POLYMERS Communiqué Aug - Sep 2015

A CUSTAGE I N I T I A T I V E Aug-Sep 2015 l Issue 1.6 l ` 150

ANNIVERSARY EDITION

VISION

2020

PROCESSORS’ PERSPECTIVE

Saurabh Dhanorkar

MD, Finolex Industries Ltd.

Vivek Chaand Sehgal

Chairman, Samvardhana Motherson Group

EXCLUSIVE

In Dialogue

Vipul Shah

COO Petrochemicals Reliance Industries Ltd.

Vipul Shah talks about shale gas, the Indian petrochemical industry and the polymer industry as also the initiatives that need to be taken to move ahead on the global stage.

R. S. Sodhi

MD, GCMMF Ltd. (Amul)

POLYMERS CommuniquĂŠ l August - September 2015

1

CONTENTS

Aug-Sep 2015 l Issue 1.6

22

50

34

56

42

22

Sp e c i al Feature

PETCHEM Business: The Changing Horizon

40

Vipul Shah, COO Petrochemicals,

Saurabh Dhanorkar, Managing Director Finolex Industries Ltd., Pune

Cove r S tory

44

H U M A N CAPITAL

Prof. (Dr.) S. K. Nayak, Director General

S. Sugumar, Deputy Director and Head

CIPET, Chennai

46

Indian Plastics Industry: A Rising Business

28

34

2

28

Vipul Shah talks about shale gas, the Indian petrochemical industry and the polymer industry as also the initiatives that need to be taken to move ahead on the global stage.

Reliance Industries Ltd., Navi Mumbai

Amul Salutes the Role of Plastics In its Business

R. S. Sodhi talks about how the plastic pouch is a boon for milk suppliers and what developments in plastic packaging are needed for milk supply in the future, in dialogue with POLYMERS Communiqué.

R. S. Sodhi, Managing Director

Gujarat Co-op Milk Marketing Federation Ltd. (Amul), Anand

Vivek Chaand Sehgal talks about the possibilities of polymer and plastic use in the automotive industry and products that could look to being migrated to plastic from metal, in dialogue with POLYMERS Communiqué.

Vivek Chaand Sehgal, Chairman

Samvardhana Motherson Group, Noida

53

Finolex Tips on Business and Growth

Saurabh Dhanorkar talks about the market of PVC pipes in India, challenges that a company could face during a growth phase and the key manufacturing processes incorporated at Finolex.

Human Resources: Vital for Growth of the Plastics Industry

REPORT

Indian Manufacturing: Ready for the World

40

48

Deepak Lawale, Secretary General

Organisation of Plastics Processors of India, Mumbai

OPI N ION

Affordable Technologies: The Unexplored Realm Between Jugaad and Exotic Technologies Vikram Bhadauria, Director

Alok Masterbatches Pvt. Ltd., New Delhi

POLYMERS Communiqué l August - September 2015

Printed and Published by Manish Chawla manish@polymerscommunique.com

Designed by Custage Marketing Solutions Pvt Ltd 401, Vikas Classic Building No 4 4th Floor, Near Basant Cinema Chembur, Mumbai 400 074, INDIA

52

Editorial Advisory Board

I N TERACTIO N

Andreas Lichtenauer, Managing Partner

55

58

Kautex Maschinenbau GMBH, Germany

62

N. K. Balgi formerly President & Director at Ferromatik Milacron India Pvt. Ltd.

Sujith Kumar, Sales Manager India / Middle East Meusburger India Pvt. Ltd., Bengaluru

An Introduction to Automated Material Conveying

Doug Brewster, Conveying Product Manager The Conair Group, USA

UPDATE

Prof. (Dr.) N. C. Saha Director, Indian Institute of Packaging

Standardisation: Adding Value to Mould Making

AUTO MATIO N

Arvind Mehta Chairman and Managing Director Welset Plast Extrusions Pvt. Ltd.

Extrusion Blow Moulding: New Vistas of Applications

A Glimpse Into the Plastindia International University Arvind M. Mehta, Chairman, Empowerment

Committee - Plastindia International University

Past President - AIPMA & Plastindia Foundation

News

16

Events

66

Advertising Sales - National

Pushp Raj Singhvi formerly Vice Chairman and Managing Director at Borouge (India) Pvt. Ltd.

Mumbai Sanjana Chugh +91-99872 62726 sanjana@polymerscommunique.com

Rajesh Nath Managing Director VDMA German Engineering Federation India Liaison Office

Hyderabad Vani Sulakhe +91-93924 28927 vani@polymerscommunique.com New Delhi Vijay Babbar +91-98100 15111 vijay@polymerscommunique.com Vadodara Devindra Bhumra +91-81289 90887 devindra@polymerscommunique.com

Rakesh Shah Managing Director Windmöller and Hölscher India Pvt. Ltd. S. K. Ray Sr. Executive Vice President (Polymers) Reliance Industries Ltd.

Printed at

Silverpoint Press Pvt. Ltd. A-403, TTC Industrial Area Near Anthony Motors Mahape, Navi Mumbai - 400709 District - Thane

Advertising Sales - International Dubai Pritam Bangera +971-5548-32330 pritam@polymerscommunique.com

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USA Manisha Janjikhel +1-908-720-3510 manisha@polymerscommunique.com

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Bhavesh Brahamaniya +91-22-25204436 bhavesh@polymerscommunique.com Printed and Published by Manish Chawla, and printed at Silverpoint Press Pvt. Ltd., A-403, TTC Industrial Area, Near Anthony Motors, Mahape, Navi Mumbai - 400709, District - Thane and published from 401, Vikas Classic Building No 4, 4th Floor, Near Basant Cinema, Chembur, Mumbai 400 074, INDIA. Editor: Manish Chawla.

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Views and opinions expressed in this magazine are not necessarily those of POLYMERS Communiqué. Readers are advised to seek specialist advice before acting on information contained in this publication, which is provided for general use and may not be appropriate for the readers’ particular circumstances and so POLYMERS Communiqué does not take any responsibility for any loss or damage incurred or suffered by any of its subscribers / readers / advertisers of this magazine. The publisher makes every effort to ensure that the magazine’s contents are correct but do not take any responsibility for the absolute accuracy of the information. Subject to Mumbai Jurisdiction.

POLYMERS Communiqué l August - September 2015

No part of this publication or any part of the contents thereof may be reproduced, stored in a retrieval system or transmitted in any form without the permission of the publisher in writing.

POLYMERS Communiqué reserves the right to use the information published herein in any manner whatsoever. The ownership of trademarks is acknowledged.

3

Mind Speak ion in India is

likely to

pt Plastics consum . The flexible TPA by 2020

Rakesh Shah

touch 20 MM is largely dustry which at nearly packaging in g in ow ers is gr P and based on polym GD of th te of grow double the ra out 12 - 15% ab at ue in nt is likely to co rtunity for a huge oppo le YOY. There is g and flexib sin es oc pr best be Indian plastic n ca is Th y. dustr packaging in partnership public-private achieved by quality of on is as d emph and increase t, research en pm ui ining, eq education, tra ‘Make in e ak m ent to and developm y competitive sta to d an India’ work markets. d in the world within India an

Managing Director

Windmöller and Hölscher India Pvt. Ltd.

Not deterred by slow progress in creating ‘ease of doing business’ environment, industry leaders have proceeded implementing their ‘Make in India’ programmes, so also have our plastic processors.

N. K. Balgi

formerly President & Director at Ferromatik Milacron India Pvt. Ltd.

Machinery market has gained growth momentum since 2014-15 and expected to grow at the rate of 20% over the next five years. Processing sector is expected to consume near 25 million tonnes of polymers - virgin and recycled together by 2020, breaking away from the rhyming line of ‘20 by 2020’.

Prof. (Dr.) N. C. Saha

Director

Indian Institute of Packagin

g

Rajesh Nath

By 2020, India’s pl astic consum cross 20 MM ption would TPA, as it be VDMA German Engineering comes the th largest plastic ird m arket in the Federation relatively low world. India’s per capita co India Liaison Office nsumption of plastics - curre ntly at 9.7 kg s per annum expected to - is triple over th e next deca India’s plas de. tic processin g industry deploy more will than 1,80,000 2020 - from machines by the current 1,1 0,000 to cate booming dem r to ands.

