Modern Plastics & Polymers - june 2013

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9June 2013 | Modern Plastics & Polymers

lastics and polymers is an industrial sector that has been surging

ahead at a phenomenal pace over the recent years in tandem with

the country’s economic prosperity. This sector actually has a higher

growth rate than the country’s GDP growth. Truly reflecting an

emerging India and promising prospects of its techno-commercial prowess, the

turnover of the plastics processing industry is almost reaching the milestone of

` 100,000 crore, with a demand potential of over 12 million metric tonne.

As the number of processing units impressively increases to exceed 50,000, this

industry is expected to employ close to 7 million people, directly or indirectly, by 2015.

So much so, it is no exaggeration to state here that the plastic components industry

is likely to become larger than the auto components industry by 2020.

Although the Indian plastics industry has come a long way with a healthy growth

rate year on year, the current per capita consumption of plastics in the country

vis-à-vis the global average indicates large growth opportunities that will

only continue in the near future. It is also time for the industry to step

up investment and efforts towards capacity building, skill enhancement

and application development. A greater focus on green manufacturing

practices, technology upgradation and optimisation of operations will

take this industry to a higher level of international competitiveness.

The recent government policy of establishing plastic parks in

various states across the country will further facilitate the growth

momentum and can be the right time for the industry to reinvent

itself to cater to the surging global demand.

Against this backdrop, welcome to the 8th Anniversary

Edition of Modern Plastics & Polymers, which not only reflects

on saving in the fast-evolving Indian plastics scenario but also

takes forward this discussion to the next level of engagement

among various stakeholders.

Themed ‘The game changers: 8 winning moves to shape

success in the plastics industry’, this Anniversary Special brings

forth eight important areas that promise strategic impact in

enabling the sector to leap into the next orbit. Here’s a quick

glance of the spectrum – saving energy, saving material, saving

time, manpower management, saving capital, saving water, saving

environment and space management. All of these eight sections provide

focussed information on emerging challenges and opportunities that we

believe will empower you to successfully make the impending transition

and add miles to your success journey. After all, eight furlongs make

a mile! Have a good read and share with us your valuable feedback.

With a toast to this special edition, we thank all our internal

and external stakeholders who have inspired us for the last 8 years. Cheers!

PEight winning moves…

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

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

Special Focus: Thermoforming

Insight & Outlook: Plastics in Electronic / Electrical Appliances

Anniversary Special

8 winning moves to shape success in the plastics industry

42 Energy savings

54 Saving material

64 Saving time

70 Manpower management

80 Saving capital

90 Saving water

96 Saving environment

104 Space management

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

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

Technology & Innovation .... 30

Technology Transfer ............. 34

Projects ............................... 114

Tenders ............................... 116

Event List........................... 118

Book Review ...................... 120

List of Products.................. 132

List of Advertisers .............. 135

Cover illustration and design: Chaitanya Surpur and Sharad Bharekar

Highlights of Next Edition

In Conversation With 38 Dr Asutosh Gor, President, The All India Plastics

Manufacturers’ Association (AIPMA)

Facility Visit 112 Jain Irrigation Systems Ltd:

Fortifying water management systems in India

Details on page no. 118


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NEWS, VIEWS & ANALYSIS

22 Modern Plastics & Polymers | June 2013

Plastindia 2015 to be held in Gandhinagar, Gujarat, for the first time For the first time, Plastindia Foundation

has chosen Gandhinagar, Gujarat, as

against New Delhi, as its venue for the

country’s largest plastics trade show

Plastindia 2015. The forthcoming

9th Plastindia Exhibition & Conference

will be held on February 5–10, 2015.

The international standard arena in

Gandhinagar is spread over a large area

of 1,00,000 sq m, which is 23 per cent

more exhibition space.

Bipin Shah, President, Plastindia

Foundation, said, “Plastindia 2015 is

set to break all past records in terms

of number of exhibitors as the visitors

are from various leading countries

of the world. Nearly 40 nations and

1,25,000 visitors are expected to be a

part of this event. The strategic location,

requisite infrastructure, industry-friendly

environment and vibrancy of the state

make it conducive for such an event.

Further, the Gujarat government has

been very supportive and has promised

significant support with infrastructure

and transportation in the future as well.”

Plastindia 2015 will offer a global

platform for buyers and sellers from the

plastics industry to enhance their business

prospects, to establish strategic alliances,

technology transfer etc. Showcasing

a platform of international standard,

Plastindia 2015 will pave the way for

intra-industry cooperation and will ensure

bridging the gap between international

community and Indian enterprises to

explore bigger business avenues.

Avani Jain

HPCL board approves JV for ` 37,000 crore refinery and petrochemical complex in RajasthanState-owned Hindustan Petroleum

Corp Ltd (HPCL) has approved the

incorporation of a joint venture company

to set up a ` 37,320 crore oil refinery

and petrochemical complex in Rajasthan.

HPCL will hold 74 per cent stake in the

9 million TPA refinery and Government

of Rajasthan will hold 26 per cent. The

unit is planned to go on stream in four

years. Besides stake acquisition, the

state has given in-principle approval

for providing an interest-free loan of

` 3,736 crore per annum for 15 years

from the date of commercial production.

The state government has also assured

continuous supply of 28 MGD of water

for the project from Indira Gandhi

canal and about 3,500 acre of land for

refinery, terminal and township near

Leelala, Barmer.

The refinery will run on crude oil

from neighbouring oilfields of Cairn

India. Half of the crude oil requirement

at the proposed refinery will come from

the Barmer oilfields of Cairn and the rest

will be imported.

Innovations to dominate at the upcoming K 2013Discussing the developments taking

place in the global plastics and rubber

industry was the underlining theme

at a recent presentation event about

K 2013. Organised by Messe Düsseldorf

India Pvt Ltd, the event was held in

Mumbai and chaired by Eva Rugenstein,

Director of Press Department, Messe

Düsseldorf GmbH and

Dr Rainer Bueschl, Member

of K 2013 Exhibitor Council

along with other eminent

dignitaries such as Bipin

Shah, President, Plastindia

Foundation; Ajay Desai,

Former President, The All

India Plastics Manufacturers’

Association and Xavier

Rebello, Messe Düsseldorf India Pvt Ltd.

At the event, Dr Bueschl spoke

about the opening of new markets and

the increasing competitive pressure. He

stated, “Almost all members of the plastics

industry agree that they want to explore

existing resources to the fullest while

also increasing production efficiency.

Maximising output with minimum input

is the common objective. This can only be

achieved with a material-oriented product

design that focusses on minimum material

consumption, waste-free production

whenever possible and strategic recycling

of the used product whenever viable.”

Established in 1952, the

K International Trade Fair for Plastics

and Rubber, organised by the German

plastics industry under the supervision

of Plastics Europe Deutschland e.V. and

Messe Düsseldorf, has become an ideal

place for viewing innovative technology

and trend scouting. The event organised

in Mumbai discussed the upcoming

edition that is scheduled to take place

on October 16–23, 2013, in Düsseldorf,

Germany.

In Rugenstein’s address to the

audience during her presentation, she

spoke about innovative applications that

the plastics and rubber industry can

provide. Elaborating on the upcoming

edition, she said, “Surpassing all other

trade fairs for the plastics and rubber

industry, K offers the biggest and densest

spectrum of ideas and products. At K

2013, some 3,000 companies from all

over the world will be showing the trade

public their products and processes in the

categories of machinery & equipment,

raw materials & auxiliaries and semi-

finished products, technical parts &

reinforced plastics. The exhibiting

companies are already working flat

out to present themselves in the best

possible light, ie with inspirational

innovations. The manufacturers of

plastics and rubber products as well as

their industrial end users will be able

to witness the pinnacle of developments

in machine, process and materials

technology at K 2013.”

Dignitaries on the dais (L–R): Ajay Desai, Bipin Shah, Eva Rugenstein, Dr Rainer Bueschl and Xavier Rebello



WITTMANN BATTENFELD wins medal at PlastpolWITTMANN BATTENFELD,

Austria, a leading manufacturer of

injection moulding machines for the

plastics industry has won a medal

at Plastpol in Kielce for the second

time. This year, the company won the

first prize in the category of machine

and process technology for its newly

presented In-Mould Internal Welding

(IMIW) process.

The IMIW process has made it

possible to overmould inserts with gas

and watertight sealing. The connection

is made directly between the contact

surfaces by joining two injection-moulded

plastic halves from the inside, using the

same plastic material the parts are made

of. The finished parts show neither a

ridge nor a welding bead, the weld seam

has a high load capacity. Barkley, UK,

has developed the mould technology

and the equipment is marketed by

WITTMANN BATTENFELD. At

Plastpol, this process was demonstrated

by overmoulding an electronic part

on an EcoPower 110/350, an all-

electric machine from WITTMANN

BATTENFELD’s PowerSeries.

Bosch Rexroth inaugurates new plant in Sanand to strengthen presence in IndiaBosch Rexroth has inaugurated its new

plant in Sanand, near Ahmedabad, replacing

the previous facility in Vatva, Ahmedabad,

thereby increasing the overall square footage

at this new location. In order to be able

to address the specific regional product

and system requirements, the company is

not only expanding production but also

stepping up sales and development. Overall,

the company has invested about ` 280

crore into the expansion of its presence in

the region. Going beyond production, the

company has plans to develop the Sanand

plant into a technology centre. Further, based

on the product platforms, the company will

develop regional product variations that

meet the specific requirements of Indian

customers.

The new plant has a total area of

about 37,000 sq m, and the production

capacity is nearly two and a half times

more than the previous one. Bosch

Rexroth offers hydraulics, electric

drives & controls, pneumatics, linear

motion and assembly technology. This

expansion will definitely benefit the

plastics industry in the state as well as

the country. According to the company,

“This step will help us in serving the

plastics industry better as our drives &

controls find major usage in the plastics

industry. These products and solutions

help the plastics industry to increase its

efficiency in terms of energy savings and

maximising output.”

Avani Jain

Star Thermoplastic opens TPR labA division of Star Thermoplastic Alloys

& Rubbers Inc has opened a TPR

rheology/analytical laboratory at the firm’s

Broadview headquarters. The company’s

Thermoplastic Division built the laboratory

on two floors of the firm’s headquarters

facility in Broadview. It invested in the

fully equipped, multi-functional laboratory

to further increase the level of customer

focus, satisfaction and applications support.

Dozens of instruments are included in its

additions that cost well into the six figure

range. The company has a production line

dedicated to producing and testing samples

and finished goods.

Star is a provider of thermoplastic

elastomers with production lines to

handle large and small orders. The

new laboratory gives the company

the ability to analyse from a chemist’s

perspective any given formulation and

either precisely match it or dissect it to

determine individual elements in the

TPE formulation, tweak it to make it

perform better, and in many cases, come

up with a better price. The laboratory

measures the rheological properties

over a full range, including shear and

elongation. Thomas A Dieschbourg, Star

President, said, “The net result is that

we can offer more depth with new or

existing formulations, or determine the

precise ingredients to make a given grade

work for a customer and his application

the very first time.”

New polyethylene capacity from Chevron Philips in TexasChevron Phillips Chemical Co LP is

forging ahead with a project that will add

two PE plants with total annual capacity

of 2.2 billion pound. The plants will be

located either at the firm’s Cedar Bayou

complex in Baytown, Texas, or at its

Sweeny facility in Old Ocean, Texas. The

total cost of the project is estimated at

$ 5 billion. The PE plants are part of a

larger project that will install a new ethylene

feedstock cracker – using natural gas-based

ethane – with annual capacity of 3.3 billion

pound in Baytown.

The project is expected to create

400 permanent jobs and about

10,000 temporary engineering & construction

jobs. Chevron Phillips ranks as North

America’s largest maker of HDPE with a

market share of 20 per cent of annual capacity.

It also ranks fourth in LDPE with an 8 per

cent share and sixth in linear LDPE with a

4 per cent share.

New Bosch Rexroth plant in Sanand



Heubach Colour and Toyo Ink sign JV pact for organic pigmentsGujarat-based Heubach Colour Pvt Ltd

(HCPL) and Japan-headquartered Toyo

Ink SC Holdings signed an agreement to

establish a Joint Venture ( JV)

company – Heubach Toyo Colour

Pvt Ltd for setting up an azo

pigment manufacturing plant at

Ankleshwar. The new JV company

will cater to their individual needs

as well as work closely towards

common business objectives of

new product development and

leveraging capabilities of global

marketing & sales of organic

pigments. The JV will have

the advantage of synergising

the technological expertise and

experience of Toyo with Heubach’s

efficient and sustainable production model

strategically located in India.

The new JV company will facilitate

and strengthen Heubach’s presence

in the international market, especially

Southeast Asia. The commencement of

the construction of the JV’s factory is

expected to be finished by May 2014, after

which commercial production would start

with annual capacity of 2,000 tonne. Ravi

Kapoor, Managing Director, Heubach

Colour Pvt Ltd, said, “The pigments,

manufactured by the new JV company, will

use the most sustainable and eco-friendly

process which is a declared philosophy

of both the companies. Heubach’s

global philosophy of sustainable growth

complements well with Toyo’s strategy of

utilising the synergy between

different products within

its group.”

Soon after commissioning

of the production plant in

May 2014, the JV company

will manufacture, sell and

export disazo pigments for

different applications in the

ink industry, primarily printing

inks, resin colouring etc. The

new management team of

the JV company, comprising

members of both companies,

is constituted, and the six-

member team of the new JV company

will comprise three members each from

Heubach Colour and Toyo Ink.

Avani Jain

WACKER starts new production plant for dispersions in ChinaWacker Chemie AG officially ramped

up its new production plant for

Vinyl Acetate Ethylene (VAE)

Copolymer dispersions at its Nanjing

site ( Jiangsu Province, China). With the

additional 60,000 metric tonne from the

second reactor line, the local VAE

dispersion capacity doubles to a total of

1,20,000 metric tonne per year. The plant

complex is thus one of the largest of its kind

in China. At the same time, the Group is

currently building a new plant at Nanjing

to produce Polyvinyl Acetate (PVAc) solid

resins with an annual capacity of 20,000

metric tonne. It is scheduled to come on

stream in late 2013. Capital expenditures

for both projects will amount to about

€ 40 million.

The dispersion plant expansion

is WACKER’s response to the rising

demand for high-quality VAE dispersions,

especially in China and Southeast Asia’s

emerging markets. The project goal is to

ensure sufficient capacities for the strong

demand for VINNAPAS® VAE dispersions

now and in the years ahead.

ELPIE Engineers bags ‘Certificate of Commendation’ for PP non-woven fabric making machine

In the 3rd National Awards for

Technology Innovation in Petrochemicals

& Downstream Plastics Processing

Industry (2012–2013), a ‘Certificate of

Commendation’ was awarded to ELPIE

Engineers Pvt Ltd in recognition of the

contribution to technology innovation in

the category of ‘Innovation of Polymer

Processing Machinery & Equipments’

for ‘PP Non-Woven Fabric Making

Machine’. This award ceremony was

organised by Ministry of Chemicals &

Fertilizers, Department of Chemicals &

Petrochemicals, Government of India, to

promote innovation in the industry.

ELPIE’s PP non-woven spunbond

lines offer various customised sizes

ranging from 1.6 to 3.2 m fabric

width with 12–150 GSM. India’s first

indigenous, high-tech and high output

PP non-woven spunbond line with

3.2 m fabric width and 450 kg/hr capacity

was commissioned successfully in India

in 2012 by the company. This machine

produces zero wastage as whatever wastage

is there is fed to the recycle extruder to

make new fabric with allowable variation

of ±5 per cent only. Further, the PP non-

woven fabric making machine has energy

efficiency of 0.65–0.7 unit/kg, no noise

pollution, is environment-friendly and easy

to operate with the help of a single touch

console. ELPIE dedicates this award to

J P Aghera, Technical Director, who

is the brain behind the machine and the

real achiever.

Avani Jain

Katsumi Kitagawa, President, Toyo Ink, and Ravi Kapoor, MD, Heubach Colour

Certificate of Commendation



WACKER expands its technical centre in BrazilWacker Chemie AG is

strengthening its presence

in South America and has

inaugurated its expanded

technical centre, including

a training centre near São

Paulo, Brazil. The new regional

competence centre combines

research & development,

applications technology and

a basic and advanced-training

facility for silicone and polymer

applications under one roof.

The expansion focusses on the

laboratories for polymer binders that are

primarily used in construction chemical

applications. The integrated WACKER

ACADEMY training facility, which is

also being expanded, is furnished with

a new practice room and offers an ideal

platform for industry-specific networking

among customers, distribution partners

and WACKER specialists. With the

expansion, the Brazil technical centre

is increasing its local expertise

in applications technology,

know-how transfer and service,

thereby serving the strongly

growing markets for high-quality

silicone and polymer products in

South America.

WACKER’s own education

and training centre, the

WACKER ACADEMY, has also

been expanded locally. Training

participants now have access to

a new larger training laboratory

with state-of-the-art equipment,

allowing them not only to learn the

theory but also to perform comprehensive

practical exercises.

Evco invests $ 4 million in OshkoshEvco Plastics is planning to spend more

than $ 4 million to expand its Oshkosh

facility by 30,000 sq ft and add more

machinery. “We have several existing

customers that have given us new

projects and we getting ready for that,”

said Dale Evans, President, Evco Plastics.

He said the expansion will boost the size

of the facility to 100,000 sq ft and is

designed to strengthen and increase the

infrastructure so that it can handle larger

moulds and bigger equipment and will

include a 100 tonne crane.

Evco has had operations in Oshkosh

since 1976. It built the current plant

in 2003, and the company expects to

add as many as 20 employees within

the next two years. Overall, Evco has

800 employees in 10 manufacturing

plants that span from Deforest and

Oshkosh in Wisconsin, to Calhoun

in Georgia, Monterrey and Juarez

in Mexico and Shenzhen in China.

It has three plants in Deforest,

including its headquarters. “The initial

stage is $ 2 million, but we expect

to spend twice that much when it is

all done,” said Evans. The company

said that the construction is being

handled by general contractor Cardinal

Construction Co Inc.

Amcor launches lightweight 64-ounce PET bottleAmcor Rigid Plastics has created

the lightest 64-ounce hot-fill PET

container of its kind, weighing only

59 g. The company developed Powerblock

3.0 technology to make the bottle, which

comes with a 38 mm finish, 13.2 per

cent lighter than the typical 68-g bottle.

“The Powerblock 3.0 container is a

major breakthrough because we achieved

a highly sustainable packaging solution

without compromising performance.

Our unique lightweight design retained

line/stack handling performance and

maintained ergonomic features for

consumer handling,” said Michael Lane,

an Amcor engineer.

Advantages of the Powerblock

technology include optimised footprint

(width and depth) for improved pallet

pattern and corrugate savings. The bottles

are also easy for the consumer to handle,

the company claims. The firm is currently

only using the technology for 64-ounce

hot-fill containers but says it will adapt it

to other bottles in the future. The stock

bottle is currently commercially available

in the US. The Valox iQ recycled resins,

which are based on PBT incorporating

post-consumer PET feedstock, can

be used for cosmetics, particularly

airless covers.

Ravago buys Amco Plastic Materials Resin distribution major Ravago Americas

has expanded its presence by acquiring

distributor and compounder Amco Plastic

Materials Inc of Farmingdale, NY. Amco

co-owner and President Gary Metzger will

remain with the 57-year-old firm, which will

operate under the name Amco Distribution

as a division of Ravago Holdings America

(RHA) Inc.

“Amco will remain as a unique

and separate channel to market for

distribution,” said Jim Duffy, President,

RHA, during his announcement. Amco

represents more than a dozen resin

suppliers and has annual sales of about

$ 150 million. The firm has added at least

three sales representatives in the last year

and now has more than 90 employees.

Amco also operates 14 compounding lines

at an 80,000 sq ft plant in Farmingdale.

Its compounding specialties include

compounds for anti-counterfeiting and anti-

microbial uses.

For Orlando-based Ravago Americas, it

is the firm’s first deal since it acquired resin

distributor Performance Polymers Inc of

Leominster, Massachusetts, in 2009. Ravago

Americas is a unit of the Ravago Group

based in Brussels.

Larger training laboratory with state-of-the-art equipment

TECHNOLOGY & INNOVATION


Quinn Plastics presents extended range of lenticular productsGermany-based Quinn Plastics has extended its range of

lenticular products – polyethylene terephthalate glycol sheets for

lenticular technology. This dynamic technology leads to unique

opportunities to create striking multi-imaging visual printing

effects such as Real 3D, animation, zoom, flip and morphing.

Quinn Plastics already offered a 75 LPI grade; this is now

supplemented by 60 & 100 LPI grades, as well as a 60 LPI-3D

grade. The extended range is suitable for all kinds of standard

and special format applications.

The biggest applications for Quinn Lenticular are in

advertising and marketing communications, on items such as

displays, postcards, posters, POS material, magazine covers, DVD

boxes, promotional gifts etc. Features of Quinn Lenticular that

make it so attractive for these applications include its brilliant

clarity, excellent ink adhesion, high impact strength, good

chemical resistance and recyclability. It is also environmentally

safe and meets current food contact legislation.

KREYENBORG V-type screen changer for long-term quality

In a recycling plant

with strand pelletising,

t h e p a t e n t e d

K R E Y E N B O R G

V-type screen changer

with integrated

self-cleaning function

of the screens displays

its value on a daily

basis. The system was

installed over three

years ago and continues to perform without error. Despite the

high mechanical demands on the system technology, there are

no signs of fatigue after more than 51,000 backflush cycles. One

cycle comprises the flushing of all four screen cavities, of which

there are always at least three in production. The screen changer

makes more than one hundred backflush cycles with the same

screen pack. Then the screens are changed for security reasons

in order to avoid fatigue of the mesh. The purpose of these

preventive measures is to prevent the bypass of dirt particles

around the boundary edge of the screen packs. If and when the

screens need to be changed, the replacement of the screen packs

is very simple.

The V-type easily proves its process stability in a strand

pelletising line. Strand breaks are a thing of the past when using

the V-type because the constant pressure of this machine type

offers unequalled opportunities. In recycling applications for

medium to high viscosity materials in which economic filtration

is required, the KREYENBORG V-type technology provides

a robust and durable solution. Furthermore, it provides for an

extremely short payback time.

BASF adds variants to compostable plastic ecovio® BASF has once

again added variants

to its range of the

compostable and

partially bio-based

plastic ecovio®. The

ecovio T2308 is now

available for the

processing method

of thermoforming.

For injection moulding, the company offers the new ecovio

IS1335 grade. Because the packaging sector is displaying a

growing interest in certified compostable plastics, BASF has

now augmented its product line by new grades intended for

two other significant processing technologies. Both of these

products are now available in commercial quantities. They

consist predominantly of renewable raw materials and lend

themselves well for being dyed.

Thermoformed trays and cups can now be made with ecovio

T2308. This plastic exhibits similar mechanical properties to

those of amorphous PET, but it differs from this conventional

thermoforming material by virtue of its compostability and

its high content of renewable resources (polylactic acid). The

second novelty in the ecovio product line, viz the injection

moulding grade ecovio IS1335, also offers good stiffness. It

can be processed using single or multi-cavity moulds that are

equipped with or without hot runners. This material exhibits

moderate flowing characteristics and is dimensionally stable

under heat up to 55°C [131°F]. This variant lends itself for

thin-walled, complex and high-quality packaging, which should

preferably be manufactured by injection moulding and should

be compostable.

New hot runner for PC glazing from HRSFlowHRSFlow, based in Italy, has developed the Diamond Lux hot

runner system for polycarbonate glazing parts, such as headlamp

components, quarter windows and sunroofs. The system helps

injection moulders meet the optical and aesthetic demands of these

automotive applications through a combination of features. The

company has achieved thermal optimisation by insulating the mould

plates using spacers with low thermal conductivity and addressing

power loss in the thermal bridges. All contacts with the mould have

been geometrically optimised to reduce thermal power dissipation.

Heater positioning and nozzle tip contact have also been optimised.

Brass sleeve heaters help towards nozzle thermal control. Each

heater is dedicated to the thermal control of the gate zone that

ensures a more precise and steady process control. These technical

solutions ensure a more constant temperature, with a tolerance in

the region of 10°C across the entire system. All internal hot runner

channels have been engineered to avoid stagnation spots that could

cause unacceptable defects in crystal clear lenses.

TECHNOLOGY & INNOVATION


100 per cent recyclable, carbon positive material by Polythene UK

Polythene UK has unveiled

a new 100 per cent

recyclable, carbon positive

material called Polyair.

The new Polyair material

is bio-based. Made from

sugarcane, it is the process of

photosynthesis that makes

this product carbon positive.

Sugarcane actively captures

CO2 from the atmosphere

while at the same time

releasing oxygen, making

this material not just green

but proactively green.

Polyair can be used

across the full product

range of bags, covers, tubes,

films, wraps and stretch

film, giving customers

a significantly greener,

e n v i ro n m e n t - f r i e n d l y

option. Using a bio-based

material, such as Polyair, at a

percentage of 60 per cent in

film reduces CO2 emissions

to 0 per cent even when

considering the energy

used for manufacturing and

shipping.

Further, Polylite can

reduce the weight of

polythene consumption by

20 per cent, leading to less

polythene waste going to

landfill, thereby significantly

reducing the user’s carbon

footprint. When integrated

with Polyair, it provides

a fantastic solution to

tackling the problem of

polythene waste.

New anti-microbial masterbatch for mouldingPolyFusion, the Utah, US-based masterbatch

maker, has announced an anti-microbial

masterbatch that remains permanently

active throughout the life of the plastic,

PF100. The anti-microbial masterbatch,

which can be added in quantities as little as

0.25 per cent, is compatible with

polyethylene, polyvinyl chloride, linear

low density polyethylene, polycarbonate,

polyethylene terephthalate, polyethylene

terephthalate glycol, acrylonitrile butadiene

styrene and polypropylene.

The active ingredient is a silane functional

quaternary ammonium salt which is EPA

registered. The material kills microbes by

physically rupturing the cell wall. Because

the active ingredient is not absorbed into

the organism, it will not cause mutations.

The rate of kill is very fast compared with

biocides that work by disrupting metabolic

pathways after absorption. The material

works without leaching silver, chlorinated

phenolics or arsenic-based materials.

Further, the anti-microbial agent can

withstand temperatures of up to 315°C, and

it has been successfully used for adding to

injection moulded and extruded materials.

Toray Plastics introduces Torayfan®MWX6

Toray Plastics has launched Torayfan® MWX6

metallised white cavitated Biaxially Oriented

Polypropylene (BOPP) film. This new BOPP

film is designed with a proprietary, ‘ultra-barrier’

layer on one side for superior moisture and

oxygen barrier functionality. The other side of

MWX6 film is a hermetic, heat-sealable layer.

MWX6 film can be used as a monoweb or a

lamination. It runs on horizontal and vertical

form fill seal machines. End users will appreciate

the film’s white, glossy appearance that enhances

a package’s attractiveness inside and outside.

Besides appealing to consumers, it can contribute

to a brand’s success. Available in 100 and 110

gauges (1–1.1 mil), MWX6 film is the ideal

choice for packaging salty crisp snacks, baked

goods, confectionery items, pet food and frozen

foods. Torayfan MWX6 film can also be used for

agricultural and chemical packaging.

Smart launches new DS SeriesSmart Machineries and Moulds Pvt Ltd has

come up with the new DS Series Double Station

Blow Moulding Machine. The DS Series blow

moulding machine has five main variants

based on the capacity of bottles/cans (250 &

500 ml and 1, 2 and 5 litre). Similar to the

single station machines,

these machines can be

used to produce a wide

variety of polymers such as

high-density polyethylene,

polypropylene, low-density

polyethylene etc. The

larger platen area helps

accommodate bigger size

moulds. The machine

is flexible with centre

distances of 80, 90, 110 and

150 mm with 2/3/4 parison die heads. The DS

Series machines with faster dry cycles (capability

of 15 dry cycles/min) result in higher outputs.

The fully automatic machines are equipped

with freely programmable machine controls.

The SMART DS-5 and DS-10 litre machines

have proportional hydraulics for optimum

energy consumption.

The DS Series machines are user-friendly

and have two stations with larger platen area,

freely programmable

microprocessor controls,

heavy duty helical gear

box, superior quality

mixing screws, continuous

single or multi-parison

die heads, AC drive,

fast dry cycle and power

saver hydraulics. The new

SMART DS Series is

getting excellent response

because it enhances

the production capacity by 50–60 per cent as

compared to the single station machine while

also saving energy.

TECHNOLOGY TRANSFER


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.

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 manufacturing and plastic waste

recycling units

Forms of transferEquipment supply and turnkey

Pilot plants for small-scale productionA Chinese company is interested in

offering small capacity technology for a

wide variety of plants such as polyester

plant, polyester chip or direct spinning.

Areas of applicationChemical fibres and plastics

Forms of transferTurnkey

Plastic lightguide fibresA Chinese R&D institute offers to supply

the technology of plastic lightguide

fibres and handicraft articles made from

it. Plastic lightguide fibres are cylindrical

fibres with core-clad structure made

of two highly transparent polymers,

the advantages of which are excellent

light transmission, good toughness,

lightweight and easy to process and use.

Areas of applicationPhotoelectric switches, photosensitive

elements, linear accommodation

networks, short-distance optical

communications and medical & dental

devices

Forms of transferTechnology licensing and equipment

supply

Polyester chip plantA company from China offers polyester

production plant, polycondensation

plant, polymerisation line, hot-melt

adhesive plant (500–5,000 TPA),

polyester chip plant (2,000–1,50,000

TPA) and film-grade polyester plant

(2,000–1,50,000 TPA).

Areas of applicationPolymerisation and fibre lines

Forms of transferTechnology licensing and turnkey

Rotational moulding of plasticsAn India-based company, a leading

manufacturer of rotational moulding

machines, offers plant and machinery for

manufacture of water storage tanks and

other hollow plastic parts. Rotational

moulding is low-cost technology

to manufacture large-sized plastic

items. It can be used to manufacture

water storage tanks of capacity

500–30,000 litre.

