Modern Plastics & Polymers April 2013

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9April 2013 | Modern Plastics & Polymers

t first, the Union Budget 2013-14 appears to have treaded rather

cautiously by focussing mostly on fiscal fitness. To begin with, the

Budget emphasised two specific areas – infrastructure development and

Micro, Small and Medium Enterprises (MSMEs) – as the key to fuel

the growth of the Indian economy.

The Finance Minister’s proposal for payment of ` 9,000 crore as the first

instalment of the balance of Central Sales Tax (CST) compensation is a step in

the right direction. Although full-fledged implementation of the Goods and Services

Tax (GST) is still months away, the Budget recommendation to extend MSME

benefits for a period of three years after moving to a higher category is well timed

and meets the need of the hour. This should also motivate home-grown emerging

enterprises to take the next big leap in their growth trajectory.

The exemption of 15 per cent in investments of more than

` 100 crore to set up plant and machinery should further galvanise

industrial activity in the country. In addition, the commitment to

increase availability of low-cost funds to the infrastructure sector

augurs well for higher investments.

Furthermore, the Budget discussed the National Skill Development

Programme and a ` 200-crore outlay to fund ‘technology for

common man’. Both of these are essential to expand the

country’s growth by keeping in mind employment and the

abundance of educated youth and their aspirations. Other

noteworthy initiatives in this Budget include measures to

increase investments in manufacturing and infrastructure,

MSME growth and capital market development. These

initiatives should also benefit the plastics industry either

directly or indirectly.

Although this Budget lacks the fireworks of its previous

editions, its proposals can be considered as the best possible step

by the government in the current complex geo-political climate.

Perhaps the government missed an opportunity in this Budget to

give a greater thrust to various financial policies. However, only

effective implementation of this statement of the government’s

action plan would bring results in the current fiscal.

All said and done, at a time when the whole world is looking at

emerging nations like India to propel the global economic engine, it

is imperative for the government to ensure that policy announcements

stay on track. The industry, on the other hand, needs to leverage

the advantages offered in this Budget to take the India success story

a notch higher.

ABudget 2013-14: Financially sound reverberations?

Editorial Advisory BoardA E Ladhabhoy

Plastics Technologist

Dr Sushil K VermaFormer Director General, CIPET

Dr Swapan K DharaRegional Technical Head,

Basell Polyolefins India Pvt Ltd

Mohan K JainMD, Indoplast & Past President, AIPMA

P P KharasChairman, Ecoplast

Raman M PatelChairman, Industrial Products Mfg Co

Vijay MerchantPresident, Polycraft

Manas R [email protected]

EDITORIAL


CONTENTS

April 2013 | Modern Plastics & PolymersApril 2012 | Modern Plastics & Polymers

Note: ` stands for Indian rupee, $ stands for US dollar and £ stands for UK pound, unless mentioned otherwise

Automation Trends 78 Operator-friendly machines: Increasing production, reducing costs

Energy Management 80 Reducing energy consumption in plastics processing: Maximise output,

minimise consumption

Policies & Regulations 82 Green packaging norms: Reducing the carbon footprint

Strategy 84 Plastic packaging: Applications that enhance product shelf life

Tips & Tricks 86 Guidelines for efficient equipment: Ensuring safe and efficient processing

Event Report 92 Indo-German International Seminar: Redefining the future of

automotive plastics

94 Engineering Expo Aurangabad 2013: Exhibiting Aurangabad’s

unparallelled potential

96 Engineering Expo Aurangabad 2013 – Panel Discussion: Gauging

Aurangabad on the critical parameters

REGUL AR SECTIONSEditorial ................................. 9

News, Views & Analysis ...... 22

Technology & Innovation .... 30

Technology Transfer ............. 32

Projects ................................. 88

Tenders ................................. 89

39

Event List............................. 90

Book Review ........................ 97

Products................................ 98

List of Products.................. 106

List of Advertisers .............. 108

Injection moulding ................40

Innovative injection moulding ...42

Lightweight solutions for

automotives ...........................44

Interface:

Hitesh R Shah .............47

Praveen Sharma ............48

Roundtable ............................50

Special Focus

57Engineering thermoplastics ........................ 58

R&D initiatives ............................................ 60

Interface:

Dr Harindu Vyas ................................ 64

Satendra Kumar .................................. 66

Roundtable ................................................. 68

Filament wound composite pipes .............. 76

Green shoots .............................................. 69End-of-life applications of recycled plastics ......70Interface:

Vishal Jasrapuria ................................. 72

Dr Prakash Mahanwar ....................... 74

In Conversation With 36 Bipin Shah

President, Plastindia Foundation

Facility Visit 54 Toshiba Machine (Chennai) Pvt Ltd:

Creating exemplary manufacturing processes

Insight & OutlookEngineering plastics

Injection Moulding

Details on pg no. 90

Special Focus: Rotomoulding Insight & Outlook: Plastics in Building & Construction

Highlights of Next Edition

Cover photo courtesy: ARBURG


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NEWS, VIEWS & ANALYSIS

22 Modern Plastics & Polymers | April 2013

SACMI to manufacture Negri Bossi machines in India Italy’s SACMI Group is setting

up a manufacturing plant in

India. The company has been

assembling Negri Bossi injection

moulding machines in a rented

space in Ahmedabad since 2009.

However, when it opens a new

plant at the beginning of 2014,

it will graduate from assembly to

local manufacturing. “India is a

huge market with about 3,500–

4,000 presses sold annually. We

could grow in this market locally

as well as in the neighbouring

(South Asia) market and also

in the Middle East,” said

Selvakumar M, Regional Sales

Manager, SACMI Engineering

(India) Pvt Ltd.

The company has already

supplied about 100 hydraulic

presses, with clamping forces

ranging from 550 to 1,000 tonne,

in the Indian market. This year

the company is starting to sell

the Vector Hybrid press line in

India, with a CAN bus controller.

The company is targeting sales of

70 presses in 2013.

Plastindia Foundation provides platform for WIINTECH

On March 4, 2013, Plastindia Foundation held an

interactive session with WIINTECH to boost the

growth of small and medium entrepreneurs in India.

WIINTECH – Worldwide Intercluster Initiative

for New materials and processes focused on clean

TECHnologies – links leading European world clusters

belonging to the chemicals and materials sector and

combines their expertise with the purpose to address

the complete range of technological and business topics

in the clean technology space. The delegation addressed

the dire need for technology development, innovation

and knowledge in the chemicals and materials sector

in India.

Speaking on the occasion, Bipin Shah, President,

Plastindia Foundation, said, “We have received an

overwhelming response from the industry. This is the

first exposure of Plastindia with WIINTECH and we

are certain that the industrial tie-up will evolve after

this fruitful day. Based on the network’s success stories,

we would like to build bridges based on this method,

approach and experience in the plastics industry.”

The network links eight European leading world-

class clusters belonging to the chemicals and materials

sector such as Poolnet (Portugal), Plastival (Spain),

Chemie-Cluster Bayern (Germany), Clusterland

(Austria), Plastipolis (France), Proplast (Italy), Veneto

Nanotech (Italy), NEPIC (UK) etc. There are more than

2,500 companies and research centres working in the

materials and clean technologies sectors.

With this initiative, Plastindia created a qualitative

and quantitative platform for SMEs to work together,

derive motivation and explore progressive technology

and mass volume production areas in the international

arena. WIINTECH aims to initiate opportunities for

business development between European clusters and

Indian partner organisations, which include setting

up research & development partnerships, encouraging

technology transfer and trade arrangements. The

network’s focus is on global expanding markets in clean

technology such as renewable energy, high-efficiency

building & construction, recycling, green transportation,

water & air treatment, waste management etc.

Sweta M Nair

Alok Masterbatches expands in India, plans for international growthAlok Masterbatches Ltd is setting up its fifth production facility in India.

The facility will cater to customers in southern India and Southeast

Asia. The plant, in the southern Indian city of Ranipet, will open in

April with an annual capacity of 20,000 metric tonne. The 60,000 sq

ft plant will produce a wide range of masterbatches. This region, which

has a growing auto industry, is a big market for compounds.

The plant will give the company an overall capacity of 60,000 metric

tonne annually. Alok has four plants in India, including two in Delhi,

plus a plant that opened in Paraguay last year. Alok is considering

additional international growth. The company plans to have a plant

either in the Middle East or in Vietnam in the next couple of years.

This is because Vietnam is also offering incentives to foreign investors

setting up plants to cater to the European market.

Aliaxis buys majority stake in Indian pipe maker Ashirvad Large global pipe maker Aliaxis

SA has bought a majority

stake in one of India’s largest

plastic pipe and fittings makers,

Ashirvad Pipes Pvt Ltd,

expanding its business in the

fast-growing Indian market.

“We are very pleased to acquire

a majority stake in one of the

leading Indian plastic pipe and

fittings players. The joint venture

will give Aliaxis significant

exposure to the Indian building

and sanitary market and will

allow Ashirvad to access Aliaxis

global manufacturing network,

know-how, product expertise and

broad product range,” said Yves

Mertens, CEO, Aliaxis Group.

With this joint venture,

Ashirvad will reach to the next

level in terms of range of quality

products and technologies.

Ashirvad has production capacity

of 70,000 metric tonne a year, with

more than 2,000 employees and

a network of 1,200 distributors

and 14,000 dealers. Ashirvad

mainly manufactures PVC pipes

and fittings in the building,

plumbing and agricultural

markets. It also develops PVC

column pipes that are used in

submersible boreholes to a depth of

1,000 ft.

Members of Plastindia Foundation along with representatives of WIINTECH



PVC prices on a high in Southeast Asia due to soaring demand Price hikes for PVC have surfaced

this week in Southeast Asian countries

with many regional producers

adjusting their local and export offers.

Apart from the push from higher

input costs, the healthy demand

from the region has given sellers

real support to ask for increases. At

the same time, many buyers find

domestic prices more competitive

and prefer to meet their requirements

from local markets. In Indonesia,

local PVC prices have gone up by

$ 50–70 per tonne as compared to prices

prevalent in February.

Sumit Dhingra, Director, Dhingra

Polymers, said, “Now that demand is

improving and supply appears to remain

limited in line with the tight availability

of VCM feedstock, the PVC market is

likely to maintain its firm trend for a while.

Demand has improved in the local market,

and we are receiving more inquiries from

buyers.” The industry believes that this

price rise is due to strong local demand

and high feedstock costs which

have also caused tight supply. As it

was the case last month, producers

are allocating a limited amount for export

markets and are planning an increase

of $ 40 per tonne for PVC cargoes

with the April shipment. Meanwhile,

the same producers have revealed

their export PVC offers with

increases to the region, blaming high

feedstock costs.

Anwesh Koley

Plastic packaging to ride high on growth projectionsThe Associated

Chambers of

Commerce and

Industry of India

(ASSOCHAM)

has projected that

the market size

of the cosmetics

industry, which is

currently estimated

at ` 10,000 crore,

will double to be worth ` 20,000 crore by 2014 due

to emergence of a young urban elite population with

rising disposable incomes and increase in working

women looking for lifestyle-oriented and luxury

products. This is expected to boost the cosmetics

packaging industry as the primary cost of cosmetics

is packaging. D S Rawat, Secretary General,

ASSOCHAM, said, “Plastics companies have started

going for rural expansion and are offering specialised

products to generate revenues from all the corners of

the country. This will give momentum to cosmetics

packaging which is almost 70 per cent of the price of a

cosmetic product and has become highly evolved over

the years.”

Products falling under the price range ` 50–200

are in the mass-market category. The middle market

price can range from ` 200 to ` 1,000. In the

high-end market, pricing can range from ` 1,000

to about ` 10,000. Finally, there is the premium

range of products where the pricing can touch up

to ` 50,000. The industry has mainly been driven

by improved purchasing power and rising fashion

consciousness among people as well as industry

players spending heavily on promotional activities

to increase consumer awareness.

Anwesh Koley

O ver 180 professionals

representing 90 plus companies

across India were part of the

Open House organised by Rajoo

and Bausano. At this event,

there were live demonstrations

of a range of machines that

redefine manufacturing of

h igh-per formance p ipes .

The company stated, “As

expected, the star performer of

the show was the Twin Screw

PVC Pipe Plant running at

130 kg/hr (pipe outer diameter

of 28.6 mm; pipe thickness of

2.12 mm). Most visitors have

not been an eyewitness to such a

spectacle – a working PVC Pipe

Plant that too which started

from scratch in just under 5

minutes with less than 4 kg

scrap. Further, Rajoo successfully

showcased its indigenous raw

material compound for the

PVC machine. With this, Rajoo

became the first Indian company

to successfully demonstrate

a PVC pipe machine at an

Open House.”

Further, the Twin Screw

PVC Pipe Plant enthralled the

audience when it was being

operated at a capacity of 1,000

kg/hr, never before seen in India.

The pipe OD is 400 mm and

wall thickness is 16.2 mm. With

this Open House, Rajoo also

marked its strong penetration

into the market of drip irrigation

pipe plants. The demonstrated

line was running at 170 kg/hr

with a line speed of 80 mpm,

200 dripper insertions/min, with

the wall thickness being 0.7 mm.

The success of this pioneering

initiative emphasises the

company’s belief in innovation –

be it in product, in technology or,

as in this case, in approach.

Avani Jain

D S Rawat

Pipe manufacturers converge at India’s first-ever multi-product Open House of Rajoo



Vinyl India 2013 to be held in Mumbai With strong stimulus given to

infrastructure, agriculture and housing,

and India’s gross domestic product

growth of over 7–8 per cent in medium

to long term, the vinyl industry in

India is poised to double every five

years. Providing a further impetus and

adding to this growth, Vinyl India

2013, which is the 3rd International

PVC & Chlor-Alkali Conference,

is being organised by ElitePlus

Business Services Pvt Ltd (EPBS)

and Chemicals & Petrochemicals

Manufacturers’ Association (CPMA),

All India Plastics Manufacturers’

Association (AIPMA) and Plastindia

Foundation.

The two-day conference covering

the entire vinyl chain will be held

on April 11–12, 2013, at Hotel

Grand Hyatt, Mumbai. Over 25

countries are expected to participate

in this international event. The event

will bring together industry leaders

and specialists to examine the fast-

growing Indian vinyl industry. It

will feature many important sessions

focussing on the global scenario, the

future of polyvinyl chloride in India,

feedstock to polymer, machinery –

compounding, processing & material

handling, recent developments on the

new generation of polyvinyl chloride

compounds and more. The conference

is expected to attract nearly 600

industry experts and players (Indian

and overseas) from the vinyl industry,

including raw material providers,

compounders, channel partners of

domestic resin manufacturers, traders

and indentors, additives/plasticisers/

stabilisers suppliers, downstream

processors (pipes, calendaring, profiles,

fittings, blow moulding) machinery

suppliers, analysts, consultants and

senior managers, logistics and shipping

companies, members from associations

and trade bodies (eg CAMA,OPPI,

IPI, MCCIA), international bodies

and council members.

Avani Jain

AIPMA organises first-ever job fair in MumbaiThe All India Plastics Manufacturers’

Association (AIPMA) recently

conducted a job fair in Mumbai, a first

of its kind by any polymer association

in India. The objective was to serve the

industry in the manpower arena with a

non-commercial, service-oriented and

cost-effective model.

The first edition saw the presence of

Dr Ashutosh Gor, President, AIPMA,

and Hiten Bheda, Secretary, AIPMA. Dr

Gor spoke on the future of the industry,

while Jayesh Rambhia, Chairman

Plastivision Arabia, AIPMA, addressed

the audience about the upcoming

events of the Association. Heads of

institutions (eg MIT Pune, MIT

Aurangabad etc) graced the inauguration

ceremony. Support for this event was

also extended from Central Institute of

Plastics Engineering and Technology

(CIPET), L D College of Engineering

(Ahmedabad) and others.

The job fair had 14 visiting employer

companies participating from segments

such as raw materials, compounds/

additives, injection moulding, blow

moulding, rotomoulding, extrusion

(pipe & blown film) and machinery.

Companies such as Finolex Pipes, Borghi

Brush Machinery (Italy), Plasticon

UK, Bajaj Steel Industries, Kuloday

Technopack and others participated as

visiting employers. The fair floated 80

job openings, of which 90 per cent job

openings demanded a working experience

of 2–15 years. AIPMA addressed the

job requirements and matched befitting

candidates with employers. At the event,

182 interviews were conducted and

17 candidates were selected for a second

round of interviews; some even received

spot offers.

Following the overwhelming response

of this event, AIPMA is likely to continue

having such job fairs frequently at various

locations across the country.

Dr Asutosh Gor, President, AIPMA, lighting the lamp with AIPMA members Kishore Sampat,

Chairman, Placement Cell and Harshad Desai, Chairman, Incubation Cell. Also present at the event were Jayesh Rambhia, Chairman,

Plastivision Arabia 2014, and Ashok Mukherjee, Managing Committee Member

Total launches thinner film for flexible packaging Flexible plastic packaging converters will

be able to reduce film width by up to

25 per cent thanks to a new metallocene

polyethylene film material, developed by

Total. The Lumicene Supertough 32ST05

is a downgauging breakthrough for

multi-layer structures and can be used in

compression packaging, such as for heavy

mattresses and lightweight diapers. It can

also be used for deepfreeze and lamination

films, and highly demanding shrink

applications, eg glass bottle unitisation.

“The downgauging story is a never-

ending quest to push the thickness limits

of packaging down. Where these limits

of downgauging are reached, Supertough

32ST05 steps in to give the necessary boost

in toughness to overcome the thickness

barrier,” said Carl Van Camp, Senior VP

– Polymers Division. The material can

be used to make films on extrusion or

conversion lines.



Global rigid plastic packaging market worth $ 161.11 billion in 2013

Driven by growth in emerging markets, a

new report by Visiongain estimates that

the global rigid plastic packaging market

will reach a value of $ 161.11 billion in

2013 and will be driven by growth in

the developing markets, in addition to a

number of favourable consumer trends.

According to the report Global Rigid

Plastic Packaging Market 2013–2023,

“Emerging markets will be characterised

by clear maturity and strong economic

growth, which will increase the quality

and quantity of consumer purchases. In

addition, low labour costs will provide an

incentive for companies to expand the

scale of their operations in these markets.”

To this, Divakar Vyas, Senior Manager

(Sales), Windsor Machines Ltd (Injection

Moulding Division), added, “The rigid

packaging industry in India is growing

at the rate of 16–20 per cent per annum.

The growth in this sector is mainly driven

by food, pharmaceuticals etc. At present,

the focus in the segment is to provide

lightweight and recyclable solutions.”

Avani Jain

Oriental Energy to build the first UNIPOL Polypropylene (PP) unit in East ChinaOriental Energy has signed a license

with Union Carbide Chemicals &

Plastics Technology LLC, a wholly

owned subsidiary of The Dow

Chemical Company, for UNIPOL™

PP Process Technology for a 400 KTA

PP plant. The plant will produce

homopolymers, impact copolymers and

random copolymers using propylene

sourced from their upstream propane

dehydrogenation unit.

Speaking about this development,

Tracy Cleckler, Global Commercial

Director, Dow Plastics Licensing &

Catalysts, said, “With UNIPOL PP

Process Technology, Oriental Energy

will produce PP resins that will give

fabricators the opportunity to produce

PP products that are lighter, clearer

and cleaner, properties PP customers

are always seeking. Oriental Energy

will also be able to make PP resins

that allow fabricators to run their lines

at a faster rate, benefitting from the

higher melt flow capability of some of

the UNIPOL product grades.”

The plant located in Zhangjiagang

in Jiangsu province will be the first

Dow UNIPOL PP unit in the East

China coastal area, the centre of the

Chinese PP market. There are currently

48 operating lines worldwide using

UNIPOL PP Process Technology from

Dow Performance Plastics Licensing

and Catalysts. The UNIPOL PP Process

Technology is an all gas-phase process

for producing the broadest range of PP

resins. Its simple design is consistent

in terms of product quality and energy

efficiency, requiring no equipment

for handling, separating or recycling

solvents. The system’s fluidised-

bed reactors and high-performance

CONSISTA™ and SHAC™ catalyst

systems give manufacturers the

flexibility to produce homopolymers,

random copolymers and impact

copolymers.

Four distinguished individuals who have

made outstanding contributions to the

plastics industry will be honoured by the

Society of Plastics Engineers (SPE) at

next month’s SPE ANTEC® 2013.

The International Award, Business

Management Award, Education Award

and Research/Engineering Technology

Award will be presented to the four

individuals as part of the Society’s

Annual Awards Program at the SPE

Celebrates Banquet on April 21, 2013.

Benny Freeman, the Richard B

Curran Centennial Chair in Chemical

Engineering at The University of

Texas at Austin, will receive SPE’s

International Award, its top honour

that recognises lifetime achievement

in the plastics industry. The Business

Management Award will be presented

to Tim G Taylor for his achievements

in management with Chevron Phillips

Chemical Company. Honouring

academic excellence, Dr Robert

Y Lochhead who is the author of 300

scientific papers and 22 patents, some

for polymers that are used extensively

in topical delivery of therapeutics

and in cosmetics, will be presented

with the Education Award. In a

plastics career of more than 36 years,

Dr Robert R Gallucci, Chief Scientist,

SABIC Innovative Plastics at Mount

Vernon, Indiana, has developed many

new thermoplastic products, often

using extruder chemistry and polymer

blend compatibilisation. Recognising

his contribution in this field, he will

be presented with the Research/

Engineering Technology Award.

The upcoming Annual Awards

Program will take place on April 22–24

at the Duke Energy Convention Center

in Cincinnati, Ohio, USA.

SPE to honour achievements of industry leaders at ANTEC® 2013

Benny Freeman Tim G Taylor Dr Robert R Gallucci Dr Robert Y Lochhead

TECHNOLOGY & INNOVATION


New VacuTran breaks parts-per-million WVTR measurement barrier

The launch of VG Scientia’s new

VacuTran enables Water Vapour

Transmission Rate (WVTR)

measurement of barrier layers to

better than 10–6 g/m2/day and

simultaneous O2 permeation to

better than 10–3 cm3/m2/day. The

new VacuTran is an innovative,

time-saving, vacuum-enabled

membrane permeation measurement instrument that heralds

the next generation of ultra-sensitive membrane transmission

measurement by advancing detection levels by a factor of 50–100

compared with the one-part-in-ten-thousand measurement

capability of the current generation of instruments. The advances

in time-saving performance and higher sensitivity are significant,

with this breakthrough instrument featuring not only a first in

WVTR measurement that exceeds the specification requirements

but also the welcome reduction in results turnaround to days

rather than weeks or months.

VacuTran is a step change in order of magnitude for developers

and manufacturers involved in ultra-high barrier layer research

because until now there has been no commercially available

instrument that can measure WVTR to these very low levels or

measure WVTR and oxygen transmission rate simultaneously.

This is of particular relevance to organic light emitting displays,

organic photovoltaic devices and organic field effect transistor

device markets in the plastic electronics industry.

New NCF series super-tangential granulators from Conair require less floor space, deliver more versatility New NCF series super-tangential

granulators from Conair have

footprint dimensions that are at

least 30 per cent smaller than many

other granulators with similar

capabilities. The cutting chamber

configuration is ideal for handling

lightweight bulky parts (eg bottles)

and produces clean uniform

granulate from runners and small

parts. Different hopper designs and rotor/knife choices are

available to maximise performance with a wide variety of scrap

types. Four different models feature 8-inch (203-mm) diameter

rotors in widths of 10, 14, 19 and 24 inch (240, 360, 480 and

600 mm) and deliver standard maximum throughputs ranging

from 68 to 205 kg. The smallest unit is powered by a 5-hp

motor, and the three larger sizes have 7.5-hp motors with

options up to 15 hp. Standard rotor speed for the NCF 810 is

260 rpm, and standard speed on the larger models is 400 rpm,

although rpm of 260, 400 or 840 can be specified on any of the

granulators to increase capacity, improve regrind quality and/or

minimise energy consumption.

A tilt-back hopper and drop-down screen cradle provide

easy access to the cutting chamber for maintenance and

cleaning. These features contribute to increased productivity

and reduced downtime. An optional sound attenuation package

also makes the NCF series quieter than other small granulators.

The super-tangential chamber design ensures that the rotor

grips bulky scrap on the downward stroke, drawing the scrap

into the knives and preventing it from bouncing on the rotor.

Standard tangential and straight-drop in-feed configurations

are also available. The rotor itself can be open with three rows

of double-angled knives for a clean scissors cut with minimum

heat generation. For tougher materials, a solid rotor can be

equipped with three rows of up to five cassette knives in a

staggered array. Cassette knives allow for quick and easy knife

changes and minimise downtime for service and maintenance.

The knives require no adjusting to maintain a consistent knife

gap for improved quality.