The global po lymer industr y is expected grow with a to CAGR of 3.9% over 2015-202 The demand 0. for polymer is driven by grow in end use th markets such as packagin automotive, in g, frastructure, tra nsport rails an telecommun ication main d ly from emer economies. ging Thermoplastic s expected to wi segment is tness the high est growth ov the next five er years. Increasin g applications engineered pl of astics also is expected to this market. drive Managing Director

Pushp Raj Singhvi

formerly Vice Chairm an and Managing Director at Borouge (India) Pvt . Ltd.

Despite

of having constant criticism ics by about the usage of plast has there consumers, modern th of the grow ial nent expo an been in recent plastic packaging industry that by days. It is further estimated plastics 2020, the consumption of all other in packaging will surpass packaging materials.

Arvind

Mehta

irector aging D and Man an . rm ai Ch Pvt. Ltd rusions Plast Ext Welset

Indian polymer industry will witness

commissioning of all its planned raw material projects taking capacity to over 15 MMTPA. A new era will dawn on processing and mould making activities with active and direct participation from highly developed countries. Raw material manufacturers and processors will witness serious and experienced of shortfall qualified manpower.

of downfall current scenario s, currency ce pri de cru in and turmoil weakness ee rup , ina Ch devaluation of future for n sig od go is ultimately, a ustry, ind cs sti pla ian growth of the Ind pita ca r pe s kg of 20 with our vision 20, as it will be 20 by on pti consum rket. e in the global ma more competitiv

The

Feedback The first time when I saw the magazine, thought it was not Ind ian!!!...The content, the articles, layout, paper quality etc., everything was well layed, very me ticulous planning has gone into making...Br avo... you have made paradigm shift, it was needed as there was a big vacuum in the upp er crust...all the best keep it up, do not let you r guards down...

The quality of the public ation is go presentatio n is cohere od, nt and cont subjects are emporary been covere d.

Padma Vib

hushan Prof

.

M. M. Shar Emeritus Pr ofessor of Em ma Institute of inence Chemical Te chnology

Abhay Upadhye

Mifa Systems Pvt. Ltd.

mmuniqué MERS Co find POLY the topics of ity al e for the qu ding informativ e ith, th stan ine deals w rmat of fo the magaz e th d ributors an layout of the cont ofessional ws. The pr ie rv te a very r the in fo e ak cs also m it is and graphi after issue ad. Issue re e bl ya azine in enjo ag m l tia an influen becoming . ry st du in the e Eric Pavon eb-fed W t ni U ss ne BOBST Busi

n tion o delibera n o . rk Your won is really appreciable tio Padwal automa Shyam Pvt. Ltd. n o utomati ustrial A B&R Ind

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e pdates team for th dustry u d the in est for b ry articles an ve u all the yo h is w We es. future issu R. K. Gera ited - PET m Li dustries Division Reliance In

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OLYMER S Comm uniqué is its kind n the first iche busi of ness ma world o gazine in f polym the e rs. With written excellen articles, tly interacti etc., it h on colu as fast mns b ecome of choic a magazin e amon e g the to makers p decis of the p ion olymer fr aternity.

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magazine Communiqué not only ch hi w ’ ty inali has its ‘Orig one else no t saying wha consists in in saying o als t bu , re befo has ever said out the ab ks t one thin exactly wha industry.

POLYMERS

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Indian Institu

OLYMER S Comm uniqué magazin is a uniq e dedic ue ated fo industry r the p . The c lastics o n tents, p paper q rinting uality is and par exc stands a ellence part fro a nd m other p Keep up ublicatio the goo ns. d work.

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News The 3rd IMBM and PET International Conference

Digest

T

he 3rd Injection, Blow Moulding and PET International Conference, brought by

Elite Plus Business Services and CPMA, was AIMPLAS aims at additive manufacturing to revolutionise different sectors

held at Mumbai on 20th and 21st August,

2015. Its grand success was a result of the over-whelming response from over

540 attendees from 311 companies, representing 11 countries.

chain and advances in injection moulding

In the opening session, Kamal P. Nanavaty Axion Polymers introduces new recycled polymer grades of ABS, polyethylene (PE) and polypropylene (PP)

welcomed all the delegates and briefly

touched upon the major events of the year gone by. He was optimistic about for

the

opportunities

plastic

raw

processing industry.

available

material

and

operations.

The blow moulding and PET subjects included innovations and opportunities in PET machinery for PET packaging, latest

innovations in blow moulding and recent

developments in packaging technologies to meet consumer expectations.

The highlight of the evening was when the lucky dip was announced Berlin Packaging Acquires Vivid Packaging, an Ohiobased supplier of rigid packaging

for the Hyundai car donated by Vishal The keynote speeches were delivered

by eminent people from the industry.

Kazoo Takamura, Director and Executive Officer,

Global

Strategy

Division,

Toshiba Machine Co. Ltd. observed that BOBST & Partners roadshow focused on the latest innovations and trends in flexible packaging solutions attracts a large number of owners in Mexico

A-B

the Indian market for the automotive industry is the highest in the world.

R. S. Sodhi, Managing Director, Gujarat

Co-operative Milk Marketing Federation (AMUL) said that it is a culmination of

the foresight of visionaries like Sardar Vallabhai Patel, Tribhovandas Patel

and Varghese Kurian. Farmers are part of the complete chain of ‘Cow to Customer’.

Injection moulding subject covered were

on latest material developments and product trends, trends and innovations in injection moulding, in-moulds and hot

runner systems as well as applications for appliances, material handling, supply

16

Agarwal, President, Yudo. The lucky

winner was Vagish Dixit, Alpla. Vagish Dixit spontaneously decided to offer

the car at a discount of 10 per cent

and said that he would donate the full

price of the car to the charity round

table India Foundation in Coimbatore.

This generous offer was immediately matched

by

Vishal

Agarwal.

Bharat Vyas, CEO of Plastivision India 2017, who purchased the car will also

send the cheque to the charity. A total

of Rs. 9,60,000 was collected from this very interesting gesture. The two-day conference, thus, ended on a very

noble cause, making the summit a truly valuable experience.

W&H EXPO: Two World Premieres and Several New Developments

‘That was the most successful EXPO that

POLYMERS Communiqué l August - September 2015

30 minutes to do have been shortened to just two minutes. This is possible W&H has hosted to date. Never before have we had so many visitors in just two

days! We received very positive feedback about our new technologies and the

event as a whole’, says the company management as the EXPO came to a

close. W&H showed live demonstrations

due to a combination of an intelligent control algorithm with the automatic

pneumatic cleaning of gravimetric and vacuum conveyors.

Other developments shown at the

EXPO include:

l

on a total of 12 machines representing the company’s comprehensive range of equipment for the production of flexible

packaging. Two demonstrations were

phrase Industry 4.0.

One highlight at the EXPO was the premiere

of

the

AQUACAGE,

the

world’s first adjustable water calibrator, which runs with the AQUAREX blown

film line. Before this development, the flexibility of the line was limited by its

single-sized calibrator. Every film width change required the calibrator to be

switched out. The AQUACAGE enables width

changes

without

the

extra

steps, providing customers with more flexibility and enlarging the range of possible applications.

The

second

TURBOCLEAN,

world the

premiere

new

was

automatic

purging system for the VAREX II blown film. W&H showed how resin

change-over times of a 3-layer film could be dramatically reduced. Thanks

to new automation modules, what

used to take a machine operator

British Plastics Federation pavilion to debut at Plastics and Rubber Indonesia 2015

5-layer configuration producing a novel 5-layer stretch hood film.

l

The newly developed AD PLASTIC 2 bottomer for heat sealed valve sacks made from plastic film.

world premieres. The motto of the EXPO

was PACKAGING 4.0, inspired by the

The first OPTIMEX blown film line in

Digest

The MIRAFLEX S flexographic press for

The FILMEX cast film line producing

l

l

Brückner provides 8.7 meter polypropylene film orienter for Altopro

smaller repeats.

very thin taut stretch films for reliable load securing.

Visitors found it particularly interesting

to see PACKAGING 4.0 in action, which W&H demonstrated by connecting more than one production process. An example

of this was the VAREX II blown film line running thin, breathable backsheet diaper

BSW MACHINERY, the Austrian subsidiary of Windmöller & Hölscher, announces a new technology which allows reduction of bag weight through indexed micro perforation

film that was then brought over to the

VISTAFLEX flexographic press for high speed printing.

Windsor 5-Layer POD Line, an Empowered Solution for Affordable Excellence

A

line

that

outstanding

performance

produces

films

physical

attributes,

with

Canadian Plastics Industry Association partners with Quebec cities for polystyrene recycling

with and

more

metres/min that too with reduced

polymer consumption; all inbuilt in India’s first dedicated 5-layer Polyolefin Line – The BARON 2500 infinity POD.