Areas of applicationWater storage tanks, material handling

trolleys, pallets, containers, chemical

storage tanks etc

Forms of transferSupply of equipment

Waste plastics conversion A company offers plant technology for

converting non-recyclable waste plastics

into industrial fuel, which is more

sustainable as compared to conventional

industrial fuels such as furnace oil or

light diesel oil. The company supplies

technology to serious clients, who

would like to get their waste plastics

tested at a demo plant. The plant can

be customised for specific requirements.

Municipal bodies, industries involved

in generation of non-recyclable

plastic scrap, plastic scrap dealers who

have access to non-recyclable cheap

plastic scrap and entrepreneurs are

encouraged.

Areas of applicationPlastics scrap recycling for industrial

fuel generation

Forms of transferConsultancy, joint venture, technology

licensing, turnkey

TECHNOLOGY TRANSFER


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 and 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]

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, hay-silage foils, PET, HDPE,

PVC 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


PET polyester polyolsAn Indian trading-based company is

planning a small-scale project for PET

polyester polyols manufacturing. The

company will procure recycled PET flakes

locally, and it already has available land of

28,000 sq ft for manufacturing.

Areas of applicationPolyols


Plastic recycling technologiesA Sri Lankan company is seeking

latest plastic recycling technologies

for automatic sorting, washing, metal

detection, granulation process system,

washing plants, crushers, extruders etc.

Areas of applicationPlastics recycling


Polyacetal resinsA Gulf-based organisation wants to

promote projects in the chemicals and

petrochemicals sectors in the countries

of Gulf Cooperation Council. It is

looking for technology suppliers for the

manufacture of polyacetal resins.

Areas of applicationChemicals/petrochemicals industry

Forms of transferFeasibility study, know-how, equipment,

turnkey plant, joint venture

Recycled PET polyester polyols plantA Poland-based company specialising

in recycled PET polyester polyols

manufacturing is looking for an alternative

proposal of design and engineering of a

bigger (approximately 25 kilo tonne per

annum) production plant. It plans to start

with delivering proper, quality recycled

PET flakes in big bags. Therefore, the

company requires a complete package

offer for this service.

Areas of applicationPlastics and polymers industry


Recycled plastic-making technology A Vietnam-based company requires

technology for recycling plastics.

Diameter of recycled plastic granules

is 120–200 mm. Production capacity is

150–300 kg/hr. The technology is to be

used for manufacturing plastic products

in an eco-friendly manner, with a lowered

cost by allowing optimum use of waste.

Areas of applicationRaw materials for making plastic products


Utilisation of natural rubber in asphaltA Pakistan-based company requires

know-how on utilisation of natural rubber

in modified asphalt covering. It requires

standards and specifications guiding

the use of natural rubber in modified

asphalt, appropriate proportion of natural

rubber in mixture, handling of the

operation, additives needed and details

on improvement in asphalt properties by

using natural rubber.

Areas of applicationRubber industry


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.

Technology Requested


What is India’s current position in the global plastics industry?Plastics is a sunrise industry in India.

The demand is only set to increase here.

Currently, the per capita consumption

is 8 kg in India, whereas it is about

60 kg in the US and about 45 kg

in China. At AIPMA, our focus

is on increasing this 8 kg figure to

20 kg per capita in the next five to ten

years. This statistic shows immense

potential of growth and opportunities

for all the entities related to the Indian

plastics industry. The raw materials

consumption today is about 8 million

tonne; this too is set to double by 2020.

Thanks to globalisation, adoption of

homegrown technologies is gaining

momentum. It would be safe to say that

the Indian plastics industry has arrived

on the world stage.

INDIAN PLASTICS INDUSTRY

WORLD STAGE”

“THE

HAS ARRIVED ON THE

IN CONVERSATION WITH: Dr Asutosh Gor

…confirms Dr Asutosh Gor, President, The All India Plastics Manufacturers’ Association (AIPMA). In a conversation with Sweta M Nair, he speaks optimistically about the future of the Indian plastics industry. He attributes the projected growth of Micro, Small and Medium Enterprises (MSMEs) to environment-friendly production capacities, use of automation and formation of favourable government policies.

Pho

to: N

achi

ket

Guj

ar

Dr Asutosh Gor


How important is governmental intervention to make India a mass volume player of quality products? Plastics have become an inevitable part

of everyone’s lives. Be it in automotives,

consumer durables or medical applications,

plastics are driving other industries. I

believe it is high time we give plastics

its deserved core sector industry status.

We at AIPMA have been vehemently

supporting this. Once the core sector

status is accorded, the industry can avail

various incentives and schemes that are

introduced in Union Budgets.

We require governmental support to

be a leading player in the global market.

The government needs to monitor and

incentivise investments in the Indian

plastics industry. Taking a leaf out of

the textiles sector, the government could

provide technology upgradation funds and

schemes for this sector too.

Rising costs of raw materials and energy put constraints on processors. How does one tackle these issues in a competitive eco-system?A small entrepreneur has four basic

requirements – land, finance, technology

and market. Recognising these needs,

we have taken the initiative of setting

up plastics parks in consultation with

various state governments. We are setting

up parks in Gujarat, Karnataka, Uttar

Pradesh and Madhya Pradesh. Through

this initiative, we are offering land at a

good price. Due to a tie-up with Small

Industries Development Bank of India

(SIDBI), companies can get access to

finance faster with a lower rate of interest.

Consultants from United Nations

Industrial Development Organization

(UNIDO) are helping processing units

upgrade technology with reasonable

capital investment. Trade shows also

help in developing the market for all the

entities related to the plastics industry.

Cluster development will help individual

companies gain a strong foothold.

In this industry, the major costs are

associated with raw materials, power and

labour. Rising costs are definitely a concern

for MSMEs. Indian moulders explore

avenues of improving productivity by

reducing in-house waste and increasing

energy efficiency. Awareness has brought

about these changes. For instance, moulders

are now switching over to servo motors to

reduce consumption of energy and increase

productivity. To survive the competition,

moulders will have to apply these techniques.

Doubts have been raised on environmental sustainability of plastics processing units. What is your take on this issue? Plastics processing units have often

been questioned on their environmental

sustainability quotient. Operational and

feasible models also help the cause of the

environment. Even small manufacturers

have woken up to this cause. This is

where our tie-up with UNIDO comes

into play. The process begins with a

UNIDO consultant visiting the facility of a

particular plastics moulder. After studying

the processes in the facility, the consultant

presents a gap analysis and points out

areas that have scope for improvement

in productivity. Many companies have

benefitted from the application of suggested

techniques within their existing parameters

without investing much. Plastics processors

should take advantage of these initiatives.

When talking about disposal of

plastics, everyone has to share the

responsibility, including the end users.

Littering is bad, plastics are not bad

per se. Segregation of waste at home is one

of the simplest primary ways of initiating

a cleaner disposal system. For instance,

companies in developed countries are

obligated to collect part of their produce

to recycle it. Bottle crushers present

in most malls in developed countries

encourage consumers to recycle; this is a

fantastic mechanism against plastic bottles

that end up in landfills. We could use such

techniques in India too.

What programmes are being conducted by the Association to address the evolving needs of this segment?AIPMA recently conducted a job fair

in Mumbai, the first of its kind by

any polymer association in India. The

objective was to provide the industry in the

manpower arena with a non-commercial,

service-oriented and cost-effective

model. Fourteen visiting employer

companies, ranging from segments such

as raw materials, compounds/additives,

injection moulding, blow moulding,

rotomoulding, extrusion (pipe & blown

film) and machinery manufacturers,

participated in the fair. The fair floated

about 80 job openings, of which 90 per

cent job openings demanded 2–15 years

of experience. AIPMA addressed the

job requirements and matched befitting

candidates with employers. Following the

overwhelming response of this event, we

aim to make it regional. So far, Bengaluru,

Chennai and Delhi are on our radar. The

next fair in Bengaluru might be held in

a couple of months. Further, trade shows

are another avenue for gaining overall

development. Organised by AIPMA,

Plastivision is a renowned exhibition for

the plastics industry in India. In the last

edition, the trade fair witnessed visitor

footfalls of close to a lakh. Last year,

this trade show went global when we

organised the first Plastivision Arabia at

Sharjah Expo Centre. These initiatives

help Indian MSMEs evolve with the

changing times.

As President of a premier plastics association in India, what areas are included in your agenda? Based on AIPMA’s commitment to the

plastics industry, we continue to work

on several projects. At a personal level,

I would like to see the industry upgrade

itself technologically. Manufacturers need

to have a holistic approach as far as the

environment is concerned. International

markets and new applications are areas

of much potential. Building new ‘waste

to wealth’ models is part of my agenda.

However, this segment will receive a push

only when capital investment in waste

management is exempt from all types of

taxes. Based on suggestions made by the

Association, we expect to receive support

from the government.



ANNIVERSARY SPECIALANNIVERSARY SPECIAL


Saving Energy Motors & drives: Reducing energy consumption in injection moulding .....................................................................42 Hot runner systems: Moulding in an energy-efficient manner ....................................................................................44 Interface - Rajiv Trivedi, Vice President (Marketing), Prasad Group and Chairman,

Indian Plastics Institute - Ahmedabad Chapter ........................................................................................48 Khushboo Doshi, Executive Director, Rajoo Engineers Ltd .....................................................................50

Roundtable - How efficient are Indian processors in adopting global energy-saving techniques? .............................52

Saving Material Polymer processing: Minimising imports to maximise profits .....................................................................................54 Innovation and quality: Widening the scope for efficient plastics ...............................................................................56 Interface – Surinder Minocha, Managing Director, Minocha Enterprises Pvt Ltd ...................................................60 Roundtable - Does the Indian polymer industry have the potential to benchmark

international standards? .................................................................................................................................................62

Saving Time Silent time savers: Right tooling for faster performance ..............................................................................................64 Sustainable processes: Need for industry–government collaboration ...........................................................................66

Interface – Manish Pathania, Sales Director, Greendiamz Biotech Ltd ....................................................................68

Manpower Management Managing workforce: Of man and machine .................................................................................................................70 Skill development: Fostering talent to meet requirements ...........................................................................................72 Interface – Amit Kalra, Director, Hindustan Plastic & Machine Corporation ..........................................................76 Roundtable - Do plastics processors have access to effective skill management

techniques and programmes? .........................................................................................................................................78

8 winning moves to

shape success in the plastics

industry


ANNIVERSARY SPECIAL


ANNIVERSARY SPECIALANNIVERSARY SPECIAL

Saving Capital Cost-effective processing technology: Saving time, improving output ..........................................................................80

Cost efficiency: Integrating international techniques ....................................................................................................82

Interface – Jayesh Khimji Rambhia, Chairman, Plastic Parks & Projects,

The All India Plastics Manufacturers’ Association (AIPMA) ....................................................................86

Herbert Kraibühler, Managing Director – Technology & Engineering, ARBURG GmbH + Co KG .....88

Saving Water Effective water management: An eye towards recycling ................................................................................................90

Interface – Umakant Sharma, Head – Sales & Marketing, Matsui Technologies India Ltd.......................................92

Vishal Jasrapuria, Director, Shree Sadguru Plastic Industries .....................................................................94

Saving Environment Waste management: Addressing environmental concerns .............................................................................................96

Plastics recycling: Mapping the challenges and opportunities ......................................................................................98

Interface – Pramthesh Pandya, Head - Unit & Business Development, Parikh Packaging Pvt Ltd ........................100

Apurva Kane, Senior Vice President, Mamata Machinery Pvt Ltd .........................................................101

Roundtable - How proactive are government policies towards environment-friendly plastics processing? ................103

Space Management Compact machinery: Less is more! .............................................................................................................................104

Minimalism in manufacturing: Managing space and machinery ................................................................................106

Interface – Raj Singh Rathee, Managing Director, KUKA Robotics (India) Pvt Ltd ..............................................108

Parag N Dave, CEO, Dave Technical Services .........................................................................................109

Roundtable - How does the engineering prowess of compact machines translate to

manufacturing benefits? ................................................................................................................................................ 111

Approximately two-

thirds of the energy

costs in plastics

processing, including

injection moulding, is the result of

energy consumed by motors. The

motors in the main processing

equipment such as compounders,

moulders and extruders are obvious,

but the majority of motors are

hidden in other equipment such as

compressors, pumps and fans. Thus,

in order to ensure energy efficiency,

the selection of motor and drives is

important. Unlike the old motors

that consumed much energy, the

High-efficiency Motors (HEMs),

Variable Speed Drives (VSDs),

digital displacement pumps and

servo motors greatly help in

increasing cycle times and reducing

energy usage.

Praveen Sharma, Managing

Director, Hinds Plastic Machines

Pvt Ltd, notes, “At present, there are

an umpteen number of innovations

happening in the injection moulding

machinery segment for improving

the quality of machines. In fact, we

were one of the first manufacturers

in North India who introduced the

servo-controlled ram

type injection moulding

machine in 2009, which

saves energy up to

40 per cent.”

Motor management policyWhen the running costs increase

over the initial purchase price,

it means that companies need

to change the way they look at

motors that consume the maximum

energy. Thus, in order to reduce

costs, companies must develop and

implement a motor management

policy for the purchase and operation

of motors. This policy should include

guidelines on purchase, repair and

replacement based on lifetime

costing of the motor. Repairing a

failed motor may be a cost-effective

action in the short run but can

reduce energy efficiency by up to 1

per cent. It may also not be the most

economical long-term action. Thus,

an efficient motor management

policy is the need of the hour.

Motor sizingMotor sizing assumes importance as

a correctly sized motor also helps in

reducing energy consumption.

Motors run most efficiently close

to their design output. Motors

are most efficient when their load

equals, or is slightly greater than,

the rated capacity. If machines

larger than needed are purchased

or used, then the motor will not

reach the design load and will

never run at optimum efficiency.

Oversized motors are inefficient,

and equipment needs to be carefully

matched with the demand. The

size of motors depends on various

factors. You decide on the size of the

motor well in advance, ie during the

design stage. Any error in selecting

the correct size of the motor may

result in heavy wastage of energy.

A rise in the price of energy is a crucial issue in plastics processing, including the injection moulding industry. This has drawn the attention of processors to the motors and drives used in the machines that consume the maximum energy. Avani Jain analyses ways of reducing energy consumption in the injection moulding process through the use of energy-efficient motors and drives.

Reducing energy consumption in injection moulding

SAVING ENERGY: Motors & dr ives


Courtesy: Kone Corp

Motors & dr ives

High-efficiency motorsHEMs consume approximately half of the

energy used by conventional motors. In

addition to energy savings, better designs

and improved construction of HEMs can

lead to various other benefits. Initially, these

motors were highly priced, but now the cost

has reduced and can easily be forgone for the

fact that they help in saving on the energy

cost. HEMs can achieve efficiency levels of

up to 3 per cent more than conventional

motors and have a peak efficiency at 75

per cent of load, thus reducing both energy

costs and oversizing problems. A HEM is

not very different from the normal motor,

but manufacturers have developed it in such

a way that it consumes much less energy

than the conventional motor.

Variable speed drivesThe speed of an AC motor is fixed by

the number of poles and the supply

frequency. As a result, the hydraulic

pumps in many processing machines are

driven at a constant speed, even though

the demand varies considerably during

the cycle. Flow demand changes from the

hydraulic pump are controlled by a relief

valve and recirculation of the hydraulic

fluid. Another way of meeting the varying

demands is to fit a VSD to the motor. The

VSD can serve as a good option for energy

efficiency, as it allows the speed of an AC

motor to be varied and the pump output

can be matched to the variable demand.

Because VSDs enable the manufacturer

to increase or decrease the speed as per

requirement, energy consumption is bound

to reduce remarkably during the injection

moulding process.

In addition, a reduced demand on

the hydraulic system means that the

hydraulic oil runs at a lower temperature

and requires less cooling, which can serve

as an additional cost-saving measure.

Further, VSDs require less maintenance

cost. A VSD can also be applied to fans,

water pumps and air compressors where

the load varies considerably.

Digital displacement pumpsThese also help in attaining energy

efficiency. A digital displacement pump is a

hybrid device that combines reciprocating

hydraulics with micro-processor control,

creating a highly integrated machine

capable of producing variable flow and

power. The advantages of this pump/

motor over conventional techniques lie

on the response speed and the inherent

energy efficiency.

Servo motorsCompanies are increasingly using servo

motors for energy efficiency. The servo

motor only drives the shaft required for

the moulding process, creating a direct

exchange of energy and ensuring reduced

energy consumption. Sharma avers,

“The existing normal electric/fuel-driven

motors transmit power to various points

of movements through gears, chains,

belts and pulleys, which are heavier and

bigger. On the other hand, in the servo

motors, all movements in the machine

are powered by appropriate size of motors

controlled by drives and sensors, which

are smaller, lighter and convenient.”

These are better than VSDs, as in

case of a VSD, the motor is continuously

working, but in a servo motor, the motor

stops when there is an idle cycle, ie the

whole motor will stop automatically, so

there is no energy consumption during

that time. Moreover, the response time

for reducing or increasing the desired

levels is higher in VSDs as compared to

servo motors, where the desired levels are

achieved in a matter of five seconds. Thus,

servo motors give more accurate results

than VSDs. Further, these motors help in

reducing cycle times, thereby increasing

the speed. Thus, the servo drive facilitates

high-energy efficiency, accuracy, precision

and good control.

Hitesh R Shah, Business Head –

Injection Moulding Machines, Windsor

Machines Ltd, notes, “These days, servo

motor-driven geared pump machines are

increasingly used as the geared pump offers

highest efficiency of transmission. This,

when used with servo motor feedback

and drive, offers the best response level

of actuators resulting in high repeatability

and highest power cost savings.”


Praveen SharmaManaging Director, Hinds Plastic Machines Pvt Ltd

Hitesh R ShahBusiness Head – Injection Moulding Machines, Windsor Machines Ltd

At present, there are an umpteen number of innovations happening in the injection moulding machinery segment for improving the quality of machines.

Servo motor-driven geared pump machines are increasingly used as the geared pump offers highest effi ciency of transmission. This, when used with servo motor feedback and drive, offers the best response level of actuators resulting in high repeatability and highest power cost savings.



Keeping in mind the energy

concerns at present, the

demand for hot runner

systems is growing by the day.

A hot runner system is one of the important

enhancements that manufacturers can

incorporate into their mould to improve

moulded part quality, reduce production

times & energy usage and remain

price competitive.

Rajendran Kasi, Regional Manager

– SAARC Nations, Husky Injection

Molding Systems Pvt Ltd, says,

“Demand for direct gating of plastic

parts is increasing. Hot runners are

replacing cold runner technology, thus

allowing customers to run faster cycles

and achieve more efficient production.

In fact, the hot runner industry is

growing faster in comparison to the

overall plastics industry.”

Functioning of hot runners A hot runner system is an assembly of

heated components used in plastics

injection moulds that inject molten

plastics into the mould cavities. It

usually includes a heated manifold and

several heated nozzles. The main task of

the manifold is to distribute the plastic

material entering the mould to various

nozzles, which then meter it precisely to

the injection points in the cavities.

Hot runners are one of the most

sophisticated components of an injection

mould – a key technology in achieving

an efficient injection moulding process

that has a direct impact on profitability

and part quality.

Kasi notes, “Decreased energy

consumption can be achieved through two

ways. First, better insulation, which enhances

energy efficiency by using appropriate

materials with low thermal conductivities

in places where hot steel touches the cold

plate. Second, more efficient heaters and the

use of electrical actuated valve stems versus

pneumatic or hydraulic actuation systems.

This can be achieved through the use of

hot runner systems.”

Hot runners are fairly complicated

systems. These runners have to ensure

that the plastic material inside is heated

uniformly, while the remaining part of

the injection mould is cooled in order to

solidify the product quickly.

Types of hot runner systemsHot runner systems are of two main types

– insulated and heated.

Insulated runner moulds have

oversized passages formed in the

mould plate. The passages are of

sufficient size through which, under

conditions of operation, the insulated

effect of the plastic (frozen on the runner

wall) combined with the heat applied

with each shot maintains an open, molten

flow path.

For heated runner systems, there

are two designs – internally heated and

externally heated. In the internally heated

system, the plastic material flows directly

over slender heaters inside oversized

runners. This system takes advantage of

the insulating effect of the plastic melt

to reduce heat transfer (loss) to the

rest of the mould.

On the other hand, the externally

heated system consists of a cartridge-

heated manifold with interior flow

passages. The manifold is designed with

various insulating features to separate it

from the rest of the mould, thus reducing

heat transfer (loss).

Husky has made many changes in

their hot runner systems to help moulders

achieve maximum energy efficiency. Kasi

notes, “Two of our recent developments

help reduce overall energy consumption

With intensifying global competition for moulding plastic parts, the pressure is rising on reducing per piece moulding cost and energy consumption in the injection moulding process. This has increased the demand for hot runner systems. Avani Jain analyses the benefits of hot runner systems for reducing energy consumption during the plastics injection moulding process.

SAVING ENERGY: Hot runner systems

Moulding in an energy-efficient manner

Cou

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In

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Mol

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to a large extent in the injection

moulding process. The electric actuated

valve gates consume more than 70 per

cent less energy as compared to a similar

pneumatic or hydraulic actuation system.

Further, our new side-gating technology

allows customers to direct gate plastic

parts that previously would have to be

gated with a cold runner.”

Shorter cycle time, reduced energy usageThe cycle time of any mould is largely

influenced by the cooling cycle –

how fast the resin can be sufficiently

cooled so that the part can be ejected

without permanent deformation. The

usage of hot runners systems help in

reducing the overall moulding cycle by

individual time reductions of the various

processes involved, thereby contributing

to increased output per unit time. The

shorter cycle time also results in less

energy consumption.

Thus, although there is a more

expensive capital investment upfront, a

hot runner system is a significantly more

cost-effective means to keep production

costs to a minimum over the long run

and reduce the energy consumption to a

large extent.

Additional advantages Because there is no cold runner to discard

or recycle, resin consumption is reduced.

Hot runner systems also help reduce the

labour cost. Secondary operations, such as

manual part de-gating and trimming, are

eliminated with a hot runner system.

Further, they help in mould cost

savings, as a smaller cavitation hot

runner-equipped mould may be able

to satisfy production quotas using a

smaller number of cavities because

it runs at a faster cycle. Hot runners

allow reduced injection pressures during

packing, as the system does not have

to deal with injecting resin through

a cooled runner.

Thus, the use of hot runner systems

not only improves the energy efficiency

to a large extent but also offers

other benefits.

Amit Mahant, Director, PK Plastic

International Pvt Ltd, says, “Hot runner

systems offer high rates of efficiency

and productivity. Most notably, these

cut production costs dramatically. The

elimination of cold runners makes hot

runners the preferred solution for clean

room production and for achieving

energy efficiency.”

Hot versus cold runner systems Hot runner systems help in better

energy savings as compared to cold

runners. Kasi avers, “With cold runner

tools, a significant amount of resin

needs to be melted just for the purpose

of filling the cold runner to reach the

cavity. Even if re-used, this resin serves

no other purpose than to transport the

resin to the cavity. In contrast, with

a hot runner mould, the amount of

resin required for filling the cavity is

prepared in the injection unit and leads

to reduced shot volume. Further, cold

runners often have a higher pressure

drop compared to hot runner moulds.

The extra energy (higher machine

pressure) required to fill the cavity with

a cold runner is wasted as the pressure

drops. This is not the case with the

hot runner system.”

Future outlookDespite the high initial cost, the

long-term benefits of equipping a

mould with a hot runner system

can be easily justified. In fact,

in the future, plastics moulders will

focus on maximising productivity

and efficiency through the use of

hot runner systems.

Kasi concludes, “When compared

to cold runner technology, hot runner

technology helps customers achieve this

goal by allowing parts to be produced

at faster cycle times and with less resin.

In addition, increasing labour costs

are driving the need for more automation

and precision. Therefore, hot runner

systems are a key technology to achieve

a higher degree of automation, productivity

and precision.”


Rajendran KasiRegional Manager – SAARC Nations, Husky Injection Molding Systems Pvt Ltd

Hot runners are replacing cold runner technology, thus allowing customers to run faster cycles and achieve more effi cient production. In fact, the hot runner industry is growing faster in comparison to the overall plastics industry.

Amit MahantDirector, PK Plastic International Pvt Ltd

Hot runner systems offer high rates of effi ciency and productivity. Most notably, these cut production costs dramatically. The elimination of cold runners makes hot runners the preferred solution for clean room production and for achieving energy effi ciency.

Hot runner systems


How important is it for plastics processors to adopt energy efficiency measures?At present, energy efficiency is the main

concern of customers and manufacturers.

In fact, customers would not mind paying

a high price for an energy-efficient

machine. This is because today electricity

cost is among the highest cost incurred

in the plastics processing segment, and in

order to survive, they need to deal with

this issue at the earliest.

What are the energy saving methods adopted by plastics machines manufacturers?There are various ways and means for

saving energy. These days, manufacturers

are adopting latest technologies such

as servo-based systems, programmable

logic controllers and variable drives

for energy efficiency. Further, proper

screw and die design can help in saving

energy. Manufacturers are using these

technologies in machines irrespective

of the high cost as they greatly help in

saving energy.

How is the demand for ancillary equipment in the plastics processing machinery segment?The demand for ancillary equipment is

high in the plastics processing machinery

segment. Earlier, ancillary equipment

was considered a luxury; however, they

are now a necessity and a very important

part of machines because they help in

achieving energy efficiency to a very

large extent. Even the rising demand for

automation in the machinery segment

has provided a boost to the ancillary

equipment sector.

How does ancillary equipment help in increasing energy efficiency and overall productivity?These days, it is required of all plastics

processing machines to generate higher

output with less consumption of resources

and energy. In order to do so, ancillary

equipment is a must. Various processes

are involved in converting raw material

to finished products, such as storage,

handling, drying, conveying, colouring,

cooling, heating, counting, grinding and

recycling. For performing these functions,

ancillary equipment, such as chilling

plants, mould temperature controllers

and drying systems, assume much

importance as these help in enhancing

productivity and improving quality.

Further, the advent of automation has led

to the popularity of ancillary equipment,

which in turn has helped in decreasing

the dependence on manpower. The

development of Supervisory Control and

Data Acquisition (SCADA) systems is

one of the ways, as now an individual

can control the entire process. Robotics

has also helped increase productivity.

We have developed the SCADA system

and are working towards decreasing the

energy consumption of machines.

How is the plastics industry fairing in the country, and what would be the future trends?The plastics industry is growing at a

very fast pace. The consumption of

plastics is increasing in the flexible

packaging, cosmetics and white goods

industries. Further, major cement plants

and fertiliser producers in India are

expanding their production capacity

at a faster rate. This is creating a good

demand for raffia bags, carry bags

etc. Also, the pharmaceutical sector is

growing at a fast pace in India. All this

is leading to an increasing demand for

plastics. The future also seems bright

with the automotive segment growing

at a very fast pace. Thus, if the plastics

industry in India needs to compete with

its global counterparts, then it needs

to fight against anti-plastics lobbies by

creating awareness and emphasising on

recycling and energy efficiency. If the

concerns related to energy efficiency are

resolved at the earliest, then surely the

Indian plastics industry can touch new

heights in the times to come.


“Electricity cost is among the highest cost incurred in the plastics processing segment”

…opines Rajiv Trivedi, Vice President (Marketing), Prasad Group and Chairman, Indian Plastics Institute - Ahmedabad Chapter. In a conversation with Avani Jain, he underlines the strategies that can be adopted by plastics processors for achieving energy efficiency. He also underlines how ancillary equipment can help in this regard.

SAVING ENERGY: Inter face - Raj iv Tr ivedi


SAVING ENERGY: Inter face - Khushboo Doshi

In the present times, how important is it to save energy and how much importance is given to this issue by the plastics industry?Becoming more energy efficient is

an important first step to reduce our

impact on the environment. Energy

efficiency is also a non-controversial

issue and improving efficiency means

encouraging innovation and technology,

creating jobs, reducing our dependence

on non-renewable resources and saving

money. If we talk about the plastics

industry, then in the present scenario

of rising environmental concerns, it

is very important for the industry to

develop energy-efficient machinery to

conserve resources.

What are the recent trends related to energy efficiency in the plastics processing machinery manufacturing segment? When it comes to energy efficiency,

economy of scale coupled with

automation is the need of the hour.

Currently, the level of automation in

the Indian plastics machinery industry

is quite low due to high investment

levels required in such automation.

However, in the global market, plant

capacities are high, thus justifying high

investment in automation technologies.

Slowly and gradually, the situation is

changing even in India and the benefits

of automation are being understood and

appreciated by processors. There are

several benefits offered by automation

such as lower wastage levels, consistency

in product quality, lower labour cost and

easier process control. Basically, it helps

in reducing consumption of polymers

at the source itself by reducing wastage

levels. This also helps in reducing the

need for recycling activities that are

energy intensive. In addition, if we

talk about thermoforming segment,

then trends in automation include

temperature control, multiple axis servo

control and automatic stacking.

What are the leading innovations making headway in the segment? Increasing the efficiency by design

improvement of hot parts such as die

and screw, keeping in view the polymer

rheology, is the way ahead in the

machinery segment. In fact, we can get

more output with same size of the screw

and same motor rating by just improving

the screw geometry as compared to the

conventional design.

How does your company address the issue of saving energy? As a machinery manufacturer,

technology upgradation is the only way

“For energy efficiency, economy of scale coupled with automation is the need of the hour”

for us. We are well known for bringing

world-class technology at the door

step of the Indian industry. We have

introduced latest automation techniques

such as material conveying, multi-

component gravimetric blending,

gravimetric dosing for GSM control,

temperature control, history logging,

recipe and process parameter recall,

thickness control and integrated

supervisory process control for saving

energy in terms of power consumption

and manpower cost. In fact, we

were the first company to introduce

automation in blown film extrusion in

India 15 years ago. We have also been

successful in marrying our indigenous

hardware with automation technology

sourced from Europe. Since then, we

have supplied machines with advanced

automation both in India and overseas.

Other machinery manufacturers have

followed suit, and thus, the demand and

understanding of this technology among

processors have also increased. Further,

the unit plant capacities have increased,

thus justifying high investment for

energy-efficient machinery.

