Editor s Note
I am delighted to share with you the inaugural issue of "Polymer & Packaging International , Pakistan's premier industry magazine. As the official supporting media magazine for Arabplast 2013, this first issue will bring into focus the main players at the event and will highlight Pakistan s role in the global marketplace. Arabplast is the largest plastic, petrochemicals and rubber exhibition of the GCC region and in 2013, more than 900 world class exhibitors from over 32 countries will display their products. As the GCC becomes a robust player in the global polyethylene and polypropylene product market, Arabplast will become the platform of choice for various verticals connected with this industry. Pakistan is the second largest domestic market for plastics in South East Asia. While 80%90% of raw material used in local industry is imported, there is a growing need for imported equipment and machinery. There are about 6000 plastic product manufacturers engaging over 700,000 trained labor in various facets of manufacturing. Historically, the industry has continued to contribute consistently to overall growth rates in the country; however, with the competitive environment changing and other economic and socio-economic pressures, there is a pressing need to take concrete steps to create and sustain competitive advantages. The markets for export for Pakistan present attractive opportunities it is these that the magazine aims to harness by bringing the Pakistan context in touch with technological , manpower and product trends in the global arena. In tandem with our coverage of industry developments both locally and abroad, it is our aim to extend our services to become a knowledge sharing platform within Pakistan. To hone talent, build capability by providing a direct link between industry experts and the local market and transfer knowledge through cutting edge articles, seminars and other appropriate tools is how we intend to become not only business partners , but also the go-to forum as the fulcrum of all industry networks. We will also continue our coverage of industry related seminars and conferences which draw an audience of related professionals and students alike to benefit the industry. It is an exciting time to be part of this industry in particular, and we look forward to contributing to your success.
Content Editor s Note
The Bare Essentials: Graphical Representation of Pakistan s Imports of Plastic, Printing, Packaging Machinery & Materials (July 2011 June 2012) Greener Pastures: What Industry Leaders Say About Pakistan s Plastic Industry Local News International Developments Arabplast 2013 Pre-Show Report Plasti & Pack 2012 Post Show report Interview: Assessing Pakistan s Plastic Industry FEATURED ARTICLES: - Naphtha Needed But Ignored - Evolution of Plastic Packaging In Pakistan - A Journey from Toys to Roads - Growth Prospects For Global Plastic Film and Sheets Market - A Journey Untold: Pakistan s Plastic Packaging Industry - PCSIR and the Development of Pakistan s Polymer Industry
OUR TEAM Managing Editor S.H Rizvi editor@thesis.com.pk
Editorial Assistant Azka Rehman azka@thesis.com.pk
Business Development Manager Akbar Baseer Khan akbar@thesis.com.pk
Layout & Visualization Rehan A Hashmi rehan@thesis.com.pk
Address: 64-C, 3rd Floor, 21st Commercial Street, D.H.A Phase 2 ext Phone: +92-21-3246-1722 Website: www.thesis.com.pk
The Bare Essentials:
Graphical Representation of Pakistan s Imports of Plastic, Printing, Packaging Machinery & Materials (July 2011 June 2012) IMPORT OF PRINTING MACHINERY JULY 2011 - JUNE 2012 (US$ MILLION) HS# 84431300 US$ 2701885.3 HS# 84431100 US$ 1617596.4
14%
HS# 84431700 2481036.3
3.67
22%
3.50
24% HS# 84431600 2509558.9
22% 8%
Top 4 Importing Countries
2.60
10% 0.72
HS# 84431400 872293.2 HS# 84431200 US$ 1206471.8
04 | Polymer & Packaging
Germany
China
U.S.
Italy
IMPORT OF PLASTIC MATERIAL JULY 2011 TO JUNE 2012 (US$ MILLION)
4.94
HS# 39011000 220054178.6 HS# 39072000 91268092.6
9%
HS# 39012000 194084564.5
Top 4 Importing Countries
23%
40% 4.31
20%
1.05
8% HS# 39021000 389682072.8
K.S.A.
HS# 39023000 78499151
IMPORT OF PAPER & PAPER BOARD MACHINERY JULY 2011 - JUNE 2012 (US$ MILLION)
U.A.E.
China
0.6
Qatar
4.94
HS# 84391000 1339349.5
4.31 11%
HS# 84419090 1814796
Top 4 Importing Countries
15%
HS# 84399900 3766306.5
1.05
44%
30%
0.6 China
HS# 84411000 5382701.2
IMPORT OF PLASTIC & RUBBER MACHINERY JULY 2011 - JUNE 2012 (US$ MILLION)
Germany
U.K.
Italy
25.53
HS# 84771000 20484696.8 HS# 84807900 9392205
42%
20%
HS# 84807100 5524542.448
11%
Top 4 Importing Countries
6.94
HS# 84772000 7527872.1
4.88
16%
4.27
11% China HS# 84773090 5348313.1
IMPORT OF PACKAGING MACHINERY JULY 2011 - JUNE 2012 (US$ MILLION) HS# 84224000 14365766.26 HS# 84229090 9359713.341
Japan
Germany
Thailand
22.95 19.99
16%
Top 4 Importing Countries
11%
11.53 7.91 73%
HS# 84223000 62844862.18
Source: Pakistan Bureau of Statistics
Italy
Germany
China
Sweden
Polymer & Packaging | 05
GREENER PASTURES: What Industry Leaders Say About Pakistan s Plastic Industry
Company: Name: Designation: Response:
Aarfeen Irfan Sabir Manager Technical Services & Market Development Plastic industry is growing rapidly with growth rate of 10 15 %. Despite law and order challenges that prevail in Pakistan, a number of new industries are sprouting in the plastic sector.
Company: Name: Designation: Response:
Gatronova Masood Altaf Marketing Manager The Plastic industry of Pakistan is growing at a phenomenal rate and going strong. In recent times, we have seen 21 new projects coming up which includes large ones like Novatex and Ismail Industries (Candyland).
Company: Name: Designation: Response:
Haitian - Pakistan Ehtesham uddin Former Chairman of PPMA Pakistan being a developing country has abundant growth potential, particularly in the plastic sector. However, the need of the time is to speed up local investments. In my opinion, since Pakistan is a producer of Naptha, the need of the time is to set up a Naptha Cracking plant so the country can not only save large amounts of foreign exchange but also reduce dependency on imported raw material.
Company: Name: Designation: Response:
World Tech Simon Tsao and Aamir Habib Export department, Business Developer Manager Pakistan s economy is picking aup. With large investments being made in the plastic sector, the industry in Pakistan in my view presents far greater prospects as compared neighboring Bangladesh.
06 | Polymer & Packaging
Company: Name: Designation: Response:
Thermosole Industries Arshad Jameel Manger marketing and Customer Relations Sindh Foreigners get astonished when they see good quality Pakistani finished goods. We are meeting Japanese standards in car parts which show that Pakistani products are of good quality. We only need recognition.
