all the units are naturally ventilated, and the park is surrounded by lush green lawns. All the green space is irrigated using recycled water. Elaborating on the significance of this facility, Atul B Jain, Joint Managing Director, Jain Irrigations Systems Ltd, says, “My father Bhavarlal Jain pioneered the entry of ‘micro’ irrigation in India. While we were not the first ones to get into drip irrigation in India, our hard work has ensured a 60 per cent market share in India. Each of our products and services are aimed at conservation of precious resources and increasing productivity of agricultural land and the farmer with whom we work on the concept of ‘More from less for more’.

With worldwide experience, it is here that our intervention of delivering endto-end solutions becomes relevant even to small farmers. Having pioneered the micro irrigation systems in India, which ushered in the second green revolution, we are striving to optimise crop production, water delivery and recycling systems.”

Good measures Certified to OHSAS 18001:2007 since 2009, the Jain Plastic Park, which consists of a 3,207 strong workforce, continues to implement the occupational health and safety management system. As part of system organisation, the Group

carries out detailed hazard identification risk assessment analysis of its activities including compliance to legal and other requirements. Before any process, risk assessment and ensuring control measures are mandatorily carried out in the plant and followed in other facilities as well. Protective equipment is provided wherever required.

Right from inception, Jain Irrigation Systems Ltd has ensured to build all its activities around conserving the environment. “Two major products of the Group, micro irrigation systems and PVC & HDPE pipes, find extensive use in both water management and water conservation. Similarly, the other major product, extruded plastic sheets, primarily serves to replace the use of precious natural timber in the construction and building industry. Extruded PVC sheets, particularly in the higher thickness, are a well accepted and a popular replacement for lumber application,” states Jain.

In Jain Plastic Park, quality checks are carried out to meet or surpass the relevant national or international standards specified. The ‘Quality Assurance’ and ‘Quality Control’ departments house extensive plastics testing laboratories that work around the clock. As part of its activities, the facility carries out regular testing of air emission, wastewater analysis and suitable disposal of solid wastes as per the guidelines of the Maharashtra Pollution Control Board. The facility has created and maintained rainwater harvesting, storage, recharge & recovery structures, and now it is working on a zero discharge model.

Having pioneered the micro irrigation systems in India, which ushered in the second green revolution, we are striving to optimise crop production, water delivery systems and recycling systems.

Atul B Jain Joint Managing Director

Delighting customers With innovation being an on-going process, the Group is continuously fine tuning and modifying its products to suit individual client and situational demands. Keeping in view developments in raw material, product development is a regular activity based on requirements and cost optimisation. Jain adds, “We work closely with many international resin manufacturers to develop products surpassing client expectation and also to offer new products that delight customers. All new product enquires are reviewed by the R&D team meticulously.”

Email: sweta.nair@network18publishing.com

A well-laid out polytube plant at the facility

June 2013 | Modern Plastics & Polymers 113

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.

Corrugated pipes (PVC) Rex Polyextrusion Ltd Project type New facility Project news Rex Polyextrusion Ltd is planning to set up a new plastics project at Sangli in Maharashtra. The project involves manufacturing of corrugated pipes (PVC).

Project location Sangli, Maharashtra Project cost NA Implementation stage Planning Contact details: Rex Polyextrusion Ltd 1077, Kumar Plaza North Shivaji Nagar Opp. KWC College Tal. Miraj, Sangli 416 416 Maharashtra

Laminated printed films

Moulded industrial accessories of plastic

Polyester film

Poly Plastics Industries India Pvt Ltd

Project type New facility Project news SRF Ltd is planning to set up a new polymers project at Udhamsingh Nagar in Uttarakhand. The project involves manufacturing of polyester film.

Project location Udhamsingh Nagar, Uttarakhand Project cost NA Implementation stage Planning

Project type New facility Project news Poly Plastics Industries India Pvt Ltd is planning to set up a new plastics project at Pune in Maharashtra. The project involves manufacturing of moulded industrial accessories of plastic.

Project location Pune, Maharashtra Project cost NA Implementation stage Planning Contact details: Poly Plastics Industries India Pvt Ltd Plot No. B-30/2 MIDC Ranjangaon Karegaon Shirur Pune 412 209 Maharashtra

Colourflex Laminators Ltd Project type New facility Project news Colourflex Laminators Ltd is planning to set up a new polymers project at Gandhinagar in Gujarat. The project involves manufacturing of laminated printed films.

Project location Gandhinagar, Gujarat Project cost NA Implementation stage Planning Contact details: Colourflex Laminators Ltd Ff-130, Shukan Mall Science City Road Sola Ahmedabad Ahmedabad 380 060 Gujarat 114 Modern Plastics & Polymers | June 2013

Plastic flushing cisterns Espiem Plastics Ltd Project type New facility Project news Espiem Plastics Ltd is planning to set up a new plastics project at Kancheepuram in Tamil Nadu. The project involves manufacturing of plastic flushing cisterns.

Project location Kancheepuram, Tamil Nadu Project cost NA Implementation stage Planning Contact details: Espiem Plastics Ltd L-5, Sipcot Indl Park Phase-Ii, Sriperumbudur Kancheepuram 602 105 Tamil Nadu

SRF Ltd

Contact details: SRF Ltd C-8, Commercial Complex Sufdarjung Development Area New Delhi 110 016

Polyethylene terephthalate polymer chips Micro Polpet Pvt Ltd Project type New facility Project news Micro Polpet Pvt Ltd is planning to set up a new polymers project at Karnal in Haryana. The project involves manufacturing of polyethylene terephthalate polymer chips.

Project location Karnal, Haryana Project cost NA Implementation stage Planning Contact details: Micro Polpet Pvt Ltd 303, 304, Gopal Heights Netaji Subash Palace New Delhi 110 034

PROJECT S

Polypropylene/high-density polypropylene/laminated fabrics/ woven sacks

Polyvinyl chloride pipes and fittings Prince Industries

Ultra high molecular weight polyethylene

Project type New facility Project news Prince Industries is planning to set up a new plastics project at Haridwar in Uttarakhand. The project involves manufacturing of polyvinyl chloride pipes and fittings.

Project location Haridwar, Uttarakhand Project cost NA Implementation stage Planning

Reliance Industries Ltd

Contact details: Prince Industries Plot No. 5b, Sector 3 Iie-Sidcul Haridwar 249 403 Uttarakhand

Contact details: Reliance Industries Ltd 222, 3rd Floor Maker Chambers IV Nariman Point Mumbai 400 021

Printed poly flexibles and poly pouches

Unsaturated polyester resin

Polyvinyl chloride compound

ITC Ltd

Motherson Sumi Electric Wires

Project type New facility Project news ITC Ltd is planning to set up a new polymers project at Chennai in Tamil Nadu. The project involves manufacturing of printed poly flexibles and poly pouches.

Project location Chennai, Tamil Nadu Project cost NA Implementation stage Planning

Project type New facility Project news Graphite India Ltd is planning to set up a new polymers project at Nashik in Maharashtra. The project involves manufacturing of unsaturated polyester resin.

Project location Nashik, Maharashtra Project cost NA Implementation stage Planning

Geeta Industries Pvt Ltd Project type Facility expansion Project news Geeta Industries Pvt Ltd is planning expansion of a polypropylene/highdensity polypropylene/laminated fabrics/ woven sacks manufacturing unit.

Project location Uttarakhand Project cost ` 5 crore Implementation stage Planning Contact details: Geeta Industries Pvt Ltd A-4 & A-5, Udyog Kunj Panki Site V Kanpur 208 022 Uttar Pradesh Tel: 0512-3198080 Fax: 0512-223393

Project type New facility Project news Motherson Sumi Electric Wires is planning to set up a new plastics project at Kancheepuram in Tamil Nadu.

The project involves manufacturing of polyvinyl chloride compound.