What will be the future trends in the segment?The technology will further evolve in

reducing start-up wastage, reducing

thickness tolerances in high output

lines, more efficient use of melt

capacity to increase finished product

outputs, quality and, most importantly,

there would be an increase in energy

efficiency measures taken by companies

in the segment.


…opines Khushboo Doshi, Executive Director, Rajoo Engineers Ltd. In a conversation with Avani Jain, she underlines the need for automation technology to improve energy efficiency. She also talks about the steps that can be taken by the industry for energy efficiency.


SAVING ENERGY: Roundtable

With rising concerns on energy efficiency, the industry is realising the need of adopting measures for saving energy. Avani Jain speaks to industry experts to find out the efficiency of Indian processors in adopting global energy-saving techniques.

High energy costs and the demand from customers have forced the plastics industry to adopt energy-efficient measures. This has lead to development of servo motors, all-electric injection moulding machines, programmable logic controller-based systems and more. Although the steps taken by the

Indian plastics industry towards energy efficiency are remarkable, there is a long way to go when it comes to adopting global energy-saving techniques.

Editorial take:

HOW EFFICIENT ARE INDIAN PROCESSORS

IN ADOPTING GLOBAL ENERGY-SAVING TECHNIQUES?


Mahendra N Patel Chairman,

Mamata GroupShirish V Divgi

Managing Director, Ferromatik Milacron India Pvt Ltd

Anand Panchal Marketing Director,

N A Corporation (NAROTO)Due to the high cost of energy, technical

advancements are oriented towards

reducing energy consumption in the

plastics processing sector. Thus, many

changes are made to machinery for

improving the energy efficiency and

speed. There are constant efforts to

make machines energy efficient through

all-electric drives, servo drives, AC

variable drives, improved temperature

controls, insulation etc. All-electric

machines are the latest development in

the plastics processing machinery sector.

Further, new processing techniques

that reduce energy consumption and

moulding time are being developed.

Thus, almost all the leading plastics

processing machinery manufacturers in

the country are offering technologies

that can stand the competition faced

from foreign companies. Presently, as a

Group, we are focussing more on energy-

efficient technologies, with my company

Mamata Energy dealing in this area.

Thus, Indian processors are continuously

working towards adopting global

energy-saving techniques.

If we talk about efficiency of Indian processors in adopting global energy-saving techniques, then I would rate them six out of ten, which means that there is a long way to go. However, slowly and gradually, the industry is realising the importance of energy efficiency, and everybody is working towards it. Almost all the customers, whom I meet ask just one question – “How to save energy?”. So, changes are being made in machines to ensure energy efficiency to a very high level. At an operational level, we need to employ all possible steps to reduce energy such as using solar energy, day light, water conservation etc. We also have to provide solutions to customers with products consuming optimum energy. Ferromatik Milacron India has been following this principle for many years not only in many operational areas but also through our products. Thus, we are continuously making machines that can save energy for our customers, and our new machine series can save nearly 30–40 per cent energy.

The plastics processing segment, including rotomoulding, is growing at a fast pace. With this growth, the need for energy efficiency is also increasing, keeping in mind the high rates of power and fuel. Thus, companies in the segment are adopting steps to increase energy efficiency. They are gradually adopting global energy-efficient techniques. In rotomoulding, the future trend will focus on minimising the production cost in energy consumed by using better cooling media/programmable logic controller systems, improving oven thermal insulation to reduce heat loss, improving air circulation to reduce resin sintering time, reducing mould cooling time to increase production and using clamping devices rather than conventional nuts & bolts for quicker demoulding. Thus, as plastics processors strive to achieve economies of scale, efficient technology, energy-saving measures and green innovations will go a long way in deciding the industry’s future.

The polymer processing

industry has grown

favourably well in the

last 8–10 years. The

annual growth rate has always

been in double digits except for

the last few months where external

influences had taken a toll on this

trajectory. The best thing about

the Indian plastics industry is

that it is more domestic demand

driven rather than relying heavily

on exports like China. Growth is

taking place across all sectors in

the polymer industry, and many

investments for plastics have

occurred in the automotive industry.

India is now seen as a hub for the

automotive industry, and the plastics

industry has complemented this

sector appropriately. Ravi Kumar,

Director, Shiv Pooja Plastics, says,

“The current trend is to use more

of plastics in automobiles as it

substantially increases the power-

to-weight ratio. The increased

usage of plastics not only helps

in reducing the overall weight of

the car, and thereby increasing the

fuel efficiency but also provides

more flexible design options to

the manufacturer.”

Plastics in packaging Plastics for the packaging industry

have greatly evolved in the past

decade. “We have witnessed a shift

from the traditional materials of

paper, wood and metal used for

packaging to plastics. This has

been across all packaging forms

ranging from rigid, semi-rigid and

flexible,” adds Kumar. The growing

awareness among consumers

regarding international designs and

user-friendliness offered by plastics

go a long way in expanding the

market for plastics in packaging.

The flexibility offered by plastic

packaging and the low costs

involved have allured customers,

and manufacturers have been

quick to adapt to the changing

requirements. Also, India is a

price-sensitive market, and usually

high-end products use metals,

glass and other heavy materials for

packaging. The low and middle

end products generally have plastic

packaging as they are economical

to produce and affordable to buy.

Although there are certain

environmental issues related to

the use of plastics, the key issue is

to educate the end-user regarding

the proper methods of plastic

waste disposal. Various industry

bodies and the government

have come up with education

programmes as plastics serve more

purposes than other materials

used for similar applications. The

debate continues, but no one can

do away with the use of plastics.

In terms of biodegradable plastics,

India is still in the nascent stage,

but companies are witnessing

fast adoption of such plastics

by customers. “Gradually, as the

market evolves and the income

Polymer manufacturers across the country have geared up to meet international standards in terms of quality at affordable prices. The polymer processing industry, however, needs to complement these efforts with more research initiatives in order to create a global brand appeal for the Indian plastics industry and keep imports to the minimum. Anwesh Koley looks into the various aspects of the polymer industry in India and the way forward.

Minimising imports to maximise profits

SAVING MATERIAL: Polymer processing


Cou

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ASF


Polymer processing

levels increase, we can expect a rise in

the use of bioplastics on a more regular

basis. Another propelling factor for

bioplastics is the fact that multinationals

are entering the country rapidly, and

many of them are into the use of

biodegradables. So we can expect them

to carry out research initiatives in order

to make bioplastics more affordable,”

avers Kumar.

Compared to the global average

consumption of plastics that is about

25–30 kg per person, India has a

low plastic consumption of about 6

kg per person. Hence, there is much

scope for companies, both domestic

and international, to capitalise on the

opportunities that are yet to be tapped.

“The temporary blips like currency

fluctuations and volatility of crude oil

prices will continue, but as the current

trend suggests, investments will continue

to increase and so will consumption levels.

We do need support from the government

in terms of creating a more favourable

platform for the industry to thrive and

also provide manufacturers with the

required infrastructure,” feels Kumar.

Compounding technologyThe industry still prefers the traditional

compounding methods for polypropylene

and talc-filled compounding, but

processors are seeing an increase in the

usage of composites such as wood and

plastic composites. In countries such

as the US and UK, this trend is quite

prevalent. India is also expected to follow

this trend as there is a lot of wood waste

available in the country that can be

used. Such composites present a better

finishing of the product and offer good

value for money.

Another trend is more of engineering

plastics being compounded. Till the last

decade, not many companies were into

the use of engineering plastics such as

the mobile phone and laptop companies.

However, the recent years have seen

many domestic manufacturers using

engineering plastics. “The compounding

for commodity polymers is seeing an

organic growth, but the inorganic growth

will come from engineering plastics.

Processors import a lot of high and

medium grade compounds for wires and

cables, which are required to withstand

flow of high voltage current. However,

with evolving customers’ demands, it can

be expected that domestic companies

will start manufacturing products that

are currently imported,” says Kumar.

The traditional compounds of

calcium carbonate cannot fulfil all the

design and feature-based requirements of

companies; hence, these are now evolving.

New varieties of fillers and additives

are now being used to ensure that the

polymer is of a premium quality. Apart

from aesthetics, another requirement is

that paints should be volatile organic

compound-free. They should have less

odour and less fumes.

Safety concernsThe latest additives are those which

reduce volatile emissions and make

the final product more user-friendly.

In addition, for the people inside the

processing units, compounding activities

should emit less fumes and not have

an adverse impact on health. In India,

regulations regarding safety standards

are not stringent, and manufacturers are

also casual regarding these health issues,

which are taken up seriously in other

countries. The awareness and intent

are strong in those countries. However,

with the advent of multinationals, such

concerns are expected to be addressed.

Research initiativesIn terms of Research and Development

Ravi KumarDirector, Shiv Pooja Plastics

The current trend is to use more of plastics in automobiles as it substantially increases the power-to-weight ratio. The increased usage of plastics not only helps in reducing the overall weight of the car, and thereby increasing the fuel-effi ciency but also provides more fl exible design options to the manufacturer.

55June 2013 | Modern Plastics & Polymers 55June 2013 | Modern Plastics & Polymers

(R&D), wise Indian players are lagging

behind as many unorganised players

cannot afford huge investments.

However, the organised players

need to invest more in R&D. The

government must create conditions

where manufacturers are encouraged

to come up with ideas and techniques

that can benchmark international

standards. “Indian polymer manufacturers

have not disappointed the market

in terms of quality and availability of

polymers, but the processors should also

be encouraged to undertake research

efforts which would complement

polymer manufacturers. This will help

in bringing down the cost of the product

and create a high brand value for Indian

polymers. The vast expanse of the Indian

market will ensure that the country

remains a value-for-money oriented one

and such a market requires a harmonious

blend of quality at affordable prices,”

believes Kumar.


New varieties of fillers and additives

are now being used to ensure that

the polymer is of a premium quality.


When it comes to

packaging material

or containers, trays

& boxes, automotives

& construction, raw materials such as

polypropylene and polystyrene are fast

gaining ground in terms of usage in the

polymer processing industry in India.

The rising demand, both domestic

as well as global, has ensured that

manufacturers have their order books

full. Plastic products are fast replacing

metal as the preferred choice in various

industries. This has lead to a flurry of

innovations for the polymer processing

industry, and it has to keep up with

the design and quality requirements of

plastics manufacturers.

Why research and developmentWith increasing Research and

Development (R&D) being undertaken

in European countries such as Germany

and Asian countries such as Korea

and China, engineering polymers have

bright growth prospects in the years

to come. High-performance polymer

products, which can replace metal

and offer weight & cost reductions to

customers at the same time meeting the

functional needs of the application, have

excellent growth prospects.

The socio-economic trend of

increasing younger-age working

population (including more women)

has created new avenues for industrial

polymers as well. Lifestyles are more

hectic, dual incomes are also encouraging

the emergence of organised retail, so

new application avenues in the area of

packaging are coming up. Demand for

safe and hygienic packaging for food,

beverages and medicines is growing.

International companies are approaching

these opportunities with their unique

and high-performance offerings through

engineering polymers.

In the medium to long term,

companies are looking at opportunities

in defence, renewable energy and

materials (eg photovoltiacs, bio-ethanol

& bio-butanol) and renewably sourced

materials for different applications.

India is witnessing heavy investments

in these areas as the country provides

abundance of human talent – both

skilled and unskilled.

Where the industry standsCurrently, the polymer processing

industry is witnessing a steady increase

in the number of players who are

driven by the growth and profitability

of the sector. Rajeev Bhatia, Chief

Executive Officer, Premier Pigments &

Chemicals, says, “The Indian plastics

industry is growing at the rate of

12–15 per cent per annum since the last

few years. This means the demand of the

raw material is also growing at the same

rate simultaneously. With regard to the

Indian clientele, people are improving

with technological advancements and

have access to international standards.

However, this improvement happens

at a much higher pace for a company

that exports than for the one that

manufactures and sells in India.”

By 2012, India is projected to be

the third largest consumer market

for plastics, with a consumption of

12.75 million MT per annum. Polymer

consumption in India has historically

The Indian plastics industry is witnessing growth from all verticals. This, coupled with the increasing awareness about the importance of recycling such products, has ensured that not only do consumers get a better finished product but the environment also breathes a sigh of relief. Anwesh Koley analyses the numerous roles played by polymers in improving final product quality.

SAVING MATERIAL: Innovat ion and qual i ty

Widening the scope for efficient plastics

Cou

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grown at twice the gross domestic

product rate. This growth is driven

by all consuming segments such

as automotive, housing, packaging,

agriculture etc. “With the advancement

and developments of machinery, raw

material suppliers have increased their

production with lesser number of people.

Better consistent material is available

at much competitive prices than

before,” says Sumit Dhingra, Director,

Dhingra Polymers.

An increasing need is felt in

the construction industry to replace

conventional materials with plastics.

“Earlier, wood was the preferred choice

for construction equipment and internal

requirements, plastics, having evolved

in their applications, are fast gaining

ground in this segment as well,” says

Bhatia. Masterbatch consumption

increased from 182 thousand MT in

2010 to approximately 255 thousand

MT in 2012. This growth is attributed

to the rise in competition both

domestically as well as internationally

as manufacturers now have access to

global technology and are aware of the

changing demand patterns.

Improvement areasHowever, the rate of growth witnessed

by the Indian polymer processing

industry does not match up to standards

maintained by China. “The level of

R&D undertaken by China is more

than India. Also, the government there

is friendlier towards manufacturers as

well as exporters,” feels Dhingra. While

the government has been taking regular

measures towards easing things for

the polymer industry, the fluctuating

crude oil prices have had a negative

impact on this sector. “The government

should encourage the use of alternatives

to plastics in non-core areas, as our

business gets impacted with the global

crude oil prices,” says Bhatia.

Masterbatch manufacturers will

strive to exhaust their present capacities

with increased demand. If the present

capacity remains constant, there is

a possibility of imports as well; this

may result in higher prices. Prices of

masterbatches depend not only on the

polymer prices but also on the pigment

prices, and these have been increasing

steadily. However, with increase in

demand of masterbatches, probability

of more manufacturers jumping into

the foray is great. This will result in

an equilibrium price where the quantity

demanded by consumers (at current

price) will equal the quantity supplied

by manufacturers.

The rate of innovations witnessed by

the polymer industry is commendable,

but R&D needs support from the

government. Also, the increase in

applications for polymers has resulted

in more R&D by manufacturers,

thereby increasing competence globally.

However, the Indian polymer industry

is enthusiastic in the adoption of latest

technologies. Exposure to international

standards and quality has ensured that

more areas find plastics application,

which was earlier the forte of metals

and wood.

The polymer manufacturing sector

seems to grow and adapt according

to the changing needs of the market.

However, there are issues concerning

the sector. “As polymers use a

petroleum base, their prices have gone

up drastically. Energy and labour costs

have also increased substantially. The

challenge before the plastics processing

industry has been to manage these steep

cost increases without the same degree

of increase in sales prices and sharp

decline in margins,” laments Dhingra.

The measures taken by the industry

to cope with these shortcomings include

lowering input resources such as energy

and space. Manufacturers are coming

up with equipment that have higher

productivity and consume lesser space

within the plant. Another important

measure is to reduce all forms of

waste, which result from operational

rejections, waste heat and spillage.

Apart from technical requirements,

a major problem is the availability of

skilled workforce.


Rajeev BhatiaChief Executive Offi cer, Premier Pigments & Chemicals

The Indian plastics industry is growing at the rate of 12–15 per cent per annum since the last few years. This means the demand of the raw material is also growing at the same rate simultaneously.

Sumit DhingraDirector, Dhingra Polymers

With the advancement and developments of machinery, raw material suppliers have increased their production with lesser number of people. Better consistent material is available at much competitive prices than before.

Innovat ion and qual i ty


What are the latest innovations witnessed by the polymer compounding sector?Compounding is a continuous process.

With time, people realised the importance

of compounds. When the industry was

in its nascent stage, people were not

aware of its applications. Gradually, with

the advent of multinational companies,

domestic manufacturers understood

the need for effective compounding,

and accordingly, the market saw a

flurry of machines that catered to the

compounding process. The need was felt

for more advanced machines that could

furnish the growing needs of the market.

The market is currently growing at 10

per cent per annum. With the growth of

polymers, masterbatches will also grow.

There is a direct correlation between the

growth of polymers and masterbatches as

the demand for innovative colour options

will only increase in the future.

What are the latest machines used in this sector?Mainly twin screw extruders are used for

regular compounding of polymers. Earlier,

these were expensive to buy, but now

extruders are manufactured in India. They

are still imported, but there are many

domestic manufacturers. This has resulted

in extruders becoming cheaper over the

years. For plastic compounding, twin screw

extruders are very important. Chinese,

German and Japanese manufacturers are

also into manufacturing extruders that

are accepted globally. While Germany

is the biggest exporter of extruders to

India, a host of domestic manufacturers

have come up with machines with

international standards.

How has compounding evolved over the years?Compounding was earlier complemented

with manual colouring. Masterbatches

have recently emerged as an efficient

method of giving colour to plastics. A

couple of decades ago, the only materials

available were polystyrene and Low-

density Polyethylene (LDPE). Initially,

people used hand-moulding machines

to colour these materials. Companies

used the manual approach for colouring

before the advent of masterbatches. As

the market grew, it was not considered

feasible to outsource all the colouring

requirements; hence, they adopted

the use of masterbatches. Then came

the single screw process of colouring

plastics, which was faster and a more

convenient technique in the plastics

processing industry. Thus, compounding

was always a technical process, but the

colouring of plastics has evolved with the

use of technology.

Most of the compounds that are made

in India are tailor-made compounds.

Whenever global players enter the

country, they want materials according

to their specific requirements. There

are different minerals available, and

companies indicate to us their choice.

In the automotive industry, before the

arrival of Japanese manufacturers, most

body parts were made of metal. With

the advent of Japanese players, metals

paved the way for plastics. Along with

these changes, plastics compounding also

evolved as different components required

plastics with different properties, and

engineering plastics offered this versatility.

The additional requirement for talc, glass,

calcium and other minerals was best

fulfilled with the use of plastics.

What are the various research and development initiatives in compounding?Domestic companies find it better to

work with the existing techniques as

this helps them to save on cost – the

primary concern for the entire industry.

The masterbatch segment has witnessed

a lot of activity as the end consumer now

wants a variety of colour combinations

for the plastics they use. More companies

are exploring different combinations of

colours that can effectively supplement

the compounded polymers. Compounds

have largely remained the same, but the

efforts towards improving their external

appeal have increased.


“The colouring of plastics has evolved with

the use of technology”

…opines Surinder Minocha, Managing Director, Minocha Enterprises Pvt Ltd. In a conversation with Anwesh Koley, he explains the need for adapting to global techniques as manufacturers want international standards. He also highlights the need for robust technology at affordable prices to stay competitive.

SAVING MATERIAL: Inter face - Sur inder Minocha


SAVING MATERIAL: Roundtable

The Indian plastics industry is growing at a rapid pace in the last few years. This means the demand of raw material is also growing at the same rate. At present, processors are conscious about the quality of products and high efficiency of production. Anwesh Koley speaks to industry experts to gauge the way forward for the polymer and masterbatch industry.

The polymer industry in India is currently on the path towards achieving international standards. Domestic manufacturers and processors are keen on providing global quality to their consumers. With an increase in growth, the industry also has an eye towards cost efficiency.

Editorial take:

DOES THEDOES THE INDIAN POLYMER INDUSTRYINDIAN POLYMER INDUSTRY

HAVE THE POTENTIAL TO BENCHMARKHAVE THE POTENTIAL TO BENCHMARK INTERNATIONAL STANDARDS?INTERNATIONAL STANDARDS?


Girish DhawanProprietor, Perfect Polymers V Vikram

Proprietor, Sealers India Agencies Vijay VoraDirector, Roshma Pet Plast Pvt LtdThe plastics industry in India has a

big market potentiality and is gradually

prospering. This market potentiality

has been constantly encouraging

entrepreneurs to invest in this industry.

Entrepreneurs are trying to provide

high-quality plastic products so that

it becomes a booming industry. The

masterbatches business in India is slated

to benefit the most from the rise in

plastics consumption. Masterbatches

form about 75–80 per cent of the plastics

industry, and hence will witness a parallel

rise in demand as India becomes the

third largest plastics consumer by 2013.More processors are turning to

masterbatches on account of enhanced consistency in performance and elimination of pollution problems. New found opportunities for silicon masterbatches are in applications for PE duct for optical fibres. This could generate additional business of almost 1,500–2,000 tonne per year. Growth of polymers and masterbatches is also expected to be high as polymer manufacturers are resorting more to the use of the masterbatch system.

The plastics industry is already witnessing steady growth in consumption. With India set to become the third largest consumer of plastics, prices in the market will surely go down. The domestic market is expected to witness a boost as many plastics manufacturers are resorting to locally made materials. Also, logistics is expected to become more efficient as demand and supply will need to be better matched. The development of high productive machines has opened up a new horizon of masterbatch application. Not only this, but plastic is widely used as a first immediate replacement of metal, paper etc. This has created a compulsion for development of new blends (composite plastics) for plastics industries.

The plastics industry has shown a 20 per cent increase in volumes over the previous year, and growth is driven by all the segments where plastics find applications. Another important factor that will complement the consumption is the gradual movement from metal packaging to flexible packaging.

Masterbatch manufacturers across the country are witnessing a strong rise in demand as the market is growing strongly due to sufficient supply and availability of materials. The next year will be challenging for polymer producers and the entire polymer market. Further growth will happen because many large players are developing a number of capacities near their plant. With India emerging as the third largest consumer of plastics in the world, the north region is particularly expected to witness considerable developments in the polymer industry. Also, polymers like polypropylene have always been in excess supply in the country, and this being one of the major materials being used in manufacturing plastics will witness an even higher demand.

Growth in the plastics sector has always exceeded the GDP growth rate in the country, and with the increase in demand, both globally and domestically, manufacturers will have to increase their production capacities.

Efficient moulding

machines require an

energy-efficient design.

However, efficiency

does not depend only on the

energy consumption of machines.

Efficient operation concerns

the productivity of the system

as a whole, and aspects such

as machine availability, speed,

precision and reproducibility must

also be considered.

Precision feeders for higher accuracyThe latest additive feeders operate

under a gravimetric dosing

principle where material flow

is continuously monitored and

controlled on a loss-in-weight

basis. This is said to increase

dosing accuracy and consistency,

thanks largely to the disk-based

metering technology that releases

a precise volume of additives.

The closed loop system monitors

and compensates for changes in

flow behaviour and bulk weight.

Further, precision is derived from

shears at the dosing disk that cut

granules to ensure that the dosing

chambers are consistently filled.

A smart calibration feature on

the feeder means no component

weighing procedures have to

be undertaken during material

changes. Instead, the additives are

dosed in a synchronised manner

according to the plasticating time

of the moulding machine or the

screw speed of the extruder.

Processors using liquid

colours and additives can now

benefit from the accuracy and

simplicity of gravimetric (loss-

in-weight) metering technology.

Varun Kapoor, Director, Sarvasv

Machinery & Equipments Pvt

Ltd, says, “The liquid feeders

eliminate the need for time-

consuming colour calibration and

adjust automatically for changes in

material and processing conditions.

This, in turn, results in easier set

up and greater processing up-time

for increased productivity.”

The current equipment in

feeders use the same clean, simple

peristaltic pumping technology as

conventional volumetric dosers.

However, the liquid container

is supported on a load cell that

constantly measures the loss-in-

weight as material is pumped

into the processing machine.

Programming is easy and in

injection-moulding applications,

the operator simply enters

Precision and accuracy are the most important characteristics that ancillary equipment must have in order to ascertain accurate processing and ensure timely production. It is also important to reduce energy consumption while ensuring seamless processing of high-quality raw materials. Anwesh Koley explores the latest technologies that go into making a perfectly processed plastic product without any delay.

Right tooling for faster performance

SAVING TIME: S i lent t ime savers


Cou

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Si lent t ime savers

the part weight and the colour and

additive percentage.

High-quality feeding systemsDrying, conveying, metering and mixing

equipment make up a complete set of

feeding system for plastics processing.

Drying equipment is applicable to

pre-treat hygroscopic materials such

as acrylonitrile butadiene styrene,

polyoxymethylene, polycarbonate,

polyamide and poly methyl methacrylate

before moulding. During the processing

of polyolefin plastics, drying is

generally adopted to guarantee product

quality. For instance, in the injection

moulding of random polypropylene

and polyethylene material for cross-

linked polyethylene, the material needs

to be dried to the extent of moisture

content.

Based on the material moisture

content of products, various drying

fashions and equipment are also under

application. For the material loading

of polyvinyl chloride granules, an oven

dryer is the optimal equipment. For

plastics with strong thermo-sensitivity,

a rotary double-cone vacuum dryer is

mostly used.

However, for successive drying,

direct-type hopper dryer is the first

choice. “The central feeding system

is mostly applied on large-scale and

automated production. Equipment

in the processing units are controlled

via computers with material entering

mixers after passing metering devices

by proportion,” says Kapoor.

Each hopper is equipped with a

level sensor to detect material quantity,

which will control opening or closing

of the material tank in conveying pipes.

The critical technique in the central

feeding system is the accurate metering

of electronic scale, which will influence

whether the feeding material quantity

by proportion is right or not.

Enhancing efficiencyFor extrusion, the feeder can run on

an open loop or precisely control the

metering rate against extruder screw

speed. Once set up, the digital control

takes over, adjusting the pump speed

to meter exactly the right amount

every time, regardless of changes in

production rate, variations in viscosity,

pump/hose condition or environmental

changes.

Dhaval Bhatt, Chief Executive

Officer, Sri Sai Plasto Tech, says,

“Loaders and blenders provide more

accuracy and efficiency for reduced waste

and improved quality of parts. Higher-

performance dryers use less energy

and provide cost savings. Increased

efficiencies are being seen across the

whole range of auxiliaries, contributing

to profitability in plastics processing.

Energy savers for granulators are the

latest development the industry has

seen till date.”

In plastics processing industries

such as extrusion, injection moulding,

calendaring, hollow moulding, film

blowing and spinning, host machines

require plenty of auxiliary equipment,

which are indispensable components.

Therefore, product quality and corporate

viability depend to some extent on the

automation and rationalisation of plastics

process auxiliary equipment. “According

to the functions, there are three types of

plastics auxiliary equipment, including

feeding equipment, temperature control

equipment and granulating & recycling

equipment of rim leftover. These devices

perform various functions in plastics

processing,” adds Kapoor.

Temperature control to reduce timeHeating equipment during plastics

processing include the cylinder moulds

used for extruder, injection moulding

and rolling machines, as well as heating

controllers for forming rolls.

The heating method currently in use

is the electric heating of heat transfer oil

but not the complicated steam heating.

Heating equipment in plastics processing

mainly refers to the temperature heating

controller applicable to the cylinder

mould and stack of extrusion, injection

and calendaring production.


Varun KapoorDirector, Sarvasv Machinery & Equipments Pvt Ltd

Dhaval BhattChief Executive Offi cer, Sri Sai Plasto Tech

The liquid feeders eliminate the need for time-consuming colour calibration and adjust automatically for changes in material and processing conditions. This, in turn, results in easier set up and greater processing up-time for increased productivity.

Loaders and blenders provide more accuracy and effi ciency for reduced waste and improved quality of parts. Higher-performance dryers use less energy and provide cost savings. Increased effi ciencies are being seen across the whole range of auxiliaries.



To understand the

requirements for

recycling plastics,

it is important

to look into the chemical

structure of plastics, whereby

it can be successfully reused

without resulting in any

environmental damage. The

government has constantly

come out with measures to

ensure efficient recyclability of

plastic bottles and the industry

has also started contributing

towards this measure.

I n d i a r e c y c l e s

approximately 3.6 million

tonne of plastics every year.

There are about 3,500 organised

and 5,000 unorganised

recycling units employing 6 lakh

people directly and 10 lakh indirectly.

The major types of plastics recycled

are polyethylene, polypropylene,

Polyethylene Terephthalate (PET),

polyvinyl chloride, acrylonitrile

butadiene styrene, polystyrene, nylon,

polycarbonate, high-impact polystyrene,

poly methyl methacrylate and other

engineering plastics.

Nature of plastics in PETPET is a common plastic material used

as an ingredient to make beverage bottles.

Like most plastics, PET bottles are non-

biodegradable and will just sit in landfills

if not recycled on time. PET is made of

petroleum, so a more efficient recycling of

used PET bottles would also help reduce

dependence on oil.

Recycling is an efficient concept,

but often the recycling process ends up

wasting more energy in reprocessing the

recyclables rather than gaining it. Besides,

the industry is yet to find a cost-effective

means of recycling food containers into

new food containers.

Although there is a demand

for recycled bottle-grade PET,

the high cost of cleaning post-consumer

beverage bottles, strict Food and

Drug Administration (FDA) requirements

and outmoded technology have

favoured the use of virgin PET

over recycled PET in manufacturing

of beverage bottles. This has resulted

in most beverage bottles collected

for recycling being reprocessed into

non-food products such as fibre

and strapping.

Industry–government effortsNearly all types of

plastics can be recycled;

however, the extent to

which they are recycled

depends on technical,

economic and logistic

factors. Innovations

in plastics separation,

sorting, washing and

d e - c o n t a m i n a t i o n

technologies equipment

have made it possible to

efficiently collect, separate

and recycle mixed rigid

packaging plastics. Tej

Ram Singhal, Director,

Suraj Plastic Industries,

says, “The National

Plastics Waste Management Task Force of

the Ministry of Environment and Forests,

Government of India, has recommended

a strategy and action programme of

plastics waste management in India. Also,

the Bureau of Indian Standards (BIS),

New Delhi, has issued guidelines on

recycling of plastic waste. All responsible

manufacturers of plastic recycled products

adhere to the safety rules and regulations

laid out by the government.”

Modern technology for quick recycling Most bottles are made of PET. PET containers

are identified by a resin identification code

imprinted on the side or bottom of the

container. After collection, the bottles are

forwarded to recycling locations where they

are run through grinders that reduce them

to the flake form. The flakes then proceed

The increasing use of plastics in industrial and consumer applications, growing consumer awareness on solid waste recycling and lower cost of recycled goods have led to an increased demand for recycled plastic resin and products. However, recycling of plastics must be timely and not harm the environment. Anwesh Koley stresses on guidelines that can be implemented to achieve the desired results in the shortest possible time.

