A CUSTAGE I N I T I A T I V E Feb - Mar 2016 l Issue 2.3 l ` 150
Stretching Possibilities with Plastics The Showman Speaks
Ramesh Chauhan
Chairman Bisleri International Pvt. Ltd.
Special Focus
COMPOSITES
Composites
Integrating Solutions
Auxiliaries
3D Printing
Diversification Opportunity for Polymer Processors
With Technology at the Fore
Making Life Simpler for Plastic Processors
A Boon for Auto Components
Jeff Rodrigues, MD, Owens Corning India
Kailas P., MD, Toshiba Machine (Chennai)
Larry Doyle, President, Conair Group
Geeta Anand, MD, AG Industries
Utopeia/Reliancepolymers/1518
POLYMERS CommuniquĂŠ l February - March 2016
1
CONTENTS
Feb - Mar 2016 l Issue 2.3
22
41
56 22
68
32
45
BI G S TRETCH
R EC Y C LIN G PA GES
With 100 bottling plants in the country and over 60 per cent market share in the organised bottled water segment, Bisleri India has emerged as the leader in bottled water segment. And, what makes it even more unique is its own hygiene and purification mandates. In a candid chat with POLYMERS Communiqué, Ramesh J. Chauhan tells more about the manufacturing and packaging of Bisleri water and the role of plastics.
41
Next Generation Recyclingmaschinen GmbH
45
TEC H TA LK
Kailas P., Managing Director Toshiba Machine (Chennai) Pvt. Ltd., Chennai
48
SIVA R A M SPEA K S
Dr. S. Sivaram, Former Director, CSIR-NCL
PET: Business Driver for the Beverage Industry
Ramesh J. Chauhan, Chairman
32
AUXI CARE
Bisleri International Pvt. Ltd., Mumbai
Auxiliaries: Making Life Simpler for Plastic Processors
“I believe companies that can harness their human capital to deploy equipment in the most efficient way are the ones who will be successful”, says Larry Doyle in dialogue with POLYMERS Communiqué.
High-quality Pellets from Plastic Waste: A Case Study
Integrating Solutions with Technology at the Fore
A Responsible Approach to Microbeads
Polymers and Advanced Materials Laboratory National Chemical Laboratory, Pune
Larry Doyle, President Conair Group, USA
53
A D V ER TO R IA L
36
ENGI NEERED PERFORMANCE
Dow Packaging and Specialty Plastics
“Automation, infrastructure and best manufacturing practices, coupled with highly qualified and experienced manpower help maintain global standards”, emphasises Geeta Anand in dialogue with POLYMERS Communiqué.
3D Printing: A Boon for Auto Components
Geeta Anand, Managing Director AG Industries, Gurgaon
Simplified Flexible Packaging Innovation for Powder Detergent
56
SPEC I A L FE AT U R E : CO M P O SI T E S
Jeff Rodrigues, Managing Director Owens Corning India Pvt. Ltd., Mumbai
36
74
2
64
Composites: A Diversification Opportunity for Polymer Processors
POLYMERS Communiqué l February - March 2016
Printed and Published by Manish Chawla manish@polymerscommunique.com
Designed by Custage Marketing Solutions LLP 401, Vikas Classic Building No 4 4th Floor, Near Basant Cinema Chembur, Mumbai 400 074, INDIA
61
64
68
Editorial Advisory Board
Road to 2021: Challenges and Drivers for the Global Composites Industry
Arvind Mehta Chairman and Managing Director Welset Plast Extrusions Pvt. Ltd.
Lucintel, USA
Prof. (Dr.) N. C. Saha Director, Indian Institute of Packaging
Dr. Sanjay Mazumdar, CEO
Advanced Composites: World of Opportunities in India
N. K. Balgi formerly President & Director at Ferromatik Milacron India Pvt. Ltd.
Dr. P. K. C. Bose, Vice Chairman and Managing Director Saertex India Pvt. Ltd. (a wholly owned subsidiary of SAERTEX Group, Germany), Pune
Advertising Sales - National
Pushp Raj Singhvi formerly Vice Chairman and Managing Director at Borouge (India) Pvt. Ltd.
Fraunhofer ICT, Director Polymer Engineering
Mumbai Sanjana Chugh +91-99872 62726 sanjana@polymerscommunique.com
Rajesh Nath Managing Director VDMA German Engineering Federation India Liaison Office
T OOL TIP
Hyderabad Vani Sulakhe +91-93924 28927 vani@polymerscommunique.com
Rui Tocha, General Manager
CFRPs for Structural Components in Automobiles Michael Karcher
Fraunhofer Institute for Chemical Technology ICT Polymer Engineering, Germany
Prof. Dr.-Ing. Frank Henning, Deputy Director
Fraunhofer Institute for Chemical Technology ICT Polymer Engineering, Germany
70 72
Engineering and Tooling: The Next Future POOL-NET - Portuguese Engineering and Tooling Cluster, Portugal
GR OWTH ZONE
Arvind M. Mehta, Chairman, Governing Council – AIPMA Past President - AIPMA & Plastindia Foundation
Indian Plastics Industry: 20 kgs by 2020
Vadodara Devindra Bhumra +91-81289 90887 devindra@polymerscommunique.com
Chairman, Empowerment Committee - Plastindia International University, Mumbai
Advertising Sales - International
74
IN P E R SPECTI VE
79
E VE N T
New Delhi Vijay Babbar +91-98100 15111 vijay@polymerscommunique.com
IOCL Conclave: Insight to Knowledge
CHINAPLAS, an Event Beyond Innovation
Dubai Pritam Bangera +971-5548-32330 pritam@polymerscommunique.com
Rakesh Shah formerly Managing Director Windmöller and Hölscher India Pvt. Ltd. S. K. Ray formerly 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
Content Alliance Partners
USA Manisha Janjikhel +1-908-720-3510 manisha@polymerscommunique.com
Subscriptions
Bhavesh Brahamaniya +91-22-25204436 bhavesh@polymerscommunique.com
NEWS
18
EVENTS
80
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 February - March 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.
3
Mind Speak N. K. Balgi
formerly President & Director at Ferromatik Milacron India Pvt. Ltd.
Rakesh Shah
formerly Managing Director WindmĂśller and HĂślscher India Pvt. Ltd.
Rajesh Nath
Polymer
composites - regarded as the materials that are stronger than steel, but a fraction of the weight - made a beginning as replacement to metal parts for light weighting of transport vehicles for improving fuel efficiency. Now, composites are finding newer applications in infrastructure as well as building and construction replacing metal, wood and even concrete by virtue of its design flexibility, possibility to produce ready-to-use parts and durability as they do not corrode or decay. Application horizon for composites has been ever widening.
nd ve been arou e materials ha quently the word fre sites for centuries aterials. Compo d composite m atrices an m refers to plastic s, ial er at rious m h and are with va is high strengt e main benefit enhanced ve ha structures. Th to d ten combine now low weight; of plications are erties. The ap of life lks wa all physical prop r that they cove ment, so widespread ives, entertain ture, automot icine uc str ed m fra , in ics m ut fro rona at r machines, ae are so wide th electronics, wa ies ilit ib ss po The s can do has tic - you name it. as pl at wh ncept of could the whole co applications the coming is is going Th ry. changed and na tio lu otic to revo range from ex d business. citing field an to be a very ex
sit As such, com.poCu rrently,
r material
-tech wonde
Arvind
Mehta
ector ing Dir Manag n and td. a L m t. ir v a P Ch ns xtrusio Plast E Welset
hi withstand Composite isCoa m posites can
of this age. ture, pressure ible tempera highest poss ity. tiv sis emical re and high ch is used in it t, gh ei ht w windmill, As it is lig as such defence, applications , ts af aircr talising pi automobiles, ca is etc. India sites. A po aerospace m co growth of ission m et on the high ck ple is our ro shining exam nificant use sig w sa ch hi to Mars, w es. of composit
Over the last thirty years; compo plastics and ce site materials, ramics have be VDMA German Engineering en the domin emerging mat ant er ial Federation s. The volume of applications and number of composite India Liaison Office m grown stead aterials have ily, penetratin g and conque new markets ring relentlessly. M odern compo materials cons site titute a signi ficant propor of the engine tion ered material s market rang from everyd ing ay products to sophistica niche applica ted tions. Benefit of composites that two or m is ore materials can be combi to take advant ned age of the go od characteris of each of th tics e materials. Co mposite mat research wi erial thin mecha ni ca l engineerin typically focu g ses on desig ning stronge more rigid r and materials wh ile attemptin reduce weight g to , susceptibilit y to corrosion other undesir and able factors. Increased fu el efficiency, weight savin fatigue resista gs, nce, better du rabilit structural prop erties and lowe y, enhanced r maintenanc costs have dr e iven the aero space industr shift from m y’s etal to com posites such carbon fibre as as a building mat erial. Composit materials ha e ve been ut ilis ed within th automotive in e dustry for de creasing vibra conforming tion, to complex shapes, offer corrosion resis ing tance, enhanc ed finishes as as providing well aesthetic appe al. Armed wi wide gamut of th a advantages, co mposites have key role to play a in the growin g market in In Composites ha dia. ve made an en try into diverse end-use segm ents and th e developmen efforts for fin tal ding newer composites existing and for novel applica tions is an ar top priority. ea of Managing Director
Prof. (Dr.) N
Director
Indian Insti
. C. Saha
tute of Pack
aging
There is always a stretching possibility of making composites by using natural fibre material along with polymeric material and to make use of these composites for packaging applications.
Feedback Your ma gazine was a There much was la needed ck of a which entity. high q provid uality e d magaz re domes levant ine tically inform ation b and magaz interna oth, ine fill tionally s that magaz . You need ine is r perfectl on pa magaz y. The r with a ines an ll intern d I be benchm ational lieve y ark fo ou hav r all e set publica other the tions to In dian follow. layout plastic makes The lo it o k a , feel pleasu and yo and re to re ur team ad. I w all the ish you best.
e to se lively d n d a n a ew tion e for n blica u im d t p r a y r g e rw k fo reshin ge ev f o d e r lo le It is a nt topics. I ion and know i e at differ r Josh inform s out. erful ameeInstitute e d S m n o o c w ue stics he iss n Pla that t India
Rames
Allied S
h Paras
uram s (I) Pvt. an Ltd.
olution
l and looks beautifu articles are e Th d. ne sig de creatively it ality. Please keep really of high qu d the paper an nt pri of y alit up. The qu ent quality. Complim used are of fine wish you d an m tea d to you an all success.
Magazine
Kailas P.
(Chennai) Toshiba Machine
I beli eve, this the plas is th tics stuff indu e best . Ma mag stry ny az grea with t init congra lot o ine in t u ia f qu the latio tives ality indu ns and stry. shar for all yo ing ur this with CLA RIAN U T Ch emic mang S als ( India hah ) Ltd .