Project location Kancheepuram, Tamil Nadu Project cost NA Implementation stage Planning Contact details: Motherson Sumi Electric Wires Div. of Motherson Sumi Systems Ltd F-7, Block B1, M.C.I.E. Mathura Road New Delhi 110 044

Contact details: ITC Ltd SBU-Packaging & Printing Thiruvottiyur Chennai 600 019 Tamil Nadu

Project type New facility Project news Reliance Industries Ltd is planning to set up a new polymers project at Bharuch in Gujarat. The project involves manufacturing of ultra high molecular weight polyethylene.

Project location Bharuch, Gujarat Project cost NA Implementation stage Planning

Graphite India Ltd

Contact details: Graphite India Ltd Gut No. 523/524 Village Gonde Igatpuri Nasik 422 403 Maharashtra

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

June 2013 | Modern Plastics & Polymers 115

TENDERS

Latest Popular Tenders brought to you by www.tendersinfo.com 3D prototyping

Sanitary bags

Org : Politechnika Poznanska TRN : 16003085 Desc : Delivery, performance, configuration and start-up position for 3D prototyping BOD : 10 June 2013 Loc : Poland BT : Global (ICB)

Org

Plastic bucket

Waste collection bins and bags

Org : Ministério da Educação TRN : 15976650 Desc : Supply of plastic bucket toxic PVC resistant, graduated with a capacity of 20 litre BOD : 10 June 2013 Loc : Brazil BT : Global (ICB)

Org : Služba, Mestský Podnik Stropkov TRN : 15879302 Desc : Purchase of bins, containers, composters, collecting bags and accessories for separated waste collection BOD : 11 June 2013 Loc : Slovakia BT : Global (ICB)

Polypropylene sandbag

Packing strip roll

Org TRN Desc BOD Loc BT

Org TRN Desc BOD Loc BT

: : : : : :

Ministry of Defense 16047046 Supply of woven polypropylene sandbag 10 June 2013 Israel Global (ICB)

: Hospital Universitario Cruces - Osakidetza Servicio Vasco de Salud TRN : 15945816 Desc : Provision of sanitary bags BOD : 11 June 2013 Loc : Plaza de Cruces, Spain BT : Global (ICB)

: : : : : :

C G Rajya Beej Evam Krishi Vikas Nigam Ltd 15833171 Supply of packing strip roll 13 June 2013 Raipur, Chhattisgarh Domestic (NCB)

Plastic wrapping reels, gloves, plastic bags

Laminated sheet

Org : Egypt Air Company for Flight Services TRN : 15724900 Desc : Supply of plastic wrapping reels & gloves and plastic bags for ice and blankets BOD : 11 June 2013 Loc : Cairo BT : Domestic (NCB)

Org : North Eastern Railway TRN : 16051954 Desc : Supply of decorative thermosetting synthetic resin-bonded laminated sheet of size 2.44 m × 1.22 m, 3.0 mm thick BOD : 14 June 2013 Loc : Uttar Pradesh BT : Domestic (NCB)

Printed polythene bags

Garbage bag

Org TRN Desc BOD Loc BT

Org TRN Desc BOD Loc BT

: : : : : :

C G Rajya Beej Evam Krishi Vikas Nigam Ltd 15833074 Supply of printed polythene bags 11 June 2013 Raipur, Chhattisgarh Domestic (NCB)

116 Modern Plastics & Polymers | June 2013

: : : : : :

City of Kyoto 16066746 Supply of designated garbage bag 17 June 2013 Kyoto Global (ICB)

TENDERS

Latest Popular Tenders brought to you by www.tendersinfo.com Garbage bag

Bags

Org TRN Desc BOD Loc BT

Org

: : : : : :

Kyoto City 16066747 Supply of designated garbage bag 17 June 2013 Kyoto Global (ICB)

Garbage bags Org

: Product Distribution Centre

TRN : 16042255 Desc : Supply of medical and non-medical use bags BOD : 25 June 2013 Loc

: Columbia

BT

: Global (ICB)

: Intercommunale Hygea

TRN : 15963798

Plastic sheets

Desc : Providing bags for garbage

Org

BOD : 17 June 2013

TRN : 15833174

Loc

: Le Havré, France

Desc : Supply of mulching sheet and pond lining

BT

: Global (ICB)

BOD : 25 June 2013

Plastic injection equipment Org

: C G Rajya Beej Evam Krishi Vikas Nigam Ltd

Loc

: Raipur, Chhattisgarh

BT

: Domestic (NCB)

: Représentation Economique et Commerciale de la Région de Bruxelles

Polythene liner

TRN : 16046888

Org

Desc : Supply of horizontal injection moulding

TRN : 15999365

presses with single press blower,

Desc : Supply of alkathene liner 500 gauge (0.127 mm+/10%) thick polythene

air compressor and hot runner moulds for plastic injection

: Ordnance Factory Board

BOD : 25 June 2013

BOD : 18 June 2013

Loc

: Madhya Pradesh

Loc

: Algeria

BT

: Domestic (NCB)

BT

: Global (ICB)

Trash bags Org

Bags Org

: Communauté de Communes de l’Orée de Bercé Belinois

: Ministry of Defence

TRN : 15607193

TRN : 16035241

Desc : Supply of buoyancy bags

Desc : Supply of trash bags

BOD : 22 June 2013

BOD : 28 June 2013

Loc

: Jammu and Kashmir

Loc

: France

BT

: Domestic (NCB)

BT

: Global (ICB)

Org: Organisation’s name, TRN: Tendersinfo Ref No, Desc: Description, BOD: Bid Opening Date, Loc: Location, BT: Bidding Type.

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

June 2013 | Modern Plastics & Polymers 117

EVENT LIST

National

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

For details contact: Network18 Media & Investments Ltd, Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028.

Tel: 022 3003 4651 • Fax: 022 3003 4499 Email: engexpo@infomedia18.in Web: www.engg-expo.com

day event to be held in Hyderabad.

Industry leaders and key market regulators from processing, packaging, supply chain and converting industries will attend this show and will discuss the current trends related to these industries. Conferences, product launches, meeting with customers and networking opportunities will be the highlights of this mega event; July 5–8, 2013; at Hyderabad International Trade Exposition Centre (HITEX), Hyderabad For details contact: Prateek Kaushik Print Packaging.Com Pvt Ltd F 101, Tower No. 7, First Floor International Infotech Park Vashi Railway Station, Vashi Navi Mumbai, Maharashtra Tel: 022-27812093/27812619 Mob: 09899981610 Website: www.packplus.in

Pharmapack Expo IPLEX Chennai The Tamil Nadu Plastics Manufacturers Association, the organiser of IPLEX, has come forward to exhibit various moulds and dies, equipment and machinery exclusively required by the plastics manufacturing sector of India. The exhibitors are well versed with the respective range of products so that attendees can select the best for their firms; June 27–30, 2013; at Chennai Trade & Convention Centre, Chennai, Tamil Nadu For details contact: Senthil Kumar N The Tamil Nadu Plastics Manufacturers Association C-1, First Floor, Rams Square Village Road, Nungambakkam Chennai, Tamil Nadu Tel: 044-28250107

PackPlus South PackPlus South 2013 will be a four118 Modern Plastics & Polymers | June 2013

Pharmapack Expo is the most cost-effective marketing opportunity and is the best opportunity to meet senior buyers and decision makers from all facets of the user industry.