SAVING TIME: Sustainable processes

Need for industry–government collaboration

Courtesy: Under30CEO


Sustainable processes

through a separation and cleaning process that removes all foreign

particles such as paper, metal and other plastic materials. Among

the recently developed technologies, the automatic PET washing

system that requires less capital and energy cost is useful for

the Indian market.

“The latest PET washing/grinding/drying systems

incorporate heated pre-wash stage to remove labels from whole

bottles before grinding, a wet grinder/crusher to reduce bottles

to flake, followed by a succession of small wet-washing units

– hot and cold – that use intensive friction,” adds Singhal.

Each washer is followed by a friction dryer to strip off dirty

water. It also uses density separators and metal detectors both

before and after washing. Density separation is followed by

two friction dryers, one for the polyolefin that ‘floats’ and

second for PET ‘sinks’. The PET is air-classified for removing

fines, labels and nylon barrier material from bottles. The last

stage is the drying stage, where flakes are thoroughly dried

by friction dryers. After being cleaned according to market

specifications, the recovered PET is converted into a variety

of useful products such as carpet fibre, strapping, moulding

compounds and non-food containers.

An eye on the futureThe need for an effective means to recycle PET bottles

has urged both the industry and policy makers to look into

the problem, with particular focus on energy efficiency and

reusability of PET. With more companies becoming involved

in research to develop better means of recycling PET, the

condition is expected to improve both globally and in India.

Till then, a better understanding of the chemical structure of

PET would only help speed up its recycling.


Tej Ram SinghalDirector, Suraj Plastic Industries

The latest PET washing/grinding/drying systems incorporate heated pre-wash stage to remove labels from whole bottles before grinding, a wet grinder/crusher to reduce bottles to fl ake, followed by a succession of small wet-washing units – hot and cold – that use intensive friction.


How relevant are bioplastics in today’s world?In an age where sustainability is one of the

biggest issues facing the packaging industry,

the use of bioplastics seems the most feasible

option considering the rapid increase in

pollution levels caused by petroleum-based

plastic materials. The major difference

between biopolymers and hydrocarbon

polymers is that due to their physical

and chemical structures, biopolymers can

be decomposed by microorganisms and

assimilated in the soil again.

This property of biodegradable plastics

has made them popular across the globe.

However, the guidelines that regulate the

usage of bioplastics are not well defined in

India. In India, the ISO 17088 guidelines

rule the use of bioplastics but have not

been implemented properly. The journey

towards starting a bioplastics initiative

has been fraught with challenges and,

above all, negative sentiments, from the

plastics lobby and the government. They

perceive the initiative as a threat to

industry and livelihood. The sentiments

of people today are completely different

from the government’s perspective and are

considered as proactive in their support

for bioplastics.

What are the implications of the ISO guidelines?The ISO 17088 guidelines specify

procedures & requirements for

identification & labelling of plastics &

plastic products that are suitable for

recovery through aerobic composting.

This specification is intended to establish

the requirements for labelling of plastic

products & materials, including packaging

made from plastics, as ‘compostable’,

‘compostable in municipal and industrial

composting facilities’ or ‘biodegradable

during composting’. The labelling will, in

addition, have to conform to international,

regional, national or local regulations. In

February 2011, a Life Cycle Assessment

(LCA) by the UK Environment Agency

showed that oxo-biodegradable plastic

bags have a better LCA than paper bags

or compostable plastic bags.

The current market for bioplastics is

restricted as compared to other countries

where they have high utility. The

government is clear in terms of guidelines

issued for anti-solid waste management.

Identify the stumbling blocks hindering the growth of the bioplastics sector.Oxo-biodegradable packaging is more

expensive and requires continual exposure to

microorganisms in an industrial composting

environment; hence, this rules out the

problem of littering of plastics. Composting

is an artificial process with a shorter time-

scale than natural biodegradation, which

results in rapid, unfavourable carbon release

into the atmosphere. These cannot be

recycled in the normal recycling process and

have to be segregated from the waste stream

and treated separately, which considerably

increases the cost. Furthermore, it is difficult

for manufacturers to physically distinguish

between hydro-biodegradable and

normal plastics.

The government has made it mandatory

that plastic bags of thickness less than

40 micron cannot be manufactured for

packaging purposes. Similar standards

are yet to be implemented for bioplastics.

Our customers are sceptical about the

long-term viability of plastics, be it

classical plastics or biodegradable ones.

If the government does not demarcate

between classical plastics and bioplastics,

a substantial share of consumers will

not be able to achieve the full benefits

of bioplastics.

How do you see the future of bioplastics in India?Hydro-biodegradable and oxo-

biodegradable plastics have their own

unique merits and should compete fairly in

the market. Although oxo-biodegradable

plastics do not decompose as much as

conventional biodegradable plastics, it is a

step forward to moving away from the use

of classical plastics, which take hundreds of

years to decompose. Government policies

and guidelines are the most important

factors determining market acceptability

for biodegradable plastics.


“Biopolymers can be decomposed by

microorganisms and assimilated in the soil again”

…believes Manish Pathania, Sales Director, Greendiamz Biotech Ltd. In an interaction with Anwesh Koley, he talks about the various developments in the bioplastics sector and the key areas that need to be addressed with urgency.

SAVING TIME: Inter face - Manish Pathania

The consumption of

Indian polymer products

is on the rise. Polymer

consumption is expected

to double in the next three years.

This has directly impacted the

polymer processing industry

and its scale of operation. Now,

polymer processing companies are

expanding in terms of capacity and

production. However, they are faced

with many issues such as manpower

shortage and heavy power costs. So,

companies need to take adequate

steps to deal with these issues as

these have a direct impact on the

cost and quality of machines.

Saranjit Singh, Proprietor,

Bamra Engineering Works,

says, “Due to high labour and

power costs and shortage of

manpower, the polymer processing

machinery manufacturers are

pushed to develop machines

facilitating higher output. This

is the situation of the domestic

and global polymer processing

industries. Another trend is that

when we talk about higher output

machines, then automation has

become an obvious need. Hence,

polymer processing industries have

reacted to this demand and have

developed machines with complete

automation facilities. These two

factors have also led to increase in

energy efficiency, thereby reducing

the power cost.”

Increasing manpower efficiency through automationTo ensure consistent quality and

greater production efficiencies to

offset high cost of raw materials,

labour and power, customers

are moving towards the use

of automation and robotics.

Automation technologies have thus

gained due attention from plastics

processing companies.

These days, companies in the

plastics processing segment are

using Computer Numerical Control

(CNC) machines for manufacturing

of key components. These CNC

machines have revolutionised

machining processes as now the

parts need not be manufactured

manually. This has helped in making

highly precise machines, and the

chances of mistakes are minimised.

Further, customers want highly

automatic and synchronised

systems in order to improve their

product quality and efficiency. The

controls in use at present make

use of microprocessor-controlled

high-speed Programmable Logic

Controller (PLC) systems. The

PLC systems help in reducing the

labour costs to a very large extent

With the increase in consumption of plastics, polymer processing companies are expanding their horizons in every way. However, in doing so, they are faced with challenges such as manpower shortage and heavy power and energy costs. Anwesh Koley highlights strategies adopted by companies in the segment to deal with these challenges.

OF MAN AND MACHINE

MANPOWER MANAGEMENT: Managing workforce


Cou

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Inc

Managing workforce

as you need to have only one skilled

person to set the parameter once and then

repeatable operations can be carried out

automatically. Thus, there is no need of

manual labour.

Another system that helps in reducing

the dependence on manpower is the

Supervisory Control and Data Acquisition

(SCADA) based system, which usually

refers to centralised systems, which

monitor and control complex systems

spread out over large areas. Machines

in this system help in achieving zero

rejection. It also makes the work of the

manufacturer easy, as there is no need

to set the parameters of a repeated

process every time because the machine

will do that automatically according to

the commands given.

Neeraj Garg, Partner, Suruchi

Industries, says, “The development of

the SCADA system is one of the best

ways through which one man can control

the entire process, thus reducing the

dependence on manual labour.”

Role of ancillary equipmentAncillary equipment play a major role in

increasing energy efficiency and reducing

the dependence on labour. Singh says,

“Ancillary equipment can be seen as the

answer to automation requirements of

companies as they highly help in decreasing

the dependence on manpower. Various

processes are involved in converting raw

material to finished products, and for

performing these functions, companies

need not hire labour, instead ancillary

equipment such as chilling plants, mould

temperature controllers, drying systems

etc can be used, thereby enhancing

productivity and improving quality.” If

the right type of ancillary equipment is

used, then it will not only avoid wastage

of the raw material but also save energy

consumed during processing.

Servo motors for power and efficiencyNot only have polymer processing

companies taken novel steps for reducing

dependence on labour but they have also

developed technologies that have helped

in reducing their energy consumption

to a very large extent. The development

and usage of servo motors and drives

is a clear answer to this. These motors

seem to be the buzzword in the plastics

processing machinery segment. Almost

every processor is talking about them and

clearly think that they are the future of

the industry.

The main reasons being that servo

motors help in reducing the energy

consumption by about 60 per cent, and

the fact that they occupy less space.

The existing normal electric/fuel-

driven motors transmit power to various

points of movements through gears,

chains, belts and pulleys, which are

heavier and bigger. On the other hand,

in the servo motors, all movements in

the machine are powered by appropriate

size of motors controlled by drives

and sensors, which are smaller, lighter

and convenient.

The way forwardIn the future, the expectation from new

machines would be more from less.

In the competitive world, machines

with higher output and lower power

consumption per unit of output will

be the winners. Thus far, the efforts

of the plastics processing segment are

in enhancing quality & efficiency of

machines and reducing dependence on

labour. The innovations that have made

headway in the sector at present will

surely have a long-term impact on the

industry and will form a basis for future

advancements.


Saranjit SinghProprietor, Bamra Engineering Works

Neeraj GargPartner, Suruchi Industries

Due to high labour and power costs and shortage of manpower, the polymer processing machinery manufacturers are pushed to develop machines facilitating higher output. This is the situation of the domestic and global polymer processing industries.

The development of the SCADA system is one of best ways through which one man can control the entire process, thus reducing the dependence on manual labour.


Efforts of the plastics processing segment

are in enhancing quality & efficiency

of machines and reducing dependence

on labour.


Educating the workforce on

how a machine operates

is often a time- and cost-

consuming activity that

hampers efficiency. Usually, this results

in many functions of the machinery

remaining unused. Thus, technical

education is an urgent requirement for

the people operating on the shop floor.

Currently, plastics processors are looking

for compact machinery as they are starved

in terms of space. The dimensions of

equipment today have reduced largely

from the ones used about 5 years ago.

Besides, they are more efficient and use

less energy. Manufacturers are also opting

for machines that use fewer components,

and consequently, require less manpower.

Global companies manufacturing

ancillary equipment are fast entering

India as the cost of manufacturing is

lower, availability of raw materials is

higher and labour is far cheaper. The

Indian ancillary equipment market has

been witnessing rapid growth. Dipak

Vyas, Chief Executive Officer, Neo

Pack, says, “We hope to continue in the

same vein, partner many new companies,

bring in the latest technology as and

when they are launched globally, invest

more in research & development and

ensure higher productivity coupled with

efficiency to provide better products in

the future.”

Need for efficient skill development programmesTo support this growth of the plastics

industry in the state, several factors have

to be kept in mind. One of the important

factors is nurturing professionals and

empowering workforce in the segment

as this is necessary to increase business

and meet the global quality standards.

Technology upgradation, be it in the

mechanical or electrical aspects of plastics

processing, is continuously happening,

and if you are not aware of these changes,

then your end product may not be of

global standards. Thus, in such a case, it

is necessary to train the workforce and

make them aware about such changes and

thus enhance their productivity.

Skills and knowledge are the driving

forces of economic and industrial growth

of any state or country. Countries and

states with higher and better levels

of skills adjust more effectively to the

challenges and opportunities faced by

industries. As India moves progressively

towards becoming a ‘knowledge economy’

it becomes increasingly important that

processors should focus on advancement

of skills for the advancement of the

plastics industry. Thus, the need to focus

on developing the skilled manpower is

extremely important, and it is for the

same reason that institutes such as Indian

Plastics Institute (IPI), Central Institute

of Plastics Engineering & Technology

(CIPET), Plastindia Academy of

Technology and Management have been

set up to nurture talent from across

the country.

Skilled manpower is the demand of

every industry and the plastics industry

is no exception. Today, with the way

companies are expanding and employing

new technologies, the demand for skilled

manpower is increasing. However, it is

With the plastics industry expanding its horizon in the country, there is need of nurturing professionals and empowering workforce so as to meet global standards and provide a boost to the industry. Indian processors have realised this fact and have ensured this by setting up several educational institutions to develop a skilled workforce. Anwesh Koley highlights the needs of the industry in giving impetus to talent and in encouraging a healthy growth momentum.

MANPOWER MANAGEMENT: Ski l l development

FOSTERING TALENTTO MEET REQUIREMENTS

Cou

rtes

y: K

arto

grap

hers


a common fact that skilled manpower

is a scarce resource. Thus, investing in

human capital is an important step and

an effective way to achieve this is through

industry–academia collaboration.

In the plastics industry, all production

processes require skilled engineers and

high-grade machines require skilled

operators. Also, companies need an

efficient workforce for marketing. Thus,

through training institutes, the industry

can actually train students to meet

these requirements.

Need for further government supportVery few colleges offer courses on plastics

engineering. D S Rawat, Secretary

General, ASSOCHAM, says, “The

government has to redesign its policies.

We find it very difficult to find students

who have a diploma or a degree in plastics

engineering. Even private educational

institutes can work on this concept and

introduce courses related to plastics

engineering. There is a huge gap in

demand and supply as far as employment

is concerned. Due to the lack of proper

courses, we do not get the right people

for the job.”

“Every new recruit has to be trained

for a certain period of time until deemed

fit for the job. This process takes up a lot

of time and hampers our productivity to a

great extent. Students are opting for other

attractive courses. Hence, we have fewer

options for selection of candidates,” feels

Vyas. Paucity of manpower in the sector

has shot up the cost of construction labour

by over 25 per cent due to inflationary

pressures, leading to an upward spiral in

the basic cost of living. Besides, leading

players in this field are hiring skilled

workers from overseas, and this has almost

doubled the cost of labour.

“India’s plan for growth and

development of physical infrastructure

is in peril as the majority of projects

are getting delayed or cancelled due

to lack of skilled manpower. Besides,

lack of technology has proved to be a

bane for the growth of India’s plastics

sector. As the domestic companies adopt

automated construction machines big-

time, India is likely to be a hub and

one-stop construction equipment shop

serving domestic and overseas markets

during the course of the next few years,”

avers Rawat.

Towards an optimistic futureDespite economic slowdown, the

plastics industry has not witnessed

major dips in its projects. India has a

substantial market of about 27 lakh

tonne, and Maharashtra alone has

a market of 6 lakh tonne. “Plastics is

100 per cent recyclable, and the use of

plastic components in the auto industry,

agriculture and many other industries

will increase. The plastic component

industry will become larger than the

auto component industry by the year

2020. The central government has

given a go ahead to the establishment

of plastic parks in various states

across the country. The industry can

expect an inflow of ` 30,000 crore as

investment. This is the right time for

the Indian plastics industry to upgrade

itself. Getting the right people in the

industry would go a long way forward,”

adds Vyas.

Domestic plastics processing companies

need to invest heavily in technology to

reduce operational costs, thereby providing

additional benefits to customers and spurt

demand. With the cost of production being

almost 48 per cent cheap, this industry

in India is attracting global equipment

companies from China, Finland, Italy,

Spain, South Korea, Turkey and others

as it allows them to cater to the Indian

market effectively and generate exports.


Dipak VyasChief Executive Offi cer, Neo Pack

We hope to continue in the same vein, partner many new companies, bring in the latest technology as and when they are launched globally, invest more in research & development and ensure higher productivity coupled with effi ciency to provide better products in the future.

D S RawatSecretary General, ASSOCHAM

We fi nd it very diffi cult to fi nd students who have a diploma or a degree in plastics engineering. Even private educational institutes can work on this concept and introduce courses related to plastics engineering. There is a huge gap in demand and supply as far as employment is concerned.

Ski l l development

With the way companies are expanding and

employing new technologies, the

demand for skilled manpower is increasing.


How is the plastics industry placed in terms of manpower?With the ongoing advancements in

technology, demand for skilled labour

has increased. Efficient management

of workforce has a direct impact on

production quality. However, there is a

shortage of skilled labour especially in

unorganised sectors such as thermoplastic

recycling. Here, there is a definite need

for incorporating technology so as to

simplify the operation of machines.

This will only happen if there is a true

sense of collaboration between the

manufacturers of such machines not only

with their buyers but also with the layman

who is ultimately going to operate the

machines. So, incorporating technology

for simplifying extrusion operation is the

need of today’s times. Extrusion has a

wide range of applications, so in order

to cash in on the advantages of this

technology, one needs to have simplified

operations and higher use of automation.

How crucial is it to understand manpower needs in everyday operations?It is important to involve the plastics

machine manufacturer from an early

stage, so that the numerous challenges

inherent in the process will be much

easier to tackle. It all starts with the client

having a strong sense of knowing about

potential processing partners in order to

find the right one. It then proceeds with

the client and partner determining how

the process will work, well in advance, so

that all potential problems can be fixed

early on. Mistakes can be made if the

machine manufacturer develops complex

extrusions in a short amount of time. The

client and the supplier need to determine

in advance what might be a realistic

lead time that gives the project the best

chance to meet quality demands and the

marketing timetable. Also, downstream

processes and equipment have significant

impact on process quality and stability.

What are the key areas of concern for labour in the plastics industry?The biggest problem in India is labour

management and government formalities.

At every step, the legalities involved

make work difficult. There are instances

when more than half of the productive

time goes into tackling various legal

requirements. The availability of labour is

another major concern as unskilled labour

has become wary of coming to cities like

Delhi as various government schemes

have provided them the option to work in

smaller cities. Many new industrial areas

are coming up in states like Uttarakhand,

where the cost of living is much lower

than cities like Delhi. Hence, people end

up saving more in such areas.

A lot of these issues can be overcome

with proper planning. Everyone involved

in the process must understand that

extruded products are becoming less of

an off-the-shelf commodity. Customers

frequently want a specialised component

that will interface with an application

or product. This means cut-to-length

sizes, co-extrusion and other special

requirements, all of which have to be

handled a little differently. Having

state-of-the-art downstream equipment

and skilled operators who know how

to make adjustments to these processes

is important.

How does manpower efficiency affect the operational flexibility of a plastics processor?The machine operator is critical in

successfully running an extruder.

Sometimes, an operator is just not

capable of running a process correctly.

Having properly trained, educated and

experienced operators is very important,

but they can be hard to find. Extrusion

is not a process where one can just

press a button and have everything turn

out the same every time. The operator

must be good at running an established

process and at developing processes and

knowing what inputs affect what output.

Reacting to differences in materials in the

correct way is critical. Taking the time

to find the right operators also makes a

big difference.


“Efficient management of workforce has

a direct impact on production quality”

...believes Amit Kalra, Director, Hindustan Plastic & Machine Corporation (HPMC). In an interaction with Anwesh Koley, he explains the importance of manpower management in achieving effective operational efficiency and the areas that need to be addressed in this regard.

MANPOWER MANAGEMENT: Inter face - Amit Kalra


MANPOWER MANAGEMENT: Roundtable

The availability of a skilled workforce is imperative for any industry, and plastics processors have often emphasised the need to retain manpower – the biggest asset for any company. Anwesh Koley interacts with industry experts to gauge their responses on whether Indian processors are using right manpower management techniques.

The Indian plastics industry needs to have better training facilities and skill development programmes. In addition, suitable policies could help retain talent as well as ensure higher employee satisfaction and sustained interest in this growing sector.

Editorial take:

Do Do plastics processorsplastics processors have access to have access to effective skill effective skill

management techniquesmanagement techniques and and programmes?programmes?


Debdeep KoleDirector, Koley Converting Machinery (P) Ltd Ravi Kumar

Director, Shiv Pooja Plastics Nilkant RautDirector, Raut EngineersA major challenge for the sector is

retaining manpower. The exodus of

labour from key industrial areas like

Delhi-NCR is a concern as various

government employment initiatives like

National Rural Employment Guarantee

Act (NREGA) have resulted in an acute

shortage of manpower in the city. It is

important to change the mindset of

people. Most plastics processing units are

MSMEs. It is important to refer to such

companies as emerging enterprises so that

they do not remain tagged as ‘MSMEs’

forever. Greater emphasis should be put

on skilled manpower development as it is

one of the primary needs of the industry.

The plastics industry is not devoid

of opportunities, but it is essential to lure

professionals towards the bright future

prospects of this sector. However, this is

not a prevalent practice across the industry

due to heavy government formalities and

infrastructural bottlenecks. Government

policies can go a long way in ensuring that

these loopholes are effectively addressed.

Intense competition from countries like

China and South Korea producing cheap

plastic products together with labour

pangs are eroding the profit margins

of the Indian plastics industry, which

employs over 12 lakh men and women

across the country. Besides, successful

implementation of government

programmes like Mahatma Gandhi

National Rural Employment Guarantee

Scheme (MGNREGS) and Jawaharlal

Nehru National Urban Renewal Mission

( JNNURM) contribute to the deficient

labour force for this sector as workers

are keen on remaining within their local

habitat rather than exploring the avenues

present in industrial clusters.

Apart from rampant labour shortage,

lack of promotion, volatility of exchange

rates and usage of archaic technology

are other serious issues hurting the

industry. Managing the workforce

remains one of the most crucial problems

that the industry faces during its

regular operations.

Availing the services of skilled manpower

is an issue which the government

has acknowledged over the years.

The initiation of various government

programmes to generate employment and

increase productivity highlights this fact.

Machines cannot replace humans, and we

need to recognise this at the earliest. A

key consideration in this regard is that the

workforce today understands that they

are part of the holistic development of a

company and that their services are well

sort after. Thus, if we require an efficient

workforce, they need to be paid well which

will provide them the sense of well-being

and job security. A competent workforce

will result in high-quality machines

and better output for the company in

the long run.

Training the workforce is a mutually

benefitting exercise. However, this needs

to be implemented within the company

in order to provide hands-on experience

to employees. Training workers is never a

wasteful exercise.

Rising costs are a concern

all around the world.

Standard processing

models require a bit

of tweaking to make them more

cost effective. Despite a hefty

economic stimulus package,

banks are not lending money like

they used to, especially to the

manufacturing sector.

In times such as these, it is

vital that processors use cost-

effective processing technology

without degrading output quality.

With an average consumption

level of about 150 tonne/unit, the

Indian plastics processing industry

is largely fragmented. To meet

the growth potential of plastics,

the Indian plastics industry needs

to develop an increased capacity

– the most economic production

capacity with better efficiency to

remain competitive in the face of

global competition.

Effective initiativesFor processors, simple techniques,

such as using regrind when

possible and adapting zero-defect

production practices to reduce

scrap and start-up waste material,

can be implemented at even a

small and medium enterprise level.

Conserving electricity with efficient

and well-maintained machines,

monitoring scrap and setting goals

ensure that everyone is on the

same page at the production level.

Elaborating on the primary steps

when implementing cost-effective

processing technology, Herbert

Kraibühler, Managing Director

– Technology & Engineering,

ARBURG GmbH + Co KG, says,

“A huge amount of know-how is

necessary to find the most efficient

overall concept for the production

of a particular moulded part from

the multitude of available machine

equipment, technologies and

processes. Therefore, ARBURG has

placed the main focus on the subject

of production efficiency. Achieving

production efficiency – maximum

quality at minimum unit cost –

is a challenging task due to the

numerous influencing factors along

the entire value chain. That is why

it is important to offer consulting,

both during the planning stage in

the case of new capital investments

and during the production stage

through optimisation of existing

production facilities and processes.”

As with most industries,

controlling cost is critical to

sustainability and profitability.

However, costs can be controlled

and often reduced by implementing

measures that do not require

significant investment. In many

cases, improvements can be made

for low or no cost by making

A thermoplastic material softens and shows plastic property when heated, but it does not set or get cured. Thermoplastics, generally available in the form of pellets, become liquid when exposed to high temperature. Finding a cost-effective option for processing has been an area of constant development and innovation. Sweta M Nair delves into this cause to see the available options.

Saving time, improving output

SAVING CAPITAL: Cost -ef fect ive processing technology


Cost -ef fect ive processing technology

slight changes to the way a process or

equipment is operated to optimise its

performance. Energy efficiency offers

short- and long-term benefits, and by

increasing the efficiency of a business,

the bottom line can be strengthened. The

ability of businesses to make rational and

informed decisions about the use and

deployment of capital on site will play an

increasingly important role in helping to

manage the new challenges in a changing

business climate. Kraibühler adds, “In

adopting a holistic view, we differentiate

among the areas of product design,

mould, machine & peripheral technology,

configuration, process integration, process

control and production planning. Each

of these areas offers, to differing degrees,

potential efficiency enhancements

by shortening cycle times, reducing

energy consumption and/or optimising

production organisation. If companies

also take into account the production

environment, such as infrastructure and

facility management at the production

site, significant additional scope for

savings can be identified in order to

render production even more efficient and

cost effective.”

Feasible optionsIn an increasingly competitive environment,

moulders are driven to reduce their costs

per part by every available means. Many

other operational elements need to be

considered in achieving this and in

optimising costs. When referring to cost-

effective processing technology that will

save time without degradation in output

quality, J N Bhat, Managing Director,

Shini Plastics Technologies India Pvt Ltd,

says, “Automation is a profit maximising

tool because it eliminates space for errors

and provides maximum utilisation of time

and money. Robots are used at injection

moulding machines for removing sprues &

finished products and conveying them to

further process. This saves labour, improves

production efficiency and reduces accidents.

The continuity of process, fixed and

shortened cycle-time, perfection in timely

material handling etc improve productivity

by providing a better control on costs.

The reduction in human interference

by automation provides standard results

with stable working surroundings and

avoids rejection & wastage. Such efficient

systems not only improve quality and build

a positive corporate image but also avoid

disorder and optimise utilisation of space.

Thus, fully automatic production ensures

high efficiency with continuous workflow.

Moreover, the continuous communication

with primary machinery optimises the time

required in processing or moulding plastics.”

When referring to the processing

or moulding stage, advantages of a

centralised solution are quick to translate

to cost efficiency as well. Flexible, quick

and safe handling of polymers without

any material wastage and risk of mistake

is the main benefit of such a system. No

material degradation or formation of

dust occurs since pneumatic conveying of

granules is carried out at controlled speed.

Additionally, rational and organised

distribution ensures higher production

rhythms and constant quality along with

optimisation of energy consumption.

With regard to synchronising processes,

Kraibühler adds, “Moulders can save time

without degradation in output quality. To

reduce unit costs and remain competitive,

more upstream and downstream

operations are being integrated into the

injection moulding process, resulting in

the use of increasingly complex production

cells featuring peripherals and automation

solutions. Turnkey solutions, comprising

robotic systems and peripherals, will

increasingly be used. This is because

through integrated finishing of plastic

parts, for example, injection moulding

companies can increase their added value,

exploit further potential for reducing

unit costs and respond quickly to new

requirements. Automated systems are

available around the clock, operate fatigue-

and error-free, fast and at a consistently

high quality. A machine operator simply

cannot equal their performance. More

customers, also in Asia, are therefore

integrating our Integralpicker, linear

robotic systems or six-axis robots into

their production processes.”


Herbert KraibühlerManaging Director – Technology & Engineering, ARBURG GmbH + Co KG

J N BhatManaging Director, Shini Plastics Technologies India Pvt Ltd

In adopting a holistic view, we differentiate among the areas of product design, mould, machine & peripheral technology, confi guration, process integration, process control and production planning.

Automation is a profi t maximising tool because it eliminates space for errors and provides maximum utilisation of time and money. Robots are used at injection moulding machines for removing sprues & fi nished products and conveying them to further process.



Businesses are dealing with

the high cost of processing

plastics. Concerns about the

environmental impact of the

industry and the battle for limited natural

resources are driving businesses to

seek and implement techniques

that will help save them

money. However, no set

definitions or criteria

exist for businesses to

integrate into their

existing models

in order to reap

benefits. Most

processors seem

to know the

positive terms

in appl y ing

we l l known

techniques, but

pe rhaps the

re luctance to

change is what keeps

them from achieving

cost-efficiency in

manufacturing.

When pondering on

this topic, one cannot help

but mention the term ‘lean

manufacturing’. Having originated at

Toyota Motor Corp in the 1960s, its roots

arguably can be traced to Henry Ford’s

assembly lines from 50 years earlier. The

Toyota Production System (TPS) has an

objective of eliminating all waste, be it

wasted time, material, space or money.

Over the succeeding years, lean has taken

off in a number of directions, and many

consulting firms and management gurus

sell lean as the ultimate key to effective

business management to achieve cost

efficiency. So much so, that it now

has been elevated to almost a virtue.

However, is it apt for all businesses? The

answer is that lean certainly has benefits

to offer all businesses, even in the service

sector; however, the potential for gains

varies widely based on the unique

characteristics of the business.

Starting over‘Cost efficiency’ is a vague business

objective, but the abundance of concrete

data on what has been accomplished until

now by implementing manufacturing

techniques is merely an indicator

of its recent acceptance into

the mainstream. Although

there might not be any

reliable data from any

region or country on

how the plastics

m a n u f a c t u r i n g

marketplace has

changed, the

w i l l i n g n e s s

sensed in the

domestic circle

is substantial

evidence.

At the onset,

for better quality

output, processors

n e e d b e t t e r

quality input which

includes raw material,

manpower, machinery

and marketing. The need to

constantly train manpower for

retaining and improving efficiency

and quality output is a continuous

process from day one of setting up a

manufacturing facility. In the scheme of

things, quality of factory infrastructure

also has a major impact on the

consistent quality of output. Developing

and documenting proper processes and

systems may look time consuming and

costly in the beginning, but it is one

of the only ways to improve reliability

The cost to mould or process plastics has become a hot topic in the international plastics fraternity. Moulders are starting to take interest in the topic of integrating international techniques of cost efficiency to satiate domestic demand. Sweta M Nair assesses the international techniques of cost efficiency that can easily be integrated.

