POLYMERS Communiqué Dec 2015 – Jan 2016 by Polymers Communique

A CUSTAGE I N I T I A T I V E Dec 2015 - Jan 2016 l Issue 2.2 l ` 150

Harsh Mariwala Chairman Marico Limited

Manufacturing

It’s All About Transformation

3-D Printing of Plastics

Era of Digital Manufacturing

OPaL’s USD 4.5 bn Project A Look Into

Clear Barriers,

to Barrier Packaging

Utopeia/Reliancepolymers/1518

POLYMERS CommuniquĂŠ l December 2015 - January 2016

CONTENTS

Dec 2015-Jan 2016 l Issue 2.2

BI G S TORY

Manufacture: To Create Products, Not Just Produce

Through this interaction with POLYMERS Communiqué, Harsh Mariwala emphasises on the importance of innovation, value management, organisation culture, adoption of technology, role of research along with a socio-economic approach in creating a product to add value.

Harsh Mariwala, Chairman

OPaL, Vadodara

A Lease of Life for the Plastics Industry

Makarand Dixit, Head - Marketing

FO R WA R D TH O U GH T

Rajoo Engineers Ltd., New Delhi

Marico Limited, Mumbai

S I VARAM S PEAKS

In a world where economies of scale matter less and less, mass manufacturing of identical items may not be necessary or appropriate. 3-D printing allows product customisation, lowers the cost and the risk associated with tooling and dies, says Dr. S. Sivaram.

3-D Printing of Plastics: The Emerging World of Digital Manufacturing

Dr. S. Sivaram, Former Director

CSIR-NCL Polymers and Advanced Materials Laboratory, National Chemical Laboratory, Pune

PR O JEC T TA LK

The Dahej plant has a potential to produce about 1.5 MTPA of polymers, critical to catalyse the growth of polymer industry, generating over 1,000 permanent, 15,000 direct and indirect jobs, emphasises K. Satyanarayana in dialogue with POLYMERS Communiqué.

Industry to Benefit from OPaL’s USD 4.5 bn Dahej Plant

K. Satyanarayana, Chief Executive Officer

Pro-industry policies and new Government initiatives are likely to enable and augment entrepreneurs to excel, something which will augur well even for catalysing polymer processing. OPaL, Vadodara

Clear Barriers, to Barrier Packaging Sunil Jain, President

POLYMERS Communiqué l December 2015 - January 2016

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

Editorial Advisory Board

G R OWTH DRI VERS

Inefficiency: A Hurdle to Overcome for Plastics Processing

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

Shaily Engineering Plastics Limited, Vadodara

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

ADVE R TORI AL

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

Flexible Packaging, a Productive Option for Refiners

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

Mahendra Sanghvi, Executive Chairman

Post-metallocene Technology Solutions to Meet Growing Packaging Needs of the Edible Oil Industry Vipul Babu, Sales Director – India and Sub-continent Dow Packaging and Specialty Plastics

IN TE R ACTI ON

R. K. Aggarwal, Managing Director

Pipes and Packaging: Fuelling Masterbatch Growth Prayag Polytech Pvt. Ltd., Bhiwadi

R E C Y C L ING PAGES

Next Generation Recyclingmaschinen GmbH

Rethinking the Next Generation of PET Recycling

ME E TIN G POI NT

Harish Dharamsi, Chairman

E VE N T

Plastivision Arabia (PVA) 2016

Rakesh Shah formerly 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

CHINAPLAS 2016 The New Era of Intelligent Production

NEWS

New Delhi Vijay Babbar +91-98100 15111 vijay@polymerscommunique.com Vadodara Devindra Bhumra +91-81289 90887 devindra@polymerscommunique.com

PVA 2016 to Boost Bilateral Trade

Hyderabad Vani Sulakhe +91-93924 28927 vani@polymerscommunique.com

PRODUC TS

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

EVENTS

Content Alliance Partners

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. Domestic Subscription: Single Issue Price: Rs. 150; Annual Subscription: Rs. 900 (including shipping) Overseas Subscription: Annual Subscription: USD 60 (including shipping)

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. Some of the images used in this issue are from Shutterstock.

POLYMERS Communiqué l December 2015 - January 2016

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.

Mind Speak N. K. Balgi

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

Manufacturing comprises of manufacturing

engineering, gamut of processes from design to delivery to market, supporting through operational life, engaging people to manage processes and take decisions when needed. The distinct feature of ‘Science’ is processes are defined and results are predictable. Manufacturing engineering was always a ‘Science’. Manufacturing processes have become ‘Science’ by using techniques of Lean, JIT, Six Sigma, 8D and by deploying the scientific tools which have made results more accurate.

Rajesh Nath

Managing Director

VDMA German Engineering Federation India Liaison Office

Newly evolved technology of ‘Internet of Things’ will improve efficiency of manufacturing processes. However, making decisions will remain a ‘human art’, so the people development will stay as priority for business success.

Prof. (Dr.) N. C. Saha

Director

Indian Institute of Pac

kaging

The manufacturing process of any including materials, packaging e polymeric materials, is a new scienc in terms of newer techniques and technology, coupled with automation r to produce the goods with highe productivity, lesser wastage and high quality of finished products. turing is the

Arvind

Mehta

tor g Direc anagin and M . n td a L m t. ir Cha ns Pv xtrusio Plast E t e ls e W

biggest

ufac ns Basically man in all functio t generator

employmen ent, service l, managem i.e. technica illed floor sk skilled, un providers, . r the country manpower fo irements of anging requ ch w al market, Under ne ob gl g for the product manufacturin st be mand the ell customers de tionally as w na le ab pt which is acce ible without ss po t no is is as globally; th , innovation, of technology the support . and IT r upgradation w science fo turing is a ne ac uf an m , So a’. ‘Make in Indi

Rakesh Shah

formerly Managing Director Windmöller and Hölscher India Pvt. Ltd.

Manufacturing in future will different from look very what has be en practiced the past. Succ in essful firms wi ll be capable rapidly adaptin of g their physica l an infrastructure d intellectual s to expl oit change technology as s in manufacturin g becomes fas more respon ter, sive to changi ng global mar and closer to kets customers. Constant ad aptability wi ll pervade aspects of all manufacturin g, from rese and developm arch ent to innova tion, productio processes, n supplier and interdepende customer ncies, and lifetime prod maintenance uct and repair. Products an processes will d need to be su stainable. Clos loop systems ed will be used to eli minate energy and water wa ste. gies are ring technolo in manufactu anufacturing m of s es oc e entire pr ts of impacting th nal concep the traditio anges will ch e es as well as th d g science, an our in manufacturin man endeav pact the hu entire e th t bu s, irreversibly im tic plas g not only of g. rin tu ac manufacturin anuf nisation of m idea and orga e 3-D changes ar l rfu we po t deal ea gr a ed The most in ga g which has turing rin tu ac uf ac uf an m an m the and space in ence n io llig te nt in te l at of tificia pments in ar tive controls. ap world, develo ad as ll as we the and robotics g will change manufacturin at present. d se Decentralised ni ga or turing is s e.g. way manufac new material materials and aterials, m no na Research in s), ermosets (PHT werful recyclable th lt in some po sites etc. resu latest d an ce nano compo scien s in ts. The new an en m em hu nc of va ad e role t will impact th er their skill-se technologies alt d an s se es g proc solescence of ob manufacturin e th d an forever g bigger requirements while creatin o accelerate these will als . ut omic outp per capita econ