Company: Name: Designation: Response:
Transworld Multi purpose Farnaz Ahmad Director Keeping in view global economic turn down especially in Pakistan, trend of paper and board has shifted to plastic which has reduced the cost of production and has resulted in better quality of packaging. Heavy growth is projected along with strong competition in the plastic industry of Pakistan.
Company: Name: Designation: Response:
Clariant Nadeem Mufti Area Sales Manager New plants of Gatron, BOPET and others are setting up which shows that new developments are taking place in the plastic industry of Pakistan. Due to a growing population, the consumer demand for goods is increasing which is ultimately giving rise to the packaging segment of the country.
Company: Name: Designation: Response:
Nasir Corporation Nasir Mehmood Vice President of Karachi Chamber of Commerce The plastic packaging sector of Pakistan has enormous potential for future growth. A lot of work has been taking place all over Pakistan especially in Punjab.
LOCAL NEWS Engro Polymer & Chemicals to invest $15m in 2013
KARACHI: Engro Polymer and Chemicals Limited (EPCL) will invest up to $15 million in the calendar year 2013 to enhance the production capacity of PVC resin, which is a major product of the company, said the company s chief executive officer. EPCL will spend $10 to $15 million during 2013 to enhance production from the existing three PVC resin plants at Port Qasim, Karachi, said Khalid Siraj Subhani, president and CEO of EPCL. The company is looking into multiple ways for raising investment funds. It could be debt, equity, or a mix of debt and equity. PVC resin is a major product of the company that is a basic raw material for PVC pipes, artificial leather, shoes, rigid sheets for tables, doors and windows, panaflex, blood bags, wrappers around bottles, garden hose, fixtures and a number of other plastic products across the world. Besides, the company produces VCM, which is a raw material for PVC resin. Caustic soda is another product of the company that is used in the manufacture of textile, soap, detergents, and water treatment. Subhani said that the removal of bottlenecks will help produce an additional 35,000 to 40,000 tons of PVC resin. The company produced 150,000 tons of the said chemical in 2011 against the installed capacity of 200,000 ton per annum. He said that the usage of PVC resin made products in Pakistan is just 0.7 kilogram per person per year. This is almost double in India, which is a net importer of the chemical. The per capita consumption of PVC made products in industrial states stands at 7 to 9 kilograms. The reason behind lower use in Pakistan remains unawareness about higher quality and lower price benefits of products. However, the usage of such products in the country is increasing by seven percent per annum, he added. PVC is a poor man s plastic, which lasts for about 60 years, he claimed and added, PVC made products are 10% to 30% cheaper than the products made of non-PVC material. Sewerage pipes made of the said chemical do not choke lines as quickly as pipes made of non-PVC stuff, he said. The deposit time of non-PVC pipes is 10 times higher than the pipes made of PVC resin. He said that the import of PVC scrap through misdeclaration from origins such as Saudi Arabia and the Middle East is a huge challenge to the growing industry. The scrap is earning a bad name for products and playing a negative role in developing the downstream PVC industry in Pakistan. The company is helping businessmen to develop the downstream industry by suggesting business ideas and launching such ideas successfully, he said. Building constructors and the government are also using such products in their development schemes.
EPCL, a listed company at the Karachi Stock Exchange, is the only company that produces PVC resins in Pakistan. Engro Corporation (the then Engro Fertiliser) set up the company in 2002 under its plan of diversifying business from a single fertiliser manufacturing plant. International Financial Institution and Mitsubishi Corporation hold about 15% and 10% shares of the company, respectively. The company reported Rs83 million profitafter-tax in nine months ended September 30, 2012 against loss-after-tax of Rs440 million in the same period of 2011. The CEO said that his company incurred a cumulative loss of about Rs1.5 to Rs2 billion in the previous two years due to hiccups in establishing VCM plants imported from Germany. He elaborated that the company had imported a closed VCM manufacturing plant from a German company called Vinnolit for $260 to $270 million in 2007. The company had agreed to help relaunch such a plant in Pakistan. However, its officials did not travel to Pakistan after Germany advised its people not to travel to the country at that time. Therefore, the situation caused the company to incur steep losses, as the plant was made operational with much delay. Source: The News
CPP Film Line to be introduced next year Flexible packaging line had reached the shores of Pakistan last year Astro Films has established 1st BOPET film line in this country which is the beginning of a new era in Flexible Packaging Industry. With an annual capacity of 18000 tons per annum, this film line ensures a highly efficient production of flexible BOPET packaging film ranging from 12 to 150 microns. Supplemented with the most superior technology, this manufacturing facility can produce BOPET films for high speed with fine optical and mechanical properties. Astro Films is the only producer of all three films: CPP, BOPP & BOPET. Being a firm part of Ismail Industries Limited, Astro Films family further comprises of three reliable brand names: Astro Pack (CPP films), PlastiFlex Films Pvt. Limited (BOPP films) and Astro Plastics Pvt. Limited (BOPET films). The producer is a supplier of flexible packaging films within Pakistan and across the world by acquiring high tech plant from Bruckner deemed to be the pioneers of these manufacturing facilities. By next year, Astro Films is introducing CPP Film Line having production capacity of 12000MTA. Astro Films total installed capacity in CPP will be augmented to 17000 metric tons annually. The film-maker located in the southern region of Pakistan can now provide its customers with a total solution in flexible packaging with in-house manufacturing of PET film along with metalized and twistable PET, BOPP films and chemical-coated films in different thickness grades.
Innovation in textiles; SARK developed to protect The International Technical Textiles Conference 2012 in Karachi, Pakistan set the stage to display SARK, an ideal protective layer clothing fabric that prevents knife/slash wounds. Developed by Boston University (USA), the product has been designed to serve as a effective layer to protect policemen, armed forces and security personnel from cut and stab wounds. Originally developed in 2008, SARK was put on display at the conference by its co-inventor Professor Subhash Anand. The name SARK which means shirt in Gaelic was coined using the of alphabet of the names of its inventors Subhash Anand, Aiden Tracy, Raj Rajendran and Karthick (Kanchi Govarthanam). Made using a composite material of Polymeric Fiber, Glass Fiber, High Strengthen Fiber and the rest, SARK also uses an anti-microbial coating to protect users against viruses such as Methicillin-Resistant Staphylococcus Aureus (MRSA). While addressing an audience of industry professionals at the conference hosted by Textile Institute of Pakistan, Professor Anand said that SARK would replace chain-mail gloves that are currently being used by butchers and timber merchants which hurt the skin. According to Professor Anand, SARK the breathable fabric alternative would replace the current material and a much safer alternative.
