Etp aug sept2017

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Volume 18 Issue 3 August - September 2017

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

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Printed and published by Joji Varghese for and on behalf of owners Worldwide Media Pvt Ltd (CIN:U22120MH2003PTC142239), The Times of India Building, Dr DN Road, Mumbai 400001. Printed at JRD Printpack Private Limited, 78, Resham Bhavan, 7th Floor, Veer Nariman Road, Churchgate, Mumbai - 400 020. Editor: Niranjan Mudholkar. Published for August September 2017 Disclaimer: All rights reserved worldwide. Reproducing or transmitting in any manner without prior written permission prohibited. All photographs, unless otherwise specified, are used for illustrative purposes only. The publisher makes every effort to ensure that the magazine’s contents are correct. However, we accept no responsibility for any errors or omissions and accept no responsibility for any loss or damage caused as an effect thereof. The information provided in this publication is for general use and may not be appropriate for the specific requirements and / or conditions of the reader/s.

The4opinions expressed by experts are their own and in POLYMER no way reflect those of the publisher.

January 2014

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The need of the hour! rom agriculture to packaging, from consumer durables to healthcare, from construction & houseware to automotive and everything in between, great developments have been making plastics the material of choice because of the many advantages it offers.

Surprisingly, there are very few knowledge-based networking platforms that can stimulate greater sharing of ideas, information and insights to take the industry to the next level. In fact, when The Economic Times Polymers did some research last year, it realised that there wasn’t a single robust forum available in many years to discuss the challenges and opportunities with regards to the use With a great line-up of plastics in automotive in the country. (Incidentally, of speakers and quite a few such platforms are thriving in Europe and industry oriented the US.)

topics like light-

ET Polymers decided to bridge this knowledge gap by weighting, safety conceptualising and launching the ‘Global Conference as well as design on Plastics in Automotive’ (GCPA) in Mumbai last year.

Due to the active involvement of the entire value chain, & aesthetics, the first edition of GCPA was a great success. Considering ‘Global Conference the positive feedback received from automotive on Plastics in professionals, we promised that we would make this Automotive’ is all into an annual event. And so GCPA is back with its 2nd set to accelerate edition at The Westin in Pune on September 13. With a innovation. great line-up of speakers and industry oriented topics like light-weighting, safety as well as design & aesthetics, GCPA 2017 is all set to ‘accelerate innovation’. Importantly, we plan to make this year’s Conference a lot more engaging for all our participants.

So if automotive plastics is your passion, then you should be at the GCPA. Registration open at gcpa.themachinist.in (Terms & Conditions apply).

Editor & Chief Community Officer

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CONTENTS 8

30

News

Event: Global Conference on Plastics in Automotive

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Automotive:

22

Aiming at high quality

Interview:

26 40 44

COVER STORY Leading from the front

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Driven by innovation and sustainability Colouring the future Making it in India

Injection Moulding:

46

TEMPTing Solutions

Case Study:

48

Challenges Create Capabilities!

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Event Calendar

54

Products

AUTOMOTIVE Heat-conducting polymer

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PACKAGING A Cradle-to-Cradle Approach!

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ADDITIVE MANUFACTURING Fastening processes

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AGRICULTURE Creating a new avenue!

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NEWS NATIONAL

ADB sees improved growth prospects for developing Asia

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conomic growth prospects in developing Asia for 2017 have improved on the back of stronger-than-expected export demand in the first quarter of this year, according to a new Asian Development Bank (ADB) report.

In a supplement to its Asian Development Outlook 2017 report, ADB upgraded its growth outlook in the region from 5.7-5.9 percent in 2017 and from 5.7-5.8 percent for 2018.

The smaller uptick in the 2018 rate reflects a cautious view on the sustainability of this export push.

“Developing Asia is off to a good start this year with improved exports pushing growth prospects for the rest of 2017,” said Yasuyuki Sawada, ADB’s Chief Economist. “Despite lingering uncertainties surrounding the strength of the global recovery, we feel that the region’s economies are well-placed to face potential shocks to the outlook.”

Combined growth for the major industrial economies is forecast to remain at 1.9 percent in 2017 and 2018. Improved forecasts for the euro area and Japan due to robust domestic

demand have offset the slight growth downturn in the US to 2.2 percent from the previously projected 2.4 percent as a result of disappointing first quarter results in 2017.

South Asia will remain the fastest growing of all sub-regions in Asia and the Pacific, with growth on track to meet original projections of 7.0 percent in 2017 and 7.2 percent in 2018, according to the report. India — the sub-region’s largest economy — is expected to achieve previous growth projections of 7.4 percent in 2017 and 7.6 percent in 2018, primarily from strong consumption.

GST to boost MSMEs’ competitiveness

Big jump in CII–IBA Financial Conditions Index

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he Goods and Services Tax (GST) would boost the competitiveness of micro, small and medium enterprises (MSMEs), noted a recent joint study by ASSOCHAM- Ashvin Parekh Advisory Services (APAS).

“From an MSME perspective, GST will bring in many positives compared to the current systems such as easy process of availing input credit, single point tax, elimination of cascading tax system, and simpler taxation,” said the study titled ‘Emerging Mantras for Bankers-Borrowers,’ jointly conducted by ASSOCHAM and APAS. The report also said that though there is no doubt that GST is aimed to increase the taxpayer base, and bring majorly MSMEs into its scope and that would put some burden of compliance and associated costs to them. But eventually, it will turn these MSMEs more competitive with a level playing field between large enterprises and them.

It also highlighted certain pros of GST on MSME sector viz., improved MSME market expansion, lower logistical overheads, boon for MSMEs dealing in sales and services, unified market and purchase of capital goods.

he CII-IBA Financial Conditions Index for Q2 FY 2017-18 recorded a substantial change from 56.9 in the first quarter of FY2017-18 to 71.4 in the current quarter owing to expectation of improvement in the overall financial conditions in the economy. There seems to be substantial optimism across most of the sub-indices leading to improvement in the Financial Conditions Index in this quarter as compared to previous quarter. Among the sub-indices, the cost of Funds Index has recorded the highest level (77.6) followed by Funding Liquidity Index (72), External Financial Linkages Index (68.1) and Economic Activity Index (68.1).

A total of 29 banks and financial institutions participated in the Survey including 11 Public Sector Banks, 05 Private Sector Banks, 04 Foreign Banks, and 02 Cooperative Banks. Representing other financial institutions, 07 leading NBFCs participated in the Survey with a combined Total Assets of over 58 Lakh Crore.

Releasing the Index for the second quarter of 201718, Chandrajit Banerjee, Director General, CII said.

“GST is one of India’s most significant and ambitious reforms ever attempted and it is believed that the positive impact of GST on Indian Economy is going to be significant. Apart from the GST, implementation of various reform measures by the government including promulgation of amendment to the Banking Regulation Act giving special powers to RBI to tackle bad loans has raised the expectations of substantial improvement in the financial conditions.”

8 | The Economic Times POLYMERS | August-September 2017

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NEWS NATIONAL

New polymer based dust control technology to improve mining road safety

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lobal Road Technology (GRT) India has unveiled its unique dust control technology GRT: HAUL---LOC for DOTT Services, the contractor for Singareni Collieries Mines. Speaking on the occasion Nicholas James – Executive Director (chemical dust control & stabilisation) GRT, said “Our latest polymer product GRT: HAUL--‐LOC was used at Ramakrishnapuram Open Cast (RKPOC) mine to control dust generated by machinery and vehicles traversing haulage roads, quarry ramps, and overbur-

HPPL to install 5 panel pouch making machine

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uhtamaki-PPL Ltd (HPPL) is installing a state-of-the-art 5 panel pouch making machine at its factory in Rudrapur, Uttarakhand. This versatile equipment will produce 5 panel pouches, synonymously called box pouches, flat bottom pouches, 3D pouches etc.

5 Panel pouches provide excellent retail presence on account of increased surface area available for branding and communication.

Simultaneously, the design results in a compact pack, saving space on the supermarket shelves. Unlike conventional form fill seal pouches, these pouches offer reclose ability using a zipper. This pouch format uses less raw material for the same volume of packaging as compared to conventional packaging formats. These pouches can be used for packaging of all dry products and in India they are particularly popular for packaging of rice in 5 kg and 10 kg pack sizes. The addition of this 5 panel pouch format adds to HPPL’s already strong pouch portfolio and will provide more options to choose from, for its customers.

den dumps.” DOTT CEO – Raja Shekar Rao, said he “was pleased with the result and looked forward to working with GRT in October.” DOTT Vehicles Manager – Pashuram, said he “was amazed by the product’s ability to suppress dust for two and a half hours, and that his team of haulage truck operators were especially pleased with the safer working conditions created onsite, and that he looked forward to seeing the solution expanded to cover all kachha roads at the mine”.

INEOS Styrolution to expand its compounding capacity for styrenic polymers in India at Moxi plant

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NEOS Styrolution plans to increase its compounding capacity for engineering plastics by an additional 34,000 metric tonnes per annum at its Moxi plant located in Gujarat. Expected for completion in 2019, this expansion will grow INEOS Styrolution’s compounding capacity to 100,000 metric tonnes per annum at the site. This expansion will involve a capital expenditure of $20 mn, which also includes the upgrading of site infrastructure. Additionally the company has sanctioned a detailed engineering study to evaluate doubling the overall production capacity for ABS in India over the next years. The planned capacity expansion intends to meet the growing demand for styrenic polymers across key growth industries in India, enabling the company to sup-

port our customers’ growth plans and continuing to provide the same high quality products. The Moxi plant currently manufactures and supplies acrylonitrile butadiene styrene (ABS) and acrylonitrile styrene acrylate (ASA) for the Indian market. As part of the expansion, two new extruders will be installed at Moxi, in addition to various infrastructure upgrades to support the additional site capacity.

Sanjiv Vasudeva, MD, INEOS Styrolution India Ltd says, “This expansion follows our earlier R&D facility upgrading investment in Moxi. It will enable us to better support the success of our customers in India by providing them the best solutions and a stable local supply, therefore paving the way for further growth together.”

Uflex registers 8% growth during Q1 of 2017-18

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flex Ltd has clocked 8 percent bottom line growth (Y-O-Y) during the quarter ended June 30, 2017. Figuratively the Consolidated Net Profit stands at Rs. 93 Crore as compared to Rs. 86 Crore during the first quarter of FY 2016-17.

