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9April 2013 | Modern Plastics & Polymers
t first, the Union Budget 2013-14 appears to have treaded rather
cautiously by focussing mostly on fiscal fitness. To begin with, the
Budget emphasised two specific areas – infrastructure development and
Micro, Small and Medium Enterprises (MSMEs) – as the key to fuel
the growth of the Indian economy.
The Finance Minister’s proposal for payment of ` 9,000 crore as the first
instalment of the balance of Central Sales Tax (CST) compensation is a step in
the right direction. Although full-fledged implementation of the Goods and Services
Tax (GST) is still months away, the Budget recommendation to extend MSME
benefits for a period of three years after moving to a higher category is well timed
and meets the need of the hour. This should also motivate home-grown emerging
enterprises to take the next big leap in their growth trajectory.
The exemption of 15 per cent in investments of more than
` 100 crore to set up plant and machinery should further galvanise
industrial activity in the country. In addition, the commitment to
increase availability of low-cost funds to the infrastructure sector
augurs well for higher investments.
Furthermore, the Budget discussed the National Skill Development
Programme and a ` 200-crore outlay to fund ‘technology for
common man’. Both of these are essential to expand the
country’s growth by keeping in mind employment and the
abundance of educated youth and their aspirations. Other
noteworthy initiatives in this Budget include measures to
increase investments in manufacturing and infrastructure,
MSME growth and capital market development. These
initiatives should also benefit the plastics industry either
directly or indirectly.
Although this Budget lacks the fireworks of its previous
editions, its proposals can be considered as the best possible step
by the government in the current complex geo-political climate.
Perhaps the government missed an opportunity in this Budget to
give a greater thrust to various financial policies. However, only
effective implementation of this statement of the government’s
action plan would bring results in the current fiscal.
All said and done, at a time when the whole world is looking at
emerging nations like India to propel the global economic engine, it
is imperative for the government to ensure that policy announcements
stay on track. The industry, on the other hand, needs to leverage
the advantages offered in this Budget to take the India success story
a notch higher.
ABudget 2013-14: Financially sound reverberations?
Editorial Advisory BoardA E Ladhabhoy
Plastics Technologist
Dr Sushil K VermaFormer Director General, CIPET
Dr Swapan K DharaRegional Technical Head,
Basell Polyolefins India Pvt Ltd
Mohan K JainMD, Indoplast & Past President, AIPMA
P P KharasChairman, Ecoplast
Raman M PatelChairman, Industrial Products Mfg Co
Vijay MerchantPresident, Polycraft
Manas R [email protected]
EDITORIAL
11April 2013 | Modern Plastics & Polymers
CONTENTS
April 2013 | Modern Plastics & PolymersApril 2012 | Modern Plastics & Polymers
Note: ` stands for Indian rupee, $ stands for US dollar and £ stands for UK pound, unless mentioned otherwise
Automation Trends 78 Operator-friendly machines: Increasing production, reducing costs
Energy Management 80 Reducing energy consumption in plastics processing: Maximise output,
minimise consumption
Policies & Regulations 82 Green packaging norms: Reducing the carbon footprint
Strategy 84 Plastic packaging: Applications that enhance product shelf life
Tips & Tricks 86 Guidelines for efficient equipment: Ensuring safe and efficient processing
Event Report 92 Indo-German International Seminar: Redefining the future of
automotive plastics
94 Engineering Expo Aurangabad 2013: Exhibiting Aurangabad’s
unparallelled potential
96 Engineering Expo Aurangabad 2013 – Panel Discussion: Gauging
Aurangabad on the critical parameters
REGUL AR SECTIONSEditorial ................................. 9
News, Views & Analysis ...... 22
Technology & Innovation .... 30
Technology Transfer ............. 32
Projects ................................. 88
Tenders ................................. 89
39
Event List............................. 90
Book Review ........................ 97
Products................................ 98
List of Products.................. 106
List of Advertisers .............. 108
Injection moulding ................40
Innovative injection moulding ...42
Lightweight solutions for
automotives ...........................44
Interface:
Hitesh R Shah .............47
Praveen Sharma ............48
Roundtable ............................50
Special Focus
57Engineering thermoplastics ........................ 58
R&D initiatives ............................................ 60
Interface:
Dr Harindu Vyas ................................ 64
Satendra Kumar .................................. 66
Roundtable ................................................. 68
Filament wound composite pipes .............. 76
Green shoots .............................................. 69End-of-life applications of recycled plastics ......70Interface:
Vishal Jasrapuria ................................. 72
Dr Prakash Mahanwar ....................... 74
In Conversation With 36 Bipin Shah
President, Plastindia Foundation
Facility Visit 54 Toshiba Machine (Chennai) Pvt Ltd:
Creating exemplary manufacturing processes
Insight & OutlookEngineering plastics
Injection Moulding
Details on pg no. 90
Special Focus: Rotomoulding Insight & Outlook: Plastics in Building & Construction
Highlights of Next Edition
Cover photo courtesy: ARBURG
13April 2013 | Modern Plastics & Polymers
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Printed by Mohan Gajria and published by Lakshmi Narasimhan on behalf of Network18.Senior Editor: Manas R BastiaPrinted at Infomedia 18 Ltd, Plot no.3, Sector 7, off Sion-Panvel Road, Nerul, Navi Mumbai 400 706, and published at Network18, ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W), Mumbai - 400 028. Modern Plastics & Polymers is registered with the Registrar of Newspapers of India under No. MAHENG / 2008 / 25265. Network18 does not take any responsibility for loss or damage incurred or suffered by any subscriber of this magazine as a result of his/her accepting any invitation/offer published in this edition.
Business Insights •Technologies•Opportunities
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NEWS, VIEWS & ANALYSIS
22 Modern Plastics & Polymers | April 2013
SACMI to manufacture Negri Bossi machines in India Italy’s SACMI Group is setting
up a manufacturing plant in
India. The company has been
assembling Negri Bossi injection
moulding machines in a rented
space in Ahmedabad since 2009.
However, when it opens a new
plant at the beginning of 2014,
it will graduate from assembly to
local manufacturing. “India is a
huge market with about 3,500–
4,000 presses sold annually. We
could grow in this market locally
as well as in the neighbouring
(South Asia) market and also
in the Middle East,” said
Selvakumar M, Regional Sales
Manager, SACMI Engineering
(India) Pvt Ltd.
The company has already
supplied about 100 hydraulic
presses, with clamping forces
ranging from 550 to 1,000 tonne,
in the Indian market. This year
the company is starting to sell
the Vector Hybrid press line in
India, with a CAN bus controller.
The company is targeting sales of
70 presses in 2013.
Plastindia Foundation provides platform for WIINTECH
On March 4, 2013, Plastindia Foundation held an
interactive session with WIINTECH to boost the
growth of small and medium entrepreneurs in India.
WIINTECH – Worldwide Intercluster Initiative
for New materials and processes focused on clean
TECHnologies – links leading European world clusters
belonging to the chemicals and materials sector and
combines their expertise with the purpose to address
the complete range of technological and business topics
in the clean technology space. The delegation addressed
the dire need for technology development, innovation
and knowledge in the chemicals and materials sector
in India.
Speaking on the occasion, Bipin Shah, President,
Plastindia Foundation, said, “We have received an
overwhelming response from the industry. This is the
first exposure of Plastindia with WIINTECH and we
are certain that the industrial tie-up will evolve after
this fruitful day. Based on the network’s success stories,
we would like to build bridges based on this method,
approach and experience in the plastics industry.”
The network links eight European leading world-
class clusters belonging to the chemicals and materials
sector such as Poolnet (Portugal), Plastival (Spain),
Chemie-Cluster Bayern (Germany), Clusterland
(Austria), Plastipolis (France), Proplast (Italy), Veneto
Nanotech (Italy), NEPIC (UK) etc. There are more than
2,500 companies and research centres working in the
materials and clean technologies sectors.
With this initiative, Plastindia created a qualitative
and quantitative platform for SMEs to work together,
derive motivation and explore progressive technology
and mass volume production areas in the international
arena. WIINTECH aims to initiate opportunities for
business development between European clusters and
Indian partner organisations, which include setting
up research & development partnerships, encouraging
technology transfer and trade arrangements. The
network’s focus is on global expanding markets in clean
technology such as renewable energy, high-efficiency
building & construction, recycling, green transportation,
water & air treatment, waste management etc.
Sweta M Nair
Alok Masterbatches expands in India, plans for international growthAlok Masterbatches Ltd is setting up its fifth production facility in India.
The facility will cater to customers in southern India and Southeast
Asia. The plant, in the southern Indian city of Ranipet, will open in
April with an annual capacity of 20,000 metric tonne. The 60,000 sq
ft plant will produce a wide range of masterbatches. This region, which
has a growing auto industry, is a big market for compounds.
The plant will give the company an overall capacity of 60,000 metric
tonne annually. Alok has four plants in India, including two in Delhi,
plus a plant that opened in Paraguay last year. Alok is considering
additional international growth. The company plans to have a plant
either in the Middle East or in Vietnam in the next couple of years.
This is because Vietnam is also offering incentives to foreign investors
setting up plants to cater to the European market.
Aliaxis buys majority stake in Indian pipe maker Ashirvad Large global pipe maker Aliaxis
SA has bought a majority
stake in one of India’s largest
plastic pipe and fittings makers,
Ashirvad Pipes Pvt Ltd,
expanding its business in the
fast-growing Indian market.
“We are very pleased to acquire
a majority stake in one of the
leading Indian plastic pipe and
fittings players. The joint venture
will give Aliaxis significant
exposure to the Indian building
and sanitary market and will
allow Ashirvad to access Aliaxis
global manufacturing network,
know-how, product expertise and
broad product range,” said Yves
Mertens, CEO, Aliaxis Group.
With this joint venture,
Ashirvad will reach to the next
level in terms of range of quality
products and technologies.
Ashirvad has production capacity
of 70,000 metric tonne a year, with
more than 2,000 employees and
a network of 1,200 distributors
and 14,000 dealers. Ashirvad
mainly manufactures PVC pipes
and fittings in the building,
plumbing and agricultural
markets. It also develops PVC
column pipes that are used in
submersible boreholes to a depth of
1,000 ft.
Members of Plastindia Foundation along with representatives of WIINTECH
NEWS, VIEWS & ANALYSIS
24 Modern Plastics & Polymers | April 2013
PVC prices on a high in Southeast Asia due to soaring demand Price hikes for PVC have surfaced
this week in Southeast Asian countries
with many regional producers
adjusting their local and export offers.
Apart from the push from higher
input costs, the healthy demand
from the region has given sellers
real support to ask for increases. At
the same time, many buyers find
domestic prices more competitive
and prefer to meet their requirements
from local markets. In Indonesia,
local PVC prices have gone up by
$ 50–70 per tonne as compared to prices
prevalent in February.
Sumit Dhingra, Director, Dhingra
Polymers, said, “Now that demand is
improving and supply appears to remain
limited in line with the tight availability
of VCM feedstock, the PVC market is
likely to maintain its firm trend for a while.
Demand has improved in the local market,
and we are receiving more inquiries from
buyers.” The industry believes that this
price rise is due to strong local demand
and high feedstock costs which
have also caused tight supply. As it
was the case last month, producers
are allocating a limited amount for export
markets and are planning an increase
of $ 40 per tonne for PVC cargoes
with the April shipment. Meanwhile,
the same producers have revealed
their export PVC offers with
increases to the region, blaming high
feedstock costs.
Anwesh Koley
Plastic packaging to ride high on growth projectionsThe Associated
Chambers of
Commerce and
Industry of India
(ASSOCHAM)
has projected that
the market size
of the cosmetics
industry, which is
currently estimated
at ` 10,000 crore,
will double to be worth ` 20,000 crore by 2014 due
to emergence of a young urban elite population with
rising disposable incomes and increase in working
women looking for lifestyle-oriented and luxury
products. This is expected to boost the cosmetics
packaging industry as the primary cost of cosmetics
is packaging. D S Rawat, Secretary General,
ASSOCHAM, said, “Plastics companies have started
going for rural expansion and are offering specialised
products to generate revenues from all the corners of
the country. This will give momentum to cosmetics
packaging which is almost 70 per cent of the price of a
cosmetic product and has become highly evolved over
the years.”
Products falling under the price range ` 50–200
are in the mass-market category. The middle market
price can range from ` 200 to ` 1,000. In the
high-end market, pricing can range from ` 1,000
to about ` 10,000. Finally, there is the premium
range of products where the pricing can touch up
to ` 50,000. The industry has mainly been driven
by improved purchasing power and rising fashion
consciousness among people as well as industry
players spending heavily on promotional activities
to increase consumer awareness.
Anwesh Koley
O ver 180 professionals
representing 90 plus companies
across India were part of the
Open House organised by Rajoo
and Bausano. At this event,
there were live demonstrations
of a range of machines that
redefine manufacturing of
h igh-per formance p ipes .
The company stated, “As
expected, the star performer of
the show was the Twin Screw
PVC Pipe Plant running at
130 kg/hr (pipe outer diameter
of 28.6 mm; pipe thickness of
2.12 mm). Most visitors have
not been an eyewitness to such a
spectacle – a working PVC Pipe
Plant that too which started
from scratch in just under 5
minutes with less than 4 kg
scrap. Further, Rajoo successfully
showcased its indigenous raw
material compound for the
PVC machine. With this, Rajoo
became the first Indian company
to successfully demonstrate
a PVC pipe machine at an
Open House.”
Further, the Twin Screw
PVC Pipe Plant enthralled the
audience when it was being
operated at a capacity of 1,000
kg/hr, never before seen in India.
The pipe OD is 400 mm and
wall thickness is 16.2 mm. With
this Open House, Rajoo also
marked its strong penetration
into the market of drip irrigation
pipe plants. The demonstrated
line was running at 170 kg/hr
with a line speed of 80 mpm,
200 dripper insertions/min, with
the wall thickness being 0.7 mm.
The success of this pioneering
initiative emphasises the
company’s belief in innovation –
be it in product, in technology or,
as in this case, in approach.
Avani Jain
D S Rawat
Pipe manufacturers converge at India’s first-ever multi-product Open House of Rajoo
NEWS, VIEWS & ANALYSIS
26 Modern Plastics & Polymers | April 2013
Vinyl India 2013 to be held in Mumbai With strong stimulus given to
infrastructure, agriculture and housing,
and India’s gross domestic product
growth of over 7–8 per cent in medium
to long term, the vinyl industry in
India is poised to double every five
years. Providing a further impetus and
adding to this growth, Vinyl India
2013, which is the 3rd International
PVC & Chlor-Alkali Conference,
is being organised by ElitePlus
Business Services Pvt Ltd (EPBS)
and Chemicals & Petrochemicals
Manufacturers’ Association (CPMA),
All India Plastics Manufacturers’
Association (AIPMA) and Plastindia
Foundation.
The two-day conference covering
the entire vinyl chain will be held
on April 11–12, 2013, at Hotel
Grand Hyatt, Mumbai. Over 25
countries are expected to participate
in this international event. The event
will bring together industry leaders
and specialists to examine the fast-
growing Indian vinyl industry. It
will feature many important sessions
focussing on the global scenario, the
future of polyvinyl chloride in India,
feedstock to polymer, machinery –
compounding, processing & material
handling, recent developments on the
new generation of polyvinyl chloride
compounds and more. The conference
is expected to attract nearly 600
industry experts and players (Indian
and overseas) from the vinyl industry,
including raw material providers,
compounders, channel partners of
domestic resin manufacturers, traders
and indentors, additives/plasticisers/
stabilisers suppliers, downstream
processors (pipes, calendaring, profiles,
fittings, blow moulding) machinery
suppliers, analysts, consultants and
senior managers, logistics and shipping
companies, members from associations
and trade bodies (eg CAMA,OPPI,
IPI, MCCIA), international bodies
and council members.
Avani Jain
AIPMA organises first-ever job fair in MumbaiThe All India Plastics Manufacturers’
Association (AIPMA) recently
conducted a job fair in Mumbai, a first
of its kind by any polymer association
in India. The objective was to serve the
industry in the manpower arena with a
non-commercial, service-oriented and
cost-effective model.
The first edition saw the presence of
Dr Ashutosh Gor, President, AIPMA,
and Hiten Bheda, Secretary, AIPMA. Dr
Gor spoke on the future of the industry,
while Jayesh Rambhia, Chairman
Plastivision Arabia, AIPMA, addressed
the audience about the upcoming
events of the Association. Heads of
institutions (eg MIT Pune, MIT
Aurangabad etc) graced the inauguration
ceremony. Support for this event was
also extended from Central Institute of
Plastics Engineering and Technology
(CIPET), L D College of Engineering
(Ahmedabad) and others.
The job fair had 14 visiting employer
companies participating from segments
such as raw materials, compounds/
additives, injection moulding, blow
moulding, rotomoulding, extrusion
(pipe & blown film) and machinery.
Companies such as Finolex Pipes, Borghi
Brush Machinery (Italy), Plasticon
UK, Bajaj Steel Industries, Kuloday
Technopack and others participated as
visiting employers. The fair floated 80
job openings, of which 90 per cent job
openings demanded a working experience
of 2–15 years. AIPMA addressed the
job requirements and matched befitting
candidates with employers. At the event,
182 interviews were conducted and
17 candidates were selected for a second
round of interviews; some even received
spot offers.
Following the overwhelming response
of this event, AIPMA is likely to continue
having such job fairs frequently at various
locations across the country.
Dr Asutosh Gor, President, AIPMA, lighting the lamp with AIPMA members Kishore Sampat,
Chairman, Placement Cell and Harshad Desai, Chairman, Incubation Cell. Also present at the event were Jayesh Rambhia, Chairman,
Plastivision Arabia 2014, and Ashok Mukherjee, Managing Committee Member
Total launches thinner film for flexible packaging Flexible plastic packaging converters will
be able to reduce film width by up to
25 per cent thanks to a new metallocene
polyethylene film material, developed by
Total. The Lumicene Supertough 32ST05
is a downgauging breakthrough for
multi-layer structures and can be used in
compression packaging, such as for heavy
mattresses and lightweight diapers. It can
also be used for deepfreeze and lamination
films, and highly demanding shrink
applications, eg glass bottle unitisation.
“The downgauging story is a never-
ending quest to push the thickness limits
of packaging down. Where these limits
of downgauging are reached, Supertough
32ST05 steps in to give the necessary boost
in toughness to overcome the thickness
barrier,” said Carl Van Camp, Senior VP
– Polymers Division. The material can
be used to make films on extrusion or
conversion lines.
NEWS, VIEWS & ANALYSIS
28 Modern Plastics & Polymers | April 2013
Global rigid plastic packaging market worth $ 161.11 billion in 2013
Driven by growth in emerging markets, a
new report by Visiongain estimates that
the global rigid plastic packaging market
will reach a value of $ 161.11 billion in
2013 and will be driven by growth in
the developing markets, in addition to a
number of favourable consumer trends.
According to the report Global Rigid
Plastic Packaging Market 2013–2023,
“Emerging markets will be characterised
by clear maturity and strong economic
growth, which will increase the quality
and quantity of consumer purchases. In
addition, low labour costs will provide an
incentive for companies to expand the
scale of their operations in these markets.”
To this, Divakar Vyas, Senior Manager
(Sales), Windsor Machines Ltd (Injection
Moulding Division), added, “The rigid
packaging industry in India is growing
at the rate of 16–20 per cent per annum.
The growth in this sector is mainly driven
by food, pharmaceuticals etc. At present,
the focus in the segment is to provide
lightweight and recyclable solutions.”
Avani Jain
Oriental Energy to build the first UNIPOL Polypropylene (PP) unit in East ChinaOriental Energy has signed a license
with Union Carbide Chemicals &
Plastics Technology LLC, a wholly
owned subsidiary of The Dow
Chemical Company, for UNIPOL™
PP Process Technology for a 400 KTA
PP plant. The plant will produce
homopolymers, impact copolymers and
random copolymers using propylene
sourced from their upstream propane
dehydrogenation unit.
Speaking about this development,
Tracy Cleckler, Global Commercial
Director, Dow Plastics Licensing &
Catalysts, said, “With UNIPOL PP
Process Technology, Oriental Energy
will produce PP resins that will give
fabricators the opportunity to produce
PP products that are lighter, clearer
and cleaner, properties PP customers
are always seeking. Oriental Energy
will also be able to make PP resins
that allow fabricators to run their lines
at a faster rate, benefitting from the
higher melt flow capability of some of
the UNIPOL product grades.”
The plant located in Zhangjiagang
in Jiangsu province will be the first
Dow UNIPOL PP unit in the East
China coastal area, the centre of the
Chinese PP market. There are currently
48 operating lines worldwide using
UNIPOL PP Process Technology from
Dow Performance Plastics Licensing
and Catalysts. The UNIPOL PP Process
Technology is an all gas-phase process
for producing the broadest range of PP
resins. Its simple design is consistent
in terms of product quality and energy
efficiency, requiring no equipment
for handling, separating or recycling
solvents. The system’s fluidised-
bed reactors and high-performance
CONSISTA™ and SHAC™ catalyst
systems give manufacturers the
flexibility to produce homopolymers,
random copolymers and impact
copolymers.
Four distinguished individuals who have
made outstanding contributions to the
plastics industry will be honoured by the
Society of Plastics Engineers (SPE) at
next month’s SPE ANTEC® 2013.
The International Award, Business
Management Award, Education Award
and Research/Engineering Technology
Award will be presented to the four
individuals as part of the Society’s
Annual Awards Program at the SPE
Celebrates Banquet on April 21, 2013.
Benny Freeman, the Richard B
Curran Centennial Chair in Chemical
Engineering at The University of
Texas at Austin, will receive SPE’s
International Award, its top honour
that recognises lifetime achievement
in the plastics industry. The Business
Management Award will be presented
to Tim G Taylor for his achievements
in management with Chevron Phillips
Chemical Company. Honouring
academic excellence, Dr Robert
Y Lochhead who is the author of 300
scientific papers and 22 patents, some
for polymers that are used extensively
in topical delivery of therapeutics
and in cosmetics, will be presented
with the Education Award. In a
plastics career of more than 36 years,
Dr Robert R Gallucci, Chief Scientist,
SABIC Innovative Plastics at Mount
Vernon, Indiana, has developed many
new thermoplastic products, often
using extruder chemistry and polymer
blend compatibilisation. Recognising
his contribution in this field, he will
be presented with the Research/
Engineering Technology Award.
The upcoming Annual Awards
Program will take place on April 22–24
at the Duke Energy Convention Center
in Cincinnati, Ohio, USA.
SPE to honour achievements of industry leaders at ANTEC® 2013
Benny Freeman Tim G Taylor Dr Robert R Gallucci Dr Robert Y Lochhead
TECHNOLOGY & INNOVATION
30 Modern Plastics & Polymers | April 2013
New VacuTran breaks parts-per-million WVTR measurement barrier
The launch of VG Scientia’s new
VacuTran enables Water Vapour
Transmission Rate (WVTR)
measurement of barrier layers to
better than 10–6 g/m2/day and
simultaneous O2 permeation to
better than 10–3 cm3/m2/day. The
new VacuTran is an innovative,
time-saving, vacuum-enabled
membrane permeation measurement instrument that heralds
the next generation of ultra-sensitive membrane transmission
measurement by advancing detection levels by a factor of 50–100
compared with the one-part-in-ten-thousand measurement
capability of the current generation of instruments. The advances
in time-saving performance and higher sensitivity are significant,
with this breakthrough instrument featuring not only a first in
WVTR measurement that exceeds the specification requirements
but also the welcome reduction in results turnaround to days
rather than weeks or months.
VacuTran is a step change in order of magnitude for developers
and manufacturers involved in ultra-high barrier layer research
because until now there has been no commercially available
instrument that can measure WVTR to these very low levels or
measure WVTR and oxygen transmission rate simultaneously.
This is of particular relevance to organic light emitting displays,
organic photovoltaic devices and organic field effect transistor
device markets in the plastic electronics industry.
New NCF series super-tangential granulators from Conair require less floor space, deliver more versatility New NCF series super-tangential
granulators from Conair have
footprint dimensions that are at
least 30 per cent smaller than many
other granulators with similar
capabilities. The cutting chamber
configuration is ideal for handling
lightweight bulky parts (eg bottles)
and produces clean uniform
granulate from runners and small
parts. Different hopper designs and rotor/knife choices are
available to maximise performance with a wide variety of scrap
types. Four different models feature 8-inch (203-mm) diameter
rotors in widths of 10, 14, 19 and 24 inch (240, 360, 480 and
600 mm) and deliver standard maximum throughputs ranging
from 68 to 205 kg. The smallest unit is powered by a 5-hp
motor, and the three larger sizes have 7.5-hp motors with
options up to 15 hp. Standard rotor speed for the NCF 810 is
260 rpm, and standard speed on the larger models is 400 rpm,
although rpm of 260, 400 or 840 can be specified on any of the
granulators to increase capacity, improve regrind quality and/or
minimise energy consumption.
A tilt-back hopper and drop-down screen cradle provide
easy access to the cutting chamber for maintenance and
cleaning. These features contribute to increased productivity
and reduced downtime. An optional sound attenuation package
also makes the NCF series quieter than other small granulators.
The super-tangential chamber design ensures that the rotor
grips bulky scrap on the downward stroke, drawing the scrap
into the knives and preventing it from bouncing on the rotor.
Standard tangential and straight-drop in-feed configurations
are also available. The rotor itself can be open with three rows
of double-angled knives for a clean scissors cut with minimum
heat generation. For tougher materials, a solid rotor can be
equipped with three rows of up to five cassette knives in a
staggered array. Cassette knives allow for quick and easy knife
changes and minimise downtime for service and maintenance.
