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Volume 16 Issue 6 February - March 2016
CHIEF EXECUTIVE OFFICER Deepak Lamba CHIEF FINANCIAL OFFICER Subramaniam S PUBLISHER, PRINT & PRODUCTION CONTROLLER Joji Varghese EDITOR & CHIEF COMMUNITY OFFICER | Niranjan Mudholkar niranjan.mudholkar@wwm.co.in +91 9819531819 ASSISTANT ART DIRECTOR | Sanjay Dalvi sanjay.dalvi@wwm.co.in BRAND PUBLISHER | Rishi Sutrave rishi.sutrave@wwm.co.in +91 9820580009
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Food giver!
here is a blessing cum prayer which many devout Hindus still utter after having their meals. “Anna daataa sukhi bhava!” It simply means – “May the giver of food be happy!” I am sure some version of this blessing-prayer would also exist in other cultures and faiths as well. But it is all the more significant in an agriculturally driven country like ours. Yes, you read it right – ‘agriculturally driven country like ours!’ India still remains that and thankfully so. And this is not too belittle any other sector. In fact, as Anil B. Jain, MD, Jain Irrigation Systems Ltd. (JISL) also points out in this issue’s cover story, if agriculture does well, then it will have a positive impact on the industrial sectors as well. Jain Irrigation was started by Dr. Bhavarlal H. Jain with the objective of helping the Indian farmer become a viable and significant component of not just the food ecosystem but also of the community as a whole. The mission is still on, according to his son Anil. This quest is propelled by the efforts to make India’s farms more productive and valuable.
“It is indeed interesting and refreshing to note that plastics can be effectively used as means for bringing food security and water security, as well as for fighting against climate change.”
And the reason ‘The Economic Times Polymers’ magazine is writing about this quest is because JISL has been utilising ‘plastics and polymers’ to accomplish this mission. It is indeed interesting and refreshing to note that plastics can be effectively used as means for bringing food security and water security, as well as for fighting against climate change – three of the most important issues of our times.
Editor & Chief Community Officer
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CONTENTS 30 8
COVER STORY Farmer’s Friend
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News
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Innovation
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Training: Collaboration for skill development
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Market: Driving high performance
40
Research: Life imitating Polymer
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Event Calendar
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Industry: A stroll in the ‘park’!
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Products
PACKAGING The role of packaging in product safety
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REPORT The new dawn of PVC
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RESEARCH Breakthrough!
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PACKAGING Packed for success
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NEWS NATIONAL
Petrochemical complex in Assam dedicated to the nation by PM Modi
IndianOil organises the 5th Petrochemical Conclave
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ndianOil organised the 5th IndianOil Petrochemical Conclave at Mumbai recently to deliberate on the theme ‘Petrochemicals Vision 2025 – Challenges and Opportunities’. Speaking on the occasion, Chief Guest, Minister of State (Independent Charge), Ministry of Petroleum & Natural Gas, GoIndia, Dharmendra Pradhan, said that the entry of Oil & Gas PSUs into the field of Petrochemicals has ushered in many big ticket petrochemical projects in the country. He went on to say that the
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rime Minister Narendra Modi recently dedicated to the nation, Brahmaputra Cracker and Polymer Limited, a petrochemical complex, at Lepetkata, near Dibrugarh. He also dedicated to the nation, the wax plant of Numaligarh Refineries Limited. Speaking on the occasion, the Prime Minister said that the two projects being dedicated to the nation are important for two reasons – (a) for the value addition they would achieve for natural raw materials; (b) for the employment opportunities they would create for the youth of Assam. The Prime Minister reiterated that eastern India must develop, for the all-round development of India. In this context, he said the Union Government is paying special attention to the North-Eastern region by boosting infrastructure and connectivity. The Prime Minister said that the initiatives of the Union Government, including MUDRA and Start-up India, were aimed at creating fresh opportunities for the youth.
E-waste collection center established
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co Recycling Limited (Ecoreco) has set up E-Waste Collection Centre at Royal College, Mira Road in Maharashtra. Ecoreco has set up three bins in the college premises. This arrangement will facilitate collection of hazardous e-waste from generators of e-waste and get them disposed of in an environment friendly manner. Royal college is the first college to set up E-Waste collection bins. College’s teaching and nonteaching staff is creating awareness amongst the students through guest lecturers and seminars.
watershed moment in the Petrochemical scenario can be defined as IndianOil’s entry into the fray with big ticket investments of around Rs20,500 crore in the various segments of Petrochemicals. He also spoke about IndianOil’s planned future investments worth Rs30,000 crores in various petrochemical streams. These projects would create massive employment opportunities. Also, 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. B Ashok, Chairman, Indian Oil Corporation Ltd., highlighted that Petrochemicals have been identified as a prime driver of future growth by IndianOil. He shared IndianOil’s 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 and ethyelene derivatives complex to manufacture around 350,000 tonnes of mono-ethyelene glycols (MEG). He added that IndianOil is now looking at new projects for acrylic acid/ acrylates, oxo-alcohol and hydrocarbon resin, besides ethylene derivatives and expansions in the existing product line. The event witnessed overwhelming participation from global industry experts who engaged in vibrant discussions on a wide range of issues.
8 | The Economic Times POLYMERS | February-March 2016
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NEWS NATIONAL
Milacron displays injection molding prowess at a tradeshow in Gujarat
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ilacron Holdings Corp., a leading industrial technology company serving the plastics processing industry were proud participants at the 7th Annual Plexpoindia tradeshow in Gandhinagar, Gujarat, India. The tradeshow ran from January 7th to 11th. Plexpoindia, held every 3 years, highlights the growth and development of the thriving plastics industry in India. Throughout the show, Milacron operated a robust 150 Ton cPVC Line Servo machine that will support India’s booming construction and infrastructure industry. Shirish Divgi, Managing Director Milacron India (Ferromatik brand) stated, “Milacron was proud to participate in Plexpoindia 2016. The show was a great opportunity for the Indian market to see first-hand the capabilities of Milacron’s portfolio. We look forward to continuing our focus on the growing Indian market and manufacturing leading industry technology for not only India, but the entire globe.” Milacron continues to push the
boundaries of possibilities in plastics with breakthrough products from leading brands including Milacron, Mold-Masters, DME, Ferromatik, Uniloy and CIMCOOL.
Clariant breaks ground for new healthcare packaging plant in Cuddalore, Tamil Nadu
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lariant recently performed the groundbreaking ceremony of a new manufacturing plant in Cuddalore, for moisture-control products, intended for the pharma industry. In December 2015, Clariant had announced plans to invest CHF 10 million in this Healthcare Packaging plant, which will support the growing generic pharmaceutical industry in India. The investment will be implemented through its wholly owned 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 by rapidly addressing customer needs,” said Christian Kohlpaintner, member of the Clariant Executive Committee. The new plant will initially produce desiccant canisters and packets, which are inserted into pharmaceutical packaging to control moisture and protect the stability of the medicine during shelf life. The desiccant production area will be Clean Room Class 100,000 and certified ISO 8. It will be compliant with all relevant cGMP and US FDA standards. “This facility will enable us to expand current capacities and provide easy access to potential as well as existing customers in the pharma packaging segment in the India region,” said Deepak Parikh, Clariant Region President India.
Wide scope for industries based on re-cycling of plastics waste
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laborating the important role of plastics industry in Indian economy, Samir Kumar Biswas, Joint Secretary from the Department of Chemicals and Petrochemicals, Govt. of India has advised for a holistic approach to the industry. He was speaking at the 2nd edition of the conference on Plastic Packaging – The Sustainable choice has been organized jointly by FICCI, Department of Chemicals & Petrochemicals and Organisation of Plastics Processors of India in New Delhi recently. Biswas said that Plastics are chemically inert substances and they do not cause either environmental or health hazards. If plastics can be collected and disposed off or recycled as per laid down guidelines/rules then the issue of plastic waste can be suitably addressed. In fact there is wide scope for industries based on re-cycling of plastics waste. Prabh Das, Chairman, FICCI National Petrochemical Committee, MD & CEO, HPCL-Mittal Energy Limited focussed on the important role that the recycling industry can play to make the sector sustainable. KK Seksaria, President, Plastindia Foundation emphasize that the growth of the industry must come with greater realization of and increased attention to the safety, health and environmental standards.
10 | The Economic Times POLYMERS | February-March 2016
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NEWS INTERNATIONAL
Songwon’s new manufacturing plant in Kizad, Abu Dhabi operational
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designed to allow for fuongwon Industrial ture expansion to meet Co., Ltd. has recently the increasing demand announced that the new for OPS products in the state-of-the-art joint Middle East region and venture manufacturing beyond. “This region is plant in Abu Dhabi is one of the fastest grownow operational. The faing markets for polyolecility is located in Khalfins and already a major ifa Industrial Zone Abu consumer of OPS,” says Dhabi (Kizad), owned Maurizio Butti, Chief and managed by Abu Operating Officer, SongDhabi Ports – the master won Industrial Co., Ltd. developer, operator and “With this new facility, manager of ports in the Songwon is in a stronger Emirate. The new plant position to better meet is dedicated to manufacOfficials at the opening ceremony. Photo: Songwon Industrial Co., Ltd. the needs of current and turing One Pack Systems future customers in the Middle East. Now we are able to offer (OPS) − multicomponent, tailor made blends of additives in our customers the OPS products they demand combined with a pelletized form and then packaged in a clean, dust free enviall the advantages and service of a leading global supplier, with ronment, ready for shipping. With an initial capacity of 7’000 50 years’ experience in breakthrough solutions.” MT per annum, the manufacturing facility was specifically
US Farathane expands into Asia with Boston Plastics acquisition
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S Farathane Corporation has acquired Boston Plastics, a Shanghai headquartered manufacturer of plastic injected molded components and assemblies for the automotive, industrial, and consumer end-markets. The acquisition of Boston Plastics, alongside the previously announced acquisition of Tepso Plastics (January 2016), further accelerates US Farathane’s strategic initiative to be a global supplier to its customers. “We are very excited about the acquisition and believe it presents an extraordinary opportunity to be a part of US Farathane’s global business. The acquisition will enable us to increase US Farathane’s immediate reach into the China market, while simultaneously opening up new business with direct OEMs.” Boston Plastics’ three production facilities in China (Shanghai, Taicang, and Changchun), together with its highly experienced management team, provide US Farathane with a presence to serve the Asian market and a direct Chinese footprint to serve the largest global automobile market in the world.