At the operating level, Consolidated EBITDA rose by 4% to stand at Rs. 236 Crore as against Rs. 228 Crore during the same period in the previous fiscal. Consolidated Total Revenue for the first quarter of the current financial year is Rs. 1624 Crore as against Rs. 1516 Crore in the same quarter last financial year thereby registering a 7 percent topline growth (Y-O-Y).The total sales volume also grew by 5 percent as compared to the first quarter of FY 2016-17.

10 | The Economic Times POLYMERS | August-September 2017

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NEWS INTERNATIONAL

GW Plastics takes over Ireland-based Avenue Mould Solutions

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W Plastics has recently announced its purchase of Avenue Mould Solutions, a premier precision mould building, machining, and injection molding company based in Sligo, Ireland. This acquisition will give GW Plastics unparalleled global precision moldmaking and advanced manufacturing capability to support customers on three continents.

“GW Plastics is thrilled to partner with the Avenue team,” said Brenan Riehl, GW Plastics President and CEO. “Avenue Mould Solutions brings to GW Plastics an experienced and highly-skilled advanced manufacturing workforce, an award-winning mold-building company, and a growing medical device contract manufacturing business that has been successfully serving Ireland and other markets for 30 years. We are pleased that Avenue has

decided to join GW Plastics and help us continue to expand our capabilities to better meet our customers’ needs on a global basis.”

This acquisition will give GW Plastics a unique industry position with precision mold-building facilities in North America, Asia, and Europe, in addition to injection molding and contract manufacturing.

Avenue Mould Solutions brings to GW Plastics expertise in building ultra-

Solvay co-invests $1.9 million in MultiMechanics to speed up innovation

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olvay, Anzu Partners and Invest Nebraska are together investing a total of $1.9 million in MultiMechanics, whose virtual testing software enables to accelerate innovation in new materials. Solvay Ventures has made the investment as part of Solvay Group’s Research & Innovation function.

This joint investment will enhance the development of Solvay’s pipeline of high performance polymer and composite materials, and expand its position in aerospace, automotive markets and other markets.

“Solvay’s decision to invest in MultiMechanics is part of our ambition to accelerate innovation in complex materials and to expand the use of composites in the automotive and aerospace industries. MultiMechanic’s accuracy, speed and its efficient integration with commonly used commercial finite element software packages, is changing the way we develop new materials and interact with our customers,” said Nicolas Cudré-Mauroux, Solvay Group General Manager Research & Innovation.

“Our customers greatly benefit from the software systems we develop,” said Leandro Castro, co-founder and Chief Executive Officer of MultiMechanics, “and I am delighted that we have broad support from these new investors to help us continue to grow our team, our product offerings, and our business.”

high-cavitation tooling up to 192 cavity molds for the medical device, diagnostics, and pharmaceutical markets.

“We are delighted to partner with GW Plastics,” said Felim McNeela, Avenue Mould Solution’s Managing Director and a founder.

In the last two years, GW Plastics has completed expansions of its San Antonio, Texas; Tucson, Arizona; and Dongguan, China facilities, as well as its thermoplastics and silicones manufacturing and mold-building facilities in Royalton, Vermont. “GW Plastics has enjoyed ongoing year-over-year record revenue, and we are committed to supporting this growth by continuing to invest for our customers, worldwide,” said Riehl.

“We are excited to add the European presence that Avenue Mould Solutions brings to us and our customers.”

Lower emissions in car interiors with improved BASF polyether polyols

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ASF has now improved the process for manufacturing Lupranol (polyether polyol) so that car components which are made of BASF polyurethane systems emit an average of 20 percent less aldehyde. This allows automotive suppliers, that manufacture e.g. acoustic parts, seats and steering wheels or back-foam instrument panels and doors, to meet the increasing requirements of car manufacturers and the law for lower emissions (VOCs: Volatile Organic Compounds) in vehicle interiors. Following the process change at BASF’s Asian production sites at the beginning of 2017, the modification is now being made in Europe and will take place in the US plants during the course of this year. Alongside isocyanate, polyol is the starting product for polyurethane foam systems.

The emissions have been optimised by improving the cleaning and finishing processes of Lupranol in such a way that the mechanical properties of the material remain unchanged during the following foam and processing steps.

This means that the currently used Lupranol grades can be exchanged immediately, there is no need for elaborate tests or renewed approvals of the PU systems which are based on these improved polyol grades. BASF markets the PU systems for flexible, semi-rigid and integral foams under the trademarks Elastoflex W, Elastoflex E and Elastofoam I.

12 | The Economic Times POLYMERS | August-September 2017

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NEWS INTERNATIONAL

HTI Plastics selected as a beta test site for all-electric moulding machine

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TI Plastics was selected by Krauss Maffei as a beta test site for their new PX all-electric injection molding machine. The PX allelectric was introduced in the fourth quarter of 2016. HTI will act as a host site for the machine for a year and have the option to purchase the machine after acting as a test site.

In 2010, HTI Plastics introduced electric mold machines into its production process. The introduction of electric molding machines helps to reduce cost and increases speed and efficiency in many ways. With tight, repeatable control of operations, the product is produced with

Axalta Coating Systems to acquire Plascoat Systems from IPT Ltd.

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xalta Coating has acquired Plascoat Systems Ltd, a leading supplier of thermoplastic powder coatings, from its parent company, International Process Technologies (IPT) Ltd. Established in 1952, Plascoat has pioneered the science behind the formulation, manufacturing, and application of thermoplastic polyolefin coatings. Plascoat’s industry-leading product portfolio includes Plascoat PPA 571, a flexible, tough and highly durable plastic coating used for a wide variety of outdoor ap-

plications, Talisman, a hard wearing, tough plastic coating used extensively in the dishwasher basket coating market, and Plascoat PPA 571 Aqua, a unique plastic coating for potable water pipes, in addition to many other high performing coatings designed to meet the highest industry standards.

“Over the last 65 years, Plascoat has led the way in developing innovative, environmentally responsible coatings that meet the high corrosion resistance demands of customers around the globe,” said Michael Cash, Axalta Senior Vice President and President, Industrial Coatings. “We look forward to bringing this knowledge and expertise into Axalta to augment our existing thermoplastic powder coatings business and provide even more innovative products and solutions to our customers.”

less material and fewer additives, reducing waste. All-electric machines can result in faster cycles and lower operating costs. With the advantage of digital control, all-electric mold machines can lead to greater repeatability.

“We are excited to serve as a test site for the Krauss Maffei all-electric PX injection molding machine,” said Troy Just, President of HTI Plastics. “We are committed to investing in our facility and the latest technologies. Partnering with Krauss Maffei will allow us to remain on the cutting edge of injection molding technology and processes.”

HuntsmanClariant merger on track

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lariant and Huntsman Corporation presented a first update on the planned merger of equals to keep their shareholders informed. The preparations to create HuntsmanClariant, a leading global specialty chemicals company, are showing continued strong progress and are proceeding as planned with an unchanged closing targeted for December 2017 / January 2018.

Clariant and Huntsman have agreed on a joint strategic direction for near- and long-term value creation based on continued focus on higher growth and higher margin businesses, expansion of existing strong downstream presence, reaping benefits of complementary product portfolios and breadth of reach to deliver an additional organic sales revenue growth of around 2% p.a. at approx. 20 percent EBITDA margin and delivering synergies in excess of $400m as well as the $25m tax savings.

The merger brings together two strong specialty chemicals businesses with similar EBITDA margins at 17.2% (including synergies). It will reap complementarity benefits between Performance Products, Care Chemicals and Natural Resources, which represent approx. 35% of HuntsmanClariant combined sales and hold a comprehensive surfactants portfolio in high-end niche markets globally. It will have meaningful opportunities for growth including cross-selling potential and new product applications. The complementary assets and geographic fit provide significant commercial opportunities and more global reach within established routes to market. Furthermore, HuntsmanClariant will take advantage of its broad asset base while continuing to move downstream into specialties and more differentiated applications.

As a result of these complementary product portfolios and structures, additional organic sales revenues of around 2% p.a. at approx. 20% EBITDA margin have been identified.

14 | The Economic Times POLYMERS | August-September 2017

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NEWS INTERNATIONAL

Henkel opens new composite test center in Japan

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enkel has opened a state-of-the-art test facility for composites in Japan. The new Composite Lab in Isogo-ku, Yokohama, will allow automotive customers from across Asia to team up with Henkel experts to develop and test composite parts, and to establish the best process conditions to make their ideas ready for market.

Interest in the use of composites to reduce vehicle weight and increase performance is rising rapidly among automotive OEMs and Tier 1 suppliers. But their demands are strict: they require cost-effective processes suitable for production of more than 10,000 parts per year. In practical terms, this means they often want custom-formulated, fast-curing resins for use in short production cycles. This magnifies the importance of having reliable partners

Pretium commercialises disruptive PET container with integrated handle

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with in-house test capabilities.

This is why Henkel, a global leader in composite matrix resins, adhesives, sealants and functional coatings for the automotive industry, has opened the new Composite Lab, where automotive customers can work with Henkel experts to develop and test composite parts, and also optimize series production process conditions. They can carry out trials with different test molds on Henkel’s own High Pressure Resin Transfer Molding (HP-RTM) equipment. The HP-RTM machine includes a 380 tons press for trials close to series production conditions.

LANXESS develops new PBT compound for battery components in electric cars

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ANXESS has developed a new compound called Pocan AF4130 in collaboration with HELLA KGaA Hueck & Co., based in Lippstadt, Germany. It serves as a housing material for a battery management unit (BMU) and two cell monitoring units (CMU). The blend of polybutylene terephthalate (PBT) and acrylic ester-styrene-acrylonitrile (ASA) contains 30 percent by weight glass fibers and a halogen-based flame retardance package. “The particular advantages of the material are its extremely low warpage and shrinkage, combined with its high flame retardance. We see great potential for application in precision components for vehicle battery systems,� says Marc Marbach, head of Sales Segments E&E in the LANXESS High Performance Materials (HPM) business unit.

It took just two-and-a-half years to go from the initial idea to extensive testing and finally to use in full-scale production.

retium Packaging has developed a 64-ounce, 38-400 mm finish, stock PET container with an integrated handle. Trademarked, the SureHandle PET container, this disruptive commercialisation now gives brand owners significant shelf differentiation, handling convenience and aesthetics that were not previously possible.

SureHandle containers create multiple marketing opportunities for brand owners seeking to appeal to a wider audience. The container is easier to handle for both younger children and older adults, and those with physical

challenges, compared to pinch grip or straight-sided alternatives. The handle not only provides carrying advantages, but also improved pouring control. It has been engineered for products needing fill temperatures up to 120 degrees Fahrenheit and can accommodate an induction seal or foam liner.