SAVING CAPITAL: Cost ef f ic iency

INTEGRATING INTERNATIONAL TECHNIQUES

Efficient production means including all added value in analysis and optimisation - ARBURG


of products delivered that will match

the buyer’s satisfaction. “Customers are

willing to pay immediately or even in

advance if the product or service mix

is as per their needs. This can reduce

capital needed for selling products on

credit. Processors need to focus on

increasing the speed of conversion from

receiving plastic granules to dispatching

finished products from the factory,”

says Jayesh Khimji Rambhia, Managing

Director, Premsons Plastics Pvt Ltd.

Materials management is a key issue

in the plastics industry. There is an

ever-increasing pressure from original

equipment manufacturer customers and

even channel partners to get the price

lower. Materials management plays a

big role in determining the successful

performance of the entire organisation.

The plastics industry also has the need

for scrap management and effective

regrind processing, which are valuable

cost savings when virgin materials are not

a primary requirement. To reduce costs,

processors can leverage lightweighting

and increase the recycled content. As

markets mature, a globalised market

brings competition from across the

world. Entrepreneurs need to be aware

of latest developments worldwide so that

they are prepared to meet the customer’s

future requirements. Talking about the

developments in this field, Rambhia

adds, “Polyethylene terephthalate

bottles used for packing water, juice

and soft drinks have reduced 40 per

cent in weight in the last decade. To

save the environment, legislations in the

US have made it compulsory to use 20

per cent recycled material in packaging.

For Small and Medium Enterprises

(SMEs), techniques of cost efficiency

can be implemented by adopting new

designs and making new moulds. This

makes it possible to reduce the cost of

products. Moreover, it is important to

have a strong relationship with buyers

to make sure that they will continue

purchases from the same supplier.”

Getting the mostProcessors are looking to get the most

value out of their investments by

extending the life of existing equipment.

In the past, the cost of machinery was

the deciding factor. Now, the total cost

of ownership of machinery is emerging

as a deal making factor because the

total cost of ownership includes cost

of machine, cost of operator, cost

of electricity, cost of spares, cost of

maintenance, cost of rejections, speed of

production, life of machine, reliability

etc. Processors have the option to

retrofit their running machine with

servo motors and controls to further

save energy and subsequently costs.

Because most members in the industry

are first generation manufacturers, they

have learnt much regarding techniques

of cost efficiency. With the internet,

enough information is freely available

to those who are willing to improve.

Talking about the relevant techniques,

Rambhia adds, “By following Kaizen

(continuous improvement of processes in

manufacturing) and learning & adopting

new techniques from other industries,

we can be more competitive. Some of

the other techniques to improve overall

equipment efficiency are maintaining

JIT – just in time – which refers to

reduced inventory cost, replacing ‘stock

& sell’ with ‘make to order’ to further

reduce inventory, standardising common

parts & reducing colours offered, and

adopting Single Minute Exchange of

Dies (SMED), lean manufacturing,

5S, Kanban, balanced score card etc.

By sincerely following the International

Organization for Standardization

system, processors can be

more process and system dependent

rather than person dependent. This

reduces errors and mistakes, thereby

reducing rejections and helping in

retaining customers. Furthermore, even

enterprise resource planning systems,

which are used by multinationals,

are now available to SMEs on cloud

computing in a very affordable pay

per user model. Execution is the key

to convert available knowledge to team

work – this is the challenge SMEs need

to overcome.”

In line with cost-efficient techniques,

SMEs are also tweaking their working

capital to minimise the impact of

their business on the environment. As

cost of utilities (eg power and water)

is increasing and their availability is

also under pressure, entrepreneurs are

prudently using resources. Most plastics

are being recycled, which is keeping

the generation of waste under control.

Because plastics are hydrocarbons

derived from petroleum oil, those plastics

that cannot be recycled can be burned

to produce energy. Integrating cost-

efficiency techniques helps businesses

to deal with global rather than purely

local competition. However, before

delving into any of the aforementioned

techniques, one needs to bear in mind

that cost efficiency cannot be achieved

merely by resource minimisation but by

resource effectiveness.


Jayesh Khimji RambhiaManaging Director, Premsons Plastics Pvt Ltd

For Small and Medium Enterprises (SMEs), techniques of cost effi ciency can be implemented by adopting new designs and making new moulds. This makes it possible to reduce the cost of products. Moreover, it is important to have a strong relationship with buyers to make sure that they will continue purchases from the same supplier.

Cost ef f ic iency


What is your prediction for growth in the plastics industry beyond 2013?For those who prepare well, the future

is bigger and better. India is an amazing

land where entrepreneurship thrives. The

cost of a new start-up is probably one

of the lowest in the world. Most plastics

industries that started in India had no

factories initially. They began with getting

a mould made and engaging job workers

who use their land, machines, manpower

and material to produce goods. Only after

a market was established, did companies

set up their own manufacturing facility.

Companies that initially provided services

gradually graduated to manufacturing and

marketing their own products.

Considering domestic perspectives,

Indian plastics consumption will

approximately grow from its present figure,

which is 12 kg per capita, to 25 kg per

capita by 2020. The per capita income

in India is also rising, and this will push

consumption up. Moreover, young India

is consuming a lot more these days, which

is complementing the growth story. In the

light of such developments, manufacturers

will need to gear up their factories to deliver

products as per international quality and

that too at competitive prices, as clients are

exposed to goods from across the world.

Only those who invest ahead of the curve

will be able to reap the benefits of demand.

Additionally, with foreign direct

investment in modern retail, most

products will be packaged and branded.

This will boost demand for plastics

in packaging.

In other areas, due to the rising

cost of fuel, automobiles are becoming

more lightweight. This is ensuring a

steady increase in the amount of plastics

being used. Plastics are an affordable

replacement to metal, glass, paper and

wood, and with rising competition, this

changeover will continue.

How can plastics moulders or processors safeguard themselves from potential increases in costs of raw material?It is extremely difficult to predict oil and

forex fluctuations. Polymer hedging is

available on MCX (Multi Commodity

Exchange of India Ltd), but it still

needs to evolve to be useful to most

processors. In reality, profits of processors

are squeezed between polymer producers

and large buyers of plastic products. The

processor fraternity is much smaller

than the supplier and buyer fraternities.

Processors need to learn to add value to

their production, so it is easier to absorb

raw material fluctuations. They need

to invest in research and development

to own intellectual property rights.

When you own a product that nobody

can copy, customers will pay you for

its innovativeness, which hopefully will

not be on per kg basis. Creation of a

brand is also another option to add

value to products. The introduction

of new technology to the Indian

market also allows you to add value.

However, these suggestions form part of

a continuous process.

How are moulders, processors or small and medium enterprises affected by fluctuating energy costs? How can they protect themselves from spikes?Electricity is the second highest input for

plastics processors. India is energy deficit,

and it would take a long time to match

the growing demand for electrical power.

Modern servo-based machines consume

about 60 per cent less power compared to

traditional plastics processing machines. By

upgrading their machines by retrofitting

servo drives and controls, processors can

save a considerable amount of energy.

By using capacitors and maintaining a

power factor close to 1, the cost of energy

reduces. By using natural light through

transparent roofing, the use of light can be

minimised. Also, by replacing tube lights

with light-emitting diodes, significant

savings can take place. Electrical audits in

manufacturing facilities should be given

priority to understand areas where energy

can be saved. By balancing cooling water

circulation and keeping minimum bends in

water flow, pumping power can be saved.


“India is an amazing land where

entrepreneurship thrives”

…says Jayesh Khimji Rambhia, Chairman, Plastic Parks & Projects, The All India Plastics Manufacturers’ Association (AIPMA). In a conversation with Sweta M Nair, he talks about ways in which Indian processors can maintain cost effectiveness without compromising on output quality. Taking stock of the developments, he elaborates on simple techniques that can make a positive impact on a processor’s balance sheet.

SAVING CAPITAL: Inter face - Jayesh Khimj i Rambhia


SAVING CAPITAL: Inter face - Herber t Kraibühler

What are the developments that have taken place at the machinery end? When developing and enhancing products

for the machine sector, production

efficiency always plays an important role

because the machine has an enormous

influence on the cycle time and energy

consumption. Thanks to their energy-

saving drives, electric machines also

score highly where energy consumption

is examined in isolation. Electric drives

enable fast, independent movements,

resulting in short dry cycle times and

simultaneous ejector movements. Our

latest Edrive series makes cost-effective

the use of electric injection moulding

machines, even for standard products. In

the high-end electric ALLDRIVE series,

new machine sizes enable even more

precise adaptation to the application,

which offers benefits for cost-effective

part production.

However, the energy consumption of

hydraulic machines can also be reduced

through the use of efficiency class IE2

motors, an electro-mechanical dosage drive

or a servo-hydraulic drive system. To increase

the efficiency of hydraulic machines, we offer

a productivity package that comprises the

ARBURG Energy-saving System (AES)

with variable speed pump drive and water-

cooled drive motor. The speed of the pump

motor is adjusted to requirements by means

of a frequency converter. The advantages of

the productivity package are up to 20 per

cent lower energy requirement, shorter dry

cycle times, reduced cooling requirement

and lower noise level.

I see a further challenge in the

development of practical, innovative

solutions for new applications. I am

thinking here about techniques for

the processing of new materials, for

instance, long-fibre reinforced plastics

as substitutes for metals. In 2012, we

presented for the first time a solution

that enables long fibres with flexible

length to be fed directly into the liquid

melt. This opens up new possibilities for

lightweight construction.

Since ‘servo-drives’ has become the buzzword, how much efficiency can be achieved by them? The fact that energy efficiency is not

only achievable with electric machines is

clearly illustrated by our innovations in

the hydraulic machine segment. For our

large machines with clamping forces from

2,500 to 5,000 kN, we now offer a servo-

hydraulic drive concept. They feature a

servo motor with a constant pump, the

output of which can be continuously

adapted to the actual requirements.

No-load losses are virtually eliminated.

When the machine is not performing

“Servo-hydraulic drives offer a price advantage compared to electric ones”

any movement, the pump motor also

stops – in contrast to standard hydraulic

machines, the pump of which continues

to circulate oil when at standstill. The

energy requirement of servo-hydraulic

injection moulding machines is reduced

by 50 per cent; efficiency in production

increases accordingly.

Servo-hydraulic drives offer a price

advantage compared to electric ones during

procurement. These represent the most

energy-efficient hydraulic solution and

are particularly well suited to applications

in which no machine movements are

performed over a lengthy period, eg

during cooling. However, only serial

movements can be implemented using

these machines. They cannot therefore be

used for compression injection moulding.

For simultaneous movement sequences

and short cycle times, hybrid or electric

machines – available in various expansion

stages – are the solution.

When talking about peripheral equipment, what aspects should a moulder take into consideration to ensure its cost and performance efficacy? In addition to the injection moulding

machine, peripherals such as robotic

systems, temperature control devices as

well as material preparation and conveying

impact on efficiency in production. With

our machines, the robotic system and all

the peripherals can be integrated and

managed via the unique SELOGICA

control system by ARBURG. This ensures

minimum downtime, maximum flexibility

during configuration and fast setup.


…says Herbert Kraibühler, Managing Director – Technology & Engineering, ARBURG GmbH + Co KG. In an exclusive interaction with Sweta M Nair, he talks about the cost advantage that moulders or processors can leverage through injection moulding machines.

While there are few

industry standards,

a typical recycling

business collects

used plastic products, and then sorts

them according to the type and colour

of the plastic. The sorted plastics

are then shredded into small plastic

chips or flakes that are then cleaned

to remove any dirt, oil, food particles,

labels, glue or other contaminants,

which may be present. For instance,

the polyethylene terephthalate

stream is washed at about 90°C for

a certain period of time, while high-

density polyethylene, which has a

comparatively lower melting point,

is washed below 40°C to prevent

discolouration.

The wash down The wash solution consists of an

alkaline detergent in water, which

removes dirt and grease and

degrades protein. The detergent

used is an alkaline, cationic

detergent (ie an alkaline solution

containing a cationic surfactant).

During washing, the agitator in

the wash tank acts as an abrasive,

grinding off the glue of the labels

and reducing any paper labels

to fibres. The plastics are then

separated from the glue, paper, dirt

etc in a spinning tower in which

this very fine material is forced out

through small holes, while plastics

remain inside. The plastics are then

further rinsed and then separated

on the basis of weight. This is done

using a water cyclone, which is

designed to separate out the given

plastic from all the others.

The clean chips are then

generally pelletised or somehow

organised in a usable form for a

plastics manufacturer. Elaborating

on the above process, Vijay

Merchant, Former President,

Indian Plastics Institute, says,

“Water is used in washing and

removing all the contaminants such

as the adhesives and the labels.

Basically, any other substance that

is attached with the plastic scrap is

removed. This is a universal process.

Because water alone will not help

remove the contaminants, there are

chemicals that are added to water.

The chemicals are decided on the

material you are trying to clean

and the properties of the material

itself. Primarily, recyclers use caustic

soda with manual scrubbing. In the

hills of Kalimpong and Siliguri, the

entire plastic scrap in huge liquid

tanks is stirred so that the labels

and other impurities are separated

from the plastic scrap. Depending

on the grade of the plastic scrap, the

temperature of the liquid is raised.

The temperature ensures that the

particular adhesive or the food

particles in the plastics is completely

Expanding the recycling and process equipment service for the primary processing of plastic waste materials is the need of the hour. By offering process solutions to a wide range of difficult waste challenges in the plastics sector, recyclers need to reduce their disposal cost and increase yield and quality of their recovered materials for reuse in new products. In the light of such developments, Sweta M Nair focusses on the areas of recycling where the use of water can be optimised.

An eye towards recycling

SAVING WATER: Ef fect ive water management


Cou

rtes

y: W

RA

P

Ef fect ive water management

cleaned. This is done to ensure that the

quality of the plastics after recycling

does not suffer. The same water is used

again and again until it is full of all these

impurities after which it is disposed.”

Beneficial edge Recycling plastics prevents damage to

the environment via excessive landfilling

and use of non-renewable resources. The

process is also largely environmentally

safe, with the only effluent being from the

wash water. This is recycled in the plant

as much as possible to minimise water

use, and when it is finished with, it is

still sufficiently clean to be dumped into

sewers. However, in India, the absence

of monitoring of the fluent discharge

is leading to irresponsible disposal.

This polluted water seeps through

the ground and affects the quality of

groundwater. In some cases, this leads

to blockages in waste water disposal

canals. It also pollutes drinking water

bodies. The western countries, however,

have legislations in place to check these

practices. The recycling units in developed

economies have separate water treatment

that separate solid impurities from the

water and subsequently also remove the

chemicals from the water. The fluent is

thus no longer toxic. The treated water

is not re-circulated in the recycling plant,

but it is used in other non-manufacturing

areas. For example, if the pH level of the

water is good, then it can be used for

maintaining the lush green lawns that

surround the recycling unit.

Recycled plastics in end applications

can displace virgin plastics and save an

average of two tonne of CO2 for every

tonne of plastics recycled. Moreover, for

every 1 tonne of plastics that is recycled,

reports estimate that 7 yards of landfill

space is saved. By recycling, one can also

help conserve an additional 80 per cent of

energy that is typically used when making

new plastic bottles, containers and other

items instead of recycling. When referring

to optimising use of water in recycling,

Merchant adds, “From a plastics recycler’s

perspective, if there are no incentives

provided to optimise water, then why

would they make extra investments in

this area? I have been talking to various

plastics recycling groups based in

different regions of the country, but they

are indifferent to this. It would be more

cost economical if these groups were to

come together and set up centralised units

of water treatment plants. In India, we

have plastics recycling guidelines, but no

enforcement or awareness programmes

are conducted by the authorities.”

International examplesThe haphazard recycling segment in

India is similar to that in China’s earlier

times, when the country too had 50,000

odd plastics recyclers. Primitive recycling

methods in the country transpired to

irresponsible disposal of waste that

affected the living conditions of regions

where these recycling units were situated.

Having taken stock of the situation,

the Chinese Government came down

strongly on many recyclers and many of

them shut shop. The scene in India could

also be altered if effective government

waste policies were to come into play.

Being futuristic, making comments

about recycling techniques that use

a dry clean approach may sound lame,

but there is enough and more evidence

to support this happening. Supported

by the British Government, Axion

Recycling Ltd working with the Waste &

Resources Action Programme (WRAP)

has championed dry cleaning technology

as a highly effective and environmentally

beneficial method for cleaning

contaminants off mixed plastics. Having

conducted trials using the German

technology to dry cleaning system, the

Manchester-based company claims that

adoption of the technology could lead

to significantly greater recycling in the

UK because there is no need for a dirty

water effluent treatment plant as there

is with wet washing technology. The

economical advantages of the technology

are suitable for smaller companies that

face many hindrances when it comes to

optimising the use of water in recycling

plastics. Perhaps a far-fetched dream for

Indian recycling units, but its reality is

hard hitting, astounding and definitely

worth a shot!

In conclusionSince their creation, plastics have been

an indispensable ingredient in people’s

lifestyles. They have found their way

into various household, medical and

commercial products, such as water

bottles, food containers, medical devices,

gadgets, wire & cable insulation and

packaging material. Plastic materials are

convenient and inexpensive, but their

disposal poses an environmental dilemma.

Although current recycling rates

are not very efficient, perhaps new

plastics recycling techniques will fine

tune the entire process. Scientists and

engineers are tackling the challenge of

plastics recycling, and with increased

consumer awareness, the upcoming

technologies have the potential to

create more sustainable lifestyles and

a healthier planet.


Vijay MerchantFormer President, Indian Plastics Institute

Water is used in washing and removing all the contaminants such as the adhesives and the labels. Basically, any other substance that is attached with the plastic scrap is removed. This is a universal process. Because water alone will not help remove the contaminants, there are chemicals that are added to water.



When referring to fast and repeatable plastics processing, how much importance is given to water? What is the role that water plays? In the plastics industry, water is used in

heat exchangers of injection moulding,

blow moulding and extrusion machines,

water baths for extruders, mould heating/

cooling in the injection machine process,

water-cooled air compressors, water

cooling chillers, water cooling towers,

hydraulic oil coolers, extruder cooling

rolls etc. Water plays a vital role in

plastics processing, which requires water

supply at a constant temperature to

ensure quality moulding and to minimise

rejections. Injection moulding is one of

many technologies that use water as the

primary cooling agent. For instance, to

cool moulds, water can be fed through

a channel providing quick cooling

times. Colder moulds often work more

efficiently as they allow for faster cycle

times. Similarly, to heat up the mould,

a mould temperature controller is used

so that the water circulates in the

mould channels.

What types of water cooling systems are used in plastics Small and Medium Enterprises (SMEs)? How and why do they end up wasting water during the moulding process?Traditionally, the industry uses the open

type cooling tower for the centralised

water cooling system, and air cooled/

water cooled chillers for process water in

the case of chilled water requirements.

However, open type cooling towers are

exposed to air, leading to contamination

in process water due to dust and foreign

particles. Process water in the open cooling

tower is of low quality, contaminated

with foreign materials, gases, algae and

bacteria, accumulation of salt crystals,

rusting etc. This contamination flows

into the process line and results in scaling,

clogging the process lines of water. Due to

clogging, heat transfer does not take place

efficiently, which is the main objective.

Coming back to the cooling towers, as

these are exposed to the atmosphere,

much water is evaporated.

For these SMEs, how can the cooling process be made more efficient? To avoid water contamination, rusting

or clogging and to minimise water

evaporation losses, we recommend using

the closed loop water circulation system

as it is efficient for heat dissipation

and provides good quality of water to

the process.

How can moulders ensure good heat transfer from the plastic to the cooling water?Effective heat transfer is the prime

concern of mould analysis. This means

that the heat transferred to the mould by

the plastic and any other sources must be

removed quickly. Cooling is efficient if the

heat removal is effected with the smallest

possible expenditure of capital and

energy. To facilitate quick heat removal

in the mould itself, resistance depends

on the heat conduction properties of the

material of which the mould is made,

size & design of cooling channels and

the placement of cooling passages with

respect to the part being moulded. This

improvement consists of accelerating the

rate of heat transfer and balancing heat

transfer throughout the mould.

What are the next generation improvements in areas where water is used in the moulding process?Matsui is always keen to provide the best

technologies to industries. Matsui brings

conformal cooling, rapid heating &

cooling systems, Ecobrid systems, heating

& chilling on a single platform to make

sure energy, capital & water losses are

minimised, weld lines avoided and good

surface quality is maximised.

The mould temperature control

technology by Matsui improves moulding

cycle times (compared to conventional water

heating & cooling systems with standard

mould temperature controllers), adds value

by improving welded part strength and

reduces parts sticking in the mould, warpage

and deformation of the part.


“The industry uses the open type cooling tower for the centralised water

cooling system”

…points out Umakant Sharma, Head – Sales & Marketing, Matsui Technologies India Ltd, which in his viewpoint degrades the quality of water and affects the overall quality of production. In a conversation with Sweta M Nair, he discusses the importance of water in plastics moulding and outlines techniques that can bring in efficiency.

SAVING WATER: Inter face – Umakant Sharma


SAVING WATER: Inter face – Vishal Jasrapur ia

What are the challenges involved when reducing consumption of water during recycling of plastics?The biggest challenge is of mindset.

Most of us do not understand the need

for judicial use of water and the role that

we can play in conservation. It is deeply

entrenched in our mind that water and

air are unlimited and free resources. This

thinking needs to change, and there is a

need for creating awareness about water

conservation in the industry. Having said

that, there is always a cost attached with

taking any environment-friendly initiative,

and in a fiercely competitive industry such

as ours, this incremental cost can render

some players uncompetitive in the market

place. Thus, the government should also

try to provide some incentives to players

who are trying to do the right thing. The

incentive need not be purely monetary

but can be preferences in the government

procurement through entire supply chain

report card system, something like the

Black Economic Empowerment system

in South Africa.

What techniques are used to reduce consumption of water during the recycling process?The techniques depend on the nature of

operations and the sources of raw material.

Water is mainly used in two processes

– cleaning of inputs and for cooling of

recycled plastics. The significant savings

can come from the cleaning operations

by ensuring that recyclable plastics

are handled & collected properly at

the procurement stage, and reusing or

recycling the water used for cleaning in

the cooling process.

What technology is available to help achieve this reduction? Some of the commonly used techniques

are physical chemical treatment, sand

filtration, biological treatment and

membrane systems. At some places, even

ultraviolet and ozone are used; however,

in plastics recycling, it is not very useful.

The two techniques used widely are sand

filtration and membrane systems, where

the physical impurities are removed

from water, and the water is ready to be

reused. At some stages, physical chemical

treatment is also used to remove the

chemical and other impurities from water.

Hence, by using such techniques, one can

save up to 40–80 per cent of consumption

of water.

What is the capital involved in setting up this technology or technique?The capital expenditure of the water

treatment plants could vary from a few

lakh to about two crore depending on

the scale of operation. One of the key

decision making points while deciding

the size of the plant and the amount of

recycled water to be used is striking a

balance between the reduction in the cost

of water consumption and the capital

expenditure and operating expenditure of

the plant over a reasonable period of time.

Is technology that reduces consumption of water during recycling readily available?There are a host of companies offering a

variety of solutions across technologies.

Apart from the larger players there are

also a host of small and local players

offering some good solutions at very

competitive prices. However, one should

wisely choose the solution provider

based on the performance guarantee

and the ability/commitment to offer

after sales services.

What are the international advancements in this area?Different countries are at different stages

of implementing water conservation

policies. One thing consistent across

nations is that the emphasis on water

recycling is increasing. An increasing

number of industries are brought under

the gambit of compulsory water recycling,

eg the US government is talking about

recycling and reusing water that comes up

from hydraulic fracturing jobs. So, I think

the Indian government should take up

the issue seriously and start an initiative

where recycling and reusing of waste

water should be made compulsory across

various industries such as ours, where the

consumption of water is very high.


“There is a need for creating awareness about water conservation in the industry”

…states Vishal Jasrapuria, Director, Shree Sadguru Plastic Industries, as a step towards optimising water usage when recycling plastics. In a conversation with Sweta M Nair, he points out that the challenge is universal and needs to be dealt with an open mind.

Waste is any aspect

of operations

that fails to add

value. It is a

significant hidden cost for many

plastics companies, and it includes

the costs associated with energy

& maintenance, solid wastes,

inefficient use of water, hydraulic oil

and emissions to the atmosphere.

With rising energy costs,

soaring raw material prices and the

impacts of climate change, the need

to monitor energy consumption

and reduce waste is more important

than ever. To remain competitive,

a business must adopt effective

energy management processes and

waste reduction methods. Thus,

companies and organisations are

increasingly taking an interest in

waste reduction, which thereby

results in optimising cost. There

are many ways of reducing waste

and optimising cost such as

recycling of waste, employing

strategies for reducing energy

& water consumption, adoption

of automation solutions and

usage of energy-efficient motors.

Although the solutions are many,

the main thing is the intention and

motivation on the part of companies

to do so, and here is where the

change is coming.

Strategies by polymer processorsFrom polymer processors to plastics

processing machinery manufacturers,

it seems that the industry is

aware of its responsibilities and is

adopting various steps in reducing

waste. M M Biswal, Business Head

– Polymers, Loxim Industries Ltd,

details, “In order to reduce waste, one

has to have an appropriate system

in place as it helps in improving the

overall efficiency of the company.

In our company, whatever water is

consumed during manufacturing

of the engineering thermoplastic

compounds is recycled and used for

watering our plants in the garden.

Because we are located in a low-

lying area and experience a lot of

water accumulation, we also have a

rainwater harvesting plant. We not

only reduce waste but also consume

it. For example, we have an eco range

made of recycled products that we

offer to our customers. Further,

we believe that automation and

training of people are important;

if people are trained well, they

could contribute more towards

operating efficiencies.”

Reducing waste does not

merely mean managing solid and

liquid wastes, but it also means

avoiding the excessive use of energy.

“Energy efficiency is only possible

Addressing environmental concerns

SAVING ENVIRONMENT: Waste management

The plastics processing industry often faces heavy criticism for causing environmental damage and

industrial pollution. Processors are thus taking this issue seriously and ensuring that production

techniques do not result in heavy wastage of raw materials, energy etc. Avani Jain notes

pioneering environmentally safe processing techniques through effective waste

management initiatives.


Waste management

through a good set of machinery, which

demands good investment. Cutting cost

on infrastructure in turn would increase

the cost of efficiency, so we believe that

investing in right machinery is very

important. Using the right machinery will

result in cost & operating efficiency and

waste reduction in the long run. At the

same time, the product quality will also

be good,” Biswal opines.

Machinery manufacturers’ initiativesMany companies have taken up the task

of recycling plastic products and are also

reusing them. Bharat Mistry, Partner,

Ash Win Engineers, notes, “We make

machines that recycle plastic wastes.

For example, entire plastic tanks are cut

into small pieces by a scrap cutter; these

pieces are then fed into a solid granulator

where their size is further reduced to 10

mm. These are then put into a recycling

extrude in which fine plastic granules

are obtained; these granules are used to

make entirely new products. Thus, we

not only make machines but also reuse

the plastic waste.”

He adds further, “This is profitable as

we do not have to buy fresh plastic, and

we are making products from the already

available resources. However, customers

are not showing much interest in such

products, and hence their perception

needs to be changed.”

Thus, plastics processing machinery

manufacturers have also started adopting

novel methods for waste reduction.

Due to high power and raw material

costs, the polymer processing machinery

manufacturers are pushed to develop

machines facilitating higher output. For

that matter, automation solutions have

become an obvious need as they help in

reducing waste to a very large extent. This

has also led to increase in energy efficiency,

thereby reducing the power cost. The

return on investment is also high.

Automating for no wastageTo ensure consistent quality, reduced

wastage and greater production efficiencies

to offset high costs of raw materials,

labour and power, companies are moving

towards the use of automation and

robotics. Thus, automation technologies

have gained their due attention from

plastics processing companies. As a result,

companies in the plastics processing

segment are using numerical control

machine tools for manufacturing of their

key components. These numerical control

machine tools have highly revolutionised

the machining process as the parts need

not be manufactured manually. This

has helped in making highly precise

machines, and the chances of mistakes

are minimised, thereby reducing wastage.

At present, customers want highly

automatic and synchronised systems

to improve their product quality

and efficiency. They thus make use

of microprocessor-controlled high-

speed programmable logic controller

systems. Another system that helps in

increasing efficiency and minimising

waste is the supervisory control and data

acquisition system, which usually refers

to a centralised system that monitors and

controls complex systems spread out over

large areas. The machines in this system

help in achieving zero rejection.

Role of ancillary equipmentAncillary equipment can be the answer

to automation requirements of companies

and can help reduce wastage to a very

large extent. Various companies are

developing new technologies that enable

efficient recycling of plastic products.

Some companies make machines or

auxiliary equipment that help processors

in regrinding waste plastic materials; for

instance, injection moulding and blow

moulding screws can be ground by using

granulators and reused further.

In a nutshellAs waste is eliminated, the quality

improves while production time and

cost are reduced. With the ongoing

efforts by various companies, the future

of the plastics industry will be more

environment-friendly. Energy efficiency

and waste reduction will be other feats by

this industry.


M M BiswalBusiness Head – Polymers, Loxim Industries Ltd

Bharat MistryPartner, Ash Win Engineers

In order to reduce waste, one has to have an appropriate system in place as it helps in improving the overall effi ciency of the company. Using the right machinery will result in cost and operating effi ciency and waste reduction in the long run.

We not only make machines but also reuse the plastic waste. This is profi table as we do not have to buy fresh plastic, and we are making products from the already available resources.



To understand the requirements

for recycling plastics, it is

important to look into the

chemical structure of plastics,

whereby they can be successfully reused

without causing any environmental

damage. In India, approximately

3.6 million tonne of plastics is recycled

every year. There are about 3,500 organised

and 5,000 unorganised recycling units. The

major types of plastics recycled include

polyethylene, polypropylene, polyethylene

terephthalate, polyvinyl chloride, acrylonitrile

butadiene styrene, polystyrene, nylon,

polycarbonate, high-impact polystyrene,

poly methyl methacrylate and other

engineering plastics.