Pvt. Ltd.
e ith th sed w the impres g e in it d u I am q ublication, inclu p entire y uality. q Crowle r e p pa Debbie -Standard is v Da
Excelle n plastic t world-c lass s. Pre cover senta and tion is age the s of simp ubjec range ly sup ts ar . Tr e acr erb, uly oss a while in forma wide allow tive ing share readin indus their t g, r y views contin leade . Bes rs to ued s t wis ucces hes s. for Cons
ultan
Surin
der S
. Ah
luwa In lyme dustry Ad lia vis rs and Addit or ives
t - Po
We
fully admire this update on polymers!
Abhay Saxena
Shree Varad Vinayak Plasitc and Rubber Solution
You’ve got a You’ve got a process… process… Davis-Standard Davis-Standard can make it can make it better! better! The Global Advantage™ in ™ The Global Extrusion & Advantage Converting in Extrusion & Converting
Exceptional value, consistent performance, and outstanding service – that’s The Global Exceptional value, consistent performance, Advantage™. With installations on every and outstanding service – that’s The Global continent, our multinational team supports Advantage™. With installations on every extrusion and customers every continent, ourconverting multinational team supports step of the way. extrusion and converting customers every step of the way. With more than 70 years of industry experience, names With more our thantime-tested 70 years of brand industry and trusted reputation are synonymous experience, our time-tested brand names with design engineers, andquality. trustedProfessional reputation are synonymous laboratory personnel, training experts, a with quality. Professional design engineers, talented commercial force, hands-on field laboratory personnel, training experts, a technicians, and aftermarket parts andfield talented commercial force, hands-on service specialists comprise a powerful technicians, and aftermarket parts andforce with one mission – to ensure you have what service specialists comprise a powerful force you need, when you need it. with one mission – to ensure you have what you need, when you need it. Contact us to learn how we can improve your process and profitability. Contact us to learn how we can improve your process and profitability.
#1 Extrusion Drive Pawcatuck, CT 06379 | +860.599.1010 | www.davis-standard.com | info@davis-standard.com #1 Extrusion Drive Pawcatuck, CT 06379 | +860.599.1010 | www.davis-standard.com | info@davis-standard.com
TM
our unique
additives add value to plastics Additives that provide functional properties to a variety of applications. Compatible with most base resins like commodity and engineering plastics. Product Range: • Anti-Ripening • Anti-Microbials (Organic & Inorganic based) • VCI (Nitrite free) • Oxo-biodegradable • Repellents - Rodent, Termite & Insect • Combo (Repellent + UV + Colour) • Anti-Fog (Cold and Hot) • Anti-Static (Temporary & Permanent) • UV • Processing Aid • Fragrance • Light Diffusion • Transparent colours
Lifeline Technologies Plot No. B - 85, Road No. 34, Wagle Industrial Estate, Thane (W) - 400 604. INDIA.
Telefax: +91-22-2582 8300 / 8400 (Mobile): +91 98218 56789 E-mail: info@lifelinetechnologies.in Website: www.lifelinetechnologies.in
News Digest
Milacron Successfully Displays Injection Moulding Prowess at Plexpoindia 2016
M
ilacron Holdings Corp. is a proud
participant of the 7th Annual
AMETEK Drexelbrook now offers total tank level measurement system
Plexpoindia in
2016
Gandhinagar,
tradeshow
Gujarat
held
between
7th and 11th January, 2016. Throughout
the show, Milacron operated a robust 150 tonne cPVC line servo machine that
will support India’s booming construction Borealis introduces lightweight materials for composite applications and expands Fibremod™ capacity at Monza plant
and infrastructure industry. The features of the cPVC line servo machine include clamp
force
of
150
tonne,
screw
diameter of 60mm, injection rate being
186 cc/sec, injection pressure of 1428 bar with plasticising rate at 23 gm/sec and cycle time of 52 seconds.
Mold-Masters, DME, Ferromatik, Uniloy and CIMCOOL.
Prayag Polytech Certified Under BRC Global Standards
P
rayag Polytech Pvt. Ltd. has achieved another
milestone
as
the
only
masterbatch manufacturer accredited
with BRC (British Retail Consortium) certification in India
so far. The BRC Global
Standards is a global
product safety and
quality management system
certification
programme with a stringent
auditing
Standards
are
process. BRC Global
the
first standard to be Brückner’s first 10.4 m BOPP line for India – Cosmo Films carries forward its growth strategy
approved by the GFSI (Global Shirish
Divgi,
Managing
Director
Food
Safety
Initiative) and continues
Milacron India (Ferromatik brand) stated,
to be the most widely
Plexpoindia 2016. The show was a great
20,000 certificated sites, worldwide. The
“Milacron was proud to participate in
used of the GFSI standards with over
opportunity for the Indian market to see ELIX Polymers announces its investment in a new compounding lines
A-E
first-hand, the capabilities of Milacron’s portfolio. We look forward to continuing
our focus on the growing Indian market
and manufacturing equipment with the latest in technology, not only for India,
Standards guarantee the standardisation
to push the boundaries of possibilities
and ensure that manufacturers fulfill their
but the entire globe”. Milacron continues
in plastics with breakthrough products from leading brands including Milacron,
of quality, safety and operational criteria
legal obligations and provide protection for
the
end-consumer.
BRC
Global
Standards is now often a fundamental requirement of many leading retailers.
Prayag, as a supplier of masterbatches to the packaging material producers, is thus certified under BRC Global Standards for
packaging and packaging materials which focuses on quality and functional aspects
18
POLYMERS Communiqué l February - March 2016
of packaging material. The strict standard tests for compliance are on various
sections like hygiene practices, hazard and risk management, supplier monitoring, site
standards,
waste
management,
product and process controls, personnel training etc.
Poly India 2016, Third National Exhibition and Conference on Polymers and Plastics held at Mumbai on 29th January, 2016
of Plastics Engineering and Technology (CIPET).
The International conference with the theme, ‘Indian Plastic industry: Challenges
& Opportunities’ took place on 29th January,
2016 at Mumbai and was inaugurated by Prof. (Dr.) S. K. Naik, Director General, CIPET.
The conference debated on how to
make India a global manufacturing to balance the aspects of sustainability
P
industries. The sector has been growing
gets branded as a polluting material.
segment of the Indian economy
and are a facilitator to a large number of
at a very good pace at above 10% for the past many years and is also highly employment intensive. With a turnover
term perspective. It was specifically noted that while the usage and benefits
of plastics are manifold, it invariably It was advised that the facts or myths
regarding the polluting characteristics
Hexcel, major supplier of composite materials for the A320neo airframe, congratulates Airbus on the first delivery of the A320neo to Lufthansa
of plastics need to be addressed in
a scientific manner. Going ahead,
recycling and reuse of plastics might be a leading step towards fostering
innovation and sustainability. In fact, there is wide scope for industries based of above Rs. 90,000 crore and employing
Ferrano chooses Eastman Tritan copolyester for its blender products
hub of quality plastic products, how with economic growth with a long-
lastics constitute a very important
Digest
on recycling of plastics waste.
above 3.6 million people, it is making good
The industry was advised to give more
sector has huge unrealised potential, as
that China spends almost 12 times more
contribution to the Nation’s economy. The
focus on R&D and innovation. It was noted
indicated by the present very low per
on this as compared to India.
F-H
capita consumption levels in the country compared to global levels.
To bring a focus to this sector,
Poly India 2016, which includes an international exhibition and a
conference was organised at Mumbai between 28th and 30th January,
2016. It was inaugurated by Hansraj Gangaram Ahir, Hon’ble Minister of
State for Chemicals and Fertilizers, Government of India on 28th January,
2016 at Mumbai. The theme of the exhibition was, ‘Indian Plastic and Petrochemical Sector: Potential for Global Manufacturing Hub’ and was
jointly organised by the Department
of Chemicals and Petrochemicals, Government of India, Federation of
Indian Chambers of Commerce &
Industry (FICCI) and Central Institute
POLYMERS Communiqué l February - March 2016
19
Digest
Windsor Empowers the Processing Industry with Gen Next Italtech KL Series, Two Platen Machines
T
he next-gen two platen injection
Honeywell Refinery Technology and modular equipment powers new clean fuels refinery in Pakistan
moulding
technological
machines
strength,
showcase
fast
cycling
operations, optimised platen weights,
advanced control systems to help in
quick process set-ups and improved product quality.
equal tonnage in all 4 tie bars. This
arrangement also increases the mould life. All this will benefit the processors with a
big reduction in ‘Total cost of ownership’. With the KL Series machines, Windsor
addresses the problem of article / product accuracy, which is today an issue of concern for most of the Indian processors.
Nitin Chowdhary, Dy. CEO, Windsor states, ‘Italtech has one of the latest technologies
in the world for two platen machines; customers can optimise the machine
LyondellBasell expands its Purell portfolio for healthcare applications with two new polypropylene grades
selection based on their requirement and
not end up taking larger machines which are resource hungry’.
The prime objective of Windsor, after
the acquisition of Italtech, was to build
on Italtech’s expertise and experience, Meusburger expanded its range of insulation boards with the lattice version E 1450
innovate and adopt new technologies so as to make two platen machines at an affordable price, especially since the
Yet Again Rajoo’s Innovation Recognised
T
he industry continues to recognise Rajoo
as
an
innovator,
quality
supplier and always on the forefront
in empowering the plastics processing industry with advanced technologies.
European two platen machines typically cost twice as much when compared to the Indian made toggle or hydro
RPC Bebo Plastik extends its In-Mould Label Thermoforming (IML-T) technology for production of lids.
mechanical machines.
Italtech is a pioneer in production
of injection moulding machines for thermoplastic materials and globally
This
automotive sector such as Fiat, Renault,
was appreciated at the recent 6th National
partners leading companies in the
Nissan besides a number of Tier-1 and Solvay’s KetaSpire® PEEK food contact grades enhance Zellamid® 1500 PEEK product line from ZellMetall
H-S
Tier-2 vendors.
Italtech comes with significant experience
of manufacturing high tonnage machines. Across the globe, there are over 700
machines installed, with a clamp force of
recognition
was
further
acknowledged when Rajoo Engineers Award for Technology Innovation in Petrochemicals & Downstream Plastic
Processing Industry (2015 – 16) for its contribution to technology innovation in the category of innovation of polymer processing machinery and equipment.
over 1000 tonnes. To suit a wide spectrum
Rajoo’s Tilting Mould Thermoformer -
available in the clamp force range of 350
demand of the industry for stacking
of needs, KL series machines are today to 8000 tonnes.
DISPOTILT addressed the long-standing
The latest KL series machines come with some very impressive technological
upgrades such as high mould to machine size, increase in productivity, reliability,
accuracy with minimal moving parts and lower maintenance costs, plus more. The unique clamping mechanism ensures
20
POLYMERS Communiqué l February - March 2016
solutions for low weight disposable glasses, high productivity and comfort
of use with minimal manpower. Rajoo introduced mould
India’s
first
thermoformer.
ever
The
tilting
disposal
containers market now has an integrated
solution for thermoforming, stacking, counting and packing; Rajoo fulfilled its market commitment.