All new Anchor Culinary Classics® Convertible Containers

Anchor Packaging has launched

a new Culinary Classics® line,

which is now available with a

removable, perforated, hinged

lid. Available in 9” × 9” and 9.5”

× 10.5”, with either one or three

compartments, the six containers

that comprise this product line can handle temperatures up to

230°F; they can be staged under heat lamps or in warming units

and are microwavable. All products in the Culinary Classics®

line are made of Polypropylene (#5PP) and are microwave-and

dishwasher-safe as well as reusable and recyclable. All Anchor

products are BPA-free.

To preserve food texture and quality, the unique design of

the plastic packaging system retains internal temperature while

venting excess steam. The new Culinary Classics® Convertible

Containers feature a cut-proof base, and the removable,

hinged lid offers consumers a convenient dining experience.

With an interlocking base and lid, the containers have good

structural strength that makes them easy to stack and safe for

transportation.

Improved conductive foam from Sekisui Alveo Switzerland-based maker of polyolefin foams, Sekisui Alveo,

has developed an improved version of its Alveobloc conductive

foam, Alveobloc NACO III. Made from laminated foam sheets,

Alveobloc has a uniform closed-cell structure to absorb impact

or pressure. It discharges electrical current and static charges

generated during manufacture and transport, making it suitable

for the transportation and protection of electronic components

that are sensitive to electrostatic discharge. The manufacturer

claims that the conductivity of Alveobloc remains constant,

regardless of relative humidity, unlike competitive foams.

TECHNOLOGY & INNOVATION


New range of environmentally improved films Amcor Flexibles has launched Amcor

Light, a completely new range of

environmentally improved films for fresh

and dairy applications that offer optimum

weight while retaining perfect visual

appearance and sealing integrity. Amcor

Light reduces packaging weight and its

cradle-to-gate carbon footprint is lower

by up to one-third compared to standard

films. Thanks to the high level of film

clarity and the same functional properties

as Polyethylene (PE)-based films, it

satisfies customers’ needs for improving

their environmental credentials and at the

same time guarantees on-shelf appeal.

The Amcor Light range offers solutions

for flowpack as well as for lidding

applications. The main families are OPA

Light (replacing the traditional OPA/PE

films) and OPET Light (replacing the

OPET/PE family of films).

Hasco introduces flexible mould temperature control lineHasco Hasenclever GmbH & Co KG has

introduced a flexible mould temperature control

line. It reduces pressure loss because there are

no sharp angles. TempFlex products cool quicker

than conventional channels embedded in the

mould because the flexible lines are made of

braided stainless steel hose with quadratic cross

sections and change direction through arcs

rather than abrupt corners. Further, the lines are

simple to assemble and adaptable to the desired

groove process.

According to the company, deflecting the

coolant in the new lines through 10 arcs rather

than through 10 conventional 90° deflections

results in 300 per cent less pressure loss. TempFlex

is available in metric and imperial measurements.

These lines can be retrofitted onto existing moulds

plagued by insufficient cooling performance.

Engel unveils largest robot in its classEngel, the Austrian injection moulding machine maker, has

unveiled a new linear robot with a nominal load-bearing capacity

of 120 kg, which the manufacturer claims is the biggest in its

class. The latest member of the

Viper range, the Viper 120 can be

ordered in conjunction with Engel

injection moulding machines as

well as a replacement for existing

equipment or for use with injection

moulding machines by rival brands.

The Engel Viper 120 has a

mould take-off stroke of 3,000 mm

and a reach of 3,550 mm. The use

of laser-welded steel sections has

kept the dead weight of the robots

low, enabling the load-bearing capacity to be raised. The robot

can be fully integrated with Engel injection moulding machines

or can be supplied with an independent control unit that allows

it to work with other machines via a Euromap 67 interface.

Koch extends dosing system range Koch-Technik, the Germany-based

ancillaries maker, has introduced two

new models of its gravimetric Graviko

dosing system. The Graviko machines

dose individual components, such as

grains, powder, ground material or coarse

powders, into the weighing container

using a slider or by volume. Quantities

can be dosed with an accuracy of

0.001 s. Precision dosing coupled with

a gravimetric weighing system produces a control circuit to

ensure that dosing is carried out correctly regardless of bulk

materials used. The patented system offers accuracy with a

tolerance of ±4 grains per 1,000, a level the company claims is

better than any conventional dosing system.

The GK 65 is for machine throughputs of up to 80 kg/

hr. The GK 200 is for machine throughputs of up to 250 kg/

hr. Both are suitable for four dosing stations. Depending on

the throughput of the processing machine, up to four different

components can be processed.

Blow moulding ‘Stanyl’ grade introduced for automotive air ducts

DSM has introduced Stanyl®

Diablo OCD 2305 BM, a

high-temperature Polyamide (PA)

developed for blow-moulded

ducts for use in automotive

applications. The company said

air ducts made of the material are

lighter than parts made of metal or

Polyphenylene Sulphide (PPS) and

can handle continuous temperatures

up to 230°C.

T h e m a t e r i a l

is a heat-stabilised

blow moulding grade

of ‘Stanyl’ PA 4.6,

developed specifically

for hot charge air

ducts. DSM claims

that it is the first high-

temperature PA suitable

for processing by extrusion-blow

moulding and offers significant

cost benefit compared to PPS due

to its lower weight and scrap rate.

Part weights can be reduced by 7

per cent, thanks to improved wall

thickness distribution.

TECHNOLOGY TRANSFER


Technology Offered

Biodegradable polymersA company offers biopolymer nanoparticle technology

based on cost-effective biodegradable & biocompatible

polyolefins, copolymer of ethylene & vinyl acetate and

thermoplastic starch blend nanocomposites. These

nanocomposites have improved mechanical properties with zero

moisture content.

Areas of applicationPackaging materials, disposable non-wovens, hygiene products,

consumer goods, agricultural & horticultural tools and medical

instruments

Forms of transferTechnology licensing

Conversion of batch-poly plant to C P plantA company from China is interested in providing consultancy

services for the modification of batch-poly plant to C P plant such

as polyester plant, polyester chip or direct spinning.

Areas of applicationChemical fibres and plastics

Forms of transferTurnkey

New and rebuilt screw and barrels for all-plastic extrudersAn India-based company is manufacturing screw and barrels for

all-plastic extruders and is efficiently rebuilding worn out screws.

It is making an energy-efficient washing and drying plant for

all-plastic waste. It employs the most cost-effective and efficient

washing and drying units for plastic scrap.

Areas of applicationPlastics manufacturers and plastic waste recycling unit

Forms of transferEquipment supply and turnkey

Information courtesy: Information courtesy: Dr Krishnan S Raghavan, In-Charge, Technology Transfer Services Group, Asian and Pacifi c Centre for Transfer of Technology (APCTT) of United Nations Economic and Social Commission for Asia and the Pacifi c (UNESCAP), APCTT Building, C-2, Qutab Institutional Area, New Delhi 110 016, Tel: 011-3097 3758 (Direct), 011-3097 3710 (Board), Fax: 011 - 2685 6274, Email: [email protected], Website: www.apctt.org

For more information on technology offers and requests, please log on to www.technology4sme.net and register with your contact details. This is a free of cost platform provided by APCTT for facilitating interaction between buyers and seekers of technologies across the globe. After submitting technology offer or request to this website, you are requested to wait for at least two weeks for receiving a response from a prospective buyer/seeker through this website, before contacting APCTT for further assistance.

As part of our endeavour to spread the technology culture, this section provides a means to promote and facilitate exchange of select technologies. We strive to bring together suppliers of such technologies with suitable users for negotiations and industrial collaboration.

Disposal and recycling of plastic wasteA Polish company seeks the technology for dry

processing of all kinds of plastic wastes or a magnetic

processing method in the electrostatic field. The technology

should allow sorting of all kinds of plastic materials,

(PET, HDPE, PVC), hay-silage foils, etc by excluding

dangerous waste.

Areas of applicationPlastics industry, waste recycling, waste management

Forms of transferOthers

Laboratory-scale non-woven and monofilament plantAn Indian company is looking for a laboratory-scale, non-

woven and monofilament plant in a single station.

Areas of applicationPlastics


Polyethylene Terephthalate (PET) polyolsA trading-based company plans to manufacture PET

polyster polyols. The small-scale project will involve

procuring recycled PET flakes locally. Land available for

manufacturing is 28,000 sq ft.

Areas of applicationPolyols


Share and Solicit TechnologyThe mission of Modern Plastics & Polymers is to spread the technology culture. Here

is an opportunity to be a part of this endeavour by sending your technology on offer or technology requirements. If you belong to any of these two categories, you are invited to furnish the techno-commercial details for publication. The write-up needs to be as

per the format of this section with information about the particular technology offered or requested, its areas of application and forms of transfer.

Contact: Modern Plastics & PolymersNetwork18 Media & Investments Ltd, ‘A’ Wing, Ruby House,

J K Sawant Marg, Dadar (W) Mumbai 400 028. Tel: 022-3003 4671 • Fax: 022-3003 4499

• Email: [email protected]

Technology Requested

MPP

APR

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13_T

AB

3_E

VER

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PG_3

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MPP A

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3_MATSU

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IN CONVERSATION WITH: B ip in Shah


…says Bipin Shah, President, Plastindia Foundation, when referring to the material that has become the fabric of life. At a time when international companies are making a beeline to enter the country, Shah talks to Sweta M Nair about the prevailing domestic conditions, potential development areas and his new role as the President of one of the country’s most revered plastics associations.

Drawing on your vast experience, how has the course of the Indian plastics industry changed?In all these years I have spent

in the industry, the growth of plastics

has been inevitable. Although it was

predicted twenty years ago that plastics

were not going to last due to scarcity

of oil, the scenario has changed due

to the discovery of alternative sources

of energy. The question now is about

which route we should take:

oil-based, gas-based, naptha-based

or biomass.

The current per capita consumption

of plastics is 4–6 kg in India, whereas it

is 42 kg in China and 62 kg in the US.

So comparing the rate of consumption

will not be ideal in this situation. Within

the country, we need to focus on industry

segments such as building & construction,

“PLASTICS

LIFE”

WAYHAVE BECOME

AOF

Bipin Shah


water management, road construction,

telecommunications etc, where maximum

utilisation can take place.

Plastics have become a way of life,

and the key issue now is on energy-

efficient utilisation of plastics. During

a recent visit to Karad, we chanced

upon a prevalent phenomenon where

the women in a particular village travel

a distance of three kilometres everyday

just to fetch water. Imagine the relief

polyvinyl chloride pipes can bring

into their lives where their commute

will be cut and clean water will be

available just by turning on the tap! To

a certain extent, even the enormity of

waterborne diseases could be controlled

in such areas. Additionally, the hours

of manpower could be put into other

productive areas.

Another area that has changed

significantly is the usage of plastics

in consumer durables, followed by

automobiles, fertilisers, food packaging

and footwear soles. I believe plastics

in food packaging is growing at a

tremendous rate and will continue

to grow. I think this segment still

has untapped potential in increasing

the shelf life by ninety days. For that

matter, even plastic bottled water has

replaced the iconic water flask. To put it

in simple words, increase in disposable

income, constraints on time and the

convenience factor will influence the

course of plastics in the coming times.

With the change in trends, how have the priorities of Plastindia Foundation changed? Also, what is your agenda as the newly elected President?As President of Plastindia Foundation,

the road that I want to take is based on

knowledge-driven issues more than the

ones that are purely focussed on revenue.

It is knowledge that can empower

the industry. Here, I am referring to

practical knowledge more than mere

resource-based information. I emphasise

the former because although I graduated

with a distinction in engineering, I

lacked practical knowledge. Perhaps

this is an issue with most courses in the

country where importance is given to

theory. On the other hand, American

institutes are known for their cohesive

training programmes and hands-on

approach to problem solving. This

is one of the main reasons as to why

the Foundation has decided to start

the Plastindia International University

(PIU). In association with University of

Massachusetts Lowell (U-Mass Lowell)

and University of Wisconsin–Madison,

the PIU will be set up in Vapi, Gujarat,

where the state government has provided

35 acre of land. The undergraduate

engineering programme at the PIU will

incorporate all the components of the

curriculum that has made the U-Mass

Lowell Plastics Engineering programme

an international success. Over a period

of five years, we are going to invest

` 130 crore to create quality manpower

for the plastics industry. In addition,

we are going to focus on growth by

implementing the right technology;

hence, technology collaboration is

going to be another area. Among these

developments, we will continue to focus

our attention on environment-friendly

initiatives and programmes.

Since India is an agricultural economy, what efforts are being taken up by the Foundation with regard to agriculture?In Maharashtra, the number of suicides

of marginal farmers has become a serious

issue. They borrow but in most cases

are unable to pay off loans. Because the

agricultural sector is the backbone of the

country’s economy, this sector is of much

significance to us. Efficient utilisation of

plastics can help farmers get more yields.

One of our programmes includes offering

drip irrigation systems to farmers. With

timely inputs of water, fertilisers and

pesticides, production improved by 400

per cent. After proving successful, we

are now involving non-governmental

organisations so that farmers can benefit

from this system. Other than agriculture,

increasing the usage of plastics in public

infrastructure is also picking up pace.

What are your thoughts on the recent ban of plastic bags across various states in the nation?Plastic bags are banned in Delhi,

Chandigarh and Kerala. In Delhi, even

manufacturing of plastic bags is not

allowed. The authorities deem jute, cloth

or paper to be better options. By no way

are we in favour of plastic bags of less

than 40 micron, but bags that can be

recycled should be supported. Compared

to plastics, the deemed alternatives

require more energy for production.

Moreover, 60 per cent of a customer’s

buying is impulsive; I do not know how

many will find it convenient to always

carry with them an extra bag just in case

they decide to shop.

In the light of such events, what consumption rates do you predict?Our projected consumption of plastics

will be nothing less than 15 million

tonne by 2020. Hence, this opportunity

must be showcased to international

entities associated with the industry. The

question now remains on whether the

country can become a mass producer like

its competitor. Perhaps the organisation

of clusters will resolve this issue and put

an end to its fragmented nature.

As a veteran of the industry, what remains a challenge for you and the plastics industry?Commercialisation of innovation. I have

made more than 40 one-of-its-kind

products in my life. Commercialising

these innovations has been and remains

a challenge. In addition, this industry

lacks the presence of young blood. First-

generation entrepreneurs are not alluring

second-generation entrepreneurs into

the same business. This is a prevalent

problem. We need to set the right

examples so that the second generation

is encouraged to enter this field. Further,

getting manpower with practical

knowledge and problem-solving ability

has been a problem. With the PIU,

we hope to be able to do away with

this problem.



SPECIAL FOCUS

Injection Moulding


Injection Moulding:

Igniting increased innovations................................................................................................................. 40

Innovative injection moulding:

Automation for perfection ....................................................................................................................... 42

Lightweight solutions for automotives:

Improving performance, design and safety ............................................................................................. 44

Interface:

Hitesh R Shah, Business Head – Injection Moulding Machines, Windsor Machines Ltd ................ 47

Praveen Sharma, Managing Director, Hinds Plastic Machines Pvt Ltd .........................................48

Roundtable:

Have Indian moulders been able to significantly improve efficiency in injection moulding? ............... 50



SPECIAL FOCUS: In ject ion moulding

INNOVATIONSINNOVATIONSINCREASED

IGNITINGIGNITING

The accessibility of plastics

has increased with the rising

number of industries using

plastics. This has bolstered the

demand of injection moulding machines

that is persistently setting up new highs year

over year, thanks to the increased ability of

Indian machinery suppliers in incorporating

better technologies available in the world

in their machines. The new technologies

that have gained a widespread acceptance in

all the segments are all-electric and micro-

injection moulding machines.

Micro innovations, big impactMicro-moulding relates to moulding a part

that is measured in micron. This process

has opened the door to manufacturing

tiny parts in a relatively easier manner

at a lower cost and at a higher speed.

This translates into increased profitability

through material conservation as less

resin is used to create more parts.

Amit Mahant, Director, PK Plastic

International Pvt Ltd, notes, “Micro-

moulding is a very specialised, precision

injection moulding technique geared

specifically to mould micro-miniature

electronic components. There are a number

of benefits that can be achieved by the

micro-injection moulding process while

moulding electronic components.”

Micro-moulding is designed specifically

for producing the smallest components,

typically with component weights below

0.25 g and less. The process has many

advantages, such as greater accuracy in the

finished part. As the process is designed

for smaller parts, a few mould cavities

are used in micro-moulding. Therefore,

accuracy and reliability achieved in micro-

moulding far exceed those achieved in

conventional moulding.

Cost–quality analysisIn moulding of electronic components

in particular, micro-moulding can offer

a range of cost-effective alternatives for

components that are miniature, complex

and require high precision tolerances.

Mahant notes, “The one big reason for

companies using this technology is cost

savings. This is because the amount of

time it takes to mould a component is

a fraction of what it takes to machine a

component. Also, these machines help cut

down the cost of part per piece.”

He adds, “Micro-moulding also

gives more freedom to designers to

introduce intricate features in products,

thereby enhancing their ability to create

more innovative products. Further, small

parts require high-speed automation to

maintain part consistency, which can

only be achieved by the micro-moulding

process. Micro-injection moulding is a

low-cost solution, it leads to dimensionally

stable production process with no particle

contamination and complex geometries

Injection moulding has been the preferred processing technology for part manufacturing that requires high output and accuracy. Thus, the increase in demand for all-electric and micro-injection moulding machines has given rise to new technologies and innovations in the segment. Avani Jain notes the cost–quality ratio of these two categories of injection moulding machines.

Courtesy: Davis-Standard, LLC

In ject ion moulding


Amit MahantDirector, PK Plastic International Pvt Ltd

The one big reason for companies using this technology is cost savings. This is because the amount of time it takes to mould a component is a fraction of what it takes to machine a component. Also, these machines help cut down the cost of part per piece.

Rohan Shrikant ShahaneRegional Director – South East Asia, Machine Point Consultants SL

It is believed that the all-electric injection moulding machines have the potential to reduce energy costs for a moulder by 30–60 per cent, depending on the moulding and the machine.

(eg radii) can be achieved through it. Also,

it makes use of alternate resins or fillers

to improve mechanical and/or electrical

properties and leads to better surface

finish.” Some other benefits include

reduced tool sizes, increased part accuracy,

improved cycle times, reduced part cost

and defined colours.

Mahant notes, “The usage of all-electric

and micro-injection moulding machines

for moulding electronic components can

also offer various benefits along with

precision and accuracy. They can lead to

energy savings up to 80 per cent and help

achieve accuracy with repeatability. In

the future, these machines can also make

use of the tie bar-less mould clamping

structure that can result in much larger

mould space and can be equivalent to the

wide platen style. This will also help in

accurate and stable clamping and lead to

equalised force on the mould. Further, the

machines can incorporate a mechanical

ejector with servo control to enhance

the efficiency of the machine.” Thus, due

to the various cost benefits offered by

micro-moulding solutions, their demand

in moulding small parts will continue to

increase in the future.

Electrifying the path of energy savingsIn addition to micro-injection moulding

machines, the demand for all-electric

injection moulding machines is increasing

these days as these help in saving energy

cost to a very large extent. Rohan Shrikant

Shahane, Regional Director – South

East Asia, Machine Point Consultants

SL, says, “The energy consumption in

different injection moulding machines

depend on how the drives are powered. A

conventional hydraulic machine uses one

or more pumps as a central unit to drive

the machine. Two of the most wasteful

aspects of a hydraulic machine are the

architecture of the system and the wasted

pump power when there is no demand.

However, all-electric injection moulding

machines reduce losses by using high-

speed servo motors to drive the injection

moulding process. In fact, it is believed

that the all-electric injection moulding

machines have the potential to reduce

energy costs for a moulder by 30–60

per cent, depending on the moulding

and the machine.”

Cost advantages without compromising on qualityAll-electric injection moulding machines

save on cost, primarily the energy cost

of the processors to a very large extent.

These moulding machines consume

electric power only when necessary.

This is because, to put it simply, all-

electric injection moulding machines

are much less mechanically complex.

They are driven by digitally controlled

servo motors that operate efficiently

and at high speeds. With fewer steps in

the process, less energy is lost. In fact,

these machines often consume less than

half the electrical power consumed by

hydraulic machines.

Shahane notes, “All-electric injection

moulding machines allow machine

movements to be integrated directly

with the control system. This greatly

improves machine set up, adjustment

and process control. Also, all-electric

injection moulding machines use less

water. Depending on the product, water

consumption can be reduced by up to 65

per cent. Moreover, there is a substantial

reduction in maintenance cost as the

electric machine eliminates the need for

hydraulic oil, thereby eliminating the

need to store, dispose, maintain and cool

the oil. Further, a shorter product cycle

makes it more productive than hydraulic

injection moulding machines. All-electric

injection moulding machines are more

accurate, precise and extremely good for

repetitive operations.”

In a nutshell, the all-electric injection

moulding machines can significantly

reduce energy consumption and

production cost in moulding. Hence,

these machines are increasingly becoming

popular and their demand will definitely

increase because of their energy efficiency,

greater cleanliness, quick start up, better

repeatability, quiet operations, easy

maintenance and, above all, the ability to

save production cost for processors.



SPECIAL FOCUS: Innovat ive in ject ion moulding

The versatility offered by injection moulding in terms of design and high production output rates makes it the preferred choice in the plastics industry. Anwesh Koley analyses the current trend towards the advanced usage of robotics, which allows complete automation in the moulding process.

Higher output, lower cost

and energy efficiency have

become the key criteria

in the injection moulding

industry in India. In order to achieve

these, it is important to adopt the latest

technology through either process

optimisation or advanced automation.

Industry sources in India show that the

injection moulding market has grown at

average annual rates of 12–15 per cent

for the past eight years, outperforming

the overall economy, which grew roughly

at 6 per cent.

Industry projectionsIn India, about 60,000 injection

moulding machines are currently in

operation, serving a wide ambit of

sectors. Naveen Gupta, Senior Branch

Manager, Polymechplast Machines Ltd,

says, “Injection moulding machine sales

in India in 1990 stood at 2,500–3,000

per year, which today stands at about

8,000 machines a year.”

During 2010–11, across various plastics

processing machines, injection moulding

machines had acquired 70 per cent market

share, extrusion machines boasted of 23

per cent share, blow moulding machines

had 6 per cent of the pie and machines

for other techniques stood at 1 per cent.

Market projections show that by 2015–

16, almost 10,800 injection moulding

machines would be serving the plastics

processing industry across India.

Latest developmentsThe latest advancements in injection

moulding include servo motors for

energy-saving and all-electric machines

replacing hydraulic machines, which have

precise control and are useful for pharma

and automotive products. Harminder

Singh, AGM – Sales & Marketing,

Electronica Plastic Machines Ltd, says,

“Demand is increasing for packaging

that can be simultaneously labelled

during the injection moulding process.

This has resulted in the development of

well-packed in-mould labelling systems.

In addition to functional benefits,

this complex process offers potential

for cost reduction.”

Along with these, co-injection

and multi-colour injection moulding

techniques are used to create different

designs with a programmable logic

controller-operated system to achieve

repeatable design patterns with higher

output. The usage of robotics and

automation reduces manpower and

results in consistent output. “The

industry has benefitted from a variety

of innovations over the years. From

conventional technology to proportional

technology, production processes in

injection moulding have come a long

way,” says Gupta.

The latest technology used today in

the injection moulding industry is aimed

at developing energy-efficient and

automation-oriented final products. The

equipment within a moulding machine

are now designed to ensure that they are

digitally controlled, more precise, fast,

compact and easily compatible with the

machine controls. Also, manufacturers

are modernising their plants and

have equipped them with the latest

computer numerical control machines

AUTOMATION AUTOMATION FOR FOR

PERFECTIONPERFECTION

Courtesy: Cherry Electrical Products


Innovat ive in ject ion moulding

and other design-oriented software,

which helps in producing quality

products as well as in competing in the

international market.

“With the advent of servo control

technology, normal plastics processing

has become simpler, and engineering

plastics processing, which was earlier

considered a difficult process, has become

easier,” opines Singh. Metal injection

moulding and ceramic injection moulding

parts can now be found in all areas of

life, from automobiles to watches, from

dental braces to mobile phones, from

IT equipment to do-it-yourself tools

and many other areas.

How it worksThe injection unit is responsible for both

heating and injecting the material into

the mould. The first part of this unit is

the hopper, a large container into which

the raw plastic is poured. The hopper

has an open bottom, which allows the

material to feed into the barrel. The

barrel contains the mechanism for

heating and injecting the material into

the mould. This mechanism is usually

a ram injector or a reciprocating screw.

A ram injector forces the material

forward through a heated section

with a ram or plunger that is usually

hydraulically powered.