Dow announces start-up of new Texas Propylene production facility
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he Dow Chemical Company has recently announced that its new worldscale propane dehydrogenation unit (PDH) located at the Company’s Oyster Creek site in Freeport, Texas, has begun commercial operations. The start-up of this unit is the most recent milestone in Dow’s comprehensive plan to further integrate its U.S. operations with cost-advantaged feedstocks from increasing supplies of U.S. shale gas and create longterm, competitive advantage for Dow’s Performance Materials, Consumer and Infrastructure Solutions businesses. “This milestone solidifies our firstmover advantage by bringing our investments in the U.S. Gulf Coast to fruition,” said Andrew N. Liveris, Dow’s chairman and chief executive officer. “This is another important step in executing Dow’s global growth strategy, further increasing our feedstock flexibility by harnessing the value of integration and positioning the Company for growth in attractive, fast-growing markets.” Capacity for the new propylene production facility is 750 KTA, making it the largest on demand propylene facility of its kind, and the largest and most advanced Honeywell UOP Oleflex unit ever built.
12 | The Economic Times POLYMERS | February-March 2016
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NEWS INTERNATIONAL
New polymer developed by researchers can lift thousand times its mass
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linkers to connect the indiesearchers at University of vidual polymer strands. AnRochester have developed thamatten’s group discovered new polymer that can lift 1000 that linkers inhibit—but don’t times its mass. The material destop—crystallization when the veloped by Anthamatten and material is stretched. By altergraduate student Yuan Meng is ing the number and types of a type of shape-memory polylinkers used, as well as how mer, which can be programmed they’re distributed throughto retain a temporary shape unout the polymer network, the til it is triggered—typically by Rochester researchers were able heat—to return to its original to adjust the material’s stabilshape. “Tuning the trigger temity and precisely set the meltperature is only one part of the A time-lapse photo of a new shape-memory polymer reverting to its original ing point at which the shape story,” said Anthamatten. “We shape after being exposed to body temperature. change is triggered. Having a also engineered these materials Photo by Adam Fenster/University of Rochester polymer with a precisely tunto store large amount of elastic able trigger temperature was only one objective. Of equal energy, enabling them to perform more mechanical work durimportance, Anthamatten and his team wanted the material ing their shape recovery.” The key to developing the new polyto be able to deliver a great deal of mechanical work as the mer was figuring out how to control crystallization that ocshape transforms back to its permanent shape. Consequently, curs when the material is cooled or stretched. As the material they set out to optimize their polymer networks to store as is deformed, polymer chains are locally stretched, and small much elastic energy as possible. Anthamatten’s shape-memory segments of the polymer align in the same direction in small polymer is capable of lifting an object one-thousand times its areas—or domains—called crystallites, which fix the mateweight. For example, a polymer the size of a shoelace—which rial into a temporarily deformed shape. The ability to tune weighs about a gram—could lift a liter of soda. the trigger temperature was achieved by including molecular
Masterbatch market is projected to reach US$ 12.61 billion by 2020
Clariant and CB&I to design world’s largest single-train dehydrogenation unit in China
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ccording to a report by Research and Markets, the masterbatch market is projected to reach US$ 12.61 Billion by 2020, registering a CAGR of 7.0% between 2015 and 2020. The global masterbatch market is driven by increased demand from the end-use industries such as packaging, building & construction, consumer goods, automotive, and textiles. Asia-Pacific, with its growing economy and rapidly expanding commercial and industrial base is projected to witness the highest growth in the masterbatch market between 2015 and 2020. Automotive is the fastest-growing market for masterbatch. Plastics are commonly used in the automotive industry for vehicle interiors. Lately, the use of plastics for exterior applications has also increased. Some of the vehicle components made of plastics are bumpers, seating, dashboards, windows, screens, light covers, air bags, insulation, seat belts, and door panels. Thus, the increasing use of plastics in the automotive industry is driving the demand of masterbatch. Moreover, the growing automotive industry is also driving the masterbatch market in Asia-Pacific and South America.
lariant has been awarded a contract by Hengli Petrochemical (Dalian) Refinery Co. Ltd to develop an extensive propane and butane dehydrogenation unit in cooperation with CB&I. The project includes the license and engineering design of the co-processing unit, which is to be built in Dalian, Liaoning Province, China. The design will be based on CB&I’s Catofin catalytic dehydrogenation technology using Clariant’s tailor-made Catofin catalyst and Heat Generating Material (HGM) to process feedstock containing 300,000 metric tons of propane and 600,000 metric tons of isobutane annually for the joint production of propylene and isobutylene. When completed, it will be the largest single-train co-processing dehydrogenation unit in the world, and will play a key role in Hengli’s expansion plans. The Catofin process is recognized as a highly reliable and efficient technology for producing propylene from propane, and isobutylene from isobutane. The process operates at optimum reactor pressure and temperature to maximize conversion of propane and isobutene for a high yield of propylene and isobutylene, and correspondingly low investment and operating costs. These performance advantages are now further enhanced through the inclusion of HGM in the Catofin process.
14 | The Economic Times POLYMERS | February-March 2016
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REPORT
The new dawn of PVC
WHILE THERE IS AN URGENT NEED TO ENHANCE THE COMPETITIVENESS OF INDIAN PVC AND CAUSTIC SODA INDUSTRY, THE INDUSTRY MAY ATTRACT RS20,000 CRORE INVESTMENT IN NEXT FIVE YEARS IF SUGGESTED MEASURES ARE APPLIED, SAYS A FICCI REPORT
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ndian Poly Vinyl industry is presently not doing well. Import of PVC, which was less than 5 percent of the country’s demand ten years ago, is now at almost 50 percent and is growing. The PVC industry also has a linkage to the Caustic soda industry. Majority of Chlorine produced goes into PVC manufacture, and if there is no PVC capacity addition, there can be no Caustic Soda capacity addition. As a result imports are increasing. That is not a healthy sign and has long term implications for national economy. To bring out the challenges and issues of the sector, a White Paper ‘Enhancing Competitiveness of Indian PVC & Caustic Soda Industries’ has been prepared by FICCI and Tata Strategic Management Group and was released by Hansraj Gangaram Ahir, Minister of State for Chemicals & Fertilizers, Govt. of India at a function in Federation House recently. The PVC industry in India is valued at over Rs20,000 crore with five major producers and over 6,000 processors, employing tens of thousands of people, making consumer and industrial products. In spite of strong economic growth, India still has a long way to go to realize its infrastructural needs - nearly US$ 650 billion will
The PVC industry in India is valued at over Rs20,000 crore with five major producers and over 6,000 processors, employing tens of thousands of people, making consumer and industrial products.”
be required for urban infrastructure in the next twenty years. Also, the construction sector contributes to 10 percent of the GDP. This provides great opportunity for investment and hence for PVC products that are used in these sectors. Despite the established importance and the rapid growth of PVC (Poly Vinyl Chloride) industry for national economy, investments are not happening. The last Greenfield investment for a PVC plant in India was conceived in the year 2002-03, when duty differential was a little over 15 percent. However, while demand has grown by almost 1.6 million tons no new capacity addition has even been envisaged.
Since 2000, the main driver for PVC consumption has been infrastructure
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REPORT
Indian import duties on PVC are lower than those in the developed world and in the ASEAN Region. Imports of PVC, which were less than 5 percent of the country’s demand ten years ago, are now at almost 50 percent and growing rapidly every year and are expected to reach to US$3 billion in few years. The forecasts for the PVC industry are bright. The global market, currently at US$ 56 billion, is expected to reach revenue of US$65 billion in 2019, with average annual demand expected to increase at 3.9 percent. The global consumption of PVC in 2014 was estimated at 40 million tons. The PVC industry in India has historically been driven by agriculture till 2000. Thereafter, the main driver for PVC consumption has been infrastructure, for instance, Pipes & Fittings, which has grown to over 70 percent from 14 percent in 1975. Globally, Pipes & Fittings account for only 43 percent of the PVC consumption, showing that PVC applications in India other than Pipes & Fittings are primed for growth. For the period between 2002 and 2015, the total demand for PVC in the country grew at a CAGR of 8.7 percent. During the same period domestic production capacity grew at a CAGR of 4.6 percent whereas imports grew at a CAGR of 32.5 percent.
Revitalising Indian PVC Industry: Some Suggested Measures Increase import duty of PVC & caustic soda from 7.5 percent to 10 percent. This will help revive the investment sentiment for the PVC industry in India. Reduce tariff on intermediates (EDC & VCM) to zero. As there is no local manufacture of EDC or VCM for merchant sale, any duty reduction will not adversely affect any domestic company. Revisit tariff concessions extended to countries with which India has signed Trade Agreements, Give thrust to the PCPIR policy, ensuring availability of ethylene for downstream units. Developed petrochemical infrastructure can greatly reduce logistics cost.
Need for strengthening domestic PVC production Indian PVC demand in the future will mainly be driven by the Agriculture, Infrastructure, Housing and other sectors like FMCG, pharmaceutical and retail segments. The estimated annual growth for PVC will be at least 13 percent in the next five years, with demand expected to cross five million tons in 2020. India’s supply – demand imbalance in PVC means that the deficit in demand is met by imports. As seen earlier, for the 2002-2015 period, the total demand for PVC in the country grew at a CAGR of 8.7 percent. During the same period domestic production grew at a CAGR of 3.7 percent whereas imports grew at a CAGR of 32.5 percent. By 2020, India would need approximately 3,700kt of imports i.e. an additional 2,300kt from the present level to meet its PVC demand. Such high levels of imports will also have a deleterious effect and the resultant net outflow of foreign exchange could be of the order of US $5 billion. Another factor that goes to show that this level of import is almost impos-
For the period between 2002 and 2015, the total demand for PVC in the country grew at a CAGR of 8.7 percent. During the same period domestic production capacity grew at a CAGR of 4.6 percent whereas imports grew at a CAGR of 32.5 percent.”
Housing will be a key driver for PVC consumption in the days to come.
sible is the estimated global trade in PVC resin by the year 2020 which is at around 10 million tons. It will again be not prudent for India to expect that almost 37 percent of this will be an inflow into the country.
Conclusion Today, close to 50 percent of the demand for PVC in the country is met by imports. When the country’s goal today is to ‘Make in India’, increased imports and lower manufacturing levels contribute to loss of potential employment and widening the current account deficit. All these measures can result in a potential investment of over Rs. 20,000 crores over the next 5-7 years.
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PACKAGING
The Role of Packaging in Product Safety WE OFTEN OVERLOOK THE IMPACT THAT CRUCIAL ASPECTS LIKE PACKAGING CAN HAVE ON THE OVERALL SAFETY AND QUALITY OF A PRODUCT. By Vimal Kedia, Managing Director, Manjushree Technopack Ltd.