According to the EU Directive on

Waste (2008/98/EC) (8), “Recycling

means any recovery operation by which

waste materials are reprocessed into

products, materials or substances whether

for the original or other purposes.”

Recycling benefitsRecycling helps in reducing waste in

landfill and the consequent methane

emissions. Recycling of plastic packaging

waste, both post-consumer and waste

at the time of manufacturing process,

is beneficial. An efficient and real-time

recycling and returnable process should be

implemented to capture and bring back

waste to recyclers or packing companies

for recycling. Recycling uses less energy

and produces less pollution than making

the products from scratch. Making bags

from recycled polythene takes one-third

the sulphur dioxide and half the nitrous

oxide than making them from scratch.

Challenges posed The market for sustainable development

and awareness about recycling is

increasing in India. However, the

technology and machines needed for

recycling are still not fully developed in

India. Companies operating in the Indian

market have to import machines and

technology from abroad, which makes it

a costly affair. Thus, recycling technology

solution providers have to spread their

wings to help their customers in the

best possible manner.

The main challenge is the correct

separation of the waste to be recycled.

Cesar Rodriguez, Chief Executive

Officer, MachinePoint Group, notes,

“For this reason, industrial recycling,

where waste separation has proved to be

easier, is economical and environmentally

more interesting than post-consumer

recycling, where the challenge is the

correct separation, cleaning and sorting

of all materials.” Thus, the development

of technologies for the separation process

employed during recycling is one of the

major challenges.

Government effortsNearly all types of plastics can be recycled;

however, the extent to which they are

recycled depends on technical, economic

and logistic factors. Innovations in

plastics separation, sorting, washing and

de-contamination technologies equipment

have made it possible to efficiently collect,

separate and recycle rigid packaging

With increasing focus on saving the environment, the plastics industry is making every effort to recycle plastics to move towards sustainability. Avani Jain notes the steps taken by the industry and government to address the concerns of the plastics recycling sector in India.

SAVING ENVIRONMENT: P last ics recycl ing

Mapping the challenges and opportunities

Courtesy: Moore Recycling Associates Inc


P last ics recycl ing

plastics. The National Plastics Waste

Management Task Force of the Ministry

of Environment and Forests, Government

of India, has recommended a strategy

and action programme of plastics waste

management in India. Also, the Bureau of

Indian Standards (BIS), New Delhi, has

issued guidelines on recycling of plastic

waste. All responsible manufacturers of

recycled plastic products adhere to the

safety rules and regulations laid out by

the government.

Further, the government has

formulated several rules and regulations

so as to cause minimum environmental

damage. These rules fall under the

Environment Protection Act 1986.

According to the Act, all recycling of

plastics shall be undertaken strictly in

accordance with the BIS specification IS

14534:1998, ‘The Guidelines for Recycling

of Plastic Products’. Manufacturers of

plastic products also have to incorporate

markings and codings. These markings

indicate the type of plastic and also

whether it is virgin or recycled. Apart

from regulations, The Plastics Industry

Association through its member units

undertakes self-regulatory measures to

protect the environment.

Industry initiativesNot only the government but industries

are also doing their bit to move towards

saving the environment through efficient

plastics recycling. Various strategies are

adopted by companies for recycling

plastics. Rodriguez notes, “Reducing

plastic packaging wall sizes with multi-

layer products will make them lighter but

stronger. Another way is to develop mono-

polymer products, where a bottle, cap and

label are made from the same material.

The recycling of this plastic bottle is

easier because no product separation

will be required as the polymers used

are not different.”

Further, various machines that are

available in the market can enable easy

recycling of plastics. “Size reduction

machinery and re-pelletising machinery

are mainly used in industrial recycling.

Further, the recycling process usually

consists of the leftovers of the process to

input them back in the process, making

this method of recycling the most efficient

one,” notes Rodriguez.

Cost factorNoting the cost factor of plastics recycling,

K M Shah, Managing Director, NU-VU

Conair Pvt Ltd, says, “Recycling of plastics

is a cost-effective solution, which needs to

be developed in a proper manner. It gives

convertors an edge in today’s competitive

market. There are certain areas where

recycled plastics in tolerable percentage

can be used effectively, and this also

makes the products cost effective.”

Growth scenarioThe need for effective plastics recycling

has urged both the industry and policy

makers to look into the problem, with

particular focus on energy efficiency

and recyclability of plastics. With more

companies becoming involved in research

to develop better means of recycling

plastics, the condition is expected to

improve both globally and in India.

Till then, a better understanding of the

chemical structure of plastics would make

their recycling easier.

Future trendsThe future trends will be to adopt

more efficient recycling technologies,

increase energy efficiency and further

increase economies of scale. Rodriguez

avers, “The new trends would include

the development of mono products. At

the same time, multi-layer products can

go for a weight reduction as these are

more difficult to recycle. However, the

real challenge remains the development

of technologies for separation process

employed during recycling.”

Further, the integration of

conventional waste management methods

with commercial viability requires skills

and technologies. One has to choose the

right method with all the precautions

and correct machinery for building

profitability through efficient recycling of

plastic products.


Cesar RodriguezChief Executive Offi cer, MachinePoint Group

K M ShahManaging Director, NU-VU Conair Pvt Ltd

Industrial recycling, where waste separation has proved to be easier, is economical and environmentally more interesting than post-consumer recycling, where the challenge is the correct separation, cleaning and sorting of all materials.

Recycling of plastics is a cost-effective solution, which needs to be developed in a proper manner. There are certain areas where recycled plastics in tolerable percentage can be used effectively, and this also makes the products cost effective.


Keeping in mind the environmental concerns, what are the leading innovations making headway in the plastics segment? Many new concepts have been introduced

in the market such as reduction in

the usage of plastics at the source

(yield improvement), biodegradable

laminates etc. Further, the focus today

is on sustainable development. At

present, one of the most visible trends

driving sustainability involves focus

on environment-friendly materials.

‘Renewable, recyclable, compostable’

– these green terms are showing up

on plastic packages everywhere, from

grocery aisles to shoe stores, shipping

containers to the retail shelf.

How can the use of biodegradable plastics help in saving the environment and in achieving sustainability? The American Society for Testing of

Materials (ASTM) and the International

Organization for Standardization (ISO)

define degradable plastics as plastics that

undergo a significant change in chemical

structure under specific environmental

conditions. These changes result in

a loss of physical and mechanical

properties, as measured by standard

methods. Biodegradable plastics also

undergo degradation from the action of

naturally occurring microorganisms such

as bacteria, fungi and algae. Plastics may

also be designated as photodegradable,

oxidatively degradable, hydrolytically

degradable or those which may be

composted. At present, there are many

biodegradable synthetic resins available

such as polyalkylene esters, polylactic

acid polyamide esters, polyvinyl esters,

polyvinyl acetate, polyvinyl alcohol

and polyanhydrides. These materials

exhibit degradation promoted by

microorganisms, and the reaction is often

coupled to a chemical or mechanical

degradation step. Thus, biodegradable

plastics can definitely help in saving the

environment.

How can recycling plastics help in saving the environment? Recycling should be adopted where it

results in lower environmental impacts

than alternative recovery options, and

where other requirements, such as safety,

are met. Some types of recovered material

are also a valuable source of energy

(eg incineration with energy recovery).

The optimal balance between recycling

and energy recovery varies enormously

with the composition of the waste. For

example, the optimal balance for general

waste lies at 70 per cent recycling or

composting and 25 per cent energy

recovery. By contrast, for lightweight

plastics, the optimum balance lies at

15 per cent recycling with 85 per cent

energy recovery. Thus, undertaking

recycling of plastics can help address

the environmental concerns to a very

large extent.

What are the problems associated with sustainable development?Problems of sustainable development are

rooted in issues of resource use and their

pattern of distribution and ownership.

Thus, a policy towards sustainable

development cannot be framed in

isolation to politics and state regulations.

The world community is confronted by

economic problems that have further

led to resource crisis and environmental

despoliation. This leads to constrained

economic revival due to which nations

find it more difficult to solve problems

related to the unsustainable use

of the environment.

What are the steps taken by your company in saving the environment? We are constantly involved in reducing

product waste and solvent usage across

the manufacturing process, preventing

over packaging, improving on energy

efficiency through various methods

and usage of biodegradable materials

to offer sustainable solutions to our

customers. Thus, through these steps,

we help in saving the environment to a

very large extent.


“One of the most visible trends driving sustainability involve

focus on environment-friendly materials”

…opines Pramthesh Pandya, Head – Unit & Business Development, Parikh Packaging Pvt Ltd. In a conversation with Avani Jain, he talks about the various strategies that can be adopted by companies in the plastics segment to save the environment and attain sustainability.

SAVING ENVIRONMENT: Inter face - Pramthesh Pandya


SAVING ENVIRONMENT: Inter face - Apur va Kane

The plastics industry is often blamed for polluting the environment. What is your take on this?The plastics industry is

unnecessarily blamed for

polluting the environment. If

anybody is to be blamed, then

it is the poor civic sense of the

people in terms of littering

the place and civic authorities

that are unable to take

appropriate steps for solid waste

management in urban areas.

Further, it is seen that nearly

22 per cent of agricultural

output is wasted because it is

not stored or packed properly.

Plastics serve as the cheapest,

most lightweight and durable

material that can be used to

save this wastage. Thus, putting

a ban on the usage of plastics is

pointless, since till date, there is

no alternative material that can

take the place of plastics.

With growing environmental consciousness, what innovations are making headway in the segment? What are your company’s initiatives?

Leading innovations include

usage of biodegradable/

compostable films and recyclable

& environmentally sustainable

films. Many companies recycle

plastics, which can reduce

pollution to a very large extent.

We focus on developing

machines that are versatile and

able to process not only laminates

but also more sustainable non-

laminated co-extruded films

and biodegradable films used

for making pouches and bags at

high speeds. Even the horizontal

form fill seal machine developed

by our design team based in the

US is able to run unlaminated

bare films.

What are the challenges faced by the industry?The biggest challenge faced

by the plastics industry is the

wrong perception of people

that plastic is polluting. Further,

companies need to realise their

roles and responsibilities well

and put the green foot forward

without actually being forced

by the government or other

regulatory body.


“Plastics serve as the cheapest, most lightweight and durable material”

…opines Apurva Kane, Senior Vice President, Mamata Machinery Pvt Ltd. In a conversation with Avani Jain, he talks about the perception of people on plastics. He also underlines the recent innovations and challenges faced by the industry.


SAVING ENVIRONMENT: Roundtable

Rising energy prices and environmental consciousness are driving the industry towards environment-friendly plastics processing. Avani Jain speaks to industry experts to find out how proactive are government policies towards environment-friendly plastics processing.

Sustainable development and reducing carbon footprint have become the main principles for the growth of any industry, including the plastics industry. Plastics processors are increasingly adopting steps for environment-friendly plastics processing. However, government support is required to aid the

process. The need of the hour is proactive government policies and industry initiatives for environment-friendly plastics processing.

Editorial take:

HOW PROACTIVE AREHOW PROACTIVE ARE GOVERNMENT POLICIESGOVERNMENT POLICIES

TOWARDS ENVIRONMENT-FRIENDLYTOWARDS ENVIRONMENT-FRIENDLY PLASTICS PROCESSING?PLASTICS PROCESSING?


Manish Pathania Sales Director, Greendiamz Biotech Ltd

Umesh Sharma Managing Director,

Julison Packaging India Pvt LtdJigish Doshi

Chairman & Managing Director, Vishakha GroupThe usage of environment-friendly

plastics, such as bioplastics, is still a

new concept in India. The raw materials

required to produce bioplastics are

not available in India and have to be

imported from countries like France.

Because the sourcing of bioplastics resin

is a costly affair, it makes these plastics

expensive. Hence, not many companies

take to manufacturing of bioplastics

due to low awareness and high price of

bioplastics resin. Further, at present, the

technology is not cost-competitive with

petroleum-derived plastics as the cost of

raw materials required to manufacture

bioplastics is very high. Also, the

awareness about such plastics is less,

and government support to companies

in the segment is not up to the mark.

Thus, steps need to be taken by the

government to promote bioplastics that

are environment-friendly. So, with help

from the government and industry, the

environment-friendly plastics segment

will surely grow in India.

These days, the government is banning plastic packaging in many states with a view that it harms the environment, but this is a wrong notion as there is no environmental harm caused during plastics processing. In fact, it is practically impossible to ban plastics completely because it is used everywhere. No doubt that plastics discharge harmful toxics into the environment but that is only to a certain extent. Also, no good alternative to plastics is available in the market. So, plastics is the basis of any industry in the country. However, steps can be taken by the government to effectively manage plastic waste. Instead of banning plastics usage, the government needs to formulate strict guidelines for plastics disposal. The cost of new plastics (bioplastics) could be reduced as otherwise their market would remain restricted as not every company would be able to afford to manufacture bioplastics.

There is absolutely no pollution caused during plastics processing. Also, companies are coming up with environment-friendly plastics so as to address environmental concerns. In such a scenario, blaming the industry for polluting the environment would be wrong. The industry is taking every step to save the environment. In fact, the problem is with the waste management system in the country. Moreover, it is the people who litter the streets and then put the blame on the plastics industry. Even the government is banning plastics. So, this attitude of the government and common man needs to be changed. However, by saying this, we cannot negate the efforts taken by the government. In a few months, the government will place two dustbins for different types of waste so that recycling could be easier. Undoubtedly, this could have been done earlier, but it is better late than never.

Plastics processing businesses

are under competitive

pressures and look for cost-

effective ways to increase

profits and return on assets. The way

companies manage their property,

plant and equipment assets has a

tremendous impact on their overall

competitiveness and profitability.

Optimum utilisation and performance

of these assets are not just desirable

but absolutely essential. By optimally

locating, sizing, engineering,

delivering and maintaining facilities,

plastics processing businesses can

achieve a competitive advantage

and increase profits. The way

manufacturing businesses manage

their facilities affects their ability to

produce and compete in terms of

quality, price, delivery, flexibility and

customer relationship management.

Customers expect quality products

to be delivered at competitive prices,

with shorter lead times and less waste

than competitors. In an environment

where competitors pay approximately

the same price for resins, labour and

equipment, the difference is the cost,

location and performance of their

buildings and real estate.

Word on the streetBy relocating, right-sizing and

consolidating operations, plastics

processors can become more efficient

and cost effective. Improving space

layout, workflow and process controls

to support new compact technologies,

management strategies and business

plans may be the way ahead. With

skyrocketing realty prices, it is essential

for most plastics processors to have

effective space utilisation of available

shop floor space management for

maximum performance in minimum

space. On this topic, Sundaram

Subramanian, Chief Executive

Officer, Karan Engineering Co

(exclusive agent in India for Dr Boy

GmbH & Co KG, Germany) says,

“At Dr Boy, our slogan is ‘Great

Machines - Compactly Designed’.

Owing to the small footprint, the

compact design and easy accessibility

of all components reduce the actual

space requirement by almost one-

third. Therefore, more machines can

be placed in a specified area. Our

Boy XS Ultra machine used for

micro component moulding offers

shot sizes that range from 0.1 g to

7.8 g and has a robust design and

footprint of 0.8 sq m. Ideally suited

for micro injection and sprueless

moulding, this machine is economical

and precise with good repeatability.”

Compact machinery is slowly

becoming the predominant theme

among the small and medium-

sized entrepreneurs where areas

are being explored as to how one

When referring to the topic of the greening of plastics machinery, the advantages of seeking out energy efficiency in manufacturing equipment is becoming more evident. The plastics industry has become increasingly aware that investment in manufacturing equipment and processes holds the key to making the industry more energy efficient. In the light of such developments, Sweta M Nair tracks the global trends in developing compact machinery for the plastics industry.

SPACE MANAGEMENT: Compact machiner y


Less is more!more!

Compact machiner y

can decrease footprint through innovations in manufacturing

processes. Another motivating factor in increasing the adoption

of compact machinery is energy efficiency of manufacturing

operations. On an average, manufacturing of plastic products

consumes massive amounts of electricity. Energy costs alone can

stunt a company’s competitiveness, especially small and medium-

sized companies that cannot afford a sharp rise in operating

expenses. This is one reason why small steps to increase energy

efficiency have gained momentum in the move towards installing

compact machinery.

Trending factorsGlobally, the market size of compact machinery is increasing by

20 per cent every year. For reasons such as reduced space requirement,

low energy cost, low tool investment and highly precise moulding,

compact machinery could have a significant impact on the Indian

plastics industry. “With this type of machinery, since processors

would be able to line up more machines, this would ultimately

translate into better profit margins as well,” states Subramanian.

He adds, “From our series of machines, Boy XS 10, 22, 35 and 55

tonne are being adopted by Indian processors for micro component

moulding for high precision consistency and repeatability. With a

footprint of 0.8–4 sq m, we expect a 15 per cent growth of Boy

machines in the Indian market. Less space requirement, reduced

tool investment, high precision and consistent repeatability will be

the main drivers of this machinery, which could also offer faster

payback and high profitability. With a low running cost, which

means energy saving up to 50 per cent, most compact machines

of Boy have an energy consumption of 0.8–3 units/hr, even for the

55 tonne model. Moreover, with the Procan ALPHA® 2 control,

the machines present the latest generation of machine controls.

Thus, the control combines innovative technology and long-term,

practical experience and will continue the success story of the

Procan control systems. The smart intuitive control system comes

with a touch surface that has been protected against damage with

stable single safety glass cover.”


Sundaram SubramanianCEO, Karan Engineering Co (exclusive agent for Dr Boy GmbH & Co KG, Germany)

Owing to the small footprint, the compact design and easy accessibility of all components reduce the actual space requirement by almost one-third.



With few clouds on the

horizon, strong growth

is likely for most

players in the plastics

industry. There will be ups and downs,

but overall, as far as the plastics industry

is concerned, the ups will prevail. The

next five years are going to be crucial,

where players can look at solid growth.

In practical terms, this means that

the massive capital investment of the

past five years will not only pay off

but is likely to continue. In the light

of such promising growth how are the

Indian processors or moulders prepping

themselves to withstand the upcoming

wave of demand?

In the booksContinued increases in manufacturing

productivity hold the key to maintaining

overall growth in the Indian plastics

industry. In the past few years,

productive efficiency has been rising

at a fast rate; this can be attributed

to the processors’ management skills

when it comes to space and machinery.

One of the simplest ways of achieving

efficiency is to use visual management

– where processors can implement

a shop floor layout with clear and

concise instructions at each employee’s

workstation. By removing complexity

from the shop floor and providing

concrete visual and descriptive aids,

companies can get a better control over

the plant’s overall performance. This

will utilise all personnel to develop a

particular system that will eventually

ease the load off from one’s quality

control systems.

When implemented properly,

manufacturing operation can become a

profitable venture, the result of which

is reduced scrap rates. Productivity is

increased through a well-designed

approach and downtime becomes

consistent due to the established

approach, helping companies schedule

their resources more efficiently.

Effective visual management uses

colour coding to improve workplace

performance, numbering tooling & tools,

standardising overall operation and

training & communication. Elaborating

on the manufacturing layout in a facility

so as to ensure increase in production

efficiency, Ranadip Basu, Plant Manager,

Trelleborg Industrial Products India Pvt

Ltd, says, “The manufacturing layout

has been designed to ensure there is

maximum utilisation of available space

while keeping the principles of lean

manufacturing in mind. For instance,

equipment is laid out in the sequence of

process flow, cellular concepts have been

adopted where possible, transportation

of parts from warehouse to production

floor & movement of parts between

cells are minimised and emphasis on

efficient utilisation of vertical space

have all been taken into consideration.

Layout optimisation, ergonomic design,

minimum transportation, high level of

5S and efficient ventilation systems are

prerequisites for efficient utilisation.

Automation may or may not have a role

to play depending on the product and

level of automation being used.”

Physical amendmentsAmid efficiency and improving

techniques, there is a certain solution

that can in reality open up space on

the shop floor. The global connotation

of compact machinery is finding its

way to India as well. Talking about the

development of compact machinery,

Jignesh Bavishi, Director – Neejtech

India (representing NIIGATA, Japan),

says, “Couple of decades ago, the large

amount of steel and castings used in

the structural formation of machinery

was considered to be sturdy designs.

Many a times, they were over-designed

machines. Input costs of steel for these

All available forecasts suggest a rising demand for plastics in the next few years. New technologies will allow Indian processors an unprecedented long-term boost in productivity, but their management skills with regard to space and machinery will also come into play. Sweta M Nair finds out how Indian processors can manage all of it without losing any productive efficiency.

SPACE MANAGEMENT: Minimal ism in manufactur ing

Managing space and machinery

Saturation of available space in

existing factories and skyrocketing land

& building prices are causing moulders to

look for compact and efficient machinery.

machines at that time were not much significant compared

to other parts and equipment. Over a period of time,

everywhere the slim-fit phenomenon took deeper root for

manufacturers of machinery. Designers using computer-

aided design and finite element analysis focussed on

optimised designs that resulted in lightweight machines

with better efficiencies. This in turn had reduced the

manufacturing cost of machines.”

Because Indian moulders, like the rest, want to be

more productive and cost effective, the compact machines

have opened an avenue for them to expand their business

in given land and building by securing more machines

in the given space. Saturation of available space in

existing factories and skyrocketing land and building

prices are causing moulders to look for compact and

efficient machinery. For instance, in all-electric injection

moulding machines, the utilisation of ball screws in place

of hydraulic cylinders made the mechanisms more efficient

and more compact due to no extension of clamp cylinder

behind the end platens. Large oil tanks have been replaced

by small electrical panels. Clumsy piping and hose pipes

laid across unproductive spaces have been replaced by

simple neat and clean electrical cables not protruding

outside the machines.

Peripheral controlControlling activities on the shop floor in reality could

translate to a whole lot of advantages for the company.

Understanding that each shift is an individual team, but

keeping communications effective for the whole company is

also crucial. Developing a solid approach for shift interaction

ensures that communication on quality, scheduling or

current status is crisp and clear. An engineered and well-

planned factory will keep every one on the same page as

they will all know the status of a single process, product line,

shipping dock and more. Thus, smooth functioning could be

achieved without the use of oil – at least one area evades the

occurrence of unwanted grease!


Minimal ism in manufactur ing



What are your thoughts on the adoption of automation solutions in the Indian plastics industry?Being easy to manufacture, plastics is

the chief alternative to metal. As far as

automation in this industry is concerned,

we do not follow any machinery growth

trends since that might mislead us

because the tonnage of a machine is the

deciding factor on the kind of automation

that can be used. However, in the Indian

scenario, we were the first ones in the

robotic segment to take the lead. Due

to this, we have grown considerably over

the years. Initially, a lot of questions

were asked about the benefits of

industrial automation; some companies

grasped this and standardised the use

of robots in their facilities. At present,

other than the automotive segment,

because the use of plastics has been

increasing, more companies are applying

industrial automation.

To better utilise space on the shop floor, what role does industrial automation play globally?Improving and maintaining consistency of

production along with opening up space

on the shop floor are advantages of using

industrial automation. Moreover, robots

come in handy when handling bigger

plastic parts because the work can be done

faster in comparison with manual labour.

The new generation of robots also involve

secondary operations that further justify

its cost. Taking the plastic part out from

the mould and clinching extra parts while

it is on the way to its final destination can

be considered as secondary operations.

This means the time in between cycles

can be utilised to the fullest with the

help of industrial automation. Ultrasonic

welding is another area where robotics is

used, but this is a relatively new concept.

Because the Indian plastics industry

mainly uses shelf-mounted robots, we

have launched QUANTEC K, which is

new generation automation. Owing to its

maximum flexibility in the system planning

& design phase, reduced conception &

design work and greater planning security,

this series makes automation easier in the

plastics industry. With the latest state-

of-the-art drive technology and the new

KR C4 controller, the QUANTEC K

robots achieve up to 25 per cent shorter

unloading times and up to 30 per cent less

energy consumption. The QUANTEC K

ultra line has a payload of 270 kg for

a reach of 2,900 mm and a payload of

120 kg for a reach of 3,900 mm.

What is your company’s top technology development in the recent years for the plastics industry? KUKA’s lightweight robot LBR iiwa

(intelligent industrial work assistant)

was launched at the Hanover Fair this

year. With built-in sensitivity achieved

by integrated sensors, the LWR iiwa is

ideally suited to handling and assembly

tasks. Because of its low weight of 14 kg,

the robot is energy efficient and portable,

and it can thus be used for a wide range

of different tasks.

The joints of this lightweight robot are

connected using CRP structures, and its

remaining components are also optimised

for weight. Through the integration of this

new-generation robot with the PC-based

KUKA robot controller, a completely new

type of robot is emerging. We have long

been concerned with the topic of human–

robot cooperation, and this intelligent

robot supports the human operator with

its high-quality work. The LWR iiwa is

an important milestone on the road to

service robotics.

Do you perceive indigenisation as a crucial area in terms of satisfying domestic demand?This is not necessary as our robots are

designed to work in harsh and more

demanding conditions. Our robots are

loaded with features that are not even

fully utilised in some Indian facilities.

For instance, we have different kinds of

safety norms embedded in our systems

that are normally not used by our Indian

customers. This exists because safety

regulations in Europe are relatively more

stringent. However, we have made a few

changes to the shelf-mounted series,

where we extended its base. This gives

customers the benefit of a better reach.


“More companies are applying industrial

automation”

...states Raj Singh Rathee, Managing Director, KUKA Robotics (India) Pvt Ltd, when referring to automation as an avenue to open up space on the shop floor. While talking to Sweta M Nair on the company’s latest offerings, he sheds light on the developments that are taking place in the automation side of the business.

SPACE MANAGEMENT: Inter face - Raj S ingh Rathee


SPACE MANAGEMENT: Inter face: Parag N Dave

What has led to the development of compact machinery for the global plastics industry?The plastics industry has come a long

way with new ideas and concepts being

put to work by manufacturers across the

globe aiming for better quality and output

with minimum resources involved. With

rising demands for micro mouldings and

specific parts developments that require

machines built keeping the application

in focus, conventional machines were a

compromise on all fronts. It was then

that the need for compact machinery

was being felt. Space saving is of course

the first visible benefit that anyone can

predict, but compact machinery provides

many more advantages and flexibilities.

What are the changes required to make compact machinery efficient?Choosing a right injection moulding

machine for the required product is in

itself a versatile process. It is a well-

known fact that injection machines

essentially have an injection and

clamping unit. All the developments

take place with these two units being

upgraded and built to provide adequate

injection pressure and clamping tonnage

for getting the expected level of product

quality and quantity. Earlier, the ranges

of machines were limited, with more

or less similar machines offered to

customers. At Dave Technical Services,

the DTS Mini Hand Injection Machine

is a vertical moulding machine for hand

moulds and is also available for fixed

(vertical), plunger (RAM) and lever

operated moulds. It works on single and

three phase operations.

How does one gauge the suitability of compact primary machinery?In the injection moulding process,

efficiency and profitability depend on

whether the machine chosen for the

particular product serves the purpose.

The machine has enough shot capacity

to completely fill all the cavities with

adequate pressure, while the clamping

force is higher than this injection pressure

to ensure positive mould clamping,

avoiding its opening under pressure.

Each product is unique and requires

different force to fill the cavity. Hence,

an initial study of the product mould

design with respect to requirement

is very important, and then, based on

the number of cavities in the mould,

an adequate machine must be chosen

for production.

With the availability of compact

machinery in different shot and

clamping options, flexibility is obtained

for fast production at lower power

consumption rates, lesser rejections and

better quality control. The ongoing

developments in allied fields related

to machine manufacturing such as

providing upgraded and efficient

parts and components to the machine

manufacturers (eg pump motors, gear

boxes, servo motors, automation and

hydraulics) have changed the face of

injection moulding machines across

the globe.

Could you highlight the benefits of this type of machinery? Mould designs have become flexible

with the availability of a wide range of

machines to choose from. This helps

the designer to create faster production

cycles. Micro to small and medium-

sized products such as light-emitting

diodes, watch parts, miniature moulding

parts (eg gears, connectors, electronic

parts, appliances and industrial parts),

medical parts, packaging and many

other applications are being produced

with this technological innovation. In

compact machinery, with regard to the

control system, the option to choose

from electrical panel to programmable

logic controller and full microprocessor

control system is available. Today, one

can control and monitor processing

variables (temperature and pressure) at

each specific point in the manufacturing

process, providing complete control

over the moulding machine, mould and

polymer processing. This eliminates

costly errors and enhances overall

productivity, quality and profitability of

the organisation.


“The need for compact machinery was being felt”

…says Parag N Dave, CEO, Dave Technical Services, as he narrates the rise of this profound type of machinery. Keeping in line with the changing times, he talks to Sweta M Nair about the universal amendments in compact machinery.

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 final decision regarding the selection and publication of the articles shall rest solely with

‘Modern Plastics & Polymers’. Authors whose articles are published will be sent a complimentary copy of

that particular edition.

Published by Infomedia 18 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 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,

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

D +91 22 3003 4669


SPACE MANAGEMENT: Roundtable

As economic recovery has a large impact on the plastics industry, companies are starting to invest into their pipeline. As they put more equipment back into service, they are considering different options. For small and medium-sized enterprises, the developments in the field of compact machinery seem to attract a lot of attention. Sweta M Nair gets some fresh and thought-provoking comments on its engineering prowess.

If space is a company’s most limiting factor, then compact machinery could be a blessing in disguise. However, size alone should not be the deciding factor here as volume of production is equally crucial. Nevertheless, for an industry experiencing an entrepreneurial wave, compact machinery could

make a huge difference.

Editorial take:

HOW DOES THEHOW DOES THE ENGINEERING PROWESSENGINEERING PROWESS

OFOF COMPACT MACHINES TRANSLATE TO MANUFACTURINGCOMPACT MACHINES TRANSLATE TO MANUFACTURING

BENEFITS?BENEFITS?