Thailand s Prime Minister Awards Pakistani Businessman Irshad R Adamjee Thailand s Prime Minister Yingluck Shinawatra honored Mr. Irshad R. Adamjee of Pacific Multi Products (an Adamjee Group Company) with prestigious Thailand s Best Fried award on September 11th, 2012 at Naval Banquet Hall in Bangkok during a colorful two day ceremony at Oriental Mandarin Hotel. This award was presented by Thai Government to selected businessmen from 331 countries which made Mr. Adamjee the second Pakistani ever to achieve this selected status, after Mr. Arif Suleman who was first one to receive this award in 2004. This award was presented to him in recognition of his fifteen years long and healthy business partnerships with over twelve Thai companies. He was awarded for successfully promoting and marketing various Thai Petrochemicals, Polymers and Natural Rubber etc and a joint collaboration in manufacturing plastic raw materials in Pakistan, along with his efforts for the promotion of investments, trade and cultural exchange with Pak-Thai friendship association and business forum which also includes his Thai culinary skills. Source: Dawn
Polymer & Packaging | 07
INTERNATIONAL DEVELOPMENTS Going Green: The Coca-Cola & JPF Union
Three years since the inception of the Plant Bottle technology in 2009, Coca Cola has already sold more than 10 billion packages to 24 countries of the world. Armed with a vision to replace conventional petroleum based PET bottles with the more environmentally friendly Plant Bottle Technology by 2020, Coca Cola has recently signed a deal with Indian giant JBF Industries to set up the world's largest facility in Brazil that will produce 500,000 Tons of Bio-Glycol (MEG), the key ingredient used to make Plant Bottle bottles. The state of Sao Paulo, Brazil is said to be one of the largest producers of sugarcane, second largest producer of ethanol from which Bio Glycol is drawn. According to the COO of JPF Rohit Maindwal, the location was selected as more than 35 ethanol producers are located within a 70 km radius of the plant. Commenting on the new relationship between Coca Cola and JBF, the General Manger of Coca Cola s plant bottle packaging department Scott Vitters is convinced that the project is bound to reap good harvest as both companies already have a strong working relationship in other areas. Since JBF currently supplies resin to various Cola-Cola destinations across the globe, Scott insists on calling the new project a phase rather than a destination as he believes that not only will it highlighting the benefits of Plant Bottle technology but will help others to gain an understanding on to how to build a supply chain that is truly sustainable.
Turning sewage waste to plastic A ground breaking innovation will reportedly enable turning municipal sewage sludge into raw materials that can be used by plastic industries around the world. Developed by Applied Cleantech, a company of Israeli origin, the new technology will enable turning solids in municipal sewage systems into raw materials for the plastic industry around the world. This revolutionary way of thought along with scientific research, has resulted in the development of this technology which enables sewage sludge to be used as a base for raw materials that are later sold back to the industry. The technology is said to be applied by way of a compact, automatic and efficient facility that recycles solids from raw sewage 08 | Polymer & Packaging
and turns them into high-quality consumer products through a continuous process (SRSSewage Recycling System). At the end of the process, sewage solids are turned into high quality, clean and environmentally friendly raw materials, thus naming the purification facility to a manufacturer with extra "green" points. Aside from the raw materials created at the end of the process, the new plants are said to assist in reducing regional sewage purification plant loads by about 35%. According to the CEO and founder of Applied Cleantech Dr. Refael Aharon, the innovation intends to provide a solution for issues in sewage care which would render solids in sewage not as waste to be consumed by bacteria or buried at a landfill but as a resource and base for raw materials that can be sold back to the industry. Source: britishplastics
New 'inject2blow' technology said to reduce time and costs Engel Austria, in partnership with Italian group Cantoni, says it has set a new standard for process integration. The inject2blow method, which the two companies developed together, combines the injection molding and blow molding processes in one mould on one injection molding machine and is said to significantly reduce time and costs in the manufacture of cosmetic, drug, and food containers by doing so. The process reportedly has a cycle time of less than 14 seconds for the manufacture of wide-necked jars on a 90-tonne clamping force Engel victory injection molding machine in a 2+2-cavity mould produced by Cantoni. Performs normally have to be made using injection molding first and then subjected to a second process on a blow molding machine before they become a final product, but the new method allows small ready-to-use containers to be manufactured in one process. This combination method is the first of its kind available on the market. Other benefits of integrating the processes include lower system investment costs, a smaller system footprint, higher system availability, simpler quality control, and no maximum clamping force. The inject2blow method can be used to process a wide range of thermoplastics from polyethylene, polypropylene and polycarbonates to PET. Engel and Cantoni supply the integrated
production systems from one source. In addition to the Engel injection molding machine, they include a Cantoni sliding table mould and an Engel viper linear robot which removes finished parts from the mould. Both the injection molding and blow molding processes are visualized, monitored, and controlled via the Engel injection molding machine CC 200 control unit. This means that injection molding machine operators don't have to learn how to use new technology; they will simply be guided intuitively through the integrated injection and blow molding process by the Engel control unit which they are already familiar with. Injection molding machines from the Engel victory and Engel e-victory series, which are adapted to the individual requirements of the application, can be used in the manufacturing cells. These machines offer plenty of free space for the sliding table mould because their clamping unit does not have a tie bar. As the mould clamping platens of tie-bar-less machines can be used up to their edges or even beyond, large moulds can fit on comparatively small injection molding machines. Machine size can therefore now be decided according to the required clamping force instead of the size and movement radius of the mould, which keeps investment and operating costs low. The barrier-free mould area also simplifies the automation process, because the robot can access the mould from the side without being hindered. Despite the high degree of process integration and automation, manufacturing cells are very flexible when they are in operation. Cavity inserts make it easier to change from one product to another and the production of small batches economical. As the inject2blow process is based on standard injection molding machines, the system can be used with moulds for classic injection.
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ARABPLAST 2013 Gearing up for success While the GCC is poised to become the number one source of petrochemicals and plastics products in the world, Arabplast 2013 is geared to fortify its legacy as the most popular trade show in the United Arab Emirates. Dedicated solely to the plastics and petrochemicals industry, the 11th edition of the exhibition will be the center stage of activity that will cater to the expansion needs of more than 150 countries worldwide. According to organizers Al Fajer, 703 exhibitors participated in the exhibition in 2011 whose doors were knocked on by 18,860 quality trade visitors from 107 countries; an increase of 25%. The largest number of foreign visitors that turned up were from Iran, Saudi Arabia, Oman, Qatar, Bahrain, Kuwait, Pakistan, African countries and India. In continuation of this, Arabplast 2013 is expected to be 34% larger than the previous one which reflects the high global demand for plastics, raw materials and machinery products. With confirmed participation by leading companies from 41 countries worldwide and sponsored by Qapco, Borouge, Natpet, Petrorabigh and Tasnee, Arabplast
and polymers. The show will also cover a wide spectrum of plastic machinery, plastic/rubber processing technology, pre and post-processing systems, plastic packaging technology, injection moulding, blow moulding, wrapping technology, extrusions, chemicals and additives, semi finished goods, engineering plastics and plastic products. Arabplast 2013 is also expected to reinforce its distinction of being the ideal meeting place where decision makers from the industry, technical experts, global companies, and trade meet and do business.