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hen we talk about product safety, particularly in relation to food or pharmaceutical goods, the general tendency is to focus only on the product. We often overlook the impact that crucial aspects like packaging can have on the overall safety and quality of a product. While safety was intended to be the fundamental purpose of packaging, as consumer choices evolved over time and food preparation and consumption habits changed, technology came into play and packaging began to play a bigger role – that of a brand ambassador, a crucial element of branding and marketing. In promoting aesthetics and innovation of a brand, packaging today substantially contributes to a product’s overall success.
Creating the right perception Packaging and labelling of products also has an important role
to play in creating consumer awareness about the safety of the product. Competing for consumers’ attention on retail shelves, it is the first line of communication between product and consumer. It is the primary source of information on product ingredients, nutritional contents and shelf life of the product, intended to give consumers the choice to make informed decision on product purchase. For marketers, it is a means of promoting their product. In most countries, labelling of food products is mandated under strict compliance with a regulatory framework. Food labelling guidelines in India however are still in its infancy, leading to inadequate and sometimes misleading information on harmful ingredients and also preventing strict safety checks on how healthy or harmful a product really is. Fostering awareness and understanding of the importance of enforcing regulations in packaging and labelling will contribute to creating a benchmark and a more structured food safety system with minimum scope for risk.
When Maggi and the category of instant noodles found itself in one of the biggest food standards controversy, the role of packaging of food products came to the fore, under fresh scrutiny. Manufacturers turned their attention once again, towards packaging for safety.
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PACKAGING
Fostering awareness and understanding of the importance of enforcing regulations in packaging and labelling will contribute to creating a benchmark and a more structured food safety system with minimum scope for risk. Certification and Impact on Supply Chain Value
and safety risks and providing an assurance of trust through better packaging and labelling. Most importantly, it is a catalyst for regulators Packaging is a crucial part of supply chain manMajor retailers in to bring in amendments to our country’s relaxed agement in relation to the manufacturer, supthe food industry packaging and labelling norms to ensure that the plier, retailer and the consumer. Faced with the are specifying third pressures of complying with benchmarks set party certification of entire manufacturing and supply chain process comes under stringent checks to meet safety and by all the stakeholders, companies are seeking suppliers’ products quality standards. third party certification to ensure safe delivery of in accordance Some years ago, Cadbury found itself in the goods to consumers. with Global Food midst of a quality storm across Maharashtra, Major retailers in the food industry are Safety Initiative with allegations of worms being found on bars specifying third party certification of suppli(GFSI) standards. of Dairy Milk chocolate. The FDA suspected ers’ products in accordance with Global Food Packaging that faulty packaging was an accomplice to posSafety Initiative (GFSI) standards. Packaging companies are also sible manufacturing or storage defects. It took companies are also undertaking GFSI certificaundertaking GFSI Cadbury years to recover its credibility but the tion to protect and promote their brand identity certification to company emerged stronger with revamped packand ensure safety of products within the supply protect and promote aging that restored consumer confidence. More chain. their brand identity recent incidents of supermarkets and stores selland ensure safety of ing chocolates and other products which are way Lessons learnt products within the beyond their expiry date highlight the imporWhen Maggi and the category of instant nootance of establishing packaging norms and labeldles found itself in one of the biggest food standsupply chain.” ling of products for food safety and quality. ards controversy, the role of packaging of food In the wake of the Maggi noodles ban, hunproducts came to the fore, under fresh scrutiny. dreds of packaged food products were put under the health scanManufacturers turned their attention once again, towards packagner. Some reports claimed that Maharashtra even ordered saming for safety. ples of Haldiram’s packaged snacks to be tested for pesticides and The Maggi case has had several positive implications. In toharmful bacteria. Hopefully, this will serve as a catalyst for the day’s context, what good could possibly come of it? How can packaged and processed food industry to step up and tighten the years of trust and consumer confidence that was compromised, labelling and packaging norms for the country. The onus also lies be regained? While it was a wake-up call for us, as consumers, largely on food manufacturers who need to take a proactive stance to keep a check on what we eat henceforth and pay more attenon safeguarding the health of our population by coming clean tion to product labels and ingredients, it also gives manufacturers with food safety risks. the opportunity to be transparent in addressing consumer health 22 | The Economic Times POLYMERS | February-March 2016
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INNOVATION
World’s first latex-free mono-material polyester carpet
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SM-Niaga has developed a portfolio of new, proprietary and patentprotected technologies to fully close the loop on carpet materials, allowing them to be ‘alive, again and again’, a real circular economy breakthrough. DSM-Niaga is a joint venture between DSM, a global science based company active in health, nutrition and materials, and Niaga, a Dutch provider of sustainable materials solutions. The Niaga technology is now commercially available to the industry enabling the elimination of carpet waste, based on well-defined pure materials without compromising quality of the carpet - on the contrary. These materials can be recovered in an economically sound way based on industrial-scale processes and turned into valuable materials that can be reused again to make carpets, and also other products such as automotive textiles. Courtesy: DSM-Niaga Up till now, DSM-Niaga has focused on development and upscaling tests at its Tech Center in Zwolle (the We’ve tested it in the market, worked Netherlands) using prototyping equipment. But now the Niaga with customers, and carpets made Technology is ready to take carpet production to broadloom using our technology will go commercial width and commercial production speeds. in 2016. Moreover, we have expanded “We have proven conclusively that everything works with allour capabilities to include polyamide polyester, mono-material carpets made using our Niaga Technolbroadloom carpet, polypropylene carpet ogy”, DSM-Niaga’s Chief Commercial Officer Norbert van der and even wool carpet. Nap says. “We’ve tested it in the market, worked with customers, and carpets made using our technology will go commercial in DSM-Niaga’s Chief Commercial Officer Norbert van der Nap 2016”, he says. ”Moreover, we have expanded our capabilities to include polyamide broadloom carpet, polypropylene carpet and to the rim every 12 days”, Reutelingsperger notes. “Niaga Techeven wool carpet.” nology can be applied to all commonly used carpet designs, so In addition to eliminating carpet waste, carpets made with together we can go from waste, to less waste to Niaga Technology also offer various benefits to no waste at all.” its users. The all-polyester carpets made using “Additionally”, Reutelingsperger says, “LifeNiaga Technology perform exceptionally well cycle assessments (LCAs) comparing Niaga to in fire safety and smoke tests - a vital factor in These materials conventional methods show a very significant houses, hotels and offices, but also when incan be recovered reduction of the environmental impact throughstalled in airplanes or cruise ships. While latexin an economically out the product’s full lifecycle.” based carpets release organic compounds into sound way based Niaga is made available thanks to a joint the air over time, Niaga carpets are completely on industrial-scale venture of DSM and Niaga, based on a shared latex-free. Niaga broadloom carpets also are belief: That taking ownership for the planet we lighter, softer and easier to handle. processes and “For decades”, explains DSM-Niaga Chief turned into valuable all share is not ‘other people’s’ responsibility. It is ours, yours – in fact everyone’s. “It’s clear Technology Officer Chris Reutelingsperger, “tramaterials that can that bringing in DSM’s materials sciences has ditional carpet manufacturing technologies have be reused again to been crucial. We’re delighted that as a result of involved using multiple materials that cannot be make carpets, and our partnership Niaga Technology is now comeffectively separated and recycled at the end of also other products mercially ready and will be available in markets their useful life. If you take all carpet waste that such as automotive around the world in 2016”, comments DSMends up being landfilled or incinerated, there is textiles.” Niaga’s General Manager Josse Kunst. enough waste to fill London’s Wembley Stadium
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INNOVATION
High-tech plastic for perfect eye protection
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ye injuries in the workplace are a serious occupational hazard and can have significant consequences for both employees and employers. The American Occupational Safety & Health Administration (OSHA) estimates the cost of eye injuries to be more than US$ 300 million per year. Covestro has developed an extremely impact-resistant polycarbonate for protecting the eyes of workers. Lenses made of Makrolon 3207 are lightweight and as transparent as glass, thus satisfying the strict requirements of MCR Safety, an American supplier of personal protective equipment. The Crews Glasses and US Safety series of safety glasses and face shields from MCR Safety are also certified according to the American ANSI Z871.1 standard. Bulletproof lenses Lenses made of the Covestro plastic are industrial bulletproof and passed tests with 45 gram solid steel bullets fired at the lenses at speeds of 150 until 400 feet per second. Such extreme test conditions are necessary in order to cover all of the loads that could possibly occur during routine work and lead to eye injuries: falling or flying objects, sparks, metal slivers, wood chips, nails or contact with harmful substances. MCR Safety has developed its new USS Defense safety glasses
The lenses of safety glasses from MCR Safety are made from the extremely impactresistant Makrolon® 3207 polycarbonate from Covestro.
primarily for the tightened product safety laws in Asia, where the glasses are also produced. “MCR Safety has more than 40 years of experience in setting industry standards where personal protective equipment is concerned, and this time we were looking for a world class product and a partner that could deliver it,” said David Smith, Product Manager at MCR Safety. “These goggles are tough, offer premium optical quality and impact resistance, plus offer good UV protection.” Paul Lin, Covestro Polycarbonate Key Account Manager Taiwan, added: “Another advantage of Makrolon® 3207 is the high design freedom. This allows for thinner lenses and thus greater comfort with lower production costs.”
New high-refractive-index silicones for LEDs
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ACKER, the Munich-based chemical company, has developed new encapsulants for light emitting diodes (LED) and optical components. The compounds are made of highly transparent silicone elastomers with a high refractive index. The products withstand high operating temperatures and strong light radiation without yellowing. That makes them ideal for manufacturing LEDs with high light efficiency. They also protect the LED chip against corrosive gases, which greatly extends the component’s service life. The silicone encapsulation compounds can be processed in industrial metering processes such as dispensing. LUMISIL 590 and LUMISIL 591 are highly transparent, addition curing silicone elastomers with a refractive index of 1.53, which means they rank among the high-refractive-index (HRI) encapsulants. Such grades are particularly suitable for manufacturing highly efficient LEDs. The HRI silicone protects the sensitive LED chip against mechanical influences and corrosive gases. At the same time, the silicone’s high refractive index enables optimum light efficiency. Semiconductor chips used to generate light in LEDs have a high refractive index. To maximize the amount of light emitted by the LED chip that can pass through the encapsulation, the refractive index of the chip and encapsulant must be roughly the same value. Thanks to their refractive index of 1.53,
The encapsulants stand out due to their high refractive index, excellent transparency and low gas permeability. (Photo: Wacker Chemie AG)
LUMISIL 590 and LUMISIL 591 make LEDs highly efficient. What’s more, the highly transparent silicones are almost completely transparent for light in the visible spectral range (approx. 400 to 700 nm) and do not yellow even when radiation is extremely intense. Transmission tests with LUMISIL 590 show that a one-millimeter-thick layer lets over 91 percent of visible light through.