A much awaited news! Taking the word ‘progress’ to the next level, Windsor Machines has now launched India’s

first dedicated 5-layer Polyolefin Line BARON 2500. With BARON 2500 infinity,

you can meet the most demanding

specifications of the films even after down-gauging! POD is basically a non-barrier film with a thick core

Celanese opens commercial and technology centre in Mexico

B-C

layer and thin skin layer along with

POLYMERS Communiqué l August - September 2015

17

low cost-to-feature ratio! A figure that

global companies may find it impossible to match.

Digest

The film extrusion businesses will benefit significantly with this launch. With a

Clariant’s Croda China newlaunches Vamax™ catalysts IncroMold™ improve K for the automotive economics antiof scratch the vinyl-acetate applications at monomer Chinaplas production 2015 process Datacolor® launches Davis-Standard CHECK III portable acquires Gloucester spectrophotometer, Engineering, expands continues tradition global aftermarket and of best-in-class blown film capabilities colourimetric performance Chambroad commissions first propylene Dow VORAGUARD™ and isobutylene polyurethane coproduction plant in innovation brings China using Honeywell high-resilience foam UOP technology production to the next level LyondellBasell announces definitive EVONIK introduces agreement to acquire TEGO® Dispers 673, SJS Plastiblends that the new superior will expand capabilities dispersing agent for and footprint in India solventborne plastic coatings Milliken to spotlight exceptional aesthetics, performance and INVISTA expands sustainability of production of TERRIN™ UltraClear PP for food aliphatic polyols into packaging at Pack Europe Expo 2015

CC--MI

5-layer POD line, there is a noteworthy medium intermediate layers. There is

an increased possibility to optimise the functional property of each layer. And also have a higher output by using high melt strength polymers.

With 5-layers, not only does the output

film get empowered to pass the most stringent

regulatory

standards

(that

too with a higher throughput), but also empowers you, the business owner, with

a significantly higher ROI (it is a matter of getting more with less, be it machine time or for that matter resin consumption).

With sustainability as expected on a big high, do we not all witness brand owners pushing to get as much from as little; so it is actually going green with BARON 2500 infinity.

Windsor has merged the concept of ‘Maximiser’ with the POD line. With the die

and the single cooling ring appropriately

designed, the user can enjoy all the benefits as would be expected - better

film properties, higher puncture resistance an increased film output, a BUR of 1:5 and

more. The Baron 2500 infinity POD can deliver an output of up to 550 kg/hr with the 250 mm die.

With a strong technology background and market understanding, Windsor

committed itself to this challenge and

is today successful in launching India’s first 5-layer POD line at a significantly

improvement in the impact strength and sealability of the film produced.

This dedicated POD line will empower Windsor customers to be successful in local and global markets by producing shrink

and

lamination

unmatched

quality

and

films

with

probably,

at the lowest price. The coming months will see the commissioning of the 1st

Windsor

setting

new

5-layer

standards

POD as

features-price-performance.

line,

regards

With the Government mandate of ‘Make in India’, Windsor with this pioneering initiative has on one hand made the 5-layer POD line far more affordable, opening new horizons of applications; and on the other, has saved the country valuable foreign exchange.

With the fast changing markets, with a locally available 5-layer POD line, Windsor has ensured that the Indian

processors now have a very unique opportunity to upgrade at a minimal price and not be left behind in the global

market place. For processors, greater flexibility, more bandwidth in product design and competitive advantage, all

accrue. Local manufacturing will further lower delivery time, ensure prompt support and reduce the overall cost of ownership.

Milacron India Delivers 10,001st machine to Cello Group

F

erromatik a

part

of

Milacron

Milacron

India

LLC,

(FMI), USA,

achieved a significant milestone on

2nd September, 2015 announcing the

manufacturing, selling and delivery of the 10,001st injection moulding machine

from its facility at Vatava on the outskirts of Ahmedabad.

18

POLYMERS Communiqué l August - September 2015

‘It is clear that India continues to be a

have a strong support system for faster

A number of analysts predict that by

Engineers nearer to the customers

global plastics processing powerhouse.

2020 India will be 2nd to only China in

the global polymer processing market’, says Tom Goeke, CEO, Milacron in a

statement, adding that Milacron places

great importance in the Indian market

and are uniquely equipped to serve the entire spectrum of services to the plastics industry.

response times and stationing of Service operations, he said, adding that the goal of the company is to provide complete life

cycle support and management services

so that customers feel fully supported and connected with ‘Team Milacron’.

Milacron’s expansion of the Ahmedabad

facility, to meet the increasing demand in

India and support existing customers, will

Digest Parx Plastics offers antibacterial acrylic (PMMA) for hospital beds fighting antibiotic resistance the right way

complete by January, 2016. The expansion will allow increasing production capacity by 40 per cent from 1500 injection FMI’s manufacturing team presented its 10,001st India manufactured machine

and

blow

moulding

machines

2100 machines per annum.

to

– The Milacron Hydron Servo 150 and

In a candid chat with POLYMERS

Chairman, Cello Group of Industries

function, Ron Krisanda says, ‘Indian plastic

handed it over to Ghisulal Rathod, during a function organised at FMI’s

Ahmedabad manufacturing facility in

the presence of Ron Krisanda, Milacron’s Chief Operating Officer, Advanced

Plastic Processing Technologies. ‘India is poised for quantum growth and Milacron’s Indian operations, with top

market share in the region, are rightly positioned to be a major component

in our overall growth plans across the globe’, says Ron Krisanda during the function.

Communiqué on the sideline of the

processing industry is doing much better

than many parts of the world. In fact it has seen exponential growth across the sector as a result of growth in per capita

consumption from 3.5 kgs to nearly 20 kgs. Still it will be half of the average global consumption’.

Talking about the Indian market, he

says, ‘It is a large growth market and in order to meet the increasing demand,

conveyed that the association is based on

year period’, he informs.

‘Technology and great service are pillars

in the foundation of success for any

organisation and Milacron embodies these traits at its core. Milacron has supplied

over 200 injection moulding machines to various factories of Cello Group in India and Africa’, he adds.

Shirish Divigi, Managing Director, Milacron India said that with its aggressive growth plan for the future, Milacron will introduce

is investing USD 30 million over the two-

Getting More from Less...

Rajoo Creates a New Footprint

C

ommodity markets always pose a

commercial

challenge

for

businesses. Innovations to get more out of every rupee is always welcome.

In one such approach, Rajoo today

presents ‘Lamina e’ Asia’s greenest Sheet Extrusion Line.

new value added products and services.

A meaningful innovation as this would

team directly connected with customers

industry to be competitive in their price

Milacron is focusing on strengthening its through sales, service and training to

POLYMERS Communiqué l August - September 2015

New materials from SABIC can benefit base station component designs and performance

Milacron is focusing on expansion and new investments in the country. Milacron

mutual benefits and progressive growth.

RPC Group supplies solutions for paint to move from metal pack to plastic in Ukraine

10.5 kgs and by 2020, it would be

Recalling the 18-year relationship between

Cello Group and Milacron, Ghisulal Rathod

Perstorp and Corbion jointly announce a breakthrough innovation for adhesives

only help the PP/PS disposable container

SECOS Group successfully scales up production of biohybrid films for global hygiene market

P-S

sensitive, yet rapidly growing market

19

‘I am delighted that while this line adds the much needed commercial allowance for

Digest as well as assist them in improved profitability in business.

Solvay and L’Oréal team up to promote sustainable practices among guar bean farmers in India

Power continues to hog the number two spot as the most significant cost component, after raw materials. The

research and development team at Rajoo

worked hard to find a solution. A new Veolia acquires AKG Kunststof Groep and strengthens its position as producer of recycled raw materials

companies

into

processing

of

PP/PS disposable containers; it also

design double barrier screw geometry has

resulted in an extremely energy efficient

S-V

sheet extrusion line. A 40% power saving is no mean achievement.

The 65 mm/700 mm width sheet line

with an output of 255 kg/hr (with 50% PP regrind) consumes a minimal power of 0.25 units/kg, whereas the 90 mm/700 mm

width sheet line with an output 320 kg/hr (with 50% PP regrind) consumes power as little as 0.22 units/kg. Unbelievable but true.

saves energy, a precious resource.

Sustainability

continues

to

be

an

important agenda for Rajoo not only through its activities, but also through its products’, emphasises Khushboo

Chandrakant Doshi, Director, Rajoo Engineers Limited.