Andritz to demonstrate film line expertise
The Andritz Group - one of the leading producers of biaxially oriented film production technology is set to display their expertise on BOPP, BOPET, BOPS, BOPA and BIAX shrink film lines at Arabplast 2013. Having sales up to 4,600 MEUR, the group aims to boost business in the trade-fair by targeting the market involved in designing, manufacturing, installing and servicing technology for the production of biaxially oriented films. The manufacturing of biaxially oriented films involves dosing, conveying and feeding of polymer resins, melting of the materials, casing of the melted material in polished chill roll, stretching of biaxially oriented plastic films in machine directions and transverse directions, feeding of film into the pull roll stand and the winding of the finished film.
2013 will showcase new products and technologies in injection molding, blow molding, wrapping and packaging, pre and post plastic processing techniques as well as raw materials such as masterbatches, additives
Polymer & Packaging | 09
Arabplast 2013 Andritz will showcase state-of-the-art equipment and complete lines for the production of biaxially oriented films, including the unique MESIM technology.
time of under five seconds. Arburg will present a highly sophisticated application for the
Krystalite is also involved in thermoforming, making egg trays, food grade packaging and
packaging sector. The machine belongs to the high-performance hybrid Hidrive series, which is characterised by high productivity, speed and energy efficiency, and covers a clamping force range from 600 to 5,000 kN. The all rounder 720 H in the Packaging version is adapted to the application having specific requirements of the packaging sector, and features a clamping force of 2,900 kN and size 1300 injection unit. The high performance of this machine will be impressively demonstrated with a high-speed in-mould labelling application at the trade fair. The exhibit will be equipped with a 4+4-cavity stack mould from Erkoc Mold and will produce thin-walled IML tubs in a cycle time of less than five seconds. Insertion of the labels, as well as moulded part removal and set-down will be performed by an IML system from Roboplas.
customer specific packaging requirements. Moreover, the exhibitor has started a new line of BOPET Film under the name of KRYSTOFILMS which carries the capacity of 30,000 MT/Annum to produce films for flexible packaging in various microns.
Andritz can be contacted at B111 in Hall 6
Innovative parallel twin-screw extrusion lines from Theysohn sets new technological and ergonomic standards A completely new innovative extrusion line OMNIA in which all components are perfectly synchronized with each other impresses with its higher productivity- a higher level of reliability and greater efficiency and thus reduces the production costs of the user. Theysohn is showcasing four extrusion experts in Arabplast: Theysohn, Technoplast, TOPF and Extruder-Komponenten Salzgitter. Theysohn is an all-in-one provider that has developed a unique series of extrusion lines featuring a parallel twin-screw extruder, a new tooling concept, a new pipe head, a new type of calibration table and a hauloff/guillotine combination. The product development process innovatively fuses the aspects of productivity, reliability and efficiency. The all-in-one solution ensures the compatibility of all components throughout the entire installation. For the customers, this means the individual components of the extrusion line are optimally synchronized with
Arburg can be contacted at stand D110 in Hall 5
Novatex at Arabplast 2013
respect to process engineering. This significantly reduces the production costs of our customers, who will thus be able to generate major cost savings. Theysohn can be contacted at stand C114 in Hall 6
Exhibiting high-speed Packaging Machine At Arabplast 2013, Arburg - leading global manufacturers of injection moulding machines for plastics processing is set to exhibit all rounder Hidrive Machine series. A hybrid all rounder 720 H in the Packaging version will produce thin-walled IML containers in a cycle 10 | Polymer & Packaging
Novatex Limited & Gatron (Industries) one of the only manufacturers of PET Resin in Pakistan under the brand name of GATRONOVA are showcasing Resin Sample, BOPET Films, Preforms and Thermoforming products at Arabplast 2013. With a production capacity of 235,000 MT/Annum in various I.V's ranging from 0.74, 0.80 & 0.84 +/- 20.2, the company exports 70% of the Resin to several economies. Novatex -one of the largest PET Preform producers in Pakistan with capacity to produce more than 2 billion Pieces/Annum in diverse grammage for CSD and Water in different Necks (30/25 & 28mm PCO) on state of the art Husky Machines. The company is also involved in producing FR (Fast Reheat) and Hot Fill Resins. The sister concern of Gatronova, Krystalite Products (Pvt) Limited manufactures PET Sheet having capacity over 5000 MT/Annum with wide variety of thickness ranging from 150 to 1400 micron in different widths.
Gatronova can be contacted at stand D121 & D124 in Hall 8
Dolci Extrusion at Arabplast 2013 Among various novelties at the forthcoming ARABPLAST '13 Show, Dolci Extrusion will present its recent developments related to new multilayer stretch (cast) film lines optimized to produce ultra-thin film gauges. This new stretch cast film line series, which can have 2, 3 or 4 meter net width, can be equipped with a new updated version of the well tested automatic winder Rotowind 2000 for the production of hand and machine rolls, on 2 and 3 carton cores. The working speed is over 650 m/min for the 12 micron film and/or over 550 m/min for the 8-9 micron ultrathin film. One of the outstanding features of this winder is the 17 very short roll-change cycle time. The same type of line, when the customer request is for hand, machine and jumbo rolls can be equipped with the all brand new automatic winder model ARX 2012, designed for a mechanical speed of 800 m/min. The ARX winder is available in its modules of 1500 and 2000 mm net widths: for 3 or 4 meter lines the design foresees a twin configuration. In relation to the CPP / barrier film productions, the company will also present innovative 7 layer line, having width of 2400 mm and production of 1000 kg/h net that includes some features that represent innovation on CPP cast film lines. A part the ergonomic and compact line layout, the latest version of the American Cloeren feed block and diewith variable adjustment
Arabplast 2013 of the die width, the line includes -
An annealing group, just before the rewinder that helps to avoid the shrinking of the reels after rewinding and handling, and helps to increase the mechanical properties of the film
-
An innovative winding station that represents a state of the art solution and includes the use of swiveling arms with (absolute innovation) the possibility to rewind and splice in both directions and, very important, to also produce slit reels in line with multiple cuts without using a separate slitter rewinder. The slitting system includes a positioning of the Slitting blades or knives through laser position indicators
Also the inline trim recycling unit represents an absolute new application. The system is based on an independent extruder which, instead to extrude granules, it transforms (by use of a special profile screw) the trims on specific shapes and consistency that allow their recycling without any degeneration of
the recycled material melt index Among other novelties introduced at the show, Dolci Extrusion will present a special tailor made cast film line for the production of film for Lithium Ion Batteries. This special film (produced with specific resins based on PP and Polyolefilms) is used as a separator between Anode and Cathode. For this specific film the extrusion technology is based (among other steps) on a special multi-section chill-roll. On the Blown film technology side, Dolci Extrusion will present the EXTRU-CONVERT Series, a combined line for extrusion and converting : the 3, 5 or 7 layer blown film line can be composed by its state of the art ultra-productive extrusion hot part, by an
in-line micro embossing unit and by an in-line 4 or 6 colour servo-driven flexo printing unit. The all-in line philosophy is back again and grants sizeable cost reductions, especially for the short jobs. Dolci Extrusion can be contacted at stand no. B126 in Hall 6
EXPECTATIONS OF ARABPLAST 2013 EXHIBITORS Name: Masood Altaf Company: Gatronova We have high expectations from Arabplast 2013. A good number of potential customers are expected who will buy our products.