Parag N DaveCEO, Dave Technical Services Jignesh Bavishi

Director, Neejtech India (representing NIIGATA, Japan) Sundaram Subramanian

CEO, Karan Engineering Co (exclusive agent for Dr Boy GmbH & Co KG, Germany)

Apart from offering conventional

moulding machines, we have taken

a step ahead by providing small

investment projects in the form of small

vertical injection moulding machines

suitable for hand/fix moulds. The

machines are simple to operate and are

efficient because they have control over

temperature and pressure, thus providing

similar quality parts that one would get

from conventional machines. Regarding

the engineering prowess of compact

machinery, at Dave Technical Services

we offer vertical injection machines for

hand moulds in 20 & 40 g shot capacity

and machines for fix moulds plunger

(Ram) type in 40/60 & 80 g. The fully

automatic vertical screw type moulding

machines are available in 60/80/100 g

capacity. We are working on an ambitious

project that will offer a very small

automatic pneumatic injection machine

working on a single phase. We aspire to

generate industry development in rural

areas and thereby increase employment.

Sky rocketing prices of real estate has made expansions of manufacturing facilities difficult. Effective utilisation of shop floor space by investing in compact machinery could be a real boon for plastics processors. Moulders can conserve capital investment in land and further accommodate more compact machines in the available space. Compact machinery can help reduce energy costs. Its application is suitable for producing high-precision components, and the benefits of its repeatability for maximum performance with minimum space requirement can be reaped. This leaves the processor with additional space that could be utilised for automation integration in the production environment. Also, after considering certain aspects, more machines could transpire to more profits. For product variants demanding factory machinery layout, changes can be done with relative ease and with less constraints using compact machinery.

With compact machinery, we are looking at benefits of maximum flexibility, small footprint, optimum production conditions etc. Dr Boy compact machines offer maximum flexibility; the two platen clamping system is suited for compact clean room applications, automation and integration into various production environments. The machine’s small footprint (ranges from 0.8 sq m for 10 tonne machines to 4.65 sq m for 90 tonne ones) reduces space requirement by one-third, thereby allowing more machines to be placed in a specified area. The machine also provides easy access to all machine components such as the mould area and peripheral equipment. Its intuitive control system has a touch screen where operating functions such as scrolling and page changes can be done by swiping. Further, energy savings up to 50 per cent can be achieved with the help of a servo motor pump system.

FACILIT Y VISIT: Ja in I r r igat ion Systems Ltd


FACILIT Y VISIT: Ja in I r r igat ion Systems Ltd

A multinational company with a turnover in excess of ` 4,200 crore, Jain Irrigation Systems Ltd attributes its pan-India and global presence to its 27 manufacturing facilities that are spread across four continents. Sweta M Nair visits the Jain Plastic Park at Jalgaon to experience manufacturing by the largest processor of thermoplastic piping in India.

Being one of the largest micro

irrigation companies in the

world, Jain Irrigation Systems

Ltd’s businesses include a

complete range of micro irrigation

systems and components, Polyvinyl

Chloride (PVC) & Polyethylene (PE)

piping systems, PVC sheets, solar water

heaters, lighting & pumping solutions,

processed fruits & vegetables, tissue

culture, green houses etc. With regard to

the Group’s plastics business, the facility

in Jalgaon is spread on approximately 325

acre of land and stands as an epitome

of manufacturing exuberance. The Group

commenced operation at the Jain Plastic

Park in 1986–87 by manufacturing pipes

and gradually expanded its portfolio. Prior

to this, in the 80s, the company was a

dealer of several plastics manufacturers.

However, it forayed into manufacturing

to satisfy the rising demand.

Urban designThe Jain Plastic Park is a systematically

laid out production park that manufactures

the inputs required for water extraction

and management. The fully integrated

plastics processing plant is equipped

with state-of-the-art manufacturing

and testing equipment. This facility, in

particular, has quite a few distinctions to

its credit. Other than being one of the

largest processors of thermoplastic resins

in India, it is capable of manufacturing

PE piping in up to 1.6 m in diameter,

including all types of fittings. Being the

largest micro dripper manufacturing

facility in the world, it is also the only

integrated fittings manufacturer with

extensive in-house capability for mould

design, manufacturing and injection

moulding. Owing to its huge capacity

of manufacturing Linear Low-density

Polyethylene (LLDPE) drip tubes and

tapes, this facility also produces most

components required for micro irrigation

systems such as PVC & High-density

Polyethylene (HDPE) piping, LLDPE

drip tubes & tapes, drippers, stakes,

An employee verifying the thickness of a polyethylene pipe

Jain I r r igat ion Systems Ltd


couplers, fittings, valves, sprinklers

of all types, filter elements & filters,

venturi etc.

The park is divided into smaller

facilities based on production and works

24/7. Due to the scorching temperatures

that are prevalent in Jalgaon in the

summers, all the units are naturally

ventilated, and the park is surrounded by

lush green lawns. All the green space is

irrigated using recycled water. Elaborating

on the significance of this facility, Atul

B Jain, Joint Managing Director, Jain

Irrigations Systems Ltd, says, “My father

Bhavarlal Jain pioneered the entry of

‘micro’ irrigation in India. While we were

not the first ones to get into drip irrigation

in India, our hard work has ensured a

60 per cent market share in India. Each

of our products and services are aimed

at conservation of precious resources and

increasing productivity of agricultural land

and the farmer with whom we work on

the concept of ‘More from less for more’.

With worldwide experience, it is here

that our intervention of delivering end-

to-end solutions becomes relevant even

to small farmers. Having pioneered the

micro irrigation systems in India, which

ushered in the second green revolution, we

are striving to optimise crop production,

water delivery and recycling systems.”

Good measuresCertified to OHSAS 18001:2007 since

2009, the Jain Plastic Park, which consists

of a 3,207 strong workforce, continues

to implement the occupational health

and safety management system. As

part of system organisation, the Group

carries out detailed hazard identification

risk assessment analysis of its activities

including compliance to legal and

other requirements. Before any process,

risk assessment and ensuring control

measures are mandatorily carried out in

the plant and followed in other facilities

as well. Protective equipment is provided

wherever required.

Right from inception, Jain Irrigation

Systems Ltd has ensured to build all

its activities around conserving the

environment. “Two major products of

the Group, micro irrigation systems and

PVC & HDPE pipes, find extensive use

in both water management and water

conservation. Similarly, the other major

product, extruded plastic sheets, primarily

serves to replace the use of precious

natural timber in the construction and

building industry. Extruded PVC sheets,

particularly in the higher thickness, are a

well accepted and a popular replacement

for lumber application,” states Jain.

In Jain Plastic Park, quality checks are

carried out to meet or surpass the relevant

national or international standards

specified. The ‘Quality Assurance’ and

‘Quality Control’ departments house

extensive plastics testing laboratories that

work around the clock. As part of its

activities, the facility carries out regular

testing of air emission, wastewater analysis

and suitable disposal of solid wastes as

per the guidelines of the Maharashtra

Pollution Control Board. The facility

has created and maintained rainwater

harvesting, storage, recharge & recovery

structures, and now it is working on a zero

discharge model.

Delighting customersWith innovation being an on-going

process, the Group is continuously fine

tuning and modifying its products to

suit individual client and situational

demands. Keeping in view developments

in raw material, product development is

a regular activity based on requirements

and cost optimisation. Jain adds, “We

work closely with many international

resin manufacturers to develop products

surpassing client expectation and also

to offer new products that delight

customers. All new product enquires

are reviewed by the R&D team

meticulously.”


Atul B JainJoint Managing Director

Having pioneered the micro irrigation systems in India, which ushered in the second green revolution, we are striving to optimise crop production, water delivery systems and recycling systems.

A well-laid out polytube plant at the facility

PROJECTS


Corrugated pipes (PVC)Rex Polyextrusion LtdProject type

New facility

Project news

Rex Polyextrusion Ltd is planning to

set up a new plastics project at Sangli

in Maharashtra. The project involves

manufacturing of corrugated pipes (PVC).

Project location

Sangli, Maharashtra

Project cost

NA

Implementation stage

Planning

Contact details:

Rex Polyextrusion Ltd

1077, Kumar Plaza

North Shivaji Nagar

Opp. KWC College

Tal. Miraj, Sangli 416 416

Maharashtra

Laminated printed filmsColourflex Laminators LtdProject type

New facility

Project news

Colourflex Laminators Ltd is planning

to set up a new polymers project at

Gandhinagar in Gujarat. The project

involves manufacturing of laminated

printed films.

Project location

Gandhinagar, Gujarat

Project cost

NA


Planning

Contact details:

Colourflex Laminators Ltd

Ff-130, Shukan Mall

Science City Road

Sola Ahmedabad

Ahmedabad 380 060

Gujarat

Moulded industrial accessories of plasticPoly Plastics Industries India Pvt LtdProject type

New facility

Project news

Poly Plastics Industries India Pvt Ltd is

planning to set up a new plastics project

at Pune in Maharashtra. The project

involves manufacturing of moulded

industrial accessories of plastic.

Project location

Pune, Maharashtra

Project cost

NA


Planning

Contact details:

Poly Plastics Industries India Pvt Ltd

Plot No. B-30/2

MIDC Ranjangaon

Karegaon Shirur

Pune 412 209

Maharashtra

Plastic flushing cisternsEspiem Plastics LtdProject type

New facility

Project news

Espiem Plastics Ltd is planning to set up

a new plastics project at Kancheepuram

in Tamil Nadu. The project involves

manufacturing of plastic flushing cisterns.

Project location

Kancheepuram, Tamil Nadu

Project cost

NA


Planning

Contact details:

Espiem Plastics Ltd

L-5, Sipcot Indl Park

Phase-Ii, Sriperumbudur

Kancheepuram 602 105

Tamil Nadu

Polyester film SRF LtdProject type

New facility

Project news

SRF Ltd is planning to set up a new

polymers project at Udhamsingh Nagar

in Uttarakhand. The project involves

manufacturing of polyester film.

Project location

Udhamsingh Nagar, Uttarakhand

Project cost

NA


Planning

Contact details:

SRF Ltd

C-8, Commercial Complex

Sufdarjung Development Area

New Delhi 110 016

Polyethylene terephthalate polymer chips Micro Polpet Pvt LtdProject type

New facility

Project news

Micro Polpet Pvt Ltd is planning

to set up a new polymers project

at Karnal in Haryana. The project

involves manufacturing of polyethylene

terephthalate polymer chips.

Project location

Karnal, Haryana

Project cost

NA


Planning

Contact details:

Micro Polpet Pvt Ltd

303, 304, Gopal Heights

Netaji Subash Palace

New Delhi 110 034

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.

PROJECTS


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]

Polypropylene/high-density polypropylene/laminated fabrics/woven sacks Geeta Industries Pvt LtdProject type

Facility expansion

Project news

Geeta Industries Pvt Ltd is planning

expansion of a polypropylene/high-

density polypropylene/laminated fabrics/

woven sacks manufacturing unit.

Project location

Uttarakhand

Project cost

` 5 crore


Planning

Contact details:

Geeta Industries Pvt Ltd

A-4 & A-5, Udyog Kunj

Panki Site V

Kanpur 208 022

Uttar Pradesh

Tel: 0512-3198080

Fax: 0512-223393

Polyvinyl chloride compoundMotherson Sumi Electric WiresProject type

New facility

Project news

Motherson Sumi Electric Wires is

planning to set up a new plastics project

at Kancheepuram in Tamil Nadu.

The project involves manufacturing of

polyvinyl chloride compound.

Project location

Kancheepuram, Tamil Nadu

Project cost

NA


Planning

Contact details:

Motherson Sumi Electric Wires

Div. of Motherson Sumi Systems Ltd

F-7, Block B1, M.C.I.E. Mathura Road

New Delhi 110 044

Polyvinyl chloride pipes and fittingsPrince IndustriesProject type

New facility

Project news

Prince Industries is planning to set up

a new plastics project at Haridwar

in Uttarakhand. The project involves

manufacturing of polyvinyl chloride pipes

and fittings.

Project location

Haridwar, Uttarakhand

Project cost

NA


Planning

Contact details:

Prince Industries

Plot No. 5b, Sector 3

Iie-Sidcul

Haridwar 249 403

Uttarakhand

Printed poly flexibles and poly pouchesITC LtdProject type

New facility

Project news

ITC Ltd is planning to set up a new

polymers project at Chennai in Tamil

Nadu. The project involves manufacturing

of printed poly flexibles and poly pouches.

Project location

Chennai, Tamil Nadu

Project cost

NA


Planning

Contact details:

ITC Ltd

SBU-Packaging & Printing

Thiruvottiyur

Chennai 600 019

Tamil Nadu

Ultra high molecular weight polyethyleneReliance Industries LtdProject type

New facility

Project news

Reliance Industries Ltd is planning

to set up a new polymers project at

Bharuch in Gujarat. The project involves

manufacturing of ultra high molecular

weight polyethylene.

Project location

Bharuch, Gujarat

Project cost

NA


Planning

Contact details:

Reliance Industries Ltd

222, 3rd Floor

Maker Chambers IV

Nariman Point

Mumbai 400 021

Unsaturated polyester resinGraphite India LtdProject type

New facility

Project news

Graphite India Ltd is planning to set

up a new polymers project at Nashik

in Maharashtra. The project involves

manufacturing of unsaturated polyester

resin.

Project location

Nashik, Maharashtra

Project cost

NA


Planning

Contact details:

Graphite India Ltd

Gut No. 523/524

Village Gonde

Igatpuri

Nasik 422 403

Maharashtra

TENDERS


Latest Popular Tenders brought to you by www.tendersinfo.comLatest Popular Tenders brought to you by www.tendersinfo.com3D prototypingOrg : Politechnika Poznanska

TRN : 16003085

Desc : Delivery, performance, configuration and

start-up position for 3D prototyping

BOD : 10 June 2013

Loc : Poland

BT : Global (ICB)

Plastic bucket Org : Ministério da Educação

TRN : 15976650

Desc : Supply of plastic bucket

toxic PVC resistant, graduated

with a capacity of 20 litre

BOD : 10 June 2013

Loc : Brazil

BT : Global (ICB)

Polypropylene sandbagOrg : Ministry of Defense

TRN : 16047046

Desc : Supply of woven polypropylene sandbag

BOD : 10 June 2013

Loc : Israel

BT : Global (ICB)

Plastic wrapping reels, gloves, plastic bagsOrg : Egypt Air Company for Flight Services

TRN : 15724900

Desc : Supply of plastic wrapping reels &

gloves and plastic bags for

ice and blankets

BOD : 11 June 2013

Loc : Cairo

BT : Domestic (NCB)

Printed polythene bagsOrg : C G Rajya Beej Evam Krishi Vikas Nigam Ltd

TRN : 15833074

Desc : Supply of printed polythene bags

BOD : 11 June 2013

Loc : Raipur, Chhattisgarh

BT : Domestic (NCB)

Sanitary bagsOrg : Hospital Universitario Cruces - Osakidetza -

Servicio Vasco de Salud

TRN : 15945816

Desc : Provision of sanitary bags

BOD : 11 June 2013

Loc : Plaza de Cruces, Spain

BT : Global (ICB)

Waste collection bins and bagsOrg : Služba, Mestský Podnik Stropkov

TRN : 15879302

Desc : Purchase of bins, containers, composters,

collecting bags and accessories for

separated waste collection

BOD : 11 June 2013

Loc : Slovakia

BT : Global (ICB)

Packing strip rollOrg : C G Rajya Beej Evam Krishi Vikas Nigam Ltd

TRN : 15833171

Desc : Supply of packing strip roll

BOD : 13 June 2013


BT : Domestic (NCB)

Laminated sheetOrg : North Eastern Railway

TRN : 16051954

Desc : Supply of decorative thermosetting synthetic

resin-bonded laminated sheet of

size 2.44 m × 1.22 m, 3.0 mm thick

BOD : 14 June 2013

Loc : Uttar Pradesh

BT : Domestic (NCB)

Garbage bagOrg : City of Kyoto

TRN : 16066746

Desc : Supply of designated garbage bag

BOD : 17 June 2013

Loc : Kyoto

BT : Global (ICB)

TENDERS


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

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

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]

Garbage bagOrg : Kyoto City

TRN : 16066747

Desc : Supply of designated garbage bag

BOD : 17 June 2013

Loc : Kyoto

BT : Global (ICB)

Garbage bagsOrg : Intercommunale Hygea

TRN : 15963798

Desc : Providing bags for garbage

BOD : 17 June 2013

Loc : Le Havré, France

BT : Global (ICB)

Plastic injection equipmentOrg : Représentation Economique et

Commerciale de la Région de Bruxelles

TRN : 16046888

Desc : Supply of horizontal injection moulding

presses with single press blower,

air compressor and hot runner moulds

for plastic injection

BOD : 18 June 2013

Loc : Algeria

BT : Global (ICB)

BagsOrg : Ministry of Defence

TRN : 15607193

Desc : Supply of buoyancy bags

BOD : 22 June 2013

Loc : Jammu and Kashmir

BT : Domestic (NCB)

BagsOrg : Product Distribution Centre

TRN : 16042255

Desc : Supply of medical and

non-medical use bags

BOD : 25 June 2013

Loc : Columbia

BT : Global (ICB)

Plastic sheetsOrg : C G Rajya Beej Evam Krishi Vikas Nigam Ltd

TRN : 15833174

Desc : Supply of mulching sheet and pond lining

BOD : 25 June 2013


BT : Domestic (NCB)

Polythene linerOrg : Ordnance Factory Board

TRN : 15999365

Desc : Supply of alkathene liner 500 gauge

(0.127 mm+/10%) thick polythene

BOD : 25 June 2013

Loc : Madhya Pradesh

BT : Domestic (NCB)

Trash bagsOrg : Communauté de Communes

de l’Orée de Bercé Belinois

TRN : 16035241

Desc : Supply of trash bags

BOD : 28 June 2013

Loc : France

BT : Global (ICB)

EVENT LIST


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

For details contact:

Senthil Kumar N

The Tamil Nadu Plastics

Manufacturers Association

C-1, First Floor, Rams Square

Village Road, Nungambakkam

Chennai, Tamil Nadu

Tel: 044-28250107

PackPlus SouthPackPlus South 2013 will be a four-

day event to be held in Hyderabad.

Industry leaders and key market

regulators from processing, packaging,

supply chain and converting industries

will attend this show and will discuss

the current trends related to these

industries. Conferences, product

launches, meeting with customers and

networking opportunities will be the

highlights of this mega event; July

5–8, 2013; at Hyderabad International

Trade Exposition Centre (HITEX),

Hyderabad


Prateek Kaushik

Print Packaging.Com Pvt Ltd

F 101, Tower No. 7, First Floor

International Infotech Park

Vashi Railway Station, Vashi

Navi Mumbai, Maharashtra

Tel: 022-27812093/27812619

Mob: 09899981610

Website: www.packplus.in

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 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


Plastics Design & Moulding Exhibition & ConferencePlastics Design & Moulding Exhibition

& Conference will be organised by the

Plastics News Global Group owned by

Detroit-based Crain Communications

Inc. The event will assemble designers

and moulders representing end-use

markets such as automotives, medical,

packaging, electrical & electronics,

sports, domestic & leisure goods.

The focus will be on the market

opportunities and future challenges of

the plastic design & moulding industry;

June 18–19, 2013, Telford International

Centre, Telford, UK


Matthew Barber

Crain Communications Ltd

1155 Gratiot Ave., Detroit

Michigan, USA

Tel: +44-20-82539628

Fax: +44-20-82539651


Website: www.pdmevent.com

InterPlas ThailandInterPlas Thailand will bridge and

culminate business and industrial

excellence for all active players in plastic

and rubber industries. It will benefit the

Thai industrial potency with machinery,

technology and know-how through

exhibition, activities and a series of

conferences and seminars; June 20–23,

2013; Bangkok International Trade &

Exhibition Centre (BITEC), Bangkok,

Thailand


Orachorn Wongpan-ngam

Reed Tradex

100/68-69, 32nd Floor

Sathorn Nakorn Tower

North Sathorn Road

Silom, Bangkok

Thailand

Tel: +(66)-(2)-6867299

Fax: +(66)-(2)-6867288


Website: www.interplasthailand.com

BioplastekBioplastek 2013 will be an interactive

forum on ‘Bioplastics Today and Tomorrow’

and an exhibition cum conference. The

exposition will take place with an objective

to promote the products and services of

those in the field of bioplastics. Leading

companies from different industries will

be attending the conference to find the

products and services for their specific use;

June 26–28, 2013; at Hilton San Francisco,

San Francisco, USA


Schotland Business Research, Inc

16 Duncan Lane Skillman

NJ 08558-2323, USA

Tel: +1-609-4669191

Fax: +1-609-4668833

Website: www.bioplastek.com

MSIA-PLASMSIA-PLAS is an international exhibition

for the plastic & plastic products industry

in Malaysia. The event will showcase the

latest products and equipment under a

single roof. This is the 24th edition of the

exhibition. This trade show will be held

concurrently with MIMF – AseanSign;

July 4–7, 2013; at Putra World Trade

Centre (PWTC), Kuala Lumpur, Malaysia


ES Event Management Sdn Bhd

153-3, Jalan Lancang

Taman Sri Bahtera, Cheras

56100 Kuala Lumpur

Malaysia

Tel: +603 9132 1922

Fax: +603-9133 1920


Website: www.esevent.com.my

CamboPlasCamboPlas is considered one of the most

popular and well attended trade shows

catering to the requirements of the plastics

industry in Cambodia. Since the main

industry in the country is agriculture, all

the other industrial activity revolves around

it. This trade event will play an important

role in ensuring an overall growth and

development for the plastics industry;

August 8–11, 2013; at Diamond Island

Convention & Exhibition Center, Phnom

Penh, Cambodia


Tracy Chang

Chan Chao International Co Ltd

3-F, No. 185, Kangchien Road

Nei Hu District

Taipei, Taiwan

Tel: +(886)-(2)-26596000

Fax: +(886)-(2)-26597000


Website: www.camboexpo.com/CIMIF/

camboplas

K 2013K 2013 is one of the world’s leading trade fairs

for the rubber and plastics industries. This

event has a record of bringing international

exhibitors and trade visitors with great

decision-making powers under one roof.

This event covers the entire segment of the

rubber and plastics industries from basic

products and innovations to efficient high-

tech solutions; October 16-23, 2013; at

Dusseldorf Exhibition Centre, Dusseldorf,

Germany


Messe Dusseldorf GmbH

Stockumer Kirchstrasse

61 Messeplatz Dusseldorf

Germany

Tel: +(49)-(211)-4560900/4560175

Fax: +(49)-(211)-4560668/4560740


Website: www.k-tradefair.com

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


BOOK REVIEW


Current interest in sustainable polymeric materials has created interest in rosin, which is derived from pine tress. Rosin is used in many kinds of polymers and polymer chemicals for applications such as printing inks, adhesives, paints, varnishes, coatings, alkyd resins, polyurethanes, epoxy resins, polyesters and polyamides. Rosin has been historically ignored as biomass for manufacturing ‘Green Plastics’ and composites. This is largely due to the difficulties of precisely controlling the molecular structure through molecular engineering. However, in recent years, rosin acids have received growing interest as feedstock chemicals.

The editor has summarised the recent progress in chemicals and polymers derived from rosin and turpentine as feedstock chemicals. Various chapters focus on rosin-derived epoxies curing and coating applications, turpentine-derived polyols and polyurethane applications, rosin-derived monomers in thermoplastic polymers, rosin-derived surfactants and finally biological activities of rosin-derived chemicals.

This book is a useful guide and reference for those involved in the investigation of chemicals and polymers based on pine resin.

Rosin-based Chemicals and PolymersEditor: Jinwen ZhangPrice: ` 8,237

Forming tools, ie the extrusion die and the calibration systems used, are the key components of extrusion lines. The objective of an extrusion line is to produce, at a high rate and quality, the required product. These two goals are generally conflicting. Optimisation of the processing conditions and design of extrusion tools demand deep knowledge and careful study of all the phenomena involved during the extrusion process.

Authors have felt that there is a clear lack of literature devoted to the design of extrusion forming tools and integrating the different phenomena involved. This book fills up the gap.

It is a useful reference for higher education students, teachers, researchers and engineers active in the extrusion industry. It is also a practical guide for those involved in the design of forming tools. Each chapter is written by researchers, both from academic and industrial communities, whose contribution in the specific field is internationally recognised.

Chapters are arranged in logical sequence, starting with objectives and the most relevant problems associated with design of tools, polymer properties required for design process, specific chapters on pipes, flat film & sheet, blown film, profiles, flexible dies and rotating mandrel dies.

Design of Extrusion Forming Tools

Available at: Wisdom Book Distributors,Hornby Building, Ist Floor, 174, D.N. Road, Mumbai - 400 053 Tel: 022-22074484 66318958 • Telefax: 022-22034058

Reviewer: Dr R Rangaprasad, Experienced Polymer Professional

Authors: Olga S Cazneiro and J Miguel NobregsPrice: ` 10,838

PRODUCTS


Looking For A Specific Product?Searching and sourcing products were never so easy.

Just type MPP (space) Product Name and send it to 51818eg. MPP Moulding and send it to 51818



Servo-driven beam robotRedstone series servo-driven beam robot

is applicable to all types of horizontal

injection machines ranging from 50

tonne to 500 tonne. It has a full AC

servo motor driven on each axis, taken

out at super high speed. By using linear slide rail, adjusting the gap is not

needed, and it is stable, wear-proof and has a long life. Besides high speed

take-out product, insert moulding, picking up the inserts of two combined

IMM, IML and collocation of peripheral automation are provided. The

range of services includes home appliances, computer peripherals, office

products, food packaging, toys, PET, precision gear etc.

Dongguan Alfa Automation

Dongguan - Taiwan

Tel: +86-769-83180326, Fax: +86-769-83180329


Website: www.alfarobot.com

Label printing machinePrinting speed of PCD-

80-08H-RE (UV ) is

80–100 pcs/min. The

features include double

t ransferr ing rol ler

design, stopples roller

adjustment design,

plate wheel outer fine-tune mechanism, quick release ink rollers,

printing wheel clean system (200 mm dischargeable), sleeve printing

and plate wheel pre-register mechanism that make production

more smooth.

Bonmart Enterprise Corp

Taipei City - Taiwan

Tel: +886-2-2299 4281, Fax: +886-2-2299 4284


Website: www.bonmart.com.tw

PRODUCTS


Multi-cavity hot runner controllerThe TC5200 multi-cavity hot runner

controller features a 12–60 point temperature

combination controller and multi-machine

networking. Maintenance operations can be

simplified with its modularised device design

and requirement-based configuration. The

purchasing costs are greatly reduced by its

unique temperature control, with two points

within one level. The GUI-based user interface,

along with its adjustable perspective angle, is

easy for fast adoption in multi-points control.

The RS485 communication function enables

you to set up multiple controls at once to

simplify the required operations. The built-in

and practical current sensor and indicator functions benefit various

applications, especially automotive, bottle billet injection and medical

supplies, by realising the concept of one-stop control.

Arico Technology Co Ltd

Taipei City – Taiwan

Tel: +886-2-2910-1266, Fax: +886-2-2915-9434


Website: www.arico.com.tw

Film blown machinePE stretch film blown machine is

for producing PE stretch film &

PE cling film. Liquid PIB injection

system is used to inject the liquid

adhesive into the screw to get

sticky film. This technology allows

adjusting the stickiness and saving

resin cost. The winder is equipped

with no-tension control that allows the film to be at the same tension

and it will not tighten the paper cores. The co-speed controller controls

the speed of take-up unit and winder to be the same, so the film will

not be stretched and can keep the stretch after winding. This machine

can produce 10 rolls of film width 300 mm or 6 rolls of film width 500

mm at one time, and the output can be 100-150 kg/hr for 1-layer 75mm

extruder. For industrial purpose, multi-layers stretch film blown machine

is also available. Three rewinder machines are also available, one is for

fixed film width 300 mm, one is for fixed film width 500 mm and one

is for film width 300-530 mm. These three machines can automatically

feed the paper core, rewind, cut film and change paper cores. The

maximum speed of the new “Rewinder machine” can go to 18-20 pcs/

min at 20 m length.

Chyi Yang Industrial Co Ltd

Taoyuan - Taiwan

Tel: +886-3-3288686, Fax: +886-3-3283737


Website: www.cymw.com.twMould change systemQuick mould change

system uses hydraulic

drive to achieve a

simple, convenient and

quick mould change

steps. Compared to the

traditional way of fixing

mould by hand, it not

only reduces half machine

idle time, the labour force

and cost of production but also increases machine utilisation and

productivity. Quick mould change system includes power unit,

die clamps, hydraulic parts and electrical control box. They can be

customised according to the customer’s machine requirements. In

case of sudden stop power supply, the quick mould change system

can supply pressure for more than 48 hours to avoid the mould from

falling. When clamping abnormally, it can connect with the machine

to stop the operation immediately to protect personnel safety.

Forwell Precision Machinery Co Ltd

Zhejing - China

Tel: +86-574-86599196

Fax: +86-574-86599197


Website: www.forwell.com

Mould labelling machineUnder the concept of

environmental protection

and to satisfy the increasing

requirements of the one-

step producing container

packaging market, new

A-pack In Mold Labeling

(IML) System has vacuum

and static labelling, reduces the cycle time and greatly saves total

production cost. A-PACK IML Turnkey Solution could be applied to

all kinds of beverage and food packages such as tea, coffee, juice, water,

yogurt and dairy products. It consists of four components including FCS

AF series, hi-speed hybrid close loop injection moulding machine, hot-

runner mould, robot, product stacking system and label inserting system.

In addition, FCS can also provide customised label for this turnkey

solution. In fact, customers only need to decide what kind of container

they want, and then FCS will provide optimal solutions, even including the

installation and training for technicians to make sure the whole system is

working well.

Fu Chun Shin Machinery Manufacture Co Ltd

Tainan City - Taiwan

Tel: +886-6-5950688, Fax: +886-6-5951129


Website: www.fcs.com.tw

PRODUCTS


Multi-layer co-extrusion blown film machineMulti-Layer co-extrusion blown film

machine is constructed on the basis of

a green eco-friendly design principle,

which cleverly integrates the latest proven

technologies in plastics, mechanical,

electrical and automation. The JC-CX

series multi-layer co-extrusion blown

film extrusion line is available

in three layer or five layer configuration producing

variety of quality film for various industries. From general purpose

packaging film or lamination film of complex technical film or

food packaging with high grade barrier properties, the

JC-CX series multi-layer blown film line is a convincing solution

to every customer’s need. The line is built with the concept

of modular system promised to meet each specific demand.