The knives require no adjusting to maintain a consistent knife
gap for improved quality.
All new Anchor Culinary Classics® Convertible Containers
Anchor Packaging has launched
a new Culinary Classics® line,
which is now available with a
removable, perforated, hinged
lid. Available in 9” × 9” and 9.5”
× 10.5”, with either one or three
compartments, the six containers
that comprise this product line can handle temperatures up to
230°F; they can be staged under heat lamps or in warming units
and are microwavable. All products in the Culinary Classics®
line are made of Polypropylene (#5PP) and are microwave-and
dishwasher-safe as well as reusable and recyclable. All Anchor
products are BPA-free.
To preserve food texture and quality, the unique design of
the plastic packaging system retains internal temperature while
venting excess steam. The new Culinary Classics® Convertible
Containers feature a cut-proof base, and the removable,
hinged lid offers consumers a convenient dining experience.
With an interlocking base and lid, the containers have good
structural strength that makes them easy to stack and safe for
transportation.
Improved conductive foam from Sekisui Alveo Switzerland-based maker of polyolefin foams, Sekisui Alveo,
has developed an improved version of its Alveobloc conductive
foam, Alveobloc NACO III. Made from laminated foam sheets,
Alveobloc has a uniform closed-cell structure to absorb impact
or pressure. It discharges electrical current and static charges
generated during manufacture and transport, making it suitable
for the transportation and protection of electronic components
that are sensitive to electrostatic discharge. The manufacturer
claims that the conductivity of Alveobloc remains constant,
regardless of relative humidity, unlike competitive foams.
TECHNOLOGY & INNOVATION
31April 2013 | Modern Plastics & Polymers
New range of environmentally improved films Amcor Flexibles has launched Amcor
Light, a completely new range of
environmentally improved films for fresh
and dairy applications that offer optimum
weight while retaining perfect visual
appearance and sealing integrity. Amcor
Light reduces packaging weight and its
cradle-to-gate carbon footprint is lower
by up to one-third compared to standard
films. Thanks to the high level of film
clarity and the same functional properties
as Polyethylene (PE)-based films, it
satisfies customers’ needs for improving
their environmental credentials and at the
same time guarantees on-shelf appeal.
The Amcor Light range offers solutions
for flowpack as well as for lidding
applications. The main families are OPA
Light (replacing the traditional OPA/PE
films) and OPET Light (replacing the
OPET/PE family of films).
Hasco introduces flexible mould temperature control lineHasco Hasenclever GmbH & Co KG has
introduced a flexible mould temperature control
line. It reduces pressure loss because there are
no sharp angles. TempFlex products cool quicker
than conventional channels embedded in the
mould because the flexible lines are made of
braided stainless steel hose with quadratic cross
sections and change direction through arcs
rather than abrupt corners. Further, the lines are
simple to assemble and adaptable to the desired
groove process.
According to the company, deflecting the
coolant in the new lines through 10 arcs rather
than through 10 conventional 90° deflections
results in 300 per cent less pressure loss. TempFlex
is available in metric and imperial measurements.
These lines can be retrofitted onto existing moulds
plagued by insufficient cooling performance.
Engel unveils largest robot in its classEngel, the Austrian injection moulding machine maker, has
unveiled a new linear robot with a nominal load-bearing capacity
of 120 kg, which the manufacturer claims is the biggest in its
class. The latest member of the
Viper range, the Viper 120 can be
ordered in conjunction with Engel
injection moulding machines as
well as a replacement for existing
equipment or for use with injection
moulding machines by rival brands.
The Engel Viper 120 has a
mould take-off stroke of 3,000 mm
and a reach of 3,550 mm. The use
of laser-welded steel sections has
kept the dead weight of the robots
low, enabling the load-bearing capacity to be raised. The robot
can be fully integrated with Engel injection moulding machines
or can be supplied with an independent control unit that allows
it to work with other machines via a Euromap 67 interface.
Koch extends dosing system range Koch-Technik, the Germany-based
ancillaries maker, has introduced two
new models of its gravimetric Graviko
dosing system. The Graviko machines
dose individual components, such as
grains, powder, ground material or coarse
powders, into the weighing container
using a slider or by volume. Quantities
can be dosed with an accuracy of
0.001 s. Precision dosing coupled with
a gravimetric weighing system produces a control circuit to
ensure that dosing is carried out correctly regardless of bulk
materials used. The patented system offers accuracy with a
tolerance of ±4 grains per 1,000, a level the company claims is
better than any conventional dosing system.
The GK 65 is for machine throughputs of up to 80 kg/
hr. The GK 200 is for machine throughputs of up to 250 kg/
hr. Both are suitable for four dosing stations. Depending on
the throughput of the processing machine, up to four different
components can be processed.
Blow moulding ‘Stanyl’ grade introduced for automotive air ducts
DSM has introduced Stanyl®
Diablo OCD 2305 BM, a
high-temperature Polyamide (PA)
developed for blow-moulded
ducts for use in automotive
applications. The company said
air ducts made of the material are
lighter than parts made of metal or
Polyphenylene Sulphide (PPS) and
can handle continuous temperatures
up to 230°C.
T h e m a t e r i a l
is a heat-stabilised
blow moulding grade
of ‘Stanyl’ PA 4.6,
developed specifically
for hot charge air
ducts. DSM claims
that it is the first high-
temperature PA suitable
for processing by extrusion-blow
moulding and offers significant
cost benefit compared to PPS due
to its lower weight and scrap rate.
Part weights can be reduced by 7
per cent, thanks to improved wall
thickness distribution.
TECHNOLOGY TRANSFER
32 Modern Plastics & Polymers | April 2013
Technology Offered
Biodegradable polymersA company offers biopolymer nanoparticle technology
based on cost-effective biodegradable & biocompatible
polyolefins, copolymer of ethylene & vinyl acetate and
thermoplastic starch blend nanocomposites. These
nanocomposites have improved mechanical properties with zero
moisture content.
Areas of applicationPackaging materials, disposable non-wovens, hygiene products,
consumer goods, agricultural & horticultural tools and medical
instruments
Forms of transferTechnology licensing
Conversion of batch-poly plant to C P plantA company from China is interested in providing consultancy
services for the modification of batch-poly plant to C P plant such
as polyester plant, polyester chip or direct spinning.
Areas of applicationChemical fibres and plastics
Forms of transferTurnkey
New and rebuilt screw and barrels for all-plastic extrudersAn India-based company is manufacturing screw and barrels for
all-plastic extruders and is efficiently rebuilding worn out screws.
It is making an energy-efficient washing and drying plant for
all-plastic waste. It employs the most cost-effective and efficient
washing and drying units for plastic scrap.
Areas of applicationPlastics manufacturers and plastic waste recycling unit
Forms of transferEquipment supply and turnkey
Information courtesy: Information courtesy: Dr Krishnan S Raghavan, In-Charge, Technology Transfer Services Group, Asian and Pacifi c Centre for Transfer of Technology (APCTT) of United Nations Economic and Social Commission for Asia and the Pacifi c (UNESCAP), APCTT Building, C-2, Qutab Institutional Area, New Delhi 110 016, Tel: 011-3097 3758 (Direct), 011-3097 3710 (Board), Fax: 011 - 2685 6274, Email: [email protected], Website: www.apctt.org
For more information on technology offers and requests, please log on to www.technology4sme.net and register with your contact details. This is a free of cost platform provided by APCTT for facilitating interaction between buyers and seekers of technologies across the globe. After submitting technology offer or request to this website, you are requested to wait for at least two weeks for receiving a response from a prospective buyer/seeker through this website, before contacting APCTT for further assistance.
As part of our endeavour to spread the technology culture, this section provides a means to promote and facilitate exchange of select technologies. We strive to bring together suppliers of such technologies with suitable users for negotiations and industrial collaboration.
Disposal and recycling of plastic wasteA Polish company seeks the technology for dry
processing of all kinds of plastic wastes or a magnetic
processing method in the electrostatic field. The technology
should allow sorting of all kinds of plastic materials,
(PET, HDPE, PVC), hay-silage foils, etc by excluding
dangerous waste.
Areas of applicationPlastics industry, waste recycling, waste management
Forms of transferOthers
Laboratory-scale non-woven and monofilament plantAn Indian company is looking for a laboratory-scale, non-
woven and monofilament plant in a single station.
Areas of applicationPlastics
Forms of transferOthers
Polyethylene Terephthalate (PET) polyolsA trading-based company plans to manufacture PET
polyster polyols. The small-scale project will involve
procuring recycled PET flakes locally. Land available for
manufacturing is 28,000 sq ft.
Areas of applicationPolyols
Forms of transferOthers
Share and Solicit TechnologyThe mission of Modern Plastics & Polymers is to spread the technology culture. Here
is an opportunity to be a part of this endeavour by sending your technology on offer or technology requirements. If you belong to any of these two categories, you are invited to furnish the techno-commercial details for publication. The write-up needs to be as
per the format of this section with information about the particular technology offered or requested, its areas of application and forms of transfer.
Contact: Modern Plastics & PolymersNetwork18 Media & Investments Ltd, ‘A’ Wing, Ruby House,
J K Sawant Marg, Dadar (W) Mumbai 400 028. Tel: 022-3003 4671 • Fax: 022-3003 4499
• Email: [email protected]
Technology Requested
IN CONVERSATION WITH: B ip in Shah
36 Modern Plastics & Polymers | April 2013
…says Bipin Shah, President, Plastindia Foundation, when referring to the material that has become the fabric of life. At a time when international companies are making a beeline to enter the country, Shah talks to Sweta M Nair about the prevailing domestic conditions, potential development areas and his new role as the President of one of the country’s most revered plastics associations.
Drawing on your vast experience, how has the course of the Indian plastics industry changed?In all these years I have spent
in the industry, the growth of plastics
has been inevitable. Although it was
predicted twenty years ago that plastics
were not going to last due to scarcity
of oil, the scenario has changed due
to the discovery of alternative sources
of energy. The question now is about
which route we should take:
oil-based, gas-based, naptha-based
or biomass.
The current per capita consumption
of plastics is 4–6 kg in India, whereas it
is 42 kg in China and 62 kg in the US.
So comparing the rate of consumption
will not be ideal in this situation. Within
the country, we need to focus on industry
segments such as building & construction,
“PLASTICS
LIFE”
WAYHAVE BECOME
AOF
Bipin Shah
37April 2013 | Modern Plastics & Polymers
water management, road construction,
telecommunications etc, where maximum
utilisation can take place.
Plastics have become a way of life,
and the key issue now is on energy-
efficient utilisation of plastics. During
a recent visit to Karad, we chanced
upon a prevalent phenomenon where
the women in a particular village travel
a distance of three kilometres everyday
just to fetch water. Imagine the relief
polyvinyl chloride pipes can bring
into their lives where their commute
will be cut and clean water will be
available just by turning on the tap! To
a certain extent, even the enormity of
waterborne diseases could be controlled
in such areas. Additionally, the hours
of manpower could be put into other
productive areas.
Another area that has changed
significantly is the usage of plastics
in consumer durables, followed by
automobiles, fertilisers, food packaging
and footwear soles. I believe plastics
in food packaging is growing at a
tremendous rate and will continue
to grow. I think this segment still
has untapped potential in increasing
the shelf life by ninety days. For that
matter, even plastic bottled water has
replaced the iconic water flask. To put it
in simple words, increase in disposable
income, constraints on time and the
convenience factor will influence the
course of plastics in the coming times.
With the change in trends, how have the priorities of Plastindia Foundation changed? Also, what is your agenda as the newly elected President?As President of Plastindia Foundation,
the road that I want to take is based on
knowledge-driven issues more than the
ones that are purely focussed on revenue.
It is knowledge that can empower
the industry. Here, I am referring to
practical knowledge more than mere
resource-based information. I emphasise
the former because although I graduated
with a distinction in engineering, I
lacked practical knowledge. Perhaps
this is an issue with most courses in the
country where importance is given to
theory. On the other hand, American
institutes are known for their cohesive
training programmes and hands-on
approach to problem solving. This
is one of the main reasons as to why
the Foundation has decided to start
the Plastindia International University
(PIU). In association with University of
Massachusetts Lowell (U-Mass Lowell)
and University of Wisconsin–Madison,
the PIU will be set up in Vapi, Gujarat,
where the state government has provided
35 acre of land. The undergraduate
engineering programme at the PIU will
incorporate all the components of the
curriculum that has made the U-Mass
Lowell Plastics Engineering programme
an international success. Over a period
of five years, we are going to invest
` 130 crore to create quality manpower
for the plastics industry. In addition,
we are going to focus on growth by
implementing the right technology;
hence, technology collaboration is
going to be another area. Among these
developments, we will continue to focus
our attention on environment-friendly
initiatives and programmes.
Since India is an agricultural economy, what efforts are being taken up by the Foundation with regard to agriculture?In Maharashtra, the number of suicides
of marginal farmers has become a serious
issue. They borrow but in most cases
are unable to pay off loans. Because the
agricultural sector is the backbone of the
country’s economy, this sector is of much
significance to us. Efficient utilisation of
plastics can help farmers get more yields.
One of our programmes includes offering
drip irrigation systems to farmers. With
timely inputs of water, fertilisers and
pesticides, production improved by 400
per cent. After proving successful, we
are now involving non-governmental
organisations so that farmers can benefit
from this system. Other than agriculture,
increasing the usage of plastics in public
infrastructure is also picking up pace.
What are your thoughts on the recent ban of plastic bags across various states in the nation?Plastic bags are banned in Delhi,
Chandigarh and Kerala. In Delhi, even
manufacturing of plastic bags is not
allowed. The authorities deem jute, cloth
or paper to be better options. By no way
are we in favour of plastic bags of less
than 40 micron, but bags that can be
recycled should be supported. Compared
to plastics, the deemed alternatives
require more energy for production.
Moreover, 60 per cent of a customer’s
buying is impulsive; I do not know how
many will find it convenient to always
carry with them an extra bag just in case
they decide to shop.
In the light of such events, what consumption rates do you predict?Our projected consumption of plastics
will be nothing less than 15 million
tonne by 2020. Hence, this opportunity
must be showcased to international
entities associated with the industry. The
question now remains on whether the
country can become a mass producer like
its competitor. Perhaps the organisation
of clusters will resolve this issue and put
an end to its fragmented nature.
As a veteran of the industry, what remains a challenge for you and the plastics industry?Commercialisation of innovation. I have
made more than 40 one-of-its-kind
products in my life. Commercialising
these innovations has been and remains
a challenge. In addition, this industry
lacks the presence of young blood. First-
generation entrepreneurs are not alluring
second-generation entrepreneurs into
the same business. This is a prevalent
problem. We need to set the right
examples so that the second generation
is encouraged to enter this field. Further,
getting manpower with practical
knowledge and problem-solving ability
has been a problem. With the PIU,
we hope to be able to do away with
this problem.
Email: [email protected]
39April 2013 | Modern Plastics & Polymers
SPECIAL FOCUS
Injection Moulding
39April 2012 | Modern Plastics & Polymers
Injection Moulding:
Igniting increased innovations................................................................................................................. 40
Innovative injection moulding:
Automation for perfection ....................................................................................................................... 42
Lightweight solutions for automotives:
Improving performance, design and safety ............................................................................................. 44
Interface:
Hitesh R Shah, Business Head – Injection Moulding Machines, Windsor Machines Ltd ................ 47
Praveen Sharma, Managing Director, Hinds Plastic Machines Pvt Ltd .........................................48
Roundtable:
Have Indian moulders been able to significantly improve efficiency in injection moulding? ............... 50
39April 2013 | Modern Plastics & Polymers
40 Modern Plastics & Polymers | April 2013
SPECIAL FOCUS: In ject ion moulding
INNOVATIONSINNOVATIONSINCREASED
IGNITINGIGNITING
The accessibility of plastics
has increased with the rising
number of industries using
plastics. This has bolstered the
demand of injection moulding machines
that is persistently setting up new highs year
over year, thanks to the increased ability of
Indian machinery suppliers in incorporating
better technologies available in the world
in their machines. The new technologies
that have gained a widespread acceptance in
all the segments are all-electric and micro-
injection moulding machines.
Micro innovations, big impactMicro-moulding relates to moulding a part
that is measured in micron. This process
has opened the door to manufacturing
tiny parts in a relatively easier manner
at a lower cost and at a higher speed.
This translates into increased profitability
through material conservation as less
resin is used to create more parts.
Amit Mahant, Director, PK Plastic
International Pvt Ltd, notes, “Micro-
moulding is a very specialised, precision
injection moulding technique geared
specifically to mould micro-miniature
electronic components. There are a number
of benefits that can be achieved by the
micro-injection moulding process while
moulding electronic components.”
Micro-moulding is designed specifically
for producing the smallest components,
typically with component weights below
0.25 g and less. The process has many
advantages, such as greater accuracy in the
finished part. As the process is designed
for smaller parts, a few mould cavities
are used in micro-moulding. Therefore,
accuracy and reliability achieved in micro-
moulding far exceed those achieved in
conventional moulding.
Cost–quality analysisIn moulding of electronic components
in particular, micro-moulding can offer
a range of cost-effective alternatives for
components that are miniature, complex
and require high precision tolerances.
Mahant notes, “The one big reason for
companies using this technology is cost
savings. This is because the amount of
time it takes to mould a component is
a fraction of what it takes to machine a
component. Also, these machines help cut
down the cost of part per piece.”
He adds, “Micro-moulding also
gives more freedom to designers to
introduce intricate features in products,
thereby enhancing their ability to create
more innovative products. Further, small
parts require high-speed automation to
maintain part consistency, which can
only be achieved by the micro-moulding
process. Micro-injection moulding is a
low-cost solution, it leads to dimensionally
stable production process with no particle
contamination and complex geometries
Injection moulding has been the preferred processing technology for part manufacturing that requires high output and accuracy. Thus, the increase in demand for all-electric and micro-injection moulding machines has given rise to new technologies and innovations in the segment. Avani Jain notes the cost–quality ratio of these two categories of injection moulding machines.
Courtesy: Davis-Standard, LLC
In ject ion moulding
41April 2013 | Modern Plastics & Polymers
Amit MahantDirector, PK Plastic International Pvt Ltd
The one big reason for companies using this technology is cost savings. This is because the amount of time it takes to mould a component is a fraction of what it takes to machine a component. Also, these machines help cut down the cost of part per piece.
Rohan Shrikant ShahaneRegional Director – South East Asia, Machine Point Consultants SL
It is believed that the all-electric injection moulding machines have the potential to reduce energy costs for a moulder by 30–60 per cent, depending on the moulding and the machine.
(eg radii) can be achieved through it. Also,
it makes use of alternate resins or fillers
to improve mechanical and/or electrical
properties and leads to better surface
finish.” Some other benefits include
reduced tool sizes, increased part accuracy,
improved cycle times, reduced part cost
and defined colours.
Mahant notes, “The usage of all-electric
and micro-injection moulding machines
for moulding electronic components can
also offer various benefits along with
precision and accuracy. They can lead to
energy savings up to 80 per cent and help
achieve accuracy with repeatability. In
the future, these machines can also make
use of the tie bar-less mould clamping
structure that can result in much larger
mould space and can be equivalent to the
wide platen style. This will also help in
accurate and stable clamping and lead to
equalised force on the mould. Further, the
machines can incorporate a mechanical
ejector with servo control to enhance
the efficiency of the machine.” Thus, due
to the various cost benefits offered by
micro-moulding solutions, their demand
in moulding small parts will continue to
increase in the future.
Electrifying the path of energy savingsIn addition to micro-injection moulding
machines, the demand for all-electric
injection moulding machines is increasing
these days as these help in saving energy
cost to a very large extent. Rohan Shrikant
Shahane, Regional Director – South
East Asia, Machine Point Consultants
SL, says, “The energy consumption in
different injection moulding machines
depend on how the drives are powered. A
conventional hydraulic machine uses one
or more pumps as a central unit to drive
the machine. Two of the most wasteful
aspects of a hydraulic machine are the
architecture of the system and the wasted
pump power when there is no demand.
However, all-electric injection moulding
machines reduce losses by using high-
speed servo motors to drive the injection
moulding process. In fact, it is believed
that the all-electric injection moulding
machines have the potential to reduce
energy costs for a moulder by 30–60
per cent, depending on the moulding
and the machine.”
Cost advantages without compromising on qualityAll-electric injection moulding machines
save on cost, primarily the energy cost
of the processors to a very large extent.
These moulding machines consume
electric power only when necessary.
This is because, to put it simply, all-
electric injection moulding machines
are much less mechanically complex.
They are driven by digitally controlled
servo motors that operate efficiently
and at high speeds. With fewer steps in
the process, less energy is lost. In fact,
these machines often consume less than
half the electrical power consumed by
hydraulic machines.
Shahane notes, “All-electric injection
moulding machines allow machine
movements to be integrated directly
with the control system. This greatly
improves machine set up, adjustment
and process control. Also, all-electric
injection moulding machines use less
water. Depending on the product, water
consumption can be reduced by up to 65
per cent. Moreover, there is a substantial
reduction in maintenance cost as the
electric machine eliminates the need for
hydraulic oil, thereby eliminating the
need to store, dispose, maintain and cool
the oil. Further, a shorter product cycle
makes it more productive than hydraulic
injection moulding machines. All-electric
injection moulding machines are more
accurate, precise and extremely good for
repetitive operations.”
In a nutshell, the all-electric injection
moulding machines can significantly
reduce energy consumption and
production cost in moulding. Hence,
these machines are increasingly becoming
popular and their demand will definitely
increase because of their energy efficiency,
greater cleanliness, quick start up, better
repeatability, quiet operations, easy
maintenance and, above all, the ability to
save production cost for processors.
Email: [email protected]
42 Modern Plastics & Polymers | April 2013
SPECIAL FOCUS: Innovat ive in ject ion moulding
The versatility offered by injection moulding in terms of design and high production output rates makes it the preferred choice in the plastics industry. Anwesh Koley analyses the current trend towards the advanced usage of robotics, which allows complete automation in the moulding process.
Higher output, lower cost
and energy efficiency have
become the key criteria
in the injection moulding
industry in India. In order to achieve
these, it is important to adopt the latest
technology through either process
optimisation or advanced automation.
Industry sources in India show that the
injection moulding market has grown at
average annual rates of 12–15 per cent
for the past eight years, outperforming
the overall economy, which grew roughly
at 6 per cent.
Industry projectionsIn India, about 60,000 injection
moulding machines are currently in
operation, serving a wide ambit of
sectors. Naveen Gupta, Senior Branch
Manager, Polymechplast Machines Ltd,
says, “Injection moulding machine sales
in India in 1990 stood at 2,500–3,000
per year, which today stands at about
8,000 machines a year.”
During 2010–11, across various plastics
processing machines, injection moulding
machines had acquired 70 per cent market
share, extrusion machines boasted of 23
per cent share, blow moulding machines
had 6 per cent of the pie and machines
for other techniques stood at 1 per cent.
Market projections show that by 2015–
16, almost 10,800 injection moulding
machines would be serving the plastics
processing industry across India.
Latest developmentsThe latest advancements in injection
moulding include servo motors for
energy-saving and all-electric machines
replacing hydraulic machines, which have
precise control and are useful for pharma
and automotive products. Harminder
Singh, AGM – Sales & Marketing,
Electronica Plastic Machines Ltd, says,
“Demand is increasing for packaging
that can be simultaneously labelled
during the injection moulding process.
This has resulted in the development of
well-packed in-mould labelling systems.
In addition to functional benefits,
this complex process offers potential
for cost reduction.”
Along with these, co-injection
and multi-colour injection moulding
techniques are used to create different
designs with a programmable logic
controller-operated system to achieve
repeatable design patterns with higher
output. The usage of robotics and
automation reduces manpower and
results in consistent output. “The
industry has benefitted from a variety
of innovations over the years. From
conventional technology to proportional
technology, production processes in
injection moulding have come a long
way,” says Gupta.
The latest technology used today in
the injection moulding industry is aimed
at developing energy-efficient and
automation-oriented final products. The
equipment within a moulding machine
are now designed to ensure that they are
digitally controlled, more precise, fast,
compact and easily compatible with the
machine controls. Also, manufacturers
are modernising their plants and
have equipped them with the latest
computer numerical control machines
AUTOMATION AUTOMATION FOR FOR
PERFECTIONPERFECTION
Courtesy: Cherry Electrical Products
43April 2013 | Modern Plastics & Polymers
Innovat ive in ject ion moulding
and other design-oriented software,
which helps in producing quality
products as well as in competing in the
international market.
“With the advent of servo control
technology, normal plastics processing
has become simpler, and engineering
plastics processing, which was earlier
considered a difficult process, has become
easier,” opines Singh. Metal injection
moulding and ceramic injection moulding
parts can now be found in all areas of
life, from automobiles to watches, from
dental braces to mobile phones, from
IT equipment to do-it-yourself tools
and many other areas.
How it worksThe injection unit is responsible for both
heating and injecting the material into
the mould. The first part of this unit is
the hopper, a large container into which
the raw plastic is poured. The hopper
has an open bottom, which allows the
material to feed into the barrel. The
barrel contains the mechanism for
heating and injecting the material into
the mould. This mechanism is usually
a ram injector or a reciprocating screw.
A ram injector forces the material
forward through a heated section
with a ram or plunger that is usually
hydraulically powered.
Higher output at lower costsAdvanced usage of robotics ensures that
output is higher, but total moulding cost is
low due to lower cost of the machine. All
principal modules – the clamping unit,
injection unit, drive, protective covers
and control system – are coordinated and
geared towards efficient production. Even
complex products are manufactured at
the highest reproducibility level. Multi-
cavity production reduces the number
of machines and manpower, with less
energy consumption by the servo drive,
and hot runner moulds lower cycle time
with zero wastage.