Name: Brigitte Stoimenov Company: Theysohn Group We would like to gain customers by discussing future products and plans that are mutually beneficial. Also we would like to welcome all the people in business interested in producing PVC profiles and pipes to have an interesting discussion about business opportunities with Theysohn Group. Name: Nasir Mahmood Company: Nasir Corporation-Pakistan Representative of Hiplas Taiwan Pakistan market can gain large-scale business in Arabplast event due to global participation. Our goal is to finalize deals of 3/5/7 extrusion machine with our customers. Name: Ms. Sturm Company: Andritz AG The purpose of exhibiting in Arabplast is to meet customers as we are expecting to engage potential clients from there. We are looking to new display of technologies for our benefits. Name: Ibrahim Kusumbi Company: Umair Petrochemicals I am looking forward to provisional networking with people associated to similar industry especially potential suppliers. I would like to introduce myself with new material, development, machineries and changes in raw materials. (Visitor)
Polymer & Packaging | 11
ASSESSING PAKISTANÂ’S PLASTIC INDUSTRY
Dr. Tahir Shah is a renowned polymer scientist and a member of the academic staff at Bolton University, U.K. The core of his research being the underlying themes of smart materials and technical textiles, he research interests also include controlling polymer structure and morphology in order to manipulate material properties. Settled in the U.K for all his professional life and a Pakistani by birth, Dr. Shah believes that PakistanÂ’s plastic industry needs to create closer liaison between academia and industries to address mutual benefits that will not only raise the standard but also drive Pakistani products to be more competitive in the international market. Polymer & Packaging International recently had the pleasure of meeting with him and discussed the scope of the polymer and packaging industry in Pakistan. Q. Pakistan is a major domestic market for plastics in South East Asia. How do you rate the local plastics industry/developments in Pakistan? A.
Pakistan is the second largest domestic market in South East Asia after India. However, there are not many manufactures of plastic resins in Pakistan. The main polymer resin currently being manufactured in Pakistan is polyester (PET) and to my knowledge there is only one commercial manufacturer that is producing nearly 130,000 tonnes of resin out of which more than 60% is consumed locally. Pakistan is an emerging consumer market for plastics and there are significant opportunities for growth in domestic consumption and well as export. However, the weakness of the Pakistani plastic industry is that it is scattered and needs to be better organized. Also, since the manufacture and processing of plastics is a highly energy intensive process, shortage of energy too poses to be a major obstacle in the development this and other sectors. Polymers being the feedstock for all materials, Pakistan should focus on bio polymers, thermostat polymer and bio material.
Q. Pakistan does not have a Naphtha cracking plant and therefore has to rely on imported inputs. Since the local industries are strapped for funds, is there any scope of FMCGs investing in Pakistan to set up one? A.
Plastic manufacturing in Pakistan is highly dependent on imported raw materials and this makes it what makes it difficult for manufacturers and products to compete in the international market. There is a strong need to develop a viable infrastructure for the petrochemical industry in Pakistan. I feel that in the present climate, more than any other entity, Pakistani Government has to play a major in the development of the petrochemical industry. International conglomerates will not invest in any major manufacturing ventures due to the security concerns and the high risks involved.
14 | Polymer & Packaging
Q. What is your assessment of PakistanÂ’s packaging industry? A.
Pakistan has easy availability of cheap labor and is strategically placed. Packaging is one of the major growth areas where new and innovative products can be introduced. Particularly interesting areas would be bio-based plastics and smart packaging - such as biodegradable and self-indicating packaging materials. To promote environmental health, resource conservation as well as more sustainable way of life, Pakistan must promote the use of bioplastics.
Q. You claim that it is the need of time to ensure effective communication between industry, universities. What kind of development institutes do you feel need to be set up in Pakistan? A.
Seeing the success stories of Bolton University UK and MIT University India, I believe educational institutes in Pakistan should also develop their own technology. Pakistan needs to invest in R&D and set up a Centre of Excellence. The government as well as industries should invest on research institutes that can not only find solutions to the problems faced by industry but also develop new material suited to their specialized needs.