Quality, reliability, efficiency and high productivity are the essential

characteristics of the JC-CX series multi-layer co-extrusion blown

film line.

Jenn Chong Plastics Machinery Works Co Ltd

Chia-Yi Hsien - Taiwan

Tel: +886-5-2376175, Fax: +886-5-2376176


Website: www.jennchong.com.tw

3-Axis CNC double column machining centre NX series double column CNC

vertical machining centre is an

ideal heavy duty machine for both

roughing and finishing of bigger

components greatly increasing

work envelope, permitting large

workpieces to be machined and a wider range of tool lengths to be used in

the same set-up. With a load capacity range of 10,000 kg, this series has been

designed to accommodate large mould and mould base machining. With the

architecture of Y-axis on cross beam, moving table on X-axis and Z-axis on

ram-type head, greater extensions from head-stock and better reach to table

area is achieved without much interference of axis elements. Wider gaps

are maintained between columns to accommodate large size components.

NX 2215 has X/Y/Z (2200/1500/800 mm) and 24-tool ATC. Thus, with

mentioned machining features, symmetrically designed heavily ribbed cast

iron structure with wider columns providing high level machining geometric

stability, wider door opening various options in head and spindle, the NX

series becomes an ideal choice for modern machine shops.

Jyoti CNC Automation Ltd

Rajkot - Gujarat

Tel: 02827-287081, 287082


Website: www.jyoti.co.in


Anaerobic adhesivesA high performance

anaerobic adhesive,

Sonlok is pre-

applied to thread

parts forms a

unique coating that

converts ordinary

fasteners into self-

locking and self-

sealing fasteners. Dry to touch, Sonlok pre-applied thread

locker becomes an integral part of the fastener and stays inert

until parts are used. During the assembly process, Sonlok pre-

applied is activated by assembly forces, releasing anaerobic

adhesive that locks and seals parts securely. This product may

be used successfully, without solvents, in extreme temperature

and pressure environments to lock and seal against air, steam,

most fluids and lubricants.

Parson Adhesives India Pvt Ltd

Vadodara, Gujarat

Tel: 0265-6541638, 2972191

Mobile: 094285-11765, 098252-99551


Website: www.parsonadhesives.in

Monofilament extrusion line

Monofilament extrusion line is the most flexible monofilament

line at the forefront of the global market. It provides technical

solutions in the production of PP, HDPE, PA and PET

monofilaments. The JC-MNP series monofilament extrusion

line is conceived to process PP and HDPE. Extruder is

available from standard Ø 55 mm to Ø 100 mm for production

of monofilament diameter range from Ø 0.15 mm to

Ø 1.00 mm. With its high level of reliability, efficiency, energy

saving concept and top quality finish, monofilament extrusion

line ensures a modest investment compared with its high

productivities to facilitate the ever-demanding requirement of

all market sectors.

Jenn Chong Plastics Machinery Works Co Ltd

Taiwan, Chia-Yi Hsien

Tel: 886-5-2376175

Fax: 886-5-2376176


Website: www.jennchong.com.tw

PRODUCTS


Thermoplastic elastomerPhoenix compound is

high performance styrene-

based thermoplastic

elastomer that contains

features of vulcanised

rubber at normal

temperature and plastics

when heated. It means

that once they are formed, they can be heated and reformed repeatedly

by conventional plastics processes, such as injection moulding, blow

moulding and extrusion. This property allows for easy process and

facilitates recycling. The compound has been used in a wide range of

markets and applications. The features and benefits of Phoenix allow

the customer to design products without limit. They can be hard

or soft. They can bond to a variety of engineering thermoplastics.

They can be sleek, silky, opaque, transparent and colourful. Phoenix

can be made even more flexible according to different customers’

requirements.

Phon Tech Industrial Co

Yunlin - Taiwan

Tel: 886-5-5574567

Fax: 886-5-5574553


Website: www.phon-tech.com.tw

Gear boxCorresponding to the

increasing demand of the

twin-screw extruder, sun lung

has developed a series of high-

performance gear box for

the twin-screw extruder. The

gearboxes of this series have

been developed by featuring

high torque and high speed output rate. The series of gearboxes is

embedded with excellent high dissipation and oil lubrication system

to perform stable output under heavy-loading force. The axial thrust

is supported by an axial roller-type swivel thrust-bearing of the

294.e series, coupled with thrust bearings assembled in a tandem

way. The gearbox features high torque and high output speed rate

design coupled with thrust bearings assembled in a tandem way, best

transmission efficiency, high torque and sufficient safety coefficient.

The precision of the gear grinding is up to DIN 1–3 grade, operation

noise is kept below 80 dB.CE and the gear box is TUV certified

Sun Lung Gear Works Co Ltd

Tainan - Taiwan

Tel: +886-6-2639969

Fax: +886-6-2639626


Website: www.slgear.com.tw


Plastic palletA wide range of plastic pallets

is offered for every application

in material handling. These

pallets are made of prime grade

advanced polyethylene materials. The pallets are known for longer

life, superior performance and ensuring the best in industry quality

standards in both automated and traditional material handling and

distribution systems. The heavy-duty steel reinforced plastic pallets

are ideal alternatives for steel and wooden pallets.

Swift Techno Plast Pvt Ltd

Navi Mumbai - Maharashtra

Tel: 022-22978351, Mob: 09769220221


Website: www.plasticpallet.co.in

Injection moulding Injection moulding technology is used across

the range of polymer families from polyolefins

to engineering polyamides, styrenes and various

special compounds to meet the specific needs of

the parts. Parts from sizes as small as a button

to as large as the front hood of heavy commercial vehicles are moulded,

covering products of both technical and aesthetic requirements. It has the most

advanced technology ranging from 50 tonne to 3000 tonne across reputed

brands in the industry. Application areas include production of HVAC unit,

rack system for retail, ice twister, radiator grill, bumper system, blower case,

truck front panel, fan unit, pillars, door bin and washing machine tub.

Mutual Industries Ltd

Mumbai - Maharashtra

Tel: 022-66895300

Website: www.mutual-industries.com

Multi-layer polyethylene film The multi-layer polyethylene film is coated

with pressure sensitive adhesive. A wide

range of innovative solutions for protection

of PVC section with an extensive range of

adhesion level, film thickness of 50 micron

to 80 micron and colour are available. It has

a maximum length of 1000 m per roll and maximum width of 1550 mm.

It provides outdoor weather resistance. The protective film peels out easily

after finishing operations. It preserves the quality of surface without leaving

residue or any marks once the protective film is removed. It provides uniform

and stable adhesion throughout the life cycle of the product.

Ecoplast Ltd


Tel: 022-26830064, 26840359


Website: www.ecoplastindia.com

PRODUCTS


Moulding solutionThe moulding solution includes

technical injection moulding

applications such as insert moulding,

multi-component (or multi-colour)

moulding, thermoset injection moulding

(for BMC and rubber), liquid injection

moulding (for LSR), powder injection

moulding (for metal and ceramic),

in-mould-decoration moulding (IML/IMR/IMF) and micro injection

moulding etc. Machine production status and real-time production

data are instantly transmitted to the central monitor and control

station through various remote connections. This smart production data

management system is able to read and acquire the machine operation

status and real-time production data instantly via the central monitor

and control station. Image of machine production status is visually

transmitted via a video camera to the central monitor station in which

operator can observe machine production status on a real-time basis. The

defective/rejected products are shown in the central monitor in a timely

manner allowing managers to update production status of the products.

Multiplas Enginery Co Ltd

Taoyuan - Taiwan

Tel: +886-3-3180090, Fax: +886-3-3975498


Website: www.multiplas.com.tw

Silicone transparent tubing and braided hosePolyester-reinforced silicone

transparent braided hose is made

for food, pharmaceutical, chemical,

medical and heavy engineering

industries, thermal power stations and

PSUs. This braided hose is made of

100 per cent pure silicone rubber by

using fully automatic state-of-the art machines and technologies. It

already caters to all the major pharmaceutical companies in India

and is also exported to overseas customers. Medical grade braided

hose is manufactured under stringent quality control and is made

of medical grade silicone rubber, temperature-resistant from -80°C

to 250°C (-110°F to 480°F), non-reactive to body tissue and fluid,

unaffected by most water-soluble materials, sterilisable by steam, dry

heat, ethylene oxide and gamma radiation and has an indefinite shelf

life. The silicone transparent tubing sizes are available from 0.5 mm

ID to 200 mm ID, and braided hoses have sizes available from

ID range ½” to 2 ½”.

Ami Polymer Pvt Ltd


Tel: 022-28555107/631/914, Mob: 09223290931

Fax: 022-28555378


Website: www.amipolymer.com

PRODUCTS


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


Mould-temperature controller and chillerThe mould temperature controller

and special custom-made chiller

are new products that include cold-

hot all-in-one mould temperature

controller, die-casting mould

temperature controller, quick-cooling

& heating mould temperature

controller, two machines in one water

circulation temperature controller

and 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

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

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

Crystallised hopper dryerCrystallised hopper dryer is ideal

for users who have trouble with

oily, sticky, abnormal shaped resin

and recycled material such as PET.

Its patented drying technology

can mix evenly and crystallise

well as a result it shortens drying

time and saves cost. Crystallised

hopper dryer prevents bridge

making when drying oily, sticky,

abnormal shaped resin. It is easy to have the bridge making. To use

the crystallised hopper dryer can prevent the bridge making effectively.

Yann Bang provides three different kinds of unique mixers to suit your

special needs.

Yann Bang Electrical Machinery Co Ltd

Taiwan Taichung City

Tel: 886-4-22710000

Fax: 886-4-22711988


Website: www.yannbang.com

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LIST OF PRODUCTS


3 Axis CNC Double Column Machining Centre ...... 123

AC / DC Panel For Pipe Plant ...................................69

AC Drive ............................................................................... 35

Acoustic Enclosure ........................................................... 11,93

Additive Masterbatch ............................................................ 10

Air Audits Blower ................................................................. 21

Air Bubble Sheet Plant ......................................................... 53

Air Compressor ..................................................................... 45

Air Cooled Chiller ................................................................ 16

Air Treatment ........................................................................ 45

Air-Conditioner Part ........................................................ FGF

Airconditioning Plant ........................................................... 45

All Electric Machine ............................................................. 23

Aluminium Die Casting Machinery Diesel Generator ........ 45

Anaerobic Adhesive............................................................. 124

Auto Dosing And Mixing System ........................................ 67

Auto Vacuum Loader ............................................................ 67

Automation ............................................................................. 6

Automation System ............................................................... 77

Automotive ............................................................................ 75

Barrel ......................................................................138

Barrels for Plastic & Rubber Injection Moulding ................ 29

Batch Weigh Blender ............................................................ 18

Bed Knife .............................................................................. 83

Biodegradable Masterbatch ................................................... 10

Black Masterbatch ................................................................ 10

Blender ............................................................................... FIC

Blending Unit ................................................................... FGF

Blower Series ......................................................................... 77

Blown Film Extrusion System ............................................ BC

Bulk Level Measurement System ......................................... 19

Cam Follower ..........................................................124

Capacitive Sensor .................................................................. 87

Capping Machine ................................................................. 51

Carbon Black ...................................................................... 121

Cast Film Line ...................................................................... 53

Central Material Conveying System ..................................... 67

Chiller ................................................................................. 127

Cim Mould ........................................................................... 37

Circular Weaving Machine ................................................... 14

Clean Room Application ...................................................... 25

Cleaning Oven .................................................................... 138

Cluster Facia ..................................................................... FGF

CNC Machine ...................................................................... 63

CNC Vertical Machining Centre ......................................... 79

Co-Extruded Sheets and Telecom Cable ............................. 59

Colour Masterbatches ...................................................... 10,15

Compact Chiller.................................................................. 137

Compressed Air Dryer .......................................................... 57

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

Compressor ................................................................... 21,BIC

Conductive Compounds ....................................................... 10

Connector .......................................................................... FGF

Connector and Cable Assembly ........................................... 87

Connector Type ..................................................................... 87

Connectors Screw Type ........................................................ 87

Continuous Screen Changer ............................................... 138

Contrast/Colour Scanner ...................................................... 95

Control Panel ...................................................................... 124

Convertor ............................................................................ 124

Conveying ............................................................................... 6

Crusher .................................................................................. 67

Crystallised Hopper Dryer.................................................. 128

Crystalliser............................................................................. 57

Cutting and Stitching Machine ............................................ 14

Cylinder Engraving - Lenticular & Optical Roll Mould ... 126

Cylindrical Sensors................................................................ 95

Datalogging Software .............................................. 124

Dehumidified Air Dryer ................................................... FGF

Dehumidified Dryer ........................................................... FIC

Dehumidifying Air Dryer ................................................... 137

Dehumidifying Dryer....................................................... 67,85

Dessicant Compressed Air Dryer ....................................... 125

Die Face Cutter .................................................................... 83

Die Plate ............................................................................... 83

Differential Pressure Transmitter .......................................... 87

Digital Panel Meter .............................................................. 12

Digital Temperature Controller .......................................... 124

Door Trim ......................................................................... FGF

Dosing & Blending ................................................................. 6

Dosing & Mixing.................................................................. 77

Double Column Vertical Machining Centre ........................ 63

Double Sheet Monitoring ..................................................... 95

Drive.................................................................................... 124

Dry Van Pump ................................................................. 11,93

Dry-Break Coupling ............................................................. 21

Drying ..................................................................................... 6

Drying & Dehumidfying ...................................................... 77

Drymax Air-Hot Air Dryer............................................... FIC

Drymax Dryer .................................................................... FIC

Drymax Pet-Dehumidified Dryer ...................................... FIC

Dual Channel With Modbus ............................................. 124

Dynamic Controller ............................................................ 124

Ejector.......................................................................21

Electric Injection Moulding Machine Gearboxes .................. 7

Electrical................................................................................ 75

Element Shrink Disc .......................................................... 124

Evaporative Cooling Tower .................................................. 45

Exhibiiton - Plastivision 2013 ............................................ 102

Extruder Machine ............................................................ 27,73

Extruder Screws .................................................................... 83

Extrusion .........................................................................BC,37

Extrusion Coating Lamination Plant ................................... 53

Extrusion Coating Lines (Lamination Ant) ......................... 14

Extrusion Dies ........................................................................ 8

Extrusion Machinery ............................................................ 29

Extrusion Pump .................................................................... 49

Extrusion System ................................................................ BC

Feed Roll ...................................................................83

Feeding & Conveying ...................................................... 57,77

Fibre Optic Amplifier ........................................................... 95

Filling Machine ..................................................................... 51

Film Blown Machine .......................................................... 122

Film Cutter ........................................................................... 83

Forked Photoelectric Sensor ................................................. 95

Freewheel-Oneway-Clutches .............................................. 124

Fueling System ...................................................................... 21

Fully Automatic Strapping Plant .......................................... 53

Furnace .................................................................................. 45

Gear Box ................................................................. 125

Gear Pump ..................................................................... 49,138

Granulating & Recycling ...................................................... 77

Granulator .............................................................. 57,137,FIC

Granulator Blade ................................................................... 83

Gravimetric Blender ............................................................ 137

Gun Drilling Process ............................................................ 29

HDPE Pipe Plants ....................................................69

Head Lamp & Tail Lamp................................................. FGF

Heart Valve Frame ................................................................ 61

Heat Transfer Equipment ..................................................... 31

Heat Transfer Roll .............................................................. 138

Heating & Cooling ............................................................ 6,77

High Cavitations ................................................................... 25

High Performance Screw .................................................... 138

High Pressure Blower ........................................................... 31

High Speed Mixer ........................................................... 27,73

HM/HDPE/LDPE/LLDPE ............................................... 53

Hold Back ........................................................................... 124

Hopper Dryer........................................................................ 67

Hopper Loader.................................................................... 137

Hot Air Dryer .......................................................FGF,85, 137

Hot Runner System .............................................................. 77

Hydraulic Block .................................................................... 29

Hydraulic Injection Moulding Machine ............................... 23

Hydraulic Piston Ram .......................................................... 29

I/O Junction Box With Profibus ................................87

IMLTechniqe ........................................................................ 25

Inductive Sensor .................................................................... 87

Inductive Switch ................................................................... 95

Injection Moulding ............................................................ 126

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 PRODUCTS


Injection Moulding Machine ....................FGF,5,17,37,89,133

Keyless Transmisson Element ..................................124

Knob & Switch ................................................................. FGF

Label Printing Machine ...........................................121

Largeflow Water Heater ....................................................... 77

Loader ................................................................................ FIC

Loading Arm ........................................................................ 21

Long Fibre Rigid Thermoplastic Polyurethane ................. 128

LSR Machine ........................................................................ 37

M12 Screw Type Connector .......................................87

M8 Screw Type Connector ................................................... 87

Manual & Hydraulic Screen Changers .............................. 138

Master-Batch Feeder ............................................................. 67

Masterbatches........................................................................ 59

Masterbatches. Wire & Cable .............................................. 75

Material Storage .................................................................. 137

Measuring And Control Equipment .................................. 126

Measuring Sensor .................................................................. 95

Medical Food ........................................................................ 75

Medical Mould ..................................................................... 25

Mini Sensors ......................................................................... 95

Mould Repair ...................................................................... 126

Mould Temperature Controller ............................................. 85

Moulding ............................................................................... 25

Mono and Multilayer Sheet Line ......................................... 14

Monofilament Extruding Line ........................................... 124

Monofilament Line ............................................................... 14

Monolayer Blown Film Line .............................................. BC

Mould Change System ....................................................... 122

Mould Labelling Machine ................................................. 122

Mould Temperature Controller ........................................... 137

Mould Temperature Controller and Chiller ...................... 128

Moulding Solution ............................................................. 127

Mould ............................................................................... 27,73

MTC .................................................................................. FIC

Multi-cavity Hot Runner Controller .................................. 122

Multi-component Moulds .................................................... 25

Multi-layer Cast Film Line .................................................. 14

Multi-layer Blown Film Line .........................................14,BC

Multi-layer Blown Film Plant .............................................. 53

Multi-layer Co-extrusion Blown Film Machine ............... 123

Multi-layer Polythylene Film ............................................ 126

Napkin Dies ..............................................................83

Nitrogen Generator ............................................................. 125

Oil Chillers / Brine Chillers / Liquifiers /

Chillers for Batching Plant ........................................16

Oil Cooler ........................................................................... 127

Optical Brightner .................................................................. 10

Oxygen Generator ............................................................... 125

Panel Cooler ............................................................ 127

Paperless Recorder ................................................................ 12

Parallel & Right Angle Axes Gearbox ................................... 7

Pelletiser ......................................................................... 83,138

Pelletiser Parts ....................................................................... 83

PET / PE Washing Line ...................................................... 14

PET Box Strapping Plant..................................................... 53

PET Perform Didicated Machine ........................................ 47

Petline Injection Moulding Machine .................................... 23

Photoelectric Sensor .............................................................. 87

PID Controller .................................................................... 124

Pipe Extrusion Line For PVC / PPR / PE ......................... 89

Plastic Auxiliary Equipment ................................................. 18

Plastic Conveyor Belt ............................................................ 27

Plastic Machinery.................................................................. 45

Plastic Masterbatches ................................... 101,105,107,BGF

Plastic Pallet ........................................................................ 126

Plastic Processing Machines ................................................. 14

PLC ................................................................................... 124

PLC and HMI ...................................................................... 35

Power Generator Shaft ......................................................... 29

PP TQ Plant ......................................................................... 53

PP/ HDPE-Semi Automatic Strapping Plant ..................... 53

PP/HDPE Rafffia Tape Lines .............................................. 53

Precision Moulding ........................................................... FGF

Precision Temperature Control ........................................... 124

Priming Valve ........................................................................ 21

Printing And Cutting / Rewinding Machines ..................... 14

Printing Machine .................................................................. 37

Process Controller .......................................................... 12,124

Process Gas Blower ............................................................... 31

Process Machinery ................................................................ 45

Profile Controller ................................................................ 124

Pulveriser .......................................................................... 27,73

Pulveriser Discs ..................................................................... 83

Pump ........................................................................... 11,21,93

PVC Compound ................................................................... 59

Recycling .................................................................... 6

Recycling Lines ..................................................................... 14

Resin Dehumidifier ............................................................... 57

Resin Dryer ........................................................................... 33

RH (Humidity) & Temperature Indicator ........................... 87

Right Angle ........................................................................... 87

Robot .................................................................................. FIC

Rock N Roll Machine...................................................... 27,73

Roots Blower .................................................................... 11,83

Rotary Cutters ....................................................................... 83

Rotary Dies ........................................................................... 83

Rotary Dry Vacuum Pump ................................................... 31

Round Table Carrousels ........................................................ 27

RTD .................................................................................... 124

Safety Access Equipment ...........................................21

Safety Light Curtain ............................................................. 87

Sensors & Switch .................................................................. 19

Sensors’ Connectors............................................................... 87

Servo-driven Beam Robot ................................................. 121

Servo Energy Saving Machine ............................................. 47

Servo System ......................................................................... 35

Shut Off Nozzles ................................................................ 138

Silence Flow Packages Centrifugal Fan ................................ 31

Silicone Transparent Tubing and Braided Hose ................ 127

Single Mill Pulveriser ...................................................... 27,73

Single Screw Extruder Gearbox.............................................. 7

Single Screw Pipe Plant for RPVC ...................................... 69

Slot Type ............................................................................... 87

Software For Central Monitoring ......................................... 57

Solid State Relay ................................................................. 124

Stack Mould .......................................................................... 25

Storage Tank Equipment ...................................................... 21

Submicron Filter ................................................................. 125

Switch Gear .......................................................................... 35

System Solution .................................................................... 77

Tank Truck Equipment ..............................................21

Tape Stretching Line With Inverter

Driven Cheese Winder ......................................................... 14

Technical Mould ................................................................... 25

Temperature Controller.................................................. 12,124

Temperature Sensor ............................................................ 124

Tensioner Nut ..................................................................... 124

Testing ................................................................................. 126

Thermocouple ..................................................................... 124

Thermoformer ..................................................................... BC

Thermoforming & Ps Foam ............................................... BC

Thermoplastic Elastomer .................................................... 125

Three Arm Bi-Axial Roto Moulding Machine ............... 27,73

Thyristorised Power Controller .......................................... 124

TIE Bar ................................................................................. 29

Toggle Injection Machine ..................................................... 23

TPU Masterbatches .............................................................. 15

Track Rollers ....................................................................... 124

Transmissions & PTOS ........................................................ 21

Truck Blowers ....................................................................... 31

Twin - Screw Co-Rotating Extruder ............................... 20,61

Twin - Screw Element ..................................................... 20,61

Twin - Screw Extruder .................................................... 20,61

Twin Mill Pulveriser ........................................................ 27,73

Twin Screw Extruder Gearbox ............................................... 7

Twin Screw Pipe Plant For RPVC Pipe .............................. 69

Two Platen Injection Moulding Machine ............................ 23

Ultra Sonic Flow Meter .............................................12

Ultrasonic Sensor .................................................................. 95

Universal Controller ............................................................ 124

Universal Input Temp Scanner ........................................... 124

UV Stabiliser ......................................................................... 10

Vacuum Booster Pump .......................................... 11,93

Vacuum Dryer ....................................................................... 85

Vacuum Forming Machine ................................................. BC

Vacuum Loader ................................................................. FGF

Vacuum Pumps & System .................................................... 21

Vacuum System ................................................................ 11,93

Variable Displacement Pump Energy-Saving Machine ....... 47

Vertical Machining Centre ................................................... 63

Vibro Screen..................................................................... 27,73

Vinyl Technologies ................................................................ 75

Volometric Dosing Unit ........................................................ 57

Water Cooled Chiller .................................................16

Water Jetting ......................................................................... 21

Water Chiller ........................................................................ 57

WFR .................................................................................. FIC

White Masterbatches ............................................................ 10

Wire EDM ........................................................................... 79

Wireless ................................................................................. 87

Wireless I/O Junction Box ................................................... 87

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


ACS Auxiliaries India Pvt Ltd ...................... 18

T: +91-02135 - 329112

E: [email protected]

W: www.aecinternet.com

Adinath Controls Pvt Ltd ............................124

T: +91-2764-286573


W: www.adinathcontrols.com

Aerodry Plastics Automation Pvt Ltd .............. 6

T: +91-120 4766777


W: www.aerodry.com

All India Plastics Mfrs Association ..............102

T: +91-22-28217324


W: www.plastivision.org

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

T: +91-011-41612244


W: www.alokmasterbatches.com

Boge Compressed Air Systems Pvt Ltd ...... BIC

T: +91-44-43593453


W: www.boge.in

Bry Air (Asia) Pvt Ltd .................................. 33

T: +91-011-2390677


W: www.bryairsystems.com

C & G Extrusion Machines .......................... 69

T: +91-9272235867


W: www.cgext.com

Continental Carbon India Ltd .....................121

T: +91-120-6721200


W: www.continentalcarbonindia.com

Engineering Expo ........................................131

T: +91-09819552270


W: www.engg-expo.com

Everest Blower Systems .......................... 11, 93

T: +91-11-45457777


W: www.everestblowers.com

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

T: +91-79-25890081


W: www.milacronindia.com

Freeze Tech Equipments Pvt Ltd .................127

T: +91-044-42152387


W: www.freezetechequip.com

Gardner Denver Engineered Pro. (I) ............. 21

T: +91-79-40089312


W: www.gardnerdenver.com

Gem Equipments Ltd ................................... 45

T: +91-0422-2363800


W: www.gemindia.com

Glaves Innovations Pvt Ltd .......................... 83

T: +91-141-2460324,

E: [email protected], [email protected]

W: www.glaves.biz

Hindustan Plastic and

Machine Corporation ........................... Booklet

T: +91-011-25473361


W: www.hindustanplastics.com

Indo-Tech Engineers .................................... 29

T: +91-79-22870368


W: www.indotechengineers.com

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

T: +91-2646-222163


W: www.jpextrusiontech.com

Jacobsen Lenticular Tool & Cylinder Engraving

Technology Co., ( Jaco Tech) ........................126

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.................... 63

T: +91-2827-287081


W: www.jyoti.co.in

Karan Engineering Co. ................................. 37

T: +91-022-40214997


W: www.karanengineers.com

Katlax Enterprises Pvt Ltd ............................ 87

T: +91-9328197614


W: www.katlax.com

Konark Plastomech Pvt Ltd .......................... 53

T: +91-79-22891670


W: www.konarkplastomech.com

Larsen & Toubro .......................................... 35

T: +91-022-67525733


W: www.lntebg.com

Leuze Electronic .......................................... 95

T: +91-80-40854444


W: www.leuze.in

Matsui Technologies India Ltd. .................... 85

T: +91-0120-4243862


W: www.mifasystems.com

Mifa Systems ...............................................123

T: +91-79-26870825


W: www.mifasystems.com

N.A. Corporation ......................................... 73

T: +91-79-25840374


W: www.naroto.com

Neejtech India (Braunform) .......................... 25

T: +91-79-26561312


W: www.neejtech.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


Neejtech India (Niigata) ............................... 17

T: +91-9909974224


W: www.niigataindia.com

NMTG Mechtrans Techniques Pvt Ltd. ......124

T: +91-79-22821527


W: www.nmtgindia.com

Nordson X-Aloy Asia (Thailand) Ltd. ..........138

T: +91-79-40327380


W: www.xaloy.com

Norka Instruments Shanghai Co., Ltd. ........126

T: 86-21-6118-4181

E: [email protected];

W: www.norka.com.cn

Nu-Vu Conair Pvt. Ltd ................................137

T: +91-9376783206


W: www.conairgroup.com

Piovan India Pvt Ltd .................................... 57

T: +91-22-27782367


W: www.piovan.com

Plastiblends India Ltd .................................. 10

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 ......101, 105, 107, BGF

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

Reynold India Pvt Ltd .................................. 16

T: +91-0120-4664000


W: www.reynoldindia.com

S&T Engineers ............................................ 79

T: +91-422-2590810


W: www.stengineers.com

Sacmi Engineering India Pvt Ltd .................133

T: +91-7600003968


W: www.negribossi.com

SCJ Plastics Ltd ........................................... 59

T: +91-011-25439950


W: www.scjindia.com

Shini Plastics Technologies I Pvt Ltd ............ 77

T: +91-250-3021166


W: www.shini.com

Shri Ram Polytech ....................................... 75

T: +91-011-23316801


W: www.shrirampolytech.com

Specific Engineering .................................... 20

T: +91-265-2646871


W: www.specificgroup.com

Sri Sai Plasto Tech ....................................... 47

T: +91-044-42994365


W: www.srisaiplastotech.com

SS Packaging Industries ............................... 51

T: +91-011-45072942


W: www.sspackaginggroup.com

Steer Engineering Pvt Ltd ............................ 61

T: +91-80-23723309


W: www.steerworld.com

Swam Pneumatics Pvt Ltd ............................ 31

T: +91-0120-4696222


W: www.swamatics.com

Toshiba Machine (Chennai) Pvt.Ltd. ........ FGF

T: +91-044-26812000


W: www.toshiba-machine.co.in

Trident Pneumatic Pvt Ltd ..........................125

T: +91-422-2400492


W: www.tridentpneumatics.com

UWT Level Control India Pvt Ltd ............... 19

T: +91-124-412-1684


W: www.uwt-india.com ......................

Windsor Machines Limited .......................... 89

T: +91-79-25841591


W: www.windsormachines.com

Witte Pumps & Technologies ....................... 49

T: +91-11-41613643


W: www.witte-pumps.de

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

T: +91-044-42077009


W: www.wittmann-group.com

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

T: +91-9810043265

E: [email protected]; [email protected]

W: www.plaimm.com

Yann Bang Electrical Machinery Co.,Ltd. ..... 67

T: +91-886-4-2271-6999


W: www.yannbang.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

Mod

ern

Pla

stics & P

olym

ers

Jun

e 2

013

Reg No: MH/MR/WEST/234/2012-2014 RNI No: MAHENG / 2008 / 25265 Licence to Post at Mumbai Patrika Channel Sorting Offi ce, Mumbai GPO., Mumbai 400 001.

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

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