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Volume 17 Issue 3 August - September 2016
CHIEF EXECUTIVE OFFICER Deepak Lamba CHIEF FINANCIAL OFFICER Subramaniam S PUBLISHER, PRINT & PRODUCTION CONTROLLER Joji Varghese EDITOR & CHIEF COMMUNITY OFFICER | Niranjan Mudholkar niranjan.mudholkar@wwm.co.in +91 9819531819
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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 2016 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. The opinions expressed by experts are their own and in no way reflect those of the publisher.
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Faster, lighter, stronger! kay, I know that the Olympic motto is actually ‘Faster, Higher, Stronger’. I have just replaced ‘higher’ with ‘lighter’. And there is a reason for doing so. Think of it, these are the three major attributes that plastics offer to the modern day automobile.
In the famous 1967 Hollywood film The Graduate, Mr. McGuire tells Ben that “There’s a great future in plastics.” That future has arrived. And in the context of the automotive industry, it is very bright. OEMs and their suppliers know that plastics are indispensible in terms of “Not surprisingly, light-weighting, design flexibility, cost competitiveness, durability and fuel efficiency of vehicles. we have received a Innovators and inventors are making every second count by providing the right kind of materials and machines to the automotive industry to help them take the best out of plastics. In this light, ‘The Economic Times Polymers’ (ET Polymers) Magazine has created a knowledge-based networking platform for the various stakeholders to come together and take advantage of each other’s expertise and experience.
very good response for the GCPA. And if you still haven’t registered then please visit http:// gcpa.themachinist. in/ for more details.”
This ‘Global Conference on Plastics in Automotive’ (GCPA) will discuss use of plastics across different components. It will synergise the work of suppliers with the requirements of automakers. Not surprisingly, we have received a very good response for the GCPA. And if you still haven’t registered then please visit http://gcpa.themachinist.in/ for more details. And since I started with it, it is only pertinent that I end the note with Olympics. All the medals given away to the winners at the Rio Olympics were hung from plastic ribbons! And, 50 percent content of these ribbons came from recycled plastics! Says a lot about this ‘Champion’ material, isn’t it?
Editor & Chief Community Officer
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CONTENTS 8
32
News
Packaging:
28
High demand!
Recycling:
30 40
Recycled plastic to power ship engines Rebirth of Polycarbonates!
Automotive:
36 42 TECHNOLOGY Switched ON to the future
45 47 54
52
The Power of Polymer! Plasma-coated Polycarbonate Rear Quarter Window Plastics in 3D printing –Opportunities in the automotive industry Plastic engine oil pans Encapsulation, impregnation and potting
Healthcare:
44
Say no to microbes!
Bioplastic:
50 55 59
From plants to plastics! Eggshell marvels! Updates
3D Printing:
58
RESEARCH A potential game-changer!
61 63
26
Next gen polymers for additive manufacturing
Event Calendar Products
41
INNOVATION Smart electronics for smart clothing
AUTOMOTIVE Tequila shots!
56
ROTOMOULDING Supporting customers is a key
Corrigendum: In the June-July 2016 issue, the slug of the interview from Ferromatik Milacron was wrongly printed as ‘Extrusion’. Also, few words were repeated in the article. The errors are regretted.
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NEWS NATIONAL
STEER makes processing mica-based pigments easy
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TEER has introduced Omega platform with specially designed screw configuration and technology, process knowhow for compounding special effect pigments with minimal damage to sensitive platelet structure, retaining up to 80 percent of the particle size in the compound from the pigment. Mica, a delicate, natural, mineral is an integral part of special effect pigments used across various end user markets such as automotive, electronics, cosmetics, building materials, paints & coatings. Atanu Maity, CEO, STEER Engineering said, “The demand for performance and special effect pigments is seeing a dramatic rise, driven by developed market and the emerging economies like China and India. The Omega platform is configured to process mica-based pigments with minimum damage to the platelet structure, it not only provides greater product appearance but effectively eliminates issues related to quality of properties, adaptability and damage. Omega platform will change the way industry is processing effect pigment.” Coated mica crystalline platelets, like those used in effect pigments in thermoplastics (ex: for pearlescent appearance, colouration, lustre, sheen, glitter, sparkle or multicolour effects), are extremely sensitive. Any alteration or change in size of the structure will hinder effective coloration and alter the appearance of the pigments and plastics. Unfortunately the technology available today doesn’t account for exposure to shear—the biggest cause for attrition and damage to the structure. The Omega Platform along with patented special elements eliminate shear peaks. Further, the special mixing elements with fully intermeshing and self-wiping profile prevent stagnation & degradation and the resultant char formation. The OMEGA’s ‘Barrel to Screw Gap and Screw to Screw Gap’
is maintained at less than 0.25 mm to have fully wiping effect rather than shearing effect addressing the issue of ‘leakage’ and the deeper root depth (1.71) draws more of the resin into the screw root and away from the shear forces that occur when the melt contacts the barrel wall. Rob Roden, AVP and Global Head, Continuous Manufacturing Technology, STEER said, “The Omega allows manufacturers to create brilliant effect pigment masterbatches. The production trials conducted at our Application Development Center in Bengaluru have given us phenomenal results. The root of all evil is SHEAR. The standard elements used by the industry today are brutal, it virtually reduces pigment particle size by half due to various inefficiencies and therefore quality of the compound is compromised. STEER brings a revolutionary platform for compounders and producers of end use products to be able to capture the full value and elegance of special effect pigments.”
Astral joins hands with Sekisui
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stral Poly Technik Ltd has joined hands with Japan-based Sekisui Chemical Co. Ltd. to source chlorinated poly vinyl chloride (CPVC) resin for hot and cold water plumbing system. This strategic tie-up between Astral and Sekisui enables Astral to go for backward integration into developing its own CPVC compound. On account of this tie-up, Astral has launched its own brand ‘Astral CPVC PRO’ for CPVC pipes and fittings for hot and cold water application. This product has NSF-61, ISI, UIPC approvals. The CPVC compound is also NSF certified for potable water. According to Sandeep Engineer, MD, Astral “With this strategic tie-up and backward integration, we plan to take Astral to new heights and make ourselves self-sufficient with
our own brand. It is a matter of great pride for all our stake holders that Astral has decided to join hands with Sekisui.” Toshiya Yasunaga at Sekisui stated, “Astral’s impressive growth over the last 8-10 years and innovations in terms of products and stateof-the-art facilities are some of the key factors, which ensured we enter into this partnership. Through Astral, it will be our endeavour to bring in latest technology and manufacture the best CPVC pipes in India. Sekisui ensures their partners to supply CPVC with stable and good quality so that they can manufacture the most superior quality CPVC pipes and fittings for the plumbing industry. Sekisui promises to contribute developing Indian infrastructure and good life through our innovations and technical know-how in this field.”
8 | The Economic Times POLYMERS | August-September 2016
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NEWS NATIONAL
SABIC modernises polymer lab at M. S. University Of Baroda
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round two hundred students every year at The Maharaja Sayajirao University of Baroda will now be able to pursue their passion for polymer science and technology in a state-ofthe-art polymer laboratory following an extensive modernisation program by SABIC, one of the world’s largest diversified chemical companies. The upgraded polymer science laboratory was unveiled at The Majaraja Sayajirao University of Baroda (M.S. University) at an event jointly inaugurated by Janardhanan Ramanujalu, Vice President, SABIC South Asia and ANZ and Prof Parimal Vyas, Vice Chancellor, M.S. University. The modernisation of the polymer laboratory was aimed at creating a learning environment, which would encourage university students
from graduate level to Ph.D. level to participate in hands-on learning of polymer sciences. Speaking on the occasion, Janardhanan Ramanujalu said, “Education is one of the key focus areas of our CSR strategy and SABIC’s expertise in the polymers industry allowed us to evaluate needs and gaps of the polymer laboratory of The Majaraja Sayajirao University of Baroda. This is the culmination of our 3-year program to bridge the gap and transform it into a hi-tech laboratory.” The laboratory is now home to internationalstandard lab equipment such as a Lab Scale Extruder with Feeder and Pelletizer, Injection Moulding Machine, Universal Testing Machine and a Melt Flow Index Measurement Instrument with accessories. Its infrastructure has also been revamped, with the upgrading of its electrical distribution system and the replacement with energy efficient LED lights. The modernisation of the laboratory demonstrates SABIC’s support to education and innovation as well as its commitment to society. Prof Parimal Vyas said, “As one of the leading universities in India in Gujarat with a renowned faculty of technology & engineering, this modernised polymer laboratory will help equip students with practical knowledge and the skills set required in the plastics industry. We are thankful to SABIC for coming forward and addressing the need of application based research and new technologies in our university.”
Paper Boat forays into 500ml packs with Tetra Pak
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aper Boat, has recently launched its two most successful variants; Aamras and Anar in Tetra Pak’s distinctive Tetra Prisma Aseptic (TPA) 500ml cartons with the re-sealable StreamCap. These variants will be available across the country at modern trade stores. Neeraj Kakkar, Co-Founder, CEO, Hector Beverages commented on the launch, “Since our inception, the Doy pack has been the biggest contributor of our identity. Our 500ml pack is a result of innumerous feedback from our consumers for a bigger volume pack. After chasing this project for about a year, we have finally launched our 500ml pack with a lot of help from the entire team at Tetra Pak. We are extremely happy to give our consumers more reasons to share our drinks.” Kandarp Singh, South Asia Markets Managing Director, Tetra Pak said, “The TPA 500ml package with the re-sealable screwcap will give consumers not just a superior drinking experience from a modern and distinctive pack but also many opportunities to share Paper Boat’s delicious ethnic flavours with special people in their lives. We are happy that this pack will help
further strengthen Paper Boat’s brand appeal and offer differentiation on the shelves.” The Tetra Prisma Aseptic carton offers an easy ‘gulp-from’ and ‘pour-from’ experience, and the fully re-sealable screwcap provides hassle-free and convenient consumption. The octagonal shape of the pack fits perfectly in all hands for a comfortable grip. Moreover, being paper-based and fully-recyclable, the cartons are good for the environment.
10 | The Economic Times POLYMERS | August-September 2016
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NEWS NATIONAL
rose plastic sets up manufacturing unit in India
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ose plastic, globally leading company in protective & innovative plastic packaging systems for precision tooling, cutting tools and precision engineering parts, has set up a subsidiary with manufacturing unit in India. The Pune base unit is manufacturing the standard packaging products in same design and according to same quality specifications as at their German head-office factory. The Pune unit is headed by Siddharth U. Pawar, General Manager. rose plastic is following the demand by many export-orientated Indian cutting tool manufacturers but also by request of their European and US clients with manufacturing & sales units in India requiring the same kind and quality of packaging as their parent companies are using since many years. The substantial investment of rose plastic in India reflects the importance and growth of the Indian cutting tool industry with increasing global presence. Packaging is the ‘first impression and touch’ of a consumer
to a product. A high quality image, brand recognition and attractive product presentation are also important to Indian cutting tool manufacturers, competing on the global market. rose plastic, participating since many years at all leading cutting tool exhibitions (EMO-Europe, IMTS – USA, JIMTOF - Japan, CIMT – China) will also exhibit at IMTEX 2017 in Bangaluru.
Skipper opens new facility in Hyderabad
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kipper Ltd, one of the market leaders in the Polymer Pipes business, has announced its debut in the southern part of the country by setting up its new manufacturing plant in Hyderabad. The state-of-the-art manufacturing unit has come up at Medak district near Bollaram, Jinnaram Mandal to produce plumbing and agriculture pipes. Spread over nearly 2.25 acre, the plant will have a manufacturing capacity to produce 6,000 MTPA of both plumbing and agriculture pipes. The company has already hired 100+ employees and implemented recruiting and training programs since last couple of months. Production from the project’s first phase will begin later this month. Sharing his thoughts on the occasion Devesh Bansal, Director, Skipper Ltd. said, “At Skipper Ltd, we are constantly in pursuit of innovation and have dedicated our resources to expand our cutting-edge products and value added propositions to the rest of the country.” Siddharth Bansal, Director, Skipper Ltd added, “The Hyderabad Unit is an excellent example of how we continue to invest in our national presence. This factory will contribute to accelerate the production capacities and illustrates our forte of producing Polymer Pipes of international standards which combines strong and sustainable production efficiency”. He
also added, “Telangana is crucial for our growth and we are looking at achieving a substantial market share in the next few years.” In the recent past Skipper Ltd also had been awarded with the contract of delivering the mega flag project for the occasion of Telangana Formation Day i.e. June 2, 2016. The height of the flag pole is 291 ft., while the bottom diameter is 1800 mm; 16 mm Solid Steel sheets are used to create this mammoth structure. With the setting up of this new plant in Hyderabad, Skipper Ltd aims to support the Prime Minister’s initiative of ‘Make In India’. With this policy, India will be the next manufacturing hub and a competitive market globally. The company has chosen Hyderabad to target the entire southern region Andhra Pradesh, Tamil Nadu, Karnataka and Kerala market. The hassle free industrial policy of Govt. of Telangana has helped the company in successfully establishing the manufacturing unit in a very short span. Also, the smart and talented workforce of the state makes this place a great destination for business establishments. Skipper Ltd.’s PVC Pipes manufacturing units are currently spread across 5 locations including Uluberia (Howrah), Guwahati, Sikandrabad, Ahmedabad and the newly launched Hyderabad.
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NEWS INTERNATIONAL
Bostik opens new manufacturing plant in Sweden
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ostik has developed its cementitious product manufacturing capacities, based on its world-class Polymer Modified Binder (PMB) technology, with the opening of a new plant in Helsingborg, Sweden. As a leading global adhesive specialist for construction, consumer and industrial markets, Bostik is extending its presence to serve growing market demand in Northern Europe and the Baltic region. The facility enlarges the firm’s manufacturing footprint in Europe and will produce a variety of cement-based construction products including tile adhesives, mortars and flooring products, including the firm’s renowned Bostik 1055 Fiber Maxi floor screed. In the presence of Thierry Le Hénaff, Chairman and CEO of Arkema, at the official plant inauguration, Roland Albers, Senior Vice President of EMEA, Bostik said, “We are delighted to expand our manufacturing presence in Europe and enhance our ability to serve construction customers in these high growth markets. International expansion in both established and emerging regions remains one of the central elements of our growth strategy and we will continue to invest in new facilities to ensure we effectively meet customer needs.”
The plant boasts state-of-the-art production equipment and will use the latest manufacturing techniques to ensure the highest levels of safety, quality and efficiency. It offers high levels of production flexibility and will enable the firm to deliver in a variety of formats delivered direct to construction sites as well as through distributors including builders merchants and DIY outlets.
BASF introduces new polyphthalamide (PPA) portfolio
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ASF is expanding its range of partially aromatic polyamides and launching a new polyphthalamide (PPA) portfolio on the market. The portfolio with the name Ultramid Advanced N comprises unreinforced compounds and compounds reinforced with short or long glass fibers as well as flame-retardant grades. They exceed the properties of conventional PPA plastics: constant mechanics up to 100°C (glass transition temperature: 125°C), outstanding chemical resistance and low water absorption as well as low friction and wear. Ultramid Advanced N enables short cycle times and a wide processing window. The new product line is supplemented by detailed material characterisation and the proven BASF application development capabilities. BASF offers selected grades for customer projects around the world from now on. The new portfolio gives customers from different industries greater freedom for innovations in order to develop technically sophisticated end-consumer products. With Ultramid Advanced N, customers are able to satisfy demands for miniaturization, functional integration and freedom of design. They are also able to comply with energy efficiency and safety parameters – factors that are crucial to market success. With the new BASF PPA these high standards for mechanics, chemical resistance and dimensional stability can be met across a wide temperature range. “Ultramid® Advanced N is BASF’s response to the rising demands on plastics that are employed today under increasingly challenging operating con-
ditions”, says Dr Melanie Maas-Brunner, Sr Vice President, Performance Materials Europe. “Developing specialties such as Ultramid Advanced N is in-line with our strategy to provide our customers with a broad range of solutions.” Using Ultramid Advanced N allows customers to design lighter, smaller and stronger plastic components for challenging environments where other materials reach their limits. The special properties of the new BASF PPA can be combined to create unique product profiles. The material is able to solve application problems in a wide range of different uses: Ultramid Advanced N is suitable for small connectors and function-integrating housings in white goods, consumer electronics and mobile devices. It can be used in automotive components and structural parts near the engine and the gearbox in contact with hot, aggressive media and different fuels. Applications like gear wheels and other wear parts can be implemented, too. Ultramid Advanced N possesses lead-free soldering properties that find application within the electronics and electrical industry, e.g. to assemble circuit boards using SMD (SMD: surface mounted device) technology. “We will actively approach our customers to understand their specific requirements and offer them solutions based on BASF’s expertise in application development and product know-how,” says Abdullah Shaikh, Head of PPA Business, Performance Materials Europe. “We are looking forward to providing more insight into our portfolio and discuss applications with our customers during the K fair in October 2016.”