Additionally, the container has been designed with enhanced top load capabilities. This enables the use of a shrink wrapped tray pack (vs. a corrugated case) which can withstand stacking of five layers to a pallet, four pallets high.

Using a tray pack can potentially reduce secondary packaging costs by up to 80 percent. This also means easier unloading at the retail level, as well as retail-ready displays for big box stores.

The end result is a cost-competitive container alternative, with significant convenience benefits and reduced secondary packaging.

16 | The Economic Times POLYMERS | August-September 2017

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EVENT

Global Conference on Plastics in Automotive GCPA’S SECOND EDITION TO DISCUSS NEW TRENDS AND CHALLENGES

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panel discussion on the ‘Use of Plaslowly and steadily, tics in the context of Safety’ will touch plastics’ imporupon one of the most crucial areas of tance in the autothe automotive industry. While, in motive industry is the panel discussion on ‘Impact of on the rise. ConPresents Plastics on Design & Aesthetics’ will sidering various discuss new trends and technologies advantages that the material features, in automotive aesthetics. it holds immense capability to mould Light-weighting has been an imthe future of the automotive industry. portant topic for the global automoBearing this in mind, we established tive industry. In this regard, plastics a platform of ‘Global Conference of play an important role in making the Plastics in Automotive’ (GCPA) in vehicle lighter. In the effort, safety 2016 to discuss on latest technologies. and compliance aspects should not Also, it acts as a forum for brainstorm13 September 2017, The Westin Pune be compromised. Considering this, ing on the upcoming trends and know what OEMs are looking at.

After the successful maiden edition of The Economic Times Key topics of discussion Polymers Global Conference on Plastics in Automotive (GCPA), we are announcing the sec• CEO Panel Discussion - What Auto Industry Wants? ond edition of the confer• Presentation - Engineering Plastics in Automotive ence. The programme with • Presentation - Future Challenges & Way Forward the theme of ‘Accelerating Innovation’ will take place • Panel Discussion - Design & Aesthetics on September 13, 2017 at • Panel Discussion - Light-weighting The Westin, Pune.

The CEO panel discuswhere is the plastics industry heading in order to deliver better sion is planned on the topand more fuel efficient vehicles? The panel will discuss various ic of ‘What auto industry aspects of light-weighting with regard to plastics. wants?’ As the Indian auto In addition to these knowledge-enriching sessions, the conindustry evolves further, ference will see few presentations from industry leaders. The presand adopts new norms, entation on ‘Engineering Plastics in Automotive’ by Varun Gupwhat automobile industa, Director, Calco Poly Technik will give a sneappeak into the try is expecting from auto materials that will make future cars. As we speak about the future component manufacturers of the automotive industry, we can not neglect challenges that are and material developers? expected to be faced in the future. In this regard, a presentation One can seek the answers on ‘Future Challenges & Way Forward’ by Sandeep Raina, Vice to these questions at the President – Engg, Maruti Suzuki India Ltd. will offer an insight panel discussion.

Rajan Wadhera, Mahindra & Mahindra on what is likely to be in the near-future.

On the other hand, the speaks at GCPA 2016 Presenting Partner

Gold Partner

Associate Partner

18 | The Economic Times POLYMERS | August-September 2017

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AUTOMOTIVE

Heat-conducting polymer ADVANCED PLASTICS COULD USHER IN LIGHTER, CHEAPER, MORE ENERGYEFFICIENT PRODUCT COMPONENTS, INCLUDING THOSE USED IN VEHICLES

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dvanced plastics could usher in lighter, cheaper, more energy-efficient product components, including those used in vehicles, LEDs and computers—if only they were better at dissipating heat. A new technique that can change plastic’s molecular structure to help it cast off heat is a promising step in that direction. Developed by a team of University of Michigan researchers in materials science and mechanical engineering and detailed in a new study published in Science Advances, the process is inexpensive and scalable.

The concept can likely be adapted to a variety of other plastics. In preliminary tests, it made a polymer about as thermally conductive as glass—still far less so than metals or ceramics, but six times better at dissipating heat than the same polymer without the treatment. “Plastics are replacing metals and ceramics in many places, but they’re such poor heat conductors that nobody even considers them for applications that require heat to be dissipated efficiently,” said Jinsang Kim, U-M materials science and engineering professor. “We’re working to change that by applying thermal engineering to plastics in a way that hasn’t been done before.”

The process is a major departure from previous approaches, which have focused on adding metallic or ceramic fillers to plastics. This has met with limited success; a large amount of fillers must be added, which is expensive and can change the properties of the plastic in undesirable ways. Instead, the new technique uses a process that engineers the structure of the material itself.

Plastics are made of long chains of molecules that are tightly coiled and tangled like a bowl of spaghetti. As heat travels through the material, it must travel along and between these chains—an arduous, roundabout journey that impedes its progress.

The team—which also includes U-M associate professor of mechanical engineering Kevin Pipe, mechanical engineering graduate researcher Chen Li and materials science and engineering graduate student Apoorv Shanker—used a chemical process to expand and straighten the molecule chains. This gave heat energy a more direct route through the material. To accomplish this, they started with a typical polymer, or plastic. They first dissolved the polymer in water, then added electrolytes to the solution to raise its pH, making it alkaline. The individual links in the polymer chain—called monomers—take on a negative charge, which causes them to repel each other. As they spread apart, they unfurl the chain’s tight coils. Finally, the water and polymer solution is sprayed onto plates using a common industrial process called spin casting, which reconstitutes it into a solid plastic film.

A sample of heat-conducting polymer is tested for thickness in U-M’s Lurie Nanofabrication Facility. Image credit: Joseph Xu, Michigan Engineering

The uncoiled molecule chains within the plastic make it easier for heat to travel through it. The team also found that the process has a secondary benefit—it stiffens the polymer chains and helps them pack together more tightly, making them even more thermally conductive. “Polymer molecules conduct heat by vibrating, and a stiffer molecule chain can vibrate more easily,” Shanker said.

“Think of a tightly stretched guitar string compared to a loosely coiled piece of twine. The guitar string will vibrate when plucked, the twine won’t. Polymer molecule chains behave in a similar way.” Pipe says that the work can have important consequences because of the large number of polymer applications in which temperature is important. “Researchers have long studied ways to modify the molecular structure of polymers to engineer their mechanical, optical or electronic properties, but very few studies have examined molecular design approaches to engineer their thermal properties,” Pipe said. “While heat flow in materials is often a complex process, even small improvements in the thermal conductivities of polymers can have a large technological impact.”

The team is now looking at making composites that combine the new technique with several other heat dissipating strategies to further increase thermal conductivity. They’re also working to apply the concept to other types of polymers beyond those used in this research. A commercial product is likely several years away.

“We’re looking at using organic solvents to apply this technique to non-water soluble polymers,” Li said. “But we believe that the concept of using electrolytes to thermally engineer polymers is a versatile idea that will apply across many other materials.”

The study is titled “High thermal conductivity in electrostatically engineered amorphous polymers.”

Source: University of Michigan, US

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AUTOMOTIVE

Aiming at high quality SUDHIR MEHTA, CHAIRMAN AND MANAGING DIRECTOR, PINNACLE INDUSTRIES LTD SAYS THAT HIS COMPANY AIMS TO BECOME THE PARTNER OF CHOICE FOR AUTOMOTIVE SEATING AND INTERIORS FOR ALL BUSES AND TRUCKS.

By Swati Deshpande How has been the last one year for Pinnacle Industries and what are expectations from current financial year?

In the last one year, we saw two major economic decisions taken by the government, one being the Goods and Services Tax (GST) and the second being the demonetisation move announced on November 8, 2016. The BS-III ban also had its bearing on the automobile segment, eventually impacting our business as well.

Having said that, we still registered double-digit growth, thanks to the market demand for our state-of-the-art products and solutions. We are looking to build on this success by introducing more innovative offerings in the future and expanding our foothold in potential markets.

With our diverse product portfolio, trusted partners and effective solutions, we aim to become and be perceived as the partner of choice for automotive seating and interiors for all buses and trucks. We look forward strengthening our partnerships with industry players and the government whilst developing the ecosystem, in addition to fostering greater customer relationship.

The Indian auto industry is one of the largest in the world. The industry accounts for 7.1 per cent of the country’s Gross Domestic Product (GDP).

Can you please tell us about company’s journey in the automotive industry since its inception in 1996?

Pinnacle Industries Ltd was set up in 1996 in Pithampur, near city of Indore in Madhya Pradesh. Over the last several years we have continuously invested in and expanded our technology partnerships, manufacturing systems, product range and clientele to emerge as India’s largest commercial vehicle, bus seating and Interiors Company.

Today, Pinnacle Industries has the largest engineering and development team focused on commercial vehicle seating and

interiors. Our vision is to be the preferred Seating and Interiors systems partner for our customers by providing a full range of solutions starting from Product design to manufacturing.

Tell us about your manufacturing capabilities and capacities.

Our manufacturing facility is based in Pithampur, Madhya Pradesh and is certified for ISO/TS 16949, ISO 14001 and OHSAS 18001. Our production capacity has grown manifold over the years with current installed capacity standing at 24 lakh seats per annum. The plant, sprawling over 18 acres possesses injection moulding machines ranging from 60–650 T, multi-axis CNC tube bending machines, press for stamping of sheet metal parts using 10–400 T mechanical and hydraulic presses, a fully automated powder coating plant with conveyor speed of 5 meters per min, two oval carousals for flexible Polyurethane foams and rigid integral skin PU foams for steering and grab handle etc. We have high-tech ‘Polyol ’blending plant to back up the Flexible PU foam manufacturing. The state-of-the-art factory also houses ultra-modern facilities for upholstery stitching and facility for PU moulding dashboard. Modern robotic welding facility is setup to ensure consistent quality and improved productivity.

We are one of the largest manufactures of extruded ABS sheets – having thermoforming capacity along with 5 axis CNC routers for trimming. Additionally, we also have in-house demo

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AUTOMOTIVE

Our goal is to scale up not just in numbers but also keep on improving the quality of our products.

Sudhir Mehta centre and a customer support centre. We have been manufacturing hi-tech quality products for both national as well as global markets in compliance with all the international safety and quality norms.

Our goal is to scale up not just in numbers but also keep on improving the quality of our products. For this, we have a dedicated R&D unit in Pithampur and Pune that comprises of research scholars, skilled engineers and acclaimed automotive designers for product innovation and betterment of our manufacturing standards.