This universal machine can be seamlessly operated with available thermoformers

for an end-to-end solution. A growing market for semi-flexible packaging,

an attractive ROI with the Rajoo Sheet Extrusion Line ‘Lamina e’ (minimal

capital and operating costs), proven

Rajoo post-sale-support and technical assistance, will help in your business

success. With this ‘Lamina e’ Sheet

Extrusion Line, engineering at Rajoo moves a notch higher. Another first for Asia from Rajoo!

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POLYMERS Communiqué l August - September 2015

SPECIAL FEATURE

PETCHEM Business

The Changing Horizon Vipul Shah talks about shale gas, the Indian petrochemical

industry and the polymer industry as also the initiatives that need to be taken to move ahead on the global stage.

Q. Innovation or economies of scale or a combination of both? Your thoughts on the market building a competitive edge.

Innovation and economies of scale are powerful tools for augmenting the competitive edge of a business in the market place. In today’s complex world, growing product commoditisation

and diminishing differentiation necessitate a combination of

tools, for any manufacturer aspiring for a market leading position.

Innovation need not be confined only to products. It needs to encompass production processes, business systems and even our

approach to market and product delivery. World-scale plants may

have built-in economies of scale, but innovation and an innovative approach to satisfying our customer’s needs would help it stand out and make money.

22

POLYMERS Communiqué l August - September 2015

Vipul Shah COO Petrochemicals Reliance Industries Ltd. Navi Mumbai

POLYMERS CommuniquĂŠ l August - September 2015

23

Q. The fluctuations in the crude prices have been a cause for concern for the industry. Can the market use this to its advantage?

a significant manner. As the benefit of

The fluctuation in the crude price has

In addition, passed on reduction in prices

brought in a major element of uncertainty in the business environment for the petrochemical industry. Fall in crude

prices has not only impacted India, but also the global market. While low crude

oil prices have put downward pressure on other commodity prices, including

low polymer prices are passed down the

chain, there would be more demand for plastic products.

of transport fuel and household gas is likely to place higher disposable income in

the hands of consumers for discretionary spends. This is likely to help catalyse the sales of our downstream product manufacturers too.

over, low but stable prices would only

Q. What is your assessment on the impact of the developments relating to shale gas on the petrochemical business here?

and hence would be beneficial for the

disruptive effect on global hydrocarbon

polymers, in the long term this could only benefit an oil importing economy like India. Once the price volatility is

give a boost to the demand for polymers future growth of our industry as well.

For downstream companies in polymer

products and applications, capturing the

incumbent growth would be the key to using these low prices to their advantage.

In the Indian SME context, cash flow cycle,

working capital and cash turnaround at

the customer end is quite important.

Low crude and product price scenario allows this.

I expect the Indian market to show healthy growth in a market scenario of low polymer prices.

This

benefit

would our

customers in

Emergence of shale oil / gas has had a and petrochemical industry. Singlehandedly, it caused global oil prices

to drop, with its cascading positive

effect on petrochemical demand, as elaborated earlier. Shale play has caused

a resurgence of US manufacturing, both

in commodity petrochemical segment as

well as downstream processing industry; it has emerged as a credible and large volume supplier of liquefied natural gas

to the world, thus allowing lowering

of energy (natural gas) prices, globally.

The competitive advantage of shale gas

based new polymer capacity in the US has gotten substantially eroded due to low

prices of oil and is, thus, unlikely to have any major impact on the petrochemical business in India in the short term.

However, this may change in future if the global economy revives, pushing

oil

prices

again. In that situation, producers

in

up

shale gas rich regions would gain back their cost position and advantage.

Availability threat of shale gas and shorter turnaround of new shale gas wells from

exploration to production, however, could also help keep the oil prices realistic.

Q. What change of thought, approach or mindset, according to you, is required as India continues to grow globally as far as the polymer business is concerned?

The polymer business in India is still at

a very nascent stage. Our current per capita demand of 10 kg is one third of

the global average and far below the per

The growth in

polymer industry has

outpaced the GDP in India from 2005 to 2012.

Average GDP growth in

India was

8.5 per

cent, whereas the polymer

growth was about

11 per cent. In the current

Five Year Plan

(2012-2017), these

comparative growth

figures are expected to be almost

similar.

24

POLYMERS CommuniquĂŠ l August - September 2015

capita demand in developed countries.

Many companies, no doubt, have

recommendations and other non-

more disposable income in the hands

philosophy. The rigours of global

Given this propensity of customers

already

As the Indian economy grows and puts

mix,

in life. Given the versatility and end-use

the

downstream converting industry in India still lacks in innovation and scale.

In order to avail the mega opportunity expected from India’s fast increasing

GDP, our downstream industry would need a change in mindset, especially with respect to the following: l

Thinking global while acting local. This could be a key mantra to their long

term success. Major Indian companies should target global markets, even

while focusing on the Indian market.

POLYMERS Communiqué l August - September 2015

to strive to be an integral part of

identify

new

their current customer’s experience

value-added

of delight. They need to pro-

actively understand their customer’s

their manufacturing.

growth is immense.

exceptions,

extremely important for companies

application and generally scale-up

applications of polymers, the scope for

l

communications.

to pre-research their suppliers, it is

standards, improve their product

so would the demand for good things

few

supplier-owned

this

could help them raise their quality

Indian would also get better. Inevitably,

a

embracing

marketing and competition, I believe,

of consumers, the lifestyle of an average

Baring

started

A customer centric approach - an

needs and go all out to satisfy them, so

in the market place. Customers

while going out to engage new ones.

as to ring-fence their current customer

essential pre-requisite to success are extremely demanding now-adays. Research indicates that not

only B2C, but even B2B customers are now waiting until they are, at

an average, half way through their purchase process before engaging

in serious contact with the supplier’s sales team. In addition to using supplier information, customers are

now educating themselves through websites, social media, third-party

l

Societal stakeholder approach - Every business, irrespective of their size

and product profile, now needs to consider itself as one of the major stakeholders in society.

It is a fact that life is unimaginable To know more, please subscribe to Polymers Communiqué at

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25

COVER STORY

R. S. Sodhi , Managing Director Gujarat Co-op Milk Marketing Federation Ltd. (Amul) Anand

Amul Salutes the Role of Plastics

in Its Business

28

POLYMERS CommuniquĂŠ l August - September 2015

Q. We all talk about the success of the white revolution; what role has plastic as a packaging medium played to make this revolution a success according to you?

today reach the consumer in a way that is very

Our Founder Chairman, Dr. Verghese Kurien

about the packaging material cost, it is actually the

conceptualised and implemented this idea of the need to provide market access for rural produce like milk. What was, thus, required was processing

and then packaging which could absorb shocks, bear all the transit hurdles, and at the same time, look attractive and be economical. We all know

that milk, till the late 70s was sold in the loose form. I remember milk used to be pasteurised and

then put back in cans to sell loose. This caused

the problem of adulteration. Simultaneously, in bigger cities, transporting milk in glass bottles over large distances threw up different challenges.

Getting the bottles back, hygiene etc. were other big concerns.

efficient, cost effective and hygienic.

I was recently questioned about rigid plastic as

a packaging medium for milk. I said it is not only packaging system cost i.e. filling lines, containers and

transportation. Also, as soon as you pack your product in packaging like tetra pack, the retailers expect

around 8 - 10 per cent margin (as it becomes an FMCG product) whereas in a pouch, the retailer will be okay

with 3 - 4 per cent as the margin. The contribution of plastic is tremendous. Take the example of milk

powder which we used to sell in tin containers till the 90s. The price of the packaging kept on increasing and about 25 - 26 per cent of the product was the

cost of packaging. Then came the solution of flexible

multi-layer laminated film with metallised aluminium foil which totally changed things for us. Now we sell about 80 per cent of our produce in such pouches. It

However, the thing which really revolutionised

milk marketing was plastic pouches. These are very economical even during mass production. Now, for

has reduced the transportation cost, packaging cost and the consumer is also happy as he is paying less.

12,000 packs per hour and if you have 10 such

Q. How do you compare the prevalent dairy packaging in New Zealand and Australia to India?

well. So, by using this packaging solution, we can

Their products are in two categories; one is a

example, we have machines that produce about machines, the scale up is easier and economical as

R. S. Sodhi talks about how the plastic pouch is a boon for milk suppliers and what developments in plastic packaging are needed for milk supply in the future, in dialogue with POLYMERS CommuniquĂŠ.

POLYMERS CommuniquĂŠ l August - September 2015

29

commodity,

which is packed

in laminated bags and

exported and the other is a very

small quantity is packed in value-added forms.