The award was received on 20th January
from Ananth Kumar, Hon’ble Minister of
Chemicals and Fertilizers, Government
of India by Sunil Jain, President, Rajoo Engineers Limited in the presence of Avinash Joshi, Jt. Secretary, Ministry of Chemicals and Fertilizers.
Clariant Performs Groundbreaking for New Healthcare Packaging Plant in India
C
lariant, a world leader in speciality chemicals,
performed
the
groundbreaking ceremony of a new
manufacturing plant in Cuddalore, for
moisture-control products, intended for
the pharmaceutical industry. In December 2015, Clariant had announced plans to invest CHF 10 million in this healthcare packaging
plant
that
will
support
the growing generic pharmaceutical industry in India. The investment will be
implemented through its wholly owned
Digest Teknor Apex now offers diverse TPE and TPV compounds for seals, gaskets, motor mounts and other major-appliance components
subsidiary in India. “The
new
healthcare
packaging
manufacturing plant here in Cuddalore is
another important step within our strategy to intensify growth and increase our market share in the emerging India region”,
says Christian Kohlpaintner, member
of the Clariant Executive Committee. “With this new plant, we are responding to
our customers’ growing demand for highquality desiccants”, says Deepak Parikh,
T
Clariant Region President India. The plant is slated for inauguration in 2017.
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 February - March 2016
Tape Extrusion . Winding . Circular Weaving . Coating . Printing . Bag Conversion . Yarn Spinning
21
BIG STRETCH
Ramesh J. Chauhan Chairman Bisleri International Pvt. Ltd. Mumbai
PET
Business Driver for the Beverage Industry With 100 bottling plants in the country and over 60 per cent
market share in the organised bottled water segment, Bisleri India has emerged as the leader in bottled water segment. And, what makes it even more unique is its own hygiene and purification mandates. In a candid chat with POLYMERS Communiqué,
Ramesh J. Chauhan tells more about the manufacturing and packaging of Bisleri water and the role of plastics.
Q. While the industry is ‘Stretching Possibilities with Plastics’, readers of POLYMERS Communiqué will like to know, what kind of fit is this statement with the Bisleri (bottled water) business? Bottled water has undergone an evolution, specifically in terms of its
packaging. When we started distribution of water, glass bottles were in
practice and we faced many challenges in maintaining those bottles. From glass, we moved to PVC, and now, it is PET bottles that the industry uses.
The industry was happy letting go of the glass bottles, which were heavier and a burden to maintain. While plastics came in like a much-needed change
that ensured low maintenance in comparison to glass, low transportation
cost and of course, the light weight for consumers to carry it around. Plastics, therefore, has enabled the industry to do more with the available
capital it has in its kitty. However, the only challenge that still exists (was prevalent earlier - in the glass bottle era as well) is the counterfeiting of
bottles, as vendors refill Bisleri bottles with unpurified water and sell under our brand. Therefore, material suppliers, pack designers, label makers and additive suppliers have the biggest challenge now, on how they can defend
their products / bottles against the counterfeiting attack, especially in the Asian markets.
Therefore, it is important to introduce innovations like destructible caps, which do not allow refilling of bottles.
Q. ‘Sustainable PET’, a global movement as far as beverage packaging is concerned. Your thoughts, please. We, at Bisleri, think that PET is a great material from which we can make our
containers, as we are able to downgauge, while retaining the strength of
PET. One aspect that we need to pay heed to is that care has to be taken to
prevent littering of post-consumer waste. Recycling
However, we should not overlook the fact that glass
PET lends itself to reprocessing into many items.
thus carbonated drinks and soft drink companies
of PET is also a highly profitable affair as the versatile
However, this recycling process is only sustainable if the collection of these PETs can be streamlined. As of today, we still have to struggle to acquire back the empty bottles circulated in the market and have depended on rag-pickers for their collection as there is no segregation system in garbage collection. Also, another problem is the collection of
bottles provides its advantage of reuse (not recycle), still stick to using them too, while cans too will have their market, primarily due to the status symbol
attached to it.
Q. What are the packaging technologies implemented by Bisleri to make more out of less? The advantage of PET is that we are able
large number of bottles from remote destinations
where
they
consumed. Therefore, as an
to make our bottle in-house and have
are
an online production. This helps in reducing transportation costs
industry, we need to focus on
better
collection
methodologies and
weight, but ensuring product safety and
do not believe in using nitrogen while packaging bottles; we prefer to use sturdy plastic instead. Our love for our consumers does not end here. The brand has also transformed the 5 litre jar into a ‘Rocking Bottle’ which allows ‘easy-pour’ facility. Now, that is what we feel is
material to handle, but also acidic and when
carbonated drinks were poured into them,
one could see etched particles floating in the drink making it dangerous for consumption.
Plastics gives us a comfort zone of easy transport, easy handling and low manufacturing costs. Every manufacturer of water and soft drink
is making a shift towards PET as hygiene,
transport cost, damage and breakages, besides transparency and good barrier properties of the material have made it an attractive option, the
pack integrity. We
mind
keep
requirements,
in
consumer thus
we
buy sturdy plastics. While we
caring for our consumer.
a material not only was glass a difficult
use
bringing down the
value for money and convenience of use. We
and rather, a much required one. As
optimising
of the material by
requirements and focus on giving them
glass to plastics was a no-brainer
24
in
about our consumer’s health
The migration process from
world over.
have also been successful
We, at Bisleri India, are concerned
practices.
Q. Plastics, the material of choice for the beverage industry. How do you see the migration trends?
and it improves hygiene. We
Consumer First
have an option of converting
our plastic into lighter / cheaper
versions as well, we refrain from
doing that as on opening such bottles,
there is a high chance that the bottle
will collapse.
Several soft drink companies use light bottles and at the time of packaging, they use nitrogen
to pressure the liquid so that the bottles look
sturdy and do not collapse. This, according
to us is an unfair practice to the consumer. We believe that consumer is the king, and therefore, ensure that our packaging is for the
consumer - honest and fair - rather than just profit-oriented.
POLYMERS Communiqué l February - March 2016
B2B Marketing Communication Specialists RELATIONSHIPS All India Plastics Manufacturers Association
Asian Packaging Federation
AVI Global Plast Pvt. Ltd.
Bennett, Coleman and Company Ltd.
Blend Colours
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.
Sintex Industries Ltd.
Technical Training and Research Institute
The Economic Times Polymers
Welset Plast Extrusions Pvt. Ltd.
Windsor Machines Limited
World Packaging Organisation
Adeka India Pvt. Ltd.
THE TIMES OF INDIA
Key Services l
l
Corporate Communication Consultancy Content Development
l
Building Mailing Lists
l
Media Dissemination
l
Developing Customer Case Studies
l
Sales Lead Qualification
l
And more...
CUSTAGE Marketing Solutions LLP a
marcom
company
HO: 401, Vikas Classic, Building No.4, Near Basant Cinema, Dr. C. G. Road, Chembur, Mumbai 400 074 +91-22-2520 4436 l info@custage.com l www.custage.com Branches: Hyderabad l New Delhi l Vadodara
Reliance Industries Ltd.
Vasantha Tool Crafts Pvt. Ltd.
and more...
Q. Do you see any limitations of available processing technologies? Any message to the technology providers?
meets our standards online. Presently, we are required
We have technical limitations in 20 litre jar as we
machine capacity, which at the moment processes
are not able to get the full value of PET. Also, we are not able to stretch the preform adequately due to physical limitations. As large jars are obviously recovered from institutions, cleaned and repacked
at plants, one would like to see minimum scratches on the outer surface to retain glass-like clarity for
20 or 30 trips. We are working hard towards
this as even 5 more trips would make a lot of
to do batch processes.
Another big gap that we see is in the blowing
90 bottles a minute and we will want it to go up to
200 bottles a minute. Since all other processes take care of 200 bottles a minute, the blowing machines become a bottleneck. Currently, the high
speed bowing machines that are available are at an exorbitant cost, which does not suit our purpose. Labelling is yet another challenge that the industry
business sense.
To know more, please subscribe to
POLYMERS Communiqué at subscriptions@
We have not got suppliers who can give us RO
polymerscommunique.com
membranes such that the TDS (total dissolved solids)
STATEMENT OF OWNERSHIP - FORM IV (See Rule 8) Statement about ownership and other particulars about newspaper namely POLYMERS Communiqué to be published in the first issue every year after the last day of February
1. Place of publication
: 401, Vikas Classic Building No 4, 4th Floor, Near Basant Cinema, Chembur, Mumbai 400 074, INDIA
2. Periodicity of publication : Bi-monthly 3. Printer’s Name
: Manish Chawla
: 401, Vikas Classic Building No 4, 4 Floor, Near Basant Cinema, Chembur, Mumbai 400 074, INDIA
Address
n
Nationality : Indian
th
4. Publisher’s Name
: Manish Chawla
: 401, Vikas Classic Building No 4, 4 Floor, Near Basant Cinema, Chembur, Mumbai 400 074, INDIA
Address
n
Nationality : Indian
th
5. Editor’s Name
: Manish Chawla
: 401, Vikas Classic Building No 4, 4 Floor, Near Basant Cinema, Chembur, Mumbai 400 074, INDIA
Address
n
Nationality : Indian
th
6. Names and addresses of individuals who own the newspaper and partners or shareholders holding more than one
per cent of the total capital: Manish Chawla, 401, Vikas Classic Building No 4, 4th Floor, Near Basant Cinema, Chembur, Mumbai 400 074, INDIA
I, Manish Chawla, hereby declare that the particulars given above are true to the best of my knowledge and belief.
Date: 1st March, 2016 MANISH CHAWLA
Signature of the Publisher
POLYMERS Communiqué l February - March 2016
27
AUXI CARE
“I believe companies that can harness their human capital to deploy equipment in the most efficient way are the ones who will be successful”, says Larry Doyle in dialogue with POLYMERS Communiqué.
Q. What challenges does ‘integrated automation’ throw to auxiliary equipment manufacturers?
source is connected to the selected destination. Operators simply connect the material line hose to the appropriate port. If an incorrect connection is
I would say most of the challenges come on the
made, the control will not allow the vacuum pump
truly wants out of an integrated system. Getting the
In addition, ‘next generation’ material-handling
front-end in working to identify what a processor
processor to not only verbalise what they need, but to take it a step further and understand why they
need it and what they intend to accomplish is a bigger challenge.
to begin conveying the material.
proofing system uses machine vision to help prevent
material contamination due to operator error. This
new vision system includes a motorised camera that automatically confirms that the connection between
Q. The changing role of material handling to reduce human error. Please comment.
the material sources and destinations has been made correctly and conveying can begin.
attention, language difficulties, inexperience – all can
Q. How different are the needs of the Indian plastic processing industry when compared to other markets?
material conveying, operator error can result in the
the world. Processors in India have customers with
Sometimes
the
most
difficult
challenges
in
manufacturing arise from human frailty. Lack of
lead to errors of judgment and execution. In plastics
I believe the challenges are similar to markets all over
wrong resin being sent to the wrong processing
similar demands. They want their product delivered
destination, which in turn can lead to downtime, scrap and even, product liability.