Advances

Feedback I

want to thank highlig you fo ht the r takin develop g initia techno ments tive to logies and esp a n d ben within ecially e fits an new the po d lymers develop publish commu ments ing PO n it L y Y M in Ind ERS Co your ori ia by mmuniq ginality , and th ué! I ap was no e fact th preciate t canne at your d or ge presen unique neric in tation style to any wa it, and a y, but h good in ctually ad a formati gave in on that dustry we can some I thoug use. ht the special toward coverag s ‘R&D e that y and Inn ou pro useful to ovation vided the ind ’ were ustry p practica attentio rofessio l and n right n a ls . a You go t the b to keep t their eginnin expert’s g and attentio all are manag n till n actually ed o w . e I believ njoying update e that the be d indu nefits o stry info It’s not f gettin rmation always g and ha easy to industry ppenin g e t the ri gs. happen g ht conte ings, b great jo ut you nt and b of it. manag Again th to rec ed to d ank you ommen o a a n d I’d be d POL anyone YMERS pleased who ask Comm s about uniqué it. to Nortech

h a muc reating c h rc is a e ic res gazine This ma blend of academtions. This d plica of neede ial ap cause industr s the e rv e with and s y h ll a rc ea t re r res concep ased olyme ge b ed p owled n k advanc in s n tio applica . wivedi society yank D pment a M . r D Develo arch & tion (DRDO) e Rese isa Defenc Organ has Communiqué excellent an as ut shaped-o short period. I am magazine in a very e having such zin ga ma a yet to see en of tire industry a wide coverage mmuniqué. My Co RS ME like POLY tion to the entire sincere apprecia . Please keep it up m. tea publishing

POLYMERS

A Trinity In shutosh Gu pta dia Priv ate Lim ited

uage, er, lang e matt th both f o n o ty sentati e quali re th is p e ir e I adm etc. and th ith layout which é. u w s iq ty n to li u o a h m u p m nt q RS Co h and pri OLYME d wit paper your P nnecte o c in s s s nce ie o la c n a p p rm o to tf com ur pla nd tional use yo rofile a Interna et will ader p rk a re m e cide e th d t u o o h Indian w r ab akers eir re clea s in th ision m they a rchase to dec u p h e c c a what n e w u o fl n the re in k or ho hases ant ting w marke ems w on purc value it hose in T n h . s ig ft s h e o g st e busin offerin ho mo ects w and are s or p s s s m e la ro c it p is rs in to new h senio witch to reac e or s g n a h c er. decide am. do bett your te ses to u and o y proces t to f luck erchan , best o Vijay Mm Plastics Manish Dyna

Mihir Banerji

titute

Indian Plastics Ins

‘Infor mat ion have to foun to b d PO enlighte eac omp LYMERS n yours tota e lete l ins mag Commu lf ’, I ig ht a give azin niqu bou idea e t t o the s to prov é and indu loo ide t stry exce he exp k ahead . The and to ert llenc o e. con pinio tent ns are par P

ra ex In shant T dust ries rivedi Limit ed

Sint

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has Communiqué established itself as a sector focused publication, and is a good way to keep updated about developments, trends and outlook of the sector. The refreshed content and design of the magazine makes it very reader friendly and relevant.

Vikram Bhadauria

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Screw Chiller

News Alok Inaugurates its R&D Centre

Digest

lok (formerly, Alok Masterbatches) formally inaugurated its technology

centre, officially referred to as Alok

BASF and Dunlop create revolutionary Power Flex technology for padel bats

Technology Incubation Centre (ATIC) on 11th December, 2015 in New Delhi.

The ATIC Lab is based in New Delhi and provides a state-of-the-art facility with a wide array of testing equipment required

Berlin Packaging has been honoured with 3 winning entries in the WorldStar Awards 2016

Bio-On and S.E.C.I. S.p.A will see Italy’s and world’s first production facility of PHAs bioplastic from biodiesel production co-product glycerol

to drive innovation in the masterbatch

Amit Puri, Director, International Sales

and Marketing, Alok says, ‘ATIC is an

opportunity to create novel solutions that address real life needs of our customers. The centre also welcomes academia and

students focussing on polymer studies to use ATIC and challenge the status quo’.

While ATIC is a significant investment, monetary and otherwise, the team is

positive about creating breakthroughs in the polymer industry in the coming years.

industry. ATIC brings a new standard for

The

speciality masterbatches.

innovative and prominent industry players.

creating customised and need-based

On this occasion, Vikram Bhadauria, Director, Alok says, ‘Affordable solutions do not equate with cutting costs or

compromising on quality. It is through

innovation and use of technology that we can customise solutions for a better world.

inauguration

event

witnessed

participation from some of the most

The 2nd National Conference, ‘Plastic Packaging - The Sustainable Choice’ on 19th January, 2016 at FICCI, New Delhi

he Indian plastics industry is making significant contribution to the growth

of various key sectors in the National

economy. Packaging is emerging as the

People are moving away from low-cost solutions to value-based solutions that Braskem hires Saulsbury Industries to construct new UHMWPE plant at Texas

look at safety and sustainability – We are

guiding philosophy behind setting ATIC is

better positioned than ever before to play a significant part in this journey’.

ATIC will be accessible to all customers and suppliers of Alok and the academia – the

to co-create solutions that allow plastics to be safer, sustainable and affordable.

most important and fast growing segment of the Indian plastics industry. This segment is likely to witness high growth

in the coming times with lifestyle changes in society. The growth will primarily be driven by end-user segments. While this

offers large opportunities for the industry to grow, there is a need for that to happen

in a very harmonious and sustainable

manner with due regard to environmental concerns. The same can be facilitated by greater focus to R&D and innovations.

To bring a focus to this important sector

of chemical industry and deliberate on

POLYMERS Communiqué l December 2015 - January 2016

Speciality Colour Masterbatches l

Endless Shade Possibilities

Next Generation Metallics

White Masterbatches â&#x20AC;&#x2DC;High Loading

l l

Path Breaking Colouring & Compounding Solutions

High Quality Packaging Film

High Performance Blacks l

High Strength Blacks

High Dispersability

Additive Masterbatches Exhaustive Range to Modify and Enhance Polymer Properties

GOI Recognised Export House

Welset Plast Extrusions Pvt Ltd Arvind Mehta Group Company

8, New Metalage Industrial Premises, Subhash Marg, Off Caves Road, Jogeshwari (E), Mumbai 400 060. INDIA

info@custage.com

T : +91-22-2821 5734, 2838 7054 F : +91-22-2838 1088 E : info@welset.com W : www.welset.com

the issues, FICCI jointly with Department

morale, is of fundamental interest to

Government of India & OPPI is organising

stakeholders and is a key determinant of a

Digest Canadian Plastics Industry Association highlights how plastics innovations modernise winter sports

Carbodeon granted a U.S. patent for its technology which enables nanodiamonds to be combined with polymers for use in personal electronics and machine tools, among others

Chemicals

Petrochemicals,

the 2nd National Conference on, ‘Plastic

Packaging – The Sustainable Choice’ on

19th January, 2016 at Federation House,

New Delhi. Shri Ananth Kumar, Hon’ble

Minister for Chemicals and Fertilizers,

Government of India has consented to inaugurate the conference and also deliver the inaugural address.

Akij Group Enters the Plastic Film Business with Brückner

he demand for high quality packaging film in Bangladesh is rising. However,

at present, there are no adequate local

production capacities. Akij Group, now

enters this promising business with a Brückner BOPP line. The explicit decision

company’s character.

As a corporate aware of its social responsibilities, Reliance Foundation, led by Chairperson Mrs. Nita Ambani, has

touched the lives of over 4 million people

across India, in more than 5,500 villages and urban locations.

Living to Expectations and Beyond – Rajoo Receives Order for a Third Blown Film Line from Devendran Plastic, Tamil Nadu

evendran Plastic Private Limited, one

of the youngest but fastest growing

companies in the business of flexible packaging in South India, now orders its third blown film line from Rajoo.

Satisfied with the Rajoo fully loaded 7-layer for a high performance line clearly points

Dow Chemical announces start-up of its new propylene production facility at Texas

customers, investors and other key

to the future. This perfectly matches the Akij Group’s expansion strategy – at home as well as in export markets.

RIL Wins Platts Global CSR Award

Blown Film Line for barrier packaging and

the Rajoo OBC 3-layer Line, Devendran

Plastic has now ordered the Rajoo fully loaded 3-layer line to specifically meet the

needs and address the challenges of films for milk packaging as well as lamination grade films.

eliance Industries Limited (RIL) has

DSM Engineering Plastics expands EMEA distribution through strengthened strategic partnership with Resinex

bagged the Platts Global Energy Award

in the Corporate Social Responsibility (CSR) category from among the 12 finalists

in the CSR category. The 17th Platts Global

Energy Awards 2015 were held at New York in December, 2015.