The exhibits will include packaging materials & products, glass & plastic jars and bottles, aluminium & plastic tubes, corrugated & cardboard boxes, dosing machines for liquids & powders, filling machines, blister packing machines, strip packing machines, labels & labelling equipment, form-fill-seal machines etc; September 12–14, 2013; at Bombay Exhibition Center (BEC), Mumbai For details contact: Intel Trade Fairs & Expositions Pvt Ltd 113, New Sonal Link Industrial Estate Building No. 2, Link Road Malad (W ), Mumbai 400 064 Tel: 022-26003977 Email: info@intelexpo.com Website: www.pharmapackexpo.in

PlastShow PlastShow is dedicated to offering a comprehensive range of plastic products and processing equipment. The event strives to offer complete information about the recent inventions of the plastic manufacturing sector. The exhibitors find this expo to be the perfect business meeting place where the exhibiting companies get an opportunity to establish themselves and promote their brands; September 27–30, 2013; at Vapi Industrial Association Ground, Vapi, Gujarat For details contact: Brijesh Purohit Sunline Infotech, 118, Lotus Arcade Opposite Automotive, Gondal Road Rajkot, Gujarat Tel: 0281-2460135

Plastivision India Designed to help exhibitors and visitors to discover potential markets, Plastivision India will be the 9 th in the series of national exhibitions and seminars organised by the All India Plastics Manufacturers’ Association (AIPMA). With participation from more than 45 countries and visitors from over 61 countries, the event will include exhibitors from categories such as raw materials & chemicals, plastic packaging machinery & equipment, machinery & equipment for processing, recycling, pre & post processing machines, plastic extrusions, thermoforming/films/ thermoplastics etc; December 12–16, 2013; at Bombay Exhibition Center (BEC), Mumbai For details contact: AIPMA A-52, Street No. 1, M I D C, Marol Andheri (East), Mumbai Tel: 022-28217324/28217325/ 28352511/283 Fax: 022-28216390 Email: marketing@plastivision.org Website: www.plastivision.org

EVENT LIST

International Plastics Design & Moulding Exhibition & Conference Plastics Design & Moulding Exhibition & Conference will be organised by the Plastics News Global Group owned by Detroit-based Crain Communications Inc. The event will assemble designers and moulders representing end-use markets such as automotives, medical, packaging, electrical & electronics, sports, domestic & leisure goods.

The focus will be on the market opportunities and future challenges of the plastic design & moulding industry; June 18–19, 2013, Telford International Centre, Telford, UK For details contact: Matthew Barber Crain Communications Ltd 1155 Gratiot Ave., Detroit Michigan, USA Tel: +44-20-82539628 Fax: +44-20-82539651 Email: mabarber@crain.com Website: www.pdmevent.com

InterPlas Thailand InterPlas Thailand will bridge and culminate business and industrial excellence for all active players in plastic and rubber industries. It will benefit the Thai industrial potency with machinery, technology and know-how through exhibition, activities and a series of conferences and seminars; June 20–23, 2013; Bangkok International Trade & Exhibition Centre (BITEC), Bangkok, Thailand For details contact: Orachorn Wongpan-ngam Reed Tradex 100/68-69, 32nd Floor Sathorn Nakorn Tower North Sathorn Road Silom, Bangkok Thailand Tel: +(66)-(2)-6867299 Fax: +(66)-(2)-6867288

Email: interplas@reedtradex.co.th Website: www.interplasthailand.com

Bioplastek Bioplastek 2013 will be an interactive forum on ‘Bioplastics Today and Tomorrow’ and an exhibition cum conference. The exposition will take place with an objective to promote the products and services of those in the field of bioplastics. Leading companies from different industries will be attending the conference to find the products and services for their specific use; June 26–28, 2013; at Hilton San Francisco, San Francisco, USA For details contact: Schotland Business Research, Inc 16 Duncan Lane Skillman NJ 08558-2323, USA Tel: +1-609-4669191 Fax: +1-609-4668833 Website: www.bioplastek.com

MSIA-PLAS MSIA-PLAS is an international exhibition for the plastic & plastic products industry in Malaysia. The event will showcase the latest products and equipment under a single roof. This is the 24th edition of the exhibition. This trade show will be held concurrently with MIMF – AseanSign; July 4–7, 2013; at Putra World Trade Centre (PWTC), Kuala Lumpur, Malaysia For details contact: ES Event Management Sdn Bhd 153-3, Jalan Lancang Taman Sri Bahtera, Cheras 56100 Kuala Lumpur Malaysia Tel: +603 9132 1922 Fax: +603-9133 1920 Email: esevent@esevent.com.my Website: www.esevent.com.my

CamboPlas CamboPlas is considered one of the most popular and well attended trade shows catering to the requirements of the plastics

industry in Cambodia. Since the main industry in the country is agriculture, all the other industrial activity revolves around it. This trade event will play an important role in ensuring an overall growth and development for the plastics industry; August 8–11, 2013; at Diamond Island Convention & Exhibition Center, Phnom Penh, Cambodia For details contact: Tracy Chang Chan Chao International Co Ltd 3-F, No. 185, Kangchien Road Nei Hu District Taipei, Taiwan Tel: +(886)-(2)-26596000 Fax: +(886)-(2)-26597000 Email: service@chanchao.com.tw Website: www.camboexpo.com/CIMIF/ camboplas

K 2013 K 2013 is one of the world’s leading trade fairs for the rubber and plastics industries. This event has a record of bringing international exhibitors and trade visitors with great decision-making powers under one roof.

This event covers the entire segment of the rubber and plastics industries from basic products and innovations to efficient hightech solutions; October 16-23, 2013; at Dusseldorf Exhibition Centre, Dusseldorf, Germany For details contact: Messe Dusseldorf GmbH Stockumer Kirchstrasse 61 Messeplatz Dusseldorf Germany Tel: +(49)-(211)-4560900/4560175 Fax: +(49)-(211)-4560668/4560740 Email: k-online@messe-duesseldorf.de Website: www.k-tradefair.com The information published in this section is as per the details furnished by the respective organiser. In any case, it does not represent the views of Business Insights •Technologies•Opportunities

June 2013 | Modern Plastics & Polymers 119

BOOK REVIEW

Rosin-based Chemicals and Polymers Editor: Jinwen Zhang Price: ` 8,237 Current interest in sustainable polymeric materials has created interest in rosin, which is derived from pine tress. Rosin is used in many kinds of polymers and polymer chemicals for applications such as printing inks, adhesives, paints, varnishes, coatings, alkyd resins, polyurethanes, epoxy resins, polyesters and polyamides. Rosin has been historically ignored as biomass for manufacturing ‘Green Plastics’ and composites. This is largely due to the difficulties of precisely controlling the molecular structure through molecular engineering. However, in recent years, rosin acids have received growing interest as feedstock chemicals.

The editor has summarised the recent progress in chemicals and polymers derived from rosin and turpentine as feedstock chemicals. Various chapters focus on rosin-derived epoxies curing and coating applications, turpentine-derived polyols and polyurethane applications, rosin-derived monomers in thermoplastic polymers, rosin-derived surfactants and finally biological activities of rosin-derived chemicals.

This book is a useful guide and reference for those involved in the investigation of chemicals and polymers based on pine resin.

Design of Extrusion Forming Tools Authors: Olga S Cazneiro and J Miguel Nobregs Price: ` 10,838 Forming tools, ie the extrusion die and the calibration systems used, are the key components of extrusion lines. The objective of an extrusion line is to produce, at a high rate and quality, the required product. These two goals are generally conflicting. Optimisation of the processing conditions and design of extrusion tools demand deep knowledge and careful study of all the phenomena involved during the extrusion process.

Authors have felt that there is a clear lack of literature devoted to the design of extrusion forming tools and integrating the different phenomena involved. This book fills up the gap.

It is a useful reference for higher education students, teachers, researchers and engineers active in the extrusion industry. It is also a practical guide for those involved in the design of forming tools.

Each chapter is written by researchers, both from academic and industrial communities, whose contribution in the specific field is internationally recognised.

Chapters are arranged in logical sequence, starting with objectives and the most relevant problems associated with design of tools, polymer properties required for design process, specific chapters on pipes, flat film & sheet, blown film, profiles, flexible dies and rotating mandrel dies.

Reviewer: Dr R Rangaprasad, Experienced Polymer Professional Available at: Wisdom Book Distributors,Hornby Building, Ist Floor, 174, D.N. Road, Mumbai - 400 053 Tel: 022-22074484 66318958 • Telefax: 022-22034058

120 Modern Plastics & Polymers | June 2013

PRODUCT S

Looking Looking For For AA Specific Specific Product?

Product?

Searching Searchingand andsourcing sourcingproducts productswere werenever neverso soeasy. easy.