State-of-the-art R&D centre is ready to support global and domestic needs of customers with back up of in-house and external test facility. We check the seats with help of 95 percent Manikin available in-house. The design team is strongly backed up by in-house Styling team helping us to provide end to end solution to our customers. In-house tooling facility for injection moulding, sheet metal stamping, robotic welding fixtures, foam moulding, thermoforming, etc. reduces the time to market.

Now that GST is implemented, how do you look at its impact on the automotive industry?

The GST implementation has indeed been a transformational

move by the Government of India and will benefit the creation of a national market; enhanced ease of doing business; greater productivity and efficiency; and improved tax compliance. We are positive towards the unified tax regime and are working together for a seamless transition to this new paradigm.

The implementation of the crucial tax reform gives tremendous confidence to the industry that the government will continue to facilitate investments and simplify the business environment. In the long term, this surely will benefit both, businesses as well as consumers.

Overall, GST will have a positive impact on automotive industry because of its competence and removal of cascading or double taxation.

The auto and automotive industry is on transitional phase.

There have been changes with regards to norms as well technologies. In this case tell us about your roadmap ahead.

The Indian auto industry is one of the largest in the world. The industry accounts for 7.1 per cent of the country’s Gross Domestic Product (GDP). Moreover, the growing interest of the companies in exploring the rural markets further aided the growth of the sector. India is also a prominent auto exporter and has strong export growth expectations for the near future.

In a fiercely competitive market like India, it is also impor-

The implementation of the crucial tax reform gives tremendous confidence to the industry that the government will continue to facilitate investments and simplify the business environment. tant to be price sensitive and strengthen service quality to ensure customer loyalty. The Government of India and the automobile industry will have to together devise a two way road map to encourage the next generation of opportunities, to make the Make in India campaign a real success.

At Pinnacle Industries, we look forward to increase our market share in each segment. Our constant efforts in expanding our production capacities and capabilities to cater to the evolving consumer demands have enabled us to tackle the changing market trends.

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INTERVIEW

Driven by innovation and sustainability VIKRAM BHADAURIA, DIRECTOR - ALOK MASTERBATCHES, EXPLAINS HOW HIS COMPANY IS ‘ADDING GOOD’ TO MAKE PLASTICS SAFER, SUSTAINABLE AND AFFORDABLE.

By Niranjan Mudholkar First of all, heartiest congratulations on winning the second ‘National Innovation Award’. It is indeed a commendable achievement. Tell us more about this innovation that has fetched you the national award.

On behalf of Team Alok, I take this opportunity to thank everyone who has played a part in our journey. I take pride in the team that we’ve built over the years and our approach to make a difference with safer, sustainable and affordable plastics.

This year, we won the first place, in the National Award for Innovation, Government of India for our work in supporting the Indian agriculture sector.

Over the years, many Indian film manufacturers have tried to

develop solutions for plasticulture, but performance and durability were two distinct challenges that could not be addressed. At Alok, we undertook the task to introduce an exhaustive portfolio of offerings to support the Indian agriculture sector, in line with the Government’s objective to double farmer’s income by 2022.

Our solutions are customised to withstand seasonal climatic fluc-

While India continues to be our priority market, we cater to a loyal clientele in more than 20 countries across. tuations and high agrochemical resistance to protect the final produce from unwanted contamination and damage. These solutions further support the irrigation, greenhouse and shade net needs of the sector. The additives used in their making are not only economical, but also at par with globally available solutions.

You have been personally leading the technology team at Alok for creating innovative solutions that cater to the industry needs. What kind of R&D capabilities does Alok have and what is the level of investments that you make regularly to enhance the innovative edge of your organisation?

Over the past three-four decades, India has fared reasonably well in the services sector. Yet, one element that is conspicuous by its absence is innovation and R&D in manufacturing.

To address this, we invested in introducing our very own innovation lab, Alok Technology Incubation Centre (ATIC), which happens to be India’s first such initiative. At ATIC, we offer a state-of-the-art facility with a wide array of testing equipment required to drive innovations in the masterbatch industry.

The entire proposition of ATIC is to co-create and collaborate with customers and academia to customise solutions that can be developed and tested on a smaller scale before mass production. This facility is well-equipped with Chemical, Mechanical and Characterization laboratories. ATIC propagates the Government’s flagship ‘Make in India’ initiative and is accredited by the National Accreditation Board for Testing and Calibration Labo-

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INTERVIEW

ratories (NABL) and based in Delhi.

What kind of manufacturing capabilities does Alok have?

Alok is known to have the finest manufacturing facilities in India.

Each facility is equipped with top of the line production equipment and protocols that give us the highest level of efficiency and operational excellence.

We have facilities in New Delhi, Dadra & Nagar Haveli, Tamil Nadu and Rajasthan which have a combined production capacity of 70,000 tonnes. Our upcoming plant in Dadra & Nagar Haveli will be one of the largest in the country and will set new benchmarks in safety, occupational health while maximizing efficiency. Our long-standing commitment to quality, backed with on-going investments in technology and R&D has made Alok a preferred partner for a host of industry verticals. Our zeal to develop customised formulations using the latest technologies is the cornerstone of the business. Today, we have the largest additive MB portfolio, widest range of filler MBs and industry leading black MBs. I understand that with more than 5000 Masterbatches (MB), Alok has the largest additive MB portfolio in the country.

Tell us something about your specialities and range.

We unveiled our proprietary ‘Periodic Table of Masterbatches’ in 2016 which is a summation of 22 specialty solutions that we have launched over the years to address real-time needs of our customers. The solutions defined here offer a range of properties for the key sector verticals that we serve – agriculture, packaging, industrial and automotive and can be viewed on our website alokmasterbatches.com under the innovation story.

Lumanex (light diffusing masterbatch) and Thermoflux (thermally conductive polymer) which have been recognised as breakthrough innovations by the Government of India in the previous year, are a part of our Periodic Table of Masterbatches.

Do you also cater to the exports market? Tell us about the same. In terms of percentage, how much of your business is coming from exports?

While India continues to be our priority market, we cater to a loyal clientele in more than 20 countries across. Besides direct exports, we have a joint venture operation in South America by the name of Carmenta. Carmenta serves the MERCOSUR trade bloc through its facility in Asuncion, Paraguay.

The versatile nature of this wonder material – plastic – makes it extremely useful. And yet, big question marks are raised against it when it comes to issues like safety and sustainability. What are organizations like Alok doing to address this issue?

Sustainability stands on the principle of identifying gaps and thereby developing solutions to address the concerns whilst ensuring ecological and consumer safety. The chemistry that goes into making plastics is a misunderstood concept in common discourse. Today, the industry is striving towards an equilibrium

At ATIC we designed Envoplast based on Biodegradable technology which is an affordable insurance against plastic waste accumulation in the environment.

Envoplast based plastic degrades by conventional means of Oxidation, but at an accelerated rate.

Vikram Bhadauria, Director - Alok Masterbatches between innovation and sustainability.

For instance, unmanaged disposal of plastic waste has been a mounting environmental concern. Conventional non-biodegradable plastics, when unmanaged, accumulate and leave behind an undesirable visual footprint that has an adverse impact on the environment.

At ATIC we designed Envoplast based on Biodegradable technology which is an affordable insurance against plastic waste accumulation in the environment. Envoplast based plastic degrades by conventional means of Oxidation, but at an accelerated rate. This solution was a big hit at the Kumbh Mela Festival in Madhya Pradesh, where we assisted the local Ujjain municipality in disposal of waste with over 20 lakh bio-degradable garbage bags being put to use. This exemplifies our value proposition of ‘Adding Good’ to make plastics safer, sustainable and affordable.

You are a polymer engineer from University of Mysore and hold a Master’s Degree in Plastics Engineering from University of Massachusetts, USA, where you specialised in polymer materials and process technologies. That’s a fairly high level of qualification. How easy or difficult is it to attract qualified young engineers to this profession?

As per the current statistics, nearly 1.5 million new engineers step out into the market each year, fuelled with a desire to make a difference and create their own unique success story. Unfortunately, as more of them settle into predictable and conventional roles, the aspiration to make that difference dies down. The opportunity for innovative and creative talent to flourish is fairly limited.

Today’s talent is increasingly looking for opportunities in R&D and flexibility from the industry to innovate and create new products with advanced technologies. I am a firm believer of creating those avenues that foster innovation. In today’s information rich and technology enabled world, India could significantly leverage this talent pool to propel manufacturing excellence exponentially. It is not a question of how, but when.

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COVER STORY

Leading from the

FRONT

ABHISHEK JAIN, CHIEF EXECUTIVE OFFICER AND MANAGING DIRECTOR, PPAP LTD BELIEVES THAT RIGHT ATTITUDE LEAD TOWARDS SUCCESS AND HAS INCULCATED THE SAME CULTURE IN THE COMPANY.

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COVER STORY

leading from the front. With the motto of ‘Taking challenges, together’, he encourages his team to overcome challenges with calculative risk. However building such a team was not an easy task for him. Speaking on it, Jain says, “Every day brings a new challenge in the automotive industry. It depends on how much you can see and how much you can hear. The evolution will always bring about new challenges. At PPAP, we motivate our team which is always ready to face and overcome these challenges. I think the biggest challenge that I faced was to develop my team to take calculated risks to achieve breakthrough results. I always tell them, that if you are taking a calculated risk, then success is yours and failure is mine.”

In this journey, setting short term goals can give tremendous results. “Daily small improvement is our key mantra for success.

We firmly believe that today’s result should be better than yesterday’s result. The team is motivated to challenge each activity of their daily routine and are focused to doing the same activity more efficiently,” he stated.

Innovation The mantra of continuous development has translated into new developments. Giving an example of an innovation that stands tall amongst others, Jain narrates, “One of our customers requirement was the part that must be bent to match the body shape. It was possible if we used steel in our profile and bent it conventionally using a special machine. But in this case ,the customer did not want to increase the weight of the product but at the same time required the body matching of the part. Our engineers took the challenge and decided to make it by using a typical process (refer to fig. 1).”

One of the other innovations that helped PPAP Automotive Ltd bag the ET Polymers Award 2017 for Excellence in Automotive was Body slide moulding for Baleno. Speaking on this, Jain says, “Body Side Molding is used to add aesthetics and also provide safety to the vehicle in case of minor accidents. PPAP’s in-house designed part is light in weight, and easy to install on the

By Swati Deshpande

M

aruti Suzuki India (then Maruti Udyog Ltd) launched its first car in 1983-84 with the aim of bringing out affordable vehicles. PPAP Automotive has been the part of that historic moment. Speaking on the history of the company, Abhishek Jain, Chief Executive Officer and Managing Director, PPAP Ltd mentions, “We have been in the industry since the launch of the first Maruti car in the country.