The Platts CSR Award recognises the organisation that best demonstrates leadership, commitment to action and

C-D

real-world impacts from across its business. The

signifies

award the

blown film extrusion, coupled with a strong intent and astute comprehension

of Devendran Plastic in understanding the market needs has helped create this winning combination.

ever important

‘This far, we have produced high quality

of profitability

using the Rajoo machines and I remain

convergence and company values.

Platt’s

adjudicators have stated that CSR is

not an obligation, but a voluntary commitment, which motivates employee

Technological supremacy of Rajoo in

barrier (7 layer) and non-barrier films

confident that the new Rajoo fully loaded 3-layer line will exceed our expectations, help us add capacity and

address the stringent requirements of

speciality films’, accentuates D. Ashok

POLYMERS Communiqué l December 2015 - January 2016

Kumar, Director, Devendran Plastic Pvt.

‘A repeat order is most gratifying;

business of coal trading, we were keen

from a relatively new entrant, who is

Ltd. ‘Diversifying from our traditional

to work with a company that could help us make a mark in this field of speciality packaging; we now order our third machine from Rajoo’, adds D. Ashok Kumar.

The new machine is customised to produce films for milk packaging as

well as lamination grade films. The line is equipped with 75 mm x 2, 90 mm x 1 - 3 extruders along with 12 component

material conveying, gravimetric batch blending & GSM control systems to produce a film width of 2400 mm with

output of 650 kg/hr. Other technological advancements include circumferential profile control system with controllable

external automatic air ring with triple

especially when it is the third machine,

producing one of the best barrier and

non-barrier films on our machines and effectively competing with machines imported from other parts of the world’,

states Khushboo Chandrakant Doshi, Executive Director, Rajoo Engineers Ltd.

The 3rd National Conference ‘Poly India – 2016: Indian Plastic Industry Challenges & Opportunities’ on 29th January, 2016 at Mumbai

he Indian plastics industry has huge

unrevealed potential of growth, given

presently very low level of consumption

compared to the global scenes. However, that needs to happen in a very sustainable

lip, width measurement and control and integrated computerised touch screen

based

control panel.

supervisory

process

Digest ELIX Polymers with its new high heat ABS delivers weight reduction for roof hatch application

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POLYMERS Communiqué l December 2015 - January 2016

manner. For that R&D and innovation are the key.

Digest

To bring a focus and debate to the

challenges and opportunities of Indian plastics

ENGEL industry partners in the Gulf States for solutions in injection moulding machines, automation, integration of upstream and downstream processes and more

European Bioplastics is supporting initiatives to develop global carbon pricing mechanisms and implement them effectively

industry,

Department

FICCI

C&PC,

jointly

with

Government

of India and CIPET is organising the

3 National conference ‘Poly India – 2016’ rd

on polymers and plastics on 29th January,

2016 at The Westin Mumbai Garden City, Goregaon (East), Mumbai.

and

adept

Meusburger’s new DLC coated two stage ejectors particularly suitable for medical and food processing applications

E-M

technical

assistance have been instrumental in the company surpassing its exports targets.

Blend Colours Pvt Ltd, a respected company in the business of manufacturing

exports in 2010. The company, in a very short time span, has expanded its export footprint to over 25 countries with a

35% growth in FY 2015. This growth is testimony to the right blend of product quality, price, delivery and sound business known for.

instrumental in the company surpassing

its exports targets. The company now plans to extend its commitment by

initiating stock and sale in most promising global markets.

‘An elaborate R&D and testing facility allows

class equipments such as DSC, TGA. This

will further enhance customer delight’, explains Shailesh Lahoti, Director, Blend Colours Pvt. Ltd., and responsible for the

company’s export business. ‘In specific,

as regards exports, I see vibrant times ahead for us and for other masterbatch manufactures as well’, adds Shailesh.

SABIC and CIPET Expand Collaboration for Skill Development

ABIC

announced

the

expansion

of its skill development Corporate

Social Responsibility (CSR) programme aimed at developing capacity in the

plastics processing industry in India. The

programme, run in collaboration with the Central Institute of Plastics Engineering & Recognised by the Government as a

Technology (CIPET), under the Department

through its export office in Mumbai,

of Chemicals and Fertilizers, trained 50

globally which are now used for a range

Chennai in its first phase, and now further

injection moulding, blow moulding,

and Ahmedabad in the next phase.

‘Export House’, Blend Colours Pvt. Ltd.

of Chemicals and Petrochemicals, Ministry

exports a wide range of its products

youth from less-privileged backgrounds at

of applications across rotomoulding,

targeting to train 90 more from Hyderabad

multilayer and monolayer extrusion, PET fibres and preforms, woven sacks etc.

As product, the colour masterbatches contribute the maximum and as market, the

African

countries

contribute

healthy 40%; Latin America being the latest addition.

With a recently increased production

capacity (24,000 MTPA), the company is

adept technical assistance have been

been expanded by incorporating world

practices that the Group has always been LINPAC slashes carbon footprint even further for EPS packs

marketing, robust support systems and

for their applications. R&D setup has

masterbatches in India, commenced Evonik’s VESTANAT PP technology developed for more efficient production of components from composite materials

50% in exports for FY 2016. Aggressive

comfort by offering a better handholding

ggressive marketing, robust support systems

traders to achieve its planned growth of

us the possibility to increase customer

Blend Colours Achieves 35% Growth in its Exports Business in 2015; targets for 50% Growth in 2016

now looking to appoint distributors and

The program entails a six month-long residential skill development course including a full scholarship that covers course fee, boarding and lodging costs.

POLYMERS Communiqué l December 2015 - January 2016

PILLOW POUCH Substantial Savings for Refineries • Higher packing line speed • Leaker rate reduced to less than 0.1% Benefits of ELITETM AT • Improved Production Efficiency by the maximum utilization of filling machines • Good seal integrity through contamination • Waste Reduction in leakages during filling and supply chain • Easy processing at optimized film thicknesses • Operational Efficiency with reduced energy consumption Packaging material required for 1 litre Pack 70

Packaging Cost (%) for Flexible Pack

60 50 40

1.0%

30 20

1.7%

10 0 Tin Plate Container

HDPE Container

Lined Carton

PVC/PET Container

Weight, in gms

Flexible Plastic Pouch

Loss due to Pack Leakers Cost of Packaging Material

Source: Indian Institute of Packaging (IIP)

®™

Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow

Products Three in One: The Kosme 3Bloc

Krones

subsidiary

M&H Package the New B. Men Moisturiser for Potter & Moore and Superdrug

Kosmes.r.l.,

Roverbella, unveiled in the shape of the

3Bloc, the innovative concept of a block configuration available in two different

upto

variants, for PET and for HDPE containers. The

3Bloc

for

PET

comprises

three

concatenated machines: blow-moulder,

filler and labeller. The particular version of the Flexa labeller can vary, either featuring pressure-sensitive labelling with a Flexa Sensicol station or wrap-around labelling

with a roll-feed capability. This version is

suitable both, for cylindrical and square

PET bottles and also for containers with special shapes. The maximum speed is 16,000 bottles per hour. In the case of HDPE

25,000

per hour.

bottles

The 3Bloc’s technically sound design concept

scores particularly well with its significantly reduced energy consumption compared to individual machines, and also with its

higher efficiency and enhanced operatorfriendliness, thanks to the Human Machine

Interface (HMI). The block configuration will benefit the footprint of the machinery layout, plus the capital investment and operating costs.

containers, the blow-moulder is replaced by

For further details please contact:

fed in. This 3Bloc variant is able to handle

Web: www.krones.com

&H Plastics, part of the RPC Group of companies, has

recently been commissioned to package a new range of men’s

moisturiser for Potter & Moore and Superdrug.

Using the 50 ml Airfree® Vega and Ecosolution pump, the package

allows for products that are sensitive to oxygen to be used. The combination of the co-extruded blow moulded bottle

and

injection

moulded

pump gives superb barrier qualities.

KRONES AG, Germany

an unscrambler for erecting them as they are

MENSHEN Relies on KRAIBURG’s THERMOLAST K for Dosing Valves

ENSHEN, manufacturers of closures,

with no mess. An additional benefit to the

materials to ensure production of high-

longer due to prevention of contamination

places high requirements on its

performance packaging solutions. For its new dosing valves, for example, MENSHEN relies

on THERMOLAST® K. The new compound series from KRAIBURG TPE is used for dosing

valves to seal viscous food. The package opens only at a defined pressure and then is

reliably sealed again as soon as the pressure decreases. It also allows convenient dosing

user is that the packaged product will stay and oxidation.