Newer systems available today use non-electrical sensing technology to confirm that the proper resin
on time and without defect. To that end, customers are the same, the world over.
Q. With changing materials of construction such as composites and bioplastics, what
Larry Doyle President Conair Group, USA
Auxiliaries
Making Life Simpler for Plastic Processors
impact can it have / has it had on auxiliary equipment suppliers? I do not see these materials creating a major impact on auxiliary equipment; but yes, we
do have to make modifications to our existing equipment and control. We do this on a case-to-
case basis and we are always ready for challenges.
Q. In coming times, what according to you will be the most critical parameter for business success - equipment, knowledge or capabilities? I believe it will be a combination of all of these.
More specifically, how to apply equipment and
automation in a knowledgeable way that gives you a competitive advantage. It is one thing to know how to build a high quality piece of
equipment that can do a job on the plant floor; while another to be able to know what that job
is, to know how it must be done and what it will take. I believe companies that can harness
their human capital to deploy equipment in
34
the most efficient way are the ones who will
be successful.
Q. How is Conair tapping the power of advanced connectivity via ‘Internet of Things’ to make operations simpler for plastics processors? Conair is tapping the power of the ‘Internet of Things’ to make life simpler for plastic processors.
Two examples – a next-generation plant-wide control platform based on SCADA technology
and a new tablet-computer-based ‘universal’ machine-control interface.
The third generation of ControlWorks™ is the
‘portal to the process’. From one PC interface,
ControlWorks makes it possible to monitor
the operation of blenders, loaders, dryers, To know more, please subscribe to
POLYMERS Communiqué at subscriptions@ polymerscommunique.com
POLYMERS Communiqué l February - March 2016
ENGINEERED PERFORMANCE
Geeta Anand Managing Director AG Industries Gurgaon
3D Printing
A Boon for Auto Components 36
POLYMERS CommuniquĂŠ l February - March 2016
“Automation, infrastructure and best manufacturing practices, coupled with highly qualified and experienced manpower help maintain global standards”, emphasises Geeta Anand in dialogue with POLYMERS Communiqué.
Q. What are the global trends of increasing use of plastics in automotives?
whether it is in style, cost or features. Though
component manufacturers and OEMs are investing
There is huge scope to make automotive products
lot of funds in R&D, yet the progress needs to be at par
lighter and fuel-efficient by use of plastics. Currently,
with international levels. Development of speciality
the average use of plastics in automotive is 7 – 8 kgs
products will supplement growth to a large extent.
which is expected to grow to 20 kgs in another 5 years time. There is huge scope for under bonnet plastics
Q. Do you see an increasing role of 3D printing in creating automotive end parts?
parts which are not only going to replace metal, but
will reduce the noise level as well. Use of plastics muffler is an area of great potential. The metal doors in cars can be changed to plastics, which needs to be explored.
Q. Niche markets or scale of volume, your take please, on these approaches. Today, customers are looking for speciality products
Yes, there is huge potential for the use of 3D printing
to make prototype samples and low volume parts. It is today available for metals and plastics. Currently, it
takes 2 - 3 months time to develop proto samples. If it To know more, please subscribe to
POLYMERS Communiqué at subscriptions@ polymerscommunique.com
A CUSTAGE I N I T I A T I V E
SUBSCRIPTION OPPORTUNITIES
Years
Cover Price (6 Issues)
Special Discount
Net Payable
1
Year
`
900
15%
765
2
Years
` 1800
20%
1440
3
Years
` 2700
25%
2025
Payment Options
Cheques / Demand Drafts in favour of CUSTAGE MARKETING SOLUTIONS PVT LLP, to be couriered to us at our address :
401, Vikas Classic Building No. 4, 4th Floor, Near Basant Cinema, Chembur, Mumbai 400 074, India. Online payments NEFT. Please send a confirmatory email for all NEFT transfers
Account Name: CUSTAGE MARKETING SOLUTIONS LLP Bank: IDBI (Chembur Branch) Account Number: 0018102000027186 IFSC Code: IBKL0000018
POLYMERS Communiqué l February - March 2016
37
RECYCLING PAGES
Sponsored by
High-quality Pellets from Plastic Waste
A Case Study
Regardless of the feed material, whether thick-walled parts, film material such as in LDPE recycling or the raffia tapes that is used to weave big bags – in a single process step, the shredder-feeder-extruder combination system shreds the plastic material and generates high-quality pellets. The finer and cleaner the pellets, the more high-quality material can be used for further processing.
P
lastic production is focused, primarily for cost
Maris follows the Japanese production concept
waste as possible. However, in order to
organises its lean production system around
reasons, on generating as little production
be integrated effectively in the material logistics
known as 5S workplace design, and the company
process, the leftover material has to be pelletised. For
About Maris
in Tamil Nadu, manufactures a complete range of
a complete range of polypropylene woven
example, Maris Associates Private Limited, located polypropylene woven sacks and flexible intermediate
bulk containers (FIBCs), has implemented a zeroscrap production system using a shredder-feeder-
extruder combination system. This recycling system does not generate any temperature spikes in the
plastic during recycling, thus uniform pellets are
produced. The two to three per cent waste that is produced in the plastics recycling process can be returned conveniently to the main production system, thanks to this efficient material recycling
process, and this in turn, allows the company to generate further profits. The entire recycling process, thus, takes place in a single step.
POLYMERS CommuniquĂŠ l February - March 2016
Maris Associates Private Limited manufactures
sacks and flexible intermediate bulk containers (FIBCs),
has
implemented
a
zero-scrap
production system using a shredder-feederextruder
combination
system
from
Generation Recyclingmaschinen GmbH.
Next
The company produces a complete range
of polypropylene woven sacks and FIBCs, including circular woven sacks, as well as regular and ventilated FIBCs, so-called big bags. Maris has the capacity to produce over 9000
metric tonnes per annum and is a part of the A.V.M. Group.
41
Sponsored by
Maris currently produces 4 mn FIBCs per year, majority of which are exported. Smaller bags are used in the local market. (Source: Maris)
Maris produces big bags as well as circular woven sacks.
the principles of sorting, straightening up
the material and return it to the production
as making all arrangements into rules and
same time, the new solution saves space, as
and ensuring workplace cleanliness, as well complying with all requirements. One aspect
of this approach is the in-house recycling
of plastic waste, which is produced, for
(Source: Maris)
process with the original material. At the no storage area is needed for the recycled plastic waste.
example, when making big bags and which
This machine can process thick-walled and
commissioning the shredder-feeder-extruder
extruder
can lead to significant cost savings: Prior to combination system, the company could only sell the waste product at a fraction of the cost of the raw material. Now, it is able to prepare
bulky material, and its shredder-feedercombination
highly-efficient
system
material
provides
recycling.
7
machine models offer a wide range of solutions that meet different needs depending
on
customer
requirements.
Worldwide, over 800 solutions have been installed already in more than
70 countries. With the help of a remote service module, customers
S:GRAN
on other continents can have their machines checked at any time.
In
addition,
processing
parameters are queried and this data is sent via internet to the NGR main office ensuring that the customer benefits from a
recycling solution with low operating costs.
(Source: Next Generation Recyclingmaschinen GmbH) 42
POLYMERS CommuniquĂŠ l February - March 2016
Sponsored by
‘Go Green’ Initiative through Recycling of Production Waste The
shredder-feeder-extruder
system
transforms
production
combination waste
into
valuable raw material and thus not only reduces
costs, but also plays an important role in
conserving resources and protecting the environment.
The raffia tapes, (for the local market)
contain some five to seven per cent
recycled material; upto half of the
plastics used in LD liners comes from
newly recycled pellets. The company
reports
that
no
difference in quality is identified for the products made from Production waste is used to produce high-quality plastic pellets through recycling. (Source: Maris)
Ensuring Highest Resin Quality through Uniform Temperature shredder with small cutting blades. A conveyor transports the material into the cutting area,
where it is shredded. The feeder supplies the extruder screw, where the plastic waste is
finally heated and homogenised. The result
is high-quality pellets that can be used for further processing. feeding
process
can
take
100 per cent original material. Further
The one-step technology is based on a reliable
The
the recycled and the
place
discontinuously, since the control unit regulates
all the necessary elements: In the hopper, the material level is regularly checked and the
material feed is adjusted accordingly. The
shredder is configured so that the blades turn
slowly, which prevents temperature spikes from developing in the material. High temperatures
OPINES
for
the
benefits Indian
company include the
on/off
automatic switch,
which enables a restart with filled hopper and filled extruder
screw
minutes
after
in less than two an
unplanned
shutdown. are
common
on the subcontinent, this practical solution helps to ensure downtimes are as short as possible.
Once the machine is configured, it adjusts itself
Installation and commissioning of a recycling
or bulkiness of the feed material. The recipe
site and takes about one week to complete. An
predefined programs, depending on the material and its quality.
POLYMERS Communiqué l February - March 2016
Maris Associa tes Private Lim ited Tamil Nadu
As
Delivery and Commissioning on All Continents
the control panel, can also be used to select
an
power outages
material thermally.
management system, which is found directly on
O
Regardless of the feed mater ial, whether thickwalled parts, fil m material such as in LDPE recy cl ing or the raffia tape s that we use to w eave our big bags – in a single pr oc es s step, S:GRAN shreds the plastic mat er ia l and generate s high-quality pellets for further proc essing. In orde r to ensure that th e quality of th e pe llets is consistently high, the mec ha ni cal properties an d flow charac teristics are regularly m easured.
in the cutting area would further impact the
automatically, regardless of the size, thickness
M. V. Sivaram
Owner and CE
machine is performed directly at the customer
ironed-out process of ensures reviews of the layout, performance checks before delivery,
acceptance test on site as well as user ease in use.
43
A CUSTAGE I N I T I A T I V E
India’s premium bi-monthly magazine TM
W HE RE
ROY LTY
S ROY LTY
a comprehensive print-cum-digital approach to meet your marcom needs, for a truly 360° experience
N O W, A B U S I N E S S R E A S O N T O A D V E R T I S E !
CUSTAGE Marketing Solutions LLP a
marcom
company
+91-22-2520 4436 info@polymerscommunique.com www.custage.com
TECH TALK
Integrating Solutions with Technology at the Fore
Kailas P., Managing Director Toshiba Machine (Chennai) Pvt. Ltd. Chennai
“We are capable of designing and executing fully automated centralised drying, conveying and
blending systems for plastic processing shops”, elaborates Kailas P. in dialogue with POLYMERS Communiqué.