Just Justtype typeMPP MPP (space) (space)Product Product Name Name and andsend sendititto to51818 51818

eg. eg.MPP MPP Moulding Moulding and and send send itit to to 51818 51818 Servo-driven beam robot

Label printing machine

Redstone series servo-driven beam robot is applicable to all types of horizontal injection machines ranging from 50 tonne to 500 tonne. It has a full AC servo motor driven on each axis, taken out at super high speed. By using linear slide rail, adjusting the gap is not needed, and it is stable, wear-proof and has a long life. Besides high speed take-out product, insert moulding, picking up the inserts of two combined IMM, IML and collocation of peripheral automation are provided. The range of services includes home appliances, computer peripherals, office products, food packaging, toys, PET, precision gear etc.

Printing speed of PCD80-08H-RE (UV ) is 80–100 pcs/min. The features include double transferring roller design, stopples roller adjustment design, plate wheel outer fine-tune mechanism, quick release ink rollers, printing wheel clean system (200 mm dischargeable), sleeve printing and plate wheel pre-register mechanism that make production more smooth.

Dongguan Alfa Automation Dongguan - Taiwan Tel: +86-769-83180326, Fax: +86-769-83180329 Email: info@alfarobot.com Website: www.alfarobot.com

Bonmart Enterprise Corp Taipei City - Taiwan Tel: +886-2-2299 4281, Fax: +886-2-2299 4284 Email: bonmart@bonmart.com.tw Website: www.bonmart.com.tw

June 2013 | Modern Plastics & Polymers 121

PRODUCT S

Mould labelling machine

Film blown machine

Under the concept of environmental protection and to satisfy the increasing requirements of the onestep producing container packaging market, new A-pack In Mold Labeling (IML) System has vacuum and static labelling, reduces the cycle time and greatly saves total production cost. A-PACK IML Turnkey Solution could be applied to all kinds of beverage and food packages such as tea, coffee, juice, water, yogurt and dairy products. It consists of four components including FCS AF series, hi-speed hybrid close loop injection moulding machine, hotrunner mould, robot, product stacking system and label inserting system.

In addition, FCS can also provide customised label for this turnkey solution. In fact, customers only need to decide what kind of container they want, and then FCS will provide optimal solutions, even including the installation and training for technicians to make sure the whole system is working well.

PE stretch film blown machine is for producing PE stretch film & PE cling film. Liquid PIB injection system is used to inject the liquid adhesive into the screw to get sticky film. This technology allows adjusting the stickiness and saving resin cost. The winder is equipped with no-tension control that allows the film to be at the same tension and it will not tighten the paper cores. The co-speed controller controls the speed of take-up unit and winder to be the same, so the film will not be stretched and can keep the stretch after winding. This machine can produce 10 rolls of film width 300 mm or 6 rolls of film width 500 mm at one time, and the output can be 100-150 kg/hr for 1-layer 75mm extruder. For industrial purpose, multi-layers stretch film blown machine is also available. Three rewinder machines are also available, one is for fixed film width 300 mm, one is for fixed film width 500 mm and one is for film width 300-530 mm. These three machines can automatically feed the paper core, rewind, cut film and change paper cores. The maximum speed of the new “Rewinder machine” can go to 18-20 pcs/ min at 20 m length.

Fu Chun Shin Machinery Manufacture Co Ltd Tainan City - Taiwan Tel: +886-6-5950688, Fax: +886-6-5951129 Email: fcsco@fcs.com.tw Website: www.fcs.com.tw

Mould change system Quick mould change system uses hydraulic drive to achieve a simple, convenient and quick mould change steps. Compared to the traditional way of fixing mould by hand, it not only reduces half machine idle time, the labour force and cost of production but also increases machine utilisation and productivity. Quick mould change system includes power unit, die clamps, hydraulic parts and electrical control box. They can be customised according to the customer’s machine requirements. In case of sudden stop power supply, the quick mould change system can supply pressure for more than 48 hours to avoid the mould from falling. When clamping abnormally, it can connect with the machine to stop the operation immediately to protect personnel safety.

Forwell Precision Machinery Co Ltd Zhejing - China Tel: +86-574-86599196 Fax: +86-574-86599197 Email: forwell@forwellnb.com Website: www.forwell.com 122 Modern Plastics & Polymers | June 2013

Chyi Yang Industrial Co Ltd Taoyuan - Taiwan Tel: +886-3-3288686, Fax: +886-3-3283737 Email: cymw@cymw.com.tw Website: www.cymw.com.tw

Multi-cavity hot runner controller The TC5200 multi-cavity hot runner controller features a 12–60 point temperature combination controller and multi-machine networking. Maintenance operations can be simplified with its modularised device design and requirement-based configuration. The purchasing costs are greatly reduced by its unique temperature control, with two points within one level. The GUI-based user interface, along with its adjustable perspective angle, is easy for fast adoption in multi-points control.

The RS485 communication function enables you to set up multiple controls at once to simplify the required operations. The built-in and practical current sensor and indicator functions benefit various applications, especially automotive, bottle billet injection and medical supplies, by realising the concept of one-stop control.

Arico Technology Co Ltd Taipei City – Taiwan Tel: +886-2-2910-1266, Fax: +886-2-2915-9434 Email: info@arico.com.tw Website: www.arico.com.tw

PRODUCT S

Multi-layer co-extrusion blown film machine

3-Axis CNC double column machining centre

Multi-Layer co-extrusion blown film machine is constructed on the basis of a green eco-friendly design principle, which cleverly integrates the latest proven technologies in plastics, mechanical, electrical and automation. The JC-CX series multi-layer co-extrusion blown film extrusion line is available in three layer or five layer configuration producing variety of quality film for various industries. From general purpose packaging film or lamination film of complex technical film or food packaging with high grade barrier properties, the JC-CX series multi-layer blown film line is a convincing solution to every customer’s need. The line is built with the concept of modular system promised to meet each specific demand.

Quality, reliability, efficiency and high productivity are the essential characteristics of the JC-CX series multi-layer co-extrusion blown film line.

NX series double column CNC vertical machining centre is an ideal heavy duty machine for both roughing and finishing of bigger components greatly increasing work envelope, permitting large workpieces to be machined and a wider range of tool lengths to be used in the same set-up. With a load capacity range of 10,000 kg, this series has been designed to accommodate large mould and mould base machining. With the architecture of Y-axis on cross beam, moving table on X-axis and Z-axis on ram-type head, greater extensions from head-stock and better reach to table area is achieved without much interference of axis elements. Wider gaps are maintained between columns to accommodate large size components.

NX 2215 has X/Y/Z (2200/1500/800 mm) and 24-tool ATC. Thus, with mentioned machining features, symmetrically designed heavily ribbed cast iron structure with wider columns providing high level machining geometric stability, wider door opening various options in head and spindle, the NX series becomes an ideal choice for modern machine shops.

Jenn Chong Plastics Machinery Works Co Ltd Chia-Yi Hsien - Taiwan Tel: +886-5-2376175, Fax: +886-5-2376176 Email: sales4@jennchong.com.tw Website: www.jennchong.com.tw

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

June 2013 | Modern Plastics & Polymers 123

Anaerobic adhesives A high performance anaerobic adhesive, Sonlok is preapplied to thread parts forms a unique coating that converts ordinary fasteners into selflocking and selfsealing fasteners. Dry to touch, Sonlok pre-applied thread locker becomes an integral part of the fastener and stays inert until parts are used. During the assembly process, Sonlok preapplied is activated by assembly forces, releasing anaerobic adhesive that locks and seals parts securely. This product may be used successfully, without solvents, in extreme temperature and pressure environments to lock and seal against air, steam, most fluids and lubricants.

Parson Adhesives India Pvt Ltd Vadodara, Gujarat Tel: 0265-6541638, 2972191 Mobile: 094285-11765, 098252-99551 Email: bijay@parsonadhesives.in Website: www.parsonadhesives.in

Monofilament extrusion line

Monofilament extrusion line is the most flexible monofilament line at the forefront of the global market. It provides technical solutions in the production of PP, HDPE, PA and PET monofilaments. The JC-MNP series monofilament extrusion line is conceived to process PP and HDPE. Extruder is available from standard Ø 55 mm to Ø 100 mm for production of monofilament diameter range from Ø 0.15 mm to Ø 1.00 mm. With its high level of reliability, efficiency, energy saving concept and top quality finish, monofilament extrusion line ensures a modest investment compared with its high productivities to facilitate the ever-demanding requirement of all market sectors.

