POLYMERS Communiqué Feb - Mar 2016

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.

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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.

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

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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

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

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

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Delivering Advantages

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

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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

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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

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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

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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

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POLYMERS CommuniquĂŠ l February - March 2016

53

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54

POLYMERS Communiqué l February - March 2016

Speciality Colour Masterbatches l

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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

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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

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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

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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

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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

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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

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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

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PyGas PyGas (165 (165kTPA) kTPA)

POLYPROPYLENE POLYPROPYLENE (340 (340kTPA) kTPA)

HDPE HDPE/ /LLDPE LLDPE Swing Swing (720 (720kTPA) kTPA)

CBFS CBFS (70 (70kTPA) kTPA)

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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.

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