The usage of robots adds accuracy and
speed to the injection moulding process.
Injection moulding machines produce
the same results at the same speed every
time. “Robots are able to keep pace and
improve the efficiency of the entire
system with quick material handling, few
mistakes, if any, and effective palletising,”
adds Gupta. Industrial robots add
flexibility to the design of plastics. It
is used for all types and sizes of parts,
from tiny assembly components to large
automotive body pieces. Robots can be
quickly programmed to handle different
products. They can also easily tend to
more than one machine at a time. These
can also be programmed to palletise or
place parts on a conveyor.
Also, the usage of robotics creates
a safer work environment. “Typically,
workers are required to work in close
proximity to injection moulding machines,
reaching to remove parts and stack them
repeatedly. Those removing the parts
from an injection moulding machine are
prone to repetitive movement injuries.
With robots, human contact with the
injection moulding machine is minimised,”
says Singh.
Challenges facedThe primary challenge is the advent of
Chinese machines that are priced low.
Often customers do not understand the
importance of after-sales and service and
opt for Chinese machines. Visibility is
another area of concern. “Even with a
population of about one billion, India
remains essentially unknown to most
moulders from the US. In terms of
gross domestic product per head, India
lags behind almost all countries in Asia,
except Bangladesh,” laments Gupta.
Most moulders from the US have
either lost their business to Chinese
imports or considered relocating some
manufacturing to China. The problem
of low-cost inputs needs to be dealt with
urgency. While India exports bulk of
its products to African markets, China
remains the largest exporter to India.
Also, there is a need to increase the
level of automation within the injection
moulding industry, which would ensure
higher output, lower wastage and greater
energy efficiency.
Email: [email protected]
Naveen GuptaSenior Branch Manager, Polymechplast Machines Ltd
Robots are able to keep pace and improve the effi ciency of the entire system with quick material handling, few mistakes, if any, and effective palletising.
Harminder Singh AGM – Sales & Marketing, Electronica Plastic Machines Ltd
With the advent of servo control technology, normal plastics processing has become simpler, and engineering plastics processing, which was earlier considered a diffi cult process, has become easier.
44 Modern Plastics & Polymers | April 2013
SPECIAL FOCUS: L ightweight solut ions for automotives
From bumpers to door panels, lightweight plastics give cars better mileage and allow designers and engineers the freedom to create innovative concepts that otherwise would not be possible. Anwesh Koley explores the advantages offered by injection moulded plastics such as heat and chemical resistance, high impact strength and ease of moulding.
Cou
rtes
y: C
N M
ould
ing
Injection moulded parts constitute 70
per cent of the total processed plastics
market. From home appliances to
parts for automobiles, as well as the
construction industry, injection moulded
parts are found everywhere today. There
was a time when the automotive sector
was not in favour of using plastics for
parts. Gradually, the importance of plastic
parts grew as manufacturers understood
the importance of weight reduction, which
aids fuel efficiency. With the automobile
industry witnessing intense competition
over the years, plastics have been used
in strategic areas to provide durability
and enhance visual appeal of vehicles.
Engineering plastics provide strength due
to their inherent properties.
Conventionally, metal alloys were
synonymous with auto body exterior
design and manufacturing. However,
metal alloys are susceptible to dents,
dings, stone chips and corrosion. They
are also heavier and more expensive than
plastics. Ayush Lohia, CEO, Lohia Auto
Industries, says, “Choosing plastics for auto
body exterior parts allows manufacturers
to adopt modular assembly practices,
lower production costs, improve energy
management, achieve better dent resistance
and use advanced styling techniques for
sleeker, more aerodynamic exteriors.”
Evolution of injection moulding Moulding has a rich history in the plastics
industry. The moulding process was
invented only a few years after the invention
of plastics. Initially, hand moulding was
used. Moulders had a conventional screw
barrel setup, and external heating was
applied manually. Even the moulds were
opened and closed in a similar manner.
Gradually, as automation began, the
injection moulding machine as we know
today was developed with a circuit installed
in it to regulate the machine. “Hydraulic
systems were developed during the same
time. For many years, hydraulic machines
were used by a majority of companies. The
current generation of injection moulding
machines works on servo motors that save
electricity and thus saves cost,” adds Lohia.
Over the years, hydraulic machines
have been replaced with Programmable
Logic Controller (PLC) units. Ashwani
Aggarwal, President, Brose India
Automotive Systems Pvt Ltd, says,
“Injection moulding has always been a step
ahead in terms of operational versatility
than extrusion. With injection moulding,
all that is needed is changing the mould,
and one can achieve the desired design.
Today, PLC has become mandatory for
machines, and servo motors are also in
vogue as these consume less electricity.
Various safety features have also been
IMPROVING PERFORMANCE, DESIGN AND SAFETY
46 Modern Plastics & Polymers | April 2013
Lightweight solut ions for automotives
adopted in injection moulding machines,
which essentially regulate the opening and
closing of the mould cavity.”
Plastics in automotivesThe automotive market is an important
market for plastic resins such as
polypropylene, polyurethane, nylon, other
engineering polymers and thermoplastic
polyesters. “Light vehicle applications
account for over 30 per cent of the
demand for each resin. Other resins used
include acrylonitrile butadiene styrene and
polyvinyl butyral. Engineering polymers
such as nylon, polycarbonate and others are
supplanting metals in many applications,”
adds Aggarwal.
Typical plastics and composite
applications include exterior panels, trim
& bumper fascia, interior trim panels,
window encapsulation, headlamp housings,
manifold & valve covers, electronic/electric
parts & components, wiring harnesses,
steering wheels, insulation, dampers
& deadeners, upholstery, mechanical
parts & components and safety glass.
Most of these are processed through
injection moulding.
Design flexibilityNew processes enable manufacturers
to reuse scrap plastics and recycle used
plastics cost-effectively. Also, plastic
components weigh approximately 50 per
cent less than their steel counterparts.
This enables automobile components to
be substantially lighter, while retaining
the needed strength, and contributes to
an overall lighter vehicle with improved
mileage and less emissions.
Low-cost, single-unit production of
large automobile parts, such as a front
grille, is nearly impossible when using
metal. “Plastics offer auto engineers
a variety of practical, cost-effective
alternatives and tremendous advantages
over conventional automobile production
materials,” says Lohia.
Automotive safetyThe versatility of plastics allows design
options that produce lighter and safer
vehicles. From concept to reality, injection
moulded parts offer a wide variety of
advantages to customers. For example, a
driveshaft made from plastic composites
can help increase torque as well as
passenger safety. Conventionally made of
steel, a driveshaft transfers power from the
transmission to the rear axle of the vehicle.
If a steel driveshaft fails, it can project
shrapnel in all directions and even dig into
the ground, catapulting the vehicle into
the air. Composite driveshafts are made of
carbon and polymer fibre that is designed
to break into small fibre fragments or
‘broom’ upon failure, posing less danger.
Composite driveshafts are also lightweight
and require less energy to spin, effectively
increasing the amount of power that the
engine can transmit to the wheels.
Plastics are making inroads into the
chassis market as well. Innovations in
plastics technology have brought about
the development of successful chassis
applications that would not be possible
using any other family of materials. A
lot of chassis parts are also made through
injection moulding.
Fibre-reinforced polymer composite
materials weigh about 50 per cent less
than steel, though these are characterised
by a higher absorption of crush energy
per kilogram. On impact, carbon fibres
can have four to five times higher energy
absorption than steel or aluminium. Front-
end components made of these lightweight
energy-absorbing composite materials are
specially designed to fracture in a manner
that utilises impact energy.
Non-metallic alternativePlastics have found remarkable acceptance
as a substitute for metal in transmission
components. These performance
characteristics can be tailored by material
suppliers to meet the particular needs of
automotives. The usage of additives, fillers
and reinforcements will cause variations in
the properties of plastics to meet specific
customer requirements. Polyetherimide
is used extensively in transmissions for
its superior dimensional, heat and creep
performance, while a single piece of nylon
can replace several steel washers.
Email: [email protected]
Ayush LohiaCEO, Lohia Auto Industries
Choosing plastics for auto body exterior parts allows manufacturers to adopt modular assembly practices, lower production costs, improve energy management, achieve better dent resistance and use advanced styling techniques for sleeker, more aerodynamic exteriors.
Ashwani AggarwalPresident, Brose India Automotive Systems Pvt Ltd
Light vehicle applications account for over 30 per cent of the demand for each resin. Other resins used include acrylonitrile butadiene styrene and polyvinyl butyral. Engineering polymers such as nylon, polycarbonate and others are supplanting metals in many applications.
47April 2013 | Modern Plastics & Polymers
SPECIAL FOCUS: Inter face – Hitesh R Shah
How is the demand for plastics processing machines in the country?Ease of manufacturing and versatility have
made plastics the most preferred material
in the industrial & consumer products
segment, and plastics are fast replacing
other materials such as glass, wood and
metal. Their demand is continuously
growing in the automotive, construction,
packaging, electrical & electronics, pipe
fittings, agriculture, houseware, medical
and pharmaceutical sectors. All this has
constituted a huge demand for high-
precision plastics processing machines
and moulding equipment. The plastics
processing machinery industry is growing
at a compounded annual growth rate of
15 per cent, indicating a healthy growth.
Apart from good domestic growth, there
is an increase in demand for plastics
processing machines in the neighbouring
and African countries.
What are the recent trends in the segment? Earlier, the demand for higher tonnage
machines was less and smaller tonnage
machines were sold in a large number.
However, with changing times, the
demand for higher tonnage machines
is also increasing. Another trend is that
with the growth of the automotive,
pharmaceutical and healthcare segments,
the demand for plastics processing
machines is also growing, and the focus is
on technology that gives higher efficiency
at a lower cost. Further, the demand for
machines that consume less energy is
increasing.
What are the leading innovations making headway in the segment? Hybrid technology and all-electric
machines are really picking up well in
the market. Wherever there is need to
maintain a clean environment such as
in healthcare and medical applications,
the demand for all-electric machines is
increasing. The usage of servo technology
is also increasing as it helps in decreasing
energy consumption to a large extent. In
addition, innovations are being made in
machines to increase productivity without
increasing the cost.
What are the challenges and opportunities for the injection moulding machinery segment in India?Various challenges before the industry
include raw material availability and their
fluctuating prices, requirement of trained
manpower and automated solutions. In
addition, competition from global players
in terms of low-cost machines is a major
challenge. The import of used machines
and other high-end machines in large
volumes is another major challenge for
the industry. Despite these challenges,
there are opportunities for growth as
well because awareness on the injection
moulding process is increasing. Further,
processors are continuously involved in
improving operational efficiencies by
focussing on productivity, meeting quality
standards and reducing the overall cost
of machines. This will also increase
the demand of machines and help the
segment to overcome challenges. Also,
growing awareness and adoption of IT
solutions can increase the productivity of
machines, thus increasing the demand.
What could drive the future growth in this segment? The future growth in the segment
will be solely defined by customer
demand. Machines that ensure accurate
repeatability of the process, faster cycle
times, 24/7 failure-free operation, low
energy consumption, less noise and
address environmental concerns will be
more in demand. A company capable of
making such plastics processing machines
will rule the market. Further, in the global
competitive market, every producer is
required to offer high quality and efficient
machines at lower costs; thus, this serves
as a major driver for growth in the future.
What are the growth plans of your company?In the last few years, we have been
focussing on the overall growth of the
company and not only on increasing
productivity. We have focussed on
employee development, infrastructural
development, improving manufacturing
practices by moving towards zero defect
products etc, thus ensuring that the total
culture of the company improves and
customer expectations are met. We have
also taken up new product development
with reducing the cost as a major concern.
Hence, we want to and are providing total
solutions to the customer. Last, but not
the least, we want to continue to grow at
the pace at which we are growing since
the last few years.
Email: [email protected]
…opines Hitesh R Shah, Business Head – Injection Moulding Machines, Windsor Machines Ltd. In an exclusive conversation with Avani Jain, he talks about the demand for plastics processing machines in the country. He further elaborates on the current trends, challenges and opportunities in the industry.
“The future growth in the segment will be solely defined by customer demand”
48 Modern Plastics & Polymers | April 2013
SPECIAL FOCUS: Inter face – Praveen Sharma
What is the current scenario of the injection moulding industry in India?The injection moulding industry is quite
positive overall, but the current demand
for injection moulding varies according
to the different sectors that use injection
moulded parts. In the automobile sector,
the demand has decreased in the last 3–4
months as the overall economic growth has
shown signs of slowing down. However,
if we consider commodity plastics and
packaging, the demand is quite high.
In this sector, the demand is regularly
increasing and has shown a good scope for
Injection Moulding Machines (IMMs).
The market is very competitive; therefore,
every player is conscious about the
existing price and quality.
What are the key reasons for the growth of injection moulding?Most sectors use plastics or things related
to plastics, and today, plastics play a
major role in everyone’s life, whether it
is a household item, engineering item or
automobile part. As compared to other
developed countries, there is a large scope
for growth of the injection moulding
industry in India. At present, the per
capita usage of plastics is 5–6 kg in India,
whereas it is 14–15 kg in developed
countries. Therefore, this industry has
potential to grow further.
Various research and development
initiatives in sectors like agriculture have
also bolstered the growth of injection
moulding. The drip irrigation system and
new tools used in farming have provided a
great scope and have opened new channels
and avenues for injection moulding. In
addition, most manufacturers are now
going into the conversion mode towards
more modern automatic programmable
logic controlled machines. Thus, a lot
of scope and demand for modern and
energy-efficient machines is currently
being generated.
What are the latest innovations witnessed by the industry?Many developments have been witnessed
by this sector, whether it is polymers,
moulds, IMMs, auxiliary equipment or
plant automation. Major developments
in this or any other sector are focussed
towards saving energy and optimising
costs. The latest development being
biopolymers and green plastics, both of
which are environment friendly. Following
similar trends, machine manufacturers are
also making machines that reduce wastage,
have lower noise levels, are highly energy
efficient and environment friendly.
Due to the advancements in polymer
science and developments in engineering
plastics today, most of the parts are being
converted from aluminium to plastics, which
results in lower cost and lightweighting with
more durable parts. These components play
a major role in the automobile sector, which
helps in improving fuel efficiency and aids
in cost reduction.
What is the extent of automation and the energy-efficient standards in the industry?Automation is involved in every
stage of moulding, from the initial
production stage to the final packaging
phase. In plastics processing industries,
automation plays a major role, whether
it is moulds, machines or in the post-
moulding process. In the current
scenario, moulds are advanced and
automated, and they are equipped with
hot runner systems that produce parts
with minimum rejection and effective
cooling systems that lead to shorter
cycle times.
In injection moulding, automation
plays a major role in increasing production
and in ensuring accurate moulding.
Without automation, manufacturing
energy-efficient machines would
not be possible. The current crop of
IMMs are energy efficient and equipped
with hydraulic pumps driven by servo
motors that save up to 40–60 per cent
energy, depending on the moulding
parameters.
What are the challenges faced by the injection moulding industry?The main challenge faced by IMM
manufacturers in India is to compete
with international manufacturers. Most
materials used in making the machine,
with the exception of raw materials,
are imported, whether it is the servo
system, programmable logic controller
or advance hydraulics or robotics.
After payment of customs and duties,
the parts become more expensive and
thus affect pricing of machines. These
machines are eventually unable to
compete in the international market.
There are no definite schemes by the
government to provide infrastructure or
for the procurement of raw materials at
subsidised rates. This makes it difficult
for small and emerging businesses to
survive in the market.
Email: [email protected]
...avers Praveen Sharma, Managing Director, Hinds Plastic Machines Pvt Ltd. In an interaction with Anwesh Koley, he explains the various reasons for the growth of the injection moulding industry in India and the various challenges it faces today.
“Without automation, manufacturing energy-efficient machines would not be possible”
SPECIAL FOCUS: Roundtable
50 Modern Plastics & Polymers | April 2013
Jagmeet RatraManager, R S Associates Pvt Ltd
The Indian market is price sensitive and non-quality conscious. Companies are initially attracted by the low sticker price, and quality considerations come after the machines are used over a period of time. However, Indian companies offer better after-sales service. Since the majority of the market for injection moulding machines is in the unorganised sector, manufacturers do have a reason to smile. The future of the injection moulding industry is bright as the growth rate is high and the number of applications of injection moulding has gone up. Indian machines are now being considered globally because of durability and after-sales service. The Middle East and Africa are the largest importers of Indian injection moulding machines.
Indian processors import the largest number of machines from China; these low-priced imports are a major threat. Unlike in India, Chinese manufacturers get benefits of subsidies and tax concessions from the government.
High productivity and energy efficiency have characterised the injection moulding industry for a long time. However, with global advancements making rapid strides in India, it is important to gauge whether Indian injection moulders have been able to remarkably improve their productivity to cater to the ever-increasing market for injection moulded products. Anwesh Koley interacts with industry experts and shares their views on the current scenario of the injection moulding industry in India.
Thankur Singh DhooperDirector, Popular Engineers (India)
Current generation servo motors used in injection moulding ensure energy saving and low noise levels. The rpm control of the hydraulic servo pump drive system with AC servo motor ensures energy savings and noise reduction. Moulders can achieve almost 65 to 75 per cent energy savings through these techniques in comparison with a fixed-type pump motor-based system. High-precision stability control can be achieved through the closed-loop method of hydraulic servo pump drive system with servo motor reproducibility. This ensures optimum usage of power and consistency in operations.
The hydraulic method and the screw-drive method are combined to form a synchronous operation based on the various complex coordination of parts. This improves productivity by reducing the process time. Increasing the screw revolutions per minute using a high-output servo motor helps reduce the charge process time. This system also accommodates tandem mould and stack mould usage.
Kewal Krishan AjimalDirector, Vishavakarma Hydraulic Pvt Ltd
Currently, the injection moulding industry uses energy-efficient machines called servo motor machines that consume less power. Earlier only one type of machine was used, and if it worked well, it was used for all major applications. However, this did not provide the required efficiency in terms of production and energy consumption. Today, companies offer machines with different kinds of applications. Thin-walled applications require specific machines; PET bottle manufacturing requires another technique. This results in higher output at lower costs. Toggle-type injection moulding machines are in vogue, while many manufacturers continue with hydraulic ones. A toggle-type machine consumes less power with faster production.
Manufacturers in India have still not adopted fully automatic machines on a large scale as the availability of manpower is high. However, they now develop machines that not only produce higher output but also save energy and cost.
While there are varieties of techniques that can be used to ensure energy efficiency in an injection moulding machine, it is important to choose the right equipment and system to enable precise moulding along with efficient production set up. This will result in product
consistency and customer satisfaction.
Editorial take:
HaveHave Indian mouldersIndian moulders been able to been able to significantly improvesignificantly improve efficiencyefficiency inin
injection moulding?injection moulding?
Email: [email protected]
FACILIT Y VISIT: Toshiba Machine (Chennai) Pvt Ltd
54 Modern Plastics & Polymers | April 2013
From its rich lineage to setting benchmarks in manufacturing techniques, Toshiba Machine (Chennai) Pvt Ltd plans to increase its foothold in the Indian injection moulding market. Sweta M Nair visits its facility in Chennai to assess if the company’s aspirations have a physical backing.
Creating exemplary manufacturing processes
Considered one of the prime
processes for producing plastic
products ranging from micro
to large components, injection
moulding is virtually used in all sectors
of manufacturing. Size flexibility, design
freedom and maintenance of production
quality have enabled processors to extend
the boundaries of plastics. Capitalising
on the growing prowess of the plastics
sector is Toshiba Machine (Chennai) Pvt
Ltd. While this company has achieved a
turnover of ` 226 crore and is known for
its range in injection moulding machines
and auxiliary equipment, its innovative
manufacturing processes are now gaining
much attention.
An interesting lineageLocated on the Chennai–Bengaluru
Highway, the manufacturing facility
of Toshiba Machine is spread over an
area of 9.16 acre. With a workforce of
220 employees, the company has been
setting benchmarks by successfully
implementing and executing process-
related innovations. This facility is not
only a testament of the changing times
but also an enabler of transmitting
indigenised adaptations to the company’s
range of machines. Explaining the lineage
of Toshiba Machine, Parameswaran
Kailas, Managing Director, says, “The
Toshiba Machine (Chennai) you see
today is a result of a number of successful
collaborations that have occurred in the
past. Our plastics machinery business
started in 1991 when we at L&T were in
technical collaboration with world leaders
Demag, Germany [now Sumitomo (SHI)
Demag]. In 2001, the management of
Demag and L&T sensed the untapped
potential of this business. This led to the
formation of a 50:50 joint venture. We
moved to this modern facility on October
2, 2005. In 2008, Demag was acquired
by Sumitomo Japan, which then came
to be called as Sumitomo (SHI) Demag.
This acquisition was soon followed by
the company offloading its shares, all of
which were bought by L&T.
In January 2009, the company became
a fully owned subsidiary of L&T and
renamed as ‘L&T Plastics Machinery
Ltd’. In order to grow multifold, in
2010–11, L&T management decided to
exit from its non-core businesses. What
followed shaped the present company. On
September 28, 2012, Toshiba Machine
Co Ltd, Japan, acquired all of the shares
in the Indian firm of L&T Plastics
Machinery Ltd and made it a subsidiary
of their company. The latest identity
Toshiba Machine (Chennai) Pvt Ltd is a
member of the Toshiba Machine Group,
Japan. Toshiba’s idea of acquiring L&T
Plastics Machinery was for obtaining a
wider product reach and for accessing the
Indian market in a big way.”
Divisions and processesThe spacious facility, now in its eighth
year, has received accolades time and
again from Frost & Sullivan for its design
and machine manufacturing systems. The
main building houses the administration Assembly and testing area
55April 2013 | Modern Plastics & Polymers
office and shop floor. The latter is well
ventilated and is divided into three bays.
As per process, the first bay is for the
entry of materials and the assembly of
parts. Smaller tonnage injection moulding
machines (up to 180 tonne) are assembled
in the middle bay. The last bay is utilised
for assembling machines belonging to the
middle and higher tonnage machines. “For
us, any machine that ranges between 180
and 300 tonne falls in the middle tonnage
category, whereas machines that range
from 350 to 1000 tonne are categorised
as higher tonnage machines,” says M
Kumar, Head – Manufacturing. Other
sections include a display of products
that can be produced by the machines,
a cut-section of components used in
manufacturing, storage units and a paint
booth. The facility also houses sections for
the manufacturing of auxiliary equipment
for the plastics processing industry and
other supporting facilities like canteen,
parking, wastewater processing, an organic
converter for compost unit etc.
At Toshiba Machine, the number of
initiatives to encourage innovation among
employees is remarkable. One such
initiative ‘Hunt for Innovative Thoughts
(HINT)’ is where on-line suggestions
for improvements/new manufacturing
concepts are brought to light. Another
initiative is the ‘Stride Towards
Excellence Programme (Step)’. Toshiba
Machine is the first injection moulding
machinery manufacturer in the country
to have started assembling machines on a
moving platform. Recipient of the Indian
Machine Tool Manufacturers’ Association
– SIEMENS Productivity Championship
Award, this concept is a 10-stage paperless,
single-piece flow moving assembly. Every
stage has a dedicated set of tools, and
assembly activity is electronically stored.
On an average, the machine moves to
another stage (or level of completion)
after 2 to 3 hours, which signifies that
this single-piece flow facility allows the
company to produce three machines in
a shift of 8 hours. In the consecutive
shift, the feeding of the material takes
place. Unlike conventional methods, this
platform is levelled to perfection, which
ensures that testing of machines is carried
out seamlessly.
The congenial attitude of the company
of encouraging innovations has lead to a
number of productive developments on
the shop floor. For instance, the creation
of a cell quantum, consisting of prismatic,
round and hydraulic block cells, is
where minimum testing is conducted in
this facility.
Practical efficacy Along with paying attention to product,
quality and safety, this ISO 9001:14001
company emphasises its economical,
environmental and social role. Falling in
line with this philosophy, the company has
installed three solar panels on the rooftop
of its canteen so as to enable solar cooking.
“For the panels, with an investment of
` 9.6 lakh, we have received a government
subsidy of about ` 3.5 lakh. With this
system in place, we have managed to save
one industrial gas cylinder everyday, which
approximately costs ` 3,500. Due to the
good dividends that we have received,
we are contemplating in implementing
solar technology in our office building.
Moreover, the waste food from the canteen
is used to prepare manure in our very own
organic converter plant. We are a zero
water discharge facility, where the waste
water is treated and used for nourishing
the lush greenery in the facility,”
affirms Kailas.
Automotive, packaging, construction,
electr ical accessor ies, medical
components and writing instruments
are major markets for Toshiba Machine.
According to plan, the company aspires
to start the manufacturing of all-electric
injection moulding machines in this
facility by October 2013. Extending
its product base in hydraulic machines
and introducing die-casting machines
are also tentatively planned. “By
providing additional safety features that
protect the machines against power
spikes, fluctuations and cuts – general
phenomena in India, we have been able
to suitably modify our machines with
international technology to suit Indian
conditions to a certain extent. Amid
these introductions, our attention will
be fixed on providing after-sales support
to all our customers,” states Kailas.
Email: [email protected]
Parameswaran KailasManaging Director
By providing additional safety features that protect the machines against power spikes, fl uctuations and cuts – general phenomena in India, we have been able to suitably modify our machines with international technology to suit Indian conditions to a certain extent.