Jenn Chong Plastics Machinery Works Co Ltd Taiwan, Chia-Yi Hsien Tel: 886-5-2376175 Fax: 886-5-2376176 Email: sales@jennchong.com.tw Website: www.jennchong.com.tw 124 Modern Plastics & Polymers | June 2013

PRODUCT S

Thermoplastic elastomer

Gear box

Phoenix compound is high performance styrenebased thermoplastic elastomer that contains features of vulcanised rubber at normal temperature and plastics when heated. It means that once they are formed, they can be heated and reformed repeatedly by conventional plastics processes, such as injection moulding, blow moulding and extrusion. This property allows for easy process and facilitates recycling. The compound has been used in a wide range of markets and applications. The features and benefits of Phoenix allow the customer to design products without limit. They can be hard or soft. They can bond to a variety of engineering thermoplastics.

They can be sleek, silky, opaque, transparent and colourful. Phoenix can be made even more flexible according to different customers’ requirements.

Corresponding to the increasing demand of the twin-screw extruder, sun lung has developed a series of highperformance gear box for the twin-screw extruder. The gearboxes of this series have been developed by featuring high torque and high speed output rate. The series of gearboxes is embedded with excellent high dissipation and oil lubrication system to perform stable output under heavy-loading force. The axial thrust is supported by an axial roller-type swivel thrust-bearing of the 294.e series, coupled with thrust bearings assembled in a tandem way. The gearbox features high torque and high output speed rate design coupled with thrust bearings assembled in a tandem way, best transmission efficiency, high torque and sufficient safety coefficient.

The precision of the gear grinding is up to DIN 1–3 grade, operation noise is kept below 80 dB.CE and the gear box is TUV certified

Phon Tech Industrial Co Yunlin - Taiwan Tel: 886-5-5574567 Fax: 886-5-5574553 Email: phon.tech@msa.hinet.net Website: www.phon-tech.com.tw

Sun Lung Gear Works Co Ltd Tainan - Taiwan Tel: +886-6-2639969 Fax: +886-6-2639626 Email: david@slgear.com.tw Website: www.slgear.com.tw

June 2013 | Modern Plastics & Polymers 125

Plastic pallet A wide range of plastic pallets is offered for every application in material handling. These pallets are made of prime grade advanced polyethylene materials. The pallets are known for longer life, superior performance and ensuring the best in industry quality standards in both automated and traditional material handling and distribution systems. The heavy-duty steel reinforced plastic pallets are ideal alternatives for steel and wooden pallets.

Swift Techno Plast Pvt Ltd Navi Mumbai - Maharashtra Tel: 022-22978351, Mob: 09769220221 Email: sales@swiftind.co.in Website: www.plasticpallet.co.in

Multi-layer polyethylene film The multi-layer polyethylene film is coated with pressure sensitive adhesive. A wide range of innovative solutions for protection of PVC section with an extensive range of adhesion level, film thickness of 50 micron to 80 micron and colour are available. It has a maximum length of 1000 m per roll and maximum width of 1550 mm.

It provides outdoor weather resistance. The protective film peels out easily after finishing operations. It preserves the quality of surface without leaving residue or any marks once the protective film is removed. It provides uniform and stable adhesion throughout the life cycle of the product.

Ecoplast Ltd Mumbai - Maharashtra Tel: 022-26830064, 26840359 Email: info@ecoplastindia.com Website: www.ecoplastindia.com

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

Mutual Industries Ltd Mumbai - Maharashtra Tel: 022-66895300 Website: www.mutual-industries.com 126 Modern Plastics & Polymers | June 2013

PRODUCT S

Moulding solution The moulding solution includes technical injection moulding applications such as insert moulding, multi-component (or multi-colour) moulding, thermoset injection moulding (for BMC and rubber), liquid injection moulding (for LSR), powder injection moulding (for metal and ceramic), in-mould-decoration moulding (IML/IMR/IMF) and micro injection moulding etc. Machine production status and real-time production data are instantly transmitted to the central monitor and control station through various remote connections. This smart production data management system is able to read and acquire the machine operation status and real-time production data instantly via the central monitor and control station. Image of machine production status is visually transmitted via a video camera to the central monitor station in which operator can observe machine production status on a real-time basis. The defective/rejected products are shown in the central monitor in a timely manner allowing managers to update production status of the products.

Multiplas Enginery Co Ltd Taoyuan - Taiwan Tel: +886-3-3180090, Fax: +886-3-3975498 Email: multiplas@multiplas.com.tw Website: www.multiplas.com.tw

Silicone transparent tubing and braided hose Polyester-reinforced silicone transparent braided hose is made for food, pharmaceutical, chemical, medical and heavy engineering industries, thermal power stations and PSUs. This braided hose is made of 100 per cent pure silicone rubber by using fully automatic state-of-the art machines and technologies. It already caters to all the major pharmaceutical companies in India and is also exported to overseas customers. Medical grade braided hose is manufactured under stringent quality control and is made of medical grade silicone rubber, temperature-resistant from -80°C to 250°C (-110°F to 480°F), non-reactive to body tissue and fluid, unaffected by most water-soluble materials, sterilisable by steam, dry heat, ethylene oxide and gamma radiation and has an indefinite shelf life. The silicone transparent tubing sizes are available from 0.5 mm ID to 200 mm ID, and braided hoses have sizes available from ID range ½” to 2 ½”.

Ami Polymer Pvt Ltd Mumbai - Maharashtra Tel: 022-28555107/631/914, Mob: 09223290931 Fax: 022-28555378 Email: amipolymer@vsnl.com Website: www.amipolymer.com June 2013 | Modern Plastics & Polymers 127

PRODUCT S

Crystallised hopper dryer

Mould-temperature controller and chiller

Crystallised hopper dryer is ideal for users who have trouble with oily, sticky, abnormal shaped resin and recycled material such as PET. Its patented drying technology can mix evenly and crystallise well as a result it shortens drying time and saves cost. Crystallised hopper dryer prevents bridge making when drying oily, sticky, abnormal shaped resin. It is easy to have the bridge making. To use the crystallised hopper dryer can prevent the bridge making effectively.

Yann Bang provides three different kinds of unique mixers to suit your special needs.

The mould temperature controller and special custom-made chiller are new products that include coldhot all-in-one mould temperature controller, die-casting mould temperature controller, quick-cooling & heating mould temperature controller, two machines in one water circulation temperature controller and rubber/high temperature/roller mould temperature controller. These machines are intended for processes such as plastic injection moulding, extrusion moulding, blow moulding, chemical industry, dye-casting, reaction axe rubber tyre, rubber vulcanisation, electric wire, calendar, printing, banburying and other related industries.

Yann Bang Electrical Machinery Co Ltd Taiwan Taichung City Tel: 886-4-22710000 Fax: 886-4-22711988 Email: yb@yannbang.com Website: www.yannbang.com

Weichi Enterprise Co Ltd Guangzhou - China Tel: +86-020-36850626 Email: weichimaster@163.com Website: www.weichigz.com

Long fibre rigid thermoplastic polyurethane

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

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

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

RTP Company Chennai – Tamil Nadu Tel: 044-42147313 Email: srengasamy@rtpcompany.com Website: www.rtpcompany.com

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

128 Modern Plastics & Polymers | June 2013

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LIST OF PRODUCT S

Looking For A Specific Product?

Searching and sourcing products were never so easy.