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TRAINING
Collaboration for skill development SABIC AND CIPET HAVE EXPANDED THEIR JOINT COLLABORATION FOR SKILL DEVELOPMENT CSR PROGRAM IN PLASTICS PROCESSING IN INDIA.
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ABIC has announced the expansion of its skill development Corporate Social Responsibility (CSR) program aimed at developing capacity in the plastics processing industry in India. The program, run in collaboration with the Central Institute of Plastics Engineering & Technology (CIPET), under the Department of Chemicals and Petrochemicals, Ministry of Chemicals and Fertilizers, trained 50 youth from less-privileged backgrounds in Chennai in its first phase, and now further targeting to train 90 more from Hyderabad and Ahmedabad (From Left to Right)- Himanshu Bhatt, Senior Technical Assistant, CIPET, Dr. Sandesh K. Jain, Chief Manager in next phase. This collaboration is a part (Technical), CIPET, Janardhanan Ramanujalu, Vice President, SABIC South Asia & ANZ, Dr. Pradeep Upadhyaya, of SABIC’s corporate social responsibility Professor & Head –High Learning Centres, CIPET, G.V. Ramgopal, Head Polymers, Indian Sub-Continent, SABIC, J. (CSR) commitment to create lasting value Bosco, Senior Lecturer, CIPET, Ahmedabad. opment course including a full scholarship that covers course fee, across the economic, social, human and boarding and lodging costs. The students were selected through environmental dimensions. a comprehensive screening process undertaken independently by The program entails a six month-long residential skill develCIPET. Based on a special curriculum developed by CIPET with inputs from SABIC, students in CIPET, Hyderabad will be trained Given the potential of the plastics on plastics extrusion while students in CIPET, Ahmedabad will processing industry in India, we believe be trained to operate Injection Moulding Machines. Upon sucthat this program will add more skilled cessful completion of the course, the students will be certified by frontline workers to the industry and CIPET and SABIC. These students will be equipped with skills to contribute to Govt. of India’s vision of gain employment in various plastics processing hubs. making India a global manufacturing Speaking at the launch in Ahmedabad, Janardhanan Ramanuhub. jalu, Vice President, SABIC South Asia & ANZ, said, “Given the Janardhanan Ramanujalu, potential of the plastics processing industry in India, we believe Vice President, SABIC South Asia & ANZ that this program will add more skilled frontline workers to the industry and contribute to Govt. of India’s vision of making India a global manufacturing hub.” Dr. Pradeep Upadhyaya, Professor We believe that the success of such and Head, High Learning Centres, CIPET Ahmedabad said, “CIprograms rests heavily on collaboration PET conducts programs to equip people with skills that are in line with industry leaders such as SABIC, with the latest requirements in the plastics industry. We believe which help bring in industry orientation that the success of such programs rests heavily on collaboration to the curriculum and greatly benefit with industry leaders such as SABIC, which help bring in indusstudents. try orientation to the curriculum and greatly benefit students. We Dr. Pradeep Upadhyaya, are confident that the skills acquired by the participants of this Professor and Head, High Learning Centres, program will help them capitalise on the opportunities presented CIPET Ahmedabad by the growth in the plastics processing industry.” 28 | The Economic Times POLYMERS | February-March 2016
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COVER STORY
FARMER’S FRIEND
ANIL B. JAIN, MD, JAIN IRRIGATION SYSTEMS LTD. EXPLAINS HOW HIS ORGANISATION IS USING PLASTICS TO HELP FARMERS GROW AND PROSPER By Niranjan Mudholkar
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his work as were his colleagues at the breakfast table. He took me around showing the farms, the facilities, the labs, the solar installations, the training centers, the demo centers, the green houses, the poly houses, the dam built by JISL for the community and the Gandhi Tirth (a monumental creation that depicts the life and teachings of Mahatma Gandhi – the founder’s inspiration). And after a tiring and yet refreshing two-day tour in and around the campus, I finally met Anil B. Jain at his office in the Plastics Park, which is located outside the main campus. The 30-minute drive from the main campus to the Plastics Park itself was quite revealThe journey ing as it clearly showed a newly evolving Jalgaon City. It was at the breakfast table at one of the guest houses inside the A quick formal introduction and Anil B. Jain, one of the four approximately 1600-acre Jain Irrigation campus that I started to Jain brothers running this large organisation, was all set for the get a feel of the organisation’s pulse. While enjoying the farm fresh interview. There was no tea or coffee offered! Those are considered snacks, most associates sitting around me were discussing about as unhealthy drinks at all Jain facilities. Visitors are usually offered how they were bringing positive difference to the productivity of flavoured milk, something I did not fancy at that time of the day. the farmers they were working with across geographical locations. “My focus is on plastics and polymers,” I told him. His response “From Rs500/- per day, my farmer is now earning Rs2500/- per was sharp and yet quite friendly. “We do not look at our busiday on the same strawberry field with lesser water,” said one of ness as plastics; polymers and them. “Oh, we are doing a plastics play a very important huge project in Nigeria where We think plastics can play a further role in what we do. But we use we are turning around hunimportant role in precision agriculture; plastics in providing solutions dreds of hectares of average to deliver to farmers not only water but for agriculture,” he said. Then, fields into agriculturally rich also fertilisers and nutrients so that the he went on to explain the sigfarms,” said another. And plants can grow healthy. nificance of plastics not just similar conversations kept from his Company’s perspecdoing the rounds of the table tive but also from the overall economic and environmental points along with the simple yet delicious food being served. It was a of view. JISL’s primary product is drip irrigation which it provides good start, I thought. to farmers to save water, to improve productivity, to save cost and Things were to become more interesting. I was then to be to actually change the way agriculture is done. “We have been the taken around on a guided tour to make me understand about the pioneers and we are also the leading players in this segment, not various activities of the organisation. My guide for the tour? A only in India but also globally. We think plastics can play a further Ph.D. from IIT Mumbai with post doctoral qualifications from important role in precision agriculture; to deliver to farmers not the US. While I was expecting a rather serious kind of a person only water but also fertilisers and nutrients so that the plants can with loads of technical information, I was pleasantly surprised grow healthy,” Jain says. to see a young project manager who was just as passionate about t would have been easier for me to meet Anil B. Jain, MD, Jain Irrigation Systems Ltd. at his Mumbai office. It is just about 10 minutes drive from my own office. But he insisted that I undertake a 7-hour train journey to Jalgaon and meet him at the Company’s headquarters. The reason? “You will know when you come to Jalgaon,” I was told. So Jalgaon it was.
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COVER STORY
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Plastics and climate change! It is not uncommon for me to meet people in the plastics industry who take a defensive stance while talking about this material, particularly when it comes to its impact on the environment. And there are those who are not from this industry and who would identify plastics as a culprit when it comes to climate change. Anil B. Jain offers a significantly different dimension to this situation. He believes that plastics can actually be an effective tool in the fight against climate change! “Well, plastics are already being used so and they can be further utilised so. Plastics can be extremely useful and value additional if used and handled properly with the thought-process of zero waste in any product lifecycle.”
Beyond piping and irrigation Dr. Bhavarlal H. Jain, the founder of Jain Irrigation Systems Ltd. (JISL) would have actually become a bureaucrat had it not been for the advice of his mother. He already had a deputy collector’s job in his pocket but his mother asked him to do something that would have a larger positive impact on the society. And thus, with the objective of fulfilling his mother’s vision, he started his entrepreneurial journey in 1963. That journey has resulted in the creation of a global organisation that has progressed by helping the farmer grow and prosper. And while the Company name is synonymous with the micro irrigation industry in India and is also the largest producer of thermoplastic piping systems for all conceivable applications with pipes ranging from 3 mm to 1600 mm in diameter, it goes much beyond piping and irrigation. For example, the Group’s relatively recent venture into food processing called ‘Farm Fresh’ endeavours to provide a ready market for the farmers its serves through other businesses. The idea is to create another value addition and touch point with the farmer across the value chain.
Jain strongly believes that plastics and polymers also play an important role – in fighting the consequences of climate change on agriculture. “If you read newspapers every day, you will find that there is some headline related to climate change. It is about earth heating in some places and freezing snows in other places, it is about rains in Chennai and odd-even cars in Delhi, it is about droughts and farmers committing suicide and so on. We obviously have to face the consequences of climate change. And the primary consequence of earth heating is in the reduction of the agricultural yields. I think with the help of plastics, we can solve that. One way to solve is to do cooling of the crops. So even if the earth heats, and if you can provide cooling to the crops then the yield will not go down as much as it is feared it will go down,” he explains. He gives another example. “As a result of climate change, we have hailstorms and untimely rains which destroy standing crops leading to huge losses for farmers. We have developed greenhouses, poly houses and shade houses from plastics, which can protect against these natural calamities. So you can say that plastics can be connected to food security eventually.” Jain also points out that usually, plastics are seen as something more convenient than what we had before, something which is recyclable, something which is lower in cost compared to metal, something which is light in weight and something which is easier to handle. These are the basic features why plastics are promoted and used in a variety of applications. “But I am talking about agriculture where we are using plastics to create fundamental solutions. With plastics, we are creating better water security for the nation, we are creating food security for the nation and eventually we would also be fighting climate change. This is quite important as well as unique. Nobody thinks of plastics in this way.” Indeed, nobody does.
About value addition For Jain, plastic is not about just convenience, or being light-inweight and or the ease of production; for him it is about tremendous value addition. And he knows what he is talking about. “In the case of drip irrigation, the way we have used plastics, the value
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addition has been enormous. Many farmers have been able to get extra value. They have been able to get more output from the same land and by using less water compared to earlier. This has been made possible with plastics. So plastics are playing crucial role in ensuring next generation agriculture and, as I already said, for food security and water security for nation.” And there are many more ways in which plastics can be really helpful to us, he adds. Traditionally, water is transported from dams by open canals to the farms. A lot of water is evaporated in these open canals. Some water also percolates in the ground.