The 10-stage single-piece flow moving assembly
ToToshiba Machine (Chennai) Pvt Ltd
Engineering Plastics
INSIGHT & OUTLOOK
57April 2013 | Modern Plastics & Polymers
Engineering thermoplastics:Turning the heat on metals! ........................................................................................................ 58
R&D initiatives:Improving the inherent properties of engineering plastics ......................................................... 60
Interface:
Dr Harindu Vyas, Consultant, Polymer & Plastics Technologist ........................................64
Satendra Kumar, CMD, Quadrant EPP Surlon India Ltd .............................................. 66
Roundtable:
How have engineering plastics revolutionised lightweighting for automotives? ........................68
Green shoots ........................................................................................................................... 69
End-of-life applications of recycled plastics:Setting benchmarks! ....................................................................................................................70
Interface:
Vishal Jasrapuria, Director, Shree Sadguru Plastic Industries ............................................ 72
Dr Prakash Mahanwar, Head – Dept of Polymer and Surface Engineering, Institute of Chemical Technology ...........................................................................................74
Filament wound composite pipes:Technological triumph for Indian industrySangeeta Baksi and Soumitra Biswas, TIFAC, Department of Science & Technology, Government of India; and Leena Modi and Jayrah Shah, EPP Composites Pvt Ltd ....................... 76
58 Modern Plastics & Polymers | April 2013
INSIGHT & OUTLOOK: Engineer ing thermoplast ics
Engineering thermoplastics
exhibit higher performance
than commodity materials and
are suitable for applications
that require engineering to design parts
that perform. In the past, these plastics
were not considered in application areas
that require high temperature. Instead,
metals and other conventional materials
were used. Due to primitive manufacturing
techniques, in some cases, even production
technologies were clumsy, which resulted
in difficulty while assembling. The usage
of traditional plastics in thermo-sensitive
applications also had limitations. To begin
with, service temperature requirements
and limitations in product design were a
couple of issues in engineering safety.
Components in automotive,
electrical & electronics and aeronautical
& space applications need thermo-
resistant materials. Satisfying this crucial
requirement, engineering plastics are
thus replacing metal, rubber, glass, paper
and, in some cases, even concrete. “Along
with being thermo-sensitive, engineering
plastics are corrosion-free and have better
noise dampening characteristics. They
offer ease of processing or production,
lightweighting and more freedom in
product design. In the last decade, the
usage of engineering plastics has been
extended to automotive applications
including replacement of bumper, fuel
tank, metal fuel lines and other fluid
transport lines. In the infrastructure
industry, these plastics have given
designers freedom – from fluid transport
management to replacement of wood
and glass – with better safety, ease of
handling and durability. The enhanced
usage of these plastics in white goods is
to make products better and attractive
with flame retardant and higher safety
index features. Lighter and attractive
electronic goods like vacuum cleaners,
coffee makers, washing machines, metal-
free refrigerator interiors, smarter and
lighter mobile phones and replacement of
other metal parts in electrical & electronic
items are achievements of engineering
plastics,” says Mandar Amrute, Sales and
Market Development Manager, Speciality
Polyamides, Arkema India.
The hot onesWhen referring to heat-resistant
engineering plastics, the demand is
skyrocketing around the globe by the
minute. A specific set of thermoplastics
caters to this niche requirement
beautifully. The most common being
Polycarbonate (PC), which not only has
strength similar to non-ferrous metals but
also has good impact strength, ductility
and durability. Due to excellent clarity,
METALS!HEAT
TURNING THE
ON
Engineering thermoplastics are now the accepted replacement solution in demanding engineering applications where traditional materials are less economical. Sweta M Nair delves deeper to gauge the enhanced usage of engineering plastics in thermo-sensitive applications.
Courtesy: Arkema Inc
58 Modern Plastics & Polymers | April 2013
Engineer ing thermoplast ics
59April 2013 | Modern Plastics & Polymers
any colour blends well with it. PC has
broad applications, including safety lamp
cover, signal lamp, high-rise building
glass, aircraft cockpit glass, glass and sheet
material substitutes and storage optical
discs. Because of superior mechanical and
chemical properties, Polyoxymethylene
(POM), dubbed as ‘super steel’, can be
used for various precise micron gear,
instrument elements and components
with geometrically sophisticated surfaces,
bib nozzles and valves for the deflagrator
pipeline. In fact, POM is used in
applications where metal and non-metallic
materials are sometimes incompetent.
Polybutylene Terephthalate (PBT)
is a type of thermoplastic polyester with
qualities such as high insulativity and
wet strength. Non-enhanced PBT has
good workability and electrical properties.
With extensive uses in electrical &
electronics and automotive industries,
it is low in glass transition temperature,
and therefore, short in processing cycle. It
can be crystallised even when the mould
temperature is at only 50°C. PBT has
applications in production of kickback
transformer of television sets, automobile
section boards and ignition coils, exterior
components of various automobiles, fans
of air conditioners, bases of electronic
ovens etc. Talking about the advantages
of engineering plastics, Geetha Baskaran,
Director, Suba Plastics Pvt Ltd, affirms,
“Faster cycle times in production and
lightweighting in automotives, which
leads to economical fuel consumption, are
the brightest aspects. We can further push
the boundaries in lightweighting by using
MuCell™ Molding Technology.”
Like hot cakesIn the last five years, engineering plastics
have entered new industry segments and
have growing usage in spacecraft and
automotive applications. Because there is
a strong drive to replace metals, Amrute
adds, “Many traditional under-the-bonnet
car parts are being made with thermo-
sensitive engineering plastics. This grade
has also made significant improvement
in packaging for chemicals as well as
microwaveable food packs. It has also
gained a strong foothold in the medical
industry for applications such as artificial
transplants and better surgical equipment
like skin-feel gloves, anti-static textiles
and so forth. The latest usage is in
temperature-sensitive decorative paints or
films for exterior and interior applications
in the infrastructure industry.”
When talking about demanding
applications such as bearings, piston parts,
pumps, compressor plate valves and cable
insulation, a colourless organic polymer
thermoplastic that comes to mind is
Polyetheretherketone (PEEK). Considered
an advanced biomaterial used in medical
implants, PEEK is extensively used in
the aerospace, automotive and chemical
process industries. The other variety nylon
6-6 is used frequently when mechanical
strength, rigidity and stability under heat
are required. This polymer is made of
hexamethylenediamine and adipic acid.
It is used for ball bearing cages, electro-
insulating elements, pipes, profiles and
various machine parts. “With the usage of
engineering plastics increasing in under-
the-bonnet applications, we are seeing
more glass-filled nylon, POM and glass-
filled polypropylene. The usage of PBT
and PEEK has increased in applications
where resistance to high temperature is
required. PC is being used increasingly
in headlamps as well. At Suba Plastics,
we specialise in automotive components
such as high-abrasive plastic gears with
close tolerances, gear housing and engine
belt tensioners that work closely with the
engine belt drive. In our products, we have
used carbon fibre-filled nylon 4-6 for some
special applications. We make components
with nylon 6-6 with 50 per cent glass-
filled material for gears for starter motor
applications. These components made
from engineering plastics can withstand
temperatures of more than 150–200°C.
They are also proven to perform well in
extreme climatic conditions. New additive
technology is being used to make it more
heat resistant. In the next ten years, I
believe engineering plastics will take over
at least 40 per cent of all under-the-bonnet
applications,” says Baskaran.
Email: [email protected]
Mandar AmruteSales and Market Development Manager, Speciality Polyamides, Arkema India
Geetha BaskaranDirector, Suba Plastics Pvt Ltd
Along with being thermo-sensitive, engineering plastics are corrosion-free and have better noise dampening characteristics. They offer ease of processing or production, lightweighting and more freedom in product design.
Faster cycle times in production and lightweighting in automotives, which leads to economical fuel consumption, are the brightest aspects. We can further push the boundaries in lightweighting by using MuCell™ Molding Technology.
INSIGHT & OUTLOOK: R&D in i t iat ives
60 Modern Plastics & Polymers | April 201360 Modern Plastics & Polymers |
The untapped potential and
growing opportunities in
the engineering plastics
industry are gaining
worldwide attention. Replacing metal
with plastics in cars & trucks, household
appliances and building & construction
is becoming the order of the day. In
such circumstances, high endurance,
performance, wear resistance and anti-
static properties of engineering plastics
are areas of maximum effort in R&D.
Driven by the ongoing replacement
of metal parts with engineering plastics,
the demand is expected to rise globally.
In Asia, the usage of engineering plastics
has increased in segments such as
electrical & electronics, construction and
automotives. As forecasted by TechNavio,
the global engineering plastics market
will reach $ 69.12 billion by 2016. The
report covers the Americas, Europe,
the Middle East and Africa (EMEA)
and Asia-Pacific (APAC) regions. The
reason for this rise in demand has been
attributed to the increasing demand for
lightweight products.
Inherent assets Components made from engineering
plastics are usually used in tough
environments. The reliability of working
in harsh conditions coupled with
durability gives engineering plastics an
edge over generic plastics. For instance,
engineering plastics in hydraulic gear
pumps have a working life of 50,000
hours. Apart from industrial applications,
the usage of engineering plastics in body
implants requires that these plastics
go through sterilisation of ultra-violet
or gamma radiation. This signifies that
the chemical resistance of engineering
plastics is higher than that of generic
plastics. Talking about the present
scenario, Nanda Kishore, Director,
Jayashree Horologicals Pvt Ltd, says,
“Engineering plastics are here to replace
metals, and they can also emulate the
look and feel of metals. This is achieved
by reinforcing the base material with
glass, sand or talc-filled additives. Much
R&D to obtain certain anti-static grades
of engineering plastics is currently
ongoing for electronic applications.”
With the stiffness and toughness
exhibited by these plastics, continued
research is aimed at outperforming
traditional metal applications while
providing many advantages. In this era
when weight reduction is the key to
fuel efficiency, engineering plastics have
a high strength-to-weight ratio and
are lighter than metals. Reflecting his
thoughts on new application areas, Scott
E Fleming, Vice President & Business
Manager, Nylon Division, Teknor Apex
Co, says, “Engineering applications are
less expensive than metals in terms of
raw material cost and provide substantial
cost savings as a result of their design
freedom. This freedom makes possible
parts consolidation and moulded-in
multi-functionality, replacing the time
and labour required for metal fabrication
and assembly. Finally, by resisting
corrosion and providing inherent thermal
and electrical insulation, engineering
plastics are less expensive on a lifetime
cost basis. The automotive sector is the
largest market for the Nylon Division
of Teknor Apex. New automotive
applications keep appearing as a result
of two trends – continued proliferation
of electronic devices & information
systems and an increasing demand for
weight reduction.”
Beneficial shift When it boils down to the basic process
Improving the inherent properties
of engineering plastics
Valued for their outstanding mechanical and optical properties, engineering plastics have many diverse applications in the automotive and electronics segments. Good chemical resistance, dimensional stability, low moisture absorption and good flow properties are the other known attributes. Sweta M Nair brings to light the continued Research & Development (R&D) initiatives that are taking place in this space.
62 Modern Plastics & Polymers | April 2013
R&D ini t iat ives
Nanda KishoreDirector, Jayashree Horologicals Pvt Ltd
Scott E FlemingVice President & Business Manager, Nylon Division, Teknor Apex Co
Engineering plastics are here to replace metals, and they can also emulate the look and feel of metals. This is achieved by reinforcing the base material with glass, sand or talc-filled additives.
Engineering applications are less expensive than metals in terms of raw material cost and provide substantial cost savings as a result of their design freedom. This freedom makes possible parts consolidation and moulded-in multi-functionality.
itself, metals require heat energy of up
to 1,200° C to enter into a molten stage,
whereas any kind of polymer can be
plasticised at 300°C. Highlighting this
point, Kishore talks about the advantage
that engineering plastics brings to his
line of horological business, where
tolerance levels are very critical. “Earlier,
generic plastics were used for horological
applications where a lot of shrinkage
used to happen. After considerable
research from the solutions provider
side, the expertise in polymer blending
helped us reduce the shrinkage rate.
Engineering plastics respond well to the
production process, thereby helping us
reduce shrinkage and rejection rate. For
instance, our watch movement holders
were made using polyoxymethylene, but
now we have shifted to grylamide (a
nylon co-polymer). Because grylamide
has excellent dimensional stability, it has
helped us do away with shrinkage.”
The successful penetration of
engineering plastics into various
segments is based on different criteria.
Research is being extended to areas
such as under-the-bonnet parts, exterior
parts (window wiper holders & exterior
mirror housing), high heat distortion
temperatures and electrical insulation.
The telecommunications sector has
similar uses for engineering polymers,
notably used in mobile phone casings,
through the desire for light and durable
phones. Other applications may include
building, textile bobbins, meter housings
and small niche applications. Although
most of these research studies are still
in a pilot stage, there have been a few
commercially successful innovations.
Regarding Teknor Apex’s work in this
area, Fleming says, “Our Chemlon®
813 CI and 830 GHI fibre-reinforced
compounds, based on the nylon 6/12
polymer, are in commercial use and
provide the excellent chemical resistance
and low moisture absorption required in
fuel line components. The 13 per cent
loading of carbon fibre in the Chemlon
813 CI product also provides anti-static
conductivity often called for in fuel
line components. Chemlon 830 GHI
compound has a 30 per cent loading
of glass fibre for enhanced strength
and rigidity in applications such as
connectors. The new compounds pick
up only slightly more moisture than
nylon 12 and achieve acceptable finished
part dimensions in tooling previously
used for nylon 12. At the same time,
Chemlon 800 series materials process
in shorter cycles and at higher melt
temperatures than nylon 12. We are now
fully commercial with a new range of
compounds incorporating recycled nylon,
chiefly nylon 6 and 6/6. We are offering
these compounds under the brand name
Recyclon and have customers ranging
from automotive manufacturers to patio
furniture makers.”
Unlocking potentialWith lightweighing becoming a focus of
attention, engineering plastics are being
harnessed into new applications with the
right R&D support. Kishore would like
to see some miraculous developments
where the property of heat and light
transfer could occur using engineering
plastics. He believes that if this property
could be given to all grades available
in the market, then the application
areas would grow manifold. For Teknor
Apex, its latest R&D initiatives include
working on flame retardant formulations
of nylon compounds to meet new, more
stringent requirements for under bonnet
components from one major automotive
original equipment manufacturer, where
the components must pass the V-0
flame test. Another area of research is
to develop new nylon 6/10 and nylon
6/12 alternatives from nylon 12. For
this company, automotive industry
mandates for sustainability have also led
to a systematic programme designed to
recover used nylon products and recycle
them into valuable compounds. From an
outsider’s perspective, recycling could be
the next big R&D area for engineering
plastics. However, research forms a
stepping stone to success, whether these
will become commercially viable is a
factor only time can tell.
Email: [email protected]
64 Modern Plastics & Polymers | April 2013
INSIGHT & OUTLOOK: Inter face – Dr Har indu Vyas
How is the demand for engineering plastics in the country?Today, the total worldwide market for
engineering plastics is estimated to be
more than $ 30 billion. Polyamide (PA),
Polycarbonate (PC) and Polyoxymethylene
(POM) are the dominant products in
the market. Within the spectrum of
engineering plastics, the annual growth
rate is 10 per cent for PA, 9 per cent for
PC and 5 per cent for POM. In India,
the consumption of engineering plastics
in the automotive and electrical &
electronics industries is more than half of
the total demand of engineering plastics.
Compact discs, where only PCs are used,
represent 11 per cent of the total market.
PA films shares 4 per cent of the total
market. Thus, the demand for engineering
plastics in the country is increasing by
4–8 per cent annually. On a larger scale,
the demand of engineering plastics is
growing at the fastest rate (8 per cent) in
Asian countries, in comparison to Europe
and America (5 per cent).
What are the recent trends in the segment?A recent trend is using engineering
plastics in a variety of products. These
days, the usage of thermoplastic polyester,
acrylonitrile butadiene styrene, acetal
polymers, nylon, phonilics, PA-imide and
PC has drastically increased in a variety
of applications.
What are the benefits offered by engineering plastics as compared to commodity plastics?The most important benefit of engineering
plastics over commodity plastics is that it
can be used as a replacement to metals.
Engineering plastics have excellent
electrical properties, such as high
breakdown voltage, tracking resistance,
arc resistance etc, in comparison to
commodity plastics. Further, some of
the engineering plastics have excellent
dimension stability, heat resistance, low
coefficient of friction, abrasion resistance,
fatigue endurance and resistance to creep,
but general commodity plastics lack
these properties.
What are the leading innovations making headway in the segment?Engineering plastics – through research
and development, we can engineer these
plastics for any desired property that is
required. The innovations that are making
headway are as follows:
Polyetheretherketone (PEEK): This
semi-crystalline thermoplastic has a
high operating temperature that is apt
for injection moulding. It is tough,
strong, rigid, resistant to ultraviolet
light, steam and creep. PEEK is used
in the nuclear, electronics, aerospace
and medical industries.
Polimide (PI): This polymer is heat
& fire resistant, with a self-lubricating
property. It is used in semi-conductors,
aircraft, off-road vehicles etc.
Polyphenylene Oxide (PPO): This
innovative engineering plastic is a
combination of polyphenylene oxide
& styrene. It has excellent hydrolytic
& dimensional stability, low moisture
absorption and good electrical
properties. It has a wide area of
applications in medical, automotive
and electrical & electronics industries.
Polyphenylene Sulphide (PPS): It
offers the best chemical resistance in
comparison to any other engineering
plastic. It is used in chemical reactors,
halogen lamp sockets, medical devices,
pump housing etc.
Polyphenylsulphone (PPSU): This
amorphous engineering plastic
has better resistance to chemicals
and impact than polysulphone and
polyetherimide. It can be used for
making medical instruments.
What are the challenges and opportunities faced by the industry? The industries that are using engineering
plastics have a bright future, as research
is going on in the area of specialised
engineering plastics that can replace
expensive metals. In such a scenario,
industries have the opportunity to
develop new products from engineering
plastics. These plastics have huge scope
in the areas of building & construction.
The only challenge that the industry has
to face is the high raw material cost. This
problem will persist till more research in
the synthesis of specialised engineering
plastics is carried out to reduce the cost.
What will be the future trends?To replace metal parts with engineering
plastics as these possess properties of
minimum wear & tear, lightweight and
easy processability. The future trend
also lies in the reactive compounding
of engineering plastics with general
purpose plastics to reduce cost without
compromising on the properties.
Email: [email protected]
…opines Dr Harindu Vyas, Consultant, Polymer & Plastics Technologist. In an exclusive conversation with Avani Jain, he talks about the demand for engineering plastics in the country. He further elaborates on the advantages offered by engineering plastics and future trends.
“The demand for engineering plastics in the country is increasing by 4–8 per cent annually”
66 Modern Plastics & Polymers | April 2013
INSIGHT & OUTLOOK: Inter face – Satendra Kumar
What are the various opportunities for engineering plastics in wind generation?Alternative energy sources account for
a significant part of the total global
energy production today, and their
importance is constantly increasing.
Engineering plastics have transformed
the wind energy generation industry
across the globe. Engineers are using
engineering plastics worldwide to
improve product quality and increase
profitability of manufacturing processes
and equipment. Parts and components
made from high-quality materials
support the technical development in
all major sectors of alternative energy
generation. Preserving or maximising
energy is the key requirement of energy
generation and forms the top priority
for the government and generation
companies today.
However, certain natural cautions
are required to be observed while
generating energy through wind turbines.
Abrasion, erosion and wear of critical
parts in a facility and the equipment
within the production chain cause
immense loss. Related maintenance
services and production downtime can
impact the financial performance of
a project and business significantly.”
Valves, bearings, seals, guiders and rolls
require regular maintenance. High-grade
engineering plastics solutions can increase
equipment lifetime, improve mean time
between repairs, reduce waste and limit
replacement needs. Thus, it is important
for plastics used in turbine technology to
meet the highest challenges concerning
temperature, chemical resistance,
corrosion, wear and stability.
What are the future component development trends witnessed by you?New component developments will
significantly change materials usage
patterns. Generally, there are trends
toward lighter weight materials, as long
as the life cycle cost is low. Most rotor
blades in use today are built from glass
fibre reinforced plastic (GRP). Other
materials that have been tried include
steel, various composites and carbon
fibre reinforced plastic (CFRP). As the
rotor size increases on larger machines,
the trend will be toward high strength,
fatigue-resistant materials. As the turbine
designs continually evolve, composites
involving steel, GRP, CFRP and possibly
other materials will likely come into use.
Rotor blades are either GRP, wood-epoxy
or CFRP.
The step-up gearbox used on large
turbines today is expected to be replaced
in future machines. Most small turbines
designed for battery charging use a
variable speed, permanent magnet,
variable frequency generator connected
to a rectifier. As high-power solid-state
electronics are improved, larger machines
are likely to use AC-DC-AC cyclo-
converters. This trend will increase the
usage of magnetic materials in future
turbines. Large epicyclic gear boxes used
in large ships may continue to be the
drive system for some large turbines.
What kinds of innovative solutions do you offer at Quadrant?Competition in the engineering plastics
market is intense, and quality of services
and product differentiation are the
key to ensure a steady customer base.
Our ability to offer reliable products
and service levels are based on the
Total Quality Management approach
reinforced by ISO 9001-2000 standards.
Quadrant can meet your requirements
for consistent quality, performance
and machinability. As the first to line
mark shapes materials, Quadrant set
the standard for careful selection of
raw materials and resins, leading-edge
process technologies and highest quality
of manufacturing. Keeping pace with
industry standards, the company has
developed quality systems that comply
with industry needs.
Engineering plastics are exceptionally
easy to machine and a slight modification
in the tools produces an outstanding
smooth surface finish that helps with
aesthetics and performance of machines.
Because almost all engineering plastics
are easy to machine, it further broadens
the gap between traditional materials
due to reduced labour time and reduced
energy cost due to faster component
production times. The market for
engineering plastics is growing by the
day, and customers demand quality
and reliability from their purchases.
With steady research and development
initiatives that result in path-breaking
products, Quadrant has already become a
major player in the industry. We plan to
increase our production facilities beyond
the current limits to help us serve our
customers better.
Email: [email protected]
…opines Satendra Kumar, CMD, Quadrant EPP Surlon India Ltd. In an interaction with Anwesh Koley, he explains the various innovations brought about by engineering plastics in the field of wind energy generation and the way forward for plastics in key industrial operations.
“Engineering plastics have transformed the wind energy generation industry across the globe”
68 Modern Plastics & Polymers | April 2013
INSIGHT & OUTLOOK: Roundtable
Mandar AmruteSales & Market Development Manager,
Speciality Polyamides, Arkema India
Presently, the automotive industry is looking at alternatives to cut down CO2 emissions. Some of the possible ways of achieving this is by exploring alternative vehicles, but that is still in the pilot stage. Engine refinement is not a cost-effective option, and new propelling energy sources are accompanied with availability issues. Thus, the proven and easiest way of achieving weight reduction is by replacing metal and rubber with engineering plastics that also have better designing ability. By using engineering plastics in automotives, one can achieve weight reductions of 10–12 per cent with better aerodynamic designs, 1–2 per cent with better air conditioning designs and 4–5 per cent with better wheel and tyre designs. Further, significant weight reduction can be brought about by weight modularity in the range 12–20 per cent. With metal and rubber replacement in power train inclusive gearbox, fuel lines and other fluid transport lines, one can reduce weight to about 45–55 per cent.
The usage of plastics in automotives is now touching upon points such as efficiency and aesthetics besides providing design functionality and freedom. Being less dense than metals, engineering plastics are being used in automobiles where they face some highly commanding circumstances. Sweta M Nair interacts with experts who bring out interesting insights on this trend.
T K PurushothamanManaging Director, Rosti Technical
Plastics (India) Pvt Ltd
Engineering plastics have innumerable applications in automotives because of being light in weight, durable and easy to manufacture. The wide range of applications includes: interiors – pillars, instrument panel, dash board, seats, door trims and steering wheel; exteriors – bumpers, lamp holders, rear view mirrors, handles, spoilers, wipers, wheel caps and mud flaps; under-the-bonnet parts – oil pans, radiator tanks, fans, cylinder head covers and manifolds. Plastics are replacing metal in almost every area thought to be impossible two to three decades ago. With a variety of long and short fibres, plastics have increasingly become popular and can provide incomparable products with superior performance, aesthetics, safety and durability. With increasing global oil prices, the weight of automotives has become the key factor as it influences fuel efficiency to a large extent. From a mere 5 per cent of overall body weight during the 1970s, the plastic content in automotives has increased to more than 50 per cent now.
Geetha BaskaranDirector, Suba Plastics Pvt Ltd
Engineering plastics have found wide application areas. They are now used in front-end modules, air intake manifolds, bearings, motor parts and so forth. In automotives, engineering plastics play an important role in the under-the-bonnet area, where these special plastics are able to perform at temperatures above 170°C. At such high temperatures, engineering plastics are creep resistant and offer better retention over service life. In addition, by using a higher impact balanced resin, the weight of the component or part can be reduced by lessening wall thickness. Thus, the applications of engineering plastics are definitely increasing. Casing or housing that was made of castings earlier is now being replaced by engineering plastics. These plastics are also being used in fuel injection systems and door panels. Engineering plastics are replacing metal in many applications. To a certain extent, I believe that engineering plastics can help build economical vehicles, where one can get more mileage due to lightweighting.
While passenger cars are required to adhere to mandatory safety requirements, environmental norms, better aesthetics, entertainment, communication and comfort features are still going to be in demand. Achieving these at a reduced price is a difficult feat. Although
engineering plastics are replacing metal in many applications, further reduction in their cost would increase their adoption.
Editorial take:
How haveHow have engineering plastics engineering plastics revolutionised lightweighting forrevolutionised lightweighting for
automotives?automotives?