Just type MPP (space) Product Name and send it to 51818

eg. MPP Moulding and send it to 51818 Product

Pg No

Product

Pg No

Product

Pg No

3 Axis CNC Double Column Machining Centre ...... 123

Compressor ................................................................... 21,BIC

Extruder Screws .................................................................... 83

AC / DC Panel For Pipe Plant ...................................69

Conductive Compounds ....................................................... 10

Extrusion .........................................................................BC,37

AC Drive............................................................................... 35

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

Extrusion Coating Lamination Plant ................................... 53

Acoustic Enclosure........................................................... 11,93

Connector and Cable Assembly ........................................... 87

Extrusion Coating Lines (Lamination Ant) ......................... 14

Additive Masterbatch............................................................ 10

Connector Type..................................................................... 87

Extrusion Dies ........................................................................ 8

Air Audits Blower ................................................................. 21

Connectors Screw Type ........................................................ 87

Extrusion Machinery ............................................................ 29

Air Bubble Sheet Plant ......................................................... 53

Continuous Screen Changer ............................................... 138

Extrusion Pump .................................................................... 49

Air Compressor ..................................................................... 45

Contrast/Colour Scanner ...................................................... 95

Extrusion System ................................................................ BC

Air Cooled Chiller ................................................................ 16

Control Panel ...................................................................... 124

Feed Roll ...................................................................83

Air Treatment........................................................................ 45

Convertor ............................................................................ 124

Feeding & Conveying ...................................................... 57,77

Air-Conditioner Part ........................................................ FGF

Conveying ............................................................................... 6

Fibre Optic Amplifier ........................................................... 95

Airconditioning Plant ........................................................... 45

Crusher .................................................................................. 67

Filling Machine..................................................................... 51

All Electric Machine............................................................. 23

Crystallised Hopper Dryer.................................................. 128

Film Blown Machine .......................................................... 122

Aluminium Die Casting Machinery Diesel Generator ........ 45

Crystalliser............................................................................. 57

Film Cutter ........................................................................... 83

Anaerobic Adhesive............................................................. 124

Cutting and Stitching Machine ............................................ 14

Forked Photoelectric Sensor ................................................. 95

Auto Dosing And Mixing System........................................ 67

Cylinder Engraving - Lenticular & Optical Roll Mould... 126

Freewheel-Oneway-Clutches .............................................. 124

Auto Vacuum Loader ............................................................ 67

Cylindrical Sensors................................................................ 95

Fueling System ...................................................................... 21

Automation ............................................................................. 6

Datalogging Software .............................................. 124

Fully Automatic Strapping Plant .......................................... 53

Automation System............................................................... 77

Dehumidified Air Dryer ................................................... FGF

Furnace .................................................................................. 45

Automotive ............................................................................ 75

Dehumidified Dryer........................................................... FIC

Gear Box ................................................................. 125

Barrel ......................................................................138

Dehumidifying Air Dryer ................................................... 137

Gear Pump ..................................................................... 49,138

Barrels for Plastic & Rubber Injection Moulding ................ 29

Dehumidifying Dryer....................................................... 67,85

Granulating & Recycling ...................................................... 77

Batch Weigh Blender ............................................................ 18

Dessicant Compressed Air Dryer ....................................... 125

Granulator .............................................................. 57,137,FIC

Bed Knife .............................................................................. 83

Die Face Cutter .................................................................... 83

Granulator Blade ................................................................... 83

Biodegradable Masterbatch ................................................... 10

Die Plate ............................................................................... 83

Gravimetric Blender ............................................................ 137

Black Masterbatch ................................................................ 10

Differential Pressure Transmitter .......................................... 87

Gun Drilling Process ............................................................ 29

Blender ............................................................................... FIC

Digital Panel Meter .............................................................. 12

HDPE Pipe Plants ....................................................69

Blending Unit ................................................................... FGF

Digital Temperature Controller .......................................... 124

Head Lamp & Tail Lamp................................................. FGF

Blower Series......................................................................... 77

Door Trim ......................................................................... FGF

Heart Valve Frame ................................................................ 61

Blown Film Extrusion System ............................................ BC

Dosing & Blending ................................................................. 6

Heat Transfer Equipment ..................................................... 31

Bulk Level Measurement System ......................................... 19

Dosing & Mixing.................................................................. 77

Heat Transfer Roll .............................................................. 138

Cam Follower .......................................................... 124

Double Column Vertical Machining Centre ........................ 63

Heating & Cooling ............................................................ 6,77

Capacitive Sensor .................................................................. 87

Double Sheet Monitoring ..................................................... 95

High Cavitations ................................................................... 25

Capping Machine ................................................................. 51

Drive.................................................................................... 124

High Performance Screw .................................................... 138

Carbon Black ...................................................................... 121

Dry Van Pump ................................................................. 11,93

High Pressure Blower ........................................................... 31

Cast Film Line ...................................................................... 53

Dry-Break Coupling ............................................................. 21

High Speed Mixer ........................................................... 27,73

Central Material Conveying System..................................... 67

Drying ..................................................................................... 6

HM/HDPE/LDPE/LLDPE ............................................... 53

Chiller ................................................................................. 127

Drying & Dehumidfying ...................................................... 77

Hold Back ........................................................................... 124

Cim Mould ........................................................................... 37

Drymax Air-Hot Air Dryer............................................... FIC

Hopper Dryer........................................................................ 67

Circular Weaving Machine ................................................... 14

Drymax Dryer .................................................................... FIC

Hopper Loader.................................................................... 137

Clean Room Application ...................................................... 25

Drymax Pet-Dehumidified Dryer...................................... FIC

Hot Air Dryer .......................................................FGF,85, 137

Cleaning Oven .................................................................... 138

Dual Channel With Modbus ............................................. 124

Hot Runner System .............................................................. 77

Cluster Facia ..................................................................... FGF

Dynamic Controller ............................................................ 124

Hydraulic Block .................................................................... 29

CNC Machine ...................................................................... 63

Ejector.......................................................................21

Hydraulic Injection Moulding Machine ............................... 23

CNC Vertical Machining Centre ......................................... 79

Electric Injection Moulding Machine Gearboxes .................. 7

Hydraulic Piston Ram .......................................................... 29

Co-Extruded Sheets and Telecom Cable ............................. 59

Electrical................................................................................ 75

I/O Junction Box With Profibus ................................87

Colour Masterbatches ...................................................... 10,15

Element Shrink Disc .......................................................... 124

IMLTechniqe ........................................................................ 25

Compact Chiller.................................................................. 137

Evaporative Cooling Tower .................................................. 45

Inductive Sensor .................................................................... 87

Compressed Air Dryer .......................................................... 57

Exhibiiton - Plastivision 2013 ............................................ 102

Inductive Switch ................................................................... 95

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

Extruder Machine ............................................................ 27,73

Injection Moulding ............................................................ 126

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

132 Modern Plastics & Polymers | June 2013

LIST OF PRODUCT S

Product

Pg No

Product

Pg No

Product

Pg No

Injection Moulding Machine ....................FGF,5,17,37,89,133

Photoelectric Sensor.............................................................. 87

Stack Mould .......................................................................... 25

Keyless Transmisson Element .................................. 124

PID Controller.................................................................... 124

Storage Tank Equipment ...................................................... 21

Knob & Switch ................................................................. FGF

Pipe Extrusion Line For PVC / PPR / PE ......................... 89

Submicron Filter ................................................................. 125

Label Printing Machine ........................................... 121

Plastic Auxiliary Equipment ................................................. 18

Switch Gear .......................................................................... 35

Largeflow Water Heater ....................................................... 77

Plastic Conveyor Belt ............................................................ 27

System Solution .................................................................... 77

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

Plastic Machinery.................................................................. 45

Tank Truck Equipment ..............................................21

Loading Arm ........................................................................ 21

Plastic Masterbatches ................................... 101,105,107,BGF

Tape Stretching Line With Inverter

Long Fibre Rigid Thermoplastic Polyurethane ................. 128

Plastic Pallet ........................................................................ 126

Driven Cheese Winder ......................................................... 14

LSR Machine ........................................................................ 37

Plastic Processing Machines ................................................. 14

Technical Mould ................................................................... 25

M12 Screw Type Connector .......................................87

PLC ................................................................................... 124

M8 Screw Type Connector ................................................... 87

PLC and HMI...................................................................... 35

Manual & Hydraulic Screen Changers .............................. 138

Power Generator Shaft ......................................................... 29

Master-Batch Feeder............................................................. 67

PP TQ Plant ......................................................................... 53

Masterbatches........................................................................ 59