Obviously, farmers are unable to use this lost water. “Approximately, only about thirty percent of the actual amount distributed to the farms reaches to the farmers. Despite the time, efforts and money spent in creating the canal systems, the final efficiency is only about thirty percent. Now, instead of open canals, if you use large diameter plastic pipes with drip and sprinkler systems at the final output then the efficiency is more than doubled. So in the context of overall water availability and water conveyance, this is a much better solution. Moreover, to build a new canal, you need to acquire land. And land acquisition is a huge political and social issue today as land is extremely valuable. Alternatively, you can go about 2-3 meters below the ground by digging the soil to install the large diameter pipes and then cover the pipes with soil again, farmers can easily use the same land for farming! So plastic is actually solving social issues and agricultural issues while creating value additions. It is creating better income for farmers and it is bringing prosperity to the rural areas.” By the way, canal water is also open to pilferage, a problem that can also be addressed with large diameter plastics pipes. But Jain doesn’t want to talk about that. “I prefer to highlight the increased efficiency,” he says.
Business growth JISL’s plastics business is primarily divided into three main divi-
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COVER STORY
ferings span requirements across rural, urban and infrastructural segments. “We are across the spectrum. But we started with rural and rural remains our primary focus. At the same time, slowly, steadily and surely, we are also moving into urban.” The country as we see today stands on the verge of transformation and Jain Irrigation is providing solutions to almost every key aspect of the economy. “Our conscious thought has been that as we build the modern India, we must play an important role in terms sions: micro irrigation, pipes With plastics, we are creating better of building the infrastructure and plastic sheets. “About 47 water security for the nation, we are across the landscape - be it urpercent of our revenues come creating food security for the nation and ban or rural.” from micro irrigation, almost eventually we would also be fighting And Jain is also aware of 23 percent comes from the climate change. This is quite important the challenges in the market. pipes and about three percent as well as unique. Nobody thinks of “We are ready to address the or so comes from the plastics plastics in this way. huge infrastructural requiresheets,” he informs. Thus, ments of the country in terms more than 70 percent of the of solutions for wide ranging industries like telecom to ports and company’s revenue is actually driven by plastics products. “Today, water and gas supply to roads. We already have successful case we are company with revenues of almost a billion dollars. We studies in different regions but there is some resistance within the have been able to grow significantly because of the organic growth country to accept plastics for these segments. The old-school deciwithin India where we have invested in Maharashtra, Andhra sion makers cannot go beyond metal when it comes to these inPradesh, Tamil Nadu, Rajasthan and Gujarat with various manudustries. It is the mind-set that needs to change.” Of course, Jain facturing facilities. We also did acquisitions outside India. Thus, is happy that the new generation is more open towards plastics. today as a company, our nature is global. We have 12 manufacImportantly, data is now available with the government agencies turing plants in India and 17 manufacturing plants outside India as well. And then there are global case studies. “It is evident that including in countries like US, Spain, Israel, Switzerland, Chile around the world plastic is the preferred material. There is no and so on. We sell our products in hundred different countries. need to take any material except plastic up to two meters. Of So the growth has been in the domestic market as well as globally. course, in India, it will take time some time across all departments In terms of drip irrigation, earlier we used to focus only on fruits. and consumers to accept that plastic is strong, flexible, good, costToday, we also do vegetables, cotton and sugarcane covering a competitive, and on a life-cycle basis always cheaper than any othwide range of crops which has also helped us grow,” he shares. er material. But we are not complaining because we understand Talking purely about the plastics business, JISL’s processing the merit of our products. Sometimes, we feel that we are in the capacity is about 300,000 tonnes annually. And its product of34 | The Economic Times POLYMERS | February-March 2016
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COVER STORY
Make in India with a twist!
concept selling business. In drip irrigation, we sold a concept and proved that you can get more productivity with less water. And we are doing the same (concept selling) with HDPE pipes as well. We have to tell people that these pipes can be used in larger applications that they did not think were possible earlier,” he explains.
Jain says that PM Modi’s ‘Make in India’ initiative is indeed quite remarkable. “It has a laudable objective and it is feasible. India can definitely be a low cost and high quality manufacturing center. JISL has already been making in India for a long time. But for this initiative to truly succeed, red-tape must be removed, cost of energy must come down and infrastructure must improve drastically. Once that happens then India definitely has the potential to be the world’s largest manufacturing hub,” he says adding that we have definitely come a long way from where we were twenty years ago. So far so good. And now comes the twist. “In ‘Make in India’, they must also consider agriculture as an industry. For us, a farmer is also an entrepreneur. He is also investing, taking risks and running a business. But he is never treated as such. Of course, we at Jain Irrigation, practice what we preach. We treat every farmer as an entrepreneur. All our products reduce his risk and help him
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ans of that wealth.” Besides his succeed and prosper. The five In ‘Make in India’, they must also father’s teachings, the MD of million farmers that we have consider agriculture as an industry. For JISL wants the next generation been able to reach are dous a farmer is also an entrepreneur. to adopt and make full use of ing well. They are producing He is also investing, taking risks and digital technology. We want to more, they are making more running a business. But he is never become a truly global organisamoney and they have become treated as such. tion and the next generation prosperous. And we will conmust blend understand of diftinue to do so. But India has ferent cultures and technology to drive this organisation ahead. The 120 million farmers. And we have a long way to go. But we have world is far more dynamic and volatile today than it was ten years helped create an industry. Agriculture is the biggest opportunity back. So they need to be extremely hardwired and agile,” he says. for ‘Make in India’. If we focus on agriculture then we will have better food and water security and it will have a direct impact on the industrial sector,” he says emphatically. Empathy with farmers Then I take the conversation to my experience at the breakfast table in the guest house. I share with him the talks that I had Generation to generation overheard there. He smiles. “When someone tells me that JISL Being a son of an illustrious father is a responsibility in itself. Anil is a family-run business, I totally disagree with them. It is acB. Jain understands it and takes it in his own stride. “The first tually an extended-family-run business. Each of our more than and foremost lesson that I have learnt from my father is that of our ten thousand associates is part of this family and together ‘Work Ethics’. For him work is worship. That’s the first article of we run this business. The company is not just run by me or my faith. Secondly, he has focused on growth and development but brothers but by these more than ten thousand professionals. It is with conscience. And thirdly, he has taught us that whatever wealth the sense of ownership and responsibility amongst the associates we have created, it belongs to the society. We are merely custodithat powers our organisation. They Some of Jain Irrigation’s product ranges believe that they are making a differHi-tech agri products & services Plastic piping Natural Resource ence. And they take pride in making a products Conservation Products positive difference to the farmers’ lives PVC Pipes PVC Sheets R&D Demonstration and Training and the society. We do not sympathise Polyethylene Pipes Jain Solar Water Heaters Centre, Tissue Culture Lab and Agri with farmers, we empathise with them Bio-Tech Lab Polypropylene Pipes Jain Solar Photovoltaic and that is what JISL is all about,” he Turnkey Services and Hi-tech Agri PVC Fitting Appliances says. “I wanted you to come to Jalgaon Consultancy Polyethylene Fittings Jain Jeevan Solar Surface/ because I wanted you to experience Polypropylene Fittings Submersible Pumps Tissue Culture, Hybrid and Grafted this empathy. And by the way, Jalgaon MDPE Pipes (Gas) Jain Solar Photovoltaic Plants will always remain our hub. My father Module (Panels) Greenhouses, Poly & Shadehouses Corrugated Pipes was always clear on that right from the Bio-Gas Power Plant Drip Irrigation beginning. Branch office in New York Sprinkler Irrigation and Turf Irrigation but headquarters in Jalgaon.” 36 | The Economic Times POLYMERS | February-March 2016
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MARKET
LANXESS compounding facility for high-tech plastics in Gastonia, North Carolina, USA. Photo: LANXESS AG.
Driving high performance
A SPECIALTY CHEMICALS MAJOR HAS STARTED UP A SECOND PRODUCTION LINE FOR HIGH-PERFORMANCE PLASTICS COMPOUNDING AT ITS FACILITY IN US WITH AN INVESTMENT OF ABOUT US$ 15 MILLION.
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pecialty chemicals company LANXESS has started up a second production line for high-performance plastics compounding at its facility in Gastonia, North Carolina, as planned. The new line represents an investment of about US$ 15 million and doubles the site’s production capacity from 20,000 to 40,000 metric tons annually. In the plant, the basic polymers polyamide (PA) and polybutylene terephthalate (PBT) are mixed and refined with special additives and glass fiber, according to client requirements, to make the high-performance plastic product lines Durethan and Pocan. They are used primarily in the automotive industry to manufacture lighter-weight plastic components that can replace metal parts in vehicles, contributing to greater fuel efficiency and reduced emissions. “This investment shows our strengthened focus on high-performance compounds and underlines our strategy to shift this business towards higher-value-added markets,” said Hubert Fink, Member of the Board of Management of LANXESS AG. “The capacity expansion in Gastonia also shows our commitment to North America, which we see as major growth region.”
The high-tech plastic Durethan is supplied to customers in the form of granules. Durethan is used in the automotive industry among other sectors. Photo: LANXESS AG
The U.S. automotive sector remains strong, and the demand for engineering plastics in cars is growing. With our expanded capacity, we are in a position to support this growth and remain a reliable supplier to our North American customers. Antonis Papadourakis, President and CEO, LANXESS Corporation In the coming years, LANXESS plans to further invest EUR 50 to 100 million for organic growth in its high-performance plastics business. “With the investments, we will be further balancing the capacities in our polyamide value chain and driving the globalization of our engineering plastics business,” said Michael Zobel, head of LANXESS’ business unit High Performance Materials. Lightweight automotive construction as key driver for highperformance plastics: LANXESS expects global demand for engineering plastics in automotive applications to grow by 7 percent annually (CAGR 2015-2020). This is being driven by rising car production and the trend towards more fuel-efficient automobiles. E.g., in the U.S., automakers must meet governmentmandated Corporate Average Fuel Economy (CAFE) regulations which indicate the average distance that has to be covered per one gallon of fuel. By 2025, an average fleet-wide fuel efficiency of 54.5 miles per gallon will be required compared to 34.1 miles per gallon in 2016. “The U.S. automotive sector remains strong, and the demand for engineering plastics in cars is growing,” said Antonis Papadourakis, LANXESS Corporation President and CEO. “With our expanded capacity, we are in a position to support this growth and remain a reliable supplier to our North American customers.” February-March 2016 | The Economic Times POLYMERS | 37
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RESEARCH
in the journal Advanced Materials. Conjugated semiconducting polymers (plastic) possess exceptional optical and electronic properties, which make them highly attractive in the production of organic opto-electronic devices, such as for instance photovoltaic solar cells (OPV), light emitting diodes (OLED) and lasers.