Email: [email protected]
69April 2013 | Modern Plastics & Polymers
INSIGHT & OUTLOOK: Green Shoots
With numerous green initiatives on the horizon, we bring to you in association with the United Nations Industrial Development Organization (UNIDO) this section ‘Green Shoots’ – the latest to keep you updated on the green phenomenon and to help promote the eco-friendly manufacturing philosophy.
We will get you closer to several green practices, products and technologies that not only have a lower impact on the environment but are also safer for company personnel. Read on to get more eco-friendly, energy-saving and economical solutions that can give Indian companies a global business edge.
70 Modern Plastics & Polymers | April 2013
INSIGHT & OUTLOOK: GREEN SHOOTS: End-of - l i fe appl icat ions of recycled plast ics
An activity that involves the
efficient working of the
entire eco-system, recycling
of plastics involves meeting
recovery targets, improving collection
procedures and encouraging product
users to recycle. In the long run, the
focus will be on smarter product design,
more efficient use of resources during
manufacturing, reducing transportation
costs and encouraging communication
among parties involved in the plastic
life cycle. End-of-life applications
accommodate industry segments
such as packaging, construction and
automotive products.
Currently, recycling is one of the
most sustainable end-of-life options for
plastics. The infrastructure and facilities
for alternative processing options, such as
energy recovery and composting (for 100
per cent degradable plastics), have not
been developed commercially, although
they may provide alternative processing
options for non-recyclable plastics in
the future. Thus, some of the factors
influencing end-of-life applications are
the overall public welfare, adherence
to waste management plans, meeting
international recovery benchmarks and
recovered material as a potential resource
as raw material prices increase.
Major outletsRecycled plastics can be used in almost
as many applications and products as
prime plastics. In packaging, recycled
Polyethylene Terephthalate (PET) and
High-density Polyethylene (HDPE) are
increasingly used in primary packaging
by retailers and branded manufacturers
for bottles and trays. Brands such as Coca
Cola, Marks & Spencer, Boots, The Body
Shop etc are currently using recycled
plastics in select product lines. Recycled
PET flakes are spun into thread and yarn
that is gaining popularity as a fabric used
in the clothing industry. Polyester fibre
is the single largest market for recycled
PET bottles worldwide. Polyester fleece
clothing and polyester filling for duvets,
coats etc are frequently made from
recycled PET bottles. This can be used
either alone or in combination with
other fibres to create a wide variety of
fabrics. These fabrics are generally strong
and durable.
Other major outlets for recycled PET
are food-contact or non-food-contact
containers, injection-moulded engineering
components and some building materials.
HDPE is processed into plastic lumber,
tables, roadside curbs, benches, truck
cargo liners and other high in-demand
durable plastic products. When referring
to cost-competitiveness, street furniture,
seating, bins, street signs and planters
are made from recycled plastics as the
preferred material because it is resistant
to vandalism as well.
BENCHMARKS! Recycling plastics is a multi-dimensional activity. Recovering scrap from plastic waste and reprocessing the material into a completely different product is referred to as an end-of-life application. Material recycling will continue to be the primary end-of-life option for plastics, followed by energy recovery for non-recyclable materials. Sweta M Nair illustrates processing phenomena that exemplify end-of-life applications.
SETTING
71April 2013 | Modern Plastics & Polymers
GREEN SHOOTS: End-of - l i fe appl icat ions of recycled plast icsEnd-of - l i fe appl icat ions of recycled plast ics
Additional applicationsDue to the lack of incentive to invest
in the compactors and logistical systems
required, most polystyrene products
are currently not recycled. As a result,
manufacturers cannot obtain sufficient
scrap. Expanded Polystyrene (EPS) scrap
can be easily added to products such
as insulation sheets for construction
applications. This foam scrap can also
be used in the manufacture of clothes
hangers, park benches, flower pots, toys,
rulers, stapler bodies, seedling containers,
picture frames and architectural moulding.
Recycled EPS is also used in many metal
casting operations.
In order to save energy and landfill
space, the percentage of recycled
plastics being used in new building and
construction applications is increasing
every day. These plastics can be blended
with virgin plastics to reduce cost without
sacrificing performance. Such plastics are
being used to make polymeric timber
for use in everything from picnic tables
to fences. It is widely being used in
mainstream construction products such
as damp-proof membrane, drainage pipes,
ducting and flooring. Because recycled
plastics are durable, low maintenance,
vandal resistant and resistant to rot, these
plastics are the ideal material to be used
in the making of walkways, bridges, fences
and signboards.
Societal commitment Recycling plastics is an environmentally
safe process that can help companies
gain a competitive edge. Elaborating on
this aspect, Vishal Jasrapuria, Director,
Shree Sadguru Plastic Industries, says,
“Reprocessed plastics can be used
anywhere and everywhere where virgin
plastics are used. If virgin plastics give
you a 100 per cent result, then good
quality reprocessed plastics can give you
results varying from 90 to 95 per cent.
Major areas where there is a good scope
for end-of-life reprocessed plastics are
construction, automotives, warehousing &
material movement solutions, agriculture,
household & furniture etc. Depending on
the type of plastic, on an average, it can be
recycled about 5–10 times. Reprocessed
plastics can be used over and over
again, only the applications would keep
changing depending on the quality of the
material. For example, if the material has
been recycled once, then it can be mixed
with some percentage of virgin material to
manufacture toothbrushes. However, after
that, when it is reprocessed again, then the
application would change maybe to either
furniture or something else depending
on the quality of the material and the
end use application of the product. If the
quality of reprocessed plastics is excellent,
then 80 per cent of it can be mixed in
manufacturing of a certain product along
with virgin materials. The next time, the
percentage of mixed reprocessed material
would reduce and the percentage of virgin
material would increase. Thus, applications
would keep changing according to the
quality of the material.”
Recycling materials uses far less
energy than creating them anew. As
the world becomes more eco-friendly
and environmental hazards increase,
recycling and reusing plastics are
expected to continue on a much larger
scale. Cristina Monge Frontinan, General
Director, Plastival, which is a cluster
that ensures the interests of the plastics
sector in Valencia, Spain, summarises
the scenario well. She elaborates, “The
percentage of applications of recycled
plastics is increasing. It is gaining a lot
of attention. Moreover, recycled plastics
are able to address the increasing demand
for raw materials to a certain extent.
With furniture and pipes constituting the
main segment of end-of-life applications
of recycled plastics, new applications
are being researched. New regulation
allows recycled material to be used in
secondary food packaging material. Also,
the business of recycling is picking up
pace globally. The problem of recycling
material is prevalent all around the world.
For India, the growth is only beginning so
the problem might not appear to be that
grave at this moment. Having systems
put in place right now would help in the
long run.”
Email: [email protected]
Vishal JasrapuriaDirector, Shree Sadguru Plastic Industries
Cristina Monge FrontinanGeneral Director, Plastival
Major areas where there is a good scope for end-of-life reprocessed plastics are construction, automotives, warehousing & material movement solutions, agriculture, household & furniture etc.
With furniture and pipes constituting the main segment of end-of-life applications of recycled plastics, new applications are being researched. New regulation allows recycled material to be used in secondary food packaging material.
72 Modern Plastics & Polymers | April 2013
INSIGHT & OUTLOOK: GREEN SHOOTS: Inter face – Vishal Jasrapur ia
How has the plastics recycling sector grown?As compared to other raw materials like
wood and metal, plastics have various
benefits. Since plastics are inert and
non-corrosive, they have broad
applications in different products.
Plastics are light in weight, easily
available and relatively cheaper.
According to an industry report, the
per capita consumption of plastics is a
meagre 5 kg in India as compared to
90 kg in North America, 65 kg in West
Europe, 12 kg in China, 39 kg in the
Gulf, 18 kg in Latin America and 10
kg in South East Asia. India is also
a large importer of hydrocarbons and
virgin plastic compounds.
I believe that recycling can reduce
the outflow of currency on account of
polymer purchases to a certain extent.
It can also address issues related to the
efficient disposal of plastics. The usage
of recycled material not only reduces
the cost of plastics but also increases
their viability for low-end applications.
Although this particular segment has
grown well over the last decade, there is
still scope for growth and improvement
in the recycling industry. I believe that
the current market size is just a tip of
the iceberg.
What are the challenges you have faced as a manufacturer of reprocessed plastics?There are no entry barriers in our
industry. Any fringe player can enter our
market without proper technology and
with minimal investment. These fringe
players throw the market off balance
by reducing the prices to unsustainable
levels and then start compromising on the
quality and consistency. When customers
deal with these fringe players, they do not
get proper quality inputs consistently and
thus hesitate using reprocessed material.
Due to these reasons and because they are
not able to partner with the right kind of
manufacturer, customers are not reaping
the benefits of using reprocessed materials
in a big way. Also, as manufacturers of
recycled plastic material, we face shortage
of manpower since this is a labour
intensive industry.
What are the possible solutions to overcome these challenges?Industry associations can act as a catalyst
to grow this industry by organising
workshops and seminars for the potential
customer industries whereby they
can be made aware of the benefits of
recycled material as well as the means
to unlock these benefits. The customers
should differentiate between quality
manufacturers and fringe players, and
strike a balance between the pricing and
quality. I can see that this has already
started happening. The government can
also aid this industry segment by giving it
a ‘Green Industry’ status and help us scale
up by providing incentives like interest
subsidy on capital expenditure, duty
exemption on import of machinery etc.
The recycling industry is important for
the proper disposal of plastics. We at Shree
Sadguru Plastic Industries are associated
with many industrial and environment-
friendly organisations like Indian Centre
for Plastics in the Environment (ICPE).
What should the industry do in order to increase the recycling of plastics?In order to grow, serious differentiation
has to be made between fly-by-night
operators and quality-conscious suppliers.
Customers need to be assisted to achieve
a balance between price and quality.
By avoiding the short-cut route of low
pricing and quality, the industry would be
able to grow at a much faster rate. This
is a sunrise industry, which is at a very
nascent stage. The industry should take a
long term view and focus on maximising
the growth opportunities.
Email: [email protected]
“Fringe players throw the market off balance”...opines Vishal Jasrapuria, Director, Shree Sadguru Plastic Industries, when talking about the Indian recycling segment. In a one-on-one with Sweta M Nair, he brings to light the challenges faced by processors of recycled plastics.
74 Modern Plastics & Polymers | April 2013
INSIGHT & OUTLOOK: GREEN SHOOTS: Inter face – Dr Prakash Mahanwar
How is the reprocessed plastics segment in India?The plastics recycling segment in the
country is extremely unorganised.
Businesses in this segment are mostly
micro and small scale enterprises.
Labourers in these sorting units work in
extremely unhygienic conditions. With
no skilled manpower, safety norms are
openly flouted. To fund their day-to-day
sustenance, workers segregate consumer
waste plastics with their bare hands and
without wearing face masks. This is the
prevalent scenario only in the recycling
segment; you will never find such
depressing working conditions in units
processing virgin material. Although few
prominent players have a turnover of about
` 2–3 crore, the industry is plagued by the
inability to invest in modern technology
due to the lack of funds. The reason being
that modern technology for segregating
consumer plastics waste comes at a high
price – perhaps a reason as to why the
industry is in such a dismaying state.
On a daily basis, we need cutting-edge
technology to separate and process the
fifty tonne of consumer waste that is
offloaded in Dharavi, Mumbai. Even
though the plastics waste is collected and
deposited, the thin polyethylene bags,
which are neglected by rag pickers, create
societal problems. These thin polyethylene
bags, as well as small chocolate wrappers,
shampoo sachets etc, do not fetch
a good price.
What sort of government support would you suggest that is needed to get to the crux of this matter?Recently, I have put forth a proposal to
the Ministry of Petroleum & Natural Gas
regarding the menace of thin consumer
plastics waste. I have proposed that the
authorities create and support technology
that will make use of such waste to create
fuel. Recycling is a societal matter that
needs governmental intervention. If a
plastics recycling processor wants to use
new technology, then it would involve
high capital. This coupled with a long
gestation period is not commercially
viable for companies; hence, we require
subsidies in this segment. To begin with,
the local authorities need to make sure
that rag pickers are well compensated
to collect small wrappers. Although
the end result after processing is low in
quantity, the authorities must subsidise
these processes so that it becomes
profitable to companies.
What are the possible solutions to these problems?Plastics is not a by-product of
urbanisation. We need solutions that will
address local problems. At the onset, we
need to sort out manpower requirements,
improve hygiene conditions and create
awareness among processors. The
government could start by setting up
common collection and automatic
segregation centres. When segregated,
the material can be sold to processors.
The government needs to invest funds
in Research & Development (R&D)
on plastics recycling. Businesses are not
going to invest in R&D activity because
it involves high capital and high gestation
period. Also, commercial success is
uncertain. Considerable research must
take place in waste plastics for fuel
generation, to create comingled plastics
for roads, new technology for composites
(where it can be reinforced with fillers)
and utilisation of additives that can help
in degradation of plastic materials.
From a processor’s perspective, what are the other end-of-life applications of reprocessed plastics?Road dividers, sideboards, drainage
pipes (made from reprocessed polyvinyl
chloride) are made from recycled plastics.
Recycled e-waste is used in automotive
applications and in road construction. In
the latter, we need to degrade the plastics
to a certain level so that it can become a
homogeneous mass with asphalt. Roads
laden with plastics are proving to be
better than roads made of concrete.
Email: [email protected]
“Plastics is not a by-product of urbanisation”…says Dr Prakash Mahanwar, Head – Dept of Polymer and Surface Engineering, Institute of Chemical Technology, when talking about end-of-life applications of plastics that could benefit society. In an exclusive conversation with Sweta M Nair, he brings to light the abominable conditions prevailing in this segment and the measures required for improvement.
74 Modern Plastics & Polymers | April 2013
INSIGHT & OUTLOOK: F i lament wound composite p ipes
76 Modern Plastics & Polymers | April 2013
Sangeeta Baksi, Leena Modi, Soumitra Biswas and Jayrah Shah
Advancements in exploration
and production technologies
have helped locate and
recover supply of oil and
natural gas from major reserves across
the globe. As a result, the emphasis
on pipelines has been gaining major
significance, as these offer a more eco-
friendly, safe and cost-effective mode
of transportation of fluids. Pipeline
designers and operators are looking at
alternative materials to conventional
steel pipes in order to meet the
increasing demands and maintain
safety & reliability. High-performance
polymers, rubber, glass fibre-reinforced
plastics (composites) etc are increasingly
used for pipes and pipe fittings. Being
highly corrosion resistant, composite
pipes have found extensive applications
in the oil & gas industry since the last
two decades. Applications of composite
piping are increasing following the
concurrent knowledge generation in the
area, with some key advantages such as
lightweight, high strength-to-weight
ratio, excellent flow characteristics,
low thermal conductivity and low
thermal expansion, corrosion resistance
and size variability. Besides, high cost
of replacing steel piping in retrofit
applications and increased longevity
in new construction drive the use of
composites, which can withstand
severe conditions as experienced in
offshore environment.
India has witnessed aggressive
growth in exploration and production in
the oil & gas sector, which would attract
enormous capital investment in the
future. Composite pipes in the last five
years have gained a strong foothold in
India and are gaining wide acceptance
for application in the transportation
of potable water, sewage, desalination,
offshore oil production, paper & pulp
industry, power plant etc. The demand
for composite pipes from the oil & gas
sector alone is expected to grow by 9-10
per cent Compounded Annual Growth
Rate (CAGR) over the next five years,
thus driving the overall demand growth
in India at 8-9 per cent CAGR.
Reinforcement material As a reinforcement material, fibre is
the primary contributor to the stiffness
and strength of composite pipes. The
dominant, commercially available fibres
are glass, aramid and carbon/graphite
systems. Fibre glass, when combined with
thermosetting resin, cures to form a rigid
composite structure, which is suitable for
a variety of applications. The different
types of fibre glass used are single- or
multi-end roving, woven roving, textile
yarn, chopped strand, chopped strand
mat, combo mat, veil, multi-axial or
unidirectional fabrics, wet chop etc.
Developments in technology have resulted in high-performance polymers and glass fibre-reinforced plastics (composites) that find extensive applications in making pipes and pipe fittings, especially for the oil & gas industry. Here is an overview of what makes this material ideal for use in aggressive environments.
TECHNOLOGICAL TRIUMPH for INDIAN INDUSTRY
Fi lament wound composite p ipes
77April 2013 | Modern Plastics & Polymers
MatrixThe resin is the ideal matrix that
holds the fibres together, providing the
load transfer mechanism between the
fibres that are wound into structural
forms. The resin matrix also provides
corrosion resistance, protects the fibres
from external damage and contributes
to the overall composite toughness from
surface impacts, cuts, abrasion & rough
handling. Different types of resins are
used for composite pipes, viz isophthalic,
vinyl ester and epoxy, depending on the
extent of chemical properties required
for the final product. The resin system
is chosen for its chemical, mechanical
and thermal properties. Epoxy resins are
used primarily for the manufacture of
small-diameter piping, while polyester
resins are commonly used for large-
diameter piping and storage tanks.
Although glass fibre resists a wide
range of chemicals and temperatures,
it requires the right design, fabrication
and installation to match the appropriate
application. For example, glass fibre may
undergo chemical attack from hydrolysis,
oxidation, pyrolysis or incompatible
solutions. Therefore, a proper resin/glass
matrix will help minimise chemical attack.
Auxiliary raw materials/additivesOther raw materials such as catalysts,
accelerators, inhibitors, aggregates and
pigments are used in resin and fibre
reinforcements to achieve desired
properties of the composite product. A
catalyst is an organic compound which
when added to resin in the presence of an
accelerator initiates the polymerisation
reaction at ambient temperature. An
accelerator is a chemical compound used
together with a catalyst to accelerate the
polymerisation process. An inhibitor is
added to the resin to reduce its reactivity
at ambient temperature. Often, sand
is used as filler during the winding
process to increase wall thickness in
certain cases.
Glass Reinforced Epoxy (GRE) technologyA valid alternative to carbon steel
pipes, especially for use in corrosive,
aggressive and normal environments, is
GRE pipe technology. It is based on
the discontinuous filament winding
process, where continuous glass fibres
are helically wound at predetermined
angles and bonded with the epoxy
resin. GRE pipes offer a unique
combination of good mechanical,
thermal and chemical resistance,
which is obtained by a selection of
high-performance components and
a proper design of the structure.
GRE pipes, with smooth internal
surface resulting in reduced friction
and high flow rate, are commonly
used in oil transportation calling for
lower resistance to crude oil, paraffin
build-up and high internal pressure.
Low thermal conductivity of GRE
pipes as compared to steel minimises
the cost of insulation and heat loss.
Another major benefit of GRE pipes
is that once installed, these are virtually
maintenance-free.
Sangeeta Baksi and Soumitra Biswas
are from Advanced Composites
Programme, Technology Information,
Forecasting & Assessment Council (TIFAC),
Department of Science & Technology
(Government of India), New Delhi.
Email: [email protected]
Leena Modi and Jayrah Shah are from
EPP Composites Pvt Ltd, GIDC Lodhika
Industrial Estate, Rajkot, Gujarat.
Email: [email protected]
Advantages of GRE pipes Wide range of diameters from 1
inch (25 mm) up to and including 54 inch (1,400 mm) Standard lengths of 6, 9 and 12 m Adhesive, locked bell/spigot,
lamination and flanged joining systems Corrosion-free in most
environments Long life (50 years) + zero
maintenance = low life cycle cost Ultra-violet resistant; can be safely
installed above ground Conductive pipe and fittings
available Fast, low-cost assembly due to
lightweight and simple joining techniques Lighter support needed for above-
ground systems
Physical properties of GRE pipes
Physical properties Unit Value
Specific gravity - 1.8
Density kg/m3 1,800
Coefficient of thermal expansion mm/mm/°C 1.8 × 10-5
Barcol hardness - 45
Degree of cure °C 150
Glass content % wt 60-65
Resin content % wt 40-35
Mechanical properties Unit Value
Hydro test for one minute mPa 11
Mill pressure test (1.5 * design) mPa -
Axial tensile strength mPa 60-65
Hoop tensile strength mPa 155-165
Hoop tensile modulus mPa 20,000-25,000
Axial tensile modulus mPa 9,000
External collapse pressure mPa 0.8
Initial stiffness factor mm3.kPa 113
Beam bending modulus mPa 8,200
AUTOMATION TRENDS: Operator- f r iendly machines
78 Modern Plastics & Polymers | April 2013
The Indian plastics processing
industry has seen major
innovations in the recent
past, which have resulted in
a long-term impact on the functioning
of machines. With overall cost reduction
and quality improvement being the main
driving forces, the plastics processing
industry offers a comprehensive choice of
technologies and application techniques.
Some of the major trends for increasing
the operating efficiency and reducing
costs in all the sectors of the plastics
processing machinery segment, such as
injection moulding, blow moulding and
extrusion, include usage of Supervisory
Control and Data Acquisition (SCADA)
system, Programmable Logic Controller
(PLC) and PC-based control systems.
Jaymin Pithwa, Director, Konark
Plastomech Pvt Ltd, notes, “With each
passing day, companies are developing
new technologies that can generate
maximum output at a lower cost.
These days, customers want highly
automatic and synchronised systems
so as to improve their product quality
& efficiency and reduce overall costs.
Thus, at present, although priced a bit
higher, highly automatic machines are
demanded by every customer.”
PC-based operationThe most important aim of any control
system for equipment in the plastics
industry is to provide a simple but
powerful user interface. Its function
must be intuitive and easy to use, and
depending on the familiarity level of the
user, the complexity of the functions
can increase. At present, machines with
PC-based control systems are the most
operator-friendly machines available
in the market. PC-based automation
basically includes a PC platform and a
Windows-operating system. It ensures a
host of benefits to the plastics industry,
ranging from higher quality parts,
improved equipment uptime, faster cycle
times and more predictable production
flow to reduced employee turnover. A
PC-based system solution offers a style
of operation similar to desktop PC
applications, which any individual can
use today.
Further, the installation of software
with a colourful graphical user interface on
PCs not only makes machine operations
interesting and motivating to operators
but also shortens the learning curve for
them. Thus, machine operations become
more enjoyable to the operator, and at
the same time, production is improved.
Simple button clickIn a PC-based system, at the press of
a button, the set-up person can select a
completely different procedure or adapt
its function to the required procedure.
The ‘simple view’ selections of tried-
and-tested standard procedures of the
controller are available to the operator
for different automation applications.
The set-up person does not require any
programming know-how; one can simply
select a procedure and then adapt the
process sequences to the requirements
demanded by changing variants. All
settings necessary for a sequence (position,
speed and time) are displayed on a clearly
With the advent of automation and the demand for operator-friendly machines growing in the plastics processing segment, many companies in the country have started employing machines with PC-based automation or control systems. Avani Jain takes a closer look at the benefits of using such operator-friendly machines and how they help in increasing production without increasing the costs.
78 Modern Plastics & Polymers |
INCREASING PRODUCTION, REDUCING COSTS
Operator- f r iendly machines
79April 2013 | Modern Plastics & Polymers
arranged setting page. Commands to
be inserted are simply selected from an
extensive functions list and placed at the
desired point in the sequence. Pressing
the symbols in the sequence editor
immediately calls up the respective screen
page on which the parameters can be set.
Even complex sequences can be quickly
configured. An operator is able to create
movement sequences for linear robots and
thus can learn to program articulated-arm
robots within minimum time. Thus, all
the tasks can be performed by just clicking
the button, thereby reducing the need of
labour for performing each task manually.
This leads to reducing the labour costs
and the production is increased.
The ‘soft’ware touchOne of the key benefits of process control
system based on PC technology is that
it is easy to use because the software
is running on a familiar platform and
that makes it cost-effective too. Because
these systems are software-based, they
are more powerful and more flexible.
PC-based systems are inherently user-
friendly, and operation can be intuitive.
The biggest convenience for users is the
ability to see the ‘big picture’. Instead of
viewing process conditions in isolation,
this type of system allows users to readily
see data of all equipment from a single,
central monitoring station and view that
data over time via trending screens.
User-friendly Human Machine Interface (HMI)These days, machines with PC-based
controls are equipped with user-friendly
HMI, which is easily accessible for
process parameters. It provides excellent
troubleshooting guidelines along with
the help and alarm menu pages. It has
features such as functionally oriented
screen layouts; process parameter
monitoring in real-time and feeding
value on absolute basis; simple &
pictorial diagrams to enable operator
understanding; auto temperature
and temperature profile selection for
homogenous melt from the first shot;
extruder overrun for uninterrupted auto
cycle; auto heating start, shut down and
standby to save time and energy during
operation; intrusion insert moulding,
gas assist interface, core pulling etc for
multi-tasking utilisation; auto purging
for smooth shutdown; mould cooling,
mould gate option, sprue break, nozzle
shut-off valve, cold slug removal etc for
various applications and smart input/
output for uninterrupted production.
PLC and SCADA systems for reducing labour dependenceThe controls in use at present make
use of microprocessor-controlled high-
speed PLC and SCADA systems, which
also help in reducing the overall costs
and increase production. Rajiv Trivedi,
Vice President (Marketing), Prasad
Group & Chairman, Indian Plastics
Institute – Ahmedabad Chapter, notes,
“The machines with this system help in
achieving zero rejection. Further, these
systems help in reducing the labour costs
to a large extent as you need to have only
one skilled personnel to set the parameter
once, and then repeatable operations can
be carried out automatically. Hence,
production is improved and increased.”
Future trendsThe plastics processing industry is in
the midst of a transformation as far
as machine construction and system
engineering are concerned, leading to the
development of versatile and innovative
control technology.