Since then we have consistently worked on ourselves to remain the best in technology and capability. One of our key strengths is our integrated operations that support our customers from print to build. We engage with the OEM right at the development stage and assist from part design and development to mass production.”

Along with company, Abhishek also inherits the skill of

The prime focus on reduction of fuel consumption has led many automakers to focus on reducing the weight of their car by using light weight components.

Use of Engineering Plastic has been playing a major role in replacing traditionally used steel in many components. door panel. These features have resulted in improving the vehicle’s fuel efficiency and time saving in part assembly. Despite weight reduction, product quality requirements were ensured through DFMEA, Design Reviews, Mould flow Analysis, material testing, PFMEA, performance testing & Inspection.” The key features of this product include weight reduction (by 17 percent) - reduced wall thickness and addition of aesthetics with chrome Insert.

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COVER STORY

bilities and facilities, localising supply chain to the maximum extent possible and focusing on preserving the environment.

Customer delight While the team is ready to take new challenges, customers also play in important role in the success of the company. “Continuous engagement with customers helps us identify their pain areas.

What further leads to offering better results is focusing on achieving manufacturing and business excellence across all facets of the organisation,” he noted.

This mantra has helped the company deliver exceptional results even in the turbulent times. Speaking on the company’s last year’s results, Jain says, “Our journey on the path of continuous improvement and Muda elimination continued during the year and brought creditable results with the EBITDA margin crossing 21 percent in the last quarter of the Financial Year 2016-17.

In the current financial year, we have targeted to grow at higher than industry rate, acquire more customers and consolidate the improvements achieved.”

Eventful period

Daily small improvement is our key mantra for success. We firmly believe that today’s result should be better than yesterday’s result. The team is motivated to challenge each activity of their daily routine and are focused to doing the same activity more efficiently.

In bringing out innovations, what helps the company is their strong infrastructure. Speaking proudly on the same, Jain says, “Improving the cost competitiveness of our products is driving us to challenge the current designs and come up with innovative solutions to meet our customer’s expectations. To enable this, we have a Design Center, which is supported by an exhaustive validation facility as well as a tooling facility to make the dies and fixtures. We also design and manufacture the machines that are required to make these products. With the help of our state-of-theart facilities, we were able to match the bending properties of steel with thermoplastics.”

In addition to the infrastructure and attitude of taking challenges, Jain also believes in developing local R&D capaFigure 1

The last few months have been quite eventful and equally turbulent to the automotive industry. Some of the key instances are demonetisation that affected the automobile and hence automotive industry for short period of time, introduction of GST and adoption of BS IV regulations. “GST regime will definitely support the competitiveness of the automotive industry as it will remove the state boundaries and goods can be easily transferred from one state to another. The biggest change that has come about is that all expenses towards business furtherance barring a few items that are specifically blocked are now eligible for Input Tax Credit. As a result the cost of production is expected to come down. While, transition is obviously challenging, the process can be said to have become simplified. On the whole we are very positive about this significant reform,” opines Jain.

“We are continuously adapting to the changing environment

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COVER STORY

Manufacturing excellence PPAP Automotive Ltd’s state-of-the-art manufacturing facilities are located in Noida (UP), Greater Noida (UP), Chennai (Tamil Nadu) Pathredi (Rajasthan) and Surajpur. The company has an integrated development center, which designs the products using the latest softwares. It also has a validation and testing facility to validate the designs along with a tool manufacturing facility which makes all the tools required to manufacture the products. The company has Extrusion lines that are capable of processing Engineering polymers like PVC, PP, TPO, TPE and TPV materials.

The Co-extrusion facilities are capable of extruding up to 4 different hardness materials into a single profile based on the customer’s requirements.

The company also has EPDM Rubber Extrusion lines and TPV Glass Run Channel line in its joint venture company. All the lines are fully automated and use the best and most cost effective technology. Besides Extrusion lines, the company also has Injection Molding machines ranging from 60–2500 tons. and continue to focus on delighting our customers with their stated and implied needs in a proactive way,” he adds.

Projecting the future developments Jain states “The paradigm shift that is taking place in the industry is towards the reduction of fuel consumption and a connected car concept where the car is an extension of yourself. We are continuously challenging our designs and providing lower weight solutions to our customers.”

“The prime focus on reduction of fuel consumption has led many automakers to focus on reducing the weight of their car by using light weight components. Use of Engineering Plastic has been playing a major role in replacing traditionally used steel in many components. PPAP has been consistently supporting this initiative by efforts towards reducing the cross section of its profiles as well as wall thickness of Injection Molding parts, thereby reducing the weight of the components manufactured by it,” he

We will be a seeing a lot of technology getting changed on the fuel intake systems, emissions and the exhaust systems. Many component suppliers are ready with the technology to cater to BS VI requirements. elaborates.

The plastic has been playing a crucial role in the automotive industry. “While motorists want high performance cars with greater comfort, safety, fuel efficiency, style and lower prices, society demands lower pollution levels and increased recovery at end of life. Continual innovation is a key feature in the use of plastics in cars. Plastics will continue in the next decade to help designers and engineers to innovate and take car performance further,” Jain opines.

He further adds, “The innovative use of plastics and plastic composites is driving a revolution in the capabilities of automotive industry. Lightweight plastics allow automotive designers and engineers the freedom to deliver innovative concepts cost effectively. Some of the key attributes that plastic features are durability, strength, lightweight, resistance to chemicals and harsh environments, thermally and electrically insulating, transparent, translucent, or opaque. Additionally, the material is also soft, flexible, or hard in almost any shape and size as well as heat- and corrosion-resistant. Its recyclability and cost-efficiency make it a preferred material.”

Looking ahead at the adoption of BS VI regulations that is expected to be implemented by 2020, Jain suggests “We will be a seeing a lot of technology getting changed on the fuel intake systems, emissions and the exhaust systems. Many component suppliers are ready with the technology to cater to BS VI requirements. The biggest foreseeable change will happen when India decides to adopt Hybrid and Electric vehicle technology in a big way,”

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PACKAGING

A cradle-to-cradle approach!

WITH INCREASING POPULATIONS, VOLATILE MARKET CONDITIONS AND UNSUSTAINABLE HUMAN INTERVENTIONS, TODAY THE WORLD IS HELPLESSLY STARING AT FALLING FOOD SUPPLIES AND UNSUSTAINABLE ECONOMIC MODELS.

By Vipul Babu

I

n 2016, the Government of India notified plastic packaging manufacturers and users about the new Plastic Waste Management Rules that would mandate use of recyclable, sustainable packaging material, extend the jurisdiction of recycling waste collection to rural areas, promote use of plastic waste in road construction, waste to energy or waste to fuel among other provisions.

This is a welcome move for a country that faces the challenge of handling 10,000 tonnes of plastic waste generated per day – while thermoplastic (inherently recyclable) waste forms 80 percent of this waste, the 20 percent of thermoset plastics, which include metalized and multilayered plastics and essentially all flexible food packaging of today, is the most visible and perceptibly problematic waste that municipal authorities deal with. Littered plastics are not just an eyesore – they practically choke cities, whether caught in drains, burnt or worse still, left unprocessed mixed with biodegradable waste.

If we want circular economy of waste management to take root, we must incentivize the entire value chain.

Completely recyclable packaging solutions that improve the value of the waste constitute a step towards that direction.

While globally, governments and municipal authorities have tried multi-pronged approaches to increase recovery and recycling as well as reduce consumption and littering of flexible plastic waste, in India so far, we have not been able to achieve an optimal level of waste management. As per the CPCB report in 2015, 51.4 million tonnes of solid waste was generated in the country that year, of which 91 per cent was collected, 27 per cent was

treated and remaining 73 per cent disposed of at dump sites. We still see a lot of plastic waste that remains littered, spoiling the view of landscape and raising concerns about India’s capability to achieve the objective of ‘Swachch Bharat’ promised by Prime Minister Modi.

While many solutions have been discussed on public forums on plastic waste management so far, I believe the answer for India would lie in the concept of Circular Economy.

Moving from linear to circular The First Industrial Revolution opened the gateways of prosperity, increased production capacities and mass exploitation of natural resources. However, with increasing populations, volatile market conditions and unsustainable human interventions, today the world is helplessly staring at falling food supplies and unsustainable economic models.

A recent article published by the World Economic Forum stated that the present situation is the direct outcome of the linear model of resource consumption that follows a take-make-dispose pattern. Hence, the report suggested that an alternative economic model in the form of Circular Economy must be pursued and the consumption of non-renewal resources must be encouraged by way of recycling and reusing them appropriately. Circular econ-

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PACKAGING

A report from the World Economic Forum suggests that an alternative economic model in the form of Circular Economy must be pursued and the consumption of nonrenewal resources must be encouraged by way of recycling and reusing them appropriately. omy believes in extending the life cycle of a material to extract maximum value. The concept of Cradle-to-Cradle® design and material reuse by Michael Braungart speaks about this very life cycle of complete material re-integration into the value chain and reuse.

Circular economy is not new to India – for years, we as a community have strived to extract maximum value out of everyday items. We collect stale newspapers, used plastic milk packs and other scrap of value to sell back to scrap collectors. Exchanging-old-for-new schemes are always popular in India, from cell phones and mixer grinders to cars.

However, for circular economy of plastic packaging to be established in India, we need more. Until a few years ago, the complete re-integration of recycled plastic into the value chain was a challenge. Because of layers of multiple materials used in food packaging to preserve food better and ensure minimal wastage, complete re-integration of the material is complicated. However, we now have effective solution for this – mono-material layers of packaging that, upon recycling, can be re-integrated into the value chain. This material can be effectively used to create new packaging of same quality, with minimal material loss.

This is a significant breakthrough of technology packaging convertors and brand owners need to embrace, as it would create an incentive for them to collect back the packaging material for reuse.

Incentive better than restrictions In the past we have experienced that complete bans and / or usage penalties for any particular packaging material in the state or country are incredibly difficult and costly to implement, not to mention are easily violated.

If we want circular economy of waste management to take root, we must incentivize the entire value chain. Completely recyclable packaging solutions that improve the value of the waste constitute a step towards that direction. What must follow is a collective effort by industry and governing bodies to make sure this incentive reaches the direct consumers of packaged goods.

Unless that happens, change in consumer behavior is difficult to be swung and sustained. Here, incentives from governing bodies such as Pollution Control Boards, municipal corporations etc will play a major role. For post-consumption waste to find its way

back into the value chain, providing artificial economic value for exchange is one of the best ways to ensure compliance.