Higher output at lower costsAdvanced usage of robotics ensures that

output is higher, but total moulding cost is

low due to lower cost of the machine. All

principal modules – the clamping unit,

injection unit, drive, protective covers

and control system – are coordinated and

geared towards efficient production. Even

complex products are manufactured at

the highest reproducibility level. Multi-

cavity production reduces the number

of machines and manpower, with less

energy consumption by the servo drive,

and hot runner moulds lower cycle time

with zero wastage.

The usage of robots adds accuracy and

speed to the injection moulding process.

Injection moulding machines produce

the same results at the same speed every

time. “Robots are able to keep pace and

improve the efficiency of the entire

system with quick material handling, few

mistakes, if any, and effective palletising,”

adds Gupta. Industrial robots add

flexibility to the design of plastics. It

is used for all types and sizes of parts,

from tiny assembly components to large

automotive body pieces. Robots can be

quickly programmed to handle different

products. They can also easily tend to

more than one machine at a time. These

can also be programmed to palletise or

place parts on a conveyor.

Also, the usage of robotics creates

a safer work environment. “Typically,

workers are required to work in close

proximity to injection moulding machines,

reaching to remove parts and stack them

repeatedly. Those removing the parts

from an injection moulding machine are

prone to repetitive movement injuries.

With robots, human contact with the

injection moulding machine is minimised,”

says Singh.

Challenges facedThe primary challenge is the advent of

Chinese machines that are priced low.

Often customers do not understand the

importance of after-sales and service and

opt for Chinese machines. Visibility is

another area of concern. “Even with a

population of about one billion, India

remains essentially unknown to most

moulders from the US. In terms of

gross domestic product per head, India

lags behind almost all countries in Asia,

except Bangladesh,” laments Gupta.

Most moulders from the US have

either lost their business to Chinese

imports or considered relocating some

manufacturing to China. The problem

of low-cost inputs needs to be dealt with

urgency. While India exports bulk of

its products to African markets, China

remains the largest exporter to India.

Also, there is a need to increase the

level of automation within the injection

moulding industry, which would ensure

higher output, lower wastage and greater

energy efficiency.


Naveen GuptaSenior Branch Manager, Polymechplast Machines Ltd

Robots are able to keep pace and improve the effi ciency of the entire system with quick material handling, few mistakes, if any, and effective palletising.

Harminder Singh AGM – Sales & Marketing, Electronica Plastic Machines Ltd

With the advent of servo control technology, normal plastics processing has become simpler, and engineering plastics processing, which was earlier considered a diffi cult process, has become easier.


SPECIAL FOCUS: L ightweight solut ions for automotives

From bumpers to door panels, lightweight plastics give cars better mileage and allow designers and engineers the freedom to create innovative concepts that otherwise would not be possible. Anwesh Koley explores the advantages offered by injection moulded plastics such as heat and chemical resistance, high impact strength and ease of moulding.

Cou

rtes

y: C

N M

ould

ing

Injection moulded parts constitute 70

per cent of the total processed plastics

market. From home appliances to

parts for automobiles, as well as the

construction industry, injection moulded

parts are found everywhere today. There

was a time when the automotive sector

was not in favour of using plastics for

parts. Gradually, the importance of plastic

parts grew as manufacturers understood

the importance of weight reduction, which

aids fuel efficiency. With the automobile

industry witnessing intense competition

over the years, plastics have been used

in strategic areas to provide durability

and enhance visual appeal of vehicles.

Engineering plastics provide strength due

to their inherent properties.

Conventionally, metal alloys were

synonymous with auto body exterior

design and manufacturing. However,

metal alloys are susceptible to dents,

dings, stone chips and corrosion. They

are also heavier and more expensive than

plastics. Ayush Lohia, CEO, Lohia Auto

Industries, says, “Choosing plastics for auto

body exterior parts allows manufacturers

to adopt modular assembly practices,

lower production costs, improve energy

management, achieve better dent resistance

and use advanced styling techniques for

sleeker, more aerodynamic exteriors.”

Evolution of injection moulding Moulding has a rich history in the plastics

industry. The moulding process was

invented only a few years after the invention

of plastics. Initially, hand moulding was

used. Moulders had a conventional screw

barrel setup, and external heating was

applied manually. Even the moulds were

opened and closed in a similar manner.

Gradually, as automation began, the

injection moulding machine as we know

today was developed with a circuit installed

in it to regulate the machine. “Hydraulic

systems were developed during the same

time. For many years, hydraulic machines

were used by a majority of companies. The

current generation of injection moulding

machines works on servo motors that save

electricity and thus saves cost,” adds Lohia.

Over the years, hydraulic machines

have been replaced with Programmable

Logic Controller (PLC) units. Ashwani

Aggarwal, President, Brose India

Automotive Systems Pvt Ltd, says,

“Injection moulding has always been a step

ahead in terms of operational versatility

than extrusion. With injection moulding,

all that is needed is changing the mould,

and one can achieve the desired design.

Today, PLC has become mandatory for

machines, and servo motors are also in

vogue as these consume less electricity.

Various safety features have also been

IMPROVING PERFORMANCE, DESIGN AND SAFETY


Lightweight solut ions for automotives

adopted in injection moulding machines,

which essentially regulate the opening and

closing of the mould cavity.”

Plastics in automotivesThe automotive market is an important

market for plastic resins such as

polypropylene, polyurethane, nylon, other

engineering polymers and thermoplastic

polyesters. “Light vehicle applications

account for over 30 per cent of the

demand for each resin. Other resins used

include acrylonitrile butadiene styrene and

polyvinyl butyral. Engineering polymers

such as nylon, polycarbonate and others are

supplanting metals in many applications,”

adds Aggarwal.

Typical plastics and composite

applications include exterior panels, trim

& bumper fascia, interior trim panels,

window encapsulation, headlamp housings,

manifold & valve covers, electronic/electric

parts & components, wiring harnesses,

steering wheels, insulation, dampers

& deadeners, upholstery, mechanical

parts & components and safety glass.

Most of these are processed through

injection moulding.

Design flexibilityNew processes enable manufacturers

to reuse scrap plastics and recycle used

plastics cost-effectively. Also, plastic

components weigh approximately 50 per

cent less than their steel counterparts.

This enables automobile components to

be substantially lighter, while retaining

the needed strength, and contributes to

an overall lighter vehicle with improved

mileage and less emissions.

Low-cost, single-unit production of

large automobile parts, such as a front

grille, is nearly impossible when using

metal. “Plastics offer auto engineers

a variety of practical, cost-effective

alternatives and tremendous advantages

over conventional automobile production

materials,” says Lohia.

Automotive safetyThe versatility of plastics allows design

options that produce lighter and safer

vehicles. From concept to reality, injection

moulded parts offer a wide variety of

advantages to customers. For example, a

driveshaft made from plastic composites

can help increase torque as well as

passenger safety. Conventionally made of

steel, a driveshaft transfers power from the

transmission to the rear axle of the vehicle.

If a steel driveshaft fails, it can project

shrapnel in all directions and even dig into

the ground, catapulting the vehicle into

the air. Composite driveshafts are made of

carbon and polymer fibre that is designed

to break into small fibre fragments or

‘broom’ upon failure, posing less danger.

Composite driveshafts are also lightweight

and require less energy to spin, effectively

increasing the amount of power that the

engine can transmit to the wheels.

Plastics are making inroads into the

chassis market as well. Innovations in

plastics technology have brought about

the development of successful chassis

applications that would not be possible

using any other family of materials. A

lot of chassis parts are also made through

injection moulding.

Fibre-reinforced polymer composite

materials weigh about 50 per cent less

than steel, though these are characterised

by a higher absorption of crush energy

per kilogram. On impact, carbon fibres

can have four to five times higher energy

absorption than steel or aluminium. Front-

end components made of these lightweight

energy-absorbing composite materials are

specially designed to fracture in a manner

that utilises impact energy.

Non-metallic alternativePlastics have found remarkable acceptance

as a substitute for metal in transmission

components. These performance

characteristics can be tailored by material

suppliers to meet the particular needs of

automotives. The usage of additives, fillers

and reinforcements will cause variations in

the properties of plastics to meet specific

customer requirements. Polyetherimide

is used extensively in transmissions for

its superior dimensional, heat and creep

performance, while a single piece of nylon

can replace several steel washers.


Ayush LohiaCEO, Lohia Auto Industries

Choosing plastics for auto body exterior parts allows manufacturers to adopt modular assembly practices, lower production costs, improve energy management, achieve better dent resistance and use advanced styling techniques for sleeker, more aerodynamic exteriors.

Ashwani AggarwalPresident, Brose India Automotive Systems Pvt Ltd

Light vehicle applications account for over 30 per cent of the demand for each resin. Other resins used include acrylonitrile butadiene styrene and polyvinyl butyral. Engineering polymers such as nylon, polycarbonate and others are supplanting metals in many applications.


SPECIAL FOCUS: Inter face – Hitesh R Shah

How is the demand for plastics processing machines in the country?Ease of manufacturing and versatility have

made plastics the most preferred material

in the industrial & consumer products

segment, and plastics are fast replacing

other materials such as glass, wood and

metal. Their demand is continuously

growing in the automotive, construction,

packaging, electrical & electronics, pipe

fittings, agriculture, houseware, medical

and pharmaceutical sectors. All this has

constituted a huge demand for high-

precision plastics processing machines

and moulding equipment. The plastics

processing machinery industry is growing

at a compounded annual growth rate of

15 per cent, indicating a healthy growth.

Apart from good domestic growth, there

is an increase in demand for plastics

processing machines in the neighbouring

and African countries.

What are the recent trends in the segment? Earlier, the demand for higher tonnage

machines was less and smaller tonnage

machines were sold in a large number.

However, with changing times, the

demand for higher tonnage machines

is also increasing. Another trend is that

with the growth of the automotive,

pharmaceutical and healthcare segments,

the demand for plastics processing

machines is also growing, and the focus is

on technology that gives higher efficiency

at a lower cost. Further, the demand for

machines that consume less energy is

increasing.

What are the leading innovations making headway in the segment? Hybrid technology and all-electric

machines are really picking up well in

the market. Wherever there is need to

maintain a clean environment such as

in healthcare and medical applications,

the demand for all-electric machines is

increasing. The usage of servo technology

is also increasing as it helps in decreasing

energy consumption to a large extent. In

addition, innovations are being made in

machines to increase productivity without

increasing the cost.

What are the challenges and opportunities for the injection moulding machinery segment in India?Various challenges before the industry

include raw material availability and their

fluctuating prices, requirement of trained

manpower and automated solutions. In

addition, competition from global players

in terms of low-cost machines is a major

challenge. The import of used machines

and other high-end machines in large

volumes is another major challenge for

the industry. Despite these challenges,

there are opportunities for growth as

well because awareness on the injection

moulding process is increasing. Further,

processors are continuously involved in

improving operational efficiencies by

focussing on productivity, meeting quality

standards and reducing the overall cost

of machines. This will also increase

the demand of machines and help the

segment to overcome challenges. Also,

growing awareness and adoption of IT

solutions can increase the productivity of

machines, thus increasing the demand.

What could drive the future growth in this segment? The future growth in the segment

will be solely defined by customer

demand. Machines that ensure accurate

repeatability of the process, faster cycle

times, 24/7 failure-free operation, low

energy consumption, less noise and

address environmental concerns will be

more in demand. A company capable of

making such plastics processing machines

will rule the market. Further, in the global

competitive market, every producer is

required to offer high quality and efficient

machines at lower costs; thus, this serves

as a major driver for growth in the future.

What are the growth plans of your company?In the last few years, we have been

focussing on the overall growth of the

company and not only on increasing

productivity. We have focussed on

employee development, infrastructural

development, improving manufacturing

practices by moving towards zero defect

products etc, thus ensuring that the total

culture of the company improves and

customer expectations are met. We have

also taken up new product development

with reducing the cost as a major concern.

Hence, we want to and are providing total

solutions to the customer. Last, but not

the least, we want to continue to grow at

the pace at which we are growing since

the last few years.


…opines Hitesh R Shah, Business Head – Injection Moulding Machines, Windsor Machines Ltd. In an exclusive conversation with Avani Jain, he talks about the demand for plastics processing machines in the country. He further elaborates on the current trends, challenges and opportunities in the industry.

“The future growth in the segment will be solely defined by customer demand”


SPECIAL FOCUS: Inter face – Praveen Sharma

What is the current scenario of the injection moulding industry in India?The injection moulding industry is quite

positive overall, but the current demand

for injection moulding varies according

to the different sectors that use injection

moulded parts. In the automobile sector,

the demand has decreased in the last 3–4

months as the overall economic growth has

shown signs of slowing down. However,

if we consider commodity plastics and

packaging, the demand is quite high.

In this sector, the demand is regularly

increasing and has shown a good scope for

Injection Moulding Machines (IMMs).

The market is very competitive; therefore,

every player is conscious about the

existing price and quality.

What are the key reasons for the growth of injection moulding?Most sectors use plastics or things related

to plastics, and today, plastics play a

major role in everyone’s life, whether it

is a household item, engineering item or

automobile part. As compared to other

developed countries, there is a large scope

for growth of the injection moulding

industry in India. At present, the per

capita usage of plastics is 5–6 kg in India,

whereas it is 14–15 kg in developed

countries. Therefore, this industry has

potential to grow further.

Various research and development

initiatives in sectors like agriculture have

also bolstered the growth of injection

moulding. The drip irrigation system and

new tools used in farming have provided a

great scope and have opened new channels

and avenues for injection moulding. In

addition, most manufacturers are now

going into the conversion mode towards

more modern automatic programmable

logic controlled machines. Thus, a lot

of scope and demand for modern and

energy-efficient machines is currently

being generated.

What are the latest innovations witnessed by the industry?Many developments have been witnessed

by this sector, whether it is polymers,

moulds, IMMs, auxiliary equipment or

plant automation. Major developments

in this or any other sector are focussed

towards saving energy and optimising

costs. The latest development being

biopolymers and green plastics, both of

which are environment friendly. Following

similar trends, machine manufacturers are

also making machines that reduce wastage,

have lower noise levels, are highly energy

efficient and environment friendly.

Due to the advancements in polymer

science and developments in engineering

plastics today, most of the parts are being

converted from aluminium to plastics, which

results in lower cost and lightweighting with

more durable parts. These components play

a major role in the automobile sector, which

helps in improving fuel efficiency and aids

in cost reduction.

What is the extent of automation and the energy-efficient standards in the industry?Automation is involved in every

stage of moulding, from the initial

production stage to the final packaging

phase. In plastics processing industries,

automation plays a major role, whether

it is moulds, machines or in the post-

moulding process. In the current

scenario, moulds are advanced and

automated, and they are equipped with

hot runner systems that produce parts

with minimum rejection and effective

cooling systems that lead to shorter

cycle times.

In injection moulding, automation

plays a major role in increasing production

and in ensuring accurate moulding.

Without automation, manufacturing

energy-efficient machines would

not be possible. The current crop of

IMMs are energy efficient and equipped

with hydraulic pumps driven by servo

motors that save up to 40–60 per cent

energy, depending on the moulding

parameters.

What are the challenges faced by the injection moulding industry?The main challenge faced by IMM

manufacturers in India is to compete

with international manufacturers. Most

materials used in making the machine,

with the exception of raw materials,

are imported, whether it is the servo

system, programmable logic controller

or advance hydraulics or robotics.

After payment of customs and duties,

the parts become more expensive and

thus affect pricing of machines. These

machines are eventually unable to

compete in the international market.

There are no definite schemes by the

government to provide infrastructure or

for the procurement of raw materials at

subsidised rates. This makes it difficult

for small and emerging businesses to

survive in the market.


...avers Praveen Sharma, Managing Director, Hinds Plastic Machines Pvt Ltd. In an interaction with Anwesh Koley, he explains the various reasons for the growth of the injection moulding industry in India and the various challenges it faces today.

“Without automation, manufacturing energy-efficient machines would not be possible”

SPECIAL FOCUS: Roundtable


Jagmeet RatraManager, R S Associates Pvt Ltd

The Indian market is price sensitive and non-quality conscious. Companies are initially attracted by the low sticker price, and quality considerations come after the machines are used over a period of time. However, Indian companies offer better after-sales service. Since the majority of the market for injection moulding machines is in the unorganised sector, manufacturers do have a reason to smile. The future of the injection moulding industry is bright as the growth rate is high and the number of applications of injection moulding has gone up. Indian machines are now being considered globally because of durability and after-sales service. The Middle East and Africa are the largest importers of Indian injection moulding machines.

Indian processors import the largest number of machines from China; these low-priced imports are a major threat. Unlike in India, Chinese manufacturers get benefits of subsidies and tax concessions from the government.

High productivity and energy efficiency have characterised the injection moulding industry for a long time. However, with global advancements making rapid strides in India, it is important to gauge whether Indian injection moulders have been able to remarkably improve their productivity to cater to the ever-increasing market for injection moulded products. Anwesh Koley interacts with industry experts and shares their views on the current scenario of the injection moulding industry in India.

Thankur Singh DhooperDirector, Popular Engineers (India)

Current generation servo motors used in injection moulding ensure energy saving and low noise levels. The rpm control of the hydraulic servo pump drive system with AC servo motor ensures energy savings and noise reduction. Moulders can achieve almost 65 to 75 per cent energy savings through these techniques in comparison with a fixed-type pump motor-based system. High-precision stability control can be achieved through the closed-loop method of hydraulic servo pump drive system with servo motor reproducibility. This ensures optimum usage of power and consistency in operations.

The hydraulic method and the screw-drive method are combined to form a synchronous operation based on the various complex coordination of parts. This improves productivity by reducing the process time. Increasing the screw revolutions per minute using a high-output servo motor helps reduce the charge process time. This system also accommodates tandem mould and stack mould usage.

Kewal Krishan AjimalDirector, Vishavakarma Hydraulic Pvt Ltd

Currently, the injection moulding industry uses energy-efficient machines called servo motor machines that consume less power. Earlier only one type of machine was used, and if it worked well, it was used for all major applications. However, this did not provide the required efficiency in terms of production and energy consumption. Today, companies offer machines with different kinds of applications. Thin-walled applications require specific machines; PET bottle manufacturing requires another technique. This results in higher output at lower costs. Toggle-type injection moulding machines are in vogue, while many manufacturers continue with hydraulic ones. A toggle-type machine consumes less power with faster production.

Manufacturers in India have still not adopted fully automatic machines on a large scale as the availability of manpower is high. However, they now develop machines that not only produce higher output but also save energy and cost.

While there are varieties of techniques that can be used to ensure energy efficiency in an injection moulding machine, it is important to choose the right equipment and system to enable precise moulding along with efficient production set up. This will result in product

consistency and customer satisfaction.

Editorial take:

HaveHave Indian mouldersIndian moulders been able to been able to significantly improvesignificantly improve efficiencyefficiency inin

injection moulding?injection moulding?


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FACILIT Y VISIT: Toshiba Machine (Chennai) Pvt Ltd


From its rich lineage to setting benchmarks in manufacturing techniques, Toshiba Machine (Chennai) Pvt Ltd plans to increase its foothold in the Indian injection moulding market. Sweta M Nair visits its facility in Chennai to assess if the company’s aspirations have a physical backing.

Creating exemplary manufacturing processes

Considered one of the prime

processes for producing plastic

products ranging from micro

to large components, injection

moulding is virtually used in all sectors

of manufacturing. Size flexibility, design

freedom and maintenance of production

quality have enabled processors to extend

the boundaries of plastics. Capitalising

on the growing prowess of the plastics

sector is Toshiba Machine (Chennai) Pvt

Ltd. While this company has achieved a

turnover of ` 226 crore and is known for

its range in injection moulding machines

and auxiliary equipment, its innovative

manufacturing processes are now gaining

much attention.

An interesting lineageLocated on the Chennai–Bengaluru

Highway, the manufacturing facility

of Toshiba Machine is spread over an

area of 9.16 acre. With a workforce of

220 employees, the company has been

setting benchmarks by successfully

implementing and executing process-

related innovations. This facility is not

only a testament of the changing times

but also an enabler of transmitting

indigenised adaptations to the company’s

range of machines. Explaining the lineage

of Toshiba Machine, Parameswaran

Kailas, Managing Director, says, “The

Toshiba Machine (Chennai) you see

today is a result of a number of successful

collaborations that have occurred in the

past. Our plastics machinery business

started in 1991 when we at L&T were in

technical collaboration with world leaders

Demag, Germany [now Sumitomo (SHI)

Demag]. In 2001, the management of

Demag and L&T sensed the untapped

potential of this business. This led to the

formation of a 50:50 joint venture. We

moved to this modern facility on October

2, 2005. In 2008, Demag was acquired

by Sumitomo Japan, which then came

to be called as Sumitomo (SHI) Demag.

This acquisition was soon followed by

the company offloading its shares, all of

which were bought by L&T.

In January 2009, the company became

a fully owned subsidiary of L&T and

renamed as ‘L&T Plastics Machinery

Ltd’. In order to grow multifold, in

2010–11, L&T management decided to

exit from its non-core businesses. What

followed shaped the present company. On

September 28, 2012, Toshiba Machine

Co Ltd, Japan, acquired all of the shares

in the Indian firm of L&T Plastics

Machinery Ltd and made it a subsidiary

of their company. The latest identity

Toshiba Machine (Chennai) Pvt Ltd is a

member of the Toshiba Machine Group,

Japan. Toshiba’s idea of acquiring L&T

Plastics Machinery was for obtaining a

wider product reach and for accessing the

Indian market in a big way.”

Divisions and processesThe spacious facility, now in its eighth

year, has received accolades time and

again from Frost & Sullivan for its design

and machine manufacturing systems. The

main building houses the administration Assembly and testing area


office and shop floor. The latter is well

ventilated and is divided into three bays.

As per process, the first bay is for the

entry of materials and the assembly of

parts. Smaller tonnage injection moulding

machines (up to 180 tonne) are assembled

in the middle bay. The last bay is utilised

for assembling machines belonging to the

middle and higher tonnage machines. “For

us, any machine that ranges between 180

and 300 tonne falls in the middle tonnage

category, whereas machines that range

from 350 to 1000 tonne are categorised

as higher tonnage machines,” says M

Kumar, Head – Manufacturing. Other

sections include a display of products

that can be produced by the machines,

a cut-section of components used in

manufacturing, storage units and a paint

booth. The facility also houses sections for

the manufacturing of auxiliary equipment

for the plastics processing industry and

other supporting facilities like canteen,

parking, wastewater processing, an organic

converter for compost unit etc.

At Toshiba Machine, the number of

initiatives to encourage innovation among

employees is remarkable. One such

initiative ‘Hunt for Innovative Thoughts

(HINT)’ is where on-line suggestions

for improvements/new manufacturing

concepts are brought to light. Another

initiative is the ‘Stride Towards

Excellence Programme (Step)’. Toshiba

Machine is the first injection moulding

machinery manufacturer in the country

to have started assembling machines on a

moving platform. Recipient of the Indian

Machine Tool Manufacturers’ Association

– SIEMENS Productivity Championship

Award, this concept is a 10-stage paperless,

single-piece flow moving assembly. Every

stage has a dedicated set of tools, and

assembly activity is electronically stored.

On an average, the machine moves to

another stage (or level of completion)

after 2 to 3 hours, which signifies that

this single-piece flow facility allows the

company to produce three machines in

a shift of 8 hours. In the consecutive

shift, the feeding of the material takes

place. Unlike conventional methods, this

platform is levelled to perfection, which

ensures that testing of machines is carried

out seamlessly.

The congenial attitude of the company

of encouraging innovations has lead to a

number of productive developments on

the shop floor. For instance, the creation

of a cell quantum, consisting of prismatic,

round and hydraulic block cells, is

where minimum testing is conducted in

this facility.

Practical efficacy Along with paying attention to product,

quality and safety, this ISO 9001:14001

company emphasises its economical,

environmental and social role. Falling in

line with this philosophy, the company has

installed three solar panels on the rooftop

of its canteen so as to enable solar cooking.

“For the panels, with an investment of

` 9.6 lakh, we have received a government

subsidy of about ` 3.5 lakh. With this

system in place, we have managed to save

one industrial gas cylinder everyday, which

approximately costs ` 3,500. Due to the

good dividends that we have received,

we are contemplating in implementing

solar technology in our office building.

Moreover, the waste food from the canteen

is used to prepare manure in our very own

organic converter plant. We are a zero

water discharge facility, where the waste

water is treated and used for nourishing

the lush greenery in the facility,”

affirms Kailas.

Automotive, packaging, construction,

electr ical accessor ies, medical

components and writing instruments

are major markets for Toshiba Machine.