Despite increasing complexity,
the user-friendliness of systems and
processes requires to be maintained as
well as improved. The operator must
only be confronted with one central
operating concept and user interface.
Therefore, control systems that enable
the integration of peripherals, a uniform
operating concept, simple programming,
clear representation of complex processes,
a high degree of process reliability and
comprehensive motoring functions for
quality assurance are required to increase
machine user-friendliness for increased
production at lower costs.
Email: [email protected]
Jaymin PithwaDirector, Konark Plastomech Pvt Ltd
With each passing day, companies are developing new technologies that can generate maximum output at a lower cost. These days, customers want highly automatic and synchronised systems so as to improve their product quality & effi ciency and reduce overall costs.
Rajiv TrivediVice President (Marketing), Prasad Group & Chairman, Indian Plastics Institute – Ahmedabad Chapter
These systems help in reducing the labour costs to a large extent as you need to have only one skilled personnel to set the parameter once, and then repeatable operations can be carried out automatically.
ENERGY MANAGEMENT: Reducing energy consumption in p last ics processing
80 Modern Plastics & Polymers | April 2013
Although energy conservation
is not a major factor in the
field of machine building,
there are possibilities to
reduce energy consumption of injection,
blow moulding or hydraulic machines.
Over the years, processors have realised
the long-term benefits of reducing energy
consumption in plastics processing as it
not only helps achieve higher output but
also saves cost substantially.
Moulding machines are used to
manufacture a complex array of industrial
products. Ravi Kumar, Director, Shiv Pooja
Plastics, says, “To offset rising production
costs stemming from demanding
applications, manufacturers turn towards
machines that can deliver higher
precision levels, greater cost efficiencies
and maximum flexibility.” For decades,
companies have developed blow moulding
technology to help them remain at the
forefront of high-performance motion
control technologies for hydraulic blow
moulding machines, which reduce time
and result in increased energy savings
through the moulding process.
However, there are various challenges
in ensuring energy savings in this
process while providing quality output.
Manufacturers are fast realising the
challenges in managing the required
compressed air systems from an energy
efficiency standpoint using high-speed
precision equipment.
Reducing energy consumptionHigh-speed electric feeder solutions
help machines consume up to 30 per
cent less energy than competitive
hydraulic machines. These produce
higher quality and more repeatable
parts today. End users are continually
searching for the edge in product
quality, from plastic bottles that utilise
30 per cent less material to complex
package designs. High-speed precision
motion control would ensure uniform
wall thickness and guarantee that all
parts meet quality specifications.
The compact design of high-speed
electric solutions helps save valuable floor
space, which means customers can increase
the number of machines at work at any
given time. “To ensure safe operations,
built-in safety features including fail-
safe and slow set-up mode help reduce
unplanned downtime and foster operator
safety,” adds Kumar. Efficient engineering
will help facilitate future blow moulding
machine technologies. High-performance
engineering means that a blow moulding
machine is always ready for the latest
advancements in machine technology.
Today, blow moulding machines are
used to make everything from vessels
to toys to car petrol tanks. To offset
rising production costs from evermore
demanding applications, customers need
blow moulding machines of even higher
accuracy, efficiency and versatility. Neeraj
Garg, Partner, Suruchi Industries, says, “To
solve the challenge of accurate positioning
Maximise output,
The blow moulding process involves various complex stages of operations, coupled with high-speed precision moulding techniques. Moulders are increasingly opting for energy-efficient mechanisms that complement high productivity standards. Anwesh Koley analyses the challenges in achieving production efficiency in blow moulding and the measures required to rectify them.
MINIMISE CONSUMPTION
Reducing energy consumption in p last ics processing
81April 2013 | Modern Plastics & Polymers
under high-speed motion, it is important
to ensure more accurate parison thickness
control for highest product quality and
lower production costs.”
A complete system of high-response
servo valves, the machine controller and
an advanced man–machine interface
will help overcome technical challenges.
Highly accurate multi-axial control system
yields faster and more stable close-loop
mould movement speed. The hardware/
software design of the machine controller
should provide control of cover wall
thickness, weight temperature, motion
and other measured values. To address
upgrading requirements, the controller
must integrate intelligent temperature
control, closed-loop motion control,
dedicated wall thickness control and a
servo valve current drive.
By focussing on specific requirements,
high-speed blow moulding solution
providers are able to provide high-
performance solutions that ensure energy
savings at various stages during the
moulding process. “Today, it is important
to ensure commitments that go beyond
the initial collaboration to facilitate
reliable and flexible products worldwide.
For smooth functioning of a technology
as well as timely delivery of the final
product, service technicians worldwide
are ensuring timely and precise repair
of components,” adds Garg. Machinery
manufacturers are focussing on developing
efficient and low-cost plastics processing
equipment. Such equipment will be
smaller, multi-functional and flexible.
Challenges for compressed airRotary Reheat Stretch Blow Moulding
(RSBM) machines from leading
manufacturers across the globe provide
challenges to the efficiency of compressed
air systems. These challenges include
significant pressure drops in the RSBM
machine with large instantaneous air
demand swings. High horsepower
for individual compressors increase
consumption of compressed air, and the
usage of high historical pressure equipment
also add to the problem. Besides, a single
facility may have multiple pressure
requirements, making steady monitoring
a tough task. Despite these challenges, it
is possible to achieve 15 per cent energy
savings on the supply side with another
15 per cent achievable by focussing on the
pressure drops in blow moulding machines.
Pressure-drop situations in the processorStabilising air pressure is a primary
objective. Pressure fluctuations occur
in most stretch machines and are
significantly lower than expected.
Correcting this can lead to increased
productivity and reduced air consumption.
“Blow moulders must understand the
air pressure requirements of their blow
moulding machines. For example, the
blowing process consumes about 60 per
cent of the air. The remaining pneumatic
applications, using 40 per cent of the air
for control components and packaging
or decorating, will typically require lower
pressures. The blow moulder must install
a dedicated piping system to the blow air
circuits to reduce air consumption during
the blowing process,” says Garg.
In process industries, companies are
taking most of the measures available
to optimise their processes in order to
gain on productivity and reduce waste.
“As compressors have the largest motors
among the auxiliaries, consuming millions
of dollars worth of electric power every
year, anything we can do to save its energy
remains our focus,” adds Kumar.
By adding air recovery systems to
blow moulding machines, the used high-
pressure air can be recycled after blowing
the bottles for machine running, thereby
reducing energy consumption. Such a
process has various advantages. When
using the low-pressure air compressor with
same specifications, this system would
extend the rest time of the air compressor,
reduce its energy consumption and extend
the service life of the machine. After
adopting the air recovery system, the blow
moulding machine can be equipped with
a smaller low-pressure air compressor,
thereby decreasing energy consumption
and reducing production costs.
Email: [email protected]
Ravi KumarDirector, Shiv Pooja Plastics
To offset rising production costs stemming from demanding applications, manufacturers turn towards machines that can deliver higher precision levels, greater cost effi ciencies and maximum fl exibility.
Neeraj GargPartner, Suruchi Industries
To solve the challenge of accurate positioning under high-speed motion, it is important to ensure more accurate parison thickness control for highest product quality and lower production costs.
82 Modern Plastics & Polymers | April 2013
Regulatory frameworks across the globe have shown tremendous enthusiasm in bringing down the carbon footprint generated
by business houses in order to create a sustainable manufacturing environment with healthier practices. Plastics generally have a poor or negative image in comparison with other materials, in particular with regard to their perceived impact on the environment and use of resources. This also has to do with various government initiatives banning the use of plastics below certain thickness for packaging purposes. While plastics from renewable resources are now being developed, their current market penetration is not high enough to have a significant effect on the overall results.
Material regulationsThe choice of materials used to produce
plastic food packaging is evolving, and the considerations for materials are increasingly influenced by cost, environmental impact and the ability to be recycled. Deepak Takkar, Proprietor, Takkar Industries, says, “Packaging companies that use plastics are looking at ways in which mineral content can be combined with plastics to produce packaging that changes the balance of raw materials used. There is also pressure on the industry to reduce the weight of packaging. Major retailers across the globe have agreed to follow green packaging norms with the aim of having less food products and packaging ending up as household waste. The packaging industry is supporting this through the design of containers and materials used, while making sure that food safety is not compromised.” In the case of flexible food packaging, the average pack weight has
been reduced by almost 25 per cent over the past half decade.
Shop-floor initiativesThe manufacture of plastic packaging is energy intensive and as a result contributes to the carbon footprint. However, this is an area where negative environmental impact can be reduced. R Varadrajan, Senior Country Technical Manager – India & SAARC, Dassault Systèmes, SolidWorks, says, “Over the past five years, the production process in most countries has changed dramatically. For example, originally the production of hollow thermoformed bottles consisted of relatively inefficient ‘flat-bed’ thermoforming machines alongside energy-efficient rotary machines. These flat-bed machines have now been phased out, and they have been replaced by high-output rotary machines. This has
THEREDUCING
FOOTPRINTFOOTPRINTCARBON
POLICIES & REGULATIONS: Green packaging norms
Carbon emissions from plastics processing techniques have been under the scanner for a long time. Although the per capita emission of greenhouse gases by India is quite low, plastics processors have undertaken numerous initiatives to ensure sustainable processing that yields environmental benefits in the long run. Anwesh Koley analyses the various imperatives that must be observed to achieve successful green packaging norms.
Green packaging norms
83April 2013 | Modern Plastics & Polymers
resulted in a reduction in energy use, thereby reducing the carbon footprint substantially.” Various processing companies have reduced the amount of energy used by almost 30 per cent through such practices. Over time, this efficiency is expected to result in meaningful cost savings.
Proper recycling and disposal of plasticsIn theory, plastic packaging has the capability of being a cradle-to-cradle product – a product that can be recycled or reused with no loss of quality. This is the way in which glass is currently disposed, where facilities collect and recycle waste glass. However, there are a number of obstacles that currently prevent this happening with plastics. Only very few plastic products consume more energy than their possible substitutes made of different materials. Most plastic products need lesser energy to be produced than their alternatives. Additionally, many plastic products save significant amounts of energy during the use phase.
On an average, 85 per cent of waste plastics go to landfill, about 10 per cent is incinerated and about 5 per cent is recycled. However, even less can go back into food packaging because of food safety issues with recycled plastics and because customers still prefer virgin materials. “If better collection services existed for plastic trays and if there was a common standard for local authorities collecting recyclable plastics, plastic packaging has the potential to be as recyclable and reusable as glass or tin,” believes Varadrajan. According to research studies by the Waste and Resources Action Programme (WRAP), the collection of mixed plastic packaging is ‘technically and economically viable’ on a commercial scale. The challenges that now lie ahead for local authorities are the provision of collection and dropping sites, and encouraging consumers to utilise these services.
Role of plastics in generating renewable energyPlastics play an increasing role in the generation of renewable energy. Examples are the plastic rotor blade of a wind
turbine and thin film photovoltaic units, where non-silicon semiconductors, both metal and organic, are printed on plastic films. Wind power turbines ensure high greenhouse gas emission savings within the use phase. These are 140 times higher than the emissions from conventional production because one-third of greenhouse gas emission savings enabled by the wind power plant are allocated to the rotor.
Deriving energy-efficient polymersIt is important to understand the possible future role of renewable resources in the plastics industry. “Two categories of plastics are possible from renewables. One option is the production of monomers to make new polymers such as polylactic acid. Here, the commercial challenge is to compete with existing large-volume plastics in terms of production economics and adapting processing equipment. The other route is to make high volume monomers such as ethylene or other ethylene derivatives from ethanol derived from renewable sources. These can then be used in existing polymerisation plants making the well-known polyethylene grade ranges,” says Takkar. In both cases, the chemistry is proven, but a key consideration will be the amount of non-renewable energy used in the overall manufacturing chain.
Towards a sustainable futureWhile efforts are being made globally towards reducing carbon footprint from plastics processing, it is important that the packaging industry continues to work together to drive innovation in design, materials, production processes and disposal. “While the ebb and flow of the economy will present varying financial demands on the packaging industry, the challenges posed by the need to reduce the carbon footprint are sustained and long term. It is by mirroring this need with a long-term and credible plan to tackle these challenges that will ensure that plastics are not looked down upon,” adds Takkar. The plastic packaging industry can then evolve in a way that meets the retail demands of convenience and cost, while reducing the carbon footprint.
Email: [email protected]
R VaradrajanSenior Country Technical Manager – India & SAARC, Dassault Systèmes, SolidWorks
If better collection services existed for plastic trays and if there was a common standard for local authorities collecting recyclable plastics, plastic packaging has the potential to be as recyclable and reusable as glass or tin.
Major retailers across the globe have agreed to follow green packaging norms with the aim of having less food products and packaging ending up as household waste. The packaging industry is supporting this through the design of containers and materials used.
Deepak Takkar Proprietor, Takkar Industries
STRATEGY: P last ic packaging
84 Modern Plastics & Polymers | April 2013
Advantages that plastic packaging brings to the table are many. Besides fu l f i l l ing pac kag ing
requirements, it makes a good medium for advertising and presenting products. Ease of transportability and extending the shelf life of packaged products are the other benefits of using plastics as a packaging material.
Plastics such as Polypropylene (PP), Polystyrene (PS), Polyvinyl Chloride (PVC), Low-density Polyethylene (LDPE), High-density Polyethylene (HDPE), Polycarbonates (PC) and Polyethylene Terephthalate (PET) are being used by food processors for packaging food. However, some grades of plastics do have certain disadvantages when they come in direct contact with food. For instance, grades such as PVC, PS and PC leach chemicals that are way above the acceptable limit. These plastics also have limitations in terms of prolonging the shelf life of packed products in controlling microbial, enzymatic and biochemical reactions of the internal environment of the packaging via strategies such as oxygen removal, controlled release of salts etc.
However, there are new varieties that do not affect the quality of food products but instead increase shelf life. Playing a
protective role, modern plastics are doing a lot more than their key functions.
Multi-layer filmsMulti-layer co-extruded or laminated flexible materials are a significant development in modern packaging technology. Most extruded multi-layer structures are based on polyolefins because of their low cost, versatility, processability, chemical inertness and high moisture barrier properties accompanied by their poor ability to inhibit oxygen and aroma transitions. These multi-layer structures are produced by processing commodity plastics such as PE and PP, tie resins and centre barrier resins [eg ethylene vinyl alcohol (EVOH) and polyamide]. An extruder, a feed block and a die are used to produce a five-layer film. The multi-layer films could be of seven layers or nine layers depending on the number of extrusion lines when a multi-layer film is made.
Polyamide resins are also an important class of polymers used in the packaging industry and owe their popularity to good barrier properties against oxygen, aromas and organic solvents along with high tensile strength and toughness. “The thin barrier layer, which is usually made of EVOH, Polyvinylidene Chloride (PVDC), polyester, acrylic co-polymer or
similar material, is designed to preserve freshness and lengthen shelf life by preventing the migration of gas in or out of the package; for example, to keep oxygen out of a frozen food package or to keep carbon dioxide inside a beer bottle,” says Dr Subhas Chandra Shit, Professor & Head-HLC, Department of Chemicals & Petrochemicals, Central Institute of Plastics Engineering & Technology (CIPET), Ahmedabad.
Multi-layer containers have a layer of EVOH sandwiched between PP and any other plastic grade. EVOH provides oxygen and moisture barrier properties to the container. This keeps the product in the container fresh with a shelf life of over 12 months.
Blends and nanomaterialsCyclic Olefin Copolymers (COC) are also being increasingly used in polyolefin blends to produce barrier films for packaging because it has one of the highest moisture barriers of any polymer (four to five times better than LDPE). COC is not considered to have a high gas barrier, but it is still significantly better than LDPE. When COC is added to Linear Low-density Polyethylene (LLDPE), it increases modulus by two times while maintaining low haze. Similarly, when HDPE is blended with polyamide, its
The right material is crucial for the success of any packaging application. With continued innovations, new grades of plastics are being developed to extend the shelf life of packaged food products. Although studying the total system for a complete analysis is required, Sweta M Nair presents the latest in this segment that is making big waves.
APPLICATIONS APPLICATIONS THAT ENHANCE THAT ENHANCE
PRODUCT PRODUCT SHELF LIFESHELF LIFE
Plast ic packaging
85April 2013 | Modern Plastics & Polymers
barrier properties increase significantly.Nanocomposites are also at the
forefront of food packaging development. Nanocomposite film enriched with an enormous number of silicate particles reduces the entry of oxygen and other gases and the exit of moisture, thus preventing food from spoilage. Dr Shit adds, “Some companies have developed nanocrystals for making a nanocomposite that would be used in beer bottles. Most polymer composite materials are based on fossil fuel derivatives; however, research on biopolymers is offering biodegradable alternatives. The inherent drawbacks of pure bio-polymers that depend on type can include poor barrier properties or poor mechanical properties can be mitigated by the inclusion of nanofibres to form nano-biocomposites.” Most nanocomposite materials employed or being developed for use in the food packaging industry contain nanoclay particles; however, other composites containing nanoparticles, nanotubes or nanofibres of metals, metal oxides, biopolymers or other carbon-based material are being developed.
New systems and filmsTo arrest oxygen, new polymer systems with special barrier properties are used on the surface of the plastic container. A recent study conducted by Dr Philip Labuschange and his team claimed that the developed polymeric system (inter polymer complexation system – close-knit polymer network formed by hydrogen bonds with a high density) reduces oxygen permeability by a factor of about 20 (for polyester-based plastics) and by a factor of about 150 (for polyolefin-based plastics). This simply increases the shelf life of any oxygen-sensitive beverage in plastic containers by up to 150 times.
In the food sector, multi-layer films occupy the major share of the food packaging market since nano-based materials are yet to be effectively commercialised and are presently priced at a high cost. “Nanostructured material will have better capability than others because of the high barrier capacity and environment-friendly character,” affirms Dr Shit.
Email: [email protected]
Dr Subhas Chandra ShitProfessor & Head – HLC, Department of Chemicals & Petrochemicals, CIPET, Ahmedabad
Some companies have developed nanocrystals for making a nanocomposite that would be used in beer bottles. Most polymer composite materials are based on fossil fuel derivatives; however, research on biopolymers is offering biodegradable alternatives.
TIPS & TRICKS: Guidel ines for ef f ic ient equipment
86 Modern Plastics & Polymers | April 2013
The plastics processing industry requires heavy maintenance and constant monitoring of numerous equipment that are used in order to remain in optimum working conditions. Anwesh Koley notes various pointers to ensure seamless processing and cost efficiency.
The growth witnessed by the plastics industry has a direct implication on the performance of the ancillary
equipment sector, which forms the backbone of the plastics machinery
industry. The numerous machines used in the plastics industry require a host of equipment that depend upon the application and requirement of the final product. The global trend towards faster processing equipment
and better accuracy in terms of productivity has led manufacturers across the country to adopt technologies that help achieve higher end user satisfaction.
Email: [email protected]
Being environment-friendly is a key requirement for equipment in plastics processing. Use of consumables that are recyclable or environment-friendly must be adopted. Water is being increasingly used as heat transfer medium instead of thermal oil in temperature control units. Refrigerant units use environment-compatible refrigerants, and lead soldering of printed circuit boards has been given up by most processors.
When the processing unit has reached a consistent temperature, the extruder machine is ready to be turned on. It is important to speed up the screw rod manually and start the feeding process of the material into the machine. Also, the material must be checked on its way out of the machine to make sure there are no impurities, no foam, no coke burning and no colour change.
The current trend in user-friendly networked controls is towards graphical, menu-driven touch screen controls. Different parts of the system can communicate with each other through CANbus or ethernet protocols . Anci l lar y equipment are designed with digitally controlled, more precise, fast, compact graphical interfaces that are easily compatible with machine controls.
It must be ensured that before commencing operation, the water, electricity, gas levels and temperature systems are properly checked and in good working order. When this inspection is complete, the die head must be calibrated and installed. This is essential as equipment break down might occur during non-working hours. After this is done, the heating power may be turned on.
Latest technology aids in efficient processing. Advanced features are options for connectivity with Wi-Fi & SCADA solutions through which all the machines are connected with a single PC, or a smart phone through which processors can access their machine production and status from anywhere in the world. These must be installed at all levels to achieve the desired results.
Energy efficiency and conse r va t ion have become imperative for ancillary equipment usage. Minimising energy input in processes, decreasing energy losses and recovery of waste heat need to be seamless. This is important in drying, granulation, temperature control and chiller systems, which are energy intensive. Lowering costs through reducing inputs, wastage and labour has been the focus in blending and conveying systems.
Ensuring SAFE and EFFICIENT processing
Follow these pointers for effective ancillary equipment maintenance:
PROJECTS
88 Modern Plastics & Polymers | April 2013
High-density polyethylene/polypropylene/nylon/polyester and their products including fishing ropes, fishing nets and fishing twinesTufropes Pvt LtdProject typeNew facilityProject newsTufropes Pvt Ltd is planning to set up a new polymers project at Vadodara in Gujarat. The project involves manufacturing of all types of high-density polyethylene/polypropylene/nylon/polyester and their products including fishing ropes, fishing nets and fishing twines.Project locationVadodara, GujaratProject costNAImplementation stagePlanning
Contact details:Tufropes Pvt Ltd507, Embassy CentreNariman Point Mumbai – 400 021Tel: 022-40502600 Fax: 022-22844167 Email: [email protected]
High-density polyethylene/polypropylene woven sacks Ankit Polysack India Pvt LtdProject typeNew facilityProject newsAnkit Polysack India Pvt Ltd is planning to set up a new polymers project at Tikamgarh in Madhya Pradesh. The project involves manufacturing of high-density polyethylene/polypropylene woven sacks. The company has received industrial license from Secretariat of Industrial Assistance (SIA), Department
of Industrial Policy and Promotion, Government of India, for setting up the project.Project locationTikamgarh, Madhya PradeshImplementation stagePlanningProject costNA
Contact details:Ankit Polysack India Pvt LtdNo. 431, Tal Kalol Santej–Vadsar Rd Ahmedabad – 382721Gujarat Tel: 027-64286673 Plastic polymer plantIndian Oil Corporation Ltd (IOC)Project typeNew facilityProject newsIndian Oil Corporation Ltd (IOC) is planning to set up a polybutylene terephthalate, semi-crystalline thermo plastic polymer plant. The refinery will also include a petrochemical complex with a 553,000 tonne/year purified terephthallic acid production facility from naphtha supplied by the Panipat and Mathura refineries in close proximity.Project locationPanipatProject costNAImplementation stagePlanning
Contact details:Indian Oil Corporation Ltd (IOC)3079/3, J B Tito MargSadiq Nagar New Delhi – 110 049Tel: 011-26260000
Plastic shopping bagsNational Small Industries Corporation LtdProject typeNew facilityProject newsSupply of one set of plastic shopping bags.Project locationIndiaProject costNAImplementation stagePlanning
Contact details:National Small Industries Corporation LtdNSIC BhawanOkhla Industrial EstateNew Delhi – 110 020 Tel: 011-26926275, 26926370Fax: 011-26932075
Tarpaulin made of high-density polyethylene and polypropylene bagsJBS Rasayan Pvt LtdProject typeNew facilityProject newsJBS Rasayan Pvt Ltd is planning to set up a new polymers project at Burdwan in West Bengal. The project involves manufacturing of tarpaulin made of high-density polyethylene Leno bags, polypropylene jumbo bags and cement/fertiliser bags.Project locationBurdwan, West BengalProject costNAImplementation stagePlanning
Contact details:JBS Rasayan Pvt Ltd24, Hemanta Basu Sarani Kolkata – 700 001 West Bengal
New projects and expansion activities are the barometers of industrial growth. These also present business opportunities to service providers like consultants, contractors, plant & equipment suppliers and others down the value chain. This feature will keep you updated with vital information regarding new projects and capacity expansions being planned by companies in the plastics, polymers and allied industries.
Information courtesy: Tendersinfo.com
1, Arch Gold, Next to MTNL Exchange, Poisar, S V Road, Kandivali (W), Mumbai - 400 067, Maharashtra, India
Tel: 022 28666134 • Fax: 022 28013817 • Email: [email protected]
TENDERS
89April 2013 | Modern Plastics & Polymers
Latest Popular Tenders brought to you by www.tendersinfo.comGarbage bags and sacksOrg : Thisted Kommune
TRN : 14976438
Desc : Provision of garbage bags and sacks
BOD : 10 Apr 2013
Loc : Denmark
BT : Global (ICB)
Silicone rubber and rimsOrg : Fars Regional Electric Co
TRN : 15225218
Desc : Supply of 80 and 120 kN
silicone rubber and rims
BOD : 10 Apr 2013
Loc : Shiraz, Palestine
BT : Global (ICB)
Polythene bagsOrg : Ordnance Factory Board
TRN : 15162162
Desc : Supply of polythene bags
BOD : 11 Apr 2013
Loc : Kanpur, Uttar Pradesh
BT : Domestic (NCB)
Moulding machineOrg : Plastyko Word SRO
TRN : 14976520
Desc : Supply, installation and commissioning
of special thermoforming moulding machine
BOD : 12 Apr 2013
Loc : Czech Republic
BT : Global (ICB)
Plastic seatsOrg : North Western Railway
TRN : 15060588
Desc : Supply of plastic seat, ie bottom top
for commode of coaching stock
BOD : 12 Apr 2013
Loc : Jaipur, Rajasthan
BT : Domestic (NCB)
Low-density polyethylene filmOrg : India Government Mint
TRN : 15161245
Desc : Procurement of low-density polyethylene film
BOD : 16 Apr 2013
Loc : Hyderabad, Andhra Pradesh
BT : Domestic (NCB)
Plastic films and bagsOrg : ICDI
TRN : 14976268
Desc : Acquisition and recycling of plastic waste – planting
pots, plastic film (polyethylene) and expanded
polystyrene (frigolite) from parks, recycling ICDI
and delivery bags
BOD : 16 Apr 2013
Loc : Couillet, Belgium
BT : Global (ICB)
Polyvinyl chloride flooring sheetOrg : Central Railway
TRN : 15140302
Desc : Supply of flexible polyvinyl chloride
flooring sheet
BOD : 18 Apr 2013
Loc : Mumbai, Maharashtra
BT : Domestic (NCB)
Carbon molecular sieveOrg : Tamil Nadu Generation and Distribution
Corporation Ltd
TRN : 15224227
Desc : Carbon molecular sieve for pressure
swing adsorption in N2 adsorption tower
BOD : 19 Apr 2013
Loc : Ramanathapuram, Tamil Nadu
BT : Domestic (NCB)
Org: Organisation’s name, TRN: Tendersinfo Ref No, Desc: Description, BOD: Bid Opening Date, Loc: Location, BT: Bidding Type.