Brand owners and value chain partners can build in a recovery value incentive at every step so recyclable packaging material is used and is recovered to maximum possible level. The recovery of this incentive needs to be built into product value.

Once customers get used to getting money back or discount on next purchase of packaged products if they bring back the post-consumption packaging, the recycling mechanism can backintegrate from collection points (shops / malls / in online models the delivery person can collect). The adage “polluters pay!” can then be truly delivered on ground, as those not returning plastic waste actually end up paying more per product.

Come together to save the planet To enable the circular economy of plastic waste, the immediate need is for the consumer goods and packaging industries to come together to self-regulate and implement this change. The second step is to make communities aware about the new technologies, the incentives and greater common goal of protecting the environment we live in.

While I completely support policy-level push for sustainable technologies, I think as industry representatives we must be ready to take the first step rather than waiting for the government to push for change. If we do it today, the consumers will follow suit tomorrow and the circular economy of waste management will come as close to cradle-to-cradle re-integration as possible.

Many countries in the west have undertaken similar initiatives effectively.

Let us lead the way. We owe it to planet earth, and most importantly our future generations.

The author is Head, Packaging & Specialty Plastics Business, Dow India All images Courtesy: Dow

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INTERVIEW

Colouring the future SHIVAM BANSAL, DIRECTOR, JJ PLASTALLOY PVT. LTD. SPEAKS TO ET POLYMERS ABOUT COMPANY’S BUSINESS, R&D EFFORTS AND INNOVATIONS

By Swati Deshpande Can you please briefly tell us about JJ Plastalloy Pvt. Ltd.?

JJ Plastalloy began its operations in 1995 and continues with its journey of satisfying customer requirements with Quality Masterbatches. The company is one of the largest manufacturers and exporters of various Masterbatches from India with a combined annual installed capacity of 65000 MT at its Dahej (Gujarat) and Varanasi plant. The company is recognised for exporting its products to more than 30 countries across the globe. Having its headquarters at Varanasi, the company is well supported with strategically located warehouses and sales offices at Gurgaon, Haridwar, Ahmedabad, UAE and other places.

Tell us about your manufacturing capabilities and capacities Last year the company started its Dahej operations. This stateof-the-art plant houses latest and most modern machines from globally renowned sources. The Varanasi plant is also working in full swing. We manufacture entire range of Masterbatches ranging from Black MB, White MB, Colour MB, Additive MB, Calcium Carbonate MB and Automobile Compounds and serve the customers from both the plants. Necessary equipment have been installed to serve the customers with consistent product. Additionally, the company has a significant budget for learning, development and growth of its human resource as human resource builds strong foundation of any organisation. Hence with good team members and most modern equipment, the company is capable to meet the customers expectations. With its quality and consistent products the company is catering to the requirements of entire Polyolefin sector with full customer satisfaction.

With increased consumerism and developing retail market, the need for more attractive packaging is growing and ultimately company is getting requirement from newer and newer customers in the sector

Regular interaction with academia helps to innovate.

Shivam Bansal R&D is an important aspect in the polymers industry. Can you please tell us about your efforts in this domain?

R&D Center based at Dahej is a government recognised R&D Center and well approved by DSIR. Here on regular basis newer products are experimented with so as to serve the customer with better options. The company has marked a significant budget for R&D activities as well. Regular interaction with academia helps to innovate. The R&D Center is state-of-the-art having latest development and testing equipment. The R&D team is very well versed with industry requirements and processing conditions.

Can you please tell us about one of your innovations that has been well-received by the industry?

Recently for automobile application, company got success in replacing ABS based auto part with Reinforced PP part. This helped the customer to reduce part weight as well as cost reduction without any compromise in part quality. Apart from this, the company launched its Black Masterbatches for Geo Textile application, which is giving good results in Woven or Extruded Fabrics. Additionally, the company has its strong focus on agri films applications and developing Masterbatches for Agricultural applications.

The company is catering to multiple industries. Amongst them, which industries are driving the growth of the business?

Primarily the company has got very good exposure in Infrastructure segment, Flexible Packaging applications and Woven Fabrics.

With government thrust on infrastructure, the demand for Masterbatches in pipe sector is growing. With increased consumerism and developing retail market, the need for more attractive packaging is growing and ultimately company is getting requirement from newer and newer customers in the sector. Woven Fabric being a sector having diversified applications, the demand is continuously growing for various Colour Masterbatches as well as Black and Additive Masterbatches.

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13 September 2017 The Westin, Pune

Presents

Gold Partner

Associate Partner

Some of our speakers

Varun Gupta Sandeep Raina Gajanan Gandhe Sandeep Waykole B.Thej Kumar Vishal Agarwal Maruti Suzuki IAC Asia Faurecia India Toyoda Gosei Calco Poly Technik Yudo

2017 Topics • CEO Panel Discussion • Light-weighting • Design & aesthetics • Safety For Speaker Opportunities, contact

Niranjan Mudholkar | +91 9819531819 For Partnership, contact

Mahadev B (South) +91 9448483475 | Ranjan Haldar (West)+91 9167267474 Ashish Sahay (North) +91 9899688440 For more details, visit: gcpa.themachinist.in (Delegate registration open for automotive professionals only)

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ADDITIVE MANUFACTURING

Fastening processes CONSUMER GOODS GIANT UNILEVER ITERATES 50 PERCENT FASTER WITH 3D PRINTING

T

oday’s global market has created a variety of challenges for consumer brands.

Products that used to be visibly unchanged for years may now be in a state of continuous evolution. The on-going development of product design can be time-consuming and costly for companies because of the scale and processes involved. This is why the Italian division of international consumer goods giant, Unilever, invested in 3D printing to make injection moulds, blow moulds and thermoform (vacuum) moulds for accelerated prototype and part development without the need for conventional tooling.

Competitive time and cost Challenge With more than 400 brands in its four divisions, Unilever needs to ensure that all are competitive, meet ever-changing product standards and differentiate themselves on the shelf. Developing and refining components for the Home Care, Personal Care, Food and Refreshment divisions is, in part, the responsibility of Unilever’s facility in Caselpusterlengo, Italy. “The idea was to move from relying on images and 3D files to rapid prototyping machines and reduce our time to market,” explains Stefano Cademartiri, R&D, CAP and prototyping specialist at Unilever.

“The new vision for the future of CAD development was to invest in a 3D printer that was easy to use and could produce fast concept prototypes using heat resistant ABS materials.”

Before, we would have to wait several weeks to receive prototype parts using our traditional tooling process; not only would this lengthen lead times, it would also increase costs if iterations were required. With 3D printing, we’re now able to apply design iterations to the mould within a matter of hours.

Localised Supply Chains The investment in an Objet500 Connex 3D Printer1 helped transform the Caselpusterlengo facility from a satellite of the main design center in Port Sunlight, United Kingdom, to a much bigger player in Unilever’s €1 billionplus R&D establishment.

Cademartiri says 3D printing lets Unilever produce parts in the final materials for functional and consumer tests more quickly. “Before, we would have to wait several weeks to receive prototype parts using our traditional tooling process; not only would this lengthen lead times, it would also increase costs if iterations were required. With 3D printing, we’re now able to apply design iterations to the mould within a matter of hours, enabling us to produce prototype parts in final materials such as polypropylene much faster – often on the same day.”

Unilever uses the Objet500 Connex

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ADDITIVE MANUFACTURING

3D Printer to produce injection and blow mould tools for part development across its divisions for regional and global markets.

Cademartiri and his team 3D print injection mould tools in Digital ABS, a material with high temperature resistance and toughness.

“By 3D printing the injection moulds with Digital ABS, we’re able to achieve the high quality associated with traditional manufactured prototypes, while ensuring that the high temperatures and pressures of the injection moulding process can be sustained,” Cademartiri explains.

The 3D printed moulds not only meet these requirements, but can also be produced in significantly reduced times and at 20 percent the cost. Compared to traditional model making, Unilever’s Objet500 Connex 3D Printer delivers iterations 50 percent faster, reducing development turnaround times by 40 percent.

The Unilever brands that are being prototyped with the 3D printer include Domestos, Comfort and Metadent. “Mould tools for parts such as bottle caps and closures and toilet rim blocks are produced in runs of about 50 units for functional and consumer testing,” Cademartiri says.

Lead times reduced by 35 percent Complementing injection mould tool production at Unilever is an FDM- based Fortus 360mc 3D Production System. The Fortus system employs ABS-M30 and polycarbonate productiongrade plastics.

The 3D printed moulds not only meet these requirements, but can also be produced in significantly reduced times and at 20 percent the cost. Compared to traditional model making, Unilever’s Objet500 Connex 3D Printer delivers iterations 50 percent faster, reducing development turnaround times by 40 percent.

“The strength and flexibility of these materials enable us to develop thermoformed prototypes in final production materials for testing and evaluation,” says Cademartiri. “Having previously outsourced our thermoforming requirements for handmade wooden moulds, we found that we were accumulating significant labor costs and having to contend with lengthy lead times. However, since 3D printing these tools ourselves, we’ve reduced lead times in the conceptual phase by approximately 35 percent.”

Cademartiri concludes, “The technology has enhanced our overall manufacturing process, allowing us to evaluate our designs quickly and eliminate those that are not suitable, before committing to significant investment towards mass production.”

Source: Stratasys

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INTERVIEW

Making it in India P K PATKAR, TECHNICAL DIRECTOR, JP EXTRUSIONTECH LTD (JPEL) TALKS TO ET POLYMERS ABOUT THE COMPANY AND THE NEW INNOVATIONS IT HAS BROUGHT IN THE MARKET RECENTLY.

By Swati Deshpande Tell us about JP Extrusion’s journey since inception in 1987 JP Extrusiontech Ltd (JPEL) is known as a leading high quality plastic processing machinery producer in India. Since its establishment, the company has a vision to offer latest techno economical machine to end users so as to create solutions to their clients’ need. We offer one stop solution to woven sack industry. We have series of machines that have been doing well in the market such as Tape Extrusion Line with Inverter, Driven Tape Winders, Circular Weaving Looms, Extrusion Coating Lines, Printing and Bag Conversion Line and Online Recycling Machine.

Earlier woven sack industry was running with old technology blown film plant to produce raffia tapes (HDPE only). However, by replacing blown die with coat hanger die, we were able to double the production and were capable to run PP/HDPE material by replacing blown die with coat hanger die.

In our efforts of continuous development, JPEL has brought in numerous machines for the first time in the Indian maket.