The packaging is very developed and is mostly in

An area of concern that still remains is labelling. What

with in-mould labelling. Their percentage spend on

find ways to minimise production steps that get

rigid containers - good looking rigid containers packaging is far above what is done here. These are

developed economies with saturated local markets.

Packaging becomes one of the important ways to innovate and thus, sell. The main agenda of packaging is to attract consumers.

There will be a section of the audience in India,

added due to labelling, caps and closures. Another challenge with rigid containers is the availability of

high speed and efficient filling lines. A challenge that was faced when Amul packed 200 grams butter

in rigid containers for the first time in the country - a product that will hit the retail shelves soon.

who I feel, will upgrade from flexible packaging to

Providing high speed filling lines for dairy products is

of consumers moving to the flexible packaged milk

need to work on. We have skill and skilled labourers

rigid packaging and there will be a large number instead of the loose milk they currently buy.

Q. What demands would you place on technology providers for the betterment of this industry?

One important point to note here is that earlier

rigid

packaging

constituted

about

15 - 16 per cent of the MRP cost and now it is reduced

to 9 - 10 per cent. This is primarily due to the fact

that the cost of packaging has not increased over

a crucial area that packaging machinery companies

and the manufacturers here should look at the possibility of aligning with European machine

manufacturers to build high speed packaging lines

for dairy products in India. It would then be easy to multiply as the markets are big and growing. On account of size, it is still possible for us to import

expensive lines, something that may not be feasible for smaller players.

a period of time while the cost of contents has.

To know more, please subscribe to

could pose a good opportunity for milk packaging.

polymerscommunique.com

With the similar trend continuing, rigid packaging

30

the rigid packaging companies could work on is to

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COVER STORY

Indian Manufacturing

Ready for the World Vivek Chaand Sehgal talks about the possibilities of polymer and plastic use in the

automotive industry and products that could look to being migrated to plastic from metal, in dialogue with POLYMERS Communiqué.

Q. What are your thoughts on the spirit of Indian manufacturing?

industry to the world, what according to you are the key steps required?

Indian manufacturing has been on the rise

It is important to perform well on all the

productive. The stage is set for India to claim the

Development, Management, Safety, Environment

during the last decade in terms of being lean and leading position of a global manufacturing hub. The

manufacturing sector in India is robust, propelled

with its core strength of human resource capital,

entrepreneurial skill and backed by a growing domestic demand, improvement in infrastructure,

ease of business and other conducive business environment as enablers. Indian manufacturing is ready for the world.

We trust that with the focus on ‘Make in India’, there

would be lot more opportunities for us to offer more and more products manufactured in India.

Q. To take the Indian polymer processing

34

parameters of QCDDMSES (Quality, Cost, Delivery,

and Sustainability). We always focus on these

parameters, which helps in adding new customers and cementing the trust of existing customers.

While the performance on QCDDMSES will overall

influence the Indian polymer industry to reach the global level, it is important that the industry recognises and brings in future technologies in line

with the customer expectations and requirements.

It is also key that the industry develops engineering capabilities locally and innovate low cost solutions

in areas of raw materials and processes. To visualise the future requirements of global customers and prepare in advance is the key for survival.

POLYMERS Communiqué l August - September 2015

Vivek Chaand Sehgal Chairman Samvardhana Motherson Group, Noida

POLYMERS CommuniquĂŠ l August - September 2015

35

Q. In context of the automotive industry, which are the most promising replacements that polymers could be suited for in the coming years?

in high temperature resistance polymers should also

pave way for various new applications. Furthermore,

in the interest of the society, we also need to develop

Polymers have been constantly replacing metal

environment

friendly

solutions.

Biodegradable

reduction has always been the focus of OEMs and

we need to always keep in mind the recyclability of

of usage of hybrid solutions like metal and plastic

Q. For your needs, do you see any limitations of available technologies for polymers processing?

components in the automotive industry. Weight

plastics is also something which is of interest to us as

will continue to be so in the coming years. The trend

the materials we use in our components.

bounded is also picking up. In addition to interior and exterior parts which have already migrated to plastic – there are further opportunities like plastic tail gates,

energy absorbers, bumper reinforcements, front end

carriers and some engine parts are real contenders for replacing with polymers in the coming years.

Q. What developments in polymer material science, you think, could help your growth?

Constant innovation in polymer material science is

not only necessary for our growth, but in the interest of the entire global automotive community. We are constantly looking at innovative solutions for the automotive industry, to substitute metal by lighter,

cheaper and environmental friendly polymer wherever possible, without compromising on the quality,

36

strength, safety or manufacturability. Developments

We, at SMG, are adequately positioned to leverage

technology for polymer products with the spread of

our

operations

worldwide.

Samvardhana

Motherson Peguform (SMP) and Samvardhana Motherson Reflectec (SMR) have always been high

technology driven companies with SMP leading the technology drive in polymer processing in association with various OEMs.

Limitations lead to new opportunities. We are a ‘NOT To know more, please subscribe to

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POLYMERS Communiqué l August - September 2015

B2B Marketing Communication Specialists RELATIONSHIPS

Key Services l

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Corporate Communication Consultancy Content Development

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Building Mailing Lists

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Media Dissemination

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Adeka India Pvt. Ltd.

All India Plastics Manufacturers Association

Arihant Industrial Corporation Ltd.

Asian Packaging Federation

AVI Global Plast Pvt. Ltd.

Bennett, Coleman and Company Ltd.

Blend Colours Pvt. Ltd.

Brückner Maschinenbau GmbH & Co. KG

Central Institute of Plastics Engineering and Technology

Chemicals & Petrochemicals Manufacturers’ Association of India

Ferromatik Milacron India Ltd.

Indian Centre for Plastics in the Environment

Indian Institute of Packaging

Indplas Exhibition

IPLEX Exhibition

India Trade Promotion Organisation

J P Plaschem Ltd.

Kandui Industries Pvt. Ltd.

Mitsu Chem Pvt. Ltd.

Organization of Plastics Processors of India

Pennwell Publishing

Plastindia Foundation

Plastindia Foundation

Rajoo Engineers Ltd.

Reliance Industries Ltd.

Sintex Industries Ltd.

Technical Training and Research Institute

The Economic Times Polymers

Vasantha Tool Crafts Pvt. Ltd.

Welset Plast Extrusions Pvt. Ltd.

World Packaging Organisation

Developing Customer Case Studies

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37

COVER STORY

Saurabh Dhanorkar talks about the market of PVC pipes in India, challenges that a company could face during

a growth phase and the key manufacturing processes incorporated at Finolex.

Q. At Finolex, what key manufacturing processes have you incorporated to ensure product quality with productivity?

preferences and needs is very important for the

At Finolex Industries Limited, the highest level of

Q. What according to you is the market of PVC pipes in India and what growth do you see until 2020?

quality in all products and processes is a way of life.

We believe that quality is not the responsibility of just the quality control department, but it is a result

of a strong commitment and culture that flows

across the organisation from the top management to every employee. All products at Finolex go through various levels of testing before being released in the market. Highest standards of quality

are maintained right from selection of the raw material and using the best available equipment and technology right through to using the best quality packing material.

Finolex pipes have a distinct advantage of having their own captive production of key raw material, the PVC resin. In fact, Finolex Industries which

started off as a modest PVC pipes manufacturer went for a backward integration project to manufacture PVC resin only to ensure an

uninterrupted supply of high quality inputs. While ensuring high quality of processes, Finolex ensures efficient use of natural resources and assets. There are continuous innovative efforts made towards improvement of productivity, quality, safety and

reliability. We also take environment preservation very seriously.

We also take extensive feedback from direct

customers / farmers to understand their needs and

actively follow the same.

The Indian pipes business has been growing rapidly since the past several years mainly due to increasing demand for pipes in the irrigation sector, real estate industry and growth in Gross Domestic Product (GDP) of the country. Among

the several varieties of pipes available in the market, the demand for PVC pipes is on the rise due to

their low cost, high quality and high durability.

The current size of the PVC pipes market in India

is around 18 lakh MTs per annum. The market has been growing at a double digit rate over the past

decade and we expect this trend to continue over

the coming years. Various new initiatives by the Central Government such as ‘Pradhan Mantri Krishi

Sinchai Yojana’ which promises water for every field and ‘Pradhan Mantri Awas Yojana’ which promises shelter for every Indian and the announcement of the plan to develop 100 ‘smart cities’ indicates that

there will be a surge in demand for PVC pipes and fittings in the coming years.