In the present work, a team of chemists and materials scientists, led by Professor David R. Barbero at Umeå University, has found a new method to align chains vertically and to produce efficient transport of electric charges through the chain backbone.”
Vertically aligned chains in the organic semiconducting polymer inside microscopic patterns. Credit: UMEÅ University
Breakthrough! A RESEARCH TEAM AT UMEÅ UNIVERSITY IN SWEDEN HAS SHOWED, FOR THE FIRST TIME, THAT A VERY EFFICIENT VERTICAL CHARGE TRANSPORT IN SEMICONDUCTING POLYMERS IS POSSIBLE BY CONTROLLED CHAIN AND CRYSTALLITE ORIENTATION.
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research team at Umeå University in Sweden has showed, for the first time, that a very efficient vertical charge transport in semiconducting polymers is possible by controlled chain and crystallite orientation. These pioneering results, which enhance charge transport in polymers by more than 1,000 times, have implications for organic opto-electronic devices and were recently published
Polythiophene polymers, such as poly(3-hexylthiophene), P3HT, have been among the most studied semiconducting polymers due to their strong optical absorbance and ease of processing into a thin film from solution. In both OPVs and OLEDs, charges must be transported in the out of plane (vertical) direction inside the polymer film. However, until now the vertical charge carrier mobility of organic semiconductors, i.e. the ability of charges to move inside the material, has been too low to produce fast charge transport in electronic devices. Faster charge transport can occur along the polymer chain backbone. However, a method to produce controlled chain orientation and high mobility in the vertical direction has remained elusive until now. In the present work, a team of chemists and materials scientists, led by Professor David R. Barbero at Umeå University, has found a new method to align chains vertically and to produce efficient transport of electric charges through the chain backbone. In this new study, moreover, high charge transport and high mobility were obtained without any chemical doping, which is often used to artificially enhance charge transport in polymers. “The transport of electric charge is greatly enhanced solely by controlled chain and crystallite orientation inside the film. The mobility measured was approximately one thousand times higher than previously reported in the same organic semiconductor,” says David Barbero. In what way will these results affect the field of organic electronics? “We believe these results will impact the fields of polymer solar cells and organic photodiodes, where the charges are transported vertically in the device. Organicbased devices have traditionally been slower and less ef-
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RESEARCH
ficient than inorganic ones (e.g. made of silicon), in part due to the low mobility of organic (plastic) semiconductors. Typically, plastic semiconductors, which are only semi-crystalline, have hole mobilities about 10,000 times lower than doped silicon, which is used in many electronic devices. Now we show it is possible to obtain much higher mobility, and much closer to that of silicon, by controlled vertical chain alignment, and without doping,� says David Barbero. The charge transport was measured using nanoscopic electrical measurements, and gave a mobility averaging 3.1 cm2/V.s, which is the highest mobility ever measured in P3HT, and which comes close to a theoretical estimation of the maximum mobility in P3HT. Crystallinity and molecular packing characterisation of the polymer was performed by synchrotron X-ray diffraction at Stanford University’s National Accelerator (SLAC) and confirmed
The transport of electric charge is greatly enhanced solely by controlled chain and crystallite orientation inside the film. The mobility measured was approximately one thousand times higher than previously reported in the same organic semiconductor. Professor David R. Barbero at UmeĂĽ University
Plastics and electrical properties Regular plastic materials are non-conducting, but if they contain conjugated double bonds, with delocalized electrons, which run alongside the chain backbone, they can conduct charges and transport electricity. However, these electrons (or their positive counterpart, holes) are still not as mobile as in metals or silicon, and therefore their mobility is much lower. To increase the charge mobility, the polymer is usually doped, which means introducing impurities into the material for the purpose of modulating its electrical properties.
that the high mobilities measured were due to the re-orientation of the polymer chains and crystallites, leading to fast charge transport along the polymer backbones. These results, published in Advanced Materials, may open up the route to produce more efficient organic electronic devices with vertical charge transport (e.g. OPV, OLED, lasers etc.), by a simple and inexpensive method, and without requiring chemical modification of the polymer. Source: UMEA University
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RESEARCH
Life imitating Polymer! A COMPLETELY NEW HYBRID POLYMER HAS BEEN DEVELOPED BY NORTHWESTERN UNIVERSITY RESEARCHERS THAT MIGHT ONE DAY BE USED IN ARTIFICIAL MUSCLES OR OTHER LIFE-LIKE MATERIALS; FOR DELIVERY OF DRUGS, BIOMOLECULES OR OTHER CHEMICALS; IN MATERIALS WITH SELF-REPAIR CAPABILITY; AND FOR REPLACEABLE ENERGY SOURCES.
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‘supramolecular polymers’. The integrated polymer offers two disesearchers develop completely new kind of tinct ‘compartments’ with which chemists and materials scientists polymer: Hybrid polymers could lead to new can work to provide useful features. concepts in self-repairing materials, drug de“Our discovery could transform the world of polymers and livery and artificial muscles. start a third chapter in their history: that of the ‘hybrid polymer’,” These functions require polymers with Stupp said. “This would follow the first chapter of broadly useful both rigid and soft nano-sized compartments covalent polymers, then the more recent emergwith extremely different properties that are organing class of supramolecular polymers. ized in specific ways. A completely new hybrid “We can create active or responsive materipolymer of this type has been develals not known previously by taking oped by Northwestern University advantage of the compartments researchers that might one day be with weak non-covalent bonds, used in artificial muscles or other which should be highly dylife-like materials; for delivery of namic like living things. Some drugs, biomolecules or other chemforms of these polymers now under icals; in materials with self-repair cadevelopment in my laboratory behave pability; and for replaceable energy like artificial muscles,” he said. sources. Polymers get their power and features “We have created a surprising from their structure at the nanoscale. The new polymer with nano-sized compartcovalent rigid skeleton of Stupp’s first hybrid ments that can be removed and chemically polymer has a cross-section shaped like a regenerated multiple times,” said materials Northwestern University researchers have developed ninja star -- a hard core with arms spiralscientist Samuel I. Stupp, the senior author a new hybrid polymer with removable supramolecular ing out. In between the arms is the softer of the study. compartments, shown in this molecular model. CREDIT: ‘life force’ material. This is the area that “Some of the nanoscale compartments Mark E. Seniw, Northwestern University can be animated, refreshed and recharged, contain rigid conventional polymers, but features that could be useful in a range of valuothers contain the so-called supramolecular polable applications. ymers, which can respond rapidly to stimuli, be “The fascinating chemistry of the hybrid delivered to the environment and then be easily Stupp and his polymers is that growing the two types of polyregenerated again in the same locations. The suresearch team mers simultaneously generates a structure that is pramolecular soft compartments could be anialso discovered completely different from the two grown alone,” mated to generate polymers with the functions that the covalent Stupp said. “I can envision this new material bewe see in living things,” he said. polymerization ing a super-smart patch for drug delivery, where Stupp is director of Northwestern’s Simpthat forms the rigid you load the patch with different medications, son Querrey Institute for BioNanotechnology. compartment is and then reload it in the exact same compartHe is a leader in the fields of nanoscience and ‘catalyzed’ by the ments when the medicine is gone.” supramolecular self-assembly, the strategy used supramolecular Stupp also is the Board of Trustees Professor by biology to create highly functional ordered polymerization, thus of Materials Science and Engineering, Chemisstructures. yielding much higher try, Medicine and Biomedical Engineering and The hybrid polymer cleverly combines the holds appointments in Northwestern University two types of known polymers: those formed molecular weight Feinberg School of Medicine, the McCormick with strong covalent bonds and those formed polymers.” School of Engineering and Applied Science and with weak non-covalent bonds, well known as 40 | The Economic Times POLYMERS | February-March 2016
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RESEARCH
the Weinberg College of Arts and Sciences. We can create active or responsive Stupp and his research team also discovered that the covalent materials not known previously by polymerization that forms the rigid compartment is ‘catalyzed’ taking advantage of the compartments by the supramolecular polymerization, thus yielding much higher with weak non-covalent bonds, which molecular weight polymers. should be highly dynamic like living The strongly bonded covalent compartment provides the things. Some forms of these polymers skeleton, and the weakly bonded supramolecular compartment now under development in my laboratory can wear away or be used up, depending on its function, and then behave like artificial muscles. be regenerated by adding small molecules. After the simultaneous polymerizations of covalent and non-covalent bonds, the two Samuel I. Stupp, the senior author of the compartments end up bonded to each other, yielding a very long, study. perfectly shaped cylindrical filament. To better understand the hybrid’s underlying chemistry, Stupp “We’re just at the very start of this process, but further down and his team worked with George C. Schatz, a world-renowned the road it could potentially lead to materials theoretician and a Charles E. and Emma H. with unique properties -- such as disassembling Morrison Professor of Chemistry at Northwestand reassembling themselves -- which could ern. Schatz’s computer simulations showed the have a broad range of applications,” Lovinger two types of compartments are nicely integrated I can envision this said. with hydrogen bonds, which are bonds that can new material being The paper is titled “Simultaneous covalent be broken. Schatz is a co-author of the study. a super-smart patch and noncovalent hybrid polymerizations.” In “This is a remarkable achievement in making for drug delivery.” addition to Stupp and Schatz, other authors polymers in a totally new way -- simultaneously of the paper are Zhilin Yu (first author), Faifan controlling both their chemistry and how their Tantakitti, Tao Yu and Liam C. Palmer, all from Northwestern. molecules come together,” said Andy Lovinger, a materials science program director at the National Science Foundation, which funded this research. Copyright & Source: Northwestern University
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CALENDAR
Mark your DIARY
April 5-7, 2016
March 3-6, 2016
A LIST OF KEY TRADE SHOWS HAPPENING BETWEEN MARCH 2016 TO JANUARY 2017 Plastasia 2016
Location: New Delhi Organised by: Triune Exhibitors Pvt. Ltd. Website: www.plastasia.in/ Background Over the last 12 years, Plastasia Exhibitions have built a reputation as an ideal place to discover the latest innovations in plastics, witness live demonstrations, share ideas and most importantly, secure orders. The 2016 edition of Plastasia promises to be India’s flagship event in the field of plastics, raw materials, processing, machinery and finished goods. With its carefully focused profile and highly targeted audience, Plastasia allows you to direct your sales and marketing efforts cost-effectively. It will help makers and users of plastic to understand the trends and future of plastics.