Q. We understand that Japan’s Toshiba Machine Co. Ltd. plans to expand the product range of its Indian plastics machinery subsidiary. Share with us more details on the same. We are incorporating some design changes on existing models with Japanese technology and also
improving shop floor quality and inspection process to make highly reliable machines. This will also help us to focus more on the export markets. We have
plans for manufacturing die casting machines and large tonnage machines in future, but are yet to be finalise anything conclusively.
Q. The company had stated that it has made some significant developments in customdesigned auxiliary systems. Your thoughts on this. We are capable of designing and executing fully automated centralised drying, conveying and
blending systems for plastic processing shops and have always been executing big systems in India.
Since these systems are custom-designed to suit specific customer requirements, we have been To know more, please subscribe to
POLYMERS Communiqué at subscriptions@ polymerscommunique.com
Innovative Plastic Recycling Solutions
S:GRAN 75 Shredder-Feeder-Extruder Combination
It takes sophisticated technology to make plastics recycling sustainable and more efficient and to continuously improve pellet quality. And it takes commitment to really be successful. SIMPLY ONE STEP AHEAD
www.ngr.at
SIVARAM SPEAKS
A Responsible Approach
to Microbeads
Kernels of apricot and almond shells, common salt and even sugar can be used as exfoliants in lieu of microbeads. Products derived from rice and bamboo have also been developed; amorphous synthetic silica microbeads are also effective as exfoliants, opines Dr. S. Sivaram.
O
n 28th December, 2015, the US President,
Barack Obama signed into law a bill phasing out the manufacture of face
wash, toothpaste, shampoo and other such personal care products containing plastic
microbeads by 1st July, 2017 and the sale of such products by 1st July, 2018 (Microbead-Free Waters
Act). The Netherlands, Austria, Luxembourg,
Belgium and Sweden will enact similar laws shortly. International Maritime Organization is
discussing possible regulatory interventions.
Need to Know What
are
microplastics?
Why
are
they
biologists
and
attracting such huge attention from scientists, environmentalists,
marine
Governments? Why are they used extensively
in personal care products such as shampoo, toothpaste, deo, lipstick and face wash? Are safer
alternatives available for this application? Is an ocean clean up strategy feasible? We shall try and address some of these issues.
Plastic microbeads or microplastics are those tiny,
Microplastics are pieces of polymers of less
in the plastic industry, yet pollute lakes, rivers
to be pervasive in lakes, beaches and oceans.
to marine flora and fauna . One tube of face
300,000 tonnes. Experts speculate that this is
estimated that close to five trillion microbeads are
giant shredder breaking tiny plastics into tinier
almost invisible materials, hardly talked about
than 5 mm in diameter. They have been found
and oceans and is causing substantial damage
Estimates place the quantity in oceans at close to
1
wash can contain over 350,000 microbeads. It is
only a lower estimate, since oceans work like a
spread across all the oceans of the world.
ones which are then widely dispersed through the world’s oceans. Plastics enter waterways
not merely as microbeads; they enter in various dimensions, typically, less than 1 mm, between Dr. S. Sivaram Former Director, CSIR-NCL Polymers and Advanced Materials Laboratory National Chemical Laboratory, Pune
48
To know more, please subscribe to
POLYMERS Communiqué at subscriptions@ polymerscommunique.com
POLYMERS Communiqué l February - March 2016
INNOVATIONS TO PRESERVE RESOURCES AND REDUCE WASTE... STARTING NOW. Non-rigid containers that offer numerous sustainability benefits. Protective wraps that can double the shelf life of fresh-cut produce.* And that’s just a sample of real-world answers in place today from Dow. Learn more about how Dow can help address today’s challenges and inspire packaging solutions of tomorrow.
PERFORMANCE PACKAGING | dowpackaging.com
*Per independent tests. Additional information is available upon request. ®™ The DOW Diamond Logo is a trademark of The Dow Chemical Company © 2016
Media for Packaging Professionals Your Partner in Packaging Sector Editor: Prof. (Dr.) N. C. Saha (Director - IIP) - 9819996630 For Advertisement and Articles Contact: Asst. Editor: Bhushan Surpur (Assistant Director) - 9821022112 Email: director-iip@iip-in.com/infoiip@iip-in.com Website: www.iip-in.com
Published By
ADVERTORIAL
Simplified Flexible Packaging Innovation
for Powder Detergent
A Dow India Case Study: DOWLEXTM polyethlyene resins can be easily processed in conventional and latest extrusion lines and reduces the complications from polymer blends, offering converters greater flexibility and control over the quality of their films.
I
n flexible packages for powder detergent,
brand owners are actively reaching out to
performance DOWLEX™ polyethlyene resin
its increasing popularity and capability to
Dow
has
formulated
a
unique
high
to simplify the packaging film structures for better control of quality.
Brands Reaching Out to More Markets The laundry detergent market is one of the key growth segments in India dominated by both, global and local suppliers. Powder
detergent
currently
has
rural markets through flexible packaging with easily replace conventional rigid packaging.
Flexible pouches are customisable from unit
to larger packs of upto 3 kgs and have to meet stringent standards on leakage proof, aesthetics, durability and sustainability.
Packaging to Protect Consumer Trust
the largest market share and is
Brands often face issues when packaging
soap bars and liquid detergent.
are usually packed in either pre-packaged
expected to continue outgrowing To increase their market share,
Incumbent Structure
laundry powder detergents. These detergents pouches or co-extruded multilayer films,
Proposed Structure
Skin layer C4-LLDPE + LDPE Core Layer m-LLDPE + LDPE + C4-LLDPE Sealant Layer m-LLDPE + LDPE
Skin layer DOWLEXTM 2645G Core layer DOWLEXTM 2645G LDPE 310E
Sealant Layer DOWLEXTM 2645G.11G LDPE 312E
Figure 1: Layer Ratio: 1 :1 : 1; Film Thickness: 30 microns.
POLYMERS CommuniquĂŠ l February - March 2016
53
5 4 3 2 1 0
Tensile Strength (TD) Tensile Strength (MD) Secant Modulus (2%TD)
Puncture Resistance Elmendorf Tear@1600g (MD) Elmendorf Tear@1600g (TD)
Secant Modulus (2%MD)
Hot Tack (N/25mm)
Dart Impact A
which are then placed inside cardboard boxes. Problems arise when some of these pouches
leak during handling and transportation, due to which the detergent trickles out
and stains the cardboard. Leaked pouches are ultimately left unsold on the shelves, which negatively impacts product sales and brand value.
90
100
industry placing emphasis on optimising packaging materials through the process of down-gauging. To meet the growing performance demands for lightweight flexible
to blend polymers
Simplified packaging film structure
Improved abuse properties
Machinability Easy to process
polymer blends
Wide sealing window;
line speed
higher packaging
Energy
Reduced sealing
Shelf Appeal
Excellent aesthetics
Efficiency
140
The focus on flexible pouches has seen the
Sustainable
Productivity
130
Optimisation to Drive Sustainability
packages, convertors
Durability
120
Figure 3: Improved sealing performance.
Market Needs Dow’s Solution Packaging
110
Temperature (° C)
Regular (C4+competitor mLLDPE) based film DOWLEXTM 2645G based film
Regular (C4+competitor mLLDPE) based film DOWLEXTM 2645G based film Figure 2: Significant improvement in mechanical properties.
18 16 14 12 10 8 6 4 2 0
temperatures
Dow Products
are currently forced of
different
types
such as conventional linear
low-density
polyethylene (LLDPE),
resins
low-density
polyethylene resins (LDPE),
metallocene LLDPE and highdensity
polyethylene
resins
(HDPE). As the source of polymer
resins may vary at different times, the use of different resin types makes
it difficult to control the consistency of
quality and laminate in the final packaging film.
lnnovation Means Simplification
Dow Product
MI
Density(g/cm3)
DOWLEXTM 2645G
0.85
0.918
DOWLEX 2645.11G 0.90
0.921
LDPE 310E
0.75
0.924
LDPE 312E
0.75
0.924
(with additives)
and latest extrusion lines and reduces the
LDPE 150E
0.25
0.921
converters greater flexibility and control over
TM
Dow Packaging and Specialty Plastics brings to
the market a blend of DOWLEX™ polyethylene resins
and
economically
LDPE
which
efficient
and
is
sustainable,
simplifies
the
structure of existing packaging films. These
resins can be easily processed in conventional complications from polymer blends, offering the quality of their films.
®TM Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow
54
POLYMERS Communiqué l February - March 2016
Speciality Colour Masterbatches l
Endless Shade Possibilities
Next Generation Metallics
l
White Masterbatches ‘High Loading
l l
Path Breaking Colouring & Compounding Solutions
High Quality Packaging Film
High Performance Blacks l
High Strength Blacks
High Dispersability
l
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
l
T : +91-22-2821 5734, 2838 7054 F : +91-22-2838 1088 E : info@welset.com W : www.welset.com
COMPOSITES
A Special Feature
Jeff Rodrigues Managing Director Owens Corning India Pvt. Ltd. Mumbai
“With synergy in terms of end-market or channel, composites should, in
most cases, be a potential downstream or lateral
diversification opportunity for polymer processors”, says Jeff Rodrigues in dialogue with POLYMERS Communiqué.
56
POLYMERS Communiqué l February - March 2016
Composites
A Diversification Opportunity for Polymer Processors Q. What key trends / opportunities, over the next 3 years, will prove to be significant to the growth of the composites market in India? Continued focus on sustainability, carbon footprint reduction, corrosion-resistance and light-weighting will drive increased use
of composites in India. The per-capita consumption of composites is currently one-tenth or so of that in China, and even lower than
that compared to the US, so there is significant scope for upside in composites adoption. In particular, the construction industry and
corrosion-resistant applications should see increased composites penetration in India, going forward.
Q. A reputed research agency has indicated that the future markets of composites are expected to be highly competitive and companies with innovative capabilities can thrive and gain market share. Your take on this statement. The composites industry has and will continue to rely on innovation to drive substitution of metals and other conventional materials.
This will include not just product innovation, but also innovative
processes, channels-to-market and life-cycle cost optimisation. Owens Corning having a global footprint, consistent quality and a history of innovation will help it gain share in new markets.
Q. Hand-holding of the composites industry can usher faster growth. Your thoughts please. Some initial support in terms of faster approvals, creating more
forward-looking codes and regulations along with a robust
POLYMERS CommuniquĂŠ l February - March 2016
57
COMPOSITES
A Special Feature
COMPOSITES
A Special Feature
will help them gain market share
enforcement mechanism, and a
v/s traditional materials than just
faster path to commercialisation
polymers alone.
of new applications without
being blocked by entrenched
Also, having a common converting
lobbies will help tremendously. In
addition,
making
platform
sure
reinforcements)
industry
critical scale.