Naphtha NEEDED BUT IGNORED By Riaz Andy
For the booming plastic industry, Pakistan, with its population of around 180 million constitutes a significant market. Unfortunately, while the industry is considered to be the largest manufacturing sector in the developed world, the performance of the plastic industry is not optimal in Pakistan. Yet, the industry has managed to provide more than 0.7 million job opportunities and contributes Rs30 billion towards local revenue generation. At 4kg per annum, the per capita consumption of plastic in Pakistan is the lowest in the South East Asian region. According to Naseer Hayat Maggo, CEO of Al Riaz Industry, nonavailability of units for producing raw material for plastic, or a cracking plant for producing polypropylene, polyethylene, polycarbonate and ABS resin is the main reason for the low per capita consumption of the material. He further added that Pakistan has to import these raw materials from the Middle East, which increases the cost of production and unit price in Pakistan. And the import bill seems to be moving northward: during July Jan of the current fiscal year, Pakistan imported plastic materials worth Rs79 billion, against Rs72 billion imported during the same period last year. Naphtha is one such raw material of which the low production and lack of refining capacity has put the local plastic industry at a disadvantage. There are four major naphtha producing refineries in Pakistan: PRL (Pakistan Refinery Limited), NRL (National Refinery Limited), ARL (Attock Refinery Limited) and BYCO (Formerly Bosicor). Together, these produce approximately one million tonnes of naphtha per annum, which is largely exported due to the absence of naphtha cracker units in Pakistan. The Commercial Counselor of Pakistan, Dr
Iqbal Thaheem highlighted that Japanese buyers imported naphtha worth US$270 million from Pakistan in the fiscal year 2011. This amount could have been much higher if the country had more naphtha producing plants or a naphtha cracking plant. Adding to this, naphtha imported from pakistan is processed in South Korea and Singapore before it reaches Japan. Given the great demand and immense potential for naphtha usage in Japan, it was suggested that the government encourage the Japanese private sector to set up a naphtha processing plant in Pakistan. This step would reduce the cost of doing business for naphtha importers in Japan, and would also allow local refineries to reap profits from exporting refined naphtha products. The vision did come close to being implemented in 1970 when Japan consented to build a naphtha raw material producing plant which using sugarcane molasses as feedstock. Unfortunately, according to Mr. Ehtesham-uddin, Chairman of Korangi Association of Trade and Industry (KATI), subsequent to nationalization, the project went into the doldrums and nothing related to it has materialized so far. For a plastic industry growing at a rate of 15% per annum, the country needs one million tons of plastic granules. Industry experts believe that though this seems like a magnanimous amount, it still does not reflect Pakistan s true potential because the packaging industry still relies on paper and cotton. Just the provision of raw materials for the plastic industry can extend benefits to other sectors of the economy as well, such as the market for electronic gadgets, highend cars and house hold utensils. It s not that human resources are a problem
for Pakistan. Backed by a large population of youth, ours is a country that has produced battery-charged cars for the Canadian market! As for technology, Pakistani companies are now producing biodegradable plastic bags with relatively new but eco-friendly technology. For further value addition in the plastic industry of Pakistan, Dr. Thaheem suggests the country have a naphtha cracking plant of its own to switch from exporting raw cotton and cotton yarn to more fabrics and garments. Besides, the global textile industry is also advancing further in the technology arena, with Japanese textile tycoons, Toyobo and Teijin, developing new products for which most of the raw material comes from petroleum products. Needless to say, it is important that Pakistan s textile sector is benefits from the Japanese technology. However, the humungous investment of around $1 billion required for a naphtha cracking plant has put the Board of Investment (BOI) in a tight spot. Regardless of the heavy cost, one has to understand that the local plastic industry has immense potential to grow. Having a naphtha cracking plant could be beneficial for setting up downstream resin plants, which would then provide an adequate supply of raw materials to various industries and save significant foreign exchange. Unfortunately, despite the tremendous advantages of a naphtha project, it seems the Planning Commission of Pakistan has not done much to analyze the pros and cons of such a large-scale investment from a costbenefit perspective. It is lamentable that like many other industries, the plastic industry may also fall prey to the economic vulnerabilities arising out of the political instability in the country. Polymer & Packaging | 15
EVOLUTION OF PLASTIC PACKAGING IN PAKISTAN by Aamir Bin Munir
Plastic is quite a useful packaging material. It s cost effective, moisture and air proof, gives a longer shelf life for packed products, has an aesthetic appeal, and provides a good barrier for preserving aroma and flavor of packed goods.
companies started to produce quality packaging products that met the required standards of multinational and national companies. Some of the noteworthy pioneers include Tripack Films, Metatex, Packages Flexible Unit and Converters.
One genre of plastic packaging worth mentioning is flexible plastic packaging, which is has been around for over sixty years. Plastic film constitutes a major raw material for this form of packaging, with several kinds of films having different characteristics and barrier properties.
Quality of plastic packaging in Pakistan
The most commonly used films are BOPP & CPP (Polypropylene), PET (Polyester), PE (Polyethylene), PVC (PVC Rigid, PVC Shrink & PVC Blister) and cellulose. BOPP is mostly used for packaging snacks while PET is more suitable for packing biscuits. Where these films are used as skin film, PE and CPP are mostly used as laminates having great sealing properties that prevent leakage of air, nitrogen or liquids. PVC, on the other hand, is mainly used for high quality shrinkage or blister.
Evolution of flexible packaging Production of flexible packaging started in the US and Europe during the 50 s and was introduced in Pakistan in during the 70 s. Production was still in the nascent stages in Pakistan during the 70 s and 80 s. It was during the 1990 s that flexible packaging saw a major turnaround when new machines from Taiwan were introduced in Pakistan. With the help of investment in high-tech machinery and lab equipments, local printing and packaging
Despite the efforts put towards uplifting the plastic packaging industry, Pakistan still faces a huge gap in producing A or A-Plus quality packaging. As a result, printed film has to be imported from Malaysia, UAE, Oman, Saudi Arabia, Indonesia and some other countries. Yet, in terms of growth of the industry, Pakistan is among the top five countries (the others being China, India, Malaysia and Brazil) with an average annual growth rate of about 17 percent.
One can count on their finger tips the number of local printing and packaging companies producing A category plastic. Even though most companies try their utmost to do high quality jobs, a lack of lab equipments and trained professional human resources puts them at odds. On the other hand, many Pakistani companies, especially in Karachi, are run by owners as opposed to qualified professionals which poses another, albeit secondary, short coming for the industry.
The scope for plastic packaging There is tremendous scope for plastic packaging in Pakistan. Not only is there a huge local market, but African countries and, regional
peers of Pakistan like Sri Lanka, UAE, Afghanistan and Central Asian States also offer a lucrative market that can be captured by local manufacturers. However, this target can only be achieved if logical road maps are made, technical education is provided and long-term government policies are made for the awareness of duties and taxes remission for exports. Appointing capable consultants and advisors can help mitigate the problem, as they can help prioritize business goals, helping companies make significant profits.
Need of a strong platform Unlike other countries, there is no exclusive platform in Pakistan for the plastic packaging industry. Other countries, such as the US, have strong associations for protecting the interests of the local plastic industry, such as the Gravure Association of America (GAA), which is the biggest platform in the world on a countrylevel helping member companies and monitoring local government and policies affecting their plastic industry. There is dire need for a similar platform in Pakistan for the packaging industry, whereby this body will be responsible for helping the government draft long-term policies related to the industry, be wary of business saturation, help member companies get special incentives from the government and also from financial institutions with respect to working capital and other financial needs, arrange training programs, business trips and trips to international exhibitions and trade fairs, and conduct international seminars and workshops.