14 | The Economic Times POLYMERS | August-September 2016
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NEWS INTERNATIONAL
Essel Propack opens new modern factory in Colombia
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ssel Propack Ltd inaugurated a new plant in Cali, Colombia. The facility inauguration was attended by the Indian Ambassador to Colombia Prabhat Kumar. “I am happy to be here on the occasion of the inauguration of the factory of Essel Propack in Villa Rica in Cauca. On behalf of the government of India I extend my best wishes to Essel Propack, their partners in Colombia, the city of Villa Rica and the Department of Cauca,” said Kumar. This new facility will have a capacity to manufacture 180 million tubes a year and the capability for making Essel’s new generation laminated tubes targeting the high value Beauty & Cosmetics category along with a pharma clean room. Located in special economic zone, the facility will efficiently cater to the growing export opportunity in the adjacent Andean markets of Ecuador, Peru, Bolivia, Venezuela, Chile, etc., besides servicing the strong local demand. Regional Vice President Ted Sojourner in the opening inaugural address stated, “Today is an important milestone in Essel’s Journey of Success. Our new plant investment known as Essel Colombia SAS is a significant strategic event for our
continued long term growth and development here in Colombia, and throughout the South America continent. This facility is built with an infrastructure that will support the future capacity expansions and growth. We have now established our Gateway to South America”. The new facility, with state-ofthe-art equipment and technology is an expression of Essel’s confidence in the growth potential of the markets it has been serving for over 15 years. It will facilitate servicing the rapidly evolving needs of categories like beauty & cosmetics, pharma and food from reputed local and multinational brands. Ashok Goel, Vice Chairman & Managing Director, Essel Propack said, “Essel Colombia is a strategic unit for us. On top of our strong local market, it opens up for us the markets in the Andean Regions and the rest of South America. Our deep knowledge of these markets coupled with our long term commitment, we are confident that this unit will benefit from some of Essel’s globally recognised innovative solutions and processes. We are truly excited at the opportunity to serve the Latin and South American markets.”
Green packaging for smartphones
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olegear Bioplastic Technologies Inc have announced a replenishment order from r-pac International, to provide Solegear’s proprietary TF4000 bioplastic for the production of smartphone case packaging to support an upcoming launch at a leading US-based consumer electronics retailer. This order represents a forecast of 600,000 smartphone case packages to be produced by r-pac from Solegear’s plantbased bioplastic with delivery commencing in this quarter. “Following an initial launch of plant-based smartphone case packaging, this latest order represents an on-going commitment from the retailer to meet demand from consumers for more sustainable products and packaging,” said Paul Antoniadis, CEO, Solegear. “Our collaborative partnership with r-pac International means that we continue to develop packaging materials that meet real-world performance and manufacturing requirements for Fortune 500 brands, and these solutions are resulting in long-term customer relationships and commitments.” Solegear’s Traverse TF4000 is a USDA BioPreferred packaging material with independently verified plant-based content and enhanced thermal properties. Designed as a drop-in replacement for petroleum-based plastic packaging, TF4000 can be readily processed in standard thermoforming equipment and contains no BPAs, phthalates or other chemicals of concern. “Delivering innovative solutions is a key to nurturing long-term partnerships with our clients,” stated Michael Teitelbaum, CEO, r-pac. “Through our continued collaboration with Solegear, we have been able to execute on this goal with industry-leading plant-based plastic packaging without sacrificing logistic or brand performance.”
Eco-friendly process for plastic manufacturing
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cientists from ExxonMobil and Georgia Institute of Technology have developed a potentially revolutionary new technology that could significantly reduce the amount of energy and emissions associated with manufacturing plastics. If brought to industrial scale, this breakthrough could reduce industry’s global annual CO2 emissions by up to 45 mn tons. It could also reduce global energy costs used to make plastics by up to $2 bn a year. Using a molecular-level filter, the new process employs a form of reverse osmosis to separate para-xylene, a chemical building block for polyester and plastics, from complex hydrocarbon mixtures. The current commercialscale process used around the world relies on energy and heat to separate those molecules.
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NEWS INTERNATIONAL
BASF launches new global pigments brand
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ASF has recently announced the launch of its Colors & Effects brand, bundling BASF’s global pigments business. The new brand encompasses the company’s distinct colorants and effect pigments portfolio, and serves customers across five key industries, including coatings, plastics, printing, cosmetics, and agriculture. “To continue to grow and develop their business, our customers need a diverse selection of pigments and global expertise,” said Alexander Haunschild, Senior Vice President, Global Pigments Business. “In this competitive marketplace, we created a brand focused entirely on pigments to provide our customers Alexander Haunschild, Senior Vice President of the global pigments business, during the reveal of the new Colors with products and solutions from one & Effects brand. single source.” al supplier to our customers. This brand underlies the key BASF organised its global pigments business in an indusstrengths we bring to the market: chemical expertise and a try approach and established teams concentrated solely on the broad portfolio of colorants and high performance effect pigcoatings, plastics, printing, cosmetics and agriculture markets. ments,” said Haunschild. “BASF continues to invest resources This is the first time the company has created dedicated global into this change and we are confident we have the right experts pigment teams for the agriculture and cosmetics industries. and portfolio to help our customers continue to innovate.” “Our number one priority is to remain a reliable glob-
Market for smart polymers to grow
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he global smart polymers market report for 2016-20 says evolution of drug delivery systems will be a key trend for market growth as smart polymers are showcasing controlled delivery systems for medications having a short halflife, narrow therapeutic window, liable to gastric and hepatic degradation, and medications that are dynamic at low plasma concentrations. These delivery systems experience numerous difficulties connected with their advancements that are identified with medication stability, drug discharge kinetics, and the conditions under which the system is delivered to the body. Smart polymers sensitive to the proximity of some biomarkers could be valuable in focusing on particular disease conditions. For instance, smart polymers sensitive to folate receptor can be used to convey anti-cancer agents to tumor cells. The analysts forecast global smart polymers market to grow at a CAGR of 19.98 percent during the period 201620. According to the 2016 smart polymers market report, one of the key drivers for market growth will be application of shape memory polymer in automotive industry. In the automotive industry, shape memory polymers are used in vehicle subsystems. These polymers self-heal in the case of damage, polymers can also be designed to change appearance or color. In addition, the polymers can be used in sensors in
safety systems. Shape memory polymers showcase new platform for variable elements in vehicles. The novel materials include new innovative components that can enhance vehicle performance at lower costs. The America is the major revenue contributing region in the smart polymers market and is likely to occupy more than 45 percent of the overall market revenue by 2020. Much of the region’s growth can be attributed to the growing focus on temperature and pH-sensitive polymers. With the governments trying to improve public healthcare systems, the demand for such smart polymers will increase significantly in the region’s medical industry. The smart polymers market in the region is anticipated to grow at a high CAGR of more than 22 percent during the predicted period. Moreover, these polymers have promising applications in the biomedical field as conveyance systems of therapeutic agents, actuators systems, bio-separation devices, cell culture support systems, sensors, or tissue engineering frameworks. Recently, these polymers have come up with new application areas including medicinal diagnostics, pharmaceuticals, implants, and treatments sectors. They have properties like adaptability and compatibility that make them valuable in medical treatments involving the immune system.
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CMYK
CMYK
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CMYK
COMING SOON
• Case Studies • Panel Discussions • Presentations • Key Note Address • CEO Roundtable • Hall of Fame
CMYK
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NEWS INTERNATIONAL
Bioplastics & biopolymers market to reach $5.08 bn by 2021
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he report Bioplastics & Biopolymers Market by Type (Bio-PE, Bio-PET, PLA, Starch Blends, Biodegradable polyesters, Regenerated Cellulose and PHA), Application (Packaging, Bottles, Agriculture), and by Region - Trends & Forecast to 2021’’, published by MarketsandMarkets suggests that the global market is projected to witness a CAGR of 12.0 percent from 2016 to reach a market size of $5.08 billion by 2021. This growth is mainly driven by implementation of strict environment regulations to reduce carbon content and fluctuating fuel prices, which is compelling manufacturers to use a stable source of raw material. Bio-PET is projected to remain the dominant bioplastics during the forecast period. The major reason of Bio-PET
domination is the comparable physical properties to petroleum based PET, that makes it suitable for all applications, without making much technological changes. Packaging segment is projected to witness highest CAGR in the market during the forecast period. The bioplastics & biopolymers market in the packaging industry is projected to witness the highest CAGR between 2016 and 2021. The rising awareness of consumers about sustainable environment and improved lifestyle, which is driving consumers to purchase high quality products, is expected to influence the demand for bioplastics & biopolymers during the forecast period. R&D departments of manufacturers are doing research to widen the application area of bioplastics, which will drive the growth of the bioplastics & biopolymers market.
DSM and NHU inaugurate joint venture to produce high performance PPS compounds
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oyal DSM, a global science-based company active in health, nutrition and materials, and specialty chemicals producer Zhejiang NHU Special Materials Co., Ltd. (NHU), have officially inaugurated their joint venture company for polyphenylene sulfide (PPS) compounds, DSM NHU Engineering Plastics (Zhejiang) Co Ltd. The JV, which was announced May 2015, has been established in Zhejiang province, close to NHU’s linear PPS polymer plant in Shangyu, for manufacturing of the high performance compounds. DSM has a 60 percent share in DSM NHU Engineering Plastics (Zhejiang) Co Ltd., with NHU holding the remaining 40 percent. Products, which are branded Xytron PPS, are marketed globally and targeted principally at automotive, electrical and electronics, water management and industrial markets. DSM will be marketing the product globally, including China. The PPS polymer plant operated by NHU uses proven technology to provide high quality base polymer for the compounds. The joint venture will take over NHU’s existing compounding capacity. DSM for its part brings its longstanding expertise in application development and materials science, as well as access to its global customer network. “Xytron PPS compounds will further enhance DSM’s offering in the high temperature performance engineering plastics space, adding to our leadership positions with Stanyl polyamide 46 and our ForTii polyamide 4T,” says Roeland Polet, President DSM Engineering Plastics. “They also complement our offerings in Akulon polyamide 6 and 66, and in Arnite and Arnitel thermoplastic polyesters for engineering applications.” DSM NHU Engineering Plastics (Zhejiang) Co Ltd. is initially offering two standard commercial grades. These are
Xytron G4010T, containing 40 percent glass fiber reinforcement, and Xytron M6510A, which contains 65 percent glass fiber and mineral filler. Recently DSM has added to its portfolio a 30 percent glass reinforced grade and a 40 percent glass reinforced low chlorine grade (especially important for electronic applications) which are currently being evaluated by customers. Grades under development include types with enhanced wear resistance and low friction, with high flow/low flash, and with increased impact strength. In the run-up to the official inauguration, the joint venture has already captured business in three important applications in both China and Europe, with materials currently being evaluated by numerous customers, including key automotive OEMs and Tier Ones. One of the three products already commercialised is an engine block heater for electric generators, which is required to operate in continuous contact with water at temperatures between 35 and 50°C.
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NEWS INTERNATIONAL
Total launches new range of HDPE Circular Compounds
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otal has introduced a new range of high-density polyethylene (HDPE) Circular Compounds with high levels of recycled content to its packaging segment customers. With performance equal to or exceeding that of virgin resins, this new product range valorizes Total’s superior process and catalyst technology and actively contributes to the Circular Economy. Jean Viallefont, Vice President Polymers Europe, stated, “Total is currently extending the applications of the recycled compounds concept by developing additional new grades, since we believe it will be essential to place the European virgin plastics industry in a new yet essential role as ‘circularity enhancer’.” The range consists of HDPE polymer products, in natural colour, that cover all the manufacturing needs for blowmoulded bottles and heavy-duty containers for household and industrial liquids with a guarantee of 25 or 50 per cent minimum of Post Consumer Recyclate (PCR). Total’s initial production capacity of HDPE Circular Compounds amounts to 20 kT, coming fully on stream during the course of 2017. The composition and manufacturing process of these Circular Compounds is especially designed to minimise their environmental footprint, while ensuring outstanding perfor-
mance and processing properties, guaranteed by Total just as with any virgin resin. Their recycled content originates from post-consumer household waste collected in Western European countries and is recycled by selected partners chosen by Total for their outstanding product quality and recycling process capabilities. In its Antwerp plant, Total applies a last deep decontamination step, which transforms the PCR into an absolute fragrance-free resin. Finally, the PCR is compounded in Total’s plant with highly technological HDPE virgin products, specifically designed and produced as intermediate resins in order to overcompensate for any lack of performance and consistency of the PCR. The resulting compounds are meant to be fully equivalent to any virgin resin sold in the same application, but in reality they largely outperform them in all key aspects for their application. For the Circular Economy and for plastics in general, the innovative concept of high performance Circular Compounds allows the recycling industry and the virgin resin industry to open up new markets for high-quality recycled polymers. As a contribution in this area, Total’s objective is to enable downstream industries to rely on recycled materials and to achieve this, we are currently developing additional new grades for a wide variety of applications.
Plastic coatings market worth $7.76 billion by 2021
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ccording to the new market research report, ‘Plastic Coatings Market by Type (Polyurethane, Acrylic, Epoxy), Process (Electrophoretic Painting, Powder Coating, Dip Coating), End-Use Industry (Automotive, Aerospace & Defense, Building & Construction), and Region - Global Forecast to 2021’, published by MarketsandMarkets, the market is projected to reach $7.76 billion by 2021, at a CAGR of 5.5 percent during the forecast period, 2016 to 2021. This growth is driven by the increasing demand from automotive end-use industry and increasing trend towards green, environment-friendly coating materials. Automotive end-use industry is expected to lead the plastic coatings market by 2021 Automotive end-use industry of plastic coatings market constituted major share to the application segment of the plastic coatings market in 2015. The growing demand for plastic coatings from the automotive end-use industry is anticipated to drive the demand for plastic coatings, owing to the functionality, durability, and performance benefits. Polyurethane contributed around one third of the global plastic coatings market share in 2015. It is expected to
grow at a significant CAGR during the forecast period. Polyurethane plastic coatings have high performance benefits, such as strength, flexibility, abrasion resistance, and moisture resistance. This makes them suitable for wooden, plastic, and other surfaces. Dip coating process is expected to lead the plastic coatings market during the forecast period. This process accounted for the largest share of the plastic coatings market in 2015. It is one of the most widely used processes in the plastic coatings market, due to its ease of use to coat complex shapes. Additionally, this process does not require expensive equipment. Dip coating process is mainly used for coating medical instruments, electrical equipment, as well as automobiles. Europe accounted for the largest share of the Plastic Coatings Market in 2015, followed by North America and Asia-Pacific. Europe is one of the major consumers of plastic coatings. Increasing investment by leading automakers in European countries, followed by the growing automotive OEM market is anticipated to enhance the European plastic coatings market.
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INNOVATION
Smart electronics for smart clothing SMART CIRCUITS ARE MANUFACTURED USING AN EFFICIENT, MULTI-STAGE PROCESS.
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ovestro is showcasing an item of luminous clothing at the K 2016 plastics trade fair. LEDs make it truly stand out, but can also perform key functions such as protecting pedestrians and cyclists against accidents. What makes it special is that the light-emitting diodes are not positioned on a panel or strip, but on a piece of soft fabric. At the center of the development is an electronic system that is responsive to movements without losing its functionality. The system comprises a flexible and formable film made of thermoplastic polyurethane (TPU) from Covestro. The TPU is the substrate for the printed copper circuits, which are arranged in a meandering pattern and can thus also be bent and stretched.