PP/ HDPE-Semi Automatic Strapping Plant ..................... 53

Masterbatches. Wire & Cable .............................................. 75

PP/HDPE Rafffia Tape Lines.............................................. 53

Material Storage.................................................................. 137

Precision Moulding ........................................................... FGF

Measuring And Control Equipment .................................. 126

Precision Temperature Control ........................................... 124

Measuring Sensor.................................................................. 95

Priming Valve ........................................................................ 21

Medical Food ........................................................................ 75

Printing And Cutting / Rewinding Machines ..................... 14

Medical Mould ..................................................................... 25

Printing Machine .................................................................. 37

Mini Sensors ......................................................................... 95

Process Controller .......................................................... 12,124

Mould Repair ...................................................................... 126

Process Gas Blower ............................................................... 31

Toggle Injection Machine ..................................................... 23

Mould Temperature Controller............................................. 85

Process Machinery ................................................................ 45

TPU Masterbatches .............................................................. 15

Moulding............................................................................... 25

Profile Controller ................................................................ 124

Track Rollers ....................................................................... 124

Mono and Multilayer Sheet Line ......................................... 14

Pulveriser .......................................................................... 27,73

Transmissions & PTOS ........................................................ 21

Monofilament Extruding Line ........................................... 124

Pulveriser Discs ..................................................................... 83

Truck Blowers ....................................................................... 31

Monofilament Line ............................................................... 14

Pump ........................................................................... 11,21,93

Twin - Screw Co-Rotating Extruder............................... 20,61

Monolayer Blown Film Line .............................................. BC

PVC Compound ................................................................... 59

Twin - Screw Element ..................................................... 20,61

Mould Change System ....................................................... 122

Recycling.................................................................... 6

Twin - Screw Extruder .................................................... 20,61

Mould Labelling Machine ................................................. 122

Recycling Lines ..................................................................... 14

Twin Mill Pulveriser ........................................................ 27,73

Mould Temperature Controller........................................... 137

Resin Dehumidifier ............................................................... 57

Twin Screw Extruder Gearbox ............................................... 7

Mould Temperature Controller and Chiller ...................... 128

Resin Dryer ........................................................................... 33

Twin Screw Pipe Plant For RPVC Pipe .............................. 69

Moulding Solution ............................................................. 127

RH (Humidity) & Temperature Indicator ........................... 87

Two Platen Injection Moulding Machine ............................ 23

Mould ............................................................................... 27,73

Right Angle........................................................................... 87

Ultra Sonic Flow Meter .............................................12

MTC .................................................................................. FIC

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

Ultrasonic Sensor .................................................................. 95

Multi-cavity Hot Runner Controller .................................. 122

Rock N Roll Machine...................................................... 27,73

Universal Controller ............................................................ 124

Multi-component Moulds .................................................... 25

Roots Blower .................................................................... 11,83

Universal Input Temp Scanner ........................................... 124

Multi-layer Cast Film Line .................................................. 14

Rotary Cutters....................................................................... 83

Multi-layer Blown Film Line .........................................14,BC

Rotary Dies ........................................................................... 83

Multi-layer Blown Film Plant .............................................. 53

Rotary Dry Vacuum Pump ................................................... 31

Multi-layer Co-extrusion Blown Film Machine ............... 123

Round Table Carrousels ........................................................ 27

Multi-layer Polythylene Film ............................................ 126

RTD .................................................................................... 124

Napkin Dies ..............................................................83

Safety Access Equipment ...........................................21

Nitrogen Generator ............................................................. 125

Safety Light Curtain ............................................................. 87

Oil Chillers / Brine Chillers / Liquifiers /

Sensors & Switch .................................................................. 19

Chillers for Batching Plant ........................................16

Sensors’ Connectors............................................................... 87

Oil Cooler ........................................................................... 127

Servo-driven Beam Robot ................................................. 121

Optical Brightner .................................................................. 10

Servo Energy Saving Machine ............................................. 47

Oxygen Generator............................................................... 125

Servo System ......................................................................... 35

Panel Cooler ............................................................ 127

Shut Off Nozzles ................................................................ 138

Volometric Dosing Unit........................................................ 57

Paperless Recorder ................................................................ 12

Silence Flow Packages Centrifugal Fan................................ 31

Water Cooled Chiller .................................................16

Parallel & Right Angle Axes Gearbox ................................... 7

Silicone Transparent Tubing and Braided Hose ................ 127

Water Jetting ......................................................................... 21

Pelletiser ......................................................................... 83,138

Single Mill Pulveriser ...................................................... 27,73

Water Chiller ........................................................................ 57

Pelletiser Parts ....................................................................... 83

Single Screw Extruder Gearbox.............................................. 7

WFR .................................................................................. FIC

PET / PE Washing Line ...................................................... 14

Single Screw Pipe Plant for RPVC ...................................... 69

White Masterbatches ............................................................ 10

PET Box Strapping Plant..................................................... 53

Slot Type ............................................................................... 87

Wire EDM ........................................................................... 79

PET Perform Didicated Machine ........................................ 47

Software For Central Monitoring......................................... 57

Wireless ................................................................................. 87

Petline Injection Moulding Machine.................................... 23

Solid State Relay ................................................................. 124

Wireless I/O Junction Box ................................................... 87

Temperature Controller.................................................. 12,124 Temperature Sensor ............................................................ 124 Tensioner Nut ..................................................................... 124 Testing ................................................................................. 126 Thermocouple ..................................................................... 124 Thermoformer ..................................................................... BC Thermoforming & Ps Foam ............................................... BC Thermoplastic Elastomer .................................................... 125 Three Arm Bi-Axial Roto Moulding Machine ............... 27,73 Thyristorised Power Controller .......................................... 124 TIE Bar................................................................................. 29

UV Stabiliser ......................................................................... 10 Vacuum Booster Pump .......................................... 11,93 Vacuum Dryer ....................................................................... 85 Vacuum Forming Machine ................................................. BC Vacuum Loader ................................................................. FGF Vacuum Pumps & System .................................................... 21 Vacuum System ................................................................ 11,93 Variable Displacement Pump Energy-Saving Machine ....... 47 Vertical Machining Centre ................................................... 63 Vibro Screen..................................................................... 27,73 Vinyl Technologies ................................................................ 75

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

134 Modern Plastics & Polymers | June 2013

LIST OF ADVERTISERS Advertiser’s Name & Contact Details

Pg No

ACS Auxiliaries India Pvt Ltd ...................... 18

Advertiser’s Name & Contact Details

Pg No

Everest Blower Systems .......................... 11, 93

Advertiser’s Name & Contact Details

Pg No

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

T: +91-02135 - 329112

T: +91-11-45457777

E: acsindia@corpemail.com

E: info@everestblowers.com

T: 86-10-5900-3588

W: www.aecinternet.com

W: www.everestblowers.com

E: jingcheng_times@vip.163.com

Adinath Controls Pvt Ltd ............................124

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

T: +91-2764-286573

T: +91-79-25890081

E: info@adinathcontrols.com W: www.adinathcontrols.com Aerodry Plastics Automation Pvt Ltd.............. 6 T: +91-120 4766777 E: info@aerodry.com W: www.aerodry.com

Jyoti CNC Automation Pvt. Ltd.................... 63 E: salesfmi@milacron.com W: www.milacronindia.com Freeze Tech Equipments Pvt Ltd .................127

W: www.plastivision.org Alok Masterbatches Ltd ............................... 15

Karan Engineering Co. ................................. 37

E: sundaram@karanengineers.com

W: www.freezetechequip.com

W: www.karanengineers.com Katlax Enterprises Pvt Ltd............................ 87

T: +91-79-40089312

T: +91-9328197614

E: info.ahm@gardnerdenver.com

E: info@katlax.com

W: www.gardnerdenver.com Gem Equipments Ltd ................................... 45 T: +91-0422-2363800 E: sales@gemindia.com