Global Industry Exhibitions Arabplast 7-10 January 2013 Dubai
Plastic Japan 10-12 April 2013 Japan
Plast Expo 2013 19-22 June 2013 Morocco
IPF Bangladesh 23 - 26 January 2013 Bangladesh
Plast-Ex 14-16 May 2013 Canada
InterMold Thailand 20-23 June 2013 Thailand
Sino-Pack 4-6 March 2013 China
Chinaplas 20-23 May 2013 China
Plastasia 22- 25 February 2013 India
Plastimagen Mexico 12-15 March 2013 Mexico
RosuPack 18-22 June 2013 China
Taipei Pack 26-29 June 2013 Taiwan
Polymer & Packaging | 17
A Journey from Toys to Roads by Akbar Baseer Khan
Those days have long passed when the use of plastic was restricted to household items and an entertainment asset for children in the form of toys. Thanks to the advent of technology that has redefined the different facets of life and has brought us to a level, when the once clichéd debates related to environment and technology hazards are turning out to be a platform of opportunities. Plastic is present in all contemporary lifestyle. Its versatility allows its usage in packaging, serving, protecting and also in the disposal of consumer goods. And in recent times, the world has also witnessed an off shoot by using plastic in the construction of roads. During the mid-90 s, some researchers began to explore the hazardous affects of plastic in daily life. This activity turned out to be an opportunity for researchers belonging to unorthodox school of thought to work on recyclable plastics and polymers metal replacement. Initially, the notion to avoid plastic as far as possible was largely prevailing in the societies. The polythene used in plastic was considered to be carcinogenic i.e. something that causes cancer, and other forms of plastics were considered to be the cause of respiratory problems, skin diseases, deafness, vision problems, weakened immunity system and many others. However, Dr. Imran Ali, a 18 | Polymer & Packaging
petrochemical professional from Holland currently working at a leading university in Karachi says that with technological advancement in the recent decade, polymer has unnoticeably become a part of day to day life, and the textile goods consumed today use specific type of polymer which in spite of its use, keeps the product soft. The advent of technology has given a new shape to plastic. In Olympics 2012, the Dutch cycling team used a new cycling outfit that has been made by a company named DSM using UHMWPE fiber. The outfit was designed ensuring safety of the cyclist in these races as the speed can accelerate to 110 kilometers per hour. This outfit was designed with an emphasis to secure body areas that are more vulnerable to accidents in the competition and are produced by using world s strongest fiber named as Dyneema . The DSM claims that Dyneema is 15 times stronger than steel, have light-weight, flexibility, and extreme durability and also omits the body heat which precisely makes the outfit easy-to-wear. The versatility of plastic is not only restricted to the textile sector. The idea to use polymer in roads was floated in mid 90 s by the researchers and ever since it has been rigorously implemented by various countries around the world. However, the countries going from the development stage similar to our subcontinent, do not take adequate
measures to promote the use of recycled plastic which often leads to environmental issues and scarcity of plastic. In India, polymerized bitumen has increased three to four years life of roads, to at least another year or two. Although building a road with plastic costs approximately 3 percent more than constructing a conventional road, but in the long run, roads built with polymerized bitumen cost less because its wear and tear expenses are much lower. Seeing the successful implementation in the neighboring country, the use of polymer in Pakistan s scenario can be revitalized by making roads with the help of recycled polymer fragments. If Pakistan converts plastic waste into powder, and mixes 3 to 4% plastic with bitumen, it would increase the melting point of the black viscous mixture of hydrocarbons, hence, making the roads to retain its flexibility during winters. This would result in longer life of the roads especially in the cities exposed to extreme weathers and will also solve environmental issues as reuse of plastic preserves the environment, saves energy and reduces pollution. Countries in the subcontinent are densely populated and consume large quantum of products which abundantly generate plastic waste material on daily basis. For Pakistan, reusing generated plastic waste seems to be
It is the role of the Planning Commission of Pakistan to keep this development in to account while planning road projects in the country. The government should allocate adequate budget in the recycling of plastic which in return would provide cheaper and durable roads resulting in to a better infrastructure system. It s high time for the government of Pakistan to realize that the country has recorded one of the hottest temperatures in the world, therefore; plastic roads would be an advantage for Pakistan s extreme hot, cold and humid climate, and will also save destruction in the road infrastructure from torrential rains. It is hoped that in near future the country will have strong, durable and eco-friendly roads which will relieve the earth from all type of plastic-waste and also give a positive input to prevent climate change.
a big problem, and till date the country is unable to overcome the debate that the use of plastic has its limitations. Hence, by having a look on the successful stories of the countries, Pakistan can develop a proper mechanism for the collection of waste and use it for stronger and durable road construction as some parts of the country are exposed to extreme weathers.
Moreover, it should be kept into account that Pakistan wastes a large amount of waste material which should be monitored and used for the development. This would not only increase employment level but will also save the public expenditure of Pakistan.
Growth Prospects For Global Plastic Film and Sheets Market by Irfan Sabir
Owing mainly to the burgeoning demand from end-use markets, competitive advantages over traditional paper and foil packaging and technological advancements, the global plastic film and sheets market is forecast to reach 56.6 million tons by 2017. The biggest contribution factor to this development is changing consumer dynamics in the food and non-food packaging industries. The growing prominence of developing Asian, Middle Eastern and Latin American markets will further accelerate the pace of development. Plastic film, used for packaging both food and non-food products, is the largest sub-sector of the plastics processing industry. With commonly observed usages, such as for packaging food, shrink-wraps, stretch-wraps, carrier bags, garbage bags, heavy-duty sacks and agriculture and building applications, the importance of this material cannot be understated.
Growth dynamics of various plastic film products Changing consumer dynamics and patterns are revolutionizing the food-packaging market, which is witnessing an increased preference for plastic film and sheets over other flexible packaging materials such as kraft paper, aluminum foil and cellophane film. This trend is slowly gaining ground in non-food packaging applications as well, for instance, the increased use of BOPP films in cigarette manufacturing. In fact, BOPP films represent one of the high-
growth segments in the global plastic film and sheets industry. Over the near term, production capacity for BOPP is estimated to expand by 2-3 mln tons, with the Middle East accounting for the bulk of the capacity expansion. This growth rides at the back of rising demand from Asia particularly from China and India and other developing regions such as Latin America and Eastern Europe. It is the stretch film machinery segment that has witnessed exceptional growth in the BOPP film market. On the other hand, cast film continues to make inroads into those application areas that have historically been led by the BOPP film industry. Most of the wide existing gap between BOPP film and Cast PP film has been filled by significant advancements in process capabilities, enhanced resins and improved equipment. Other products warranting attention are the second-generation LLDPE products that are likely to substitute plastics in film and other non-plastics because of their improved properties of greater film toughness, ability to be processed, clarity and lower cost. As for the polyethylene terephthalate (PET) films segment, flat panel displays (FPDs) and packaging applications are leading to robust growth, particularly in developing countries. Spurred by high demand for PET films in Asian countries such as China and India, Asia is witnessing an intense battle between Japanese and South Korean PET films players. And this is a battle to watch out for, since the
emergence of several new players in the Indian and Chinese markets will likely intensify the competition for supremacy even more.
Where does the potential lie? The Asia-Pacific region has immense growth potential and captures the largest slice of the global market, as stated by the GIA research report on plastic film and sheets. Developing markets such as China, India and other countries in the region are rapidly emerging as dominant forces in the global plastic film and sheets industry. With China having replaced the US as the largest producer and consumer in the BOPP film market, the Asia-Pacific region is anticipated to lead the growth in the industry, with a predicted compounded annual growth rate (CAGR) of 5.3% through 2017. With regards to the global plastic films and sheet market, Polyethylene (PE) film is considered the most important products and accounts for the lion s share of the global plastic films and sheet market. Yet again, Asia and Middle East region emerges as the key growth regions for the product. Based on LLDPE swing capacity, PE capacity in Asia is expected to expand swiftly. On the other hand, polypropylene (PP) films, considered one of the most versatile and low cost barrier films in packaging and non-packaging markets displays high potential and is slated to grow at a vibrant pace.