According to plan, the company aspires

to start the manufacturing of all-electric

injection moulding machines in this

facility by October 2013. Extending

its product base in hydraulic machines

and introducing die-casting machines

are also tentatively planned. “By

providing additional safety features that

protect the machines against power

spikes, fluctuations and cuts – general

phenomena in India, we have been able

to suitably modify our machines with

international technology to suit Indian

conditions to a certain extent. Amid

these introductions, our attention will

be fixed on providing after-sales support

to all our customers,” states Kailas.


Parameswaran KailasManaging Director

By providing additional safety features that protect the machines against power spikes, fl uctuations and cuts – general phenomena in India, we have been able to suitably modify our machines with international technology to suit Indian conditions to a certain extent.

The 10-stage single-piece flow moving assembly

ToToshiba Machine (Chennai) Pvt Ltd

Engineering Plastics

INSIGHT & OUTLOOK


Engineering thermoplastics:Turning the heat on metals! ........................................................................................................ 58

R&D initiatives:Improving the inherent properties of engineering plastics ......................................................... 60

Interface:

Dr Harindu Vyas, Consultant, Polymer & Plastics Technologist ........................................64

Satendra Kumar, CMD, Quadrant EPP Surlon India Ltd .............................................. 66

Roundtable:

How have engineering plastics revolutionised lightweighting for automotives? ........................68

Green shoots ........................................................................................................................... 69

End-of-life applications of recycled plastics:Setting benchmarks! ....................................................................................................................70

Interface:

Vishal Jasrapuria, Director, Shree Sadguru Plastic Industries ............................................ 72

Dr Prakash Mahanwar, Head – Dept of Polymer and Surface Engineering, Institute of Chemical Technology ...........................................................................................74

Filament wound composite pipes:Technological triumph for Indian industrySangeeta Baksi and Soumitra Biswas, TIFAC, Department of Science & Technology, Government of India; and Leena Modi and Jayrah Shah, EPP Composites Pvt Ltd ....................... 76


INSIGHT & OUTLOOK: Engineer ing thermoplast ics

Engineering thermoplastics

exhibit higher performance

than commodity materials and

are suitable for applications

that require engineering to design parts

that perform. In the past, these plastics

were not considered in application areas

that require high temperature. Instead,

metals and other conventional materials

were used. Due to primitive manufacturing

techniques, in some cases, even production

technologies were clumsy, which resulted

in difficulty while assembling. The usage

of traditional plastics in thermo-sensitive

applications also had limitations. To begin

with, service temperature requirements

and limitations in product design were a

couple of issues in engineering safety.

Components in automotive,

electrical & electronics and aeronautical

& space applications need thermo-

resistant materials. Satisfying this crucial

requirement, engineering plastics are

thus replacing metal, rubber, glass, paper

and, in some cases, even concrete. “Along

with being thermo-sensitive, engineering

plastics are corrosion-free and have better

noise dampening characteristics. They

offer ease of processing or production,

lightweighting and more freedom in

product design. In the last decade, the

usage of engineering plastics has been

extended to automotive applications

including replacement of bumper, fuel

tank, metal fuel lines and other fluid

transport lines. In the infrastructure

industry, these plastics have given

designers freedom – from fluid transport

management to replacement of wood

and glass – with better safety, ease of

handling and durability. The enhanced

usage of these plastics in white goods is

to make products better and attractive

with flame retardant and higher safety

index features. Lighter and attractive

electronic goods like vacuum cleaners,

coffee makers, washing machines, metal-

free refrigerator interiors, smarter and

lighter mobile phones and replacement of

other metal parts in electrical & electronic

items are achievements of engineering

plastics,” says Mandar Amrute, Sales and

Market Development Manager, Speciality

Polyamides, Arkema India.

The hot onesWhen referring to heat-resistant

engineering plastics, the demand is

skyrocketing around the globe by the

minute. A specific set of thermoplastics

caters to this niche requirement

beautifully. The most common being

Polycarbonate (PC), which not only has

strength similar to non-ferrous metals but

also has good impact strength, ductility

and durability. Due to excellent clarity,

METALS!HEAT

TURNING THE

ON

Engineering thermoplastics are now the accepted replacement solution in demanding engineering applications where traditional materials are less economical. Sweta M Nair delves deeper to gauge the enhanced usage of engineering plastics in thermo-sensitive applications.

Courtesy: Arkema Inc


Engineer ing thermoplast ics


any colour blends well with it. PC has

broad applications, including safety lamp

cover, signal lamp, high-rise building

glass, aircraft cockpit glass, glass and sheet

material substitutes and storage optical

discs. Because of superior mechanical and

chemical properties, Polyoxymethylene

(POM), dubbed as ‘super steel’, can be

used for various precise micron gear,

instrument elements and components

with geometrically sophisticated surfaces,

bib nozzles and valves for the deflagrator

pipeline. In fact, POM is used in

applications where metal and non-metallic

materials are sometimes incompetent.

Polybutylene Terephthalate (PBT)

is a type of thermoplastic polyester with

qualities such as high insulativity and

wet strength. Non-enhanced PBT has

good workability and electrical properties.

With extensive uses in electrical &

electronics and automotive industries,

it is low in glass transition temperature,

and therefore, short in processing cycle. It

can be crystallised even when the mould

temperature is at only 50°C. PBT has

applications in production of kickback

transformer of television sets, automobile

section boards and ignition coils, exterior

components of various automobiles, fans

of air conditioners, bases of electronic

ovens etc. Talking about the advantages

of engineering plastics, Geetha Baskaran,

Director, Suba Plastics Pvt Ltd, affirms,

“Faster cycle times in production and

lightweighting in automotives, which

leads to economical fuel consumption, are

the brightest aspects. We can further push

the boundaries in lightweighting by using

MuCell™ Molding Technology.”

Like hot cakesIn the last five years, engineering plastics

have entered new industry segments and

have growing usage in spacecraft and

automotive applications. Because there is

a strong drive to replace metals, Amrute

adds, “Many traditional under-the-bonnet

car parts are being made with thermo-

sensitive engineering plastics. This grade

has also made significant improvement

in packaging for chemicals as well as

microwaveable food packs. It has also

gained a strong foothold in the medical

industry for applications such as artificial

transplants and better surgical equipment

like skin-feel gloves, anti-static textiles

and so forth. The latest usage is in

temperature-sensitive decorative paints or

films for exterior and interior applications

in the infrastructure industry.”

When talking about demanding

applications such as bearings, piston parts,

pumps, compressor plate valves and cable

insulation, a colourless organic polymer

thermoplastic that comes to mind is

Polyetheretherketone (PEEK). Considered

an advanced biomaterial used in medical

implants, PEEK is extensively used in

the aerospace, automotive and chemical

process industries. The other variety nylon

6-6 is used frequently when mechanical

strength, rigidity and stability under heat

are required. This polymer is made of

hexamethylenediamine and adipic acid.

It is used for ball bearing cages, electro-

insulating elements, pipes, profiles and

various machine parts. “With the usage of

engineering plastics increasing in under-

the-bonnet applications, we are seeing

more glass-filled nylon, POM and glass-

filled polypropylene. The usage of PBT

and PEEK has increased in applications

where resistance to high temperature is

required. PC is being used increasingly

in headlamps as well. At Suba Plastics,

we specialise in automotive components

such as high-abrasive plastic gears with

close tolerances, gear housing and engine

belt tensioners that work closely with the

engine belt drive. In our products, we have

used carbon fibre-filled nylon 4-6 for some

special applications. We make components

with nylon 6-6 with 50 per cent glass-

filled material for gears for starter motor

applications. These components made

from engineering plastics can withstand

temperatures of more than 150–200°C.

They are also proven to perform well in

extreme climatic conditions. New additive

technology is being used to make it more

heat resistant. In the next ten years, I

believe engineering plastics will take over

at least 40 per cent of all under-the-bonnet

applications,” says Baskaran.


Mandar AmruteSales and Market Development Manager, Speciality Polyamides, Arkema India

Geetha BaskaranDirector, Suba Plastics Pvt Ltd

Along with being thermo-sensitive, engineering plastics are corrosion-free and have better noise dampening characteristics. They offer ease of processing or production, lightweighting and more freedom in product design.

Faster cycle times in production and lightweighting in automotives, which leads to economical fuel consumption, are the brightest aspects. We can further push the boundaries in lightweighting by using MuCell™ Molding Technology.

INSIGHT & OUTLOOK: R&D in i t iat ives

60 Modern Plastics & Polymers | April 201360 Modern Plastics & Polymers |

The untapped potential and

growing opportunities in

the engineering plastics

industry are gaining

worldwide attention. Replacing metal

with plastics in cars & trucks, household

appliances and building & construction

is becoming the order of the day. In

such circumstances, high endurance,

performance, wear resistance and anti-

static properties of engineering plastics

are areas of maximum effort in R&D.

Driven by the ongoing replacement

of metal parts with engineering plastics,

the demand is expected to rise globally.

In Asia, the usage of engineering plastics

has increased in segments such as

electrical & electronics, construction and

automotives. As forecasted by TechNavio,

the global engineering plastics market

will reach $ 69.12 billion by 2016. The

report covers the Americas, Europe,

the Middle East and Africa (EMEA)

and Asia-Pacific (APAC) regions. The

reason for this rise in demand has been

attributed to the increasing demand for

lightweight products.

Inherent assets Components made from engineering

plastics are usually used in tough

environments. The reliability of working

in harsh conditions coupled with

durability gives engineering plastics an

edge over generic plastics. For instance,

engineering plastics in hydraulic gear

pumps have a working life of 50,000

hours. Apart from industrial applications,

the usage of engineering plastics in body

implants requires that these plastics

go through sterilisation of ultra-violet

or gamma radiation. This signifies that

the chemical resistance of engineering

plastics is higher than that of generic

plastics. Talking about the present

scenario, Nanda Kishore, Director,

Jayashree Horologicals Pvt Ltd, says,

“Engineering plastics are here to replace

metals, and they can also emulate the

look and feel of metals. This is achieved

by reinforcing the base material with

glass, sand or talc-filled additives. Much

R&D to obtain certain anti-static grades

of engineering plastics is currently

ongoing for electronic applications.”

With the stiffness and toughness

exhibited by these plastics, continued

research is aimed at outperforming

traditional metal applications while

providing many advantages. In this era

when weight reduction is the key to

fuel efficiency, engineering plastics have

a high strength-to-weight ratio and

are lighter than metals. Reflecting his

thoughts on new application areas, Scott

E Fleming, Vice President & Business

Manager, Nylon Division, Teknor Apex

Co, says, “Engineering applications are

less expensive than metals in terms of

raw material cost and provide substantial

cost savings as a result of their design

freedom. This freedom makes possible

parts consolidation and moulded-in

multi-functionality, replacing the time

and labour required for metal fabrication

and assembly. Finally, by resisting

corrosion and providing inherent thermal

and electrical insulation, engineering

plastics are less expensive on a lifetime

cost basis. The automotive sector is the

largest market for the Nylon Division

of Teknor Apex. New automotive

applications keep appearing as a result

of two trends – continued proliferation

of electronic devices & information

systems and an increasing demand for

weight reduction.”

Beneficial shift When it boils down to the basic process

Improving the inherent properties

of engineering plastics

Valued for their outstanding mechanical and optical properties, engineering plastics have many diverse applications in the automotive and electronics segments. Good chemical resistance, dimensional stability, low moisture absorption and good flow properties are the other known attributes. Sweta M Nair brings to light the continued Research & Development (R&D) initiatives that are taking place in this space.


R&D ini t iat ives

Nanda KishoreDirector, Jayashree Horologicals Pvt Ltd

Scott E FlemingVice President & Business Manager, Nylon Division, Teknor Apex Co

Engineering plastics are here to replace metals, and they can also emulate the look and feel of metals. This is achieved by reinforcing the base material with glass, sand or talc-filled additives.

Engineering applications are less expensive than metals in terms of raw material cost and provide substantial cost savings as a result of their design freedom. This freedom makes possible parts consolidation and moulded-in multi-functionality.

itself, metals require heat energy of up

to 1,200° C to enter into a molten stage,

whereas any kind of polymer can be

plasticised at 300°C. Highlighting this

point, Kishore talks about the advantage

that engineering plastics brings to his

line of horological business, where

tolerance levels are very critical. “Earlier,

generic plastics were used for horological

applications where a lot of shrinkage

used to happen. After considerable

research from the solutions provider

side, the expertise in polymer blending

helped us reduce the shrinkage rate.

Engineering plastics respond well to the

production process, thereby helping us

reduce shrinkage and rejection rate. For

instance, our watch movement holders

were made using polyoxymethylene, but

now we have shifted to grylamide (a

nylon co-polymer). Because grylamide

has excellent dimensional stability, it has

helped us do away with shrinkage.”

The successful penetration of

engineering plastics into various

segments is based on different criteria.

Research is being extended to areas

such as under-the-bonnet parts, exterior

parts (window wiper holders & exterior

mirror housing), high heat distortion

temperatures and electrical insulation.

The telecommunications sector has

similar uses for engineering polymers,

notably used in mobile phone casings,

through the desire for light and durable

phones. Other applications may include

building, textile bobbins, meter housings

and small niche applications. Although

most of these research studies are still

in a pilot stage, there have been a few

commercially successful innovations.

Regarding Teknor Apex’s work in this

area, Fleming says, “Our Chemlon®

813 CI and 830 GHI fibre-reinforced

compounds, based on the nylon 6/12

polymer, are in commercial use and

provide the excellent chemical resistance

and low moisture absorption required in

fuel line components. The 13 per cent

loading of carbon fibre in the Chemlon

813 CI product also provides anti-static

conductivity often called for in fuel

line components. Chemlon 830 GHI

compound has a 30 per cent loading

of glass fibre for enhanced strength

and rigidity in applications such as

connectors. The new compounds pick

up only slightly more moisture than

nylon 12 and achieve acceptable finished

part dimensions in tooling previously

used for nylon 12. At the same time,

Chemlon 800 series materials process

in shorter cycles and at higher melt

temperatures than nylon 12. We are now

fully commercial with a new range of

compounds incorporating recycled nylon,

chiefly nylon 6 and 6/6. We are offering

these compounds under the brand name

Recyclon and have customers ranging

from automotive manufacturers to patio

furniture makers.”

Unlocking potentialWith lightweighing becoming a focus of

attention, engineering plastics are being

harnessed into new applications with the

right R&D support. Kishore would like

to see some miraculous developments

where the property of heat and light

transfer could occur using engineering

plastics. He believes that if this property

could be given to all grades available

in the market, then the application

areas would grow manifold. For Teknor

Apex, its latest R&D initiatives include

working on flame retardant formulations

of nylon compounds to meet new, more

stringent requirements for under bonnet

components from one major automotive

original equipment manufacturer, where

the components must pass the V-0

flame test. Another area of research is

to develop new nylon 6/10 and nylon

6/12 alternatives from nylon 12. For

this company, automotive industry

mandates for sustainability have also led

to a systematic programme designed to

recover used nylon products and recycle

them into valuable compounds. From an

outsider’s perspective, recycling could be

the next big R&D area for engineering

plastics. However, research forms a

stepping stone to success, whether these

will become commercially viable is a

factor only time can tell.



INSIGHT & OUTLOOK: Inter face – Dr Har indu Vyas

How is the demand for engineering plastics in the country?Today, the total worldwide market for

engineering plastics is estimated to be

more than $ 30 billion. Polyamide (PA),

Polycarbonate (PC) and Polyoxymethylene

(POM) are the dominant products in

the market. Within the spectrum of

engineering plastics, the annual growth

rate is 10 per cent for PA, 9 per cent for

PC and 5 per cent for POM. In India,

the consumption of engineering plastics

in the automotive and electrical &

electronics industries is more than half of

the total demand of engineering plastics.

Compact discs, where only PCs are used,

represent 11 per cent of the total market.

PA films shares 4 per cent of the total

market. Thus, the demand for engineering

plastics in the country is increasing by

4–8 per cent annually. On a larger scale,

the demand of engineering plastics is

growing at the fastest rate (8 per cent) in

Asian countries, in comparison to Europe

and America (5 per cent).

What are the recent trends in the segment?A recent trend is using engineering

plastics in a variety of products. These

days, the usage of thermoplastic polyester,

acrylonitrile butadiene styrene, acetal

polymers, nylon, phonilics, PA-imide and

PC has drastically increased in a variety

of applications.

What are the benefits offered by engineering plastics as compared to commodity plastics?The most important benefit of engineering

plastics over commodity plastics is that it

can be used as a replacement to metals.

Engineering plastics have excellent

electrical properties, such as high

breakdown voltage, tracking resistance,

arc resistance etc, in comparison to

commodity plastics. Further, some of

the engineering plastics have excellent

dimension stability, heat resistance, low

coefficient of friction, abrasion resistance,

fatigue endurance and resistance to creep,

but general commodity plastics lack

these properties.

What are the leading innovations making headway in the segment?Engineering plastics – through research

and development, we can engineer these

plastics for any desired property that is

required. The innovations that are making

headway are as follows:

Polyetheretherketone (PEEK): This

semi-crystalline thermoplastic has a

high operating temperature that is apt

for injection moulding. It is tough,

strong, rigid, resistant to ultraviolet

light, steam and creep. PEEK is used

in the nuclear, electronics, aerospace

and medical industries.

Polimide (PI): This polymer is heat

& fire resistant, with a self-lubricating

property. It is used in semi-conductors,

aircraft, off-road vehicles etc.

Polyphenylene Oxide (PPO): This

innovative engineering plastic is a

combination of polyphenylene oxide

& styrene. It has excellent hydrolytic

& dimensional stability, low moisture

absorption and good electrical

properties. It has a wide area of

applications in medical, automotive

and electrical & electronics industries.

Polyphenylene Sulphide (PPS): It

offers the best chemical resistance in

comparison to any other engineering

plastic. It is used in chemical reactors,

halogen lamp sockets, medical devices,

pump housing etc.

Polyphenylsulphone (PPSU): This

amorphous engineering plastic

has better resistance to chemicals

and impact than polysulphone and

polyetherimide. It can be used for

making medical instruments.

What are the challenges and opportunities faced by the industry? The industries that are using engineering

plastics have a bright future, as research

is going on in the area of specialised

engineering plastics that can replace

expensive metals. In such a scenario,

industries have the opportunity to

develop new products from engineering

plastics. These plastics have huge scope

in the areas of building & construction.

The only challenge that the industry has

to face is the high raw material cost. This

problem will persist till more research in

the synthesis of specialised engineering

plastics is carried out to reduce the cost.

What will be the future trends?To replace metal parts with engineering

plastics as these possess properties of

minimum wear & tear, lightweight and

easy processability. The future trend

also lies in the reactive compounding

of engineering plastics with general

purpose plastics to reduce cost without

compromising on the properties.


…opines Dr Harindu Vyas, Consultant, Polymer & Plastics Technologist. In an exclusive conversation with Avani Jain, he talks about the demand for engineering plastics in the country. He further elaborates on the advantages offered by engineering plastics and future trends.

“The demand for engineering plastics in the country is increasing by 4–8 per cent annually”


INSIGHT & OUTLOOK: Inter face – Satendra Kumar

What are the various opportunities for engineering plastics in wind generation?Alternative energy sources account for

a significant part of the total global

energy production today, and their

importance is constantly increasing.

Engineering plastics have transformed

the wind energy generation industry

across the globe. Engineers are using

engineering plastics worldwide to

improve product quality and increase

profitability of manufacturing processes

and equipment. Parts and components

made from high-quality materials

support the technical development in

all major sectors of alternative energy

generation. Preserving or maximising

energy is the key requirement of energy

generation and forms the top priority

for the government and generation

companies today.

However, certain natural cautions

are required to be observed while

generating energy through wind turbines.

Abrasion, erosion and wear of critical

parts in a facility and the equipment

within the production chain cause

immense loss. Related maintenance

services and production downtime can

impact the financial performance of

a project and business significantly.”

Valves, bearings, seals, guiders and rolls

require regular maintenance. High-grade

engineering plastics solutions can increase

equipment lifetime, improve mean time

between repairs, reduce waste and limit

replacement needs. Thus, it is important

for plastics used in turbine technology to

meet the highest challenges concerning

temperature, chemical resistance,

corrosion, wear and stability.

What are the future component development trends witnessed by you?New component developments will

significantly change materials usage

patterns. Generally, there are trends

toward lighter weight materials, as long

as the life cycle cost is low. Most rotor

blades in use today are built from glass

fibre reinforced plastic (GRP). Other

materials that have been tried include

steel, various composites and carbon

fibre reinforced plastic (CFRP). As the

rotor size increases on larger machines,

the trend will be toward high strength,

fatigue-resistant materials. As the turbine

designs continually evolve, composites

involving steel, GRP, CFRP and possibly

other materials will likely come into use.

Rotor blades are either GRP, wood-epoxy

or CFRP.

The step-up gearbox used on large

turbines today is expected to be replaced

in future machines. Most small turbines

designed for battery charging use a

variable speed, permanent magnet,

variable frequency generator connected

to a rectifier. As high-power solid-state

electronics are improved, larger machines

are likely to use AC-DC-AC cyclo-

converters. This trend will increase the

usage of magnetic materials in future

turbines. Large epicyclic gear boxes used

in large ships may continue to be the

drive system for some large turbines.

What kinds of innovative solutions do you offer at Quadrant?Competition in the engineering plastics

market is intense, and quality of services

and product differentiation are the

key to ensure a steady customer base.

Our ability to offer reliable products

and service levels are based on the

Total Quality Management approach

reinforced by ISO 9001-2000 standards.

Quadrant can meet your requirements

for consistent quality, performance

and machinability. As the first to line

mark shapes materials, Quadrant set

the standard for careful selection of

raw materials and resins, leading-edge

process technologies and highest quality

of manufacturing. Keeping pace with

industry standards, the company has

developed quality systems that comply

with industry needs.

Engineering plastics are exceptionally

easy to machine and a slight modification

in the tools produces an outstanding

smooth surface finish that helps with

aesthetics and performance of machines.

Because almost all engineering plastics

are easy to machine, it further broadens

the gap between traditional materials

due to reduced labour time and reduced

energy cost due to faster component

production times. The market for

engineering plastics is growing by the

day, and customers demand quality

and reliability from their purchases.

With steady research and development

initiatives that result in path-breaking

products, Quadrant has already become a

major player in the industry. We plan to

increase our production facilities beyond

the current limits to help us serve our

customers better.


…opines Satendra Kumar, CMD, Quadrant EPP Surlon India Ltd. In an interaction with Anwesh Koley, he explains the various innovations brought about by engineering plastics in the field of wind energy generation and the way forward for plastics in key industrial operations.

“Engineering plastics have transformed the wind energy generation industry across the globe”


INSIGHT & OUTLOOK: Roundtable

Mandar AmruteSales & Market Development Manager,

Speciality Polyamides, Arkema India

Presently, the automotive industry is looking at alternatives to cut down CO2 emissions. Some of the possible ways of achieving this is by exploring alternative vehicles, but that is still in the pilot stage. Engine refinement is not a cost-effective option, and new propelling energy sources are accompanied with availability issues. Thus, the proven and easiest way of achieving weight reduction is by replacing metal and rubber with engineering plastics that also have better designing ability. By using engineering plastics in automotives, one can achieve weight reductions of 10–12 per cent with better aerodynamic designs, 1–2 per cent with better air conditioning designs and 4–5 per cent with better wheel and tyre designs. Further, significant weight reduction can be brought about by weight modularity in the range 12–20 per cent. With metal and rubber replacement in power train inclusive gearbox, fuel lines and other fluid transport lines, one can reduce weight to about 45–55 per cent.

The usage of plastics in automotives is now touching upon points such as efficiency and aesthetics besides providing design functionality and freedom. Being less dense than metals, engineering plastics are being used in automobiles where they face some highly commanding circumstances. Sweta M Nair interacts with experts who bring out interesting insights on this trend.

T K PurushothamanManaging Director, Rosti Technical

Plastics (India) Pvt Ltd

Engineering plastics have innumerable applications in automotives because of being light in weight, durable and easy to manufacture. The wide range of applications includes: interiors – pillars, instrument panel, dash board, seats, door trims and steering wheel; exteriors – bumpers, lamp holders, rear view mirrors, handles, spoilers, wipers, wheel caps and mud flaps; under-the-bonnet parts – oil pans, radiator tanks, fans, cylinder head covers and manifolds. Plastics are replacing metal in almost every area thought to be impossible two to three decades ago. With a variety of long and short fibres, plastics have increasingly become popular and can provide incomparable products with superior performance, aesthetics, safety and durability. With increasing global oil prices, the weight of automotives has become the key factor as it influences fuel efficiency to a large extent. From a mere 5 per cent of overall body weight during the 1970s, the plastic content in automotives has increased to more than 50 per cent now.