This should, in most cases, be a potential downstream
or lateral diversification opportunity for polymer
processors, as long as there is some synergy in terms of end-market or channel. The processes used are similar in part, and reinforcing the resins they use with glass or other reinforcements to create composites
potentially
share v/s traditional materials.
continue to grow and gain
Q. Can composites offer a natural business diversification opportunity to the polymer processing industry?
the
(producers of equipment, resin and
in at a fair market price will domestic
grow
help players in the value chain
not being dumped, but coming the
help
overall composites market and
imports into the country are
help
may
gain
Q. How do you see plastics and composites being the key to resource-efficient innovations? Composites can help optimise resources in
several ways. When used in automotive applications, for e.g., they reduce overall weight and help
increase mileage, thus reducing consumption of To know more, please subscribe to
POLYMERS Communiqué at subscriptions@ polymerscommunique.com
Get Superior Results from Your Process ...that pay you back fast
TECHNOLOGIES
Precision Measurement & Control Systems for: ► Basis Weight ► Thickness ► Coat Weight ► Barrier Layers ► Moisture
Improve Quality Increase Yield Reduce Waste
► Length & Speed Contact us today to discuss your application and get your free Web Gauging information kit. Measured by Commitment
www.ndc.com/converting AMERICAS: Tel: +1 626 960 3300 info@ndc.com
58
INDIA: Tel: +91 9650752420 ndcindia@ndc.com
An ISO9001 Company
POLYMERS Communiqué l February - March 2016
Ferromatik Milacron India
Introduces world class pipe manufacturing technology with conical twin screw counter
rotating extruders
EXPERIENCE EXTRUSION EXCELLENCE
Coming Soon: Next Generation Parallel Twin Extruders
With the wide range of Plastics Converting Machines comprising of Injection Molding, Blow Molding and Extrusion Systems, Milacron is serving the entire gamut of Plastics Application to its customers
Specific Features Offered : Tungsten Claded Barrel and Tungsten Coated Screws for enhanced life Option available for Nitrided Barrel and Molybdenum Coated Screws Online Screw Cooling and Temperature Regulating System Water Cooled Barrel Water Cooled Die Adaptor Very precise temperature control Suitable for CPVC as well as PVC
Ferromatik Milacron India Pvt. Ltd. - 93/2 & 94/1, Phase-I, G.I.D.C. Vatva, Ahmedabad - 382445, Gujarat, India. salesfmi@milacron.com
www.milacronindia.com
CIN No. U74999GJ1995FTC025783
TC 80
CPVC Output 350 Kgs/hr
+91-79-61341700.
The most important thing is that the global composites industry is about to enter a period of wide-ranging and transformative change, as demands continue to shift and environmental regulations tighten, opines Dr. Sanjay Mazumdar.
Road to 2021
Challenges and Drivers for the Global Composites Industry
G
lobally, the composites industry has recovered
The market is expected to grow to USD 37.4 billion
momentum. As more markets are emerging,
5.1% until 2021 as can be seen in Figure 1. The
from the economic crisis of 2009 and is gaining
the future of this industry looks very promising. The
most important thing is that the global composites
industry is about to enter a period of wide-ranging and transformative change, as demands continue to shift
and environmental regulations tighten. Companies that want to have a successful, long-term growth need to get key strategic decisions right during the
next few years. This article offers a perspective on
where the composites industry is headed. It is based on many discussions and interviews with the OEMs,
composites part fabricators and material suppliers
(Euro 33.7 billion) with an average CAGR of total market value for products made of composite
materials in various segments was USD 78.2 billion
(Euro 70.5 billion) in 2015. The growth in global composites market in 2015 was approximately 5.2% largely due to good growth from wind energy,
aerospace, transportation, marine and construction markets. Asia was the top continent in terms of total composites consumption in 2015.
Changing Dynamics Future markets for composites are expected to
across various markets and regions.
be more fragmented due to growth in emerging
Composites Industry, A Snapshot
projects, Government regulations, urbanisation,
In
fiscal
year
2015,
Dr. Sanjay Mazumdar CEO Lucintel, USA
POLYMERS CommuniquĂŠ l February - March 2016
economies. Population growth, new infrastructural
worldwide
increase in middle class population and the
shipments reached
new horizons in the future. New competitors are
10,448.5 kilotonnes
regional growth.
USD
transportation and construction are the attractive
total
composite materials
green movement will drive composites growth to
23.0 billion pounds or
expected to surface as a result of this anticipated
(kt) with a value of
Within
(Euro 25.0 billion).
segments and offer good growth potential in future.
27.7
billion
the
composites
industry;
aerospace,
61
COMPOSITES
A Special Feature
COMPOSITES
A Special Feature
Union to restrict carbon Value (USD Bn)
dioxide emission to 95 g/
Volume Shipment (Kilotonnes)
km against current value of about 132.2 g/km. Similarly
10,448
29.1
27.7
+3.6%
37.4
+5.1%
in the US, CAFÉ regulation
12,887
dictates
average
fuel
efficiency to 54.5 miles per
10,817
gallon (23.1 km/L) by 2025
against current value of about 28 miles per gallon.
This new challenge has
opened a new opportunity
for development of stronger and 2015
2016
2021
2015
2016
equipments
2021
Figure 1: Global composite materials market forecast by value (USD Bn) and volume shipment (kilotonnes). Note: Global composite materials market is shown at raw materials level such as fibres and resins and not at intermediate materials level such as Prepreg, SMC, BMC and LFT.
For instance, next generation aircrafts will
dioxide emission are putting pressure
will drive growth of advanced composites
manufacturers (OEM) to make their
have higher composites content, which in the aerospace industry. Government efficiency
regulations
and
stringent
on
fuel
carbon
on automotive original equipment
vehicles lighter, without compromising in passengers’ safety. For example, by 2020, it will be necessary in European
lighter
automotive
and
spare
parts - mostly made up of advanced composites.
Automakers such as BMW, Mercedes, Ford and GM
are putting efforts into incorporation of To know more, please subscribe to
POLYMERS Communiqué at subscriptions@ polymerscommunique.com
A Member of Brückner Group
High Quality Film Production Lines: Efficiency, Productivity, Flexibility Visit us at
STRETCHING THE LIMITS
CHINAPLAS 2016 HALL E1 BOOTH K03 Shanghai April 25-28 www.brueckner.com
62
POLYMERS Communiqué l February - March 2016
COMPOSITES
A Special Feature
Advanced Composites
W rld of Opportunities in India
Automotive, marine, railways,
infrastructure and construction industries will be the major
users of advanced composite
materials in the coming years
because, in India, these are the segments of industries that will grow largely, observes Dr. P. K. C. Bose.
A Growing Scenario Advanced composites market in India, is now taking off on a fast
growth path, thanks to Hon’ble Prime Minister of India and his ‘Make in India’ initiative. Composites market, as a whole, has been highly volatile for the previous decades in India and hence, growth
of the composites market has been judged with single digit most of the time. However, in the last few years, this market has witnessed double digit growth; where did this growth derive from
is a still unanswered question for many. But the fact is the basic knowledge, interest and potential has been seen and identified by many, hence the growth rate explained above is very right.
Of course, there is a still very important and unanswered question
i.e. how does one differentiate between composites and advanced
composites? Thus the question, if we can trust the double or single digit growth. Overall awareness on composites is significant in Dr. P. K. C. Bose Vice Chairman and Managing Director Saertex India Pvt. Ltd. (a wholly owned subsidiary of SAERTEX Group, Germany), Pune
64
India for sure, but awareness of advanced composites is still limited when it comes to knowledge and expertise. Application
engineering in the advanced composites sector is very limited
in India, so also the knowledge level on advanced composites has been very limited due to lack of material, data, application, interest and participation, as a whole.
POLYMERS Communiqué l February - March 2016
REMOVE MOISTURE, SAVE POWER AND ENHANCE QUALITY,
WITH OUR INNOVATIVE DRYING TECHNOLOGY.
Every single part of the process is essential for ensuring seamless operations leading up to delivering a final product that is of the highest quality. Our Dehumidifying Dryers ensure your operations run
smoothly by eliminating moisture and its effects thereof; helping you to achieve product quality which not only meets the highest standard but also surpasses it.
B E N E F I T S Fast acting tubular wire heaters
Drying Hopper designed for mass flow & uniform heat/air distribution
Lower energy compared to Twin Tower Dryers
Lower regeneration temperature
Low maintenance, few rotating parts
Selectable dew point control & monitor
Less floor space
Dew point achieved in shortest possible time
Consistent dew point
Nu-Vu
Nu-Vu Conair Pvt. Ltd.
Plot No. 147 & 148, Devraj Industrial Park, Piplaj-Pirana Road, Piplaj, Ahmedabad-382405 T: +91 79 2909 4790, +91 79 2970 8147, +91 93774 83203, +91 93774 83205 E: marketingindia@conairgroup.com | W: www.conairgroup.com/india
COMPOSITES
A Special Feature
Composites, A Game Changer As mentioned, the advanced composites market is now
becoming a game changer, specially in advanced applications
08.00
such as:
Wind energy
l
Aeronautical
l
Defence
l
Automotive
l
l l l l
Marine
Railways
Infrastructure
Construction
Wind energy is the major segment of the industry having
09.00
strong hold and knowledge on advanced composites in
India. The advanced composites are redefined in many ways; transformation from traditional woven material
and chopped strand material, it has over grown to the
high-end technological product like non-crimp fabrics or stitch bonded fabrics which have many advantages,
technically and commercially and hence, the wind industry is the largest volume users of advanced composites in
09.30
India today.
Of course, industry segments such as defence and
aeronautical are major users of CNCF (Carbon Non-Crimp Fabrics) which are again one step ahead as compared to GNCF (Glass Non-Crimp Fabrics). Automotive,
marine,
railways,
infrastructure
and
construction industries will be the major users of advanced
composite materials in the coming years because, in
10.00
India, these are the segments of industries that will grow
largely. Now, let us take the construction and infrastructure industries alone and the applications for advanced composite materials such as glass fibre fabrics which are the ideal replacement of steel and metal. At the same time, one cannot forget the major advantages of advanced
composite materials for lightweight mobility solutions, specially in the areas of automotive, marine and railways
12.00
due to the following advantages:
Much lighter than steel and metal and much stronger
Will achieve fuel efficiency considerably
Carbon emission will be reduced drastically
Less wear and tear, hence enhanced life
No rust and corrosion
Fire retardant
Less repair and maintenance cost
Longer life
l
l l l l
12.00
l l l
as well
To know more, please subscribe to
POLYMERS CommuniquĂŠ at subscriptions@ Figure 1: In 4 hours, 1 km installation was accomplished with 70 years of life.
66
polymerscommunique.com
POLYMERS CommuniquĂŠ l February - March 2016
COMPOSITES
A Special Feature
CFRPs for Structural
RTM demonstrator (front side of the demonstrator).