Tell us about your manufacturing facilities.

Our facility sprawls over area of 39,000 sq.mtrs. Over the years, the company has deployed modern and cutting-edge technologies. Also, experts on the matter help us deliver nothing but the best to our customers. Additionally, the skilled labour plays extremely important role in our manufacturing facilities. It is because of them we are able to offer such inovative machines to our customers.

How was the last year for the company? And how do you look at the current year?

I can proudly say that it was a remarkable year for us as we recorded a tremendous growth. Last year, due to the launch of new

I can proudly say that last year was a remarkable year for us as we recorded a tremendous growth.

Last year, due to the launch of new products and technology and we registered growth of 18– 20 percent over previous year.

P K Patkar

products and technology, we registered growth of 18–20 percent as compared to the year before that.

As far as this current year is concerned, I believe, we are in a good position. In fact, we have grown stronger than before. Furthermore, since the market seems to be growing, we are expecting to register yet another good year for the company.

Please tell us about the flexible lamination machine that has been newly launched by the company.

The initiation of flexible lamination machine is as a result of a random and continuous high growth in the market. Lamiflex is one of the most sophisticated extrusion coating machines within our product range. Its key feature is its user-friendliness. Furthermore, it is flexible enough for fast product changed.

The line in design for the product width from 600-1300 mm is yet another attractive feature. The machine is suitable for processing of Nucrel for better adhesion.

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INTERVIEW

design a highly efficient line that provides top quickly products.

In all, it is a machine that meets international standards while fitting into customers’ budget.

Customers can also avail a local service support, which is often a problem area in case of imported machines.

Our facility sprawls over area of 39,000 sq.mtrs. In the course of producing these great machines we already put together some things in place, therefore, we were able to have great output.

How has been the response from customers on Lamiflex?

We have been receiving lot of reviews from the customers. Many of them spoke about the great idea embedded in the production, while others talked about the economic prices that are imposed on it compare to its efficiency. In all, I can say that the responses from the customers are encouraging. They are more than satisfied with its performance and the way it is catering to multiple products in the market.

What benefits will the machine provide the customer with the other machines on the market?

As I mentioned before, Lamiflex is one of the most user-friendly machines available on the market. It is simply designed and also economically priced compared to its efficiencies. It is made to

Do you have any technical collaboration?

Well, I must say that the company has no technical collaboration with anyone. All the technologies that we offer are completely home grown in our own R&D Centre. We believe in our own nation; we believe in MADE IN INDIA.

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INJECTION MOULDING

TEMPTing Solutions CHENNAI BASED D&M ENTERPRISES HAS BEEN OFFERING RELIABLE SOLUTIONS IN INJECTION MOULDING FOR ALMOST 20 YEARS. M. UDAY KUMAR, GENERAL MANAGER OF THE COMPANY SPEAKS TO ET POLYMERS.

By Swati Deshpande Please tell us about D & M Enterprises’ journey since its inception in 1999.

D&M Enterprises was founded in 1999 with a vision of becoming a most preferred and reliable supplier of plastic equipment.

With over more than 19 years of experience in sales and service of plastic injection moulding machines and auxiliary equipment, we have a strong customer base PAN India and across the industries like automobile, FMCG, telecom, electrical, electronic, white goods, tooling, household products, etc. We assure our valuable customers Transparent, Efficient, Mutually beneficial, Professional, and Timely solutions (TEMPTing solutions).

Besides these solutions, we are exclusive agent in India for leading Brand TKC vertical injection moulding machine in 2001 and sold over 800 machines in the country.

Please tell us about machines that your company distributes.

We are exclusive agent for leading electric injection machines manufacturers— Kawaguchi. The machines have range from 50–360 Tons. The company also sells the complete range of auxiliary equipment from M/s Topstar- China. We deal with

Apart from having agency of number of foreign companies, we also manufacture our own UCAN high performance servo injection moulding machines ranging from 90–320 tons.

We assure our valuable customers Transparent, Efficient, Mutually beneficial, Professional, and Timely solutions.

M. Uday Kumar, GM, D&M Enterprises Topstar Industrial Robots, which offer automation solutions for injection moulding machines amd deliver more consistency and faster production with the reduction in labour. This further translates into customers’ profit. Moreover, D&M Enterprises represents Techmation, a Taiwan base company, for PLC Servo system and E deodar 6 axis Robot.

Tell us about you manufacturing capabilities.

Apart from having agency of number of foreign companies, we also manufacture our own UCAN high performance servo injection moulding machines ranging from 90–320 tons. Additionally, the company makes standard models of TKC Vertical injection moulding machines at Chennai facility in the name of D&M Machine Tools. We have a strong manufacturing team with qualified engineers who are capable of manufacturing standard and custom made machines as per the requirement of customer. We have the capability of manufacturing 20 machines in a month.

46 | The Economic Times POLYMERS | August-September 2017

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Powered By 16th November, 2017 - Indore

Machining Partner

Industrial Lubricant Partner

Powered By

For Speaker Opportunities, contact Niranjan Mudholkar | +91 9819531819 For Partnership, contact Mahadev B (South) | +91 9448483475 Ranjan Haldar (West) | +91 9167267474 Ashish Sahay (North) | +91 9899688440 For more details log on to: gms.themachinist.in

InjectionMoulding-D&M_SD_NM.indd 47

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CASE STUDY

Challenges Create Capabilities!

A COMPANY SPECIALISING IN DESIGN, DEVELOPMENT AND MANUFACTURING OF PLASTIC INJECTION MOULDS FOR VARIOUS INDUSTRIES USED SIMULATION SOFTWARE TO DECREASE THE CONSTRUCTION TIME AND THE NUMBER OF POTENTIAL FAILURES.

S

ridevi Tool Engineers specialises in design, development and manufacturing of plastic injection moulds for automobile, white goods, luggage and various other engineering industries.

Established in 1972, it is one of the largest commercial tool rooms in India having more than 40 years of experience in producing tools for both domestic and foreign markets. The company majorly produce moulds for automotive trims, consoles, pillars, headlamp housings, air filters, exhaust assemblies, instrument panel and its child parts, grills, motorcycle fenders etc.

Sridevi Tool Engineers has fully equipped state of the art tool room and project management skills make them one of the most preferred tooling suppliers to OEMs.

The Challenge Nowadays, more and more polymer based products are utilised in the automotive industry, in the medical science and in many other areas. As a result of the continuous developments, novel polymer materials and special processes are developed to accomplish the strict engineering claims.

The competition in the market and the strict requirements for the plastic parts require faster and more accurate mold making.

The quality of injection molded thermoplastic parts largely depends on the process parameters. “In the mold development and in the failure analysis the simulation has a great role. Simulation software allows fulfilling the injection molding process in a virtual reality, which helps the mold optimisation, the material and process parameter determination before machining the injection mold. This way decreases the construction time and the number

The analysis of mold deformation becomes a valuable reference for us, especially for optimising the manufacturing of high-precision products.

Rajendra Rindhe, Assistant Manager CAE, Sridevi Tool Engineers of potential failures,” said Rajendra Rindhe, Assistant Manager CAE Recently, while working for a leading automotive OEM on development of spoiler (800 mm x 300 mm) - inner and outer family mold, Sridevi Tool Engineers’ team faced challenging situation in designing and manufacturing of the mold cavity. Because of complex geometry of the mold it was difficult to take into consideration the physical effects ruling in the cavity. Through the mold deformation analysis using Moldflow, engineers could detect potential problematic areas in the mold. The mold cavity flange was withstanding several external loading issues; total mold displacement field in flange ranged from 0 mm to 0.3 mm and the stress distribution field in flange was 900 MPa.

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CASE STUDY

“High stresses in the flange area were the major concern as the deformation of the mold changes the cavity dimensions and decreases the precision of the final molded parts. Therefore, the analysis of mold deformation becomes a valuable reference for us, especially for optimising the manufacturing of high-precision products,” explained Rindhe

The Solution In the case of complex projects, predicting all factors determining the final quality of a part is often possible only after carrying out a series of tests. Autodesk Moldflow was used to optimise the mold design by adjusting the processing parameters, the geometry model, and the mold material. This way, the mold structural strength can be enhanced in order to extend the durability of the mold as well as to ensure the precision of the final molded products.

Since the geometry of spoiler was large and complex, Moldflow was used to target areas of concern (flange) and optimise designs to build mold accordingly so that real problems can be solved with virtual samples before the mold was built. This saved the time and money that would be required to address these problems after the first sample.

“Using Autodesk Moldflow software is essential for the design and production stage of automotive parts and in other high accurate plastic parts as well. Our clients demand the use of Moldflow software from the suppliers during the construction phase so that the deformation and other injection failures can be minimised.

I think challenges create capabilities and you need to adapt new technologies to overcome that challenges,” said Rindhe After using Moldflow for the complete simulation of the spoiler design, the analysis result showed very high stresses around 900 MPa in the flange. Based on the information obtained from the structural simulation, designers quickly optimised spoiler. It was easy to decide boundary conditions and type of meshing required using Moldflow. To improve this problem the mold material was changed and the thickness of the flange was increased.

After running Moldflow simulation on new geometry, the results

I think challenges create capabilities and you need to adapt new technologies to overcome that challenges.

Rajendra Rindhe showed stresses of around 495 MPa, reduced to half of the earlier results. Further four mechanical Locks were provided for positive alignment between mold halves that in-addition reduced stresses to 280 MPa. After the design, material changes and addition of mechanical locks Sridevi Tool Engineers’ found that Moldflow simulation analysis results were strongly correlated with the results of the actual mold trials. Moldflow’s mesh technology also made the simulation results more consistent with the actual results in manufacture. Ultimately, engineers could decide the optimal design

Based on the information obtained from the structural simulation, designers quickly optimised spoiler. It was easy to decide boundary conditions and type of meshing required using the simulation software. of spoiler within limited development time, avoid repetitive mold trials, and reduce costs.

“We are able to detect potential problematic areas in the mold and make necessary changes to address these issues before the mold is machined. We utilise Autodesk Moldflow results to optimise the mold design by adjusting the processing parameters, the geometry model, and the mold material. This way, the mold structural strength can be further enhanced to extend the durability of the mold as well as to ensure the precision of the final molded products,” said Rindhe.

The Result By using Moldflow, Sridevi Tool Engineer’ has been able to more efficiently and accurately deliver critical information to customers in need thereby insuring that the client is fully aware of the product’s capabilities and limitations before the tooling and manufacturing phases begin. Over the years, company has also been able to incorporate Moldflow into the process of streamlining productivity so customers can save substantially over the course of a product’s life cycle. This, in turn, reduces the probability of making further costly modifications after the initial trials.