The new special series for valves used in

The Vega range is unique in that the

efficiently with polyolefins in 2-component

reduced in the number of pieces it

consumer products can be processed injection

moulding,

which

achieves

reliable adhesion between hard and soft

components. In addition, this economical process also reduces the processing time

and costs. Due to the similarity of the

raw materials used for the thermoplastic packaging system consisting of polyolefins and TPEs, the packages can be recycled without having to separate the materials.

contains (this pump has only 4 pieces compared to 10 - 11 pieces for a more ‘standard’ pump) and more

importantly, all the pieces are made from plastic (most standard pumps

will have metal in them – springs, ball bearings etc.), so this makes the pack 100% recyclable in the plastics waste stream.

For further details please contact:

Web: www.kraiburg-tpe.com

Web: www.rpc-group.com

KRAIBURG TPE GmbH & Co. KG, Germany

Ecosolution pump it takes is both,

RPC, UK

POLYMERS Communiqué l December 2015 - January 2016

Eastman and colorFabb into Expansion Mode of 3D Printing Filament Range

o further expand its filament offerings for 3D printing, Eastman Chemical Company and colorFabb BV are adding to their

collaborative range of materials for the industry. The newest

filament, nGen made with Eastman Amphora™ AM3300 3D polymer, offers a wide processing temperature range allowing for

quicker printing, while maintaining many of the advantages that

Eastman Amphora™ 3D polymer brought to the colorFabb_XT

product. nGen remains a tough, low-odour, styrene-free solution suited for a variety of 3D printing needs.

The use of this material runs the gamut of 3D-printed applications, ranging from prototyping to experimenting, and from designing to making serious money. In addition, nGen made with Eastman Amphora™

AM3300

polymer will allow for casual

users and those who enjoy

do-it-yourself projects to use a high-quality filament.

SABIC Exploring Integrated Lighting Features in Car Windows

ABIC’s polycarbonate (PC) windows with integrated lighting has its rear quarter window produced through two-shot

injection moulding with LEXAN™ and CYCOLOY™ resins, featuring two

sets

decorative

lighting components: Two

blue LED light pipes and a

white LED light guide with

white laser-etched graphics.

While those elements are largely decorative, SABIC says

integrated lighting can serve a variety of functional purposes. To

illustrate

one

potential

use, SABIC released a concept sketch in which a lighting

component built into a lightweight polycarbonate window

indicates the battery status of an electric or hybrid vehicle,

from green for fully charged to red for critical condition.

For further details please contact:

Eastman Chemical Company, USA

Web: www.eastman.com

For further details please contact:

SABIC Innovative Plastics, Europe Web: www.sabic-ip.com

Get Superior Results from Your Process ...that pay you back fast

TECHNOLOGIES

Precision Measurement & Control Systems for:

Improve Quality

► Basis Weight ► Thickness

Increase Yield

► Coat Weight ► Barrier Layers

Reduce Waste

► Moisture ► Length & Speed

www.ndc.com/converting AMERICAS: Tel: +1 626 960 3300 info@ndc.com

INDIA: Tel: +91 9650752420 ndcindia@ndc.com

POLYMERS Communiqué l December 2015 - January 2016

An ISO9001 Company

Solvay’s Torlon PAI Fabricates Sealing Rings and Locking Mechanism for FTE Automotive

olvay Specialty Polymers’s Torlon®

The critical core of an automotive clutch

of needle bearings with bearings made

forms several key components in a highperforming dual concentric slave cylinder

are positioned directly around the drive shaft and on the clutch, are subject to

allows space savings of about 2.5 mm,

polyamide-imide (PAI) technology

(dCSC) developed by FTE automotive, producer of automotive drivetrain and brake systems. Signaling for the first

time, Solvay’s Torlon materials have been specified for this type of application.

system, the concentric slave cylinders

extreme loads, each time a car shifts

gear. FTE Automotive offers various CSC designs for light and heavy commercial vehicles depending on the application, more typically fabricated from aluminum or engineering polymers.

The intrinsically high wear-resistance of Torlon PAI makes it a natural candidate

for seal rings and other high-wear

of Torlon polymers. This conversion

which allows engineers to downsize metal castings and thereby achieve

significant weight reduction without compromising

incorporate

system solutions at the new MERGE Lightweight

Technology Center at the Chemnitz University of Technology.

The KraussMaffei MXW 2500 injection moulding machine is

used for conducting research for the automotive industry.

The aim is to produce parts of

a vehicle with a lightweight design, in an energy-saving way and in serial production. These prototype components

can be produced in their

original sizes. This is particularly important for industry clients who can test the properties of the parts at a 1:1 scale.

The MXW 2500 is a very compact, high-performance

two

seal

rings

made

and durable performance over the transmission’s lifetime.

For further details please contact:

Solvay Advanced Polymers, Germany Web: www.solvay.com

is the increasingly frequent replacement

raussMaffei inaugurated its modular injection moulding

of Torlon 4275 to ensure reliable

automatic transmissions. A parallel trend

performance

within FTE Automotive’s dCSC each

applications in both, dual clutch and

KraussMaffei Inaugurates Modular Injection Moulding System Solutions

reliability. Both hydraulic chambers

Hemetek Techno Instruments Develops Squeeze Force Tester

emetek Techno Instruments Pvt. Ltd. developed a squeeze force

tester for testing plastic ophthalmic bottles. First introduced

at the P-MEC India exhibition in 2015, the product has been well received from the medical testing industry for its ease of use.

The tester was developed for an Indian manufacturer of ophthalmic

squeeze bottles to test the squeezability of its plastic bottles. The

manufacturer wanted to determine the force required to deliver the first drop from single dose bottles as well as the force required to deliver subsequent drops.

Using the Chatillon squeeze force tester, the manufacturer was able to determine the finger strength needed to squeeze different bottle

designs made from a variety of plastic materials. The tests were

performed at 90 degrees to simulate assisted administration of the drop and at 45 degrees to simulate self-administration by the patient.

production system that is characterised by short machining

At the heart of the squeeze force testing system is the digital

modular design and offers a wide range of configuration

large full colour display and offers accuracy better than 0.1% of full

times, fast cycles and a high output. The series has a

options. ‘We were deliberate in choosing a large machine with a clamping force range of 25,000 kN to be able to represent large components with measurements of up to

Chatillon DFS II force gauge that features a simple user interface, scale. The Chatillon squeeze force

tester incorporates proprietary NEXYGEN DF testing software,

1.5 m x 1.5 m at a close-to-production 1:1 scale’, says Prof.

which offers pre- and post-test

Structures (IST) at the Chemnitz University of Technology

easy-to-read graphs in a Windows®-

Dr.-Ing. Lothar Kroll, Director of the Institute of Lightweight and Coordinator of the MERGE Cluster of Excellence.

based environment.

For further details please contact:

Web: www.kraussmaffei.com

Web: www.ametek.com

KraussMaffei Technologies GmbH, Germany

analysis of test results displayed as

AMETEK, Inc., US

POLYMERS Communiqué l December 2015 - January 2016

BASF Strengthening Global Network for Pigment Production

ASF is strengthening its global production network for pigments with two new investments. At the site in Nanjing, China, the

company has increased its production capacities for high-performance

diketopyrrolopyrrole pigments (DPP). The colour-intensive and extremely lightfast and weatherproof DPP pigments, which are marketed by BASF under the product name Irgazin®, are used for

automotive, industrial and powder coatings, paint and ink as well as for other plastic applications.

In Ludwigshafen, BASF is expanding its capacities for the production of versatile alpha blue pigments, which are particularly characterised

by their excellent fastness properties, by the fall of 2016. ‘While

this capacity expansion is our response to the growing demand in the market, it also increases our delivery reliability. Taking into

account the latest trends in colour, we expect that customer demand for alpha

blue pigments is going to continue to

increase significantly’, says Dr. Alexander Haunschild, Senior Vice President of the business unit Pigments & Resins Europe.

Gala High-Capacity Centrifugal Dryer for Continuous Processes

ala Industries has introduced a re-engineered highcapacity centrifugal dryer for continuous processes.