TERASEL technology also enables production of modular automotive interior components in which all functions are already integrated. This reduces complexity in assembly, cuts costs and shortens time to market. It also clears the way for new lighting concepts in automotive interiors and buildings, where designers and architects can position LEDs exactly where they are needed most.
Intelligent technology
From functional underwear to automotive interiors
Smart circuits are manufactured using an efficient, multi-stage process. First, copper films are laminated onto the polyurethane films. The printed circuits are produced in a subsequent structuring operation featuring highly effective adhesion. The coated films are then shaped as required using conventional thermoforming. “The films are resistant to standard etching and imaging processes,” said Covestro film expert Wolfgang Stenbeck. “Formable electronic systems can also be directly laminated onto textiles, as in the case of the luminous dress.” The production technology was developed as part of various projects funded by the EU Commission, among them STELLA and TERASEL. The objective is to produce 2.5-dimensional electronic circuits costeffectively using conventional forming processes. The freely formed components can be integrated seamlessly into energy-efficient electronic components. They can be processed using standard PCB industry equipment and are also suitable for applications with higher currents or voltages. The smart circuits meet a whole range of other customer needs and are thus ideal for applications in a variety of industries. Compared to conventional electronic components, they offer greater design freedom and reliability while enabling more sustainable products due to the reduced use of materials.
The technology opens up an extremely wide range of options for smart textiles alone. Besides fashion items such as the luminous dress, freely formable electronic systems are already in use in underwear, where they monitor heart rate and breathing. They assist patients with therapy and help athletes monitor their training. TERASEL technology also enables production of modular automotive interior components in which all functions are already integrated. This reduces complexity in assembly, cuts costs and shortens time to market. It also clears the way for new lighting concepts in automotive interiors and buildings, where designers and architects can position LEDs exactly where they are needed most. In consumer electronics, smart circuits are supporting the trend toward increased miniaturization of components, as they can be incorporated directly into the outer shell of products. Stretchable circuit board (SCB) technology for manufacturing stretchable electronic circuits was developed earlier as part of the European STELLA project. This was led by the Fraunhofer Institute for Reliability and Microintegration (IZM) and the Technical University of Berlin. Coated TPU films can be stretched repeatedly up to 60 percent, and on a one-time basis by as much as 300 percent. Source: Covestro
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PACKAGING
By Vimal Kedia, Managing Director, Manjushree Technopack
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ackaging trends typically reflect changes in consumption patterns. For instance, the beverage industry has seen a revolution in packaging, namely the transition from glass bottles to PET due to its convenience, mobility and user -friendly features. PET is a major rigid plastics packaging format that is used to pack a range of beverages including soft drinks, fruit juices and water. As consumption of beverages increased, it led to an increased demand for transporting and storing these products in bulk. Creating ease and convenience in sealing and transportation of PET bottles and products in bulk, shrink CREATING EASE AND CONVENIENCE IN SEALING film packaging is growing in popularity as a AND TRANSPORTATION OF PET BOTTLES AND secondary form of packaging, compared to the traditional use of corrugated cartons. PRODUCTS IN BULK, SHRINK FILM PACKAGING The shrink film industry in India is growIS GROWING IN POPULARITY AS A SECONDARY ing exponentially, led by several beverage maFORM OF PACKAGING. jors, 50 percent of whom have made a shift from traditional corrugated boxes to multilayer shrink film packaging. Shrink film serves the There are various types of shrink packaging like reverse printed shrink labels, shrink same purpose of holding several product packs sleeve, shrink pouches and shrink film in a variety of materials like PVC, POF or bottles together and one of the primary & LDPE. In keeping with current industry trends and the company’s expansion reasons for this move is the considerable cost plans, Manjushree Technopack inaugurated a fully automatic multi-layer shrink advantage-shrink film costs 1/3 that of corfilm packaging plant in Bidadi recently. As the company’s major clientele belong to rugated boxes-and also the aesthetic appeal of the beverage industry, the rapid headway into shrink film packaging contributed to transparent packaging. Shrink film packaging Manjushree’s progression towards flexible packaging. guarantees protection against Equipped with new generation machines from moisture, dirt, dust and theft. Germany’s ‘Reifenhauser’, the plant has the capacity The shrink film industry It offers perfect stackability to produce 12-15 tonnes of shrink film every day. in India is growing and maximises loading capacWith this, Manjushree Technopack will be providing exponentially, led by ity. Shrink film is made of multi-layer shrink film packaging solutions to most several beverage majors, high quality performs to form of their existing clients like Pepsi, as a tertiary pack50 percent of whom an elastic transparent film that aging solution, to make bulk packaging lighter. have made a shift from can be wrapped around prodBy entering into shrink film packaging, the comtraditional corrugated ucts to hold them together. pany will not only augment its offerings to existing boxes to multilayer shrink clients using PET performs, but become the only film packaging. packaging major in India that provides a 360 degree packaging solution. This milestone in Manjushree’s growth trajectory is expected to increase Manjushree’s overall turnover by five percent. Besides shrink film, other products like ‘printed shrink labels’, ‘shrink sleeves’ and ‘shrink pouches’ have gained popularity. The company’s foray into secondary/ tertiary packaging material in the form of shrink film packaging, will enhance its relationship with beverage players as Manjushree now becomes a one stop place for all forms of packaging. With the shrink film packaging industry envisaged to account for a global market share of more than 39 percent by 2020, in India its innumerable applications could well extend to segments beyond beverages, like food, FMCG, toys and books.
High demand!
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RECYCLING
Recycled plastic to power ship engines A RESEARCH WILL DETERMINE IF A FUEL MADE FROM RESIDUAL MIXED PLASTIC WASTE CAN BE USED EFFICIENTLY IN DIESEL ENGINES WHICH CURRENTLY USE HFO (HEAVY FUEL OIL), WITHOUT INCREASING ENGINE WEAR.
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ew research will test whether Plaxx, a fuel made from mixed plastic waste, can be used as an alternative to crude derived fuels in industrial and marine engines. The research, funded by Innovate UK and ESPRC will be led by Associate Professor Farid Dailami, BristolRobotics Laboratory (BRL), in partnership with Recycling Technologies, developers of Plaxx. The project is also supported by Swindon Borough Council, Crapper and Sons Landfill Ltd, and an international marine insurer. The research will determine if Plaxx, made from residual mixed plastic waste, can be used efficiently in diesel engines which currently use HFO (Heavy Fuel Oil), without increasing engine wear. These engines are in marine vessels such as tankers, ferries and other nautical machinery. The research is also of interest to the waste treatment companies, packaging manufacturers and local waste handling authorities. Its long term application helps create a useable resource from waste which cannot be efficiently recycled mechanically.
This new fuel could have huge environmental benefits as an alternative to HFO currently used in marine diesel engines and industrial engines. Our research will compare the performance of this fuel with standard diesel fuel in order to gain data on how it performs and to ensure it won’t damage the engine or cause harmful emissions or gases. Associate Professor Farid Dailami The waste source is the plastic entering the commercial, industrial and municipal waste streams that is mixed, laminated, contaminated and otherwise not available to conventional plastics recycling techniques. At present unfortunately this represents the bulk of plastic waste. Plaxx is the product of the depolymerisation of plastic and is made up of a mixture of hydrocarbon monomers similar to crude oil. It is however very low in sulphur and other organic/inorganic contaminants. Currently it is a soft wax at room temperature but a low viscosity liquid at 70°C. As with crude oil it can be further refined and could be used as an input to plastics manufacturing. The research will develop the use of Plaxx by testing engine performance, exhaust emissions and engine wear on different engines over a broad range of test conditions. The research will also develop software tools that will monitor
For representation only
these three aspects to enable engine users to achieve optimum performance from Plaxx. Associate Professor Farid Dailami says, “This new fuel could have huge environmental benefits as an alternative to HFO currently used in marine diesel engines and industrial engines. Our research will compare the performance of this fuel with standard diesel fuel in order to gain data on how it performs and to ensure it won’t damage the engine or cause harmful emissions or gases. The aim is to demonstrate to producers and users of these engines that Plaxx can be a viable alternative to HFO. “HFO is a fossil fuel which needs to be extracted and refined and therefore has environmental costs and consequences, whereas Plaxx is very low in sulphur and is made from a waste product which otherwise would have to go into landfill or be incinerated. Our research will seek to show if you put Plaxx into an engine it won’t harm the engine. In time Plaxx, as an alternative to HFO, has the potential to benefit local authorities and ultimately tax payers, by lowering the cost of waste management and turning plastic waste into a useable fuel.” Adrian Griffiths, CEO, Recycling Technologies says, “This research will allow Recycling Technologies to characterise the use of Plaxx for use in diesel engines thus opening up a global market for an important new innovative material to replace fossil fuels with a product derived from waste.” Plaxx is low in sulphur and complies with new emission rules. HFO, used in marine main diesel engines is a residue from crude oil refining and as such is the dregs of the process. Bristol Robotics Laboratory is a collaborative partnership between the University of the West of England (UWE Bristol) and the University of Bristol. Source: University of the West of England
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RECYCLING
Recycling plastic into fuel A NEW WAY OF RECYCLING PLASTIC GARBAGE INTO LIQUID FUEL HAS BEEN DEVISED BY RESEARCH INSTITUTES.
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available form of plastic. Their innonew way of recyvative technique centers on the use of cling millions of alkanes, specific types of hydrocarbon tons of plastic garmolecules, to scramble and separate bage into liquid fuel polymer molecules into other useful has been devised by compounds. The team’s findings were researchers from the published recently in Science Advances. University of California, Irvine and the Shanghai Institute of Organic ChemisScientists have been seeking to try (SIOC) in China. recycle plastic bags, bottles and other “Synthetic plastics are a fundamentrash generated by humans with less Scientists have come up with a way to turn the most common tal part of modern life, but their use in toxic or energy intensive methods. Curform of plastic into liquid fuel. Daniel A. Anderson / UCI large volume has created serious envirent approaches include using caustic ronmental problems,” said UCI chemist Zhibin Guan. “Our goal chemicals known as radicals or heating the material to more than through this research was to address the issue of plastic pollution 700o F to break down the chemical bonds of the polymers. as well as achieving a beneficial outcome of creating a new source In this newly discovered technique, the team degrades plastics of liquid fuel.” in a milder and more efficient manner through a process known as cross-alkane metathesis. The substances needed for the new methGuan and Zheng Huang, his collaborator at SIOC, together od are byproducts of oil refining, so they’re readily available. with their colleagues have figured out how to break down the strong bonds of polyethylene, the most common commercially Source: University of California, Irvine
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WHITE GOODS
Switched ON to the future 32 | The Economic Times POLYMERS | August-September 2016
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WHITE GOODS
THE KEY MATERIAL THAT IS USED IN MANUFACTURING OF WHITE GOODS IS PLASTIC. HERE IS A REASON BEHIND WHY THE MATERIAL IS SO POPULAR AMONGST WHITE GODS MANUFACTURERS. By Swati Deshpande
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rom its inception, plastic has revolunalised the whole manufacturing industry right from healthcare to automotive. White goods manufacturing is no exception to this rule. The use of plastics in electrical and electronic equipment is increasing due to its various advantages. Today, think of any home appliance such as mixer, food processor refrigerator, air conditioner, etc., plastic’s presence in the making of it is imperative. There are various advantages that this material brings along with it. Speaking on the same, Burzin Wadia, Executive Vice President—Technology and Engineering, Godrej Appliances said, “Use of plastic is highly favourable for industrial product designers as it helps them translate their dream product concepts into reality. Almost any shape or style can be made possible. Use of plastic makes it possible to achieve various textures, designs and colours at a very low cost. Engineering plastics are increasingly replacing metals in most cases at much lower cost of production while delivering the same performance. Even complex parts can be designed and produced with great ease.” Comparing the plastics’ features with metal, Wadia said, “Earlier, processes such as painting and lamination were carried out for enhancing aesthetics of the product. These processes were expensive and the finish was inconsistent.” The new type of plastics has not only brought the ease of processes and cost efficiency, but has also enhanced products aesthetically. “With the de-
Use of plastic is highly favourable for industrial product designers as it helps them translate their dream product concepts into reality. Almost any shape or style can be made possible. Use of plastic makes it possible to achieve various textures, designs and colours at a very low cost. Engineering plastics are increasingly replacing metals in most cases at much lower cost of production while delivering the same performance. Even complex parts can be designed and produced with great ease. Burzin Wadia, Executive Vice President— Technology and Engineering, Godrej Appliances
The use of plastics in electrical and electronic equipment is increasing due to its various advantages. Today, think of any home appliance such as mixer, food processor refrigerator, air conditioner, etc., plastic’s presence in the making of it is imperative.
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WHITE GOODS
velopment of new types of plastics, there is an economical way of achieving aesthetic excellence. Value adds such as glitters, variety of colours and shades by mixing colouring agents, etc. is possible by using additives to plastics,” he added.
Safety first Furthermore, home appliances being closely associated with electricity, safety is a vital aspect to be considered. “Safety is a key requirement for kitchen appliances such as food processors, toasters, kettles and plastics aid in making appliances safer in two ways. First and foremost is electrical safety. Being a bad conductor of electricity, plastic prevents users from electrical hazards. Secondly, the use of plastics helps in achieving transparency, which
Thermally conductive plastic - a boon for electrical & electronics equipment According a report namely ‘Thermally Conductive Plastics Market by Raw Material (PPS, PBT, PA, PC, PEI, PSU, & Others), by End-Use Industry (Electrical & Electronics, Automotive, Industrial, Healthcare, Aerospace, & Others) - Global Trends and Forecast to 2020’ released by MarketsandMarkets, the thermally conductive plastics market size is estimated to grow from $388.5 million in 2015 to $757.4 million by 2020, at a CAGR of 14.3 per cent. The report further suggests that electrical & electronics is currently the largest end-use segment and one of the major applications of thermally conductive plastics. The heat generated incised the electronic devices is most often concentrated in a small area and temperatures may reach much higher levels which results in the failure of these devices. The continuous developments and demand for smart and sophisticated electronic devices in various end-use industries is driving the demand for better thermal management. This rapid and ongoing growth in the packaging density of electronics has posed enormous challenges to electronics cooling and thus, the lightweight and easy moldability of thermally conductive plastics can be a perfect fit for these devices.
Plastics are much lighter as compared to metal, which makes them easy to handle during production. They are also economical in transportation thereafter. Apart from being lightweight, advantage that transparent plastic parts offer over glass is cost efficiency. Burzin Wadia makes it a good substitute for glass in many cases. Its break-free properties prolong the life of products,” Wadia mentioned. If compared with the glass or metal, plastic products are not only safe to use but are also easy to transport because of their break-free nature and light weight. “Plastics are much lighter as compared to metal, which makes them easy to handle during production. They are also economical in transportation thereafter. Apart from being lightweight, advantage that transparent plastic parts offer over glass is cost efficiency,” he stated. Moreover, plastic material is rust proof. “There is lesser risk of environmental impact on the product made of plastic. Therefore, its use helps in prolonging the life of the appliance compared to metal or glass.”
Other benefis Besides these, heat-insulation is a significant benefit that plastic brings. Explaining this with an example, Wadia mentioned, “Plastic is an insulator of heat, thus, it prevents heat dissipation into the appliance when not desired. For an instance, inner plastic lining of refrigerator helps in retaining cooling inside the refrigerator.” Along with the users, plastic also offers benefits to manufacturers at the production stage. Speaking about it, Wadia mentioned, “There is a single step process to produce the plastic part of an appliance. Hence, the infrastructure and space requirement is much lesser as compared to infrastructure requirement for metal parts. In other words, again it is cost effective.” Additionally, one of the other benefits of plastic is recyclability. Reducing the impact on the environment, plastic can easily be recycled and used again. With these benefits to users and manufacturers, plastic has become a ‘magic’ material for all!