“We believe that quality of the plastic injection molded part is a flawless mold - one that produces consistent pieces time and time again. Autodesk Moldflow not only ensures a precise adherence to final product requirements but also prolongs the overall mold life,” concluded Rindhe.

Source: 2017 Autodesk, Inc. All images courtesy: Sridevi Tool Engineers

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CALENDAR

Mark your

DIARY

A LIST OF KEY TRADE SHOWS HAPPENING BETWEEN SEPTEMBER 2017 TO MARCH 2018.

SEPTEMBER 2017

20-23

T-Plas

Location: Bangkok, Thailand Organised by: MDNA Website: www.tplas.com

Background A unified business platform for the plastics and rubber industries, T-PLAS - International Trade Fair for the Plastics and Rubber Industries will present a comprehensive range of solutions from the latest machinery and equipment, semi-finished products, raw materials, technical parts and reinforced plastics, to a full suite of services for the two industries.

OCTOBER 2017

17-21

Fakuma

Location: Friedrichshafen, Germany Organised by: P. E. Schall GmbH & Co. KG Website: http://www.fakuma-messe.de/en/fakuma/

Background Fakuma offers a comprehensive overview of all plastics technologies; whether injection moulding – Fakuma holds a top international position here – extrusion technology or thermoforming: the user can find out specifically about all processes machines and tools that are relevant for the working and processing of plastics.

The focus here is on practice, as around 1,700 exhibitors present the entire process chain for the economic production of plastic components.

DECEMBER 2017

6–9

Plast Eurasia

Location: Istanbul, Turkey Organised by: Tüyap Fairs and Exhibitions Organization Inc. Website: www.plasteurasia.com

Background The exhibition areas of the Plast Eurasia include plastic, machinery and equipment, mould making, plastic products, raw materials, packaging technology, hydraulics, pneumatics, etc. International exhibitors can present their latest trends, products and developments to an interested audience here. The trade fair is an ideal platform to establish new business contacts in the plastics industry.

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CALENDAR Plastivision Arabia 2017

DECEMBER 2017

11-14

Location: Sharjah, UAE Organised by: AIPMA and Expo Centre Sharjah Website: www.plastivision.ae

Background The event has become the leading platform to showcase the latest machineries and global manufacturing trends. It gives the regional plastic processors an opportunity to source the complete range of plastic converting requirements – from raw materials, additives, moulds & machinery. Moreover, since the show will be held along with 4th Arabia Mold, it will be an exclusive multi-industry trade event for the regional plastics, mold-making, printing and packaging industries.

PLASTEC West Anaheim

FEBRUARY 2018

6-8

Location: Anaheim, CA, USA Website: www.PLASTECwest.com

Background PLASTEC West is one of the premier trade fairs for plastics processing in the US. Leading suppliers will present the latest in production machinery, processing machinery, raw materials, components, automation technology, assembly equipment, materials handling, hardware and software, services and much more.

Among attendees are production managers, manufacturing engineers, product/project managers and senior plastic processing executive.

PlastIndia 2018

FEBRUARY 2018

7-12

Location: Gandhinagar, Gujarat Organised by: PlastIndia Foundation Website: www.plastindia.org/plastindia-2018/

Background One of the major exhibitions for the plastics industry in India is being held at Gandhinagar. Around 2000 exhibitors are expected to showcase technological prowess at the trade fair. Also, the around 600 international exhibitors are expected to participate from 40 countries. Some of the industry focus pavilion to be seen at the trade fair would be Composite, Automotive, Medical & Health Care, 3D Printing, Sports, etc.

OUR INHOUSE UPCOMING

EVENTS Presents

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“THE FESTIVAL OF MANUFACTURING”

Awards 2018 Excellence in Plastics

ComingAugust-September soon 2017 |18th The January, Economic2018, TimesMumbai POLYMERS | 51

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AGRICULTURE

Creating a new avenue!

ONE OF THE WORLD’S LARGEST POLYMER COMPANIES, ALONG WITH A CHENNAI BASED ORGANISATION FOCUSED ON GREEN ENERGY, HAS SUCCESSFULLY HELPED AN ENTIRE COMMUNITY OF 70 FARMERS IN TAMIL NADU’S KRISHNAGIRI TO FIND ADDITIONAL SOURCE OF REVENUE.

C

ovestro, one of the world’s largest polymer companies, along with Vivunes an organisation based at Chennai focused on green energy, has successfully helped an entire community of 70 farmers in Tamil Nadu’s Krishnagiri find additional source of revenue. The Mango farming community have acquired solar dryers which will empower them to tap demand for dry resins in both domestic and international markets.

India’s ranking in terms of food security is not on par with its status of being one of the biggest producers of vegetables. According to a research, it produces 220 million tons of vegetables and fruits in a year but about 30 percent of the production never reaches the table and the main reason for this waste is a lack of storage infrastructure, particularly at harvest-time.

To support the farmers, Covestro along with Vivunes recently executed a project for drying of multi-fruit bar which comprises of six units of Greenhouse solar dryers for MCI Agro IndustriesKrishnagiri.

“Weather, weak demands, logistical issues, long credit periods and low shelf-life have been key issues plaguing the farming community for long. Despite good harvest we have seen our produce facing a risk of spoilage. Therefore, we wanted to use dryers which will not just help us sell the fruit bars and fruits in market but also provide an entrepreneurial opportunity for women of our community,” said Sathiya Moorthy one of the farmers.

Commenting on the initiative, Richard Northcote, Chief Sustainability Officer, Covestro AG, said “India is a fast growing country and has the second largest population with agriculture being the source of income to nearly 60 percent of the total population. Still, post-harvest and storage loss is a major difficulty that needs to be addressed meticulously. Food preservation methods such as solar drying help in reducing food insecurity among farmer communities and will help in boosting the economy by supporting them with additional revenue source.”

While highlighting the impact of greenhouse solar dryer on agri-horticultural sector with this technology, AP Prabhakar, Chief Executive of Vivunes, said that it is proving to be an effective solution for commercial scale drying with not much of skills required from farmers to achieve desirable standards. It was also further stressed that this technology will find extensive applications shortly with pan India presence owing to its vantage on usage of renewable energy and on current market acceptance of the produce dried with used technology.

Despite good harvest we have seen our produce facing a risk of spoilage.

Therefore, we wanted to use dryers which will not just help us sell the fruit bars and fruits in market but also provide an entrepreneurial opportunity for women of our community.

Sathiya Moorthy, one of the farmers He further reinstated that Vivunes is very pleased to build an association with Covestro in promoting their greenhouse solar dryer technology to ideally break the boundaries and barriers on post-harvest realisation of fruits and vegetables, manage excessive yields of seasonal crops and to enhance its value adding proposition.

With the collaborative approach, both organisations involved expect this mission could greatly contribute to up-liftment of farming community, could also serve as an eye opener for effective realisation of farmers produce.

Sustainable methods for food preservation are the need of the hour and in India, solar drying is one of the most preferred choices and a promising technology owing to its vantage on utilisation of renewable energy. This initiative will enable farming communities to build more sustainable business and also contribute to the development of agricultural sector in India.

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PRODUCTS

Quickly openable but tightly sealed NEW CHIP-REPELLENT E-TUBES FROM IGUS

A

t EMO 2017, igus is presenting its R2.1 series energy-tubes, which are available immediately in new sizes and with even more accessories. In a test in the igus laboratory, it was shown that the tubes of the R2.1 series are among the best sealed energytubes for use in moving applications – In permanent movement with continuous exposure to metal chips weighing 2 kilograms in total, only 0.5 grams penetrated into the tubes after 100,000 cycles. In spite of being sealed, the tubes of the R2.1 series can be opened very easily, which makes assembly work even easier.

Doubly easy – This is the slogan for the R2.1 series energy-tubes from the motion plastics specialist igus.

Easy because the tubes, which keep chips out, only consist of two parts: a link and a crossbar that functions as a form-fit lid. Easy because these lids can be opened very easily from both sides – now, this can be done along either the inner or outer radius. Users can choose the type that is best for their needs, which makes assembly and maintenance work even easier.

The chip-proof e-tubes from igus are primarily of interest in the area of machine tool making as a reliable energy supply in an environment where chips are often present.

Lukas Czaja, Head of Industry Management Machine Tools, igus

as a version with lids that can be opened along the inner radius.

The sizes with an inner height of 26 millimetres or 40 millimetres are also available as versions that can be opened along the outer radius. Due to this expansion of the igus product range, users can always determine the filling method that is the best for them.

Assembly or later filling can therefore be carried out very quickly.

“The chip-proof e-tubes from igus are primarily of interest in the area of machine tool making as a reliable energy supply in an environment where chips are often present,” explains Lukas Czaja, Head of Industry Management Machine Tools at igus.”This industry is faced with the enormous challenge of mastering the increasing pressure of prices combined with rapidly growing technical requirements. The R2.1 series provides outstanding chip protection, can be assembled efficiently and stands out due to its very good price/performance ratio.”, During the chip test in the 2,750 square metre igus test laboratory, it was shown that the tubes of the R2.1 series are among the tightest sealed energy-tubes on the market. During this laboratory test, the tube is moved continuously in a chip drum filled with two kilograms of metal chips of very different sizes and shapes. After 100,000 cycles, the size 40 e-tube R2.1 only let 0.5 grams of chips accumulate inside.

Technical features for quiet and cable-friendly energy supply The lids of all the versions of the R2.1 series are openable and do not have to be removed completely in order to fill the tube. Their contours are smooth and the curvature and tight manufacturing tolerances guarantee that chips do not accumulate between the stops. In addition, the smooth inner contours of the R2.1 and the rounded latching separators made of identical material ensure that the cables on the inside are not damaged or abraded.

The integrated grid design also ensures a firm hold of the interior separation, even in side-mounted applications. Due to a brake in the stop-dogs of the individual chain links, operation of the chain is considerably quieter. Less vibration means more precise work on the workpiece. And due to the double stop-dogs, the energy-tube can absorb high fill weights and can even master long unsupported lengths. With the universal connecting elements of the R2.1, the strain on the cables can be relieved either inside or outside the chain cross-section.

Expansion of product range for extremely fast, individual assembly At EMO 2017, igus is presenting the R2.1 in new sizes. A completely new size with an inner height of 48 millimetres is available

For more information, contact: Harish Booshan igus (India) Pvt Ltd Harish@igus.in, www.igus.in

54 | The Economic Times POLYMERS | August-September 2017

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