Resin producers have created the need for high capacity, continuous operation centrifugal dryers. By utilising patented processes and

innovative equipment improvements, Gala

has been able to design a single centrifugal dryer (patent pending), with an output of 100 metric tonnes per hour, with improved reliability for continuous long term use. Dryer

capacity was confirmed by full scale, customer witnessed testing.

Gala Industries, manufacturer of underwater pelletising and centrifugal drying systems for the plastics industry, offers custom

designed turn-key pellet production systems

for thermoplastics, engineered resins, TPU, HMA

and compounding applications. Gala is a member of Maag AG, headquartered in Oberglatt, Switzerland.

For further details please contact:

Web: www.basf.com/in

Web: www.gala-industries.com

BASF India Limited, India

POLYMERS Communiqué l December 2015 - January 2016

Gala Industries, Inc., USA

BIG STORY

Manufacture

To Create Products, Not Just Produce

Q. Then Bombay Oil Industries, today Marico. From old business models to new generation ideas and technology, how have the changing times transformed you and Marico?

however, we interpret them with local context. As

an organisation, we strongly believe that innovation is not a one-time spark which can function in certain verticals, but one which resonates throughout the organisation. More than innovation, the integration of

When I joined my family business in 1971, the business

innovation across verticals is what our organisational

leveraged any significant brands. In this environment,

in the DNA of each and every person associated

a distinct identity for a successful brand-based

core of the upper management percolating to every

existence imparted a sharper focus and enhanced our

Over the years, we have consciously adopted a

was all about trading and manufacturing, but none

culture advocates. Innovation needs to be present

I strived over the next almost two decades, to create

with the Marico family. It has to be engraved in the

FMCG business – Marico. This separate corporate

member and ultimately, be a part of the ‘culture’.

growth potential.

gradual process of inculcating the Marico culture in

Marico’s formation in 1990 also gave me a great

acquired businesses.

opportunity to establish a culture in a new company

We saw Marico’s culture kaleidoscopically, that is, in

integrate the organisation and articulate what we

- as it was important to define a common culture,

several attributes, which includes:

Open - that allowed free sharing of information

Informal - on a first name basis

Participative - one that had consensus

Empowering - autonomous within directions

stood for. We identified and stratified values into

three segments: People, Products and Profits, which became the 3Ps for us. We have built a unique culture

over a period of time. Even when we expanded to other geographies, our values remained the same;

l l l

and communication in general

POLYMERS Communiqué l December 2015 - January 2016

Through this interaction with POLYMERS CommuniquĂŠ, Harsh Mariwala emphasises on the importance of

innovation, value management, organisation culture,

adoption of technology, role of research along with a socio-economic approach in creating a product to add value.

Harsh Mariwala Chairman Marico Limited, Mumbai

POLYMERS CommuniquĂŠ l December 2015 - January 2016

the initial wave that Marico needed in the

talent area and the

campaign

its

recall

while to come.

retained for

Ever since we started

Marico,

the

whole

journey has been of

transformation, back then

from packed edible oil to

value-added oil, hair oil

blends, edible oil blends

and now, we have got into

Merit Based - influence did not work

Apolitical - that shunned political machinations

Job Rotation - for continued stimulus to the

Learning - that encouraged higher responsibilities

l l l

individual and to the organisation with cross functional experience

These changes have touched every facet of the business, including my own role. For one, I have

passed on the oversight of the company to a

professional manager. For any family-managed business, the transition towards professionalism is

quite crucial, without giving up the entrepreneurial flair, while professionalising. In fact, the best situation

is one where professionals imbibe the goodness of entrepreneurship.

skin care and even food. This transformation has

required a different way of looking at business; it

is about product formulation, packaging, marketing and distribution.

Moreover, even the nature of competition has changed. In the branded commodities sector,

we were fighting with smaller players and more unorganised competition. Now, we compete with

the biggest MNCs and the most respected FMCG

(fast moving consumer goods) companies in India.

So, to some extent, the whole way of managing transition to this value-added brand business

requires a different approach across the organisation. I have always learnt from the professionals I hired,

so I have developed a leadership style that is highly

participative and that, in turn, has helped me

Q. How challenging has been your journey in the process of conceptualising, building, developing the brand ‘Marico’?

overcome blind spots throughout my journey.

In 1990, when we carved out the FMCG business

of the organisational apparatus and management.

into a new company called Marico, it was a leap of faith for me personally and a quantum step for

the business. While we had an enhanced growth potential, there was also a challenge of how a new

and unknown company was to attract talent. We did

inherit about 200 employees of our parent Bombay Oil, but we needed fresh talent to build profitable

brands, a talent that Bombay Oil fell short of. We could not afford mass advertising to attract new

talent. But, we did have resourcefulness and an

innovative approach that spurred us to experiment with a news-styled recruitment advertisement – that dramatically announced ‘200 employees walk out

of Bombay Oil’. The campaign was fresh, unique

and fetched us the desired attention. It created

personal products, hair care,

I have learnt quite a lot from my own growth journey. Scaling up of business requires scaling up

If a family business does not professionalise in time, it could end up restricting its growth orbit.

Therefore, it is advisable to decide and act early on professionalisation. Professional managers bring the value of a specialisation - in general, management or expert functions. I have always believed that ‘Human mind is like a parachute. It only works when it is open’.

Openness is, therefore, a very treasured value for us.

It flows in everything that we do. Each value needs

a sustained process and practice to create a strong culture. It is, therefore, necessary that our actions reinforce the values all the time.

Q. From a turnover of Rs. 50 lakh in ’71 to Rs. 5,733 crore in present and your vision

POLYMERS Communiqué l December 2015 - January 2016

of achieving the Rs. 10,000 crore mark for Marico by 2020, how are you geared towards achieving this goal?

Q. Has the ‘plastics and packaging industry’ played the role of enablers to help achieve this success?

Marico is at a point of inflection today, poised to enter

Earlier, Parachute was packed mainly in 15 litre tins.

we have outlined a picture of how we want to see

was only available in tin packs, in which the brand had

aim to double our top-line in four years, increase

us to think of changing the game - what if we offer

the next orbit of growth. Seizing this opportunity,

The market for packed coconut oil in small containers

ourselves over the next few years from now. We

an insignificant share. An innovative perspective led

our market share to further consolidate our top

consumers with coconut oil in plastics that will be

grooming portfolios in Asian and African markets.

We took this idea to our dealers and retailers, only to

wellness segments in India and Vietnam, while

containers. Their reluctance was based on their earlier

position, and expand our nourishment and male

We are further looking at growing our food and

attractive, convenient to use and cost-effective?

find huge resistance in stocking coconut oil in plastic

also increasing our visibility in the Sub-Saharan

experience of coconut oil packed in square plastic

care segment. To make Marico future ready, we

coconut oil kept spilling out of the plastic packs. This

and South African markets for our ethnic hair

shaped containers. It was a shoddy oil-filling job and

are focusing on five transformation areas, namely

had led to a bad experience for retailers as rodents

innovation, value management, IT & analytics, goto-market transformation and talent management, while

maintaining

high

standards

risk

management and governance. We have identified

these fundamental areas as core foundations of our transformation process, to help us turn our aspirations into reality.

found the square-shaped oil-smeared containers an easy and attractive target.

We leveraged this insight and developed a round To know more, please subscribe to

POLYMERS Communiqué at subscriptions@ polymerscommunique.com

lohiagroup.com

It’s reliable It’s produced on Lohia Machines Our machines not only extrude tapes and weave fabrics but also coat, print and convert to produce world class flexible packaging for a wide range of solid materials like food grains, fertilizers, cement, animal feed and minerals, including special applications like tarpaulins, geo-textile and big bags. 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. Lohia Corp Limited D-3/A Panki Industrial Estate Kanpur 208022, India T: +91 512 3045100 F: +91 512 3045299 sales@lohiagroup.com

Delivering Advantages

POLYMERS Communiqué l December 2015 - January 2016

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

SIVARAM SPEAKS

3-D Printing of Plastics The Emerging World of Digital Manufacturing

ne of the disruptive technologies to

is at the ‘intersection of hardware, software and

processing sector is the 3-D printing

converge with IT to create a distributed

emerge in recent years in the plastics

technology, also called as Additive Manufacturing

(AM). This technology is growing at a very rapid pace and is termed as the first major revolution

in manufacturing since the ‘assembly line’ concept that garnered the limelight in the late

19th century. Simply put, 3-D printing is nothing but 2-D

printing

performed

repetitively.