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AUTOMOTIVE
The Power of Polymer! THE USE OF PLASTICS AND POLYMERS WILL ONLY GROW IN THE TIMES TO COME AND ONE OF THE LEADING TIER ONE AUTO COMPONENT MANUFACTURERS WHO REALISED THIS IS THE VARROC GROUP, WHICH HAS A FULL-FLEDGED POLYMER DIVISION. ET POLYMERS CAUGHT UP WITH TARANG JAIN, THE GROUP’S MD TO UNDERSTAND MORE ABOUT ITS PROGRESS SO FAR AND THE WAY AHEAD. By Niranjan Mudholkar
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edge in their markets. arang Jain, Managing Director, Varroc Group of Companies, is a first generation In recognition of its progress, the Varroc Group was cited as entrepreneur, under whose able leadership an emerging manufacturing giant from Maharashtra by Chief the Group has grown by leaps and bound. Minister Devendra Fadnavis. How does Jain view this recogniFounded in 1990, Varroc group is an emergtion? “Varroc had its humble beginnings in Maharashtra state in ing global automotive component manu1990 and it is indeed very encouraging to be cited by the honfacturer and supplier of exterior lighting systems, powertrains, ourable Chief Minister as an emerging manufacturing giant in a electricals, body and chassis parts to leading state which houses established global giants such passenger car and motorcycle segments worldas Tata. This is a very important milestone for wide. With 35 manufacturing plants, 11 engiour own ‘Make in India’ journey that started 26 Varroc has ventured neering centres, 13,500 employees and 760 enyears back. Also, it is a humble reminder for us into mirrors for gineering experts in 10 countries, Varroc group to set standards and lead the path for the many commercial vehicle is on an exponential growth trajectory clocking small and medium enterprises that could conand is in advanced sales of US$ 1.3 billion. The company is a leadtribute to the development of the state.” development stages ing global passenger car lighting supplier and The FY 2015-16 was a good year for Varthe number one 2-wheeler automotive compo- for launching these to roc in terms of growth primarily due to the glonent supplier in India. Varroc offers best design a global HCV maker.” balized nature of its business. Does Jain see the solutions that give customers a competitive market further improving in this financial year? 36 | The Economic Times POLYMERS | August-September 2016
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AUTOMOTIVE
Businesses can compete in the Indian market only if they meet global productivity standards which in turn require manufacturing technologies that cannot be managed by less skilled labour. This will force companies to look differently at their current operating models. “Growth in the international business was in the healthy double digits, while the domestic business was impacted by the continued sluggishness in the two wheeler market. Our strategy of product and customer portfolio realignment has enabled us to derisk from the downturns as some of our high growth customers in India ensured that we fared better than the market. We continue to maintain double digit growth targets in revenues and margins overall for this year as well.� All progressive companies endeavour towards being future ready and the Varroc Group is no different. Jain has recently taking steps towards implementing Industry 4.0 solutions across all Varroc plants. Jain believes that IT
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AUTOMOTIVE
The Polymer business is unique in the sense that we have to be located close to the customer. We have added five state-of-the-art manufacturing facilities including paint shops in the past five years to support our customers all over India.
Varroc Polymer Division Varroc Polymer focuses on Indian business and provides innovative solutions to the automotive segments - two/ three/ four wheeler, commercial vehicles and off-road vehicles. The division produces a wide range of injection and compression moulded automotive and allied rubber components that include air filter assemblies, seating assemblies, plastic interiors, painted plastic parts, mirror assemblies and elastomers. Varroc is the largest polymer solution provider to the 2-wheeler industry. Varroc Polymer has a pan-India presence with 13 world class manufacturing facilities having best in class paint shops, PU molding, mirror manufacturing with in-house mold design, seat assemblies & development capability with world class tool room facility. All the manufacturing facilities are strategically located providing proximity to key customers offering quick solutions and service support that reduces customer response time. The company has invested in a state-of-the-art engineering center to handle the intricate aspects of product design with key focus on design for manufacturing, light weighting and green initiatives. The center has a Government of India approved Research and Development unit focusing on solutions for integrated modules, mirror assemblies and advanced air filter solutions. Varroc Polymer believes in pioneering excellence, enriching partnerships and building relations. Today, the division is a preferred partner to a host of clientele not only in Indian business but also for their international markets.
and Internet technologies are changing the way traditional manufacturers have been functioning all over the world. “I am proud to share that Varroc is one of the pioneers in making this push into the realm of Industry 4.0 adoption and have partnered with Altizon Systems to implement the solutions across all our plants. Our IoT journey is a part of the digital transformation initiative in Varroc around smart manufacturing. We are trying to connect all parts of the production process i.e machines, systems, people and products via the internet. Through this small step, we hope to rapidly scale multiple Industrial IoT applications across our plants and be ready for a more competitive environment in the near future in terms of speed and efficiency.” Last year, Varroc joined hands with Scorpion Automotive of the UK to produce vehicle security systems for the Indian market. The partnership aims to design, manufacture and supply security and tracking systems for the India market as Jain felt that the need for security systems was not appropriately addressed in this market for a long time. He says: “We are in various stages of discussions with multiple OEMs for understanding their requirements on these systems after having successfully demonstrated both the tracking and security systems on local bikes. Scorpion Automotive has a little pilot tracking system running on the aftermarket already to get feedback on customer requirements and preferences.” ‘Make in India’ seem to have given a boost to the Indian manufacturing industry, which was facing a sluggish market environment previously. Jain believes that the ‘Make in India’ initiative by the Government is a necessary move to prop up India’s image and invite diverse participants for transforming India into the next global manufacturing hub. “Key initiatives like opening up of the defence and aerospace sectors as part of this initiative are a welcome signal for investors to participate in the growth and development of our nation. While the emphasis has been on import substitution and boosting exports, I feel India has a very large internal economy that requires attention. Businesses can compete in the Indian market only if they meet global productivity standards which in turn require manufacturing technologies that cannot be managed by less skilled labour. This will force companies to look differently at their current operating models that are designed to run with high manual contract labour,” he says. Varroc’s crankshaft business has not delivered as per expectations. What is Jain doing to rectify the situation? “True, our crankshaft business has not ramped up as per plan as the commercial vehicle industry had gone into a slump when we invested in this business. However, it is showing signs of revival and we
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AUTOMOTIVE
see better utilisation of our capacities this year. Already the better than average monsoons have improved offtake of tractors and we should see a trickle effect on commercial vehicles very soon. We had focused on a lean manufacturing process to stay competitive last year and the wait seems to be coming to an end,” he says confidently. After lighting, polymer is the second largest business vertical for the Group. Jain now plans to grow it further. “The Polymer business is unique in the sense that we have to be located close to the customer. We have added five state-of-the-art manufacturing facilities including paint shops in the past five years to support our customers all over India. This year we have commissioned our plant in Gujarat for supplying to the leading scooter maker in India and are currently in the process of commissioning another plant in Chakan,” he shares. Varroc has ventured into mirrors for commercial vehicle and is in advanced development stages for launching these to a global HCV maker. “Discussions are also in progress for complete Instrument Panels for passenger cars which is our next target product for this market,” Jain adds. So what is Tarang Jain’s mantra for taking Indian auto components sector to the next level? Indian auto components sector has done very well due to the high growth rates enjoyed by the market in the past two decades. “Of late the slowdown, I believe, is caused by the economy not generating enough employment. The manufacturing sector’s continued reliance on antiquated manufacturing using low cost contract labour has not helped
improve purchasing power. This can be changed by investing in technologies to improve productivity and value added products that address market needs better and also contributing to wage growth. R&D investments also help companies stay competitive by differentiating their products in the market,” he explains. Tarang Jain believes in setting timeline oriented targets and working towards the same. He has a fairly robust growth strategy for 2020 in place. Accordingly, Varroc will continue to invest in cutting edge exterior lighting technologies to support the needs of its customers in the passenger car segment to differentiate while expanding its horizons in newer geographies like Brazil and intensifying its footprints in China. “We are the most diversified supplier of auto parts in the two wheeler market and not all of them are sold to all of our key customers. Therefore, in the domestic market we are accelerating our cross-sell to our customers and this offers a tremendous potential to almost triple our size by 2020. With the coming safety and emissions regulations in mind, we also have an eye on preparing our product portfolio to offer alternatives to all of our key customers in the two wheeler segment. Our success will be determined to a large extent by how we succeed in skilling up our workforce to improve productivity in the domestic market and developing products that help differentiate our customers in their local markets. 2020 in India has its own challenges of emission and safety technologies to be created in capacities of a scale never seen in any market ever; and here lies our opportunity,” he says, concluding on a positive note.
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RECYCLING
Rebirth of Polycarbonates! IBM RESEARCH SCIENTISTS HAVE DISCOVERED A NEW RECYCLING PROCESS TO CONVERT OLD SMARTPHONES AND CDS INTO NONTOXIC, HIGH-STRENGTH PLASTICS
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very year, the world generates more than 2.7 million tonnes of a plastic, known as polycarbonates, to create common household items, such as CDs, baby bottles, IBM Researchers Jeanette Garcia and Gavin Jones in San Jose, Calif. Lab eyeglass lenses and smartphones. Over time, polycarWhere they Discovered New Recycling Process for Old CDs. Courtesy: IBM Research bonates decompose and leach BPA, a chemical that, in 2008, caused retailers to pull plastic baby bottles While preventing these plastics from from store shelves due to concerns about the potential effects of BPA on entering landfills, we simultaneously the brain. recycle the substance into a new Recently, IBM Research announced that researchers from the Altype of plastic -- safe and strong maden lab in San Jose, California (US) have discovered a new, one-step enough for purifying our water and chemical process that converts polycarbonates into plastics safe for water producing medical equipment. It’s purification, fibre optics and medical equipment. an environmental win on many In the study, IBM Researchers added a fluoride reactant, a base (simifronts. lar to baking powder) and heat to old CDs to produce a new plastic with Jeanette Garcia, Ph. D., research temperature and chemical resistance superior to the original substance. staff member, IBM Research When the powder is reconstructed into new forms, its strength prevents the decomposition process that causes BPA leaching. “Polycarbonates are common plastics in our society–especially in conused to advance cognitive systems to help accelerate the sumer electronics in the form of LED screens, smartphones and Blu-rays, materials discovery process. The scale, pace and complexas well as everyday eyeglass lenses, kitchen utensils and household storage ity of materials science is a challenge for scientists workgear,” said Gavin O. Jones, Ph.D., research staff member, IBM Research ing to discover new materials. – Almaden (San Jose, California). “We now have a new way of recycling As part of the IBM Research Frontiers Institute, to improve how this prominent substance impacts the world’s health and scientists are combining expertise in informatics and environment.” polymers, and other materials, to prototype systems to “While preventing these plastics from entering landfills, we simultaextract, organise, analyse, and predict insights from maneously recycle the substance into a new type of plastic–safe and strong terials datasets. By leveraging existing knowledge from enough for purifying our the world’s scientific databases and water and producing mediaccelerating computations used in cal equipment,” said Jeanette these types of experiments, these Garcia, Ph. D., research staff cognitive tools could help identify member, IBM Research – patterns and to bring new discoveries Almaden (San Jose, Califorto realisation faster. nia). “It’s an environmental IBM Watson Discovery Advisor win on many fronts.” is an example of a cognitive system In this study, researchers available to assist pharmacological used a combination of preresearchers in finding new potential dictive modeling and experidrug molecules and IBM’s science mental lab work to make the research team continues to broaden discovery. The learning from the domain expertise into new matethese research efforts is also rial areas. Jeanette Garcia cutting a CD for recycling. Courtesy: IBM Research 40 | The Economic Times POLYMERS | August-September 2016
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AUTOMOTIVE
Courtesy: Ford
Tequila shots!
FORD MOTOR COMPANY AND JOSE CUERVO ARE EXPLORING THE USE OF AGAVE PLANTS TO DEVELOP A SUSTAINABLE BIOPLASTIC MATERIAL TO INCORPORATE IN VEHICLES, GIVING THE AGAVE FIBER BYPRODUCT A SECOND CHANCE AT USEFULNESS
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ord Motor Company is teaming up with Jose Cuervo to explore the use of the tequila producer’s agave plant byproduct to develop more sustainable bioplastics to employ in Ford vehicles. Ford and Jose Cuervo are testing the bioplastic for use in vehicle interior and exterior components such as wiring harnesses, HVAC units and storage bins. Initial assessments suggest the material holds great promise due to its durability and aesthetic qualities. Success in developing a sustainable composite could reduce vehicle weight and lower energy consumption, while paring the use of petrochemicals and the impact of vehicle production on the environment. “At Ford, we aim to reduce our impact on the environment,” said Debbie Mielewski, Senior Technical Leader, Sustainability Research Department, Ford. “As a leader in the sustainability space, we are developing new technologies to efficiently employ discarded materials and fibers, while potentially reducing the use of petrochemicals and light-weighting our vehicles for desired fuel economy.” The growth cycle of the agave plant is a minimum seven-year process. Once harvested, the heart of the plant is roasted, before grinding and extracting its juices for distillation. Jose Cuervo uses a portion of the remaining agave fibers as compost for its farms, and local artisans make crafts and agave paper from the remnants. Now, as part of Jose Cuervo’s broader sustainability plan, the tequila maker is joining forces with the automaker to develop a new way to use its remnant fibers. “Jose Cuervo is proud to be working with Ford to further develop our agave sustainability plan,” said Sonia Espinola, Director of Heritage, Cuervo Foundation and master tequilera. “As the world’s No. 1-selling tequila, we could never have imagined the hundreds of agave plants we were cultivating as a small family business would eventually multiply to millions. This collaboration brings two great companies together to develop innovative, earth-conscious materials.”
There are about 400 pounds of plastic on a typical car. Our job is to find the right place for a green composite like this to help our impact on the planet. It is work that I’m really proud of, and it could have broad impact across numerous industries. Debbie Mielewski, Ford Senior Technical Leader, Sustainability Research Department Like Ford, Jose Cuervo is family-owned and operated. Founded in 1795, it has been making tequila for more than 220 years with the same experience, craftsmanship and recipes that have been handed down generation through generation. The collaboration with Jose Cuervo is the latest example of Ford’s innovative approach to product and environmental stewardship through the use of biomaterials. Ford began researching the use of sustainable materials in its vehicles in 2000. Today, the automaker uses eight sustainable-based materials in its vehicles including soy foam, castor oil, wheat straw, kenaf fiber, cellulose, wood, coconut fiber and rice hulls. According to the United Nations Environment Programme, 5 billion metric tons of agricultural biomass waste is produced annually. A byproduct of agriculture, the supply of materials is abundant and often underutilised. Yet the materials can be relatively low cost, and can help manufacturers to offset the use of glass fibers and talc for more sustainable, lightweight products. “There are about 400 pounds of plastic on a typical car,” said Mielewski. “Our job is to find the right place for a green composite like this to help our impact on the planet.” Source: Ford
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AUTOMOTIVE
Plasma-coated Polycarbonate Rear Quarter Window
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TOYOTA’S SPECIAL EDITION 86 GRMN SPORTS CAR IS THE FIRST PRODUCTION VEHICLE TO FEATURE A REAR QUARTER WINDOW IN POLYCARBONATE (PC) MATERIAL WITH A PLASMA-COAT SOLUTION DESIGNED TO DELIVER THE HIGHEST LEVEL OF DURABILITY PERFORMANCE.