Components in Automobiles
Evaluation of the potential of thermoset and thermoplastic process technologies for high-volume production of carbon-fibre-reinforced plastics (CFRPs) automotive parts, presents Michael Karcher and Prof. Dr.-Ing. Frank Henning.
Local reinforcement for the compression moulding processes, made from UD tape.
Project Overview
composites, selection of the matrix system, the
The project MAI Qfast within the MAI Carbon Cluster
(a cluster Initiative programme), is carrying out a systematic evaluation of the potential of carbon-
fibre-reinforced plastics (CFRPs) in combination with different manufacturing process technologies
including design, manufacturing and benchmarking. Five different processes for CFRPs have been used to create structural components in automobiles. Both,
thermoset and thermoplastic matrix systems have been benchmarked and processed either by resin
transfer moulding (RTM) or compression moulding.
The project consortium consists of BASF as a material and
semi-finished
the
Fraunhofer
product
supplier,
Institute for Chemical Technology
for
material and process development and in Michael Karcher
Prof. Dr.-Ing. Frank Henning Deputy Director Fraunhofer ICT Director Polymer Engineering
Fraunhofer Institute for Chemical Technology ICT Polymer Engineering, Germany
68
particular, the two independent
OEMs
project
Qfast
Audi and BMW. The MAI
will answer questions
about carbon fibre
most suitable processing technology and the
resulting cycle time, energy need, cost effectiveness as well as static and dynamic performance of these components.
Ambitious Floor Panel Structure as Demonstrator As the main focus of MAI Qfast is a comparison of the
specific potential of thermoset and thermoplastic CFRPs for large-scale production, it was important
that the chosen demonstrator - an ambitious floor panel structure - could be produced using either RTM or compression moulding technology.
Five different CFRP-materials and three different processes (RTM, SMC and LFT-D) have been developed for benchmarking, for a demonstrator
derived from a floor panel structure. The influence of the technology, the material and the component geometry on the cost and performance and
the applicability in large-volume production is of major importance for OEMs and their To know more, please subscribe to
POLYMERS CommuniquĂŠ at subscriptions@ polymerscommunique.com
POLYMERS CommuniquĂŠ l February - March 2016
TOOL TIP
Engineering and Tooling
The Next Future
To supply global clients as a ‘one-stop-shop’, focus should be placed on human resources involving training, re-qualification, mobility, labour shifts and new professions along with co-operation between the industries, universities and research centres will be critical. Rui Tocha General Manager POOL-NET - Portuguese Engineering and Tooling Cluster, Portugal
I
n the next decade, we could face several
The world will face the need to reinforce industry
as a key point the new industrial revolution –
at the same time, problems with employment,
disruptions in different economic domains, having
the Digitising Industry – also called as INDUSTRY
4.0. This revolution will use automation with a very high level of integration and focus on efficiency and productivity, supported on the concept - ‘Zero Defects
Production’ - to increase efficiency, competitiveness and economic growth.
competitiveness (capital intensive) trying to solve,
internationalisation and global co-operation, to supply To know more, please subscribe to
POLYMERS Communiqué at subscriptions@ polymerscommunique.com
It’s our country, let’s keep it clean!
70
POLYMERS Communiqué l February - March 2016
GROWTH ZONE
Indian Plastics Industry 20 kgs by 2020
“India’s per capita consumption of virgin plastic is 11 kgs and recycled is 3.8 kgs. The investment required in projects for the next 5 years is to the tune of USD 10 billion”, points out Arvind M. Mehta. India: Per Capita Consumption, in Comparison
The processing capacity is 30 MMT.
The processing capacity CARG is 13% during
The
Investment in machinery is USD 5 billion.
Investment required for the next 5 years is
The size of the plastics and polymer industry
l l
Global economic growth is generally interlinked
to petrochemical consumption where plastic is
l
Plastic processing is the pillar of the economy
l
an important partner.
in most of the advanced economies. The per
l
whereas India’s is 11 kgs, China is 38 kgs,
l
capita consumption of the world is 28 kgs
Brazil is 32 kgs, while USA, Germany, UK, Italy, Spain, Australia, Japan, Korea and Taiwan is over 100 kgs. It can be seen that India’s per
capita consumption is one of the lowest in
Asia, implying that India has a big potential to grow.
the last 5 years. number
of
plastics
machinery
manufacturing units in India is 200+.
around USD 10 billion (Project Investments). is Rs. 1,44,000 crore.
Indian Technology, Competing Globally The
plastics
machinery
manufacturing
in
India is well developed. Use of world leading technologies
An Overview of the Indian Processing Industry
and
our
technology-savvy
entrepreneurs, including plastic processors, make us proud. Things have changed over the
India’s per capita consumption of virgin
The virgin polymer consumption in the year
The number of converting / processing units;
machines, thermoforming machines, auxiliary
unorganised sector is 20,000.
mould temperature controllers & chillers, bag
l
l
l
l
plastic is 11 kgs and recycled is 3.8 kgs. 2014 - 15 is 14 MMT.
in the organised sector is 30,000 and in the The
number
is 113,000.
of
processing
machines
past decade. The industry has witnessed good growth in exports across compounding lines, tape
lines & looms, multilayer film plants, pipe plants, injection moulding machines, rotomoulding
equipment such as material conveying systems, making machines etc.
Polymer Manufacturing Capacity The manufacturing capacity of key polymers
Arvind M. Mehta Chairman, Governing Council – AIPMA Past President - AIPMA & Plastindia Foundation Chairman, Empowerment Committee Plastindia International University, Mumbai
72
is being continuously augmented to meet the To know more, please subscribe to
POLYMERS Communiqué at subscriptions@ polymerscommunique.com
POLYMERS Communiqué l February - March 2016
IN PERSPECTIVE
T
he Indian petrochemical industry has been and
the efforts, discuss, deliberate and unscramble
to the country’s economy and it is also an
industry that was ideally called as, ‘Petrochemicals
continues to be one of the vital contributors
underlying catalyst in the development of certain
areas of economic importance like agriculture, automotive,
consumer
durables,
infrastructure,
Vision 2025 – Challenges and Opportunities’.
A Power-packed Opening
engineering, food processing etc. Although the
The welcome address of the conclave was initiated by
the GDP growth rates of India, recent developments
Indian Oil Corporation Ltd, New Delhi. He touched
petrochemical industry has consistently outperformed
consequent to advantaged feedstock availability in the US and Middle East have led to a situation where
announced investments by Indian companies on production of petrochemical building blocks have
fallen short of future requirements. In the absence
of sufficient investments, big shortfalls in the main buildings blocks like ethylene and even propylene
are projected – to the order of 9 MMTPA for ethylene and 3 MMTPA for propylene by 2025.
Building blocks shortages of such levels will lead to India becoming a very large importer of these products and hence result in a missed opportunity
D. Sen, Director, Planning & Business Development,
upon various critical aspects of the petrochemical industry. He said that the petrochemical industry in
India has been one of the fastest growing industries in the country. Ever since its beginning, the industry has shown an enviable rate of growth where plastics
and polymers play a key role in its growth potential
with high GDP growth rates underpinned by strong key macro-economical and social drivers. Globally,
the Indian petrochemical industry is expected to register a robust growth in the decade ahead with its continuous efforts towards enhancing a competitive advantage.
for the Indian downstream petrochemical industry
D. Sen further added that for the successful growth
insulated thereby from commercial shocks and raw
support from various key strategic drivers and
to grow while remaining self-sufficient upstream and
material shortages, which would ultimately hamper
the returns on the investment and hence, orderly growth. The fifth edition of Indian Oil Petrochemical
Conclave, held at Renaissance Convention Centre, Mumbai on 4th February, 2016, brought together
experts, innovators, trend-setters from the industry,
Nationally and globally under one roof to encourage
74
various pressing issues concerning the petrochemical
of the Indian petrochemical industry, it will require enablers; especially good infrastructure and logistics
networks across the country. The sector will also
require reliable and competitive utilities, good refinery and petrochemical integrations, high chemical unit
operating rates and reliability of major process units. Despite the reports of India making good quality
progress with availability of skilled manpower and
POLYMERS Communiqué l February - March 2016
IOCL Conclave
Insight to Knowledge The Indian Oil Petrochemical Conclave, ‘Petrochemicals Vision 2025 – Challenges and
Opportunities’, for the fifth year witnessed overwhelming participation from National and
global industry experts who engaged in vibrant discussions on a wide range of issues related to petrochemicals, the new global economic order, India’s focus on polymers, the impact of crude plunge and much more. A post-event report.
training, free trade agreements with very important countries and regions are
India’s petrochemical industry valued at approx. USD 40 billion, expected to grow at 14%, to touch USD 100 billion by 2020.
Success @ Shaily GROWTH
crucial for the development of special petrochemical zones.
India’s petrochemical industry is presently
valued at approximately USD 40 billion and is expected to grow at 14% annually
over the next few years and touch
USD 100 billion by 2020. The global petrochemicals market was valued at USD 472.06 billion in 2011 and is expected to reach USD 791.05 billion by
Indian Oil plans to invest Rs. 7,650 crore to set up a petrochemical complex at its Paradip refinery.
IOCL MEGA Success @ Shaily
INVESTMENT
2018, growing at a CAGR of 6.7% from 2012 to 2018.
B. Ashok, Chairman, Indian Oil Corporation
Ltd., New Delhi in his keynote address said that India, the third largest economy in the
world, has witnessed an unprecedented level of economic expansion in the
past two decades. Also, the theme, ‘Petrochemicals Vision 2025 - Challenges
and Opportunities’ was structured in such that it would lead to the emergence of
and ethylene derivatives complex to
of petrochemicals have been Hindustan
monoethylene glycols (MEG). B. Ashok
with Mittal Energy Ltd. (HMEL) and
manufacture around 350,000 tonnes of
added that Indian Oil is now looking at new projects for acrylic acid, acrylates, oxo-alcohol besides
and
ethylene
hydrocarbon
derivatives
resin,
and
expansions in the existing product line.
Petroleum Corporation in collaboration MRPL. ONGC Petro additions Ltd. (OPaL)
is also expected to join the league during the current fiscal, he mentioned.
Highlighting further on the growth of the
petrochemicals industry in India, he went
an outline for the petrochemical industry.
The Chief Guest, Dharmendra Pradhan,
on to say that the petrochemical scenario
identified as the prime driver of future
Charge),
&
the fray with big ticket investments of
the inaugural address said that the
in the various segments of petrochemicals
petrochemicals has ushered in many
raw materials. He also spoke about Indian
The petrochemical industry has been growth by Indian Oil and the company
plans to invest Rs. 7,650 crore in setting
up a petrochemical complex at its Paradip refinery in Odisha in the next 3 - 4 years.