Q. When compared, which of your businesses - agricultural, sanitation and plumbing - is the biggest operation for you in the Indian market?

identify problem areas which could be connected

Finolex Industries has always been a dominant

centric approach and adapting to changing

has been the prime driver for the company

to our consumers directly. Having a customer-

40

right product design and development and we

player in agricultural PVC pipes. Agriculture

POLYMERS Communiqué l August - September 2015

Saurabh Dhanorkar Managing Director Finolex Industries Ltd. Pune

Finolex Tips

on Business and Growth POLYMERS CommuniquĂŠ l August - September 2015

41

too. The majority of the company’s

Finolex Industries is not into the export

which are expected to witness a surge in

the agri-business.

market is so vast that our primary objective

by the Government.

growth and turnover has come from As an organisation, Finolex Industries understands the value of water and its

purpose in the agri-business. We ensure

that the available water should reach the end user in the most efficient manner.

The company has been continuously engaged

with

concerned

agencies

to create solutions and is partnering

many initiatives to help efficient water transportation as well as conservation.

Having said that, we are also aggressively expanding into other areas. We are

creating new products and technologies for the urban areas focusing on sanitation

and plumbing aspects, which will find applications in diverse areas. Thus, we see our growth coming from both, agri and non-agri markets.

Q. Your thoughts on the exports business please.

business. We feel that the scope in Indian is to meet the needs of the Indian market before we venture abroad.

Q. Which are the new business areas that Finolex Industries is planning to get into?

Finolex Industries Limited already has a strong pan India presence in the agri

side of the business. Geographically, West

demand based on various new initiatives We also have plans to enter into new products for water management which

will be distributed through our vast network across India. Currently, we are in the process of evaluating some products

and we expect these new products to

make a substantial contribution to our topline over the next four to five years.

have already opened depots at Cuttack

Q. What are the practical challenges that a company could face during a growth phase, how do you suggest a corporate gears to overcome these challenges?

and we are in the process of opening

their category for more than two decades.

India and South India have been the main markets for Finolex pipes and fittings. We

are now focusing on our distribution reach in the North and East India markets. We (Odisha), Noida (U.P.) and Indore (M.P.)

Finolex pipes have been market leaders in

further depots to cater to the ever

Over the years Finolex has developed a

increasing demand from our customers.

The company is also focusing on the nonagri business segment to fuel its growth

across India. We are primarily targeting the construction and infrastructure sectors

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lohiagroup.com

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Our continuous innovation and updated technologies help customers save material, energy and efforts to optimise cost of production and quality.

Leadership through customer satisfaction is the passion we pursue at Lohia.

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Delivering Advantages

42

Tape Extrusion . Winding . Circular Weaving . Coating . Printing . Bag Conversion . Yarn Spinning

POLYMERS Communiqué l August - September 2015

HUMAN CAPITAL

Resources

Vital for Growth of the Plastics Industry Prof. (Dr.) S. K. Nayak and S. Sugumar talk about the need to invest in human resources and India’s youth, which are the future driving force for the social and economic development of the country and CIPET’s role in attaining this goal.

India: Employment Scenario

required by 2022. Employment opportunities in India

India, with a population of 1.21 billion people as per the census of 2011, is one of the youngest Nations in the world. On the basis of NSSO 68th round, the labour

force in India is 483.72 million as of 1 January, 2013. st

With this demographic dividend waiting to be reaped,

one of the biggest challenges facing the country is that of empowering our youth with skills. It is critical to understand the

demand-supply matrix to ensure skill

training is aligned to the demand of the

industry. The Human Resource Prof. (Dr.) S. K. Nayak S. Sugumar Director General Deputy Director and Head CIPET Chennai

44

Skill

and

Requirement

Reports

estimated

that an incremental

109.7 million skilled people

will

be

would increase from 461.1 million in 2013 to 581.90 million in 2022.

The young are the pillars of the country. They

are the driving force for the social and economic development of a country. If the employability of the

youth increases, their social and economic status will also increase. The gap between the employability

of the youth and employment should decrease so

that the percentage of unemployed youth decreases.

Many sectors are available for selecting one’s career.

The demand for jobs in each sector varies from time to time depending on the global market trend. Plastics

and allied sectors have their avenues open for job

seekers and entrepreneurs at any point of time due To know more, please subscribe to

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POLYMERS Communiqué l August - September 2015

REPORT

Indian Plastics Industry

A Rising Business Deepak Lawale presents an overview on the Indian plastics industry and its future.

I

ndia is a growing market for plastics and consumes

The downstream plastic processing industry is highly

annually against the global consumption of

units. Out of 30,000 processing units, about 75 per

about 12.8 Million Metric Tonnes (MMT) of plastics,

285 MMT per year. The plastics and polymer consumption is growing at an average rate of 10 per cent. About 30,000 processing units with 1,13,000

processing machines have created a manufacturing capacity of 30 MMT per annum in India. This has

been achieved with a 13 per cent CAGR of processing capacity during the last five years. The industry has invested USD 5 billion in the machinery and it is

expected to make an investment of USD 10 billion

for further increase in capacities during the next five years.

fragmented and consists of micro, small and medium cent are in the small scale sector. The small scale

sector, however, accounts for only about 25 per cent

of polymer consumption. The industry also consumes recycled plastic, which constitutes about 30 per cent of total consumption.

The key plastic sectors include PP non-woven,

agriculture, raffia, flexible packaging, automotive and textile fibres.

Exports from India The Indian plastics industry products are exported

The expected consumption of major polymers by

to over 150 countries around the globe with major

as below:

China, UAE, Saudi Arabia, Turkey, Nigeria, Indonesia

the Indian plastic processors in the current year is

Polyethylene

Polypropylene : 4521 KT

PVC

l l l

: 4683 KT : 2960 KT

The per capita consumption of polymers in India during 2014-15 was just 10.5 kgs as compared to

109 kgs in USA, 45 kgs in China and 32 kgs in Brazil.

India is expected to be among the top ten packaging

consumers in the world by 2016. The low level of

per capita plastics consumption in India is indicative

trading partners being the European Union, USA, and Egypt, among others.

Plastic products aggregated to USD 4860 million during the year 2013-14 and during this year, the

exports of plastic polymers has been USD 3057 million. Thus, the exports of plastic polymers and

plastic

products

from

USD 7917 million.

India

totalled

to

Exports from the Indian plastics industry is expected to reach USD 10 billion by 2015-16.

of the massive growth potential of the plastics

Major exports include plastic raw materials, plastic

will be doubled in the next five years, given the

items, packaging items, woven sacks / FIBCs, all

industry. It is expected that per capita consumption

rising consumerism and modern lifestyles which have increased the usage of plastics across industries like automobiles and consumer products.

sheets, films, plates etc., other moulded and extruded types of optical items (including optical frames, lenses, sunglasses etc.), medical disposables, writing instruments, floor coverings and houseware.

Recent Innovations Deepak Lawale Secretary General Organisation of Plastics Processors of India Mumbai

46

Water Purifier: Millions of Indians have access To know more, please subscribe to

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POLYMERS CommuniquĂŠ l August - September 2015

OPINION

Affordable Technologies

The Unexplored Realm Between Jugaad and Exotic Technologies Vikram Bhaduria talks about the potential affordable technologies can offer those willing to explore this realm in the Indian innovation scenario.

Where Are We Today?

Every entrepreneur or business owner I meet yearns for the next big idea. There exists in each of us, a

thirst to do something new, something unique.

But we will not do anything new, if we keep doing tomorrow what we were doing yesterday. Yet, most

of us continue doing the same things and hope for a miracle.

to make do with the unreliable jugaad technology.

There is a vast unoccupied space between these two

poles that is waiting to be occupied by those who move first. For those willing to fulfill these aspirations with the help of affordable and durable technologies,

this is a competitively calm blue ocean that offers

an instant and appreciative clientele of a billion plus consumers.

Often enough, opportunity stares us in the face; but

Looking Beyond...

of looking around. In a country of a billion plus, I

a culture of innovation and research be incorporated

we miss it as we are looking into where we are, instead believe we have such an unexplored opportunity

waiting to be charted by those brave enough to look around and ahead.