oyota’s special edition 86 GRMN sports car is the first production vehicle to feature a rear quarter window in polycarbonate (PC) material with a plasmacoat solution designed to deliver the highest level of durability performance. The vehicle, exclusive to Japan, exhibited earlier this year at Tokyo Auto Salon 2016. The car’s rear quarter window is injection moulded with LEXAN resin, an optically clear and lightweight-enabling PC material from SABIC. The window is about 50 percent lighter compared to a conventional glass solution. Until now, manufacturers have proIn addition, strive to build light, stylish and well-finished vehicles.” duced rear quarter windows in PC using compared to other EXATEC plasma coating technology from wet-coat only solutions. Depending on vematerial solutions SABIC can make it possible for PC-glazed windows, hicle type and passenger position, wet-coat for windows, new where regulations allow for their use, to meet legislatsolutions can meet industry requirements combinations of ed driver visibility requirements. For larger PC-glazed for weatherability and abrasion resistance style and function surfaces like backlights and sunroofs, weight savings at that window location. In some cases are possible with of up to 50 percent can be possible, helping automakthough, a higher level of performance is PC glazing. For ers to improve fuel efficiency and lower emissions. required to meet driver visibility needs. example, rear In addition, compared to other material solutions Because Toyota wished to achieve quarter windows can for windows, new combinations of style and function regulatory requirements at a global level, smoothly integrate are possible with PC glazing. For example, rear quarthe Japan-based OEM turned to EXATEC an aerodynamic ter windows can smoothly integrate an aerodynamic plasma technology from SABIC. This flexspoiler, roof pillar, spoiler, roof pillar, airflow separators, door handle ible glass-like coating is deposited on top airflow separators, scallops and even rear lamps. of a base wet coat to enhance performance. door handle scallops For the 86 GRMN rear quarter window, Toyota Applying this advanced coating made it and even rear lamps. only focused on the production of a durable, lightpossible to meet Toyota’s high quality reweight part, in support of its evaluation of the plasmaquirements. coat solution for use on a mass-produced global model. Toyota’s SABIC contributed materials and development expertise to evaluation of PC glazing technology for use in high volume prothe 86 GRMN window program. “We are proud to have supportduction vehicles includes work to validate the manufacturing proed Toyota and its Tier suppliers with this first-to-market, plasmacess for plasma-coated parts. The 86 GRMN rear quarter window coated rear quarter window on a very special car,” said Scott Falis Toyota’s first use of SABIC’s plasma-coat solution for a comlon, SABIC’s automotive business leader. “No other technology mercially available vehicle. is available today with the same level of durability for PC-glazed windows than this plasma solution. It is a good example of the superior value that we can deliver to today’s automakers as they Source: SABIC 42 | The Economic Times POLYMERS | August-September 2016
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HEALTHCARE
Say no to microbes! THIS ARTICLE BRIEFLY DISCUSSES THE POTENTIAL OF AN INNOVATIVE ANTIMICROBIAL SOLUTION THAT HOLDS HUGE POTENTIAL FOR THE PLASTICS INDUSTRY. By Vikram Bhadauria
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lastics can often be a carrier of harmful germs that spread diseases and infections among humans, livestock, or raw foods. These harmful microbes not only find a conducive host in plastic surfaces to multiply, they also can be rapidly transferred across humans and animals alike. The consequences of these transmissions can range from the spread of common flu to deadly epidemics such as MRSA. Consider a hospital environment – it is germ rich and the possibility of an infection spreading is high. From door handles, public seats, to staircase railings, every touch can be a possible source of infection. The same can hold true for public transport, hotel linen, as well as damp personal spaces such as wet areas in a kitchen, refrigerator interiors, water purifiers, and many such similar sources. In order to control/ prohibit these germs from spreading, antimicrobial masterbatches are applied to plastic surfaces to guard them against germs such as bacteria, algae, fungus, and other microbes. An effective antimicrobial should be able to kill ~99 percent of all microbes that come in its contact and disrupt their further growth. A hand sanitizer is a common antimicrobial that we come across in our daily lives to counter this situation. But, despite it being very handy, it is one of the weakest types of antimicrobials available - because of its short shelf life after application. Therefore, the qualities one should look for in a good antimicrobial solution are: 1) Non Toxicity i.e. it should be safe for human contact 2) High efficiency and a strong mortality rate of 99 percent or higher 3) Permanence: it should last as long as the product lasts. Application of these antimicrobials ranges from public health, transport, and sanitation to personal wellness i.e. across metros, buses, airplanes, railways, and other such mediums. Alok, through its state-of-the-art lab– Alok Technology Incubation Centre (ATIC)–has launched Bactisafe TM, an antimicrobial solution. Not so long ago, our elders ate their food in silver utensils as silver is the most potent and safe antimicrobial known to mankind. It is safe and non-toxic unlike many other chemically derived additives, which while being very effective, have toxicity issues and un-researched effects of the human and animal bodies. Bactisafe is an FDA compliant product and is widely accepted as a benchmark of safety. The potential that an anti-microbial such as BactiSafe has is huge for the plastics industry. Given the
Infograph Credits: Alok Technological Incubation Centre, New Delhi
What is even more interesting is its permanence: the plastic surface will continue to be microbe-free for as long as it is in use. sturdiness and light-weightiness, plastics are at the intersection of many essential industries. To give a few possible uses: imagine how microbe-safe metro railways will become if all the seats, hand rails, and holding bars are made from plastic treated with BactiSafe. In our day to day life, we would not have to be concerned about microbes we may contract from touching that gym equipment handle which has passed many hands. What is even more interesting is its permanence: the plastic surface will continue to be microbe-free for as long as it is in use. One of the key global trade shows, K-Show, will take place in Germany in October this year. BactiSafe is one of the marquee innovations that we will unfold here. It is not just the product features, rooted in real needs given our current lifestyle, that makes us optimistic about its success, but also that it costs just a fraction more. This makes it a practicable innovation, which is commercially viable. The author is Director – Alok. He leads the technology team at Alok to collaboratively create solutions that address the growing needs of the plastics industry.
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AUTOMOTIVE
Future of the automotive industry-Plastic DUE TO MULTIPLE BENEFITS THAT IT OFFERS, PLASTIC’S SIGNIFICANCE IN THE AUTOMOTIVE IS RISING. READ MORE THE MARKET AND TRENDS RELATED TO THE USE OF PLASTIC IN THE INDUSTRY. By Swati Deshpande
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ver the last 5-6 decades, the automobile industry has covered a long journey from emphasizing on use of steel to preference to plastic in the manufacturing. Nowadays, there is extreme emphasis on making a vehicle lighter and more fuel efficient. In achieving these targets a material that can help the industry is plastic.
Lightweighting One of the major advantage of plastic is it makes the vehicle lighter and hence fuel efficient. Going beyond these benefits, what sets plastic apart from other material is list of advantages it offers. Plastic has entered into interiors of the cars long ago. We have been seeing dashboard made of plastic since years now. Additionally, it can also be seen in the switches, door panels, etc.
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AUTOMOTIVE
Automotive plastics are widely used in motorcycles, passenger cars and heavy vehicles with an aim to reduce the overall weight of automobiles. Reduction in weight significantly improves fuel efficiency of vehicles. This trend is expected to fuel the demand for automotive plastics over the forecast period. In exteriors as well, the plastic is already made an entry in bumpers, handles, etc. In the efforts of making the vehicles lighter and more efficient, automotive components made of plastics are playing an important role and hence its market is ever growing. According to a recent report released by Hexa Research, Global automotive plastics market is expected to grow on account of increasing preference for plastics as a substitute to metals in automotive components. Automotive plastics are widely used in motorcycles, passenger cars and heavy vehicles with an aim to reduce the overall weight of automobiles. Reduction in weight significantly improves fuel efficiency of vehicles. This trend is expected to fuel the demand for automotive plastics over the forecast period. Supporting this trend is government regulations regarding improving fuel efficiency and reducing the weight of vehicles. Increasing demand for passenger cars on account of increasing income levels in emerging markets across the globe is expected to fuel automotive production. This in turn is expected to drive the demand for automotive plastics. Plastics are ideal materials to reduce noise and vibrations in automobiles. Increasing preference for sophisticated automobiles is expected to boost the demand for automotive plastics for such applications. Improving aesthetics and reducing the overall cost of product has driven manufacturers in the market to adopt plastics owing to its cost effectiveness compared to metals and alloys. This is expected to have a positive impact on the market. Focusing on the designing aspect, the material gives freedom and flexibility to manufacturers to design the vehicle of their dream. Due to its flexibility is designing, desired shape can be given to the plastic components. Moreover, plastic is available in various colours meaning it can also achieve aesthetic appeal. Right from being transparent, translucent, opaque to range of colours, plastic can achieve desired colours and shape.
Other advantages Some of the other features of the plastic that make it an ideal choice are safety, durability, heat & electric insulation, etc. Air bags, side curtains are made of plastic that keeps driver and passengers safer in case of unlikely events. However, what is interesting to note is, all these advantages come in reasonable price. Now that there is trend of going green, plastic an useful material to achieve the targets in this regard. As mentioned earlier, one
of the foremost advantages of the material is the fuel efficiency that it achieves. In addition to that recyclability is another advantage that makes use plastic guilt free. According to a report presented by wiseguyreports, the Automotive Plastics Market is expected to reach $48.8 billion by 2022 growing at a CAGR of 14.7 percent during the forecast period 2015 to 2022. Rapidly growing automobile market, enhancement in vehicle design to reduce weight and emission control and Technological innovations are the key factors fueling the market growth. However, high cost of these materials is one of the major factors hampering the market. Improvement of new materials such as lighted PP and biodegradable plastics is anticipated to create ample of opportunities for the players in the market. Underlining the major markets, Hexa Research mentions Asia Pacific is major regional market for automotive plastics. The market in the region is characterized by huge domestic automotive manufacturing industry and growing demand for automotives in emerging markets of India and China.
Future trends With the increasing use of plastic, a one of the trends that can be seen on horizon in is 3D printing. Although 3D printing began a tool for rapid prototyping, now it is looked upon as a full-fledged technology for the automotive industry.
Plastics are ideal materials to reduce noise and vibrations in automobiles. Increasing preference for sophisticated automobiles is expected to boost the demand for automotive plastics for such applications. Improving aesthetics and reducing the overall cost of product has driven manufacturers in the market to adopt plastics owing to its cost effectiveness compared to metals and alloys. According to a report 3D Printing Automotive Market by Technology (SLA, SLS, FDM, EBM, LOM, 3DIP), Materials (Metals, Polymers), Application (Prototyping & Tooling, R&D, Manufacturing), and by Region - Global Trends and Forecast to 2020, the market is projected to reach $1.56 Billion by 2020, growing at a CAGR of 26.58 percent. Though metal is one of the materials that is used in the 3D printing, plastic is preferred material for the automotive industry. And hence, we can expect various printed auto components to be made in the future. Considering this, The ET Polymers, a premium magazine for plastics and polymers industry, is organising Global Conference of Plastics in Automotive. This knowledge-based networking platform will be held on September 22, 2016 at Mumbai.
46 | The Economic Times POLYMERS | August-September 2016
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AUTOMOTIVE
Plastic engine oil pans POLYAMIDE 6 HAS HELPED TO REDUCE THE WEIGHT OF THE UPPER AND LOWER SECTIONS OF THE OIL PAN TO 1.3 AND 1.8 KILOGRAMS RESPECTIVELY.
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he trend of manufacturing engine oil pans from plastic instead of metals like aluminium is continuing to gain ground. The plastic of choice to date has almost always been polyamide 6.6. However, newer designs are favouring polyamide 6, an alternative that offers a similarly high-quality property profile, but is more economical. The latest design of this type is the oil pan module for the new six-cylinder boxer engines of the Porsche 911 Carrera, which is being manufactured using Durethan from Lanxess. “The component fully satisfies the specific requirements for functional integration, lightweight construction and cost-effective production that the new generation of engines have to meet,” explains Jorge Soares, Project Manager for the highly complex component, Polytec Plastics Germany GmbH & Co KG. The oil pan Using plastic instead of aluminium means module has been developed in close collaborathat numerous tion between Polytec and Porsche.
Simplified production & installation
The engine oil pan for the Porsche 911 Carrera consists of an upper and a lower part made from 30 percent glass fiber-reinforced Durethan BKV 30 H2.0 from Lanxess. The upper part is screwconnected to a pipeline carrier that is also made functions can be from polyamide 6. Using plastic instead of metal shaped directly means that numerous functions can be shaped Material data during injection directly during injection moulding, thereby inIn a study carried out for Porsche, Lanxess tegrating them into the component. This has proved the feasibility of manufacturing motor moulding, thereby helped to reduce the number of separate parts oil pans from polyamide 6. For example, aging integrating them tests were carried out to determine the durability into the component.” that need to be manufactured and mounted for the oil pan from 14 on the metal design to eight. of the thermoplastic under exposure to elements The number of key work steps needed in the filike new and used engine oil. Specimen storage nal assembly of the engine has also been cut from eight to two. tests spanning a total of 3,000 hours at 150°C were performed For instance, the bulkhead panel is integrated into the lower part on highly reinforced, hydrolysis-stabilised, easy-flowing and highof the pan and no longer has to be installed separately with a seal. temperature-stabilised Durethan grades, among others. “The test Also, the oil return lines of the turbocharger, the oil separator and results show that the aging behaviour of heat-stabilised polyamide the air-oil separator are combined in the pipeline carrier. 6 is only marginally different to that of heat-stabilised polyamide Moreover, Polyamide 6 has helped to reduce the weight of 6.6 in terms of tensile strength, Young’s modulus, elongation at the upper and lower sections of the oil pan to 1.3 and 1.8 kg break and impact strength. Hence, appropriately optimised polyrespectively. Overall, the oil pan is more than 2 kg lighter than its amide 6 compounds are ideally suited for use in components that aluminium predecessor, due to the lower density of the plastic and convey engine oil,” says Christof Boden, expert for engine comthe optimised wall thicknesses. partment applications from Lanxess. The specialty chemicals company is making the test results – and other material data – available to development partners Injection moulding process with benefits as part of joint projects. Also, customers are supported through A key argument in favour of manufacturing the oil pan using inevery stage in the development of an oil pan as part of the HiAnt jection molding was the huge potential that the process offers for customer services package. This brand incorporates HPM’s exintegrating functions and thereby cutting costs. As the parts are tensive material, simulation and processing competence, which it produced in a single step in the mould, there is no need for comoffers to customers through all stages of component development. plex finishing work like deburring die-cast aluminium parts. The Services include, for example, simulating mould filling includlower energy costs are another benefit in favour of manufacturing ing warpage calculation, simulation of stone impact and sealing injection-molded parts. forces, or testing of components with regard to sealing gap expansion and stone impact. Source: Lanxess August-September 2016 | The Economic Times POLYMERS | 47
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Global Conference on Plastics in Automotive Powered By
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BIOPLASTICS
From plants to plastics!
IBM RESEARCH AND STANFORD UNIVERSITY RESEARCHERS HAVE DISCOVERED A NEW CHEMICAL CATALYST THAT WILL ENABLE CREATION OF AN INEXPENSIVE METHOD TO BRING CREATE BIODEGRADABLE PLASTICS FROM PLANTS
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hile biodegradable forks and spoons already exist on store shelves, consumers often opt for more cost-effective, petroleum-based alternatives. Recently, IBM Research announced that scientists have identified a chemical catalyst that can be used to create cheaper, biodegradable plastics from plants such as palm trees and beets. These inexpensive plastics can be used for making common consumer plasticware, such as eating utensils, as well as medical devices. “What’s exciting about this discovery is that we now have a cheaper way to convert plants into common consumer plastics that decompose over time, providing an alternative to recycling plastics,” said Gavin O. Jones, Computational Chemist, IBM Research –Almaden, San Jose, Calif. “Making biodegradable plastics mainstream means less impact on our solid waste systems.” The current method to convert plants into biodegradable plastics imparts heavy metals into the process. While used in small amounts, these heavy metals are difficult to remove, remain in the material and do not decompose over time. The new catalyst is an organic substance that lowers the energy required for the conversion from plant to plastic to occur. It does not contain heavy
What’s exciting about this discovery is that we now have a cheaper way to convert plants into common consumer plastics that decompose over time, providing an alternative to recycling plastics. Making biodegradable plastics mainstream means less impact on our solid waste systems. Gavin O. Jones, Computational Chemist, IBM Research –Almaden, San Jose, Calif.
metals and can thus degrade in the environment over time just like the plastic itself. “In this study, we used a combination of predictive modeling and experimental lab work to make the discovery,” said Xiangyi Zhang, graduate student working with Dr. Robert Waymouth, Department of Chemistry, Stanford University. “This tag-team approach takes a lot of the guess work out of the process and helps us accelerate the materials discovery process.” The learning from these research efforts can also be used to advance cognitive systems. The scale, pace and complexity of materials science is a challenge for scientists working to discover new materials. As part of the IBM Research Frontiers Institute, scientists are combining expertise in The new catalyst informatics and polymers, and other materials, to prois an organic totype systems to extract, organise, analyse, and predict substance that insights from materials datasets. By leveraging existing lowers the energy knowledge from the world’s scientific databases and acrequired for the celerating computations used in these types of expericonversion from ments, these cognitive tools could help identify patterns and to bring new discoveries to realisation faster. plant to plastic The study was published in Nature Chemistry under to occur. It does a long-standing collaboration with Stanford University’s not contain heavy Department of Chemistry and funded in part by the metals and can National Science Foundation. thus degrade in the IBM Research – Almaden is also the birthplace of environment over several recent plastics and recycling achievements intime just like the cluding the discoveries of: a new process to recycle plasplastic itself. tics into nanofibers designed to specifically target and attack fungal infections, an entirely new class of plastics, a new plastic macromolecule that could help prevent deadly virus infections and a new method for recycling CDs into non-toxic plastics for water purification and medicine.