The complex will have a 700,000 tonnes per annum polypropylene (PP) plant
76
Hon’ble Minister of State (Independent
can be defined as Indian Oil’s entry into
Natural Gas, Government of India
in
around Rs. 20,500 crore (USD 4.12 billion)
entry of oil and gas PSUs in the field of
including detergent, polyester and plastic
big ticket petrochemical projects in the
Oil’s planned future investments worth
Ministry
of
Petroleum
country. The recent entrants in the field
Rs. 30,000 crore in various petrochemical
POLYMERS Communiqué l February - March 2016
Magazin: Polymer Communiqué Sprache: EN (IND) Format: 180x260 mm Thema: Temperierelemente AS: 24.02.2016
06.–09.04.2016
Hall 2A, Stand D06 Bangalore (IND)
CoMPrEhENSIvE ExPANSIoN oF ThE tEmpEraturE rEgulation componEnts Over 40 practical new items, fOr example: E 2252 Cooling bridge for easy deflecting on mould E 2165 Manifold E 2194 Hose clamp and E 21949 Hose clamp from stainless steel
Meusburger India Pvt Ltd | # 473D/5A | 13th Cross | 4th Phase Peenya 2nd Stage | Bangalore – 560058 T 00 91 (0) 80 / 28365529 | F 00 91 (0) 80 / 28365530 sales@meusburger.in | www.meusburger.in
order now from our online shop!
streams. create
These
massive
opportunities
–
projects
direct
would
employment
employment
to around 10,000 people and indirect
employment to around 1 million people. Further, these investments would spur
the setting up of around 800 - 1000 downstream converting industries in the MSME sector, propelling the growth
of entrepreneurial landscape. These mega projects when fully operational
are expected to also save huge valuable foreign exchange over their entire life cycle. S.
Mitra,
Executive
Director,
Petrochemicals, Indian Oil Corporation
Ltd, New Delhi delivered a presentation on ‘Petrochemicals: Vision 2025 – Challenges and Opportunities’. In his presentation,
he stressed upon the challenges and opportunities in this sector. He conveyed
that India is already the 3rd largest polymer
consumer globally, where petrochemical investments
seek
a
sustainable
advantage. He explained that energy and
feedstocks make up 60 - 70% of the costs of chemical production and the proximity
to demand growth is essential without
distinct cost or technology advantage where trade access is also important. Indian
petrochemical
industry
is
currently faced with challenges like price
fluctuation that impacts the profitability of naphtha based petrochemicals and competition from gas / coal based
petrochemicals. To enhance availability
of low cost polymers in India, few initiatives that industry can take to compete globally is secure off-take
agreements with upcoming crackers in USA, Middle East and investing in downstream derivative unit or through reverse SEZ route and invest in extracting feedstock from
like
toluene
naphtha
cracker
PyGas. According to him a
few of the challenges faced
by refineries include high operating
costs
(energy),
no plug and play system
for utilities, high logistics costs,
poor
infrastructure
for raw material / product movement at ports / roads etc.,
high capital costs,
from
Middle
besides cost competition China.
S.
East
Mitra
and
further
The Chief Guest, Dharmendra Pradhan, Hon’ble Minister of State (Independent Charge), Ministry of Petroleum & Natural Gas, Government of India with Deep Kumar Upadhyay, Embassy Nepal, New Delhi.
concluded his presentation
highlighting that South Asia will have large deficits of feedstock. Although refining capacity is surplus, naphtha
availability at a single location is not enough to set up world scale
Through the Day The inaugural session was followed by extensive brainstorming sessions, each
with a Chairperson supported by a galaxy of speakers. The sessions focus included:
Session 1: Petrochemical Markets –
Session 2: Innovation and Beyond
Breakout
naphtha crackers. He opined that
l
or ethane, naphtha and /or condensate
l
either products have to be imported have to be imported as feedstock
l
and that India needs new mixed feed
crackers which can accept ethane as feedstock.
Future projects to create massive employment opportunities – direct employment ~ 10,000 people and indirect employment ~ 1 million people.
Challenges & Opportunities Session:
Redefining
Sustainability – 2016 & Beyond; A Common Future, A Common Path
l
Session 3: Breaking Barriers for Growth Facilitating Petrochemical Sector
The closing remarks and vote of thanks
yliahS @ sseccuS
HUMAN CAPITAL
was given by R. V. Prabhu, Dy. General Manager
(Petrochemicals
–
Sales),
Indian Oil Corporation Ltd. He said
that petrochemicals sector is a major segment of the manufacturing industry
and plays a fundamental role in various downstream industries. He was pleased
to learn when the speakers discussed
India is 3 largest polymer consumer, globally. rd
on the finances in the petrochemical
yliahS @ sGLORY seccuS INDIAN
industry which he considered important not only to this industry, but also to other industries. The conclave was followed by a networking dinner.
78
POLYMERS Communiqué l February - March 2016
EVENT
CHINAPLAS
an Event Beyond Innovation “CHINAPLAS 2016, through its show and concurrent events, will showcase the macro trends of the current manufacturing sectors where innovation, automation and sustainability are essential elements to take the industry to the next level”, says Ada Leung, General Manager, Adsale Exhibition Services Ltd.
C
HINAPLAS will be celebrating its
In
exhibition to be held between
Federation to organise Industry 4.0
The
show
is
of
exhibition
also its implementation and future developments,
area.
Design X Innovation
Concurrent Events
Building on the success of ‘Design X
Medical Plastics Conference
Innovation’ at CHINAPLAS 2015, this
The global medical products industry has
event will come around in Shanghai
never been more dependent on plastics
in
and rubber suppliers to help them meet of
challenging one.
In response to the rapid development ADVERTORIAL
of this area, CHINAPLAS 2016 will organise
the
2nd
Medical
Plastics
Conference between 25th and 26th
April, 2016 in an attempt to give
the visitors an insight into the new
technological breakthroughs and latest developments on medical plastics and
their applications on medical devices, medical disposables and packaging.
POLYMERS Communiqué l February - March 2016
event’s
Exclusive
to the visitors on how design and
products have used polymers as their is a lucrative market, yet also the
The
CHINAPLAS to give new perspectives
medical
major component. Medical plastic
2016.
Partner - BASF will join hands with
present day’s healthcare needs. Over kinds
practical
to follow.
theme for CHINAPLAS 2016.
different
providing
solutions for the manufacturing sectors
‘Greenovation for a Smart Future’ is the
90
up
plastics and rubber industries, but
140,000 professional buyers, on over sq.m.
teamed
about Industry 4.0 in the context of
expected
to have over 3,200 exhibitors and 240,000
Adsale
the audience a better understanding
New International Expo Centre, Pudong, China.
light,
conference which will not only give
25th and 28th April, 2016 at the Shanghai PR
this
with VDMA - German Engineering
30th edition in the forthcoming
plastics technology can together drive
innovation, that in turn, helps to make
Industry 4.0 Conference The concept of Germany-led Industry 4.0 has taken the world by storm since
its introduction in 2014. It has laid down a roadmap of the fourth industrial
revolution for realising ‘Smart Factory’ that the world has been pursuing of. As Chinese economy matures, the Chinese
a customer more successful and leads
to a more sustainable future. ‘Design X Innovation’ will engage and inspire the
audience in an array of offers including display gallery, open forum led by
revered international experts as well as interactive activities.
‘Made-
There are two types of entry tickets –
automation in a bid to help Chinese
four-day pass (RMB 50). For details,
Government
has
launched,
in-China 2025’ to promote industrial enterprises the world.
to
stay
competitive
in
a
one-day
pass
(RMB
30)
and
please visit the official show website at www.ChinaplasOnline.com.
79
Events CAPINDIA 2016
EXPO PLAST PERU 2016
20th – 22nd March, 2016 Bombay Exhibition Centre Goregaon, Mumbai, India
IPLEX 2016
K 2016
3rd – 6th May, 2016 Jockey Exhibition Centre, Lima, Peru
26th – 28th August, 2016 Cochin International Airport Limited (CIAL) Trade Fair and Exhibition Centre, Kochi, India
19th – 26th October, 2016 Düsseldorf, Germany
P4 Expo
PPPEXPO Africa
INDIA CHEM 2016
Plast Show 2016
5th – 7th April, 2016 India Expo Mart, Greater Noida, Delhi, India
16th – 18th June, 2016 The Dome, Nairobi, Kenya
1st – 3rd September, 2016 Bombay Exhibition Centre, Mumbai, India
26th – 29th November, 2016 The Gujarat University Convention & Exhibition Centre, Ahmedabad, India
VINYL INDIA 2016
PackPlus 2016
INDOPLAS
10th Plastivision India 2017
21st – 22nd April, 2016 Hotel Grand Hyatt, Mumbai, India
27th – 30th July, 2016 Pragati Maidan, New Delhi, India
7th – 10th September, 2016 JI Expo, Kemayoran, Jakarta, Indonesia
19th – 23rd January, 2017 Bombay Exhibition Centre, Mumbai, India
Chinaplas 2016
SRI LANKA PLAST
VietnamPlas 2016
Plastindia 2018
25th – 28th April, 2016 Shanghai New International Expo Centre, Shanghai
5th – 7th August, 2016 BMICH, Colombo, Sri Lanka
28th September – 1st October, 2016 Saigon Exhibition & Convention Center - SECC, Ho Chi Minh City, Vietnam
7th – 12th February, 2018 Gandhinagar, Gujarat, India
80
POLYMERS Communiqué l February - March 2016
ONGC ONGC Petro Petro additions additions Ltd Ltd Redefining Redefiningthe theFuture Future
creating creating the the building building blocks blocks for for tomorrow tomorrow
HDPE HDPEDedicated Dedicated (340 (340kTPA) kTPA)
BENZENE BENZENE (150 (150kTPA) kTPA)
BUTADIENE BUTADIENE (115 (115kTPA) kTPA)
PyGas PyGas (165 (165kTPA) kTPA)
POLYPROPYLENE POLYPROPYLENE (340 (340kTPA) kTPA)
HDPE HDPE/ /LLDPE LLDPE Swing Swing (720 (720kTPA) kTPA)
CBFS CBFS (70 (70kTPA) kTPA)
The TheOPaL OPaLmega megapetrochemical petrochemicalcomplex complex mothering motheringa aDual DualFeed FeedCracker, Cracker,isisthe the first firstofofitsitskind kindininSouth-Asia South-Asiatotoproduce produce a awide widespectrum spectrumofofpetrochemicals. petrochemicals.
The Themega megapetrochemical petrochemicalcomplex complexatat Dahej Dahej will will roll roll out out the the finest finest petrochemicals petrochemicals for for the the Indian Indian and and International Internationalmarkets. markets.
ONGC ONGC Petro Petro additions additions Ltd Ltd 1st 1stFloor, Floor,'Omkara', 'Omkara',Near NearSai SaiChowkdi, Chowkdi,Manjalpur, Manjalpur,Vadodara Vadodara- -390 390011 011Gujarat Gujarat• •www.opalindia.in www.opalindia.in