This

technology has grown from the basic concepts

of ink jet printing and stereo lithography. The process has made great strides in the thirty years since it was first reported1 (Refer Figure 1).

This process involves a layer-by-layer assembly

of materials to create an object using digital slices created by the software. As aptly stated by

Professor Joseph De Simone2, this technology

molecular sciences,’ where plastics processing

manufacturing capability often termed as ‘pointof-sale manufacturing’. AM has the potential to create ‘just-in-time’ flexible manufacturing with

major changes regarding how we manage supply chains and inventories today.

The technology is at a nascent stage and is loaded with possibilities. It is predicted that market for

polymers suitable for 3-D printing is most likely to exceed USD 1.5 billion by 20193. According

to ASTM F42 Committee, AM processes can be categorised into seven classes by the type of materials used, the deposition technique and the way the material is fused or solidified. These

are, powder bed fusion, photo-polymerisation,

material extrusion, material jetting, binder jetting, sheet lamination and directed (or focused) energy deposition. As far as plastics and polymer

Dr. S. Sivaram Former Director, CSIR-NCL Polymers and Advanced Materials Laboratory National Chemical Laboratory, Pune

composites are concerned, the most popular 3-D printing processes are selective laser sintering, stereolithography, fused deposition modelling and material jetting. Currently, ABS and poly (lactic

acid) (PLA) are the two most reported polymers

POLYMERS Communiqué l December 2015 - January 2016

Printer / Technology Advances

Material Developments

2000 to 2014

Technology advances led to increasing adoption in automotive, aerospace and medical industries

1995 to 2000

Low-cost AM systems develped around the world (Japan, United States and Germany)

1990 to 1995

Materials developed to withstand tougher conditions. Focus on developing capabilities to process newer materials (e.g. composites and metals)

2000 to 2014

New resins developed and commercialised for use in a wide range of 3D printers

1990 to 2000

First-generation acrylate resins commercialised by 3D Systems and Ciba-Geigy

1988

Printers based on new technologies introduced

1987 to 1990

First AM System: Stereolithography (SLA) system developed by 3D Systems in 1987

Figure 1: Additive Manufacturing and 3-D Printing: State of the Industry. (Source: Deloitte University Press)

for 3-D printing. However, several other

or need for assembly, possibility of local

today

PC, Nylon 12, polystyrene, polyacetal

graded materials and unlimited freedom

bearing parts and therefore limited to

polymers can be used, namely, ABS-PC, and PET. Another emerging area for 3-D

printing is thermoset liquid oligomers which can be cured with light. Examples

texturing, ability to produce functionally for product design.

Progressive Developments

are multifunctional acrylates, epoxy-

However, AM is mostly employed

silicones and a variety of photo-curable

It is predicted that

acrylates, urethane acrylates functional reactive

oligomers.

Thermoset

3-D

printing involves three steps, namely, preprocessing where a software is created to calculate the placement of the liquid reactive oligomer on a support material

in a 3-D CAD file, production, where UV cures the jet of liquid droplets of the reactive oligomer, causing the layers to accumulate on a build tray to create the

object followed by support removal by hand or using water.

The excitement of the application of AM

to polymer processing is due to the ability to produce complex parts without moulds

POLYMERS CommuniquĂŠ l December 2015 - January 2016

market for polymers suitable for 3-D printing is

most likely to exceed

USD 1.5 billion by 2019.

for

prototypes,

models

for

form, fit and function, and non-load high value, low volume customised components. However, it is believed that

continuous

development

technology will make AM competitive with other manufacturing technologies

that have been perfected over a century and move beyond mere prototyping applications. The vitality of this area is evident by the fact that from a mere 80

issued

patents

2005,

over

600 patents were issued in 2013 on AM technology4.

3-D printing allows product customisation, lowers the cost and risk associated with tooling and dies. In a world where

economies of scale matter less and less, To know more, please subscribe to

POLYMERS CommuniquĂŠ at subscriptions@ polymerscommunique.com

PROJECT TALK

K. Satyanarayana Chief Executive Officer OPaL, Vadodara

Industry to Benefit from OPaL’s USD 4.5 bn Dahej Plant

POLYMERS Communiqué l December 2015 - January 2016

Q. How will the formidable trio (ONGC, GAIL and GSPC) help revolutionise the new era of petrochemicals business with OPaL?

Q. What is the nameplate capacity of the Dahej plant and the production plans initially?

ONGC, the flagship company in exploration and

OPaL plant consists of a dual feed cracker unit

the oil and gas sector of India, accounting for over

with capability to crack both, liquid and

production (E&P) has been primarily engaged in

80 per cent of Indiaâ&#x20AC;&#x2122;s oil and gas production. With

strategic intent of adding value to the molecule, especially naphtha; ONGC conceptualised the

case of forward integration under the leadership of Late Shri Subir Raha who had a vision of transforming the enterprise from a sectoral E&P to a dominant integrated energy major in the international arena. ONGC

Petro

additions

Ltd.

(OPaL),

was

founded as a special purpose vehicle (SPV)

of 1.1 million tonnes of ethylene; equivalent

gaseous feed with downstream polymer and associated facilities.

OPaL has two swing lines of (2X360 kTPA) of LLDPE / HDPE unit by Ineos, a single train of

dedicated HDPE by Mitsui (1X340 kTPA) and that of PP by Ineos (1X340 kTPA). Other associated units include a pyrolysis gasoline, hydrogenation

unit, butadiene extraction unit and benzene extraction unit.

through forward integration getting in likeminded partners. OPaL, thus, got incorporated

Q. What were the reasons for the delay in commissioning of the Dahej plant from its original schedule?

in 2006 as a public limited company by Oil and Natural Gas Corporation (ONGC) with

The project has been delayed due to changes in

co-promoters as Gas Authority of India Ltd.

project configuration especially due to the addition of few units and a captive power plant of 200 MW,

to bring into effect the vision of adding value

(GAIL) and Gujarat State Petroleum Corporation

(GSPC) wherein financial investment has played an indelible part in the multi-billion JV.

The grassroots mega-petrochemical project is the

not conceived earlier. There were other aspects of

execution delays primarily due to slow work done by the contractor entrusted with the construction of the utilities and more.

flag-bearer of the very first Petroleum, Chemicals

However, these are things of the past and with

of India at Dahej, an indigenised version of

the OPaL team is geared up for commissioning,

and Petrochemical Investment Regions (PCPIRs) international chemical cluster with a potential

to add superlative value to various molecules.

The project mothers 1.1 MTPA of ethylene, which is an equivalent dual feed cracker at a single

the complex now being mechanically complete, once the ongoing pre-commissioning activities are concluded. The focus clearly remains on start-up of the plant by Q1 of 2016.

international; having the potential to generate

Q. What is the total cost of the Dahej project? Has it at any point of time been through cost escalation during its completion process? If yes, please elaborate?

indirect jobs propelling economic activities in

location. It is the first of its kind in South Asia with a potential to produce about 1.5 MTPA of polymers, critical to catalyse the growth

of the polymer industry both, domestic and over 1,000 permanent and 15,000 direct and

The petrochemical complex stands testimony

various domains.

(Rs. 27,011 crore). The project cost has been

POLYMERS CommuniquĂŠ l December 2015 - January 2016

investment

over

USD

4.5

Pro-industry policies and new Government initiatives are likely to enable and augment entrepreneurs to excel, something

which will augur well even for catalysing polymer processing. Makarand Dixit Head - Marketing OPaL, Vadodara

A Lease of Life for the

Plastics Industry Q. According to OPaL, what potential growth drivers do you vision for the petrochemical industry? The demand for petrochemicals in India is intertwined with the growth in GDP is an established correlation.

glass differently; the low per capita polymer

consumption in India as against global averages provides enormous potential for growth of the plastics industry in India.