Geetha BaskaranDirector, Suba Plastics Pvt Ltd

Engineering plastics have found wide application areas. They are now used in front-end modules, air intake manifolds, bearings, motor parts and so forth. In automotives, engineering plastics play an important role in the under-the-bonnet area, where these special plastics are able to perform at temperatures above 170°C. At such high temperatures, engineering plastics are creep resistant and offer better retention over service life. In addition, by using a higher impact balanced resin, the weight of the component or part can be reduced by lessening wall thickness. Thus, the applications of engineering plastics are definitely increasing. Casing or housing that was made of castings earlier is now being replaced by engineering plastics. These plastics are also being used in fuel injection systems and door panels. Engineering plastics are replacing metal in many applications. To a certain extent, I believe that engineering plastics can help build economical vehicles, where one can get more mileage due to lightweighting.

While passenger cars are required to adhere to mandatory safety requirements, environmental norms, better aesthetics, entertainment, communication and comfort features are still going to be in demand. Achieving these at a reduced price is a difficult feat. Although

engineering plastics are replacing metal in many applications, further reduction in their cost would increase their adoption.

Editorial take:

How haveHow have engineering plastics engineering plastics revolutionised lightweighting forrevolutionised lightweighting for

automotives?automotives?



INSIGHT & OUTLOOK: Green Shoots

With numerous green initiatives on the horizon, we bring to you in association with the United Nations Industrial Development Organization (UNIDO) this section ‘Green Shoots’ – the latest to keep you updated on the green phenomenon and to help promote the eco-friendly manufacturing philosophy.

We will get you closer to several green practices, products and technologies that not only have a lower impact on the environment but are also safer for company personnel. Read on to get more eco-friendly, energy-saving and economical solutions that can give Indian companies a global business edge.


INSIGHT & OUTLOOK: GREEN SHOOTS: End-of - l i fe appl icat ions of recycled plast ics

An activity that involves the

efficient working of the

entire eco-system, recycling

of plastics involves meeting

recovery targets, improving collection

procedures and encouraging product

users to recycle. In the long run, the

focus will be on smarter product design,

more efficient use of resources during

manufacturing, reducing transportation

costs and encouraging communication

among parties involved in the plastic

life cycle. End-of-life applications

accommodate industry segments

such as packaging, construction and

automotive products.

Currently, recycling is one of the

most sustainable end-of-life options for

plastics. The infrastructure and facilities

for alternative processing options, such as

energy recovery and composting (for 100

per cent degradable plastics), have not

been developed commercially, although

they may provide alternative processing

options for non-recyclable plastics in

the future. Thus, some of the factors

influencing end-of-life applications are

the overall public welfare, adherence

to waste management plans, meeting

international recovery benchmarks and

recovered material as a potential resource

as raw material prices increase.

Major outletsRecycled plastics can be used in almost

as many applications and products as

prime plastics. In packaging, recycled

Polyethylene Terephthalate (PET) and

High-density Polyethylene (HDPE) are

increasingly used in primary packaging

by retailers and branded manufacturers

for bottles and trays. Brands such as Coca

Cola, Marks & Spencer, Boots, The Body

Shop etc are currently using recycled

plastics in select product lines. Recycled

PET flakes are spun into thread and yarn

that is gaining popularity as a fabric used

in the clothing industry. Polyester fibre

is the single largest market for recycled

PET bottles worldwide. Polyester fleece

clothing and polyester filling for duvets,

coats etc are frequently made from

recycled PET bottles. This can be used

either alone or in combination with

other fibres to create a wide variety of

fabrics. These fabrics are generally strong

and durable.

Other major outlets for recycled PET

are food-contact or non-food-contact

containers, injection-moulded engineering

components and some building materials.

HDPE is processed into plastic lumber,

tables, roadside curbs, benches, truck

cargo liners and other high in-demand

durable plastic products. When referring

to cost-competitiveness, street furniture,

seating, bins, street signs and planters

are made from recycled plastics as the

preferred material because it is resistant

to vandalism as well.

BENCHMARKS! Recycling plastics is a multi-dimensional activity. Recovering scrap from plastic waste and reprocessing the material into a completely different product is referred to as an end-of-life application. Material recycling will continue to be the primary end-of-life option for plastics, followed by energy recovery for non-recyclable materials. Sweta M Nair illustrates processing phenomena that exemplify end-of-life applications.

SETTING


GREEN SHOOTS: End-of - l i fe appl icat ions of recycled plast icsEnd-of - l i fe appl icat ions of recycled plast ics

Additional applicationsDue to the lack of incentive to invest

in the compactors and logistical systems

required, most polystyrene products

are currently not recycled. As a result,

manufacturers cannot obtain sufficient

scrap. Expanded Polystyrene (EPS) scrap

can be easily added to products such

as insulation sheets for construction

applications. This foam scrap can also

be used in the manufacture of clothes

hangers, park benches, flower pots, toys,

rulers, stapler bodies, seedling containers,

picture frames and architectural moulding.

Recycled EPS is also used in many metal

casting operations.

In order to save energy and landfill

space, the percentage of recycled

plastics being used in new building and

construction applications is increasing

every day. These plastics can be blended

with virgin plastics to reduce cost without

sacrificing performance. Such plastics are

being used to make polymeric timber

for use in everything from picnic tables

to fences. It is widely being used in

mainstream construction products such

as damp-proof membrane, drainage pipes,

ducting and flooring. Because recycled

plastics are durable, low maintenance,

vandal resistant and resistant to rot, these

plastics are the ideal material to be used

in the making of walkways, bridges, fences

and signboards.

Societal commitment Recycling plastics is an environmentally

safe process that can help companies

gain a competitive edge. Elaborating on

this aspect, Vishal Jasrapuria, Director,

Shree Sadguru Plastic Industries, says,

“Reprocessed plastics can be used

anywhere and everywhere where virgin

plastics are used. If virgin plastics give

you a 100 per cent result, then good

quality reprocessed plastics can give you

results varying from 90 to 95 per cent.

Major areas where there is a good scope

for end-of-life reprocessed plastics are

construction, automotives, warehousing &

material movement solutions, agriculture,

household & furniture etc. Depending on

the type of plastic, on an average, it can be

recycled about 5–10 times. Reprocessed

plastics can be used over and over

again, only the applications would keep

changing depending on the quality of the

material. For example, if the material has

been recycled once, then it can be mixed

with some percentage of virgin material to

manufacture toothbrushes. However, after

that, when it is reprocessed again, then the

application would change maybe to either

furniture or something else depending

on the quality of the material and the

end use application of the product. If the

quality of reprocessed plastics is excellent,

then 80 per cent of it can be mixed in

manufacturing of a certain product along

with virgin materials. The next time, the

percentage of mixed reprocessed material

would reduce and the percentage of virgin

material would increase. Thus, applications

would keep changing according to the

quality of the material.”

Recycling materials uses far less

energy than creating them anew. As

the world becomes more eco-friendly

and environmental hazards increase,

recycling and reusing plastics are

expected to continue on a much larger

scale. Cristina Monge Frontinan, General

Director, Plastival, which is a cluster

that ensures the interests of the plastics

sector in Valencia, Spain, summarises

the scenario well. She elaborates, “The

percentage of applications of recycled

plastics is increasing. It is gaining a lot

of attention. Moreover, recycled plastics

are able to address the increasing demand

for raw materials to a certain extent.

With furniture and pipes constituting the

main segment of end-of-life applications

of recycled plastics, new applications

are being researched. New regulation

allows recycled material to be used in

secondary food packaging material. Also,

the business of recycling is picking up

pace globally. The problem of recycling

material is prevalent all around the world.

For India, the growth is only beginning so

the problem might not appear to be that

grave at this moment. Having systems

put in place right now would help in the

long run.”


Vishal JasrapuriaDirector, Shree Sadguru Plastic Industries

Cristina Monge FrontinanGeneral Director, Plastival

Major areas where there is a good scope for end-of-life reprocessed plastics are construction, automotives, warehousing & material movement solutions, agriculture, household & furniture etc.

With furniture and pipes constituting the main segment of end-of-life applications of recycled plastics, new applications are being researched. New regulation allows recycled material to be used in secondary food packaging material.


INSIGHT & OUTLOOK: GREEN SHOOTS: Inter face – Vishal Jasrapur ia

How has the plastics recycling sector grown?As compared to other raw materials like

wood and metal, plastics have various

benefits. Since plastics are inert and

non-corrosive, they have broad

applications in different products.

Plastics are light in weight, easily

available and relatively cheaper.

According to an industry report, the

per capita consumption of plastics is a

meagre 5 kg in India as compared to

90 kg in North America, 65 kg in West

Europe, 12 kg in China, 39 kg in the

Gulf, 18 kg in Latin America and 10

kg in South East Asia. India is also

a large importer of hydrocarbons and

virgin plastic compounds.

I believe that recycling can reduce

the outflow of currency on account of

polymer purchases to a certain extent.

It can also address issues related to the

efficient disposal of plastics. The usage

of recycled material not only reduces

the cost of plastics but also increases

their viability for low-end applications.

Although this particular segment has

grown well over the last decade, there is

still scope for growth and improvement

in the recycling industry. I believe that

the current market size is just a tip of

the iceberg.

What are the challenges you have faced as a manufacturer of reprocessed plastics?There are no entry barriers in our

industry. Any fringe player can enter our

market without proper technology and

with minimal investment. These fringe

players throw the market off balance

by reducing the prices to unsustainable

levels and then start compromising on the

quality and consistency. When customers

deal with these fringe players, they do not

get proper quality inputs consistently and

thus hesitate using reprocessed material.

Due to these reasons and because they are

not able to partner with the right kind of

manufacturer, customers are not reaping

the benefits of using reprocessed materials

in a big way. Also, as manufacturers of

recycled plastic material, we face shortage

of manpower since this is a labour

intensive industry.

What are the possible solutions to overcome these challenges?Industry associations can act as a catalyst

to grow this industry by organising

workshops and seminars for the potential

customer industries whereby they

can be made aware of the benefits of

recycled material as well as the means

to unlock these benefits. The customers

should differentiate between quality

manufacturers and fringe players, and

strike a balance between the pricing and

quality. I can see that this has already

started happening. The government can

also aid this industry segment by giving it

a ‘Green Industry’ status and help us scale

up by providing incentives like interest

subsidy on capital expenditure, duty

exemption on import of machinery etc.

The recycling industry is important for

the proper disposal of plastics. We at Shree

Sadguru Plastic Industries are associated

with many industrial and environment-

friendly organisations like Indian Centre

for Plastics in the Environment (ICPE).

What should the industry do in order to increase the recycling of plastics?In order to grow, serious differentiation

has to be made between fly-by-night

operators and quality-conscious suppliers.

Customers need to be assisted to achieve

a balance between price and quality.

By avoiding the short-cut route of low

pricing and quality, the industry would be

able to grow at a much faster rate. This

is a sunrise industry, which is at a very

nascent stage. The industry should take a

long term view and focus on maximising

the growth opportunities.


“Fringe players throw the market off balance”...opines Vishal Jasrapuria, Director, Shree Sadguru Plastic Industries, when talking about the Indian recycling segment. In a one-on-one with Sweta M Nair, he brings to light the challenges faced by processors of recycled plastics.


INSIGHT & OUTLOOK: GREEN SHOOTS: Inter face – Dr Prakash Mahanwar

How is the reprocessed plastics segment in India?The plastics recycling segment in the

country is extremely unorganised.

Businesses in this segment are mostly

micro and small scale enterprises.

Labourers in these sorting units work in

extremely unhygienic conditions. With

no skilled manpower, safety norms are

openly flouted. To fund their day-to-day

sustenance, workers segregate consumer

waste plastics with their bare hands and

without wearing face masks. This is the

prevalent scenario only in the recycling

segment; you will never find such

depressing working conditions in units

processing virgin material. Although few

prominent players have a turnover of about

` 2–3 crore, the industry is plagued by the

inability to invest in modern technology

due to the lack of funds. The reason being

that modern technology for segregating

consumer plastics waste comes at a high

price – perhaps a reason as to why the

industry is in such a dismaying state.

On a daily basis, we need cutting-edge

technology to separate and process the

fifty tonne of consumer waste that is

offloaded in Dharavi, Mumbai. Even

though the plastics waste is collected and

deposited, the thin polyethylene bags,

which are neglected by rag pickers, create

societal problems. These thin polyethylene

bags, as well as small chocolate wrappers,

shampoo sachets etc, do not fetch

a good price.

What sort of government support would you suggest that is needed to get to the crux of this matter?Recently, I have put forth a proposal to

the Ministry of Petroleum & Natural Gas

regarding the menace of thin consumer

plastics waste. I have proposed that the

authorities create and support technology

that will make use of such waste to create

fuel. Recycling is a societal matter that

needs governmental intervention. If a

plastics recycling processor wants to use

new technology, then it would involve

high capital. This coupled with a long

gestation period is not commercially

viable for companies; hence, we require

subsidies in this segment. To begin with,

the local authorities need to make sure

that rag pickers are well compensated

to collect small wrappers. Although

the end result after processing is low in

quantity, the authorities must subsidise

these processes so that it becomes

profitable to companies.

What are the possible solutions to these problems?Plastics is not a by-product of

urbanisation. We need solutions that will

address local problems. At the onset, we

need to sort out manpower requirements,

improve hygiene conditions and create

awareness among processors. The

government could start by setting up

common collection and automatic

segregation centres. When segregated,

the material can be sold to processors.

The government needs to invest funds

in Research & Development (R&D)

on plastics recycling. Businesses are not

going to invest in R&D activity because

it involves high capital and high gestation

period. Also, commercial success is

uncertain. Considerable research must

take place in waste plastics for fuel

generation, to create comingled plastics

for roads, new technology for composites

(where it can be reinforced with fillers)

and utilisation of additives that can help

in degradation of plastic materials.

From a processor’s perspective, what are the other end-of-life applications of reprocessed plastics?Road dividers, sideboards, drainage

pipes (made from reprocessed polyvinyl

chloride) are made from recycled plastics.

Recycled e-waste is used in automotive

applications and in road construction. In

the latter, we need to degrade the plastics

to a certain level so that it can become a

homogeneous mass with asphalt. Roads

laden with plastics are proving to be

better than roads made of concrete.


“Plastics is not a by-product of urbanisation”…says Dr Prakash Mahanwar, Head – Dept of Polymer and Surface Engineering, Institute of Chemical Technology, when talking about end-of-life applications of plastics that could benefit society. In an exclusive conversation with Sweta M Nair, he brings to light the abominable conditions prevailing in this segment and the measures required for improvement.


INSIGHT & OUTLOOK: F i lament wound composite p ipes


Sangeeta Baksi, Leena Modi, Soumitra Biswas and Jayrah Shah

Advancements in exploration

and production technologies

have helped locate and

recover supply of oil and

natural gas from major reserves across

the globe. As a result, the emphasis

on pipelines has been gaining major

significance, as these offer a more eco-

friendly, safe and cost-effective mode

of transportation of fluids. Pipeline

designers and operators are looking at

alternative materials to conventional

steel pipes in order to meet the

increasing demands and maintain

safety & reliability. High-performance

polymers, rubber, glass fibre-reinforced

plastics (composites) etc are increasingly

used for pipes and pipe fittings. Being

highly corrosion resistant, composite

pipes have found extensive applications

in the oil & gas industry since the last

two decades. Applications of composite

piping are increasing following the

concurrent knowledge generation in the

area, with some key advantages such as

lightweight, high strength-to-weight

ratio, excellent flow characteristics,

low thermal conductivity and low

thermal expansion, corrosion resistance

and size variability. Besides, high cost

of replacing steel piping in retrofit

applications and increased longevity

in new construction drive the use of

composites, which can withstand

severe conditions as experienced in

offshore environment.

India has witnessed aggressive

growth in exploration and production in

the oil & gas sector, which would attract

enormous capital investment in the

future. Composite pipes in the last five

years have gained a strong foothold in

India and are gaining wide acceptance

for application in the transportation

of potable water, sewage, desalination,

offshore oil production, paper & pulp

industry, power plant etc. The demand

for composite pipes from the oil & gas

sector alone is expected to grow by 9-10

per cent Compounded Annual Growth

Rate (CAGR) over the next five years,

thus driving the overall demand growth

in India at 8-9 per cent CAGR.

Reinforcement material As a reinforcement material, fibre is

the primary contributor to the stiffness

and strength of composite pipes. The

dominant, commercially available fibres

are glass, aramid and carbon/graphite

systems. Fibre glass, when combined with

thermosetting resin, cures to form a rigid

composite structure, which is suitable for

a variety of applications. The different

types of fibre glass used are single- or

multi-end roving, woven roving, textile

yarn, chopped strand, chopped strand

mat, combo mat, veil, multi-axial or

unidirectional fabrics, wet chop etc.

Developments in technology have resulted in high-performance polymers and glass fibre-reinforced plastics (composites) that find extensive applications in making pipes and pipe fittings, especially for the oil & gas industry. Here is an overview of what makes this material ideal for use in aggressive environments.

TECHNOLOGICAL TRIUMPH for INDIAN INDUSTRY

Fi lament wound composite p ipes


MatrixThe resin is the ideal matrix that

holds the fibres together, providing the

load transfer mechanism between the

fibres that are wound into structural

forms. The resin matrix also provides

corrosion resistance, protects the fibres

from external damage and contributes

to the overall composite toughness from

surface impacts, cuts, abrasion & rough

handling. Different types of resins are

used for composite pipes, viz isophthalic,

vinyl ester and epoxy, depending on the

extent of chemical properties required

for the final product. The resin system

is chosen for its chemical, mechanical

and thermal properties. Epoxy resins are

used primarily for the manufacture of

small-diameter piping, while polyester

resins are commonly used for large-

diameter piping and storage tanks.

Although glass fibre resists a wide

range of chemicals and temperatures,

it requires the right design, fabrication

and installation to match the appropriate

application. For example, glass fibre may

undergo chemical attack from hydrolysis,

oxidation, pyrolysis or incompatible

solutions. Therefore, a proper resin/glass

matrix will help minimise chemical attack.

Auxiliary raw materials/additivesOther raw materials such as catalysts,

accelerators, inhibitors, aggregates and

pigments are used in resin and fibre

reinforcements to achieve desired

properties of the composite product. A

catalyst is an organic compound which

when added to resin in the presence of an

accelerator initiates the polymerisation

reaction at ambient temperature. An

accelerator is a chemical compound used

together with a catalyst to accelerate the

polymerisation process. An inhibitor is

added to the resin to reduce its reactivity

at ambient temperature. Often, sand

is used as filler during the winding

process to increase wall thickness in

certain cases.

Glass Reinforced Epoxy (GRE) technologyA valid alternative to carbon steel

pipes, especially for use in corrosive,

aggressive and normal environments, is

GRE pipe technology. It is based on

the discontinuous filament winding

process, where continuous glass fibres

are helically wound at predetermined

angles and bonded with the epoxy

resin. GRE pipes offer a unique

combination of good mechanical,

thermal and chemical resistance,

which is obtained by a selection of

high-performance components and

a proper design of the structure.

GRE pipes, with smooth internal

surface resulting in reduced friction

and high flow rate, are commonly

used in oil transportation calling for

lower resistance to crude oil, paraffin

build-up and high internal pressure.

Low thermal conductivity of GRE

pipes as compared to steel minimises

the cost of insulation and heat loss.

Another major benefit of GRE pipes

is that once installed, these are virtually

maintenance-free.

Sangeeta Baksi and Soumitra Biswas

are from Advanced Composites

Programme, Technology Information,

Forecasting & Assessment Council (TIFAC),

Department of Science & Technology

(Government of India), New Delhi.


Leena Modi and Jayrah Shah are from

EPP Composites Pvt Ltd, GIDC Lodhika

Industrial Estate, Rajkot, Gujarat.


Advantages of GRE pipes Wide range of diameters from 1

inch (25 mm) up to and including 54 inch (1,400 mm) Standard lengths of 6, 9 and 12 m Adhesive, locked bell/spigot,

lamination and flanged joining systems Corrosion-free in most

environments Long life (50 years) + zero

maintenance = low life cycle cost Ultra-violet resistant; can be safely

installed above ground Conductive pipe and fittings

available Fast, low-cost assembly due to

lightweight and simple joining techniques Lighter support needed for above-

ground systems

Physical properties of GRE pipes

Physical properties Unit Value

Specific gravity - 1.8

Density kg/m3 1,800

Coefficient of thermal expansion mm/mm/°C 1.8 × 10-5

Barcol hardness - 45

Degree of cure °C 150

Glass content % wt 60-65

Resin content % wt 40-35

Mechanical properties Unit Value

Hydro test for one minute mPa 11

Mill pressure test (1.5 * design) mPa -

Axial tensile strength mPa 60-65

Hoop tensile strength mPa 155-165

Hoop tensile modulus mPa 20,000-25,000

Axial tensile modulus mPa 9,000

External collapse pressure mPa 0.8

Initial stiffness factor mm3.kPa 113

Beam bending modulus mPa 8,200

AUTOMATION TRENDS: Operator- f r iendly machines


The Indian plastics processing

industry has seen major

innovations in the recent

past, which have resulted in

a long-term impact on the functioning

of machines. With overall cost reduction

and quality improvement being the main

driving forces, the plastics processing

industry offers a comprehensive choice of

technologies and application techniques.

Some of the major trends for increasing

the operating efficiency and reducing

costs in all the sectors of the plastics

processing machinery segment, such as

injection moulding, blow moulding and

extrusion, include usage of Supervisory

Control and Data Acquisition (SCADA)

system, Programmable Logic Controller

(PLC) and PC-based control systems.

Jaymin Pithwa, Director, Konark

Plastomech Pvt Ltd, notes, “With each

passing day, companies are developing

new technologies that can generate

maximum output at a lower cost.

These days, customers want highly

automatic and synchronised systems

so as to improve their product quality

& efficiency and reduce overall costs.

Thus, at present, although priced a bit

higher, highly automatic machines are

demanded by every customer.”

PC-based operationThe most important aim of any control

system for equipment in the plastics

industry is to provide a simple but

powerful user interface. Its function

must be intuitive and easy to use, and

depending on the familiarity level of the

user, the complexity of the functions

can increase. At present, machines with

PC-based control systems are the most

operator-friendly machines available

in the market. PC-based automation

basically includes a PC platform and a

Windows-operating system. It ensures a

host of benefits to the plastics industry,

ranging from higher quality parts,

improved equipment uptime, faster cycle

times and more predictable production

flow to reduced employee turnover. A

PC-based system solution offers a style

of operation similar to desktop PC

applications, which any individual can

use today.

Further, the installation of software

with a colourful graphical user interface on

PCs not only makes machine operations

interesting and motivating to operators

but also shortens the learning curve for

them. Thus, machine operations become

more enjoyable to the operator, and at

the same time, production is improved.

Simple button clickIn a PC-based system, at the press of

a button, the set-up person can select a

completely different procedure or adapt

its function to the required procedure.

The ‘simple view’ selections of tried-

and-tested standard procedures of the

controller are available to the operator

for different automation applications.

The set-up person does not require any

programming know-how; one can simply

select a procedure and then adapt the

process sequences to the requirements

demanded by changing variants. All

settings necessary for a sequence (position,

speed and time) are displayed on a clearly

With the advent of automation and the demand for operator-friendly machines growing in the plastics processing segment, many companies in the country have started employing machines with PC-based automation or control systems. Avani Jain takes a closer look at the benefits of using such operator-friendly machines and how they help in increasing production without increasing the costs.

78 Modern Plastics & Polymers |

INCREASING PRODUCTION, REDUCING COSTS

Operator- f r iendly machines


arranged setting page. Commands to

be inserted are simply selected from an

extensive functions list and placed at the

desired point in the sequence. Pressing

the symbols in the sequence editor

immediately calls up the respective screen

page on which the parameters can be set.

Even complex sequences can be quickly

configured. An operator is able to create

movement sequences for linear robots and

thus can learn to program articulated-arm

robots within minimum time. Thus, all

the tasks can be performed by just clicking

the button, thereby reducing the need of

labour for performing each task manually.

This leads to reducing the labour costs

and the production is increased.

The ‘soft’ware touchOne of the key benefits of process control

system based on PC technology is that

it is easy to use because the software

is running on a familiar platform and

that makes it cost-effective too. Because

these systems are software-based, they

are more powerful and more flexible.

PC-based systems are inherently user-

friendly, and operation can be intuitive.

The biggest convenience for users is the

ability to see the ‘big picture’. Instead of

viewing process conditions in isolation,

this type of system allows users to readily

see data of all equipment from a single,

central monitoring station and view that

data over time via trending screens.