P4 Expo
Location: Greater Noida, Delhi NCR Organised by: All India Plastic Industries Association & Verifair Website: http://www.p4expoindia.com/
July 7-10, 2016
June 28-29, 2016
Background P4 Expo is international trade show and conference on four key industries: Plastics, Petrochemicals, Printing and Packaging. The event aims to create a common platform for these four industries and help industry players leverage on the promising market scenario related to all these four industries in particular and their impact on related industries in general.
Plastics Meetings France
Location: Lyon France Organised by: abe & Plastipolis Website: http://www.plastics-meetings.com/en/ Background This promises to be a unique event which offers both the possibility to receive the up-to date market news through its conference program, as well as to meet target contacts through its tried-and-tested business meetings methodology.
InterPlas Thailand 2016
Location: Bangkok Organised by: Reed Tradex Website: http://www.interplasthailand.com/ Background Following up on the success of the 2015 edition, the 2016 edition aims to repeat the performance with better results. During the last edition, 15,953 attendants found the right technology they were looking for and formed new business alliances. Exhibitors were happy to meet target customers and distribute their products. The plastics manufacturing industries have been fired up to evolve with a strong force. Increasingly confident from the networks they established and knowledge they have gained, industrialists here are more ready for the coming of larger business following AEC by the end of this year.
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January 19-23, 2017
January 8-10, 2017
October 19 - 26, 2016
August 05-07, 2016
CALENDAR
Sri Lanka Plast 2016
Location: Colombo, Sri Lanka Organised by: Enterprising Fairs (India) Pvt. Ltd. Website: http://www.srilankaplast.com/ Background Sri Lanka Plast was successfully exhibited and organized for two editions in Colombo – 2012 & 2014. The third edition in 2016 is expected to be larger.
K 2016
Location: Düsseldorf, Germany Organiser: Messe Düsseldorf Website: www.k-online.com Background For more than 40 years, K has been and still is the biggest international trade fair for plastics and rubber, and takes place once every three years. The leading raw material producers, processing companies and machinery manufacturers offer an overview of the latest technical developments, procedures and techniques, of current construction methods and future trends. The outstanding importance of K for the industry arises from the excellence and ongoing development of its product range, and the constantly growing number of more than 3,200 exhibitors from 59 nations. The fact that 218,000 trade visitors from over 120 countries expressed their full satisfaction at the last staging of K in 2013 guarantees the future success for all those involved in the industry.
Arabplast 2017
Location: Dubai, UAE Organised by: Al Fajer Information & Services Website: http://www.arabplast.info/ Background It promises to be the largest plastics, petrochemicals and rubber industry trade show in MENA region as well as the fastest way to enter the vast MENA region’s plastics, petrochemicals and rubber industry. ArabPlast 2017 is envisioned to make better business sense to the participants who are giving shape to a better world. The captains of the plastics and rubber industry would be here to unveil products solutions, cutting-edge technology, and revolutionary innovations and forge international alliances.
Plastivision India 2017
Location: Mumbai Organised by: The All India Plastics Manufacturer’s Association (AIPMA) Website: www.plastivision.org Background: It is recognised amongst the top ten global plastics exhibition. Plastivision India 2017 is likely to see participation from about 1,500 exhibitors coming from more than 25 countries. Visitors are expected from over 61 countries and the organisers are anticipating business worth Rs2000 crore to be generated at the show.
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A stroll in the ‘park’! TAKING A LEAF FROM PM NARENDRA MODI’S CALL FOR START-UP INDIA, STANDUP INDIA, THE ALL INDIA PLASTICS MANUFACTURER’S ASSOCIATION (AIPMA) AIMS TO DEVELOP AND PROMOTE PLASTICS & POLYMERS PARKS ACROSS THE COUNTRY
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he All India Plastics Manufacturer’s Association (AIPMA), the apex body and the largest industry association of the plastic industry in India has figured out plans in order to help in attaining various goals, including the ‘Start-up India, standup India’, set up by the Government of India for bringing out the socio-economic change in the country. AIPMA believes that most of the government initiatives such as ‘Swachcha Bharat’, ‘More Crop per Drop of Water’, ‘Housing for All’, developing ‘Smart Cities’, would not be possible to implement without using plastics. AIPMA is focushas already developed Dahej Plastic Park in Gujarat and is closely ing not only on generating employment but also on promoting working with Government of Uttar Pradesh for Auraiya Plastic entrepreneurship and skill development. City Project and Madhya Pradesh Government for Tamot Plastic R K Aggarwal, President, AIPMA, says, “We are very much Park. AIPMA is looking forward to work on this initiative for concerned about successful implementation of various programs Assam (Tinsukia District), Odisha (Paradeep), Karnataka (Benof the central government and want to contribute for this as our galuru) and Rajasthan (Udwaria), with the size of the park rangcorporate social responsibility. Success of various programs such ing from 100 to 250 acres. The Plastics Park would also have a as Clean India Mission, Make in India, Housing for All and Skill dedicated recycling area. Development highly relies upon utilisation of plastic.” Principal Advisor to AIPMA, Deepak Ballani who is leadPlastic is one of the best alternate materials available, and ing this initiative on the ground informed that the idea behind at times is termed as magic material for it requires minimum Plastic Parks is to create a favorable business and technology ecoenergy to be transformed in whichever way one wants it. Be it system for the plastic industry through toothbrush, cell phone, laptops, electrical cluster development approach in order gadgets and many more. Plastic has greatto derive benefits arising due to optimizaer application value. It plays vital role in tion of resources and economies of scale. most of the sectors be it agriculture, infraThis initiative will lead to increase in structure, healthcare, affordable housing Industrial Plots, competitiveness, polymer absorption caetc. Now-a-days one can’t imagine a day Common Facility Center pacity and value addition in the domestic without plastics. Tool Rooms, downstream plastic processing industry Taking a leaf from PM Modi’s call through adaptation of modern, research for Start-up India, standup India, the Skill development center and development led measurers. He furAll India Plastics Manufacturer’s Asso- Landscaped (green) areas ther stated that the Plastic Parks are being ciation (AIPMA), would develop and Buffer Zones developed so as to fulfill comprehensively promote Plastics & Polymers Park across Truck Terminal and Parking facilities the functional requirements in terms of the Country. The Plastic Park is a state- Testing and R&D Facility common facilities, physical and social inof-the-art industrial area for entrepreneurs Guest House/Hotel frastructure amidst a green environment. in Plastics and related business that may Restaurants/Cafeteria Speaking about the Plastics & Polyset up new units within the Park. AIPMA
Suggested components for the Park may include:
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mers Park, R K Aggarwal, President, AIPMA said, “Auraiya Plastic Park in U.P is already ready for allotment to units, Tamot in M.P would be ready by July 2016, however the bookings have already started for the same. The Plastics & Polymers Park at Paradeep, Odisha and the one in Assam (Tinsukia District), would be ready in 2016 while the other parks are expected to be ready in next 2 years.” Arvind Mehta, Chairman, Governing Council AIPMA said, “The Government shall also contribute and assist in developing these Parks. Carrying forward the governments’ initiatives, Skill Development and Technology Incubation Centers would be established in the Plastic Park to impart regular trainings to unskilled and semi-skilled individuals. This will further create employment opportunities for thousands of unemployed youths. Our main objective is to create jobs at local level and reduce urban migration by creating a favorable ecosystem for promoting entrepreneurs.” The main focus area under the livelihood incubation is to take up those commercial activities, which are need based to create enterprises in the Plastic Park (generally in the rural areas). The Technology Incubation Centre established in the Park Centre would impart entrepreneurship, and training in skill development to youth; provide mentoring and hand holding with facilitation for funding with a view to empower them to set up
We are very much concerned about successful implementation of various programs of the central government and want to contribute for this as our corporate social responsibility. Success of various programs such as Clean India Mission, Make in India, Housing for All and Skill Development highly relies upon utilisation of plastic. R K Aggarwal, President, AIPMA
Our main objective is to create jobs at local level and reduce urban migration by creating a favorable ecosystem for promoting entrepreneurs. Arvind Mehta, Chairman, Governing Council AIPMA
Plastic Parks are being developed so as to fulfill comprehensively the functional requirements in terms of common facilities, physical and social infrastructure amidst a green environment. Principal Advisor to AIPMA, Deepak Ballani
Proposed support infrastructure facilities for the project to include: A systematic network of internal roads Regular supply of quality water with adequate storage facilities Reliable power supply to ensure maximization of production levels Underground utility lines Firefighting system Common effluent treatment and solid waste management facilities Sturdy storm water and Sewerage networks & Sewage Treatment Plant Banks / ATMs Efficient and professional service-oriented Operations & Maintenance system
own business enterprises. While the employment potential will depend on the number and size of units, ideally, a 100 acre Park is likely to generate direct employment for around 4000-5000 people and would attract investments to the tune of around Rs. 1000 crore. The Plastics & Polymers Park would be following the likely model of PPP with the State government developing infrastructure for industries whereas AIPMA would be coordinating and assisting in setting up of the Park. AIPMA would be involved right from assessment of the land, design and operation of the park, promotion of the project to Empanelment of Engineers, architects, construction managements /other experts or agencies as needed to ensure successful implementation of the Park. The Plastics & Polymer Parks would also enjoy some initial benefits like project proposed to be implemented by a special purpose vehicle (SPV) shall be eligible for grant from the Central Government funding under the scheme up to 50 percent of the project cost not exceeding Rs.40.00 crores per project whereas, the benefits from state government could vary like say Land at Subsidized rate, VAT exemption 100 percent for 10-15 years, exemption of entry tax on plant and machinery & raw material, power subsidy, training subsidy, interest subsidy etc.. The Indian Plastics industry is growing at an impressive rate. The plastic consumption in the country is growing at 16 percent per annum and is expected to increase many folds. Some of the long-term drivers include rural income that’s expected to triple by 2020, to a total of $1.8 trillion, and annual car production projected to grow from 1.7 million vehicles last year to 9.3 million by 2020. By 2020 the Plastics consumption in India is likely to reach 20kg as compared to the current 10 kg per capita consumption. With this growth, India is all set to become the manufacturing hub with huge demand for Machinery, Equipment, Accessories and Technology. February-March 2016 | The Economic Times POLYMERS | 45
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PACKAGING
Packed for success
ORGANISED RETAIL AND BOOM IN E-COMMERCE WILL FUEL THE GROWTH OF PLASTIC PACKAGING AND PER CAPITA CONSUMPTION WILL DOUBLE IN FIVE YEARS, ACCORDING TO A REPORT RELEASED BY FICCI RECENTLY.