In India, the past decade has seen a rapid proliferation

of information through mobiles and media. Our countrymen and women have a peek into the popular

To look and act beyond the routine, it is imperative that

in the DNA of our companies. Only then, can one hope to capitalise on this unclaimed opportunity. Another unrecognised asset within our reach is the vast

talent pool available to us in India. We push out more

than 1.5 million engineers every year. This is more than the combined figures of USA and China.

culture, lifestyle, news etc. It has created an aspiration

The

sanitation, safe public transport, affordable medical

access to a large technical talent pool, there is no

in the population - for basic amenities like dignified

care etc. While these sound like table stakes to the well heeled few, such facilities are often out of reach for our masses. With the purchasing power parity (PPP) of

Rs. 10,000 a month, we are not looking at deep pockets

and high disposable incomes. They cannot afford

the pricey and exotic foreign technologies and have

above

mathematics

looks

simple

and

encouraging. With a vast aspirational market and reason why our entrepreneurs cannot develop

affordable technologies and durable products that

are safer, affordable and sustainable products that will add good value to the lives of our population.

In theory, our engineers and researchers should be

churning out newer products by the minute and our

industry should be bringing these products to the

people who should be enjoying a better quality of life.

Vikram Bhadauria Director Alok Masterbatches Pvt. Ltd. New Delhi

48

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POLYMERS Communiqué l August - September 2015

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49

INTERACTION

Extrusion Blow Moulding

New Vistas of Applications Andreas Lichtenauer talks about blow moulding machines and

the importance of service as part of their strategy for long term relationships with customers.

Andreas Lichtenauer Managing Partner Kautex Maschinenbau GMBH Germany

52

POLYMERS CommuniquĂŠ l August - September 2015

Q. Which is the recent innovation in extrusion blow moulding that has excited you?

Q. As regards the Kautex growth story, what do you consider the most defining aspect that has caused this growth?

Blow moulding is a very small business when

We are, today, one of the fastest growing companies

single aspect that excites us. With the extrusion

growth. To me, the most important factors are

compared to injection moulding. There is not one blow moulding machines, we are extremely busy

with many different applications - consumer

packaging, industrial packaging and automotive

applications. In the field of specialities we evaluate opportunities

to

transfer

other

production

technologies to blow moulding. One good example is a client from North America who has

about 100 injection moulding machines to make

in our line, with lot of factors contributing to the committed employees and the fact that we keep the customer at the centre of all that we do. We have

completely re-organised ourselves. We are, today,

process oriented and matrix oriented. We are trying to have a very flat and lean management structure.

Additionally, we invest about 3 - 4 per cent of our turnover on our employee education.

garden furniture who has now moved to our machines. He has witnessed some advantages

Q. What is your vision of the Indian polymer industry by 2020?

when compared to injection moulding. Some years ago we developed special technologies to

As a part of our vision, we look to increase our sales

make very flat and hollow parts with very good

by 40 per cent and we believe our Indian business will have a crucial role to play here. For your information,

surface finish and performance. Extrusion blow

moulding machines offer much shorter cycle times as compared to injection moulding machines; the

parts now come with reduced weight and higher

stiffness. Other specialities of our machines include NIKE air soles for sports shoes. Another big thing

that we see having a very bright future is our activities in composite cylinders. There is already

China is contributing 30 - 40 per cent of our business.

What we have done in China, we look forward to

doing in India. We believe with your new Prime Minister, things would be pushed ahead. While every

Our target for

India in the next two years is to

country has its local specifics, to us the processing

have a better

country is price sensitive and wants an aggressive ROI.

customer needs;

industry is similar as we see in other countries. Each

understanding of

One of the differences, though, that I can see in the

and for them

are on the anvil of a breakthrough in the Indian

it was something similar to what China was ten years

that we are not

compliance needs. The products are under tests.

increase productivity and quality of parts than to

of explosion is averted; in case there is a fire the

opportunities in a company like ours. It is important

still liquid) would burn.

automation. Such is the impact of automation that in

Q. There have been diverse opinions on affordable innovation. What is your take?

have more robots installed when compared to North

one line in India with Supreme Plastics where we

are making composite cylinders for LPG. Here we

Indian market is the use of automation in packaging;

to understand

market well keeping in mind, the regulatory and

ago. The agenda of automation today is more to

The product is much safer than steel, the big risk

reduce labour. Global standardisation provides good

machines, but to

plastic cylinder would melt and the gas (which is

for Indian converters to come to the next level in

relationships.

For us as a company, innovation is driven by

requests from clients and if these innovations are not affordable they are not successful. We are not

innovating because we like to innovate. We are making innovations to make blow moulding more

attractive to our clients. As a company, we have invented blow moulding and now we are celebrating

our 80th anniversary. We have, today, an installed

base over 6000 machines in the world. While we are not the cheapest machines, we explain to our

clients that with our machines his operation cost would be the lowest.

POLYMERS CommuniquĂŠ l August - September 2015

here just to sell

build long term

a recent report it was indicated that soon China would America and Europe put together. And, I believe, that

something similar can happen to the Indian market in next 5 - 7 years.

Q. What are the technological advancements over the next five years that could have a positive or negative impact on extrusion blow moulding?

I believe that shale gas will have a positive impact as To know more, please subscribe to Polymers

CommuniquĂŠ at subscriptions@polymerscommunique. com

53

INTERACTION

Standardisation Adding Value to Mould Making

Sujith Kumar Sales Manager India / Middle East Meusburger India Pvt. Ltd. Bengaluru

Sujith Kumar talks about mould making in India and how standardised parts can help the entire mould making process chain, in dialogue with POLYMERS Communiqué.

Q. How evolved do you find the Indian mould making industry?

The Indian mould making industry is quite evolved.

However, India still imports high precision, high speed moulds. An interesting observation made by Mr. Andreas Vogel, Head of Sales, Meusburger is that

the Indian mould making industry is as a whole only

5 per cent that of China’s. India is currently witnessing rapid growth in all sectors namely construction, electronics, automotive, FMCG and healthcare. The

scope of growth in the tool making industry is huge.

Q. What are the new trends in mould making, globally?

Standard parts are becoming more and more

important in modern tool and mould making due to a variety of reasons. When you take a closer look, you

can see that the use of standard parts has numerous advantages for all people and companies involved

in the development, construction and production of tools and moulds. Products are becoming more

POLYMERS Communiqué l August - September 2015

55

and more complex. Consequently, the

At the moment, the manufacturing

requirements for punching tools and

is done only in our factory in Wolfurt,

injection moulding tools are ever

Austria. Centrally located in Europe, near

more challenging. Another reason

the borders of four countries, the

for the increased use of standard

location offers modern business

parts is the very short timeframes

facilities, high training levels and

for new developments, considering

a motivated workforce as well

that it often is impossible to manufacture certain parts in a very short time.

as a high proportion of exports. Since

operations with the readers of POLYMERS Communiqué.

Q. How would your customers benefit from your standardisation?

Meusburger GmbH & Co KG is a 50 year

Meusburger is quite new to India, it would take us some more time to set up a

warehouse and later on, a manufacturing base. However, we are still open to the idea.

Standard parts help to optimise the entire

old company and a leading manufacturer

standard parts in tool and mould making

parts. We are relatively new in India; we

of components, substantial cost savings

of 2013. To better serve our customers,

Standard parts are our focus which

parts are heat treated for stress relief to

in April, 2015 with the registered office

India. With its 18,000 m² of warehouse

moulds and tools.

planning to further invest in the location

Q. Very recently, Meusburger has setup an office in India. Please share the plans for the Indian

Q. Do you see manufacturing in India a possibility for Meusburger?

process chain. With systematic use of

in the field of high-precision standard

as well as for the subsequent production

have been present here since November

Q. Which is a faster growing business for you in India, standard parts or special plates? Why?

can be made. We ensure that all standard

Meusburger India Pvt. Ltd. was formed

is also the faster growing segment in

provide excellent material for high-grade

at Bangalore. For the future, we are and enlarge our sales team.

area, Meusburger has the largest central

standard parts warehouse for plates and accessories. Nearly all catalogue items can be ordered immediately and can

be picked and dispatched in very short times - a unique selling proposition.

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POLYMERS Communiqué l August - September 2015

POLYMERS CommuniquĂŠ l August - September 2015

57

An Introduction to

Automated Material Conveying Doug Brewster talks about the advantages of automated conveyance systems at plastic processing plants.

T

he operations of the plastics industry, worldwide, are normally on

a large scale, with raw materials produced, shipped and handled in

extremely large volumes. They are delivered to processing plants in

large, skid-mounted cardboard boxes called gaylords; in oversized reinforced

plastic bags; in skidded stacks of paper bags; or, extremely large quantities,

by railcar or truckload. Once in the processing plant, resins are usually

handled through pneumatic conveying systems that typically consist of a system of pipes, manifolds, valves and controls that derive their motive

force from a high-velocity stream of air. Typically, this air stream moves as a result of a differential in vacuum pressure that is created at the head of the

system by a vacuum pump. In smaller, self-contained conveying systems,

the vacuum may be created by a motor or by a fast-moving stream of compressed air that is pulled past a venturi. When granular, pelletised or

powdered materials are exposed to this vacuum pressure differential, they

are drawn into the pneumatic conveyor, suspended in the air stream and moved to their destination.