Pic for representation only
Source: IBM Research
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RESEARCH
Hollow polymer fibers: Georgia Tech Assistant Professor Ryan Lively (left) and Postdoctoral Fellow Dong-Yeun Koh hold bundles of hollow polymer fibers that serve as precursors for the carbon membrane fiber used to separate alkyl aromatic chemicals. (Credit: John Toon, Georgia Tech)
A potential game-changer!
A RESEARCH TEAM FROM THE GEORGIA INSTITUTE OF TECHNOLOGY AND EXXONMOBIL HAS DEMONSTRATED A NEW CARBON-BASED MOLECULAR SIEVE MEMBRANE THAT COULD DRAMATICALLY REDUCE THE ENERGY REQUIRED TO SEPARATE A CLASS OF HYDROCARBON MOLECULES KNOWN AS ALKYL AROMATICS.
By John Toon
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believe the new membrane has potential for commercialization research team from the Georgia Institute of and integration into industrial chemical separation processes. The Technology and ExxonMobil has demonresearch was reported in the August 19 issue of the journal Scistrated a new carbon-based molecular sieve ence. membrane that could dramatically reduce the Separation is currently achieved through refining processes energy required to separate a class of hydrosuch as crystallization and adsorption with distillation, which are carbon molecules known as alkyl aromatics. energy-intensive. Globally, the amount of energy used in convenThe new material is based on polymer hollow fibers treated to tional separation processes for alkyl aromatics is retain their structure – and pore sizes – as they equal to that produced by about 20 average-sized are converted to carbon through pyrolysis. The power plants. carbon membranes are then used in a new “orGlobally, the amount “We see this as a potentially disruptive ganic solvent reverse osmosis” (OSRO) process of energy used technology in the way we separate xylenes and in which pressure is applied to effect the sepasimilar organic compounds,” said Benjamin ration without requiring a phase change in the in conventional McCool, one of the paper’s co-authors and an chemical mixture. separation advanced research associate at ExxonMobil CorThe hollow carbon fibers, bundled together processes for alkyl porate Strategic Research in Annandale, N.J. “If into modules, can separate molecules whose aromatics is equal we can make this work on an industrial scale, it sizes differ by a fraction of a nanometer while to that produced by could dramatically reduce the energy required by providing processing rates superior to those of about 20 averageexisting molecular sieve zeolites. Because it uses sized power plants.” these separation processes.” Fabrication of the new membrane material a commercial polymer precursor, the researchers 52 | The Economic Times POLYMERS | August-September 2016
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RESEARCH
Fiber spinning: Georgia Tech Assistant Professor Ryan Lively (left) and Postdoctoral Fellow Dong-Yeun Koh monitor the spinning process used to produce the polymeric fibers that are converted for use in the carbon membranes used for separating alkyl aromatic chemicals. (Credit: Rob Felt, Georgia Tech)
Hollow polymer fibers2: Georgia Tech Assistant Professor Ryan Lively (left) and Postdoctoral Fellow Dong-Yeun Koh hold bundles of hollow polymer fibers that serve as precursors for the carbon membrane fiber used to separate alkyl aromatic chemicals. (Credit: John Toon, Georgia Tech)
begins with hollow polymer fibers approximately 200 microns in diameter, slightly thicker than the average human hair. The fibers have pore sizes of less than one nanometer, and are treated via cross-linking before they are converted to carbon through a pyrolysis process. The pore sizes of the fibers can be adjusted during the fabrication process. “We take a scalable platform based on polymeric membranes and then turn those materials into inorganic molecular sieves,” explained Ryan Lively, an assistant professor in Georgia Tech’s School of Chemical & Biomolecular Engineering and the paper’s corresponding author. “Our membranes are mechanically robust and they can withstand the process conditions required by OSRO. They maintain advantageous mechanical properties and membrane performance as they are converted to carbon fiber.” Lively and postdoctoral fellow Dong-Yeun Koh used the OSRO process in the laboratory to separate mixtures of para-xylene and ortho-xylene, molecules whose sizes differ by one-tenth of a nanometer. By applying pressure at room temperature, the membrane can convert the 50-50 mixture to an 85-15 mixture at a high flux relative to zeolite membranes. “These molecules have incredibly similar sizes and properties, but the membranes can tell them apart,” said Lively. “This bulk cut of the mixture greatly enhances the concentration with a very low energy input. This mixture could then be fed into a conventional thermal process for finishing, which would reduce the total energy input dramatically.” In industrial use, the membranes would be bundled together in modules that would be used in chemical facilities. “In practice, you would get as many modules as you needed for a particular application, and if the need increased, you could simply add more modules,” Lively said. “It would be totally scalable.” Reverse osmosis membranes are already widely used in desalination to produce drinking water from saltwater, consuming a fraction of the energy required by thermally-driven process. Carbon fiber membranes are being used for gas separations, but
the new OSRO process is believed to be the first use of reverse osmosis with carbon membranes to separate liquid hydrocarbons. Though the membrane has demonstrated promising results, it still faces a number of challenges. The membranes will have to be tested with more difficult separations before they can be considered for commercialization and scale-up. Industrial mixtures normally contain multiple different organic compounds, and they may include materials that can foul membrane systems. The researchers will also have to learn to make the material consistently and demonstrate that it can withstand long-term industrial use. “Because we are starting with commercially-available polymers and we are using commercial-type equipment, we can see a clear line-of-sight to commercialization with this technology,” McCool said. “It’s a big advantage that the membranes are being spun on a hollow-fiber line similar to that currently used in the industry. The time horizon to make this happen and the cost of production could be highly advantaged over other inorganic systems or more exotic materials like graphene.” Development of the OSRO process resulted from a collaborative process in which Georgia Tech researchers worked closely with ExxonMobil scientists – including McCool and scientist Harry Deckman – to identify and overcome the challenges of industrial processing. “ExxonMobil is a leader in its commitment to fundamental science,” said Mike Kerby, ExxonMobil Corporate Strategic Research manager. “As part of our commitment, we continue to widen our research aperture through collaborations with academic research institutions to better enable us to identify potential breakthrough technologies to reduce greenhouse gas emissions, increase energy supplies and realize other environmental benefits.” CITATION: Dong-Yeun Koh, et al., “Reverse Osmosis Molecular Differentiation of Organic Liquids using Carbon Molecular Sieve Membranes,” (Science, 2016). Source: Georgia Institute of Technology (USA)
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AUTOMOTIVE
Encapsulation, impregnation and potting POLYMER-BASED SOLUTIONS OFFER HIGH LEVELS OF PROTECTION ENSURING THE RELIABLE PERFORMANCE OF ELECTRICAL AND ELECTRONIC COMPONENTS.
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he quantity of electronics found in all areas of modern road vehicles continues to increase, and electric drive systems are now entering the mainstream. So the need to ensure the reliable performance of electrical and electronic components and systems is taking on new importance. Polymer-based solutions from Henkel provide high levels of protection for different types of these components. Countless safety systems in cars and trucks now depend on the continuous high-level functionality of interconnected electronic components, often positioned in areas that are exposed to wide temperature variations, to oils and greases, to moisture, dust, stone impacts, and vibrations. For these reasons, it is important that, wherever possible, electronic and electrical components are securely protected from the environment.
Low-pressure hot-melt polyamide encapsulation In the low-pressure hot-melt moulding technique, resin is injected around components fixed in a closed mould. The hot-melt serves as an encapsulant and also as a housing, so there is no need for a separate shell to protect the components. Once the hot-melt material has cooled and solidified, the components are ready for further processing. Resins for hot-melt molding are single-component polyamide systems that can be used in simple and clean production processes. These processes take up little floor space, they are fast and energy-efficient. Henkel Technomelt hot-melt moulding materials provide high humidity resistance, temperature resistance up to 150°C, and impact resistance down to -50°C. This makes them superior to many other polyamide hot-melts, which normally can be used in environments of up to only 120°C and are more prone to hydrolysis. The new materials are the result of experience in hot-melt moulding for the automotive industry that dates back over 25 years. They provide new opportunities for higher temperature applications in humid environments, like sensors in door handles, rear view cameras, batteries or tire pressure monitoring systems, or for sealing aluminium cables.
Sealing gaps with acrylic impregnation Acrylic impregnation products like Loctite IS 5100 provide a sealing solution for electrical and electronic components. Microscopic voids are inherent in many electronic assemblies that combine metal and plastics elements. Over time in the field, these voids can cause product failures, so it is important that they are filled before the parts are put into vehicles. Henkel offers an im-
pregnation service, either on-site or at its own service centers, for permanently sealing parts like sensors, connectors, coils and electronic housings. Once impregnated, these components are protected from moisture, solvents, fluxes and other corrosive agents. The impregnation process involves putting parts into a vacuum chamber, which is then filled with the acrylic resin. Once this has filled all the gaps in the parts, excess resin is removed by a centrifuge and parts are then thoroughly washed and rinsed before the remaining resin is allowed to cure. All parts go through a leak test to guarantee that the process has sealed the parts. Impregnation is a fast, high quality, cost-effective sealing solution that can be used on existing parts without any need for design changes. Once treated, parts have the same dimensions and surface aspect as untreated parts, but their durability and long-term reliability is considerably improved. The specially developed acrylic resin protects against moisture, chemicals and dust, and remains flexible, retaining its sealing properties, throughout multiple thermal cycles. The process is unique to Henkel. Since it is offered as a service, customers do not need to invest in any capital equipment.
Potting with thermally conductive resins The comapny’s thermally conductive potting materials are intended for electric automobile propulsion components that require support in dissipating generated heat. Today’s compact high-performance electric propulsion components have a high power density. This inevitably leads to the generation of heat, which must be discharged to the cooling system on the outside if reliability is not to suffer. Henkel offers a variety of thermally conductive and electrically insulating potting materials that meet the technical and processing requirements of this application. Source: Henkel
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BIOPLASTICS
Eggshell marvels!
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EGGSHELL NANOPARTICLES COULD LEAD TO EXPANDED USE OF BIOPLASTIC IN PACKAGING MATERIALS
ggshells are both marvels and afterthoughts. Placed on end, they are as strong as the arches supporting ancient Roman aqueducts. Yet they readily crack in the middle, and once that happens, we discard them without a second thought. But now scientists report that adding tiny shards of eggshell to bioplastic could create a first-of-its-kind biodegradable packaging material that bends but does not easily break. The researchers presented their work at the 251st National Meeting & Exposition of the American Chemical Society (ACS). “We’re breaking eggshells down into their most minute components and then infusing them into a special blend of bioplastics that we have developed,” Adding eggshell nanoparticles to a bioplastic (shown above) increases the strength and says Vijaya K. Rangari, Ph.D. “These nano-sized eggshell flexibility of the material, potentially making it more attractive for use in the packaging industry. particles add strength to the material and make them far Credit: Vijaya Rangari/Tuskegee University more flexible than other bioplastics on the market. We believe that these traits -- along with its biodegradability in the We believe that these traits—along soil -- could make this eggshell bioplastic a very attractive alternawith its biodegradability in the soil— tive packaging material.” could make this eggshell bioplastic a Worldwide, manufacturers produce about 300 million tonnes very attractive alternative packaging of plastic annually. Almost 99 percent of it is made with crude material. oil and other fossil fuels. Once it is discarded, petroleum-based Vijaya K. Rangari, plastics can last for centuries without breaking down. If burned, Ph.D., Tuskegee University these plastics release carbon dioxide into the atmosphere, which can contribute to global climate change. looking for, but they wanted to further enhance the flexibility As an alternative, some manufacturers are producing bioplasof the material. So they created nanoparticles made of eggshells. tics—a form of plastic derived from cornstarch, sweet potatoes or They chose eggshells, in part, because they are porous, lightweight other renewable plant-based sources—that readily decompose or and mainly composed of calcium carbonate, a natural compound biodegrade once they are in the ground. However, most of these that easily decays. materials lack the strength and flexibility needed to work well in The shells were washed, ground up in polypropylene glycol the packaging industry. And that’s a problem since the vast maand then exposed to ultrasonic waves that broke the shell fragjority of plastic is used to hold, wrap and encase products. So ments down into nanoparticles more than 350,000 times smaller petroleum-based materials continue to dominate the market, parthan the diameter of a human hair. Then, in a laboratory study, ticularly in grocery and other retail stores, where estimates suggest they infused a small fraction of these particles, each shaped like a that up to a trillion plastic bags are distributed worldwide every deck of cards, into the 70/30 mixture of PBAT and PLA. The reyear. searchers found that this addition made the mixture 700 percent To find a solution, Rangari, graduate student Boniface Tiimore flexible than other bioplastic blends. They say this pliability mob and colleagues at Tuskegee University experimented with could make it ideal for use in retail packaging, grocery bags and various plastic polymers. Eventually, they latched onto a mixture food containers -- including egg cartons. of 70 percent polybutyrate adipate terephthalate (PBAT), a petroIn addition to bioplastics, Rangari’s team is investigating usleum polymer, and 30 percent polylactic acid (PLA), a polymer ing eggshell nanoparticles to enhance wound healing, bone regenderived from cornstarch. PBAT, unlike other oil-based plastic eration and drug delivery. polymers, is designed to begin degrading as soon as three months after it is put into the soil. This mixture had many of the traits that the researchers were Source: American Chemical Society August-September 2016 | The Economic Times POLYMERS | 55
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ROTOMOULDING
Supporting customers is a key ANAND PANCHAL, PARTNER, N. A. ROTO SPEAKS ABOUT BUSINESS OF THE COMPANY AND VARIOUS CHALLENGES AND OPPORTUNITIES. By Swati Deshpande N. A. Roto has completed 34 years of operations. Please tell about the journey of the company. We started our Journey in 1982 with a small shop floor for manu-
facturing Rotomolding Moulds that was spread over 300 sq. mtr. shed area. At that point, we had only five people working with us. Today, our infrastructure is spread over 16,000 sq mtr and we have strength of more than 275 people delivering highly-efficient high production machines with technology support from wellknown Rotomoulding consultants Tell us about your various offerings. What is your market position in the various segments? N. A. ROTO is a one stop solution for all rotomoulding needs and we can offer turnkey solutions for this plant. We manufacture main machines, ancillary machines, moulds & accessories required for this process. End products from our machinery are suitable for various industries such as plastic, agricultural, chemical, infrastructure, etc. We command very strong market position in main rotomoulding machine and also in the moulds segment, which are our focus areas. As selling ancillaries & accessories is not one of our priorities, we do not have a leading position in this area. Please tell us about your manufacturing facility. We have an installed capacity of manufacturing and dispatching 28-30 plants per annum, and about 1,500 moulds annually. Rotomoulding plants are voluminous in nature. We often face a typical challenge of customer not taking the delivery of the order due to their own constraints. This adversely impacts our productivity as the machines that are ready to be shipped consume lot of space in our workshop and hence, we are not able to utilise the factory space effectively. In other words, it leads to non-utilisation of installed capacity.
“Recently we have developed air venturi system to supply hot/cold air to moulds during moulding cycle, which allows manufacturing of complex shaped articles such as automotive components. It is extremely important that the component receives hot/cold air per as per the requirement.”