User-friendly Human Machine Interface (HMI)These days, machines with PC-based

controls are equipped with user-friendly

HMI, which is easily accessible for

process parameters. It provides excellent

troubleshooting guidelines along with

the help and alarm menu pages. It has

features such as functionally oriented

screen layouts; process parameter

monitoring in real-time and feeding

value on absolute basis; simple &

pictorial diagrams to enable operator

understanding; auto temperature

and temperature profile selection for

homogenous melt from the first shot;

extruder overrun for uninterrupted auto

cycle; auto heating start, shut down and

standby to save time and energy during

operation; intrusion insert moulding,

gas assist interface, core pulling etc for

multi-tasking utilisation; auto purging

for smooth shutdown; mould cooling,

mould gate option, sprue break, nozzle

shut-off valve, cold slug removal etc for

various applications and smart input/

output for uninterrupted production.

PLC and SCADA systems for reducing labour dependenceThe controls in use at present make

use of microprocessor-controlled high-

speed PLC and SCADA systems, which

also help in reducing the overall costs

and increase production. Rajiv Trivedi,

Vice President (Marketing), Prasad

Group & Chairman, Indian Plastics

Institute – Ahmedabad Chapter, notes,

“The machines with this system help in

achieving zero rejection. Further, these

systems help in reducing the labour costs

to a large extent as you need to have only

one skilled personnel to set the parameter

once, and then repeatable operations can

be carried out automatically. Hence,

production is improved and increased.”

Future trendsThe plastics processing industry is in

the midst of a transformation as far

as machine construction and system

engineering are concerned, leading to the

development of versatile and innovative

control technology.

Despite increasing complexity,

the user-friendliness of systems and

processes requires to be maintained as

well as improved. The operator must

only be confronted with one central

operating concept and user interface.

Therefore, control systems that enable

the integration of peripherals, a uniform

operating concept, simple programming,

clear representation of complex processes,

a high degree of process reliability and

comprehensive motoring functions for

quality assurance are required to increase

machine user-friendliness for increased

production at lower costs.


Jaymin PithwaDirector, Konark Plastomech Pvt Ltd

With each passing day, companies are developing new technologies that can generate maximum output at a lower cost. These days, customers want highly automatic and synchronised systems so as to improve their product quality & effi ciency and reduce overall costs.

Rajiv TrivediVice President (Marketing), Prasad Group & Chairman, Indian Plastics Institute – Ahmedabad Chapter

These systems help in reducing the labour costs to a large extent as you need to have only one skilled personnel to set the parameter once, and then repeatable operations can be carried out automatically.

ENERGY MANAGEMENT: Reducing energy consumption in p last ics processing


Although energy conservation

is not a major factor in the

field of machine building,

there are possibilities to

reduce energy consumption of injection,

blow moulding or hydraulic machines.

Over the years, processors have realised

the long-term benefits of reducing energy

consumption in plastics processing as it

not only helps achieve higher output but

also saves cost substantially.

Moulding machines are used to

manufacture a complex array of industrial

products. Ravi Kumar, Director, Shiv Pooja

Plastics, says, “To offset rising production

costs stemming from demanding

applications, manufacturers turn towards

machines that can deliver higher

precision levels, greater cost efficiencies

and maximum flexibility.” For decades,

companies have developed blow moulding

technology to help them remain at the

forefront of high-performance motion

control technologies for hydraulic blow

moulding machines, which reduce time

and result in increased energy savings

through the moulding process.

However, there are various challenges

in ensuring energy savings in this

process while providing quality output.

Manufacturers are fast realising the

challenges in managing the required

compressed air systems from an energy

efficiency standpoint using high-speed

precision equipment.

Reducing energy consumptionHigh-speed electric feeder solutions

help machines consume up to 30 per

cent less energy than competitive

hydraulic machines. These produce

higher quality and more repeatable

parts today. End users are continually

searching for the edge in product

quality, from plastic bottles that utilise

30 per cent less material to complex

package designs. High-speed precision

motion control would ensure uniform

wall thickness and guarantee that all

parts meet quality specifications.

The compact design of high-speed

electric solutions helps save valuable floor

space, which means customers can increase

the number of machines at work at any

given time. “To ensure safe operations,

built-in safety features including fail-

safe and slow set-up mode help reduce

unplanned downtime and foster operator

safety,” adds Kumar. Efficient engineering

will help facilitate future blow moulding

machine technologies. High-performance

engineering means that a blow moulding

machine is always ready for the latest

advancements in machine technology.

Today, blow moulding machines are

used to make everything from vessels

to toys to car petrol tanks. To offset

rising production costs from evermore

demanding applications, customers need

blow moulding machines of even higher

accuracy, efficiency and versatility. Neeraj

Garg, Partner, Suruchi Industries, says, “To

solve the challenge of accurate positioning

Maximise output,

The blow moulding process involves various complex stages of operations, coupled with high-speed precision moulding techniques. Moulders are increasingly opting for energy-efficient mechanisms that complement high productivity standards. Anwesh Koley analyses the challenges in achieving production efficiency in blow moulding and the measures required to rectify them.

MINIMISE CONSUMPTION

Reducing energy consumption in p last ics processing


under high-speed motion, it is important

to ensure more accurate parison thickness

control for highest product quality and

lower production costs.”

A complete system of high-response

servo valves, the machine controller and

an advanced man–machine interface

will help overcome technical challenges.

Highly accurate multi-axial control system

yields faster and more stable close-loop

mould movement speed. The hardware/

software design of the machine controller

should provide control of cover wall

thickness, weight temperature, motion

and other measured values. To address

upgrading requirements, the controller

must integrate intelligent temperature

control, closed-loop motion control,

dedicated wall thickness control and a

servo valve current drive.

By focussing on specific requirements,

high-speed blow moulding solution

providers are able to provide high-

performance solutions that ensure energy

savings at various stages during the

moulding process. “Today, it is important

to ensure commitments that go beyond

the initial collaboration to facilitate

reliable and flexible products worldwide.

For smooth functioning of a technology

as well as timely delivery of the final

product, service technicians worldwide

are ensuring timely and precise repair

of components,” adds Garg. Machinery

manufacturers are focussing on developing

efficient and low-cost plastics processing

equipment. Such equipment will be

smaller, multi-functional and flexible.

Challenges for compressed airRotary Reheat Stretch Blow Moulding

(RSBM) machines from leading

manufacturers across the globe provide

challenges to the efficiency of compressed

air systems. These challenges include

significant pressure drops in the RSBM

machine with large instantaneous air

demand swings. High horsepower

for individual compressors increase

consumption of compressed air, and the

usage of high historical pressure equipment

also add to the problem. Besides, a single

facility may have multiple pressure

requirements, making steady monitoring

a tough task. Despite these challenges, it

is possible to achieve 15 per cent energy

savings on the supply side with another

15 per cent achievable by focussing on the

pressure drops in blow moulding machines.

Pressure-drop situations in the processorStabilising air pressure is a primary

objective. Pressure fluctuations occur

in most stretch machines and are

significantly lower than expected.

Correcting this can lead to increased

productivity and reduced air consumption.

“Blow moulders must understand the

air pressure requirements of their blow

moulding machines. For example, the

blowing process consumes about 60 per

cent of the air. The remaining pneumatic

applications, using 40 per cent of the air

for control components and packaging

or decorating, will typically require lower

pressures. The blow moulder must install

a dedicated piping system to the blow air

circuits to reduce air consumption during

the blowing process,” says Garg.

In process industries, companies are

taking most of the measures available

to optimise their processes in order to

gain on productivity and reduce waste.

“As compressors have the largest motors

among the auxiliaries, consuming millions

of dollars worth of electric power every

year, anything we can do to save its energy

remains our focus,” adds Kumar.

By adding air recovery systems to

blow moulding machines, the used high-

pressure air can be recycled after blowing

the bottles for machine running, thereby

reducing energy consumption. Such a

process has various advantages. When

using the low-pressure air compressor with

same specifications, this system would

extend the rest time of the air compressor,

reduce its energy consumption and extend

the service life of the machine. After

adopting the air recovery system, the blow

moulding machine can be equipped with

a smaller low-pressure air compressor,

thereby decreasing energy consumption

and reducing production costs.


Ravi KumarDirector, Shiv Pooja Plastics

To offset rising production costs stemming from demanding applications, manufacturers turn towards machines that can deliver higher precision levels, greater cost effi ciencies and maximum fl exibility.

Neeraj GargPartner, Suruchi Industries

To solve the challenge of accurate positioning under high-speed motion, it is important to ensure more accurate parison thickness control for highest product quality and lower production costs.


Regulatory frameworks across the globe have shown tremendous enthusiasm in bringing down the carbon footprint generated

by business houses in order to create a sustainable manufacturing environment with healthier practices. Plastics generally have a poor or negative image in comparison with other materials, in particular with regard to their perceived impact on the environment and use of resources. This also has to do with various government initiatives banning the use of plastics below certain thickness for packaging purposes. While plastics from renewable resources are now being developed, their current market penetration is not high enough to have a significant effect on the overall results.

Material regulationsThe choice of materials used to produce

plastic food packaging is evolving, and the considerations for materials are increasingly influenced by cost, environmental impact and the ability to be recycled. Deepak Takkar, Proprietor, Takkar Industries, says, “Packaging companies that use plastics are looking at ways in which mineral content can be combined with plastics to produce packaging that changes the balance of raw materials used. There is also pressure on the industry to reduce the weight of packaging. Major retailers across the globe have agreed to follow green packaging norms with the aim of having less food products and packaging ending up as household waste. The packaging industry is supporting this through the design of containers and materials used, while making sure that food safety is not compromised.” In the case of flexible food packaging, the average pack weight has

been reduced by almost 25 per cent over the past half decade.

Shop-floor initiativesThe manufacture of plastic packaging is energy intensive and as a result contributes to the carbon footprint. However, this is an area where negative environmental impact can be reduced. R Varadrajan, Senior Country Technical Manager – India & SAARC, Dassault Systèmes, SolidWorks, says, “Over the past five years, the production process in most countries has changed dramatically. For example, originally the production of hollow thermoformed bottles consisted of relatively inefficient ‘flat-bed’ thermoforming machines alongside energy-efficient rotary machines. These flat-bed machines have now been phased out, and they have been replaced by high-output rotary machines. This has

THEREDUCING

FOOTPRINTFOOTPRINTCARBON

POLICIES & REGULATIONS: Green packaging norms

Carbon emissions from plastics processing techniques have been under the scanner for a long time. Although the per capita emission of greenhouse gases by India is quite low, plastics processors have undertaken numerous initiatives to ensure sustainable processing that yields environmental benefits in the long run. Anwesh Koley analyses the various imperatives that must be observed to achieve successful green packaging norms.

Green packaging norms


resulted in a reduction in energy use, thereby reducing the carbon footprint substantially.” Various processing companies have reduced the amount of energy used by almost 30 per cent through such practices. Over time, this efficiency is expected to result in meaningful cost savings.

Proper recycling and disposal of plasticsIn theory, plastic packaging has the capability of being a cradle-to-cradle product – a product that can be recycled or reused with no loss of quality. This is the way in which glass is currently disposed, where facilities collect and recycle waste glass. However, there are a number of obstacles that currently prevent this happening with plastics. Only very few plastic products consume more energy than their possible substitutes made of different materials. Most plastic products need lesser energy to be produced than their alternatives. Additionally, many plastic products save significant amounts of energy during the use phase.

On an average, 85 per cent of waste plastics go to landfill, about 10 per cent is incinerated and about 5 per cent is recycled. However, even less can go back into food packaging because of food safety issues with recycled plastics and because customers still prefer virgin materials. “If better collection services existed for plastic trays and if there was a common standard for local authorities collecting recyclable plastics, plastic packaging has the potential to be as recyclable and reusable as glass or tin,” believes Varadrajan. According to research studies by the Waste and Resources Action Programme (WRAP), the collection of mixed plastic packaging is ‘technically and economically viable’ on a commercial scale. The challenges that now lie ahead for local authorities are the provision of collection and dropping sites, and encouraging consumers to utilise these services.

Role of plastics in generating renewable energyPlastics play an increasing role in the generation of renewable energy. Examples are the plastic rotor blade of a wind

turbine and thin film photovoltaic units, where non-silicon semiconductors, both metal and organic, are printed on plastic films. Wind power turbines ensure high greenhouse gas emission savings within the use phase. These are 140 times higher than the emissions from conventional production because one-third of greenhouse gas emission savings enabled by the wind power plant are allocated to the rotor.

Deriving energy-efficient polymersIt is important to understand the possible future role of renewable resources in the plastics industry. “Two categories of plastics are possible from renewables. One option is the production of monomers to make new polymers such as polylactic acid. Here, the commercial challenge is to compete with existing large-volume plastics in terms of production economics and adapting processing equipment. The other route is to make high volume monomers such as ethylene or other ethylene derivatives from ethanol derived from renewable sources. These can then be used in existing polymerisation plants making the well-known polyethylene grade ranges,” says Takkar. In both cases, the chemistry is proven, but a key consideration will be the amount of non-renewable energy used in the overall manufacturing chain.

Towards a sustainable futureWhile efforts are being made globally towards reducing carbon footprint from plastics processing, it is important that the packaging industry continues to work together to drive innovation in design, materials, production processes and disposal. “While the ebb and flow of the economy will present varying financial demands on the packaging industry, the challenges posed by the need to reduce the carbon footprint are sustained and long term. It is by mirroring this need with a long-term and credible plan to tackle these challenges that will ensure that plastics are not looked down upon,” adds Takkar. The plastic packaging industry can then evolve in a way that meets the retail demands of convenience and cost, while reducing the carbon footprint.


R VaradrajanSenior Country Technical Manager – India & SAARC, Dassault Systèmes, SolidWorks

If better collection services existed for plastic trays and if there was a common standard for local authorities collecting recyclable plastics, plastic packaging has the potential to be as recyclable and reusable as glass or tin.

Major retailers across the globe have agreed to follow green packaging norms with the aim of having less food products and packaging ending up as household waste. The packaging industry is supporting this through the design of containers and materials used.

Deepak Takkar Proprietor, Takkar Industries

STRATEGY: P last ic packaging


Advantages that plastic packaging brings to the table are many. Besides fu l f i l l ing pac kag ing

requirements, it makes a good medium for advertising and presenting products. Ease of transportability and extending the shelf life of packaged products are the other benefits of using plastics as a packaging material.

Plastics such as Polypropylene (PP), Polystyrene (PS), Polyvinyl Chloride (PVC), Low-density Polyethylene (LDPE), High-density Polyethylene (HDPE), Polycarbonates (PC) and Polyethylene Terephthalate (PET) are being used by food processors for packaging food. However, some grades of plastics do have certain disadvantages when they come in direct contact with food. For instance, grades such as PVC, PS and PC leach chemicals that are way above the acceptable limit. These plastics also have limitations in terms of prolonging the shelf life of packed products in controlling microbial, enzymatic and biochemical reactions of the internal environment of the packaging via strategies such as oxygen removal, controlled release of salts etc.

However, there are new varieties that do not affect the quality of food products but instead increase shelf life. Playing a

protective role, modern plastics are doing a lot more than their key functions.

Multi-layer filmsMulti-layer co-extruded or laminated flexible materials are a significant development in modern packaging technology. Most extruded multi-layer structures are based on polyolefins because of their low cost, versatility, processability, chemical inertness and high moisture barrier properties accompanied by their poor ability to inhibit oxygen and aroma transitions. These multi-layer structures are produced by processing commodity plastics such as PE and PP, tie resins and centre barrier resins [eg ethylene vinyl alcohol (EVOH) and polyamide]. An extruder, a feed block and a die are used to produce a five-layer film. The multi-layer films could be of seven layers or nine layers depending on the number of extrusion lines when a multi-layer film is made.

Polyamide resins are also an important class of polymers used in the packaging industry and owe their popularity to good barrier properties against oxygen, aromas and organic solvents along with high tensile strength and toughness. “The thin barrier layer, which is usually made of EVOH, Polyvinylidene Chloride (PVDC), polyester, acrylic co-polymer or

similar material, is designed to preserve freshness and lengthen shelf life by preventing the migration of gas in or out of the package; for example, to keep oxygen out of a frozen food package or to keep carbon dioxide inside a beer bottle,” says Dr Subhas Chandra Shit, Professor & Head-HLC, Department of Chemicals & Petrochemicals, Central Institute of Plastics Engineering & Technology (CIPET), Ahmedabad.

Multi-layer containers have a layer of EVOH sandwiched between PP and any other plastic grade. EVOH provides oxygen and moisture barrier properties to the container. This keeps the product in the container fresh with a shelf life of over 12 months.

Blends and nanomaterialsCyclic Olefin Copolymers (COC) are also being increasingly used in polyolefin blends to produce barrier films for packaging because it has one of the highest moisture barriers of any polymer (four to five times better than LDPE). COC is not considered to have a high gas barrier, but it is still significantly better than LDPE. When COC is added to Linear Low-density Polyethylene (LLDPE), it increases modulus by two times while maintaining low haze. Similarly, when HDPE is blended with polyamide, its

The right material is crucial for the success of any packaging application. With continued innovations, new grades of plastics are being developed to extend the shelf life of packaged food products. Although studying the total system for a complete analysis is required, Sweta M Nair presents the latest in this segment that is making big waves.

APPLICATIONS APPLICATIONS THAT ENHANCE THAT ENHANCE

PRODUCT PRODUCT SHELF LIFESHELF LIFE

Plast ic packaging


barrier properties increase significantly.Nanocomposites are also at the

forefront of food packaging development. Nanocomposite film enriched with an enormous number of silicate particles reduces the entry of oxygen and other gases and the exit of moisture, thus preventing food from spoilage. Dr Shit adds, “Some companies have developed nanocrystals for making a nanocomposite that would be used in beer bottles. Most polymer composite materials are based on fossil fuel derivatives; however, research on biopolymers is offering biodegradable alternatives. The inherent drawbacks of pure bio-polymers that depend on type can include poor barrier properties or poor mechanical properties can be mitigated by the inclusion of nanofibres to form nano-biocomposites.” Most nanocomposite materials employed or being developed for use in the food packaging industry contain nanoclay particles; however, other composites containing nanoparticles, nanotubes or nanofibres of metals, metal oxides, biopolymers or other carbon-based material are being developed.

New systems and filmsTo arrest oxygen, new polymer systems with special barrier properties are used on the surface of the plastic container. A recent study conducted by Dr Philip Labuschange and his team claimed that the developed polymeric system (inter polymer complexation system – close-knit polymer network formed by hydrogen bonds with a high density) reduces oxygen permeability by a factor of about 20 (for polyester-based plastics) and by a factor of about 150 (for polyolefin-based plastics). This simply increases the shelf life of any oxygen-sensitive beverage in plastic containers by up to 150 times.

In the food sector, multi-layer films occupy the major share of the food packaging market since nano-based materials are yet to be effectively commercialised and are presently priced at a high cost. “Nanostructured material will have better capability than others because of the high barrier capacity and environment-friendly character,” affirms Dr Shit.


Dr Subhas Chandra ShitProfessor & Head – HLC, Department of Chemicals & Petrochemicals, CIPET, Ahmedabad

Some companies have developed nanocrystals for making a nanocomposite that would be used in beer bottles. Most polymer composite materials are based on fossil fuel derivatives; however, research on biopolymers is offering biodegradable alternatives.

TIPS & TRICKS: Guidel ines for ef f ic ient equipment


The plastics processing industry requires heavy maintenance and constant monitoring of numerous equipment that are used in order to remain in optimum working conditions. Anwesh Koley notes various pointers to ensure seamless processing and cost efficiency.

The growth witnessed by the plastics industry has a direct implication on the performance of the ancillary

equipment sector, which forms the backbone of the plastics machinery

industry. The numerous machines used in the plastics industry require a host of equipment that depend upon the application and requirement of the final product. The global trend towards faster processing equipment

and better accuracy in terms of productivity has led manufacturers across the country to adopt technologies that help achieve higher end user satisfaction.


Being environment-friendly is a key requirement for equipment in plastics processing. Use of consumables that are recyclable or environment-friendly must be adopted. Water is being increasingly used as heat transfer medium instead of thermal oil in temperature control units. Refrigerant units use environment-compatible refrigerants, and lead soldering of printed circuit boards has been given up by most processors.

When the processing unit has reached a consistent temperature, the extruder machine is ready to be turned on. It is important to speed up the screw rod manually and start the feeding process of the material into the machine. Also, the material must be checked on its way out of the machine to make sure there are no impurities, no foam, no coke burning and no colour change.

The current trend in user-friendly networked controls is towards graphical, menu-driven touch screen controls. Different parts of the system can communicate with each other through CANbus or ethernet protocols . Anci l lar y equipment are designed with digitally controlled, more precise, fast, compact graphical interfaces that are easily compatible with machine controls.

It must be ensured that before commencing operation, the water, electricity, gas levels and temperature systems are properly checked and in good working order. When this inspection is complete, the die head must be calibrated and installed. This is essential as equipment break down might occur during non-working hours. After this is done, the heating power may be turned on.

Latest technology aids in efficient processing. Advanced features are options for connectivity with Wi-Fi & SCADA solutions through which all the machines are connected with a single PC, or a smart phone through which processors can access their machine production and status from anywhere in the world. These must be installed at all levels to achieve the desired results.

Energy efficiency and conse r va t ion have become imperative for ancillary equipment usage. Minimising energy input in processes, decreasing energy losses and recovery of waste heat need to be seamless. This is important in drying, granulation, temperature control and chiller systems, which are energy intensive. Lowering costs through reducing inputs, wastage and labour has been the focus in blending and conveying systems.

Ensuring SAFE and EFFICIENT processing

Follow these pointers for effective ancillary equipment maintenance:

PROJECTS


High-density polyethylene/polypropylene/nylon/polyester and their products including fishing ropes, fishing nets and fishing twinesTufropes Pvt LtdProject typeNew facilityProject newsTufropes Pvt Ltd is planning to set up a new polymers project at Vadodara in Gujarat. The project involves manufacturing of all types of high-density polyethylene/polypropylene/nylon/polyester and their products including fishing ropes, fishing nets and fishing twines.Project locationVadodara, GujaratProject costNAImplementation stagePlanning

Contact details:Tufropes Pvt Ltd507, Embassy CentreNariman Point Mumbai – 400 021Tel: 022-40502600 Fax: 022-22844167 Email: [email protected]

High-density polyethylene/polypropylene woven sacks Ankit Polysack India Pvt LtdProject typeNew facilityProject newsAnkit Polysack India Pvt Ltd is planning to set up a new polymers project at Tikamgarh in Madhya Pradesh. The project involves manufacturing of high-density polyethylene/polypropylene woven sacks. The company has received industrial license from Secretariat of Industrial Assistance (SIA), Department

of Industrial Policy and Promotion, Government of India, for setting up the project.Project locationTikamgarh, Madhya PradeshImplementation stagePlanningProject costNA

Contact details:Ankit Polysack India Pvt LtdNo. 431, Tal Kalol Santej–Vadsar Rd Ahmedabad – 382721Gujarat Tel: 027-64286673 Plastic polymer plantIndian Oil Corporation Ltd (IOC)Project typeNew facilityProject newsIndian Oil Corporation Ltd (IOC) is planning to set up a polybutylene terephthalate, semi-crystalline thermo plastic polymer plant. The refinery will also include a petrochemical complex with a 553,000 tonne/year purified terephthallic acid production facility from naphtha supplied by the Panipat and Mathura refineries in close proximity.Project locationPanipatProject costNAImplementation stagePlanning

Contact details:Indian Oil Corporation Ltd (IOC)3079/3, J B Tito MargSadiq Nagar New Delhi – 110 049Tel: 011-26260000

Plastic shopping bagsNational Small Industries Corporation LtdProject typeNew facilityProject newsSupply of one set of plastic shopping bags.Project locationIndiaProject costNAImplementation stagePlanning

Contact details:National Small Industries Corporation LtdNSIC BhawanOkhla Industrial EstateNew Delhi – 110 020 Tel: 011-26926275, 26926370Fax: 011-26932075

Tarpaulin made of high-density polyethylene and polypropylene bagsJBS Rasayan Pvt LtdProject typeNew facilityProject newsJBS Rasayan Pvt Ltd is planning to set up a new polymers project at Burdwan in West Bengal. The project involves manufacturing of tarpaulin made of high-density polyethylene Leno bags, polypropylene jumbo bags and cement/fertiliser bags.Project locationBurdwan, West BengalProject costNAImplementation stagePlanning

Contact details:JBS Rasayan Pvt Ltd24, Hemanta Basu Sarani Kolkata – 700 001 West Bengal

New projects and expansion activities are the barometers of industrial growth. These also present business opportunities to service providers like consultants, contractors, plant & equipment suppliers and others down the value chain. This feature will keep you updated with vital information regarding new projects and capacity expansions being planned by companies in the plastics, polymers and allied industries.