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A Journey Untold: Pakistan s Plastic Packaging Industry by Saleem Mohammad
Packaging plays a vital role in terms of protection, storage and hygienic handling of a product and plays a key role in the marketing mix. However, the first 20 years of Pakistan did not see any reasonable activity in the field of soft flexible packaging due to lack of local machines and the high cost of imported machinery. Back in time, expensive wrapper cylinder required to print product wrappers were imported from England but were rejected by industry mainly due to the high costs involved.
products further sped up the pace of local developments.
In 1973, Hermetic Seals became the first company in Pakistan to introduce a basic locally fabricated packaging as well as ink refilling and liquid packaging filling machinery. Although the new technology greatly enhanced packaging capacity of local manufacturing, it was in the 80 s when plastic replaced paper, wood, steel & tin as the main material used in packaging. Simultaneously, a change in consumer preferences, greater awareness of food safety and smart packaging alternatives that increase the shelf life of consumable
In 90 s, several packaging machine manufacturers appeared in the market. This was the time when flexible packaging truly took off which continues to evolve to date. All sorts of commodities, engineering goods, food, cosmetics, pharmacy products, chemicals and others began to be wrapped in flexible packaging. With the introduction of form fill and seal machinery, it became possible to introduce products, particularly food
It was in 1986 that multilane machines were introduced into the local market. It was this change which revolutionized the scope of packaging and transformed packaging houses into large production units. With increasing consumerism, form fill seal machines, vertical and horizontal form fill machines were developed to produce wrapper bags in vertical and horizontal shape.
items, in all strata of society thereby increasing profit margins for companies manufacturing the products. Furthermore, the induction of shrink wrap technology virtually ended the use of corrugated box as packaging material that has made it possible to export made in Pakistan products to countries including Saudi Arabia, South Africa, Nigeria, Bangladesh and others.
PCSIR and the Development of Pakistan s Polymer Industry The department of polymer research It goes without saying that science and technology form the pillar stones for the development of any country, and Pakistan is no exception. Cognizant of this, the government constituted the Council of Scientific and Industrial Research as an autonomous body in 1953, and it was recognized in the report of the Scientific Commission as representing the largest research potential in the country . This institution is of pivotal importance for the industrial development of Pakistan, and is involved in 2 broad functions; firstly, the establishment of national laboratories and institutes for carrying out researches relating
to the industrial utilization of the raw material resources of the country in pure and applied fields; and secondly, the promotion of its scientific effort as a whole. Polymer Research Section of PCSIR Laboratories Complex Karachi
field. The kind of research involved includes technical analysis of raw materials and finished goods. These materials include rubber, plastics, metals, polymer composites, paint, textile chemicals, leather, bitumen, surface coating, rigid and flexible foam, insulating elastomers, concrete pipes metals and stones.
With infrastructure and trained manpower in the field of Polymer Science and Technology, the Polymer Research is an important section of the PCSIR Laboratories Complex Karachi. It provides technical services for industrial growth, assesses export items to see if they meet given requirements, and also produces technologists and scientists in the polymer
Helped by various labs equipped with state of the art equipment, the polymer section offers a wide range of mechanical, physical, analytical, and fire testing technologies for various related materials. Some of the labs include the Rubber Compound lab, Mechanical lab, Polymer Process and Analytical laboratories. In order to ensure that products
Polymer & Packaging | 21
and materials meet all required specifications, tests are carried out under environmentally controlled conditions by highly trained teams of experts in accordance with international standards such as ISO, ASTM, JIS, and BS. Plastic and Polymer Section (PPS) The testing of materials that are extremely sensitive in nature is undertaken by the Plastic & Polymer Section (PPS) of KLC (Karachi Laboratories Complex). An example of the work done by this section is the complete physico-mechanical characterization of rubber used in bearing pads and expansion joints. The expansion of rubber in these products should be specialized to meet the specifications quoted in the standards; otherwise the material would be unsuitable for the use. In addition to these responsibilities, PPS also analyzes the appropriateness of packaging material to see its suitability for food items. A complete compositional picture of the materials is obtained, i.e. identifications and percent composition of organic parts, main polymer and reinforcing agents. Besides this, the PPS also provides consultancy regarding problems related to composition of compounding and usage of end products. Other tasks undertaken by this section include testing of materials used in the construction of buildings and roads, such as evaluating the compressive strength of concrete, testing of road marking paints, cat eyes, water stopper, bitumen / asphalt, etc., and also evaluating
the quality of polymer-based pipes such as PVC, as well as of composite materials used for drainage and sewerage. The division also works on the initial selection and procurement of materials on the basis of technical information, such as the selection of iron/steel for construction, tiles, marbles etc. Besides these, testing of materials against parameters given in the Basel Convention and providing advice regarding recycling and reusing plastic waste are other important functions the PPS performs. Needless to say, a division of such vital importance has to play a pivotal role towards research and development, and PPS performs this function quite aptly. It provides expertise in applied R&D related industrial problems, such as the development of fire / flame retardant thermoplastic material for electrical industries, setting of concrete composition for compressive strength, and the development of polymer for local industries. Recent Endeavour Thermo Plastic Flame Currently, the Plastic and Polymer Section is involved with a project related to thermo plastic flame/fire retardant materials, with emphasis on properties such as resistance, chemical inertness and flame-proof characteristics. This product will be free from Halogen and Low Limiting Oxygen Index (LOI), and will be compliant with RoHS Environmental Regulations and will be listed on the UL/ FM. The materials used will be thermoplastic polymer such as polycarbonate (PC), acrylonitrile butadiene styrene (ABS),
polypropylene (PP), polyamide (PA), polyimide (PI) etc. Further details related to this product are mentioned below. Applications: · Electrical, connectivity, fixtures and accessories · Heat ventilation and air conditioning (HVAC) · Telecommunication · Electronics based equipments, devices and accessories · Fire detection alarm and suppression system (FDAS) Standards that will be met: · UL- 94 (Underwriter Laboratories) · FM (Factory Manual) · RoHS (Restrictions of Hazardous Substances) · Halogen Free Validation · Physico-mechanical parameters like tensile strength, percent elongation, flexural strength, modulus of elasticity · Impact strength · Heat deflection temperature (HDT) · Softening point · Working temperature · Flammability · Material characterization on the basis of quality and temperature · Chemical and volume resistivity Indeed, this product will be a valuable contribution of the PPS towards the development of the country s plastic and polymer industry.
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