Tell us about your R&D activities. How important is innovation in your journey? Earlier, process was in nascent stage and customer’s expectations from machinery were limited. As time passed by and market of rotomoulded products evolved, competition increased and presently customers are expecting great value from machinery and hence, we have to almost continuously innovate some engineering aspects of machine to keep up with same. For example, recently we have developed air venturi system to supply hot/cold air to moulds during moulding cycle, which allows manufacturing of complex shaped articles such as automotive components. It is extremely important that the component receives hot/cold air per as per the requirement. Hence, this
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ROTOMOULDING
have led to decrease in domestic market demand of our products. We registered growth last fiscal owing to certain markets where the market conditions were good. What kind of after sales support do you provide to your customers? Since rotomoulding machinery is specialised machinery, and customers are not fully aware about it, we support our customers in various ways. This includes guidelines about their market requirements, processing options, cost benefit analysis, break-even/payback period, machinery selection, manpower training & offering Support, efficient after sales service, etc. What is your take on our ‘Make in India’ initiative? What are the challenges and opportunities for your industry in this context? As an initiative, it is a good effort. However, skills and technology support is missing from this scheme to some extent. Technology is a big challenge in itself for this initiative; however, development of inherent skills is an opportunity. Government has already started skill development initiative and it will surely evolve in time technology is being appreciated by the customers engaged in the manufacturing complex products. Tell us about couple of your products, which have received overwhelming response from the customers. In Mould Labels (IMA) is one of our products that is being appreciated by customers. Screen-printing on products has been in practice for long time. However, it somehow lacks effective branding for companies. Additionally, it is not a long lasting option. Hence, to overcome this technological gap, we launched In Mould Labels with help of which quality products can be branded distinguishingly and be pitched appropriately. These labels, though they are costlier in price, has got a very good market response and in spite of market being price sensitive, many of our customers are now successfully using these labels enriching their products value/market. Swift Series Pulverizer is another product that has gained popularity amongst customers. In order to manufacture this system, we import disk from Canada. With this disk, output of Pulverizer is drastically increased with low power consumption resulting in better quality powder, which ultimately leads to faster processing and low fuel consumption during moulding cycle. Many of our Indian as well as overseas clients are using these new series Pulverizers now with efficient results. How has been the last one year for your company? Last year has been a year of challenge for us due to falling crude prices and currency fluctuations. Many of our customers have stalked their investment plans for future due to currency crisis. At the same time, threats from substitute products/process
to come.
We launched In Mould Labels with help of which quality products can be branded distinguishingly and be pitched appropriately. These labels, though they are costlier in price, has got a very good market response and in spite of market being price sensitive, many of our customers are now successfully using these labels enriching their products value/market. As compared to foreign countries, in general, R&D expenses for Indian Industries including heavy machinery industry as a part of fund outlay is very miniscule. This has created technology development gap forcing Indian industry to take help of foreign technology. If R&D can be improved, there lies a great opportunity for Indian Technology to give thrust to ‘Make in India’ campaign. Alternate means are technology collaborations and JVs, which are greatly increased in this time and is boosting ‘Make in India’ campaign. Tell us about your exports Presently, we are exporting to various parts of the world including Middle East Asia, Far East Asia, Africa and South America region apart from some isolated exports to CIS region, Oceania and other regions. Our export to domestic sales ratio on average is: 65%: 35%. August-September 2016 | The Economic Times POLYMERS | 57
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3D PRINTING
Next gen polymers for additive manufacturing
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A SPECIALTY ABS PRODUCER AIMS TO CREATE MATERIALS THAT WILL PRODUCE PARTS WITH BETTER MECHANICAL PROPERTIES SUCH AS RESISTANCE TO IMPACT, LOW WARPAGE, DIMENSIONAL PRECISION AND HIGH RESOLUTION. READ ON TO KNOW MORE ABOUT IT
new ‘ABS 3D printing’ R&D project initiated by specialty ABS producer ELIX Polymers aims to develop advanced versions of the terpolymer specifically for 3D printing using Fused Filament Fabrication (FFF), more commonly known as Fused Deposition Modelling (FDM). ELIX’s aim is to create materials that will produce parts with better mechanical properties such as resistance to impact, low warpage, dimensional precision and high resolution. To develop this new generation of polymer materials and their application in 3D printing, ELIX Polymers is working in collaboration with AIMPLAS Plastics Technology Centre, based in Valencia, Spain. The Spanish government-run Centre for the Development of Industrial Technology (CDTI) has confirmed that it will fund this R&D project.
Market overview
ELIX Polymers launches ABS 3D printing R&D project in collaboration with AIMPLAS. Photo: ELIX Polymers
ABS is one of the most popular thermoplastics in use today. It is based on three different monomers— acrylonitrile, butadiene and styrene—and by varying the ratio of these monomers it is possible to create materials with a wide range of properties.”
3D printing, also known as additive manufacturing, allows manufacturers to produce three-dimensional objects in a variety of materials directly from a digital file. The materials used in 3D printing include various types of polymers, metals and ceramics, among others. The different additive manufacturing technologies, which include laser sintering and stereolithography as well as FFF/FDM, provide methodologies that make complex designs easier to manufacture. The global 3D printing market in 2014 was worth an estimated €2.8 billion and is expected to grow to up to €8.7 billion in 2020. Analysts expect strong growth in various sectors, thanks to the numerous benefits offered by 3D printing, such as the speed with which an idea can be brought to reality, the reduction in manufacturing errors that can occur, the efficient use of materials, and more.
fdm technology 3D printing of parts using FDM technology is used for modelling, manufacturing prototypes, and small-scale production runs of functional parts. 3D printers using FDM technology work
with thermoplastics in the form of a continuous filament, which they heat until it reaches a molten state. They then deposit the melt in layers to form the finished part. FDM technology has a broad scope of application, including sectors such as automotive, aerospace, jewellery, architecture, biomedicine, consumer products, electrical/electronics, musical instruments, toys, and others.
ABS
ABS is one of the most popular thermoplastics in use today. It is based on three different monomers—acrylonitrile, butadiene and styrene—and by varying the ratio of these monomers it is possible to create materials with a wide range of properties, for use in a wide variety of applications. With its intrinsically high tensile strength, impact strength and processability, ABS is one of the two most popular thermoplastics used for 3D printing (the other is the biopolymer PLA). AIMPLAS and ELIX have already been working together in various stages of the new R&D project, from the development of the ABS product and modification of the formulas, through to manufacturing of filament with thicknesses of 1.75 mm and 2.85 mm, using AIMPLAS’s own filament extruder line (equipped with a single-screw extruder, controlled cooling bath, drive system and spool system), printing and validation of the product, sharing advice in the demands and requirements for final application.
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BIOPLASTICS
Resource conservation
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he Bioplastic specialist FKuR has developed a new technology for the production of compounds which can be processed into flexible packaging films with particularly low thickness and, at the same time, high puncture resistance. With Bio-Flex FX 1120 and Bio-Flex FX 1130, FKuR will be presenting the first two products based on this new technology at the K 2016. Films made from these materials are suitable for food contact and compostable according to EN 13432. Depending upon the type, the proportion of renewable raw materials is more than 50 percent. The processing of both FX types of Bio-Flex corresponds largely to standard PE processing. For especially thin films: Bio-Flex FX 1130 is designed to complement the previous standard compound Bio-Flex F 1130. Whilst films made of conventional F 1130 have a paperlike touch the FX quality offers a silky surface. Films produced with this blend are further characterised by an increased tensile strength, puncture and tear resistance. This enables converters to use less material without compromising the performance characteristics of the film. In practice, it has been proven that film thicknesses of 8 microns are possible. In addition, film manufacturers benefit from high throughputs in extrusion, as well as excellent sealing properties of the material. For 50 percent biobased bags: Bio-Flex FX 1120 is a new development for film production, especially for very thin bags, such as bio-waste bags. The increased water resistance, when compared to starch blends, permits a high retention of moisture which is originated during the decomposition of organic products in biobags. With a high proportion of renewable raw materials of more than 50 percent, the Bio-Flex FX 1120 compound fulfills the requirements of the German Bio-waste Ordinance.
Thin and puncture resistant compostable film bags are one of the main applications for the new FKuR FX series blends; © FKuR
Julian Schmeling, head of development at FKuR says: “Films made from biodegradable resins have reached sufficient performance values with thicknesses of about 15 microns. In practice, the film thicknesses today are between 18 and 26 microns. Thanks to the use of novel polymeric additive systems and an adapted compounding process, FKuR now provides converters with the possibility to follow the trend using bioplastics and combine significant material savings along with compostability.”
U.S. Patent for High Performance Bioplastics
For representation only. Courtesy - Solegear
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olegear Bioplastic Technologies Inc. has been granted US Patent 9,416,255 titled ‘Compositions Comprising Polylactic Acid, Bentonite, and Gum Arabic’. The patent broadly covers the synthesis of bio-based additives along with polylactic acid (‘PLA’) to deliver a number of key performance characteristics required for rigid packaging and durable goods applications.
This proprietary technology enables Solegear to reformulate everyday products and packaging using plant-based materials that deliver equal or better performance than traditional petroleumbased plastics. While others have achieved this by creating composite materials that may include a certain percentage of plantbased material, Solegear’s commitment to Green Chemistry adds additional rigor to ensure no additives that have been identified as potentially hazardous to human health or the environment are used to meet performance, processing or price requirements. “Our product development team is focused on developing bio-based materials that can truly replicate what has traditionally only been possible with petroleum-based plastics and additives,” said Michel Labonté, CTO of Solegear. “This patent highlights our team’s long-term commitment to creating innovative, breakthrough materials that use the maximum possible bio-based content and no chemicals of concern.” August-September 2016 | The Economic Times POLYMERS | 59
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AUTOMOTIVE
Plastics in 3D printing
–Opportunities in the automotive industry FIND OUT HOW 3D PRINTING HELPS THE AUTOMOTIVE INDUSTRY IN VARIOUS ASPECTS
By Rajiv Bajaj
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he automotive industry is on the brink of a revolution, and plastics has poised to play a major role for automakers who are challenged to the shorter timeto-market and lightweight solutions. Plastics enables better functionality by replacing heavier, traditional materials as it is lightweight when compared. Benefited by technological advancement, such as 3D printing (also known as additive manufacturing), there will be a wider range and increased use of plastics throughout the entire automotive manufacturing process, from product development to the manufacturing. One of the key benefits of early-stage vehicle R&D using plastic is the ability to provide flexibility and customisation by 3D Wheel prototype model from Japan Honda Access Co. Ltd. 3D printed by Stratasys’ printing prototypes or models at a relatively lower cost. Objet Eden500V, divided into few pieces and assembled Honda Access Co Ltd manufactures accessories for passenger vehicles, motorsider 3D printing using engineering thermoplastic in cycles and other auto parts worldwide. the manufacturing process. Opel, Europe’s third-largest One of the key One of its specialties is customising acautomotive manufacturer, is slashing assembly tool benefits of earlycessories to local buyers’ preferences. production costs by up to 90 percent using production stage vehicle R&D “We have to take into account a range of grade thermoplastics. With efficient production crucial considerations, like regional driver preferto its success, Opel’s International Technical Developusing plastic is the ences and climate and road surface condiment Center is 3D printing a range of manufacturing ability to provide tions when designing the accessories, ofand assembly tools to advance the production of its flexibility and fering distinct specifications according to customisation by 3D iconic ‘Adam’ hatchback car. These assembly tools are a country’s needs and demand,” explained used to precisely attach different components to the car, printing prototypes Hiroshi Takemori, Sr Researcher at Honsuch as the rocker molding and roof spoilers; align the or models at a da Access’ product planning department. relatively lower cost. iconic ‘Adam’ lettering on the rear-side window; and assemble the glass and retractable roofs. “Cases like Opel emphasize the massive impact that What gets customised? low risk, high-reward 3D printed parts – such as manufacturing tools Empowered by 3D printing, the company used a wider – can have on production efficiency,” says Andy Middleton, President, range of Stratasys’ resin, from rigid to transparent phoStratasys, EMEA. “The capability to produce such items on-demand at topolymers, to prototype mirrors, knobs, parts of the a reduced costs can significantly accelerate time-to-production and give trunk, and even larger parts such as wheels up to 14 inch businesses that competitive edge. Combine that with the ability to cusin size. The overall design process has been improved in tomize tools efficiently, as well as create complex geometries, and you can terms of both cost and speed. Honda Access mostly uses see why Opel is indicative of the way in which additive manufacturing is the Stratasys rigid opaque Vero family resin and paints the transforming our customer’s production operations.” With the evolution printed part with a clear coat in post-processing, resultof technologies such as 3D printing, plastic industry is expected to see ing in a texture that closely resembles the final product more opportunities applying in the automotive industry, from prototypthat supports several critical stages during the team’s deing to manufacturing tooling, and even to the end-use parts. sign process, including prototyping and testing for fit and function. In addition to accelerating product development cycle, the lower cost in tooling allows automakers to conAuthor is the Managing Director, India of Stratasys India Pvt Ltd 60 | The Economic Times POLYMERS | August-September 2016
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CALENDAR
Mark your DIARY K 2016
Location: Düsseldorf, Germany Organised by: Messe Düsseldorf Website: www.k-online.com Background For more than 40 years, K has been and still is the biggest international trade fair for plastics and rubber, and takes place once every three years. The leading raw material producers, processing companies and machinery manufacturers offer an overview of the latest technical developments, procedures and techniques, of current construction methods and future trends. The outstanding importance of K for the industry arises from the excellence and ongoing development of its product range, and the constantly growing number of more than 3,200 exhibitors from 59 nations. The fact that 218,000 trade visitors from over 120 countries expressed their full satisfaction at the last staging of K in 2013 guarantees the future success for all those involved in the industry.
ArabPlast 2017
Location: Dubai, UAE Organised by: Al Fajer Information & Services Website: www.arabplast.info
January 19-21, 2017
Background It promises to be the largest plastics, petrochemicals and rubber industry trade show in MENA region as well as the fastest way to enter the vast MENA region’s plastics, petrochemicals and rubber industry. ArabPlast 2017 is envisioned to make better business sense to the participants who are giving shape to a better world. The captains of the plastics and rubber industry would be here to unveil products solutions, cutting-edge technology, and revolutionary innovations and forge international alliances.
Indian Rubber Expo 2017
January 19-23, 2017
January 8-10, 2017
October 19-26, 2016
A LIST OF KEY TRADE SHOWS HAPPENING BETWEEN OCTOBER 2016 TO OCTOBER 2017.
Plastivision India 2017
Location: Chennai, India Organised by: All India Rubber Industries Association Website: www.indiarubberexpo.in Background: The India Rubber Expo 2017 is expected to have over 400 companies participating from India and around the globe, will be spread across 25,000 square meters and is expected to see over 30,000 visitors. Large Country Pavilions have been blocked for China, Germany and USA and for a number of companies from Japan, Korea, Malaysia, Sri Lanka, Turkey and Taiwan, among others.
Location: Mumbai Organised by: The All India Plastics Manufacturer’s Association (AIPMA) Website: www.plastivision.org Background: It is recognised amongst the top ten global plastics exhibition. Plastivision India 2017 is likely to see participation from about 1,500 exhibitors coming from more than 25 countries. Visitors are expected from over 61 countries and the organisers are anticipating business worth Rs2000 crore to be generated at the show.
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October 17-21, 2017
September 20-23, 2017
May 16-19, 2017
January 24-27, 2017
CALENDAR INTERPLASTICA
Location: Moscow, Russia Organised by: Messe Düsseldorf North America Website: www.mdna.com/trade-shows/details/interplastica Background Russia and its neighbors still have a substantial demand for investment and an unbroken interest in advanced machinery, production and process technology as well as high-tech materials. Because of the more difficult economic circumstances, the domestic consumer goods and packaging industry is under pressure to improve its competitive edge and to substitute the decline in imports. At INTERPLASTICA 2017 an impressive range of innovative products and services will again be on display and the potential of market is still substantial.
Chinaplas 2017
Location: Guangzhou, China Organised by: Adsale Exhibition Services Ltd Website: www.chinaplasonline.com Background Following the very successful staging of the 30th edition this year, CHINAPLAS 2017 will return to China Import and Export Fair Complex in Guangzhou from 16 -19 May next year, occupying 26 exhibition halls with total exhibition area reaching 250,000sqm! The show spotlights “Intelligent Manufacturing High-tech Materials Green Solutions”, featuring “Automation Technology Zone”, “Composite & High Performance Materials Zone” and “Recycling Technology Zone” which gather international suppliers of advanced plastics & rubber machinery and materials.
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.
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.