Latest Popular Tenders brought to you by www.tendersinfo.com
Information courtesy: Tendersinfo.com
1, Arch Gold, Next to MTNL Exchange, Poisar, S V Road, Kandivali (W), Mumbai - 400 067, Maharashtra, India
Tel: 022 28666134 • Fax: 022 28013817 • Email: [email protected]
EVENT LIST
90 Modern Plastics & Polymers | April 2013
Compack ChennaiCompack 2013 displays one of the
most impressive and efficient collection
of packaging equipment and materials
which are of advanced technology.
This event will demonstrate the most
important packaging and processing
solutions. The visitors coming to
Compack 2013 will comprise high
profile executives from the packaging
and transportation sectors; June 7–9,
2013; at Chennai Trade & Convention
Centre, Chennai, Tamil Nadu
For details contact:
Narendar Bafna
Smart Expos
New No. 116, Manickam Lane
Mount Road, Guindy
Chennai - 600 032
Tamil Nadu
Tel: 044-22501986/1987
Mob: 09952966752
Email: [email protected]
Website: www.compackexpo.com
IPLEX ChennaiThe Tamil Nadu Plastics Manufacturers
Association, the organiser of
IPLEX, has come forward to exhibit
various moulds and dies, equipment
and machinery exclusively required by
the plastics manufacturing sector of
India. The exhibitors are well versed
with the respective range of products
so that attendees can select the best
for their firms; June 27–30, 2013; at
Chennai Trade & Convention Centre,
Chennai, Tamil Nadu
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
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
For details contact:
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
Email: [email protected]
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
For details contact:
Brijesh Purohit
Sunline Infotech, 118, Lotus Arcade
Opposite Automotive, Gondal Road
Rajkot, Gujarat
Tel: 0281-2460135
Plastivision India Designed to help exhibitors and
visitors to discover potential markets,
Plastivision India will be the 9th in
the series of national exhibitions and
seminars organised by the All India
Plastics Manufacturers Association
(AIPMA). With participation from
more than 45 countries and visitors
from over 61 countries, the event
will include exhibitors ranging from
categories such as raw materials &
chemicals, plastic packaging machinery
& equipment, machinery & equipment
for processing, recycling, pre & post
processing machines, plastic extrusions,
thermoforming/films/thermoplastics
etc; December 12–16, 2013; at Bombay
Exhibition Center (BEC), Mumbai
For details contact:
AIPMA
A-52, Street No. 1, M I D C, Marol
Andheri (East), Mumbai
Tel: 022-28217324/28217325/
28352511/283
Fax: 022-28216390
Email: [email protected]
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
91April 2013 | Modern Plastics & Polymers
Plastic JapanPlastic Japan is one of the biggest trade
show of the plastics industry in Japan.
Over the course of three days, 25,000
professionals of the plastics industry are
expected to visit the event this year to
discuss business and expand their client
base. Plastic Japan will be visited by key
players of the plastics industry of the
country; April 10–12, 2013; at Tokyo
International Exhibition Center (Tokyo
Big Sight), Tokyo, Japan
For details contact:
Plastic Japan Show Management
Jun-yeup Lim
Reed Exhibitions Japan Ltd
18F Shinjuku-Nomura Bldg
1-26-2 Nishishinjuku, Shinjuku-ku
Tokyo 163-0570, Japan
Tel: +81-3-3349-8518
Fax: +81-3-3349-8530
Email: [email protected]
Website: www.plas.jp/en
Plastic ExpoPlastic Expo is one of the premium
exhibitions providing the latest and
the best in plastic materials for
all manufacturing and processing
industries alike. It enables foreign
and Tunisian professionals to assess
industry situations, develop their
business relationships in the domestic
and international markets, secure
technological watch, study and compare
prices, delivery times and quality,
launch partnerships, seek new raw
materials sources, supplies and potential
clients etc; April 24–27, 2013; at Tunis
Exhibition Center, Tunis, Tunisia
For details contact:
Foires Internationales De Tunis
B. P. N-1, 2015
Le Kram, Tunis, Tunisia
Tel: +(216)-(71)-730111
Fax: +(216)-(71)-730666
Email: [email protected]
Website: www.plasticexpo.com.tn
Alex PlastAlex Plast will help make technical
and professional experts related to the
plastics industry aware of the latest
trends and techniques to help advance
the plastics industry. It will bring to light
the importance & value of machinery
& equipment for plastics, reinforced
plastics and technical parts in the recent
times. This expo will also provide useful
information to contractors, consultants
and engineers; May 1–4, 2013; at
Alexandria Fairgrounds, Alexandria,
Egypt
For details contact:
Trust International Group
20 El-obour Building
Salah Salem St
Nasr City, Cairo, Egypt
Tel: +(20)-(2)-22600986
Fax: +(20)-(2)-24012121
Email: [email protected]
Website: www.alex-plast.com
Plastpol ExpoPlastpol Expo is a prestigious show
for the rubber and plastics industries
as professionals will get to exhibit new
and advanced machinery that will help
in increasing productivity. The expo is
the perfect place where new products
will be launched and the attendees
will also get to know about the recent
developments made in this sector. The
popularity of the show has brought in
the participation of leading companies
from the domestic and international
market; May 7–10, 2013; at Kielce
Trade Fair Centre, Kielce, Poland
For details contact:
Kielce Trade Fairs
(Targi Kielce S.A.)
1, Zakładowa Str
25-672 Kielce, Poland
Tel: +4841 365 12 22
Fax: +4841 345 62 61
Email: [email protected]
Website: www.targikielce.pl
Plast-Ex Being organised by Canon
Communications Llc, Plast-Ex is one of
the largest shows for attracting a large
number of people from the plastics,
printing and packaging sectors worldwide.
Plast-Ex is an eminent show that will
be hosted in Canada and will offer an
exhibiting space for displaying machinery
related to plastics, rubber, packaging and
printing; May 14–16, 2013; at Toronto
Congress Centre, Toronto, Canada
For details contact:
UBM Canon
2901 28th Street, Ste. 100
Santa Monica, CA 90405
United States
Tel: 310/445-4200
Email: [email protected]
Website: www.canontradeshows.com/expo/
plastex13
Feiplastic International Plastics Trade FairFeiplastic International Plastics Trade
Fair is not just an ordinary trade event but
is one of the largest and most informative
international gatherings of its kind in
Latin America. Recent innovative plastic
products will be showcased and reputed
brands in this domain will gather to
exhibit products and services through this
international platform, which strives to
attract top professionals from Brazil and
abroad; May 20–24, 2013; at Anhembi
Parque, Sao Paulo, Brazil
For details contact:
Reed Exhibitions Alcantara Machado
R. Bela Cintra
1200 - 7th Floor Cerqueira Cesar
Sao Paulo, Brazil
Tel: +(55)-(11)-30605000
Website: www.feiplastic.com.br
International
The information published in this section is as per the details furnished by the
respective organiser. In any case, it does not represent the views of
Business Insights •Technologies•Opportunities
EVENT REPORT: Indo-German Internat ional Seminar
92 Modern Plastics & Polymers | April 2013
Sweta M Nair
If the future of automobiles was
to be described in simple words,
then reducing manufacturing costs
and reducing weight to meet fuel
consumption regulations would become the
global mantra. Integration of functionality
coupled with new processing technologies
would be the perquisite here, but keeping
the innovative spirit burning would also
be crucial in the competitive atmosphere.
The 5th edition of the two-day Indo-
German International Seminar on ‘Plastics
in Automotives – Redefining Possibilities’
that was held on March 7–8, 2013, at the
Trident, Chennai, presented compelling
cases on this revolutionising mantra.
With support from the Department of
Chemicals and Petrochemicals, Automotive
Component Manufacturers Association
of India (ACMA) and Society of Indian
Automobile Manufacturers (SIAM), the
seminar was organised by the Organization
of Plastics Processors of India (OPPI)
and sponsored by the Verband Deutscher
Maschinen- und Anlagenbau (VDMA)
– German Engineering Federation. The
seminar kicked off with an inauguration
ceremony where the Chief Guest Manfred
Geiss, CEO, Geiss AG, Germany, addressed
the audience members in his welcome note.
What followed shortly were sessions with
speakers from companies such as Arburg,
Engel, Geiss, Hennecke, Kautex, Kiefel,
KraussMaffei, Kuka, Kurs, Sumitomo
Demag, Unicor and Wittmann-Battenfeld.
These sessions highlighted technology
that help achieve reduction in energy
consumption and increase in production
with less running cost.
High level of participationThe seminar was attended by about 215
individuals who belonged to segments
such as original equipment manufacturers,
plastics raw material manufacturers,
plastics processors producing plastic
components for automotives, automotive
paint producers, plastics processing
machinery manufacturers, consultants,
robot manufacturers etc. At the conclusion
of day one, Srinivas Sonti, General
Manager – Sales, Ferromatik Milacron
India Pvt Ltd, who was a moderator at one
of the sessions, said, “I believe the seminar
has been very informative for senior
management as well as for individuals
at the operating level. Although some
of the technologies showcased here are
a bit advanced for the industry in India,
sooner than later, it will arrive here as well.
Companies will imbibe on this level of
technology soon.”
A power-packed Q&A session
concluded most of the speaker’s
presentations. The high level of
participation proved a fruitful exchange for
problem-solving. Each presentation at the
seminar detailed trends of globalisation,
lightweighting and cost reduction.
Solutions for the industrySome of the sessions highlighted
the challenges but were also
quick to provide useful solutions.
Modern manufacturing techniques
with competitive advantages through
efficient production where parts or
components can be produced at the
lowest possible cost in the highest
possible quality were discussed extensively
in between breaks.
Selection and combination of
materials, defining tolerances especially
for plastics, integration of functions,
minimising production steps, reduction
in wall thickness thereby saving material
were other topics that sprung up during
the Q&A sessions. Lilli Rudnick,
Exhibitions – EUROMAP, VDMA, in
her feedback complimented the OPPI
for the excellent organisation of the 5th
Indo-German International Seminar. She
said, “The speakers were impressed by the
number of participants at this event. We
hope that this conference has contributed
towards bringing exciting new technology
to the Indian plastics processing industry
and that the attendees gathered new and
interesting insights that will find a place in
their future strategic plans.”
Email: [email protected]
From the seventies when plastics comprised only 6 per cent in automotives to the present scenario where these wonder materials command a 20 per cent role in European and American cars, plastics have come a long way. The increasing usage of plastics in automotives is significant and here to stay. With this trend in focus, the 2-day Indo-German International Seminar on ‘Plastics in Automotives – Redefining Possibilities’ was just what the industry needed – a fresh perspective on the latest available technology.
Redefining the future of automotive plasticsRedefining the future of automotive plastics
Speakers of the event along with members of OPPI and VDMA
EVENT REPORT: Engineer ing Expo Aurangabad 2013
94 Modern Plastics & Polymers | April 2013
Nishi Rath
It was in 1960 that the region of
Marathwada was merged with
Maharashtra. This was the time
when the industrial development
of Marathwada began. Over time, the
Maharashtra Industrial Development
Corporation (MIDC) acquired land and
set up industrial estates, which provided a
boost to the region’s tremendous growth.
Aurangabad is now one of the classic
examples of efforts towards balanced
industrialisation with factors such as
availability of labour, comparatively lower
cost for setting up base and a developing
market attracting an array of industries
to the city. Additionally, the presence of
renowned MNCs and domestic giants
in Aurangabad has further catalysed the
city’s industrial growth by offering Small
& Medium Enterprises (SMEs) a boost.
Reflecting the city’s industrial
growth was the second edition of
Engineering Expo Aurangabad. Held
during February 22–25, 2013, at Ayodhya
Nagari Grounds, the four-day Expo
was inaugurated in the presence of an
esteemed set of Guests of Honour
including Kala Ojha, Mayor, Aurangabad;
Sanjay Shirsat, MLA, Aurangabad West;
Pradeep Jaiswal, MLA, Aurangabad
Assembly Constituency; G M Ambhore,
Director, MSME Development Institute;
P Udayakumar, Director, The National
Small Industries Corporation; Sudhanva
Jategaonkar, Associate Vice President,
Network 18 Publishing; and Vijay N
Jaiswal, President, Aurangabad Industrial
Suppliers Association (AISA).
The inauguration also witnessed the
presence of Sunil Raithatha, President,
Chamber of Marathwada Industries and
Agriculture (CMIA); Dr Uday Girdhari,
President, Marathwada Association of
Small Scale Industries and Agriculture
(MASSIA); Adesh Palsingh Chabda,
President, Aurangabad Zilla Vyapari
Mahasang; and Mansingh Pawar, Past
President, MASSIA, among others.
Officially approved Organised by Network 18 Publishing with
AISA as supporting partner, the Expo
played host to various industry giants and
market leaders who showcased their best
products and services at the trade show.
Balasaheb Thorat, Minister of Revenue,
Government of Maharashtra, also graced
the Expo. He said, “Engineering Expo
Aurangabad has become a platform for
new industries developing in the region.
It has also proved to be the best platform
for students as it gives them exposure to
the real industrial world. I feel more events
on similar lines should be organised in the
near future.”
Rajendra Darda, MLA & Minister
of School Education, Government of
Maharashtra, also marked his presence
at Engineering Expo Aurangabad. “The
whole experience here was worth the visit.
The Expo was well organised and provided
a platform for local entrepreneurs. We
look forward to many more such events,”
he added.
Bright future for SMEs According to experts, the historical
background of the place helps attract
foreign investors. Aurangabad boasts of a
strong brigade of young and enthusiastic
first-generation entrepreneurs, who not
only implement new ideas but also steer
the growth. “Aurangabad has a lot of
potential when it comes to the industries.
The small scale industries here have a
Since the last few years, Aurangabad has emerged as one of the fastest growing industrial hubs. The region already has a huge industrial presence with a large number of engineering services, auto ancillary and pharmaceutical research companies setting up facilities here. The ever-evolving industrial scenario and the enterprising spirit of its entrepreneurs have helped Aurangabad grow into an industrial area of repute. Engineering Expo Aurangabad 2013 proved to be the right ‘growth tonic’ for boosting the region’s industrial might.
AURANGABADFebruary 22–25, 2013Ayodhya Nagari Grounds
Exhibiting Aurangabad’s unparallelled potential
Dignitaries unveil the Exhibitors’ Directory at the inauguration of Engineering Expo Aurangabad 2013
Engineer ing Expo Aurangabad 2013
95April 2013 | Modern Plastics & Polymers
Balasaheb Thorat, Minister of Revenue, Government of Maharashtra, being felicitated with a memento by Network 18 Publishing and AISA team
great future. They are keen to grow and
play a key role in the growth of any
particular region,” said Udayakumar.
Engineering Expo Aurangabad
focussed on providing SMEs an
opportunity to demonstrate their
capabilities, to offer a platform to
industries across the country and
enable exhibitors to formalise business
alliances for mutual growth. “The trade
show truly opened up a new world of
opportunities for the small and medium
scale industries here. The enthusiasm
among exhibitors was encouraging. It
was a good experience to be a part of
this grand show,” asserted Shirsat.
Upbeat exhibitorsThe exhibitors were overwhelmed by the
positive response they received from the
visitors. They were looking forward to
generating more business gauging from the
enquiries that they received at the Expo.
Manoj Kumar, Director, Apex Group, who
exhibited at the trade show, said, “We have
had a lot of enquiries; I cannot gauge how
many will turn out to be good business
leads, but yes, I am pleased with all the
enquiries. It proves that we have managed
to attract the target customers and create
our brand visibility.”
Another exhibitor, Nitin Bagul, Director,
Technovision Instrumentation Solution
Pvt Ltd, expressed, “We participated in
Engineering Expo Aurangabad last year
as well; it helped us build good contacts.
Aurangabad is an industrial hub and the
number of industries is increasing by the
day. This is a good place for such an event;
only awareness among the masses has to
be increased.”
Anand Pahade, Proprietor, Chintamani
Electricals, who also exhibited at the trade
show, said, “We participated in this trade
show as we wanted to create our brand
image on which customers can bank on.
The response we have received has been
mixed. Expos such as these should work
towards creating awareness among the
masses in Aurangabad.”
Initiatives in action Engineering Expo Aurangabad saw some
great initiatives in action. The ‘National
Vendor Development Programme’ acted as
a crowd puller both in terms of exhibitors
and visitors. Organised by the MSME
Development Institute, Ministry of
MSME, Government of India, the event
became an instant hit. It saw participation
from organisations such as Western
Railways, State Transport, Hindustan
Petroleum Corporation Ltd, Indo German
Tool Room and Central Institute of
Plastics Engineering and Technology.
Speaking at the event, Ambhore
stated, “Our main objective is to identify
and explore the business opportunities
in the highly competitive area. We also
encourage benchmarking for meeting the
challenges in the best way.”
Engineering Expo Aurangabad was
not all about exhibitors but it also offered
a lot to the visitors.
Visitors make the most of ExpoCommenting on how an Expo of this
stature acts as a growth catalyst, Mayur
Parikh, Senior Manager Marketing,
Sah Petroleum Ltd, said, “Exhibiting
companies fully utilised this platform
at the Expo. Such trade shows always
help the industrial circuit of a particular
region. It was great to be part of the
Expo as a visitor.”
Another visitor opined that
the turnout, despite the recession,
was commendable. “Taking into
consideration the recession, the turnout
was good. Engineering Expo is a great
platform for small and medium scale
industries to connect and understand
the market requirements,” averred
Abhay Sharma, Director, Extreme Ro
System Pvt Ltd.
Students too had a great chance to
get hands-on experience at the Expo.
Starting from market trends to new
technology, the Expo turned out to be
a helpful lesson for them. “Students can
learn a lot here; where else can they find
the latest technologies and machines at
one place?” opined Ojha.
Marking a new beginningAdding another feather to its cap,
Engineering Expo came to an end with
a promise to come back with more
enthusiasm and better opportunities
for Aurangabad. The next edition
of Engineering Expo will be held in
Hyderabad, Andhra Pradesh, during
May 31 to June 3, 2013.
Email: [email protected]
Pan India participation by 223 exhibitors
Spread across more than 10,914 sqm
18,528 business visitors visited from across India
Business transactions worth ` 74.78 crore*
More than 11,533 business leads generated*
8,500+ products displayed from different industries
More than 90,000 kg machinery moved in for display
Highlights of this edition
EVENT REPORT: Engineer ing Expo Aurangabad 2013 – Panel Discussion
96 Modern Plastics & Polymers | April 2013
Nishi Rath
Aurangabad has carved a
niche for itself among
the industrial leaders in
the country. In the era of
liberalisation and intensive competition,
Aurangabad is resolutely addressing
the challenge of moving to a higher
growth trajectory in the industry.
Taking a peek into this growth story,
Network 18 Publishing with support
from Aurangabad Industrial Suppliers
Association (AISA) organised a
panel discussion on the sidelines of
Engineering Expo Aurangabad 2013.
Held at Taj Presidency on February
22, 2013, the panel discussion served
as food for thought for more than
150 industry leaders and professionals.
Leading industr y exper ts
such as Ram Bhogale, Director,
Umasons Auto Compo Pvt Ltd;
S G Rajput, GM, District Industries
Center (DIC) & Superintendent
Industries Officer, Aurangabad;
Mukund Kulkarni, Director, Expert
Global Solutions and Ex-President
Chamber of Marathwada Industries and
Agriculture (CMIA); P Udayakumar,
Director, The National Small Industries
Corporation (NSIC) and Maithilee
Tambolkar, Director, Sanjeev Auto
Parts Manufacturers Pvt Ltd,
enlightened the audience on the
opportunities Aurangabad can provide.
The panel discussion was moderated
by Archana Tiwari-Nayudu, Editor,
Network 18 Publishing.
Is Aurangabad underrated?The first non-stick pan came from
Aurangabad; one of the best white
goods brands and electronics is offered
by this city; it also supplies the best
microfinishing machines, which also
compete with the world’s best. However,
it seems to lack visibility. “We export to
72 countries and, in the last two years,
Aurangabad-based organisations have
done acquisitions overseas. But we are
still understated because we have been
underestimating ourselves. It is high
time we move ahead,” said Kulkarni.
“We have created brands but were never
given that status. This is because we were
overshadowed by major industrial hubs such
as Mumbai and Pune. But I think it is time
for us to come out of that shadow and prove
our calibre,” observed Bhogale.
Taking the discussion ahead,
Tambolkar added, “There is no
denying that Aurangabad is underrated
as a manufacturing hub, one of the
reasons being the presence of various
first-generation entrepreneurs. Every
business has to go through a cycle and
most of them are completing the cycle
now. So, this is the time.”
Giving the discussion a twist,
Udayakumar said, “I look at it in a positive
way. In the age of competition, it can
be seen as an opportunity. Entrepreneurs
can focus on their resources and
future plans, when no one looks at you
as a threat.”
Technology takes the leadAccording to the panellists, investing
in technology and innovation will take
Aurangabad to a new level. “What we
have focussed on is right investment and
right technology; investing in the latest
technology will always pay back in the
long term. This strategy has helped us
too,” added Tambolkar.
Speaking up for technology, Bhogale
stated, “Investing in technology is one
of the reasons why we have witnessed
growth. Aurangabad is a good mix of
innovation and tradition. There are
people who have innovatively managed
their traditional ways. That has given
them a competitive edge.”
Kulkarni added, “Investing in the
best technology is key; the short-term
costs may be higher, but the long-
term gain is what people should be
looking at. Managing time, quality,
productivity and safety will also make
us competitive.”
The panel discussion received an
overwhelming response from the industry,
who actively participated as the audience.
The insightful discussion was followed by
a lively question and answer session.
Email: [email protected]
A panel discussion was organised on the sidelines of Engineering Expo Aurangabad 2013. Held on February 22, 2013, the panel discussion on ‘Trade, trends & technology: Gauging Aurangabad on the critical parameters’ was good food for thought.
Gauging Aurangabad on the critical parameters
(L–R) Maithilee Tambolkar, Director, Sanjeev Auto Parts Manufacturers Pvt Ltd; SG Rajput, GM, DIC & Superintendent Industries Officer, Aurangabad; Archana Tiwari-Nayudu, Editor, Network 18 Publishing;
Ram Bhogale, Director, Umasons Auto Compo Pvt Ltd; P Udayakumar, Director, NSIC; and Mukund Kulkarni, Director, Expert Global Solutions & Ex-President, CMIA, voice their views at the panel discussion
BOOK REVIEW
97April 2013 | Modern Plastics & Polymers
Plastic packaging of foods is not only obvious and omnipresent in developed economies but also increasingly commonplace in the developing world, where plastic packaging is instrumental in decreasing the proportion of the food supply lost to spoilage.
This new handbook is a combination of new material, unrevised chapters and updated chapters chosen by the author from recently published books on the subject. The handbook offers a practical source for engineers, scientists and managers working in the food packaging industry, providing a tailor-made package of science and engineering fundamentals, best practice techniques and guidance on new and emerging technologies.
By covering materials, design, packaging processes, machinery and waste management, all in one book, the editor enables the reader to take a lifecycle approach to food packaging.
The handbook addresses questions related to film grades, types of packages for different types of foods, packaging technologies, machinery and waste management. Additionally, the book provides a review of new and emerging technologies. Two chapters are devoted towards development of barrier films for food packaging and the regulatory and safety aspects of food packaging.
Plastic Films in Food Packaging: Materials, Technology, and ApplicationsEditor: Sina EbnesajjadPrice: ` 14,350
This book serves to bridge the values of engineering end-use parameters of Polyethylene (PE) resins and their scientific molecular and structural characteristics. The main goal is to translate common parameters such as melt flow index of a resin or the dart impact strength of a film sample into the universal language of polymer science. After this translation, many facets of the resin properties become apparent and explainable.
The contents of the book include topics such as manufacture, structure and mechanical properties of PE resins, melt index and melt flow ratio of PE, melting point of PE resin, crystallinity degree & density of PE, end-use mechanical properties of PE film, end-use testing of high molecular weight high-density PE and medium-density PE resins.
This valuable sourcebook is apt for undergraduate students who have taken polymer physics as well as for practising professionals in the industry.