E: sales@alokindustries.com

W: www.gemindia.com

Boge Compressed Air Systems Pvt Ltd ...... BIC

W: www.jyoti.co.in

T: +91-022-40214997

T: +91-011-41612244

W: www.alokmasterbatches.com

E: info@jyoti.co.in

E: info@freezetechequip.com

Gardner Denver Engineered Pro. (I) ............. 21

E: pvi13@plastivision.org

T: +91-2827-287081

T: +91-044-42152387

All India Plastics Mfrs Association ..............102 T: +91-22-28217324

W: www.jc-times.com

Glaves Innovations Pvt Ltd .......................... 83

W: www.katlax.com Konark Plastomech Pvt Ltd .......................... 53 T: +91-79-22891670 E: sales@konarkplastomech.com W: www.konarkplastomech.com Larsen & Toubro .......................................... 35 T: +91-022-67525733

T: +91-141-2460324,

E: jm.ccd@lth.ltindia.com

T: +91-44-43593453

E: sales@glaves.biz, axj@glaves.biz

W: www.lntebg.com

E: fc.jayakaran@boge.com

W: www.glaves.biz

W: www.boge.in

Leuze Electronic .......................................... 95

Hindustan Plastic and

T: +91-80-40854444

Bry Air (Asia) Pvt Ltd .................................. 33

Machine Corporation ........................... Booklet

E: manish.sahay@leuze.in

T: +91-011-2390677

T: +91-011-25473361

E: bryairmarketing@pahwa.com

E: poonam@hindustanplastics.com

W: www.bryairsystems.com C & G Extrusion Machines .......................... 69 T: +91-9272235867 E: cgext@hotmail.com W: www.cgext.com Continental Carbon India Ltd .....................121

W: www.hindustanplastics.com Indo-Tech Engineers .................................... 29

E: rkatiyar@continentalcarbonindia.com W: www.continentalcarbonindia.com

Matsui Technologies India Ltd. .................... 85 T: +91-0120-4243862 E: rahuldeep@mass.motherson.com W: www.mifasystems.com

T: +91-79-22870368 E: info@indotechengineers.com W: www.indotechengineers.com

Mifa Systems...............................................123 T: +91-79-26870825 E: info@mifasystems.com

J P Extrusiontech Limited ............................ 14 T: +91-2646-222163

T: +91-120-6721200

W: www.leuze.in

E: info@jpextrusiontech.com W: www.jpextrusiontech.com

W: www.mifasystems.com N.A. Corporation ......................................... 73 T: +91-79-25840374 E: info@naroto.com

Jacobsen Lenticular Tool & Cylinder Engraving

W: www.naroto.com

Engineering Expo........................................131

Technology Co., ( Jaco Tech) ........................126

Neejtech India (Braunform) .......................... 25

T: +91-09819552270

T: 1-630-467-0900

E: engexpo@infomedia18.in

E: gj@jacotech.com

E: info@neejtech.com

W: www.jacotech.com

W: www.neejtech.com

W: www.engg-expo.com Our consistent advertisers

T: +91-79-26561312

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

June 2013 | Modern Plastics & Polymers 135

LIST OF ADVERTISERS

Advertiser’s Name & Contact Details

Pg No

Advertiser’s Name & Contact Details

Pg No

Advertiser’s Name & Contact Details

Neejtech India (Niigata) ............................... 17

Rajoo Engineers Ltd....................................BC

T: +91-9909974224

T: +91-2827-252701

T: +91-80-23723309

E: contact@niigataindia.com

E: kcdoshi@rajoo.com

E: info@steerworld.com

W: www.niigataindia.com

W: www.rajoo.com

NMTG Mechtrans Techniques Pvt Ltd. ......124

Reynold India Pvt Ltd .................................. 16

T: +91-79-22821527

T: +91-0120-4664000

E: nmtg@nmtgindia.com

E: v.bali@reynoldindia.com

W: www.nmtgindia.com

W: www.reynoldindia.com

Pg No

Steer Engineering Pvt Ltd ............................ 61

W: www.steerworld.com Swam Pneumatics Pvt Ltd ............................ 31 T: +91-0120-4696222 E: swamatic@airtelmail.com W: www.swamatics.com Toshiba Machine (Chennai) Pvt.Ltd. ........ FGF

Nordson X-Aloy Asia (Thailand) Ltd. ..........138

S&T Engineers ............................................ 79

T: +91-79-40327380

T: +91-422-2590810

E: handigolg@toshiba-machine.co.in

E: m.sanghvi@th.xaloy.com

E: stycm@stengineers.com

W: www.toshiba-machine.co.in

W: www.xaloy.com

W: www.stengineers.com

Norka Instruments Shanghai Co., Ltd. ........126

Sacmi Engineering India Pvt Ltd .................133

T: 86-21-6118-4181

T: +91-7600003968

E: xuming@afa-tech.com.cn;

E: sales@negribossi.in

W: www.norka.com.cn

W: www.negribossi.com

T: +91-044-26812000

Trident Pneumatic Pvt Ltd ..........................125 T: +91-422-2400492 E: sales@tridentpneumatics.com W: www.tridentpneumatics.com UWT Level Control India Pvt Ltd ............... 19 T: +91-124-412-1684

Nu-Vu Conair Pvt. Ltd ................................137

SCJ Plastics Ltd ........................................... 59

T: +91-9376783206

T: +91-011-25439950

W: www.uwt-india.com ......................

E: salesindia@conairgroup.com

E: vball@scjgroup.net

Windsor Machines Limited .......................... 89

W: www.conairgroup.com

W: www.scjindia.com

Piovan India Pvt Ltd .................................... 57

Shini Plastics Technologies I Pvt Ltd............ 77

T: +91-22-27782367

T: +91-250-3021166

E: amit.bajaj@piovnindia.com

E: jnbhat@shiniindia.com

W: www.piovan.com

W: www.shini.com

Plastiblends India Ltd .................................. 10

Shri Ram Polytech ....................................... 75

T: +91-022-67205200

T: +91-011-23316801

E: rsd@koisitegroup.com

E: info@shrirampolytech.com

W: www.plastiblendsindia.com

W: www.shrirampolytech.com

E: info@uwt-india.com

T: +91-79-25841591 E: sales.imm@windsormachines.com W: www.windsormachines.com Witte Pumps & Technologies ....................... 49 T: +91-11-41613643 E: witte@goodiesons.com W: www.witte-pumps.de Wittmann Battenfeld India Pvt Ltd ............FIC T: +91-044-42077009 E: info@wittman-group.in W: www.wittmann-group.com

Prasad Koch Technik Pvt. Ltd....................... 27

Specific Engineering .................................... 20

T: +91-79-25830112

T: +91-265-2646871

E: plastics@prasadgroup.com

E: info@specificgroup.com

T: +91-9810043265

W: www.prasadgroup.com

W: www.specificgroup.com

E: in@wjpin.com; greenyc@wjpim.com

Prayag Polytech Pvt Ltd ......101, 105, 107, BGF

Sri Sai Plasto Tech ....................................... 47

T: +91-011-47262000

T: +91-044-42994365

E: delhi@prayagmb.com

E: sspt_plastics@live.in

W: www.prayagmb.com

W: www.srisaiplastotech.com

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

W: www.plaimm.com Yann Bang Electrical Machinery Co.,Ltd. ..... 67 T: +91-886-4-2271-6999 E: yb@yannbang.com W: www.yannbang.com

Procon Technologies Pvt Ltd ........................ 12

SS Packaging Industries ............................... 51

T: +91-79-27492566

T: +91-011-45072942

T: 39-0331-307-616

E: info@procon.co.in

E: ssgroup@vsnl.net

E: info@zambello.it

W: www.procon.co.in

W: www.sspackaginggroup.com

W: www.zambello.it

Our consistent advertisers

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

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

136 Modern Plastics & Polymers | June 2013

Modern Plastics & Polymers

June 2013

Modern Plastics & Polymers

June 2013

Reg No: MH/MR/WEST/234/2012-2014 RNI No: MAHENG / 2008 / 25265 Licence to Post at Mumbai Patrika Channel Sorting OfďŹ ce, Mumbai GPO., Mumbai 400 001.

Date Of Posting 1st & 2nd Of Every Month / English & Monthly.

Date Of Publication: 28th Of Every Previous Month.

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