Increasing middle class fuelled by positive economic

Pro-industry policies and the initiatives such as

improved living standards, booming aspirations

Abhiyan’ launched by the Government will give

development and rapid urbanisation is leading to creating demand for lifestyle products like that

of consumer goods, packaged food, healthcare,

automobiles etc. The sound fundamental shall

continue to remain the prime demand driver revised thrice after it was conceptualised primarily because of the change in plant configuration, higher interest payouts during the construction

phase and revision on account of start-up and commissioning expenses.

Q. How effective has been the use of stateof-the-art technology in the development stages of the plant, while being sensitive towards the environment at all times? Environment is one of our key concerns. Therefore, all our development activities are planned on

ecological principles incorporating appropriate

environmental safeguards, using state-of-the-art

technologies from the finest and most renowned

‘Make in India’, ‘Smart Cities’, ‘Swachh Bharat To know more, please subscribe to

POLYMERS Communiqué at subscriptions@ polymerscommunique.com

technology, while being sensitive towards the environment at all times.

Q. Tell us more on the OPaL’s project dual feed cracker unit? What is its production capacity for ethylene and propylene? Any plans to expand the capacity of its associated units? The complex’s main dual feed cracker unit (DFCU),

the first of its kind in South Asia has the capacity to

produce 1.1 MTPA of ethylene. The project envisages using ethane (C2), propane (C3), butane (C4), Aromatic

Rich Naphtha (ARN) and Low Aromatic Naphtha

(LAN) as feedstock to produce various downstream

technology providers in the world, ensuring OPaL

To know more, please subscribe to

To achieve this, we have made effective use of

polymerscommunique.com

facilities to be among the best-in-class in the world.

of petrochemicals in India. Looking at the

POLYMERS Communiqué at subscriptions@

POLYMERS Communiqué l December 2015 - January 2016

B2B Marketing Communication Specialists RELATIONSHIPS

Key Services l

Corporate Communication Consultancy Content Development

Adeka India Pvt. Ltd.

All India Plastics Manufacturers Association

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

Rajoo Engineers Ltd.

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FORWARD THOUGHT

Clear Barriers,

to Barrier Packaging The reason for resistance in adoption of barrier sheets by the industry is not resistance or lack of knowledge. Processors are probably waiting for the market to develop. However, the market will not wait when it demands for barrier sheets since the retail chains will have no option but to resort to imports, says Sunil Jain in dialogue with POLYMERS CommuniquĂŠ.

Sunil Jain President Rajoo Engineers Ltd., New Delhi

Q. How can the global packaging trends impact the Indian barrier packaging?

mainly catering to the Indian diaspora. It is thus true, that packing Indian food while

being a challenge, has been overcome

are efficient formats and are more environment friendly.

Q. According to you, what are the reasons for resistance in adoption of barrier sheets by the industry here?

Global packaging trends will impact

successfully. With increasing number of

used for this application are well

in India, the demand for RTE (ready-to-

India. The Indian processors are familiar

is increasing which necessitates use of

I do not think it is a question of resistance

packing of long shelf-life edible oil and

is bound to grow exponentially and will

probably waiting for the market to

Indian barrier packaging as the polymers

DINK (Double Income No Kids) couples

established globally and also available in

eat) or RTC (ready-to-cook) food in India

with such materials since it is used for

barrier packaging materials. This sector

or lack of knowledge. Processors are

milk. Packaging formats in UK and USA

be focused by the organised retail chains.

develop. However, the market will not

and will need to be appropriately

Q. In India, do we need to adopt a more serious approach to green materials and innovations? How is barrier packaging positioned in this regard?

since the retail chains will have no option

Green materials and innovations to protect

Rajoo is one of the few companies in

for Indian cuisine are well established adapted here to suit the severe Indian conditions – from the perspective of

long distances, extreme temperatures and high humidity.

Q. Impact of retail growth on barrier packaging. Please comment. The real impact of growth in organised

retail on barrier packaging has not yet

been experienced, as such. It has still to be implemented in India in totality, especially

for packing of food and groceries. What

we are seeing right now is just a tip of the

iceberg. With the Government committed to FDI in organised retail, this sector is bound to grow at an exponential rate. It is also a fact that if barrier packaging is

not offered by local processors, the retail

the environment surely need a conscious

approach. A myth prevails that only monopolymer / substrate materials are eco-

friendly which has been busted as even

laminates are now being used for various

non-critical applications. While laminates offer a barrier, even non-laminates with specific polymers offer effective barrier. Producing

non-laminates

involves

less number of production processes

and low wastage. Barrier packaging films and sheets using non-laminates

wait when it demands for barrier sheets but to resort to imports.

Q. Share with us your position of delivering ‘technology firsts’, in barrier film and sheet packaging? the world offering a complete solution

for barrier packaging. It was also the

first Indian company to successfully commission 5- and 7-layer blown film

lines in addition to 5-layer barrier sheet extrusion lines. A barrier pack ideally

needs a barrier bottom container in addition to barrier lidding films. Rajoo To know more, please subscribe to

POLYMERS Communiqué at subscriptions@ polymerscommunique.com

chains will not hesitate to import the materials since they will not wait to introduce their products.

Q. What myths need to be overcome in order to create opportunities for barrier packaging in India? A myth prevails that barrier packaging is suitable for meat and other nonvegetarian food. While it is a fact

that barrier packaging developed in the Western world primarily for

meat packaging; it did not develop in India, largely being a vegetarian country coupled with the preference for freshly cooked food. It is also a fact

that many retail chains in UK and USA have been successful in packing Indian

cuisine, laced with spices and oil,

POLYMERS Communiqué l December 2015 - January 2016

GROWTH DRIVERS

Inefficiency

A Hurdle to Overcome for Plastics Processing

Mahendra Sanghvi Executive Chairman Shaily Engineering Plastics Limited, Vadodara

We should take it upon ourselves to continuously make improvements through implementation, adherence to right systems and processes as well as through innovation in manufacturing methods for enhanced efficiency, views Mahendra Sanghvi.

Growth of the Plastics Industry The plastics industry in India is in its nascent stage; when compared to the US and China, India’s per capita plastics consumption stands at 9.7 kg v/s 109 kg in the US and 45 kg in China - purely

based on India’s population and growing middle class. India’s per capita

plastics

consumption

projected to more than

double over the next 5 years. In

order to cater to this additional demand, the plastics processing

industry will need to grow from a current installed processing capacity of 30 MMT to 45 MMT per annum by 2020.

Bulk of the additional demand is going to be driven by

three sections; packaging, infrastructure and agriculture. Therefore, from a technology perspective, it is believed that the processors which are primarily focused on implementation

of newer technologies can help to save power and labour. The two most important priorities for manufacturing should

POLYMERS Communiqué l December 2015 - January 2016

be focused on efficiencies of the current installed capacity and workforce.

Efficiency in Manufacturing The most important factors that affect the plastics processing industry are power,

logistics, infrastructure and

labour. From which, power and labour are elaborated here.

Power

diligent in their work. We

have several such programmes where we educate our workforce on cGMP, injection moulding and quality control. I believe that ‘Skill India’ is

one of the most important factors

Therefore,

for the future of manufacturing in

India and a great deal of responsibility lies

on the shoulders of manufacturers, like us, to contribute towards achieving that task.

depend

new

opportunities

historical

will

performance.

Conversion of new opportunities will depend on how much value you are

able to bring to your customer through

When it comes to power, we are aware

To put it in numbers, a study conducted

innovation and finally, both revenue

Many of whom I have interacted with

2013 pegged India’s productivity per

will depend on both, the quality of project

affirmed their inconvenience of not

China and USD 155,000 in the US.

it is executed.

feel the need to run manufacturing

Factors to Improve Customer Delight

With both, performance and project

of the shortage that our country faces.

by the Boston Consulting Group in

generations and, therefore, profitability

in the manufacturing sector have always

labour at USD 3000 v/s USD 67,000 in

execution as well as the time within which

having consistent power and, therefore, operations on a DG sets.

Labour We, at Shaily, have developed several

training programmes to educate the workforce highlighting the importance of

their work. For example, we manufacture an insulin pen for Sanofi that is basically

used by diabetics for injecting insulin. Insulin can be both, life saving and life

threatening if under dosed or over dosed; therefore, it is absolutely critical that every

pen that leaves Shaily is of the highest quality. In order to ensure that our workers

who are assembling the drug delivery device are paying extra attention to their work, we devised a training programme which showed them the implications of their actions and how important it is to be

A New Dimension to Innovation

In our experience, global giants are

looking for suppliers who can offer sustainable prices; besides lower prices, the right quality, on-time delivery,

ability to manage end-to-end supply

self-explanatory,

When we look at

approach to innovative

manufacturing

manufacturing.