Doug Brewster Conveying Product Manager The Conair Group USA

There are many advantages to pneumatic conveyance in a plastics processing plant: contamination is held to a minimum. Waste and spillage are minimised, resulting in a cleaner plant and lower housekeeping costs.

Personnel accidents, from lifting, or moving resins, or from slips and falls on spilled resin can be virtually eliminated.

Vacuum material receivers above a blending station.

58

POLYMERS CommuniquĂŠ l August - September 2015

or of supplying vacuum power to several smaller loaders at the same time. If dust generation is not a major problem, it is

possible to substitute a filter canister for a central dust-collection system. If frequent

loading cycles are expected, the pump

may be equipped with a sequencing valve

When supported

that allows the pump

to run continuously

conveyors

can

be

designed

and optimised in many different ways, virtually all have many operating features

and requirements in common. Each must create and sustain certain types of

velocity required to move pellets through the system: l

Minimum

surface

through

without damage. l

velocity:

The

velocity required to move a specific material

the

system

Settling velocity: The velocity required to keep materials suspended and flowing in the air stream.

l

All

or more self-contained loaders, which is elaborated here.

similar

physical

displacement pump. Available in a range

at one end, preceded

use a powerful rotating lobe blower,

collection system. At

long-distance

material

certain

of power or velocity required to move them properly. The specific gravity of a

by a filter or dust

are factory set to draw 12 in. (30 cm) of mercury. These pumps operate on three-

phase power and incorporate a filter to protect the pump’s inner workings. Due

to their power, they can be quite noisy, if located near the working area. Central

upstream from these large pumps to minimise the amount of residual particles,

dust or other contaminants that are generated by the conveying process.

Peripheral vacuum pumps are ideal for

or pellets of it through the system. The

applications. They are capable of moving

bulk density of materials (in powders, granules or pellets) is an important

determinant of the size of pipes and

small to medium-sized resin-conveying free-flowing materials up to 200 ft (61 m)

at rates of up to 3000 lb (1360 kg) per hour

receivers in the system. Materials with bulk

to more receivers

880 kg/m3) are relatively easy to convey;

from surge bin

densities between 25 and 55 lbs/ft3 (400 to while heavier materials may require more power. Lighter materials have no effect

on power requirements, but may require

direct feed

central vacuum line

well-engineered

pneumatic conveying

system, direct

a

of sizes, positive displacement pumps

material is related to the amount of air that will be required to lift and move particles

have

powerful type of vacuum pump: a positive

dust collection systems are installed just

characteristics which govern the amount

systems

layout. The pump is

protected by a vacuum relief valve, and

automation and a

Regardless of size, the

conveying requires the use of the most

High-volume,

of the system.

to lift pellets in vertical segments have

stopping. conveying

and so often require a sound enclosure

materials

and

appropriately by

starting

central

Drop-out velocity: The velocity required

plastic

eliminate

excessive

Figure 1: Positive displacement pump.

While

and

feed provides a

continuous and

reliable supply of resin while

the other end is one

eliminating the

or

to cleaning out

or, more likely many other

time required

material

receivers. These can

and managing

include surge bins and other storage

excess resin in the

that serve individual

when it is time for

machine hopper

containers, hoppers

moulding machines,

a new job to run.

or hoppers located

on conditioning equipment like dryers,

blenders or feeders. Operation of the entire system is directed through an integrated control system.

To know more, please subscribe to Polymers Communiqué at

subscriptions@polymerscommunique.com

from granulators

ratio valve blender

additional system or storage space.

A variety of factors, including the size

drying hopper

central dust collector

central vacuum pump

of the plant, influence the processor’s decision whether to install a centralised

vacuum conveying system or utilise one

POLYMERS Communiqué l August - September 2015

Figure 2: Schematic of central conveying system.

59

60

POLYMERS CommuniquĂŠ l August - September 2015

UPDATE

A Glimpse Into the

Plastindia International University Arvind M. Mehta talks about the upcoming international university that will be an asset to the future of the Indian plastics industry.

The current committee led by the President, Subhash Kadakia took the bold step of going

forward by making a charter which involves

Arvind M. Mehta Chairman, Empowerment Committee Plastindia International University

representatives of all seven founder members.

Till May, 2015 the empowerment committee was constituted to take this task forward. All Past

Past President - AIPMA & Plastindia Foundation

Presidents are advisors and industry stalwarts

The Indian Plastics Industry: Striving for Excellence and Innovation Plastindia Foundation signed an MoU with the Government of Gujarat during the Vibrant

have been appointed as special advisors.

We have started in right earnest and the PIU committee meetings are being held and we are going forward enthusiastically.

Gujarat 2009 event for setting up a Knowledge

The project will be implemented in three

in Gujarat state. The Plastindia Foundation

the administration and academic blocks along

Centre (Plastindia International University - PIU) requested Gujarat Government for 50 acres of land at an estimated total

investment

of

Rs. 100 crore. Accordingly, the

Gujarat

Government

allotted 35 acres of prime land for the Knowledge

Centre at GIDC Dungra, Vapi at a concessional rate for a world-class institution for plastics and polymers.

phases, beginning with the construction of with the laboratory, besides other infrastructure spread over an area of

Strategically Located The University campus is ideally located. Sixty per cent of the existing

plastics and polymer companies are located in Western India, of which

major clusters are in and around the state of Gujarat viz. Umargaon, Sarigaon, Vapi, Silvasa, Daman etc.

There is a good mix of different sectors of the plastics industry

in this belt – Daman and Silvasa are concentrated with

packaging

Umargaon, and

Vapi

units,

Sarigaon

have

other

plastic businesses. Vapi is also close to Mumbai which is another hub for

the

downstream

plastics industry and is

easily accessible by road from Mumbai.

62

70000 sq.ft. In totality, it

will cost Rs. 150 crore and more and will be funded

by Plastindia and the industry. Once started,

it will take around 18 months to complete.

The PIU is being set up

to

ensure

development

of

global the

Indian plastics industry and

to

optimise

economical industrial of

the

the

and

growth

country.

To know more,

please subscribe to Polymers

Communiqué at subscriptions@

polymerscommunique. com

POLYMERS Communiqué l August - September 2015

A TRIBUTE

Saluting the Indomitable Spirit of

Dr APJ Abdul Kalam, 1931-2015

His thoughts continue to guide us...

POLYMERS Communiqué l August - September 2015

Team POLYMERS Communiqué

63

64

POLYMERS CommuniquĂŠ l August - September 2015

Events IPLEX 2015

Indplas’15

PLASTICS RECYCLING 2016

P4 Expo INDIA 2016

25th – 27th September, 2015 BIEC, Bangalore International Exhibition Centre, Bengaluru

27th – 30th November, 2015 Science City Ground, Kolkata

1st – 3rd February, 2016 Hyatt Regency, New Orleans, Louisiana

5th – 7th April, 2016 India Expo Mart, Greater Noida, Delhi NCR

Plast Show 2015

PLASTIVISION ARABIA 2016

Chinaplas 2016

4th – 7th December, 2015 Vapi Industrial Association Ground, Vapi, Gujarat

22nd – 25th February, 2016 Expo Centre Sharjah, Sharjah

24 Fakuma

Plexpo India

5th Plastasia 2016

13th – 17th October, 2015 Friedrichshafen, Germany

7th – 11th January, 2016 Gandhinagar, Gujarat

3rd – 6th March, 2016 Pragati Maidan, New Delhi

19th – 26th October, 2016 Düsseldorf, Germany

Expo Plásticos 2015

Saudi Plastics & Petrochem 2016

PLASTIMAGEN MEXICO 2016

10th Plastivision India 2017

4th – 6th November, 2015 Expo Guadalajara, Guadalajara, Jalisco, Mexico

18th – 21st January, 2016 Riyadh International Convention & Exhibition Centre, Riyadh

8th – 11th March, 2016 Centro Banamex, Mexico City, Mexico

19th – 23rd January, 2017 Bombay Exhibition Centre, Mumbai

INDIAPACK 2015 8th – 11th October, 2015 Bombay Exhibition Centre, Mumbai

th

66

25th – 28th April, 2016 Shanghai New International Expo Centre, Shanghai

K 2016

POLYMERS Communiqué l August - September 2015