Information courtesy: Tendersinfo.com

1, Arch Gold, Next to MTNL Exchange, Poisar, S V Road, Kandivali (W), Mumbai - 400 067, Maharashtra, India

Tel: 022 28666134 • Fax: 022 28013817 • Email: [email protected]

TENDERS


Latest Popular Tenders brought to you by www.tendersinfo.comGarbage bags and sacksOrg : Thisted Kommune

TRN : 14976438

Desc : Provision of garbage bags and sacks

BOD : 10 Apr 2013

Loc : Denmark

BT : Global (ICB)

Silicone rubber and rimsOrg : Fars Regional Electric Co

TRN : 15225218

Desc : Supply of 80 and 120 kN

silicone rubber and rims

BOD : 10 Apr 2013

Loc : Shiraz, Palestine

BT : Global (ICB)

Polythene bagsOrg : Ordnance Factory Board

TRN : 15162162

Desc : Supply of polythene bags

BOD : 11 Apr 2013

Loc : Kanpur, Uttar Pradesh

BT : Domestic (NCB)

Moulding machineOrg : Plastyko Word SRO

TRN : 14976520

Desc : Supply, installation and commissioning

of special thermoforming moulding machine

BOD : 12 Apr 2013

Loc : Czech Republic

BT : Global (ICB)

Plastic seatsOrg : North Western Railway

TRN : 15060588

Desc : Supply of plastic seat, ie bottom top

for commode of coaching stock

BOD : 12 Apr 2013

Loc : Jaipur, Rajasthan

BT : Domestic (NCB)

Low-density polyethylene filmOrg : India Government Mint

TRN : 15161245

Desc : Procurement of low-density polyethylene film

BOD : 16 Apr 2013

Loc : Hyderabad, Andhra Pradesh

BT : Domestic (NCB)

Plastic films and bagsOrg : ICDI

TRN : 14976268

Desc : Acquisition and recycling of plastic waste – planting

pots, plastic film (polyethylene) and expanded

polystyrene (frigolite) from parks, recycling ICDI

and delivery bags

BOD : 16 Apr 2013

Loc : Couillet, Belgium

BT : Global (ICB)

Polyvinyl chloride flooring sheetOrg : Central Railway

TRN : 15140302

Desc : Supply of flexible polyvinyl chloride

flooring sheet

BOD : 18 Apr 2013

Loc : Mumbai, Maharashtra

BT : Domestic (NCB)

Carbon molecular sieveOrg : Tamil Nadu Generation and Distribution

Corporation Ltd

TRN : 15224227

Desc : Carbon molecular sieve for pressure

swing adsorption in N2 adsorption tower

BOD : 19 Apr 2013

Loc : Ramanathapuram, Tamil Nadu

BT : Domestic (NCB)

Org: Organisation’s name, TRN: Tendersinfo Ref No, Desc: Description, BOD: Bid Opening Date, Loc: Location, BT: Bidding Type.

Latest Popular Tenders brought to you by www.tendersinfo.com

Information courtesy: Tendersinfo.com

1, Arch Gold, Next to MTNL Exchange, Poisar, S V Road, Kandivali (W), Mumbai - 400 067, Maharashtra, India

Tel: 022 28666134 • Fax: 022 28013817 • Email: [email protected]

EVENT LIST


Compack ChennaiCompack 2013 displays one of the

most impressive and efficient collection

of packaging equipment and materials

which are of advanced technology.

This event will demonstrate the most

important packaging and processing

solutions. The visitors coming to

Compack 2013 will comprise high

profile executives from the packaging

and transportation sectors; June 7–9,

2013; at Chennai Trade & Convention

Centre, Chennai, Tamil Nadu

For details contact:

Narendar Bafna

Smart Expos

New No. 116, Manickam Lane

Mount Road, Guindy

Chennai - 600 032

Tamil Nadu

Tel: 044-22501986/1987

Mob: 09952966752


Website: www.compackexpo.com

IPLEX ChennaiThe Tamil Nadu Plastics Manufacturers

Association, the organiser of

IPLEX, has come forward to exhibit

various moulds and dies, equipment

and machinery exclusively required by

the plastics manufacturing sector of

India. The exhibitors are well versed

with the respective range of products

so that attendees can select the best

for their firms; June 27–30, 2013; at

Chennai Trade & Convention Centre,

Chennai, Tamil Nadu


Senthil Kumar N

The Tamil Nadu Plastics

Manufacturers Association

C-1, First Floor, Rams Square

Village Road, Nungambakkam

Chennai

Tamil Nadu

Tel: 044-28250107

Pharmapack ExpoPharmapack Expo is the most

cost-effective marketing opportunity

and is the best opportunity to meet

senior buyers and decision makers

from all facets of the user industry.

The exhibits will include packaging

materials & products, glass & plastic

jars and bottles, aluminium & plastic

tubes, corrugated & cardboard boxes,

dosing machines for liquids & powders,

filling machines, blister packing

machines, strip packing machines, labels

& labelling equipment, form-fill-seal

machines etc; September 12–14, 2013;

at Bombay Exhibition Center (BEC),

Mumbai


Intel Trade Fairs & Expositions Pvt Ltd

113, New Sonal Link Industrial Estate

Building No. 2, Link Road

Malad (W)

Mumbai - 400 064

Tel: 022-26003977


Website: www.pharmapackexpo.in

PlastShow PlastShow is dedicated to offering a

comprehensive range of plastic products

and processing equipment. The event

strives to offer complete information

about the recent inventions of the plastic

manufacturing sector. The exhibitors

find this expo to be the perfect business

meeting place where the exhibiting

companies get an opportunity to

establish themselves and promote their

brands; September 27–30, 2013; at Vapi

Industrial Association Ground, Vapi,

Gujarat


Brijesh Purohit

Sunline Infotech, 118, Lotus Arcade

Opposite Automotive, Gondal Road

Rajkot, Gujarat

Tel: 0281-2460135

Plastivision India Designed to help exhibitors and

visitors to discover potential markets,

Plastivision India will be the 9th in

the series of national exhibitions and

seminars organised by the All India

Plastics Manufacturers Association

(AIPMA). With participation from

more than 45 countries and visitors

from over 61 countries, the event

will include exhibitors ranging from

categories such as raw materials &

chemicals, plastic packaging machinery

& equipment, machinery & equipment

for processing, recycling, pre & post

processing machines, plastic extrusions,

thermoforming/films/thermoplastics

etc; December 12–16, 2013; at Bombay

Exhibition Center (BEC), Mumbai


AIPMA

A-52, Street No. 1, M I D C, Marol

Andheri (East), Mumbai

Tel: 022-28217324/28217325/

28352511/283

Fax: 022-28216390


Website: www.plastivision.org

National

India’s premier industrial trade fair on products and technologies related to Machine Tools,

Hydraulics & Pneumatics, Process Machinery & Equipment, Automation Instrumentation,

Packaging & Auxiliaries, IT Products, Electrical & Electronics, Material Handling and Safety

Equipment.

For details contact:Network18 Media & Investments Ltd, Ruby House, 1st Floor, J K Sawant Marg,

Dadar (W), Mumbai 400 028. Tel: 022 3003 4651 • Fax: 022 3003 4499

Email: [email protected] Web: www.engg-expo.com

HyderabadAndhra Pradesh

May 31-Jun 3, 2013

EVENT LIST


Plastic JapanPlastic Japan is one of the biggest trade

show of the plastics industry in Japan.

Over the course of three days, 25,000

professionals of the plastics industry are

expected to visit the event this year to

discuss business and expand their client

base. Plastic Japan will be visited by key

players of the plastics industry of the

country; April 10–12, 2013; at Tokyo

International Exhibition Center (Tokyo

Big Sight), Tokyo, Japan


Plastic Japan Show Management

Jun-yeup Lim

Reed Exhibitions Japan Ltd

18F Shinjuku-Nomura Bldg

1-26-2 Nishishinjuku, Shinjuku-ku

Tokyo 163-0570, Japan

Tel: +81-3-3349-8518

Fax: +81-3-3349-8530


Website: www.plas.jp/en

Plastic ExpoPlastic Expo is one of the premium

exhibitions providing the latest and

the best in plastic materials for

all manufacturing and processing

industries alike. It enables foreign

and Tunisian professionals to assess

industry situations, develop their

business relationships in the domestic

and international markets, secure

technological watch, study and compare

prices, delivery times and quality,

launch partnerships, seek new raw

materials sources, supplies and potential

clients etc; April 24–27, 2013; at Tunis

Exhibition Center, Tunis, Tunisia


Foires Internationales De Tunis

B. P. N-1, 2015

Le Kram, Tunis, Tunisia

Tel: +(216)-(71)-730111

Fax: +(216)-(71)-730666


Website: www.plasticexpo.com.tn

Alex PlastAlex Plast will help make technical

and professional experts related to the

plastics industry aware of the latest

trends and techniques to help advance

the plastics industry. It will bring to light

the importance & value of machinery

& equipment for plastics, reinforced

plastics and technical parts in the recent

times. This expo will also provide useful

information to contractors, consultants

and engineers; May 1–4, 2013; at

Alexandria Fairgrounds, Alexandria,

Egypt


Trust International Group

20 El-obour Building

Salah Salem St

Nasr City, Cairo, Egypt

Tel: +(20)-(2)-22600986

Fax: +(20)-(2)-24012121


Website: www.alex-plast.com

Plastpol ExpoPlastpol Expo is a prestigious show

for the rubber and plastics industries

as professionals will get to exhibit new

and advanced machinery that will help

in increasing productivity. The expo is

the perfect place where new products

will be launched and the attendees

will also get to know about the recent

developments made in this sector. The

popularity of the show has brought in

the participation of leading companies

from the domestic and international

market; May 7–10, 2013; at Kielce

Trade Fair Centre, Kielce, Poland


Kielce Trade Fairs

(Targi Kielce S.A.)

1, Zakładowa Str

25-672 Kielce, Poland

Tel: +4841 365 12 22

Fax: +4841 345 62 61


Website: www.targikielce.pl

Plast-Ex Being organised by Canon

Communications Llc, Plast-Ex is one of

the largest shows for attracting a large

number of people from the plastics,

printing and packaging sectors worldwide.

Plast-Ex is an eminent show that will

be hosted in Canada and will offer an

exhibiting space for displaying machinery

related to plastics, rubber, packaging and

printing; May 14–16, 2013; at Toronto

Congress Centre, Toronto, Canada


UBM Canon

2901 28th Street, Ste. 100

Santa Monica, CA 90405

United States

Tel: 310/445-4200


Website: www.canontradeshows.com/expo/

plastex13

Feiplastic International Plastics Trade FairFeiplastic International Plastics Trade

Fair is not just an ordinary trade event but

is one of the largest and most informative

international gatherings of its kind in

Latin America. Recent innovative plastic

products will be showcased and reputed

brands in this domain will gather to

exhibit products and services through this

international platform, which strives to

attract top professionals from Brazil and

abroad; May 20–24, 2013; at Anhembi

Parque, Sao Paulo, Brazil


Reed Exhibitions Alcantara Machado

R. Bela Cintra

1200 - 7th Floor Cerqueira Cesar

Sao Paulo, Brazil

Tel: +(55)-(11)-30605000

Website: www.feiplastic.com.br

International

The information published in this section is as per the details furnished by the

respective organiser. In any case, it does not represent the views of


EVENT REPORT: Indo-German Internat ional Seminar


Sweta M Nair

If the future of automobiles was

to be described in simple words,

then reducing manufacturing costs

and reducing weight to meet fuel

consumption regulations would become the

global mantra. Integration of functionality

coupled with new processing technologies

would be the perquisite here, but keeping

the innovative spirit burning would also

be crucial in the competitive atmosphere.

The 5th edition of the two-day Indo-

German International Seminar on ‘Plastics

in Automotives – Redefining Possibilities’

that was held on March 7–8, 2013, at the

Trident, Chennai, presented compelling

cases on this revolutionising mantra.

With support from the Department of

Chemicals and Petrochemicals, Automotive

Component Manufacturers Association

of India (ACMA) and Society of Indian

Automobile Manufacturers (SIAM), the

seminar was organised by the Organization

of Plastics Processors of India (OPPI)

and sponsored by the Verband Deutscher

Maschinen- und Anlagenbau (VDMA)

– German Engineering Federation. The

seminar kicked off with an inauguration

ceremony where the Chief Guest Manfred

Geiss, CEO, Geiss AG, Germany, addressed

the audience members in his welcome note.

What followed shortly were sessions with

speakers from companies such as Arburg,

Engel, Geiss, Hennecke, Kautex, Kiefel,

KraussMaffei, Kuka, Kurs, Sumitomo

Demag, Unicor and Wittmann-Battenfeld.

These sessions highlighted technology

that help achieve reduction in energy

consumption and increase in production

with less running cost.

High level of participationThe seminar was attended by about 215

individuals who belonged to segments

such as original equipment manufacturers,

plastics raw material manufacturers,

plastics processors producing plastic

components for automotives, automotive

paint producers, plastics processing

machinery manufacturers, consultants,

robot manufacturers etc. At the conclusion

of day one, Srinivas Sonti, General

Manager – Sales, Ferromatik Milacron

India Pvt Ltd, who was a moderator at one

of the sessions, said, “I believe the seminar

has been very informative for senior

management as well as for individuals

at the operating level. Although some

of the technologies showcased here are

a bit advanced for the industry in India,

sooner than later, it will arrive here as well.

Companies will imbibe on this level of

technology soon.”

A power-packed Q&A session

concluded most of the speaker’s

presentations. The high level of

participation proved a fruitful exchange for

problem-solving. Each presentation at the

seminar detailed trends of globalisation,

lightweighting and cost reduction.

Solutions for the industrySome of the sessions highlighted

the challenges but were also

quick to provide useful solutions.

Modern manufacturing techniques

with competitive advantages through

efficient production where parts or

components can be produced at the

lowest possible cost in the highest

possible quality were discussed extensively

in between breaks.

Selection and combination of

materials, defining tolerances especially

for plastics, integration of functions,

minimising production steps, reduction

in wall thickness thereby saving material

were other topics that sprung up during

the Q&A sessions. Lilli Rudnick,

Exhibitions – EUROMAP, VDMA, in

her feedback complimented the OPPI

for the excellent organisation of the 5th

Indo-German International Seminar. She

said, “The speakers were impressed by the

number of participants at this event. We

hope that this conference has contributed

towards bringing exciting new technology

to the Indian plastics processing industry

and that the attendees gathered new and

interesting insights that will find a place in

their future strategic plans.”


From the seventies when plastics comprised only 6 per cent in automotives to the present scenario where these wonder materials command a 20 per cent role in European and American cars, plastics have come a long way. The increasing usage of plastics in automotives is significant and here to stay. With this trend in focus, the 2-day Indo-German International Seminar on ‘Plastics in Automotives – Redefining Possibilities’ was just what the industry needed – a fresh perspective on the latest available technology.

Redefining the future of automotive plasticsRedefining the future of automotive plastics

Speakers of the event along with members of OPPI and VDMA

EVENT REPORT: Engineer ing Expo Aurangabad 2013


Nishi Rath

It was in 1960 that the region of

Marathwada was merged with

Maharashtra. This was the time

when the industrial development

of Marathwada began. Over time, the

Maharashtra Industrial Development

Corporation (MIDC) acquired land and

set up industrial estates, which provided a

boost to the region’s tremendous growth.

Aurangabad is now one of the classic

examples of efforts towards balanced

industrialisation with factors such as

availability of labour, comparatively lower

cost for setting up base and a developing

market attracting an array of industries

to the city. Additionally, the presence of

renowned MNCs and domestic giants

in Aurangabad has further catalysed the

city’s industrial growth by offering Small

& Medium Enterprises (SMEs) a boost.

Reflecting the city’s industrial

growth was the second edition of

Engineering Expo Aurangabad. Held

during February 22–25, 2013, at Ayodhya

Nagari Grounds, the four-day Expo

was inaugurated in the presence of an

esteemed set of Guests of Honour

including Kala Ojha, Mayor, Aurangabad;

Sanjay Shirsat, MLA, Aurangabad West;

Pradeep Jaiswal, MLA, Aurangabad

Assembly Constituency; G M Ambhore,

Director, MSME Development Institute;

P Udayakumar, Director, The National

Small Industries Corporation; Sudhanva

Jategaonkar, Associate Vice President,

Network 18 Publishing; and Vijay N

Jaiswal, President, Aurangabad Industrial

Suppliers Association (AISA).

The inauguration also witnessed the

presence of Sunil Raithatha, President,

Chamber of Marathwada Industries and

Agriculture (CMIA); Dr Uday Girdhari,

President, Marathwada Association of

Small Scale Industries and Agriculture

(MASSIA); Adesh Palsingh Chabda,

President, Aurangabad Zilla Vyapari

Mahasang; and Mansingh Pawar, Past

President, MASSIA, among others.

Officially approved Organised by Network 18 Publishing with

AISA as supporting partner, the Expo

played host to various industry giants and

market leaders who showcased their best

products and services at the trade show.

Balasaheb Thorat, Minister of Revenue,

Government of Maharashtra, also graced

the Expo. He said, “Engineering Expo

Aurangabad has become a platform for

new industries developing in the region.

It has also proved to be the best platform

for students as it gives them exposure to

the real industrial world. I feel more events

on similar lines should be organised in the

near future.”

Rajendra Darda, MLA & Minister

of School Education, Government of

Maharashtra, also marked his presence

at Engineering Expo Aurangabad. “The

whole experience here was worth the visit.

The Expo was well organised and provided

a platform for local entrepreneurs. We

look forward to many more such events,”

he added.

Bright future for SMEs According to experts, the historical

background of the place helps attract

foreign investors. Aurangabad boasts of a

strong brigade of young and enthusiastic

first-generation entrepreneurs, who not

only implement new ideas but also steer

the growth. “Aurangabad has a lot of

potential when it comes to the industries.

The small scale industries here have a

Since the last few years, Aurangabad has emerged as one of the fastest growing industrial hubs. The region already has a huge industrial presence with a large number of engineering services, auto ancillary and pharmaceutical research companies setting up facilities here. The ever-evolving industrial scenario and the enterprising spirit of its entrepreneurs have helped Aurangabad grow into an industrial area of repute. Engineering Expo Aurangabad 2013 proved to be the right ‘growth tonic’ for boosting the region’s industrial might.

AURANGABADFebruary 22–25, 2013Ayodhya Nagari Grounds

Exhibiting Aurangabad’s unparallelled potential

Dignitaries unveil the Exhibitors’ Directory at the inauguration of Engineering Expo Aurangabad 2013

Engineer ing Expo Aurangabad 2013


Balasaheb Thorat, Minister of Revenue, Government of Maharashtra, being felicitated with a memento by Network 18 Publishing and AISA team

great future. They are keen to grow and

play a key role in the growth of any

particular region,” said Udayakumar.

Engineering Expo Aurangabad

focussed on providing SMEs an

opportunity to demonstrate their

capabilities, to offer a platform to

industries across the country and

enable exhibitors to formalise business

alliances for mutual growth. “The trade

show truly opened up a new world of

opportunities for the small and medium

scale industries here. The enthusiasm

among exhibitors was encouraging. It

was a good experience to be a part of

this grand show,” asserted Shirsat.

Upbeat exhibitorsThe exhibitors were overwhelmed by the

positive response they received from the

visitors. They were looking forward to

generating more business gauging from the

enquiries that they received at the Expo.

Manoj Kumar, Director, Apex Group, who

exhibited at the trade show, said, “We have

had a lot of enquiries; I cannot gauge how

many will turn out to be good business

leads, but yes, I am pleased with all the

enquiries. It proves that we have managed

to attract the target customers and create

our brand visibility.”

Another exhibitor, Nitin Bagul, Director,

Technovision Instrumentation Solution

Pvt Ltd, expressed, “We participated in

Engineering Expo Aurangabad last year

as well; it helped us build good contacts.

Aurangabad is an industrial hub and the

number of industries is increasing by the

day. This is a good place for such an event;

only awareness among the masses has to

be increased.”

Anand Pahade, Proprietor, Chintamani

Electricals, who also exhibited at the trade

show, said, “We participated in this trade

show as we wanted to create our brand

image on which customers can bank on.

The response we have received has been

mixed. Expos such as these should work

towards creating awareness among the

masses in Aurangabad.”

Initiatives in action Engineering Expo Aurangabad saw some

great initiatives in action. The ‘National

Vendor Development Programme’ acted as

a crowd puller both in terms of exhibitors

and visitors. Organised by the MSME

Development Institute, Ministry of

MSME, Government of India, the event

became an instant hit. It saw participation

from organisations such as Western

Railways, State Transport, Hindustan

Petroleum Corporation Ltd, Indo German

Tool Room and Central Institute of

Plastics Engineering and Technology.

Speaking at the event, Ambhore

stated, “Our main objective is to identify

and explore the business opportunities

in the highly competitive area. We also

encourage benchmarking for meeting the

challenges in the best way.”

Engineering Expo Aurangabad was

not all about exhibitors but it also offered

a lot to the visitors.

Visitors make the most of ExpoCommenting on how an Expo of this

stature acts as a growth catalyst, Mayur

Parikh, Senior Manager Marketing,

Sah Petroleum Ltd, said, “Exhibiting

companies fully utilised this platform

at the Expo. Such trade shows always

help the industrial circuit of a particular

region. It was great to be part of the

Expo as a visitor.”

Another visitor opined that

the turnout, despite the recession,

was commendable. “Taking into

consideration the recession, the turnout

was good. Engineering Expo is a great

platform for small and medium scale

industries to connect and understand

the market requirements,” averred

Abhay Sharma, Director, Extreme Ro

System Pvt Ltd.

Students too had a great chance to

get hands-on experience at the Expo.

Starting from market trends to new

technology, the Expo turned out to be

a helpful lesson for them. “Students can

learn a lot here; where else can they find

the latest technologies and machines at

one place?” opined Ojha.

Marking a new beginningAdding another feather to its cap,

Engineering Expo came to an end with

a promise to come back with more

enthusiasm and better opportunities

for Aurangabad. The next edition

of Engineering Expo will be held in

Hyderabad, Andhra Pradesh, during

May 31 to June 3, 2013.


Pan India participation by 223 exhibitors

Spread across more than 10,914 sqm

18,528 business visitors visited from across India

Business transactions worth ` 74.78 crore*

More than 11,533 business leads generated*

8,500+ products displayed from different industries

More than 90,000 kg machinery moved in for display

Highlights of this edition

EVENT REPORT: Engineer ing Expo Aurangabad 2013 – Panel Discussion


Nishi Rath

Aurangabad has carved a

niche for itself among

the industrial leaders in

the country. In the era of

liberalisation and intensive competition,

Aurangabad is resolutely addressing

the challenge of moving to a higher

growth trajectory in the industry.

Taking a peek into this growth story,

Network 18 Publishing with support

from Aurangabad Industrial Suppliers

Association (AISA) organised a

panel discussion on the sidelines of

Engineering Expo Aurangabad 2013.

Held at Taj Presidency on February

22, 2013, the panel discussion served

as food for thought for more than

150 industry leaders and professionals.

Leading industr y exper ts

such as Ram Bhogale, Director,

Umasons Auto Compo Pvt Ltd;

S G Rajput, GM, District Industries

Center (DIC) & Superintendent

Industries Officer, Aurangabad;

Mukund Kulkarni, Director, Expert

Global Solutions and Ex-President

Chamber of Marathwada Industries and

Agriculture (CMIA); P Udayakumar,

Director, The National Small Industries

Corporation (NSIC) and Maithilee

Tambolkar, Director, Sanjeev Auto

Parts Manufacturers Pvt Ltd,

enlightened the audience on the

opportunities Aurangabad can provide.

The panel discussion was moderated

by Archana Tiwari-Nayudu, Editor,

Network 18 Publishing.

Is Aurangabad underrated?The first non-stick pan came from

Aurangabad; one of the best white

goods brands and electronics is offered

by this city; it also supplies the best

microfinishing machines, which also

compete with the world’s best. However,

it seems to lack visibility. “We export to

72 countries and, in the last two years,

Aurangabad-based organisations have

done acquisitions overseas. But we are

still understated because we have been

underestimating ourselves. It is high

time we move ahead,” said Kulkarni.

“We have created brands but were never

given that status. This is because we were

overshadowed by major industrial hubs such

as Mumbai and Pune. But I think it is time

for us to come out of that shadow and prove

our calibre,” observed Bhogale.

Taking the discussion ahead,

Tambolkar added, “There is no

denying that Aurangabad is underrated

as a manufacturing hub, one of the

reasons being the presence of various

first-generation entrepreneurs. Every

business has to go through a cycle and

most of them are completing the cycle

now. So, this is the time.”