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the flexible packaging is expected to grow at 25 percent p.a. and oday plastics are the material of choice in rigid packaging to grow at 15 percent p.a. The overall packaging packaging for the sectors such as FMCG, industry in India has a huge growth potential and is expected to food and beverages, pharmaceuticals etc. Plasreach ~US$ 73 Billion in the year 2020. tics are used heavily for packaging due to inIn India, the industry is driven by key factors like rising popunovative visual appeal for customer attraction lation, increase in income levels and changing lifestyles. Growth and convenience. Additionally, they improve prospects of end-user segments are leading to the hygiene quotient and shelf-life of the prodrise in the demand of the plastic packaging inucts especially in food and beverages segment. dustry. Demand from rural sector for packaged A report prepared by FICCI and Tata Strategic In a developing products is being fuelled by the increasing meManagement Group (TSMG) on plastic indusdia penetration through the means of internet try titled ‘Plastic Packaging - The Sustainable country like India, and television. Choice’ was released by FICCI recently at the it grew at a CAGR conference on the plastic packaging industry in Out of 30,000 processing units, about of 16 percent in the New Delhi. 75 percent are in the small-scale sector. The last five years and Packaging is one of the fastest growing insmall-scale sector, however, accounts for only touched ~US$ 32 dustries and stands at US$ 700 billion globBillion in FY 15. The about 25 percent of polymer consumption. ally. Globally, Plastics comprise of 42 percent The industry also consumes recycled plastic, Indian packaging of packaging with the combination of rigid and industry constitutes which constitutes about 30 percent of total flexible plastics in packaging. consumption. ~4 percent of the It has grown higher than GDP in most of global packaging the countries. In developing country like India, Challenges & Risks industry.” it grew at a CAGR of 16 percent in the last five However, there are quite a few challenges and years and touched ~US$ 32 Billion in FY 15. risks. High inflation rate and rising prices, lack The Indian packaging industry constitutes ~4 percent of the globof skilled workforce, difficulty in procuring raw material due to al packaging industry. The per capita packaging consumption in weak infrastructure, growing environmental concern, effective reIndia is quite low at 4.3 kgs, compared to countries like Germany cycling of mixed plastic waste and plastic recovery are some of the and Taiwan where it is 42 kgs and 19 kgs respectively. issues plaguing the industry. Overall, the Indian packaging industry is valued at over US$ Going ahead recycling and reuse of plastics will be an im32 billion and offers employment to more than 10 lakh people portant step towards fostering innovation and sustainability. Also across the country through ~10,000 firms approximately. In the increased awareness through help of industry groups and Governcoming years it is expected to grow at 18 percent p.a. wherein, ment could help address some of these challenges. Organised retail and boom in e-commerce to fuel growth of plastic packaging, per capita consumption to be doubled in five years. Image Courtesy: Manjushree. Trademarks belong to respective brands.
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PACKAGING
Plastic Packaging - Benefits and Reduced Environmental Impact As plastics possess versatile properties it can help us do more with less. One such property is light weight. As plastics are light in weight, they have a high product to package ratio which results in lighter weighed end product. For example: Only 1.5 pounds of flexible plastics can deliver ~60 pounds of beverage; compared to three pounds of aluminium or 50 pounds of glass. Thus, plastic packaging enables in shipping more products with less packaging material. And also brings down the fuel consumption and the overall transportation cost. Besides this, plastics can be reused and recycled. They have low energy requirements Growth prospects of end-user segments are leading to rise in the demand of the plastic packaging industry. during production, hence considered to be Image for representation only energy efficient. They consume ~25 percent less energy in production compared to other allion in the machinery and it is expected to make ternatives. They result in lower emission of CO2 further investment of $10 billion for further ingas. Thus when compared to glass or aluminium crease in capacities during the next 5 years. plastics results in lighter environmental footThe per capita consumption of polymers in India is a growing print. India during 2014-15 was just 10.5 kg as commarket for plastics pared to 109 kg in USA, 45 kg in China and and consumes about 32 kg in Brazil. India is expected to be among Plastic Packaging in India - The 12.8 Million Metric the top ten packaging consumers in the world Future Tonnes (MMT) of by 2016. The low level of per capita plastics conIndia is a growing market for plastics and plastics annually sumption in India is indicative of the massive consumes about 12.8 Million Metric Tonnes against global growth potential of the plastic industry. Given (MMT) of plastics annually against global conconsumption of 285 the rising consumerism and modern lifestyles, it sumption of 285 MMT per year. The plastics MMT per year. The is expected that per capita consumption will be and polymer consumption is growing at an averplastics and polymer doubled in the next five years. age rate of 10 percent. About 30,000 processing consumption is While the usage and benefits of plastics are units with 113,000 processing machines have growing at an manifold, it invariably gets branded as a pollutcreated manufacturing capacity of 30 MMT per average rate of 10 ing material. The facts or myth regarding the annum in India. This has been achieved with a percent.� polluting characteristic of plastic are needed 13 percent CAGR of processing capacity during to be addressed in a scientific manner. Plastics last 5 years. The industry has invested $5 bilare chemically inert substances and they do not cause either environmental or health hazards. If plastics can be collected and disposed off or recycled as per laid down guidelines/ rules then the issue of plastic waste can be suitably addressed. In fact there is wide scope for industries based on re-cycling of plastics waste. Further, India is emerging as the most favoured destination for organised retail destination in the world. And also the presence of e-commerce is expanding rapidly and is bringing around a revolution in the retail industry. Retailers are now leveraging digital retail channels thereby enabling wider reach out to customers with less amount of money spent on real estate. Therefore, organised retail and boom in e-commerce offers huge potential for future growth of retailing in India which in turn is pushing the growth of packaging sector. February-March 2016 | The Economic Times POLYMERS | 47
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PRODUCTS
Innovation Awarded
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KABRA EXTRUSIONTECHNIK WAS RECENTLY AWARDED THE DISTINGUISHED ‘NATIONAL AWARD FOR TECHNOLOGY INNOVATION’
duct Extrusion Line. Award was preith over five decsented by Ananth Kumar (Minister ades of experifor Chemicals & Fertilizers, Govence in extrusion ernment of India) in the presence of technology, Kabra ExtrusionHansraj Ahir (Minister of State for technik (KET) continues to Chemicals & Fertilizers, Governbe a leader in manufacturing ment of India) during a grand funcand export of plastic extrution organised on January 20, 2016 sion machinery. The Company at FICCI House, Delhi. The citation has set benchmarks in plastics consists of a trophy, a monetary reextrusion industry by modern ward sum of Rs. 2 lakh and an atR&D techniques and various S V Kabra (Chairman & Managing Director), P. M. Jariwala (Sr. VP – R&D) tractive scroll recognizing KET’s processes to cater the market Kabra Extrusiontechnik receiving award at the hands of Ananth Kumar technology innovation for telecom requirements for low power (Minister for Chemicals & Fertilizers, Government of India) infrastructure sector. Kabra Extruconsumption, high output, siontechnik has always offered technologically advanced plastics maintenance free and user friendly plastics extrusion plants. extrusion machinery to major processors across the globe.
Benefits to the processors
Significance & benefits of High Speed Micro-duct Extrusion Line: With Government announcing Digital India program to empower and bring together India’s social-commer• Ovality of the duct: 3 – 4 % of OD cial ecosystem, need for better communication infrastructure has seen a boost like never before. This machine contributes to • Winding capacity: up to 4 km - helps in longer the telecom infrastructure development. production run while making bundled sheathing. Producing Micro-duct at high line speed is a challenge in • Import substitute and export grade with much lower terms of maintaining good finish, wall thickness and ovality. price than foreign manufacturers. Contributes to Ovality is the most critical parameter which needs to be conIndia’s foreign exchange saving. trolled for consequent operations of bunching & sheathing. • Unique design with less space requirement & lower This has been made possible by special design of vacuum tank production cost. with closed loop control of vacuum and capstun belt haul-off. With its unique micro-duct extrusion process that adheres In recognition of KET’s efforts in Technology Innovation, to global standards, machine is capable of delivering consistcompany has been awarded the prestigious National Award unent output of micro-duct without any change der the Industry Category of “Innovation of For more information, in design, configuration & characteristics of Polymer Processing Machinery & Equipment” info@kolsitegroup.com micro-duct. for its product – High Speed Telecom Micro-
• High output rate to manufacture any type of microduct ranging from 5 mm to 16 mm OD.
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Highly attractive for thermoforming packaging
he ILLIG RV 53 utilises vacuum forming technology on unsophisticated forming tools. The automatic preblowing that pre-stretches the material on a positive forming mold ensures an evenly distributed wall thickness even for high-profile formed parts. The versatility of the RV 53 gives all the possibilities of forming, punching and stacking thermoformed parts. It’s ideal for manufacturing technical parts like transport pallets or tray inserts, but also
for packaging products for both non-food and food applications. In automatic operation mode high packaging hygiene standards can be met. The standard parts system for manufacturing molds, punches and stacking devices that was specifically designed for the RV 53 is an essential component in the success of this machine type. This enables the customer to be able to construct his own simple-design forming and punching tools.
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STATEMENT OF OWNERSHIP Statement about the ownership and other particulars about newspaper entitled THE ECONOMIC TIMES POLYMERS as required to be published in the first issue of every year after the last day of February.
FORM IV (See Rule 8) 1. Place of Publication:
The Times of India Building Dr. D. N. Road, Fort, Mumbai 400 001
2. Periodicity:
Bi-Monthly
3. Printer’s name:
Mr. Joji Varghese for the Proprietors, Worldwide Media Private Limited
Nationality:
Indian
Address:
The Times of India Building, Dr. D. N. Road, Fort, Mumbai 400 001
4. Publisher’s name:
Mr. Joji Varghese for the Proprietors, Worldwide Media Private Limited
Nationality:
Indian
Address:
The Times of India Building, Dr. D. N. Road, Fort, Mumbai 400 001
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Niranjan Mudholkar
Nationality:
Indian
Address:
The Times of India Building, Dr. D. N. Road, Fort, Mumbai 400 001
6. Names and addresses of individuals who own the newspaper and partners or shareholders holding more than one per cent of the total capital as on February 29, 2016 in the companyWorldwide Media Private Limited (Owner), The Times of India Building, Dr. D. N. Road, Mumbai 400 001 Bennett, Coleman & Co. Limited (Shareholder holding more than 1% of total capital), The Times of India Building, Dr. D. N. Road, Mumbai 400 001 I, Joji Varghese, hereby declare that the particulars given above are true to the best of my knowledge and belief.
Date: March 1, 2016
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(Joji Varghese) Signature of the Publisher
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