Innovation does not

either

level of technology and

to bring about cost reduction through improvement

process

design or material or a combination are

requirements which were not the case in the past. Indian manufacturers over the

last 10 years had to compete primarily on costs, which was a difficult situation for

Indian plastics processors to get business from the global customers. No amount

of technology, skills and infrastructure can help if a company does not excel in

performance. /

Any

business

organisation’s development

tool is its proven performance. Having said

that,

have

today

become

customers extremely

demanding in terms of

their requirements as compared to

10 or 20 years

ago. Today, it is absolutely

essential that

our

we deliver on

commitments

without any deviations either on

timelines, quality or cost.

the new role of

explained here is a novel

chains and also be innovative enough

marketing

POLYMERS Communiqué l December 2015 - January 2016

execution being fairly

in the plastics processing

necessarily mean high

automation; rather it is

industry, the

biggest challenge to overcome

the right combination

is going to be

of labour, technology and automation. For example,

Shaily,

we had taken on a project for a customer

inefficiency,

whether it is less

productive labour,

manufacture

equipment, lack

with a 2 colour handle.

processes or lack

household

brushes

While we were awarded

the project based on

of systems and of innovation.

price, however it was the innovative manufacturing setup that resulted in that

price. While others were using high tech 2 colour moulding machines for moulding

of the handles and then a fully automated

assembly process for bristling, we looked

at several options before concluding that for this particular product, it is best to do over moulding on two separate To know more, please subscribe to

POLYMERS Communiqué at subscriptions@ polymerscommunique.com

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ADVERTORIAL

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Demand for edible oil is expected to increase from the current level of 17.5 million tonnes to over 23 million tonnes by the year 2020. With technological developments, the edible oil industry has progressed to more sustainable branded plastics packaging type, including rigid and semi-rigid containers as well as flexible pouches.

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technology. This invention provides Dow a greater flexibility to tailor the molecular weight distribution, short and long

chain branching distribution across a myriad of applications such as liquid detergents, shampoo, condiments, sauces, milk and edible oil.

Case Study: India India

the

world’s

largest

importer of vegetable oil, with

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valued approximately at USD 11 bn.

Recent population increase, coupled

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POLYMERS Communiqué l December 2015 - January 2016

Flexible Packaging, a Productive Option for Refiners

Vipul Babu Sales Director – India and Sub-continent Dow Packaging and Specialty Plastics

Flexible packaging offers benefits from overall supply chain cost reduction to branding, opines Vipul Babu during an interaction with POLYMERS Communiqué. Q. Your take on the changing dynamics of packaging in edible oil industry, from rigid to flexible?

pouch can also be designed to stand-up on a shelf. PacXpert™ packaging technology (flexible bottle)

is another design innovation that gives more

The shift from rigid to flexible packaging for edible

options to a brand owner to introduce unique

of high performance sealant resins, improvement

opportunity as compared to a rigid bottle.

oil started at least three decades back. Availability

in printing technology and filling machines for

flexible pouches accelerated this shift and growth of flexible packs in the last decade. Today, flexible

packaging is the first choice for one litre pack

because of all the benefits it offers, from overall

features in the packaging with increased branding

Q. How can flexible packaging add value to the bottom line of the refiner in the coming days? Refiners have been focusing on productivity

supply chain cost reduction to branding.

gains and waste reduction as means to boost

Q. What challenges could come up in this shift?

of edible oil. Flexible packaging has been a great

the bottom line in this highly competitive market

enabler in reducing supply chain cost. Innovation

As consumers look for greater convenience

in high performance sealant resins and pouch

to evolve from its present form of a pillow pouch

have helped them to achieve this goal.

and shelf appeal in a supermarket.

Q. What is the impact of flexible packaging on modern supply chain?

compared to cost, flexible packaging will need

to having better functionality, ease of handling

Q. Any developments in material science and / or technological solutions that could enhance this adoption? There have been developments in resin technology that enable the packaging solution

provider to provide increased functionality to the packaging. For instance, higher modulus resins designed that meets all the performance requirements of a liquid pack in the form of a

design along with faster speed of packaging lines

Flexible packaging is one of the most sustainable

packaging amongst the rest of the choices.

The use of flexible packaging means we are transporting more product per litre of fossil fuel we consume, resulting in lower carbon footprint.

Improved performance of packaging resin has

also reduced the cost of secondary packaging for most brand owners, thereby further cutting supply chain cost for them.

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changes and urbanisation have also brought about rapid growth to this industry and therefore the demand for edible oil is expected to increase from the current level of 17.5 million tonnes to over 23 million tonnes by the year 2020.

Traditionally, the Indian edible oil industry

earlier relied on either unbranded loose plastic bags or tin-plated metal containers to pack

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the product. However, high cost of packing, transporting

metal

containers

and

unsafe

method of using plastic bags have proved to be

the biggest disadvantage. With technological developments,

the

edible

oil

industry

has

progressed to more sustainable branded plastics

5-layer Film Structure

packaging type, including rigid and semi-rigid

Barrier Layer Barrier Resin

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In plastics packaging, flexible pouches are fast

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Operational Efficiency: Reduces energy consumption due to low temperature sealing and wider hot tack window.

Waste Reduction: Reduction in leakages during filling and entire supply chain.

Key Benefits of ELITETM AT

Packaging machineries in India has complemented this paradigm shift by making new investments in

delivering new, energy-efficient and easy-to-operate faster oil filling lines with new machines which are Improved Production Efficiency / Higher Yield: Maximum utilisation of filling machines by running at faster packaging lines at nameplate capacity.

capable of packaging edible oil in flexible pouches at 50 pouches per minute, 150% faster than earlier packing lines. Subsequently, packaging film has

also undergone optimisation in thickness levels by 15% to 20%.

Dow’s Solution: ELITE™ Advanced Technology ELITE™ AT 6201 and 6202 polyethylene resins

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POLYMERS Communiqué l December 2015 - January 2016

INTERACTION

Pipes and Packaging

Fuelling Masterbatch Growth R. K. Aggarwal in dialogue with POLYMERS CommuniquĂŠ covers aspects relating to changing demands, growth, online selling, impact of regulated markets and more.

Q. What is the changing role of manufacturing / innovations for a masterbatch producer in todayâ&#x20AC;&#x2122;s time? Plastic is relatively a very young industry and is evolving very fast with new innovations in respect to end applications and raw materials coming to surface every day. Masterbatch producer being an intermediary supplier has to interact closely and keep evolving as per the demands of these new raw materials and end application manufacturers.

The machines for existing applications are getting even more

sophisticated. They are being designed to run at higher speed lines,

thinner gauges, longer runtime, faster changeover, compliant to new

regulations etc. All these put pressure on masterbatch producers to provide products with higher concentrations, lower filter pressure value, higher dispersion, higher heat stability, higher purity level etc. The old technologies for producing masterbatches are thus no longer effective now. Also, a onesolution-fit-all approach is also no longer true now.

At Prayag, we try to match the pace of these changes, by investing in the most advanced machineries and

conducting

technology

upgradations from time to time.

R. K. Aggarwal Managing Director Prayag Polytech Pvt. Ltd. Bhiwadi

POLYMERS CommuniquĂŠ l December 2015 - January 2016

Prayag’s white and additive masterbatch plant.

Also, maintaining multiple production

lines gives us the flexibility to select the

right machine as well as manufacturing process and design to produce the best fit

for a particular product line. Additionally, investment in advanced in-house pilot plants for each end applications helps us to pre-empt the demands.

Q. In your growth, you would have faced a number of challenges. Please share with the readers of POLYMERS Communiqué how did you overcome these? Surely, challenges are the essential

the true blessings in disguise. Sometimes, change in approach is all you need. In our case, challenges have always helped us to To know more, please subscribe to

POLYMERS Communiqué at subscriptions@ polymerscommunique.com

ingredient for any success. They, infact, are

POLYMERS Communiqué l December 2015 - January 2016

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