Giving the discussion a twist,

Udayakumar said, “I look at it in a positive

way. In the age of competition, it can

be seen as an opportunity. Entrepreneurs

can focus on their resources and

future plans, when no one looks at you

as a threat.”

Technology takes the leadAccording to the panellists, investing

in technology and innovation will take

Aurangabad to a new level. “What we

have focussed on is right investment and

right technology; investing in the latest

technology will always pay back in the

long term. This strategy has helped us

too,” added Tambolkar.

Speaking up for technology, Bhogale

stated, “Investing in technology is one

of the reasons why we have witnessed

growth. Aurangabad is a good mix of

innovation and tradition. There are

people who have innovatively managed

their traditional ways. That has given

them a competitive edge.”

Kulkarni added, “Investing in the

best technology is key; the short-term

costs may be higher, but the long-

term gain is what people should be

looking at. Managing time, quality,

productivity and safety will also make

us competitive.”

The panel discussion received an

overwhelming response from the industry,

who actively participated as the audience.

The insightful discussion was followed by

a lively question and answer session.


A panel discussion was organised on the sidelines of Engineering Expo Aurangabad 2013. Held on February 22, 2013, the panel discussion on ‘Trade, trends & technology: Gauging Aurangabad on the critical parameters’ was good food for thought.

Gauging Aurangabad on the critical parameters

(L–R) Maithilee Tambolkar, Director, Sanjeev Auto Parts Manufacturers Pvt Ltd; SG Rajput, GM, DIC & Superintendent Industries Officer, Aurangabad; Archana Tiwari-Nayudu, Editor, Network 18 Publishing;

Ram Bhogale, Director, Umasons Auto Compo Pvt Ltd; P Udayakumar, Director, NSIC; and Mukund Kulkarni, Director, Expert Global Solutions & Ex-President, CMIA, voice their views at the panel discussion

BOOK REVIEW


Plastic packaging of foods is not only obvious and omnipresent in developed economies but also increasingly commonplace in the developing world, where plastic packaging is instrumental in decreasing the proportion of the food supply lost to spoilage.

This new handbook is a combination of new material, unrevised chapters and updated chapters chosen by the author from recently published books on the subject. The handbook offers a practical source for engineers, scientists and managers working in the food packaging industry, providing a tailor-made package of science and engineering fundamentals, best practice techniques and guidance on new and emerging technologies.

By covering materials, design, packaging processes, machinery and waste management, all in one book, the editor enables the reader to take a lifecycle approach to food packaging.

The handbook addresses questions related to film grades, types of packages for different types of foods, packaging technologies, machinery and waste management. Additionally, the book provides a review of new and emerging technologies. Two chapters are devoted towards development of barrier films for food packaging and the regulatory and safety aspects of food packaging.

Plastic Films in Food Packaging: Materials, Technology, and ApplicationsEditor: Sina EbnesajjadPrice: ` 14,350

This book serves to bridge the values of engineering end-use parameters of Polyethylene (PE) resins and their scientific molecular and structural characteristics. The main goal is to translate common parameters such as melt flow index of a resin or the dart impact strength of a film sample into the universal language of polymer science. After this translation, many facets of the resin properties become apparent and explainable.

The contents of the book include topics such as manufacture, structure and mechanical properties of PE resins, melt index and melt flow ratio of PE, melting point of PE resin, crystallinity degree & density of PE, end-use mechanical properties of PE film, end-use testing of high molecular weight high-density PE and medium-density PE resins.

This valuable sourcebook is apt for undergraduate students who have taken polymer physics as well as for practising professionals in the industry.

Polyethylene: End-Use Properties and their Physical Meaning

Available at: SCI-TECH Books & Periodicals, 414, Janki Centre, Veera Desai Road, Andheri (W), Mumbai – 400053Tel: 022-26735260/66970507 • Fax: 022-6735424/26735260 • Email: [email protected]

Reviewer: Dr R Rangaprasad, Experienced Polymer Professional

Author: Yury V KissinPrice: ` 6,850

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rubber/high temperature/roller mould

temperature controller. These machines are intended for processes

such as plastic injection moulding, extrusion moulding, blow

moulding, chemical industry, dye-casting, reaction axe rubber tyre,

rubber vulcanisation, electric wire, calendar, printing, ban-burying

and other related industries.

Weichi Enterprise Co Ltd

Guangzhou - China

Tel: +86-020-36850626


Website: www.weichigz.com

Tel: 022 - 22063534, Fax: 022 - 22063533

Email: [email protected], [email protected],

[email protected]

Website: www.specialitypolymer.com

Specialty chemicalsThe Millad NX 8000 offers

important sustainability

benefits enabling PP to be

processed at significantly

lower temperatures versus

standard clarified PP. The

superior clarifying performance

enables broader use of PP, a

low-density and easily recycled plastic, to replace less-sustainable

materials in packaging, household and food storage applications.

Hyperform HPN nucleating agent for polyolefins is a family of

high-speed nucleating agents, which allow for faster crystallisation

rates, improved processing and higher throughputs. Hyperform HPR

synthetic reinforcing agents for polypropylene improve mechanical

properties, while reducing part weight as compared to traditionally

filled automotive compounds.

Milliken Asia Pte Ltd

Singapore

Tel: +65-65931319


Website: www.millikenchemical.com

Wood plastic composites

Wood Plastic Composites (WPC) are thermo-plastically processible

materials made from wood and plastics (PP, PE, PVC, PS, ABS)

for use in building, furniture, automotive, consumer goods, housing

industry etc. In order to operate with optimum function, upstream

Extrusion machineThe LIN-90II-TS is a

performance-based machine

designed to accommodate

large containers with

outstanding cycle time. It

produces from 200 ml to 4 L

of PE/PP and PVC/PTEG,

and the productivity reaches 4,500 and 860 pc/hr, respectively. To

ensure quality, mechanical and electrical components from leading

brands are used in this machine.

Akei Plastic-Machine Mfy Ltd

Kowloon - Hong Kong

Tel: +852-27411312


Website: www.akei.com.hk

Anti-static plastic palletThis anti-static plastic pallet

is available in various sizes. It

is made from virgin foodgrade

plastic materials and is used

in pharmaceutical and food-

based industries. Also offered

are grain storage pallets, steel

reinforced plastic pallets, drum pallets, moulded plastic pallets,

rackable plastic pallets etc.

Ergen Plastic Industries

Jodhpur - Rajasthan

Tel: 0291-2433737, Mob: 09414195707


Website: www.indiamart.com/plastic-pallets

and downstream equipments are designed for the best match with the

extrusion line. For further improving the output of extrusion line, each

processing device and computer-controlled possibility (eg PLC, PC

base) are recommended to suit different users’ demands.

Intype Enterprise Co Ltd

Tainan - Taiwan

Tel: +886-6-2614196


Website: www.intype.com.tw

PRODUCTS


One must consider the cost of the product before

purchasing so as to secure defi nite and assured

returns over the period of time.

Manisha Kadam (Assistant Manager)Ashok Industry

One must identify the product that best suits

his/her organisation with regards to the cost

and quality.

Suhas Kulkarni (Product Manager Marketing)Kohler India Corp Pvt Ltd

The information published in this section is as per the details furnished by the respective manufacturer/

distributor. In any case, it does not represent the views of


Long fibre rigid thermoplastic polyurethane RTP 2300 series long fibre rigid

thermoplastic polyurethane

surpasses rigorous set of tests for

reinforced shoes. The long fibre

TPU compound can be injection

moulded into toe caps. A VLF

TPU toe cap can exceed ANSI

specifications requiring that a cap

must withstand 7500 pound of

direct impact and 2500 pound

of static load. With this compound, it is possible to almost double

the static load standard for safety toe caps. Compared to steel,

this material has high strength, weight reduction and, being non-

conductive, will not activate metal detectors, insulates against heat

and cold, non-magnetic and static-free. Although this material is

ideal for safety work boots and shoes, their use has greatly expanded

into other markets such as the military.

RTP Company

Chennai – Tamil Nadu

Tel: 044-42147313


Website: www.rtpcompany.com

Thermoplastic rubber Thermoplastic rubber is

primarily an elastomer

which combines the

performance traits of

a rubber and processing

ability of plastic. It

exhibits excellent physical

and mechanical properties,

high tensile strengths and

tear strengths, good thermal properties and excellent resistance to

water, alcohol, acids and bases. It finds a wide use of applications as

gasket support and hose connectors, automobile dust cover, boots and

grommets, flexible cords and coiled cords, weather stripping for doors

and windows etc.

Welset Plast Extrusions Pvt Ltd

Mumbai – Maharashtra

Tel: 022-28215734, 28387054


Website: www.welset.com

LIST OF PRODUCTS


3, 4 and 5-Axis CNC vertical machining centre ...........983-Axis CNC double column machining centre .................... 99AC/DC panel for pipe plants......................................89Acoustic enclosure ................................................................. 33Additive masterbatch ............................................................ 45Air audits blower ................................................................... 18Air compressor ...................................................................... 49Air treatment ......................................................................... 49Air-conditioner part .......................................................... FGFAir-conditioning plant .......................................................... 49All electric machine .............................................................. 23Aluminium die casting machinery ........................................ 49Anti-static plastic pellet ...................................................... 103Automation system ............................................................... 75Barrel ...................................................................... 110Bed knife ............................................................................... 63Biodegradable masterbatch ................................................... 45Black masterbatch ................................................................. 45Blender ..................................................................... FIC,19,61Blending unit .................................................................... FGFBlow moulding ...................................................................... 35Blower series ......................................................................... 75Blown film extrusion system ............................................... BCCarbon black .............................................................85Circular weaving machine ..................................................... 14Clean room application ......................................................... 25Cleaning oven ..................................................................... 110Cluster facia ...................................................................... FGFCNC Machine ...................................................................... 29CNC vertical machining centre ............................................ 73Colour masterbatch .......................................................... 15,45Compact chiller ................................................................... 109Compounding extrusion........................................................ 20Compressed air dryer ............................................................ 65Compressed air system .......................................................BICCompressor ................................................................... 18,BICConductive compound .......................................................... 45Conical twin screw extruder ................................................... 6Connector .......................................................................... FGFContinuous screen changer ................................................. 110Coploymer emulsion ........................................................... 100CPVC pipe ....................................................................... 10,21Crystalliser............................................................................. 65Cutting and stitching machine ............................................. 14Cylinder engraving - Lenticular and optical roll mould ...... 99Dehumidified dryer .................................................FICDehumidifying air dryer ........................................... 109, FGFDehumidifying dryer ............................................................. 34Die face cutter ....................................................................... 63Die plate ................................................................................ 63Diesel generator .................................................................... 49Digital panel meter ............................................................... 12Digital temperature controller ............................................... 93Door trim .......................................................................... FGFDosing and mixing ................................................................ 75Double column vertical machining centre ............................ 29Drive...................................................................................... 93Dry van pump ....................................................................... 33Dry-break coupling ............................................................... 18Drying and dehumidfying..................................................... 75Drymax air - Hot air dryer ................................................ FICDrymax dryer ..................................................................... FICDrymax Pet - Dehumidified dryer .................................... FICDual channel with modbus ................................................... 93Dual control water-type mould temperature controller ...... 100Dynamic controller ............................................................... 93Ejector.......................................................................18Electric injection moulding machine gearbox ......................... 7Evaporative cooling tower ..................................................... 49Exhibition - Plastivision 2013 .............................................. 38Extruder machine ............................................................. 27,67Extruder screw ...................................................................... 63Extrusion ............................................................................. BCExtrusion coating lines (Lamination Ant) ............................ 14Extrusion dies.......................................................................... 8Extrusion machine .............................................................. 103Extrusion system ................................................................. BC

Feed roll ....................................................................63Feeding & conveying ....................................................... 65,75Film cutter............................................................................. 63Fueling system ....................................................................... 18Furnace .................................................................................. 49Gear pump .............................................................. 110Granulating and recycling ..................................................... 75Granulator .............................................................. FIC,65,109Granulator blade ................................................................... 63Gravimetric blender ............................................................ 109HDPE pipe plant.......................................................89Head lamp and tail lamp .................................................. FGFHeat transfer roll ................................................................. 110Heating and cooling .............................................................. 75High cavitation ..................................................................... 25High performance screw ..................................................... 110High speed mixer ............................................................. 27,67Hopper loader ..................................................................... 109Hot air dryer ..........................................................FGF,34,109Hot runner system ................................................................ 75Hot runner system mould ................................................... 100Hydraulic injection moulding machine ................................. 23IML technique ..........................................................25Industrial coolers ................................................................... 49Injection moulding ........................................................... 35,98Injection moulding machine ............................FGF,5,16,17,52Inline drip tubing ............................................................. 10,21Knob and switch ....................................................FGFLargeflow water heater ...............................................75Loader ................................................................................ FICLoading arm .......................................................................... 18Long fiber rigid thermoplastic polyurethane ...................... 104Low cost PID temperature controller................................... 99Manual and hydraulic screen changer ....................... 110Material dryer .................................................................. 19,61Material storage .................................................................. 109Measuring and control equipment ........................................ 99Medical mould ...................................................................... 25Mono and multilayer sheet line ............................................ 14Monofilament line................................................................. 14Monolayer blown film ...................................................... 10,21Monolayer blown film line .................................................. BCMould .......................................................................... 20,27,67Mould repair ......................................................................... 99Mould temperature controller ............................................... 34Mould temperature controller ............................................. 109Mould temperature controller and chiller ........................... 103Moulding ............................................................................... 25MTC .................................................................................. FICMulti component mould ....................................................... 25Multilayer blown film ...................................................... 10,21Multilayer blown film line ..............................................14,BCMultilayer cast film line ........................................................ 14Multilayer polyethylene film ................................................. 98Napkin dies ...............................................................63Optical brightner .......................................................45Paperless recorder ......................................................12Parallel and right angle axes gearboxes ................................... 7Pellet screening system ........................................................ 100Pelletiser parts ....................................................................... 63Pelletisers ........................................................................ 63,110PET Preform dedicated machine ......................................... 53PET/PE Washing line .......................................................... 14PETline injection moulding machine ................................... 23Plastic conveyor belt .............................................................. 27Plastic machinery .................................................................. 49Plastic masterbatch................................................................ 51Plastic processing machine .................................................... 14PLC ....................................................................................... 93Polyolefin pipe .................................................................. 10,21Power saving .......................................................................... 35PP-R pipes ....................................................................... 10,21Precision moulding ............................................................ FGFPriming valves ....................................................................... 18Printing and cutting/Rewinding machine ............................ 14Process controller .................................................................. 12Process machinery ................................................................. 49

Profile controller .................................................................... 93Pulveriser ..................................................................... 20,27,67Pulveriser disc........................................................................ 63Pump ................................................................................ 18,33PVC foam core pipe ........................................................ 10,21PVC mixer cooler............................................................. 10,21PVC palletising lines ........................................................ 10,21PVC pipes ........................................................................ 10,21PVC profile lines .............................................................. 10,21Rational mould ..........................................................20Rational moulding machine ................................................. 20Recycling lines....................................................................... 14Resin dehumidifier ................................................................ 65Robot .................................................................................. FICRock n roll machine ......................................................... 27,67Roots blower ......................................................................... 33Rotary cutter ......................................................................... 63Rotary dies ............................................................................ 63Round table carousel ............................................................. 27Safety access equipment .............................................18Servo energy saving machine ................................................ 53Servo pump ........................................................................... 35Shut off nozel...................................................................... 110Shuttle remoulding machine ................................................. 20Single mill pulveriser ........................................................ 27,67Single screw extruder gearboxes .............................................. 7Single screw extruder plant ..................................................... 6Single screw pipe plant for RPVC........................................ 89Software for central monitoring............................................ 65Specialty chemicals .............................................................. 103Stack mould .......................................................................... 25Storage tank equipment ........................................................ 18System solution ..................................................................... 75Tank truck equipment ................................................18Tape stretching line with inverter driven cheese winders ..... 14Tarpaulin two-in-one heat sealing machine ......................... 98Technical mould .................................................................... 25Temperature controller ..................................................... 12,93Testing ................................................................................... 99Thermoformer ..................................................................... BCThermoforming ................................................................... BCThermoforming & PS foam ............................................... BCThermoplastic rubber .......................................................... 104Three arm bi-axial rotational moulding machine ............ 27,67Toggle injection machine ...................................................... 23TPU masterbatch .................................................................. 15Transmissions and PTOs ...................................................... 18Twin mill pulveriser ......................................................... 27,67Twin screw co-rotating extruders ........................................ 107Twin screw elements ........................................................... 107Twin screw extruder gearbox .................................................. 7Twin screw extruders ........................................................... 107Twin screw extrusion line ....................................................... 6Twin screw pipe plant for RPVC pipes ................................ 89Two platen injection moulding machine .............................. 23Two-layer blown film ....................................................... 10,21Ultra sonic flow meter ................................................12Universal controller ............................................................... 93Universal PID controller ..................................................... 100UV stabilisers ........................................................................ 45Vacuum booster pump ................................................33Vacuum dryer ........................................................................ 34Vacuum forming machine ................................................... BCVacuum loader ................................................................... FGFVacuum pumps & systems .................................................... 18Vacuum system ...................................................................... 33Variable displacement pump energy-saving machine ........... 53Vertical machining centre ..................................................... 29Vibratory screening system ................................................... 20Vibro screens .................................................................... 27,67Volumetric dosing unit .......................................................... 65Water chiller ..............................................................65Water jetting ......................................................................... 18WFR .................................................................................. FICWhite masterbatch ................................................................ 45Wire EDM ........................................................................... 73Wood plastic composites ..................................................... 103

Product Pg No Product Pg No Product Pg No

FGF - Front Gate Fold, FIC - Front Inside Cover, BIC - Back Inside Cover, BGF - Back Gate Fold, BC - Back Cover



LIST OF ADVERTISERS


All India Plastics Mfrs Association ............... 38

T: +91-22-28217324

E: [email protected]

W: www.plastivision.org

Alok Masterbatches Ltd ............................... 15

T: +91-011-41612244


W: www.alokmasterbatches.com

Baumuller India Pvt Ltd ............................... 35

T: +91-020-40160303


W: www.bumuller.com

Boge Compressed Air System .................... BIC

T: +91-044-43009610


W: www.boge.in

C & G Extrusion Machines .......................... 87

T: +91-9272235867


W: www.cgext.com

Continental Carbon India Ltd ...................... 85

T: +91-120-6721200


W: www.continentalcarbonindia.com

Engineering Expo ......................................... 56

T: +91-09819552270


W: www.engg-expo.com

Everest Blower Systems ................................ 33

T: +91-11-45457777


W: www.everestblowers.com

Ferromatik Milacron India Pvt Ltd ............... 23

T: +91-79-25890081


W: www.milacronindia.com

Gardner Denver Engineered Pro. (I) ............. 18

T: +91-79-40089312


W: www.gardnerdenver.com

Gem Equipments Ltd ................................... 49

T: +91-0422-2363800


W: www.gemindia.com

Glaves Innovations Pvt Ltd .......................... 63

T: +91-141-2460324,


W: www.glaves.biz

Hindustan Plastic and Machine Corporation .. 6

T: +91-011-25473361


W: www.hindustanplastics.com

J P Extrusiontech Limited ............................ 14

T: +91-2646-222163


W: www.jpextrusiontech.com

Jacobsen Lenticular Tool & Cylinder Engraving

Technology Co., ( Jaco Tech) ......................... 99

T: 1-630-467-0900


W: www.jacotech.com

Jingcheng Times (Beijing) Plastics Machinery

Co., Ltd.......................................................... 8

T: 86-10-5900-3588


W: www.jc-times.com

Jyoti CNC Automation Pvt. Ltd.................... 29

T: +91-2827-287081


W: www.jyoti.co.in

Kabra Extrusion Technik Ltd ................... 10, 21

T: +91-22-2673 4822


W: www.kolsite.com

L & T Plastics Machinery Ltd .................. FGF

T: +91-044-26812000


W: www.larsentoubro.com

Matsui Technologies India Ltd. .................... 34

T: +91-0120-4243862


W: www.matsuiindia.in

Mifa Systems ................................................ 93

T: +91-79-26870825


W: www.mifasystems.com

N.A. Corporation ......................................... 67

T: +91-79-25840374


W: www.naroto.com

Neejtech India (Braunform) .......................... 17

T: +91-79-26561312


W: www.neejtech.com

Neejtech India (Niigata) ............................... 25

T: +91-9909974224


W: www.niigataindia.com

Nordson X-Aloy Asia (Thailand) Ltd. ..........110

T: +91-79-40327380


W: www.xaloy.com

Norka Instruments Shanghai Co., Ltd. ......... 99

T: 86-21-6118-4181


W: www.norka.com.cn

Nu-Vu Conair Pvt. Ltd ................................109

T: +91-9376783206


W: www.conairgroup.com

Piovan India Pvt Ltd .................................... 65

T: +91-22-27782367


W: www.piovan.com

Plastiblends India Ltd .................................. 45

T: +91-022-67205200


W: www.plastiblendsindia.com .......

Prasad Koch Technik Pvt. Ltd. ..........................27

T: +91-79-25830112


W: www.prasadgroup.com

Prayag Polytech Pvt Ltd ............................... 51

T: +91-011-47262000


W: www.prayagmb.com

Procon Technologies Pvt Ltd ........................ 12

T: +91-79-27492566


W: www.procon.co.in

Rajoo Engineers Ltd....................................BC

T: +91-2827-252701


W: www.rajoo.com

Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No

Our consistent advertisers COC - Cover on Cover, FGF - Front Gate Fold, FIC - Front Inside Cover, BIC - Back Inside Cover, BC - Back Cover

LIST OF ADVERTISERS


S&T Engineers ............................................ 73

T: +91-422-2590810


W: www.stengineers.com

Sacmi Engineering India Pvt Ltd .................. 52

T: +91-7600003968


W: www.negribossi.com

Shini Plastics Technologies I Pvt Ltd ............ 75

T: +91-250-3021166


W: www.shini.com

Shree Momai Autocast Containers ................ 20

T: +91-2668-266440


W: www.shreemomai.com

Specific Engineering ...................................107

T: +91-265-2646871


W: www.specificgroup.com

Sri Sai Plasto ................................................ 53

T: +91-044-42994365


W: www.srisaiplastotech.com

Toshiba Machine (India) Pvt. Ltd. ................ 16

T: +91-011-43291111


W: www.toshiba-machine.co.jp

Unimark (Arburg) ......................................... 19

T: +91-22-25506712


W: www.unimark.in

Unimark (Maguire) ....................................... 61

T: +91-22-25506712


W: www.unimark.in

Wittmann Battenfeld India Pvt Ltd ............FIC

T: +91-044-42077009


W: www.wittmann-group.com

Woojin Plaimm Co Ltd .................................. 5

T: +91-9810043265


W: www.plaimm.com

Zambello Riduttori Group ............................. 7

T: 39-0331-307-616


W: www.zambello.it

Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No

Our consistent advertisers COC - Cover on Cover, FGF - Front Gate Fold, FIC - Front Inside Cover, BIC - Back Inside Cover, BC - Back Cover

Dear Reader,

‘Modern Plastics & Polymers’ solicits original, well-written, application-oriented, unpublished articles that reflect your valuable experience and expertise in the plastics & polymers industry.

You can send us Technical Articles, Case Studies and Product Write-ups. The length of the article should not exceed 1500 words, while that of a product write-up should not exceed 100 words.

The articles should preferably reach us in soft copy (either E-mail or a CD). The text should be in MS Word format and images in 300 DPI resolution & JPG format.

The fi nal decision regarding the selection and publication of the articles shall rest solely with ‘Modern Plastics & Polymers’. Authors whose articles are published will be sent


trade publishing houses with more than 200 special interest titles and offices in every major country), it ensures that advertisers are able to promote their products and services across the globe at no extra cost.

So get going and rush your articles, write-ups, etc…

Thanking you,

Yours sincerely,

a complimentary copy of that particular edition. Published by Network18 Media & Investments Ltd, ‘Modern Plastics & Polymers’ is one of the leading monthly magazines exclusively meant for producers and user fraternities of the plastics industry. Well supported by a national readership of over 80,000 and our strong network of 26 branch offices across India, this magazine reaches out to key decision makers among the Indian manufacturers of plastics products, machinery and allied sectors. Brought out in association with Hong Kong-based Ringier Trade Media Ltd (one of the world’s largest

An invite that rewards as well...

Manas R. BastiaSenior EditorModern Plastics & Polymers

Network18 Media & Investments Limited‘A’ Wing, Ruby House,J K Sawant Marg, Dadar (W)Mumbai 400 028 India

T +91 22 3024 5000F +91 22 3003 4499E [email protected] www.network18publishing.com

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Date Of Posting 1st & 2nd Of Every Month / English & Monthly.Date Of Publication: 28th Of Every Previous Month.

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Modern Plastics & Polymers April 2013