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PRODUCTS
Emphasizing on R&D
K
KUNG HSING TO SHOWCASE ITS LATEST PRODUCT PRODUCT, HDPE SUPER HIGH SPEED BLOWN FILM MONO LAYER AT K SHOW
ung Hsing has a remarkable global share in the plastic machinery industry, and the major reasons that the plastics extruder could be represented in the Southeast Asian market owe to two particular performances: first, the efficiency and secondly the better quality that Kung Hsing’s machines generate. These exemplary features are particularly what differentiated the company amongst other. Also, because of these features the company’s customers are spread over 130 countries.
Besides strong innovation, the other critical key for Kung Hsing to rejuvenate and sustain its reputation is by establishing a clear brand impression by a secure brad value. Given the flowing energy in R&D from Kung Hsing, the manufacturer released its new machinery, The HDPE super high speed blown film line (Model KS-FEH), after three years of researches and testing. Speaking about it, Kun-Lin Tsai, Vice President of the company said, “Although this new machine is categorised as the middle-end machinery, the R&D still spend a great amount of effort in innovation. Our goal was to create a high-performing machinery that is non-precedent among the middle-end machineries.” The result proved to be a huge accomplishment, this HDPE super high speed blown film mono layer can double the production, which makes the machines relatively economical and practical for users if they evaluate their production in quality. This Model KS-FEH with a long lifespan will in no doubt provoke a leveling-up in quality and performance among the mid-to low – end plastics blown film machines.
Although this new machine is categorised as the middle-end machinery, the R&D still spend a great amount of effort in innovation. Our goal was to create a high-performing machinery that is non-precedent among the middle-end machineries. Kun-Lin Tsai, Vice President, Kung Hsing
latest research papers, he motivates Kung Hsing’s R&D team to engage in the most advanced technology, and thus initiate improvements in their machines. These are the key elements that a brand can represent trustworthy and excellence. Enhancing the brand value as the core spirit Kung Hsing will exhibit the five layer co-extrusion high Besides strong innovation power that acted as the core spirit speed blown film machine at K 2016. On one hand, they for Kung Hsing in maintaining its diversity and individuality are expecting to introduce the high-performing machineries of their products, the other critical key for a senior plastics mato the regional and global visitors. On the other hand, Kung chinery manufacturer to rejuvenate and sustain its reputation Hsing will impose its strategy to market their machineries to is by establishing a clear brand impression by a secure brad Southeast Asia. Although given the fact that Taiwan machinvalue. Vice president Kun-Lin Tsai expressed his anticipation eries might not be able to benefit from the tariff deduction that this kind of persistence of best-quality pursuit will be as agreement, Kung Hsing is confident that without the price well spread among the users - as it is urgently important that advantage, it will yet stand out from other machineries due to the both-way relations in the demand and supply of plastics the quality and uniqueness. Most importantly, for the coming machinery value a long-lasting developmental strategy, rather days, Kung Hsing promises tol keep up than a short-term profit gain. Being part to their innovations, and share their belief of the team himself, vice president KunFor more info: of a better manufacturing industry with Lin Tsai regularly participates in internaE-mail: ks.sales@kunghsing.com.tw customers. tional engineering seminars and study the www.kunghsing.com.tw August-September 2016 | The Economic Times POLYMERS | 63
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PRODUCTS
Simple Repro-Flex recycling solution POLYSTAR SHOWCASES ITS SIMPLE AND EASY TO USE MACHINE AT K 2016
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OLYSTAR has been recognised as a top choice manufacturer for plastic recycling machine after K 2013. The fast-growing Taiwanese manufacturer recorded an impressive new record by selling 12 cutter-integrated recycling machines at the K 2013. New projects have already begun for clients in Turkey, Saudi Arabia, Hungary, Portugal, Lithuania, Egypt, Venezuela, Mexico, Kenya, India, Indonesia, and the United States. POLYSTAR pay deep attention to each specific requirement and make steady improvement to satisfy the need from the customers. Now, in order to make the operation more effective and user- friendly, POLYSTAR has redesigned the recycling machine and implemented the new ‘Simple in design, Flexible in operation’ concept at K 2016. With many proven success experience and customer’s feedback, POLYSTAR found out some other electronic control system of recycling machines are ‘over-computerised’. Once the software of the control system breaks down, the machinery shuts down and this scenario greatly affects the production. Thus, POLYSTAR has developed the intelligent ‘Auto’ & ‘Manual’ dual control system. With this, operation turns to be more user-friendly and efficient as compared to other machines in the market. This is exactly the ‘Simple’ operation which POLYSTAR emphasizes on. Speaking about the after sales service, POLYSTAR has established a complete easy maintenance guide, spare parts replacement instruction, machine operation guide, commonly asked trouble shooting tool, etc. The customer can review these guide tools via on-line platform and make the operation more simple and easy. Moreover, ‘Spare parts on-line’ system is build up on POLYSTAR’s web shop to satisfy the immediate need from customers.
cycling machine prepares (pre-conditions) the material into an ideal condition for the extrusion process and feed the material directly into the extruder with a centrifugal force. Compared to conventional recycling machines, this integrated system does not require a separate crusher, and therefore, eliminates the problem of inconsistent feeding (over-feeding or insufficient feeding).
The advantages of Repro-Flex 1. An integrated system without the need for pre-crushing: The integration of the cutter compactor directly with the extruder eliminates the need for pre-crushing plastic film. The feeding is therefore much faster and more stable. High throughput with the light-weighted film flakes can be easily achieved by going through densification and compacting process first. 2. High automation with flexible waste feeding methods: The Repro-Flex recycling system can process scrap material on a conveyor and film-on-roll on nip roll film feeder simultaneously. This automates the entire process and is beneficial for producers in terms of labor cost saving, space saving and lowering energy consumption. The machine generates very low noise as it does not require a separate crusher to process the film waste in advance. 3. Lower operation cost (less space, lower energy consumption and lower labor cost): Polystar’s plastic recycling systems can process heavily printed PE/PP film in just one single extrusion stage. This replaces the traditional ‘two stage’ mother-baby extruder pelletizer with less material degradation, as the extrusion process is done in a single stage. At the same time the machine consumes less energy and takes up less space because of its compactness (requires one extruder less and less motor power). In Simple in design, Flexible in operation addition, only one person at the feeding section is sufficient POLYSTAR’s Repro-Flex one-step plastic recycling machine is for operating the machine. designed for the reprocessing of polyethylene (HDPE, LDPE, 4. High quality, uniformed sized round shape pellets LLDPE) and polypropylene flexible packaging material, The die face pelletizing system can efficiently produce high printed and non-printed. The Repro-Flex requality PP and PE pellets that are ideal for excycling machine combines cutting, extrusion trusion and injection. The water ring pelletizer For more information: and pelletizing into one compact and efficient does not create waste as it does with the spawww.polystarco.com recycling line. The cutter compactor of the reghetti type pelletizer.
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PRODUCTS
Plastic waste recycling machines YE I MACHINERY DEDICATED ITS EXPERIENCED TECHNOLOGICAL KNOWLEDGE TO THE MAKING OF HIGH-END RECYCLING MACHINE AND BLOWING FILM EXTRUSION LINE
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the overall quality of their machineries. The specification of ecently YE I stressed that plastic waste recycling mathe screw is ø160, which is a key feature of YE I’s machineries. chines are becoming to be noticed in the industry. The company guarantees the machine production of are 900kg Comparing to the general use of metal recycling trend, for PP, 950kg for HDPE, and 1,000kg for LDPE. In spite of the notion of plastics recycling is just beginning to establish the strength in its overall production amount, the shredder and among the manufacturers. Especially after the customers have pelletizer add more characteristics to this machine. The shredstarted to recognise the advantages such as saving cost and der can grind the plastic waste more completely and thus genat the same time decreasing waste and be environmentallyerate higher density pellets, in other words, better quality prodfriendly. A number of bag making manufacturers choose to ucts. The customers would not need to worry about the quality purchase plastic waste recycling machines in their factories–eiof pellets whether they are for reusing or selling purposes. ther for reusing or reselling purposes. The reason that YE I’s plastic waste recycling machines are YE I’s Multi-layer Extruder Film Machine has included popular around the world is particularly due to their distinthe function of adding Calcium carbonate as the raw materiguishing design and performance. als in bag manufacturing – it could not make the production more economic but ensure the solidity and flexibility of the YDN-2V-120 has combined shredder, extruder and pelplastic bags. Over the years, YE I keeps their letizer in one single machine–saving the factory innovation strong and leads the trend of maspace and labour needed for the equipment. For more info; chinery improvements. They wish to generate Besides, the screws and barrels are both specialE-mail: service@yei.com.tw the most practical machines for customers. ly designed in-house, thus strictly controlling www.yei.com.tw
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New high-performance plastic for continuous use in steam
sary. However, the sterilisation affect ree of lubrication, mainteis reduced significantly for product nance and corrosion, the new that uses grease. Therefore polymer igus material introduces itself bearings are offered as a lubricationas a low priced alternative to metallic free and maintenance-free alternative, options. whose materials are resistant to heat, With iglidur HSD350 the mopressure and moisture. tion plastics specialist now has a low-cost all-rounder in the product An all-rounder in the igus prodrange for steam sterilisation during uct range is iglidur HSD350, which autoclaving. Particularly in the food is suitable for the hygienic continuous and medical industries, the new plain use even for regular sterilisation. The bearing material clearly displays its advantages over metallic new material can withstand temperatures up to 180°C continubearings. ously and temporarily up to 210°C. Because of the corrosionfree property, iglidur HSD350 is ideal for use in wet areas and Autoclaving is one of the most important methods for displays a low moisture absorption and thermal expansion there. killing bacteria during the production of foodstuffs, mediThe new material also proves to be extremely resistant to mecines and in the cleaning of medical products. In the standard dia and doesn’t get ruined even in hot steam sterilisation. This method, heating to 121°C at 2 bar takes place in the pressure provides the customer with the opportunity of vessel for 15 to 20 minutes, or to 134°C for designing bearings and joints so that perfect 2 to 3 minutes at 3 bar steam pressure with For more details, contact: cleaning results can be achieved in more comparticularly resistant bacteria. It’s a challenge Santhosh Jacob, igus (India) Pvt Ltd plex, non-separable units. iglidur HSD350 is for the individual parts of the machine, as E-mail: santhosh@igus.in, now available from a quantity of one piece and well as for the bearing. For metallic bearings a Website: www.igus.in available for immediate delivery from 24 hours. special autoclavable lubrication is often necesAugust-September 2016 | The Economic Times POLYMERS | 65
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PRODUCTS
Economic Repro Air Recycling Machines for Film Waste POLYSTAR’S OFFERS A COMPACT REPRO-AIR RECYCLING MACHINE, AN ECONOMIC RECYCLING SOLUTION FOR HDPE AND LDPE FILM PRODUCERS.
The space-saving recycling machine Repro-Air (economic type - RP120) has an average output of 30~80kg per hour, 800~1000kg per day. Through the nip roll feeder, the recycling machine can process multiple film rolls simultaneously.
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OLYSTAR’s Repro-Air recycling machine is an extremely compact and economic recycling solution for HDPE and LDPE film producers. It is especially suitable for producers who are in need of less installation space and operation cost. This machine enables film producers to reprocess HDPE and LDPE film scraps, start-up or changeover film rolls (film-on-roll) without the need for pre-cutting, edge-trim waste, Tshirt bag bundles (cut- offs) from inhouse production. Lightly printed film
The film producer is now able to recycle almost all of its production waste to make high quality pellets, from HDPE film scraps to LDPE film-on-roll– and considerably increase the percentage of recycled pellets in the end product (film).
bag bundles (cut-offs) from bag making process can also be thrown directly into the recycling machine without the need for pre-crushing. This air-cooled plastic recycling line does not require any water consumption and takes up very little space, it can fit right next to or in between blown film machines. The pellets produced by the hot die face pelletizer are 100 percent dry and can be put directly back into the production line for immediate reprocessing. This plastic recycling machine is highly recommended for packaging film producers of different types of film and bags, such as flat bags, commercial bags, garbage bags, food packaging film, shrink film and many others. After the hot die-face cutting, the air-cooled pellets are transported into a spiral device for further pellet cooling and separation. This special design allows the machine to effectively pelletize HDPE and LDPE with minimal material degradation.
2. Reducing production cost The film producer is now able to recycle almost all of its production waste to make high quality pellets, from HDPE film scraps to LDPE film-on-roll– and considerably increase the percentage of recycled pellets in the end product (film). The Repro-Air provides film producers with higher production effican also be recycled into high quality, uniformed pellets. In ciency and higher film waste converting rate – a higher percentaddition, low maintenance requirement and processing stabilage of recycled pellets can be put back into the production line. ity is the core advantage of new Repro-Air machine. POLYSTAR continues to re-engineer its recycling machines in every small detail to improve the machine userfriendliness and at the same time meeting the customer’s 1. Saving space and water requirements. ‘Simple in design, Flexible in operation’ The space-saving recycling machine Repro-Air (economic type has always been the core value for - RP120) has an average output of 30~80kg POLYSTAR, providing the simplest and easy per hour, 800~1000kg per day. Through the For more information: operation recycling systems to customers nip roll feeder, the recycling machine can prowww.polystarco.com worldwide. cess multiple film rolls simultaneously. T-shirt 66 | The Economic Times POLYMERS | August-September 2016
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PRODUCTS
High-end Sheet Extrusion Line KABRA EXTRUSIONTECHNIK LAUNCHES HIGH-END SHEET EXTRUSION LINE, IN COLLABORATION WITH BATTENFELD-CINCINNATI, GERMANY.
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ackaging sector has undergone a sea change in last few years, and still an evolving market in India & other developing nations. Sheet lines are aimed at variety of end-user applications such as bakery & confectionary, stationery, food, dairy products, vegetable packaging, fresh fruit applications and beverages. Kabra Extrusiontechnik (KET) has launched high speed sheet extrusion line. This move aims to address the growing demand in food packaging & increase in organized retail. About High Speed Sheet Extrusion Line With a growing lifestyle, retail & food packaging has grown multifold. Every product has different material, process requirements and variable thickness size, dimensions & properties. Considering these market requirements, KET has introduced a new generation of high-speed extruders in collaboration with M/s battenfeld-cincinnati, Germany. This marks a quantum leap in the history of extrusion technology. The 75 mm screw diameter offers the process- technology optimum in terms of volume/screw speed ratio. All outputs in sheet extrusion are covered by one machine size, simply by adjusting the screw speed and the performance of the drive unit. The highly automatized compact design, ideally suited for mono & multilayer PP/PS/PET Sheet applications. Precision German technology gives processors excellent sheet quality with better thickness control, gloss, haze, glaze and shrinkage properties as compared to available options in the market. The output capacity range is from 300 to 1200 Kg/Hr.
Precision German technology gives processors excellent sheet quality with better thickness control, gloss, haze, glaze and shrinkage properties as compared to available options in the market. The output capacity range is from 300 to 1200 Kg/Hr. High Line speed up to 50 MPM • Each Polishing & Cooling Rolls driven by individual AC Servo Geared Motor • Turret Winder with Lay- on Tension control Rolls for excellent winding quality. On launch of this product, Sunil Ambekar, Vice PresidentMarketing, Kabra Extrusiontechnik explained, “KET’s international presence as a leading extrusion machinery manufacturer is an added advantage to promote this product globally.”
The significant attributes of high-speed extruders are: • 34 L/D Extruder with smooth Barrel • Thickness 0.2 – 2.0 mm , width to suit Application • Up to 25 percent energy savings compared to traditional machines • Reduced change over time and increased production time • Improved quality by massive reduction of residence time • Less space requirement at higher output rate Some of the notable features of are: • Compact unit – easy for maintenance • Line speed up to 50 MPM • Less spare part cost • European make machine parts: Screen Changer, Melt KET’s machines are widely recognised for their reliability, efficiency and advanced technology. Company continues Pump, Feed block, Sheet Die, etc. to be a leader in manufacturing & export of plastic extru• Extruder with Smooth Feed section allows use of regrind sion machinery. With this new launch KET up to 50 percent expects to grow further with a broad portfolio • Special design cooling Flow channel & For more information, of extrusion solutions to processors across the High Quality Polishing rolls. e-mail: info@kolsitegroup.com globe. • Additional set of Post cooling rollers for August-September 2016 | The Economic Times POLYMERS | 67
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