Polyethylene: End-Use Properties and their Physical Meaning
Available at: SCI-TECH Books & Periodicals, 414, Janki Centre, Veera Desai Road, Andheri (W), Mumbai – 400053Tel: 022-26735260/66970507 • Fax: 022-6735424/26735260 • Email: [email protected]
Reviewer: Dr R Rangaprasad, Experienced Polymer Professional
Author: Yury V KissinPrice: ` 6,850
PRODUCTS
98 Modern Plastics & Polymers | April 2013
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
DU
3, 4 and 5-axis CNC vertical machining centre The EX series 3, 4 and 5-axis CNC
vertical machining centre possesses
versatility and capacity to carry out
the maximum range of jobs within
the working envelope with very high
precision of dynamic positioning with
total geometric, mechanical and thermal stability in structural parts. EX
1680 with X/Y/Z (1600/800/800 mm) has all axis movement on spindle
head and a 20-tool ATC. Equipped with a fixed table (2000 × 800 mm),
it has a high table load carrying capacity of 4500 kg with various variants
in table configuration, while C-Axis option of rotary table-in-table of
700 × 800 mm is also available. Delivering heavy metal removal rates
with precision and accuracy, wide working window for operator ease,
machining ability from complex small parts to bigger heavy engineering
works, the EX series caters to industries like automotive, railways,
machine construction, injection moulding and many other applications
from heavy engineering to complex die and mould components.
Jyoti CNC Automation Ltd
Rajkot - Gujarat
Tel: 02827-287081, 287082
Email: [email protected]
Website: www.jyoti.co.in
Tarpaulin two-in-one heat sealing machineThe two-in-one heat sealing machine
is fabricated from high grade raw
material, which is procured from
trusted and renowned vendors. The
two-in-one machine will be on robust
structure fit for both centre and side
sealing of 70 to 450 GSM fabric up to 6 ft max. Its seals are of HDPE/
PP laminated fabric, LD sheet of above 500 gauge and PVC coated,
SRF nylon sheet, flex banner (poster) and polyester fabric coated
material. The machine has 6 ft guide rolls at the side where the fabric
enters and sealed fabric falls at the bottom where it can be folded easily
with one side open. The centre cantilever has a heavy steel structure to
mount electrical controls, air blower and pressure system assemblies.
This machine has 2 unwind, with braking attachment shafts. It also has
7.5 hp power consumption, seals 25 to 60 mtr each, side and centre
sealing fabric of 70 to 450 GSM per minute. Its size is 10 × 3 × 3 ft and
has a capacity of minimum 600 kg per shift.
Shri Gurukrupa Engineering Works
Vadodara - Gujarat
Tel: 0265-3042371, 2637718, Mob: 09898885273
Email: [email protected],
Website: www.shrigurukrupaengg.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
Multilayer polyethylene film The multilayer 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
Mumbai - Maharashtra
Tel: 022-26830064, 26840359
Email: [email protected]
Website: www.ecoplastindia.com
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
UDU
PRODUCTS
99April 2013 | Modern Plastics & Polymers
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
Email: [email protected]
Website: www.jyoti.co.in
Low cost PID temperature controller
Low cost intelligent PID temperature controller provides
thermocouple input like thermocouple K, E, J, N, RTD Pt100 and
relay or SSR voltage output. It also facilitates maximum two alarm
relay outputs. This model is available in different sizes of 48 X 48
mm², 72 X 72 mm² and 96 X 96 mm². It has measurement accuracy
of 0.3%FS±1oC and temperature display resolution of 1oC. Different
control mode can be configured as on or off, artificial intelligence
control, including fuzzy logic PID control and advanced control
algorithm with the function of parameter auto tuning. It has a
built-in switch mode power supply voltage rating of 100-240VAC/
50-60Hz and consumes only 2W.
Micon Automation Systems Pvt Ltd
Ahmedabad – Gujarat
Tel: 079 - 32900400
Email: [email protected]
Website: www.miconindia.com
PRODUCTS
100 Modern Plastics & Polymers | April 2013
Universal PID controller
The universal PID controller adopts digital calibration technology for
input measurement with input measurement accuracy 0.3 per cent FS.
Non-linear calibration tables for standard thermocouples and RTDs
are available in the instrument. All other linear inputs such as 4–20
mA, 0–10 VDC etc are also available. It can satisfy the requirements
of various applications, make quick delivery and is easy to maintain.
Its friendly and customised operating interface leads to easy learning
and simple manipulation. It has high quality and performance
hardware design, using high-performance tantalum capacitor or
ceramic capacitor. Compared to competing models, it consumes less
electricity, experiences less temperature shifting, provides higher
stability and reliability and can work in a wider range of temperatures.
Micon Automation Systems Pvt Ltd
Ahmedabad – Gujarat
Tel: 079 - 32900400
Email: [email protected]
Website: www.miconindia.com
Copolymer emulsion Dipicryl 03D6 is vinyl acetate, butyl acrylate copolymer emulsion, which is
slightly viscous and of medium particle size with excellent flow properties.
It is specially developed for making highly pigmented emulsion paints. It
has a milky white appearance with free flowing dispersion and particle size
of 0.5 to 0.8 microns. It forms tough and flexible film above 7°C which is
clear, non-tacky and free from bits. Dipicryl 03D6 has good compatibility
with pigments, extenders, protective colloids, plasticisers and other acrylic
emulsions. It is used in making premium quality interior and exterior
coating wall paints.
Speciality Polymers Pvt Ltd
Mumbai - Maharashtra
Dual-control water-type mould temperature controller The dual-control water-type mould
temperature controller is a single machine
that can simultaneously control the
temperature requirements of different
male and female moulds. The male
and female moulds require different
temperature degrees. Dual-control series
lets you control two different temperatures
accurately. The size is decreased by 40
per cent to save space. It does not need constant replacement which
helps in acquiring substantial savings with regards to cost and time and
improves work efficiency. The patented ‘Heat-insulated’ design improves
safety, extends the machine’s life and makes repair and maintenance
more efficient and safer. The water-type series does not produce oil
and gas, thereby reducing pollution in the work place which is useful
in electronics, medical and cosmetic industries. In the water-type series,
the cooling effect increases efficiency and does not pollute the mould.
It is economical and has widespread applications. The imported PID
temperature controllers are used for accurate control of temperature
within ±0.1°C.
Yann Bang Electrical Machinery Co Ltd
Taichung -Taiwan
Tel: 886-4-22710000, Fax: 886-4-22711988
Email: [email protected]
Website: www.yannbang.com
Hot runner system mould
Some characteristics of the Moki patent hot runner system mould
include short cycle time (shortest time up to 3.2 s with advanced
blowing technology), high productivity and good stability. It is suitable
for lightweight and extra-thin (thinnest up to 0.3 mm) disposable
products. Other features are waste reduction, lower production cost,
high stability of finished products, low defect rate, strong mould
structure, floating structure, thin finished products, average thickness,
stable quality and long life of mould.
Mo Chyi Enterprise Co Ltd
Changhua County - Taiwan
Tel: +886-4-7354681
Email: [email protected]
Website: www.food-mold.com
Pellet screening systemSuper Platon is the latest generation
of pellet screening system for plastics
industry. This system detects black spots
or off-colour contaminants as small as 0.1
mm in a pellet stream by using four high-
resolution line sensor cameras. The Super
Platon is installed inline or offline after
a vibratory sizing screener to detect and
remove defective pellets.
Kubota Corporation
Shanghai City - China
Tel: +86-21-63298843
Email: [email protected]
Website: www.keisoku.kubota.ne.jp/chinese
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PRODUCTS
103April 2013 | Modern Plastics & Polymers
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
Email: [email protected]
Website: www.weichigz.com
Tel: 022 - 22063534, Fax: 022 - 22063533
Email: [email protected], [email protected],
Website: www.specialitypolymer.com
Specialty chemicalsThe Millad NX 8000 offers
important sustainability
benefits enabling PP to be
processed at significantly
lower temperatures versus
standard clarified PP. The
superior clarifying performance
enables broader use of PP, a
low-density and easily recycled plastic, to replace less-sustainable
materials in packaging, household and food storage applications.
Hyperform HPN nucleating agent for polyolefins is a family of
high-speed nucleating agents, which allow for faster crystallisation
rates, improved processing and higher throughputs. Hyperform HPR
synthetic reinforcing agents for polypropylene improve mechanical
properties, while reducing part weight as compared to traditionally
filled automotive compounds.
Milliken Asia Pte Ltd
Singapore
Tel: +65-65931319
Email: [email protected]
Website: www.millikenchemical.com
Wood plastic composites
Wood Plastic Composites (WPC) are thermo-plastically processible
materials made from wood and plastics (PP, PE, PVC, PS, ABS)
for use in building, furniture, automotive, consumer goods, housing
industry etc. In order to operate with optimum function, upstream
Extrusion machineThe LIN-90II-TS is a
performance-based machine
designed to accommodate
large containers with
outstanding cycle time. It
produces from 200 ml to 4 L
of PE/PP and PVC/PTEG,
and the productivity reaches 4,500 and 860 pc/hr, respectively. To
ensure quality, mechanical and electrical components from leading
brands are used in this machine.
Akei Plastic-Machine Mfy Ltd
Kowloon - Hong Kong
Tel: +852-27411312
Email: [email protected]
Website: www.akei.com.hk
Anti-static plastic palletThis anti-static plastic pallet
is available in various sizes. It
is made from virgin foodgrade
plastic materials and is used
in pharmaceutical and food-
based industries. Also offered
are grain storage pallets, steel
reinforced plastic pallets, drum pallets, moulded plastic pallets,
rackable plastic pallets etc.
Ergen Plastic Industries
Jodhpur - Rajasthan
Tel: 0291-2433737, Mob: 09414195707
Email: [email protected]
Website: www.indiamart.com/plastic-pallets
and downstream equipments are designed for the best match with the
extrusion line. For further improving the output of extrusion line, each
processing device and computer-controlled possibility (eg PLC, PC
base) are recommended to suit different users’ demands.
Intype Enterprise Co Ltd
Tainan - Taiwan
Tel: +886-6-2614196
Email: [email protected]
Website: www.intype.com.tw
PRODUCTS
104 Modern Plastics & Polymers | April 2013
One must consider the cost of the product before
purchasing so as to secure defi nite and assured
returns over the period of time.
Manisha Kadam (Assistant Manager)Ashok Industry
One must identify the product that best suits
his/her organisation with regards to the cost
and quality.
Suhas Kulkarni (Product Manager Marketing)Kohler India Corp Pvt Ltd
The information published in this section is as per the details furnished by the respective manufacturer/
distributor. In any case, it does not represent the views of
Business Insights •Technologies•Opportunities
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
Email: [email protected]
Website: www.rtpcompany.com
Thermoplastic rubber Thermoplastic rubber is
primarily an elastomer
which combines the
performance traits of
a rubber and processing
ability of plastic. It
exhibits excellent physical
and mechanical properties,
high tensile strengths and
tear strengths, good thermal properties and excellent resistance to
water, alcohol, acids and bases. It finds a wide use of applications as
gasket support and hose connectors, automobile dust cover, boots and
grommets, flexible cords and coiled cords, weather stripping for doors
and windows etc.
Welset Plast Extrusions Pvt Ltd
Mumbai – Maharashtra
Tel: 022-28215734, 28387054
Email: [email protected]
Website: www.welset.com
LIST OF PRODUCTS
105April 2013 | Modern Plastics & Polymers
3, 4 and 5-Axis CNC vertical machining centre ...........983-Axis CNC double column machining centre .................... 99AC/DC panel for pipe plants......................................89Acoustic enclosure ................................................................. 33Additive masterbatch ............................................................ 45Air audits blower ................................................................... 18Air compressor ...................................................................... 49Air treatment ......................................................................... 49Air-conditioner part .......................................................... FGFAir-conditioning plant .......................................................... 49All electric machine .............................................................. 23Aluminium die casting machinery ........................................ 49Anti-static plastic pellet ...................................................... 103Automation system ............................................................... 75Barrel ...................................................................... 110Bed knife ............................................................................... 63Biodegradable masterbatch ................................................... 45Black masterbatch ................................................................. 45Blender ..................................................................... FIC,19,61Blending unit .................................................................... FGFBlow moulding ...................................................................... 35Blower series ......................................................................... 75Blown film extrusion system ............................................... BCCarbon black .............................................................85Circular weaving machine ..................................................... 14Clean room application ......................................................... 25Cleaning oven ..................................................................... 110Cluster facia ...................................................................... FGFCNC Machine ...................................................................... 29CNC vertical machining centre ............................................ 73Colour masterbatch .......................................................... 15,45Compact chiller ................................................................... 109Compounding extrusion........................................................ 20Compressed air dryer ............................................................ 65Compressed air system .......................................................BICCompressor ................................................................... 18,BICConductive compound .......................................................... 45Conical twin screw extruder ................................................... 6Connector .......................................................................... FGFContinuous screen changer ................................................. 110Coploymer emulsion ........................................................... 100CPVC pipe ....................................................................... 10,21Crystalliser............................................................................. 65Cutting and stitching machine ............................................. 14Cylinder engraving - Lenticular and optical roll mould ...... 99Dehumidified dryer .................................................FICDehumidifying air dryer ........................................... 109, FGFDehumidifying dryer ............................................................. 34Die face cutter ....................................................................... 63Die plate ................................................................................ 63Diesel generator .................................................................... 49Digital panel meter ............................................................... 12Digital temperature controller ............................................... 93Door trim .......................................................................... FGFDosing and mixing ................................................................ 75Double column vertical machining centre ............................ 29Drive...................................................................................... 93Dry van pump ....................................................................... 33Dry-break coupling ............................................................... 18Drying and dehumidfying..................................................... 75Drymax air - Hot air dryer ................................................ FICDrymax dryer ..................................................................... FICDrymax Pet - Dehumidified dryer .................................... FICDual channel with modbus ................................................... 93Dual control water-type mould temperature controller ...... 100Dynamic controller ............................................................... 93Ejector.......................................................................18Electric injection moulding machine gearbox ......................... 7Evaporative cooling tower ..................................................... 49Exhibition - Plastivision 2013 .............................................. 38Extruder machine ............................................................. 27,67Extruder screw ...................................................................... 63Extrusion ............................................................................. BCExtrusion coating lines (Lamination Ant) ............................ 14Extrusion dies.......................................................................... 8Extrusion machine .............................................................. 103Extrusion system ................................................................. BC
Feed roll ....................................................................63Feeding & conveying ....................................................... 65,75Film cutter............................................................................. 63Fueling system ....................................................................... 18Furnace .................................................................................. 49Gear pump .............................................................. 110Granulating and recycling ..................................................... 75Granulator .............................................................. FIC,65,109Granulator blade ................................................................... 63Gravimetric blender ............................................................ 109HDPE pipe plant.......................................................89Head lamp and tail lamp .................................................. FGFHeat transfer roll ................................................................. 110Heating and cooling .............................................................. 75High cavitation ..................................................................... 25High performance screw ..................................................... 110High speed mixer ............................................................. 27,67Hopper loader ..................................................................... 109Hot air dryer ..........................................................FGF,34,109Hot runner system ................................................................ 75Hot runner system mould ................................................... 100Hydraulic injection moulding machine ................................. 23IML technique ..........................................................25Industrial coolers ................................................................... 49Injection moulding ........................................................... 35,98Injection moulding machine ............................FGF,5,16,17,52Inline drip tubing ............................................................. 10,21Knob and switch ....................................................FGFLargeflow water heater ...............................................75Loader ................................................................................ FICLoading arm .......................................................................... 18Long fiber rigid thermoplastic polyurethane ...................... 104Low cost PID temperature controller................................... 99Manual and hydraulic screen changer ....................... 110Material dryer .................................................................. 19,61Material storage .................................................................. 109Measuring and control equipment ........................................ 99Medical mould ...................................................................... 25Mono and multilayer sheet line ............................................ 14Monofilament line................................................................. 14Monolayer blown film ...................................................... 10,21Monolayer blown film line .................................................. BCMould .......................................................................... 20,27,67Mould repair ......................................................................... 99Mould temperature controller ............................................... 34Mould temperature controller ............................................. 109Mould temperature controller and chiller ........................... 103Moulding ............................................................................... 25MTC .................................................................................. FICMulti component mould ....................................................... 25Multilayer blown film ...................................................... 10,21Multilayer blown film line ..............................................14,BCMultilayer cast film line ........................................................ 14Multilayer polyethylene film ................................................. 98Napkin dies ...............................................................63Optical brightner .......................................................45Paperless recorder ......................................................12Parallel and right angle axes gearboxes ................................... 7Pellet screening system ........................................................ 100Pelletiser parts ....................................................................... 63Pelletisers ........................................................................ 63,110PET Preform dedicated machine ......................................... 53PET/PE Washing line .......................................................... 14PETline injection moulding machine ................................... 23Plastic conveyor belt .............................................................. 27Plastic machinery .................................................................. 49Plastic masterbatch................................................................ 51Plastic processing machine .................................................... 14PLC ....................................................................................... 93Polyolefin pipe .................................................................. 10,21Power saving .......................................................................... 35PP-R pipes ....................................................................... 10,21Precision moulding ............................................................ FGFPriming valves ....................................................................... 18Printing and cutting/Rewinding machine ............................ 14Process controller .................................................................. 12Process machinery ................................................................. 49
Profile controller .................................................................... 93Pulveriser ..................................................................... 20,27,67Pulveriser disc........................................................................ 63Pump ................................................................................ 18,33PVC foam core pipe ........................................................ 10,21PVC mixer cooler............................................................. 10,21PVC palletising lines ........................................................ 10,21PVC pipes ........................................................................ 10,21PVC profile lines .............................................................. 10,21Rational mould ..........................................................20Rational moulding machine ................................................. 20Recycling lines....................................................................... 14Resin dehumidifier ................................................................ 65Robot .................................................................................. FICRock n roll machine ......................................................... 27,67Roots blower ......................................................................... 33Rotary cutter ......................................................................... 63Rotary dies ............................................................................ 63Round table carousel ............................................................. 27Safety access equipment .............................................18Servo energy saving machine ................................................ 53Servo pump ........................................................................... 35Shut off nozel...................................................................... 110Shuttle remoulding machine ................................................. 20Single mill pulveriser ........................................................ 27,67Single screw extruder gearboxes .............................................. 7Single screw extruder plant ..................................................... 6Single screw pipe plant for RPVC........................................ 89Software for central monitoring............................................ 65Specialty chemicals .............................................................. 103Stack mould .......................................................................... 25Storage tank equipment ........................................................ 18System solution ..................................................................... 75Tank truck equipment ................................................18Tape stretching line with inverter driven cheese winders ..... 14Tarpaulin two-in-one heat sealing machine ......................... 98Technical mould .................................................................... 25Temperature controller ..................................................... 12,93Testing ................................................................................... 99Thermoformer ..................................................................... BCThermoforming ................................................................... BCThermoforming & PS foam ............................................... BCThermoplastic rubber .......................................................... 104Three arm bi-axial rotational moulding machine ............ 27,67Toggle injection machine ...................................................... 23TPU masterbatch .................................................................. 15Transmissions and PTOs ...................................................... 18Twin mill pulveriser ......................................................... 27,67Twin screw co-rotating extruders ........................................ 107Twin screw elements ........................................................... 107Twin screw extruder gearbox .................................................. 7Twin screw extruders ........................................................... 107Twin screw extrusion line ....................................................... 6Twin screw pipe plant for RPVC pipes ................................ 89Two platen injection moulding machine .............................. 23Two-layer blown film ....................................................... 10,21Ultra sonic flow meter ................................................12Universal controller ............................................................... 93Universal PID controller ..................................................... 100UV stabilisers ........................................................................ 45Vacuum booster pump ................................................33Vacuum dryer ........................................................................ 34Vacuum forming machine ................................................... BCVacuum loader ................................................................... FGFVacuum pumps & systems .................................................... 18Vacuum system ...................................................................... 33Variable displacement pump energy-saving machine ........... 53Vertical machining centre ..................................................... 29Vibratory screening system ................................................... 20Vibro screens .................................................................... 27,67Volumetric dosing unit .......................................................... 65Water chiller ..............................................................65Water jetting ......................................................................... 18WFR .................................................................................. FICWhite masterbatch ................................................................ 45Wire EDM ........................................................................... 73Wood plastic composites ..................................................... 103
Product Pg No Product Pg No Product Pg No
FGF - Front Gate Fold, FIC - Front Inside Cover, BIC - Back Inside Cover, BGF - Back Gate Fold, BC - Back Cover
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
LIST OF ADVERTISERS
106 Modern Plastics & Polymers | April 2013
All India Plastics Mfrs Association ............... 38
T: +91-22-28217324
W: www.plastivision.org
Alok Masterbatches Ltd ............................... 15
T: +91-011-41612244
W: www.alokmasterbatches.com
Baumuller India Pvt Ltd ............................... 35
T: +91-020-40160303
W: www.bumuller.com
Boge Compressed Air System .................... BIC
T: +91-044-43009610
W: www.boge.in
C & G Extrusion Machines .......................... 87
T: +91-9272235867
W: www.cgext.com
Continental Carbon India Ltd ...................... 85
T: +91-120-6721200
W: www.continentalcarbonindia.com
Engineering Expo ......................................... 56
T: +91-09819552270
W: www.engg-expo.com
Everest Blower Systems ................................ 33
T: +91-11-45457777
W: www.everestblowers.com
Ferromatik Milacron India Pvt Ltd ............... 23
T: +91-79-25890081
W: www.milacronindia.com
Gardner Denver Engineered Pro. (I) ............. 18
T: +91-79-40089312
W: www.gardnerdenver.com
Gem Equipments Ltd ................................... 49
T: +91-0422-2363800
W: www.gemindia.com
Glaves Innovations Pvt Ltd .......................... 63
T: +91-141-2460324,
W: www.glaves.biz
Hindustan Plastic and Machine Corporation .. 6
T: +91-011-25473361
W: www.hindustanplastics.com
J P Extrusiontech Limited ............................ 14
T: +91-2646-222163
W: www.jpextrusiontech.com
Jacobsen Lenticular Tool & Cylinder Engraving
Technology Co., ( Jaco Tech) ......................... 99
T: 1-630-467-0900
W: www.jacotech.com
Jingcheng Times (Beijing) Plastics Machinery
Co., Ltd.......................................................... 8
T: 86-10-5900-3588
W: www.jc-times.com
Jyoti CNC Automation Pvt. Ltd.................... 29
T: +91-2827-287081
W: www.jyoti.co.in
Kabra Extrusion Technik Ltd ................... 10, 21
T: +91-22-2673 4822
W: www.kolsite.com
L & T Plastics Machinery Ltd .................. FGF
T: +91-044-26812000
W: www.larsentoubro.com
Matsui Technologies India Ltd. .................... 34
T: +91-0120-4243862
W: www.matsuiindia.in
Mifa Systems ................................................ 93
T: +91-79-26870825
W: www.mifasystems.com
N.A. Corporation ......................................... 67
T: +91-79-25840374
W: www.naroto.com
Neejtech India (Braunform) .......................... 17
T: +91-79-26561312
W: www.neejtech.com
Neejtech India (Niigata) ............................... 25
T: +91-9909974224
W: www.niigataindia.com
Nordson X-Aloy Asia (Thailand) Ltd. ..........110
T: +91-79-40327380
W: www.xaloy.com
Norka Instruments Shanghai Co., Ltd. ......... 99
T: 86-21-6118-4181
W: www.norka.com.cn
Nu-Vu Conair Pvt. Ltd ................................109
T: +91-9376783206
W: www.conairgroup.com
Piovan India Pvt Ltd .................................... 65
T: +91-22-27782367
W: www.piovan.com
Plastiblends India Ltd .................................. 45
T: +91-022-67205200
W: www.plastiblendsindia.com .......
Prasad Koch Technik Pvt. Ltd. ..........................27
T: +91-79-25830112
W: www.prasadgroup.com
Prayag Polytech Pvt Ltd ............................... 51
T: +91-011-47262000
W: www.prayagmb.com
Procon Technologies Pvt Ltd ........................ 12
T: +91-79-27492566
W: www.procon.co.in
Rajoo Engineers Ltd....................................BC
T: +91-2827-252701
W: www.rajoo.com
Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No
Our consistent advertisers COC - Cover on Cover, FGF - Front Gate Fold, FIC - Front Inside Cover, BIC - Back Inside Cover, BC - Back Cover
LIST OF ADVERTISERS
108 Modern Plastics & Polymers | April 2013
S&T Engineers ............................................ 73
T: +91-422-2590810
W: www.stengineers.com
Sacmi Engineering India Pvt Ltd .................. 52
T: +91-7600003968
W: www.negribossi.com
Shini Plastics Technologies I Pvt Ltd ............ 75
T: +91-250-3021166
W: www.shini.com
Shree Momai Autocast Containers ................ 20
T: +91-2668-266440
W: www.shreemomai.com
Specific Engineering ...................................107
T: +91-265-2646871
W: www.specificgroup.com
Sri Sai Plasto ................................................ 53
T: +91-044-42994365
W: www.srisaiplastotech.com
Toshiba Machine (India) Pvt. Ltd. ................ 16
T: +91-011-43291111
W: www.toshiba-machine.co.jp
Unimark (Arburg) ......................................... 19
T: +91-22-25506712
W: www.unimark.in
Unimark (Maguire) ....................................... 61
T: +91-22-25506712
W: www.unimark.in
Wittmann Battenfeld India Pvt Ltd ............FIC
T: +91-044-42077009
W: www.wittmann-group.com
Woojin Plaimm Co Ltd .................................. 5
T: +91-9810043265
W: www.plaimm.com
Zambello Riduttori Group ............................. 7
T: 39-0331-307-616
W: www.zambello.it
Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No
Our consistent advertisers COC - Cover on Cover, FGF - Front Gate Fold, FIC - Front Inside Cover, BIC - Back Inside Cover, BC - Back Cover
Dear Reader,
‘Modern Plastics & Polymers’ solicits original, well-written, application-oriented, unpublished articles that reflect your valuable experience and expertise in the plastics & polymers industry.
You can send us Technical Articles, Case Studies and Product Write-ups. The length of the article should not exceed 1500 words, while that of a product write-up should not exceed 100 words.
The articles should preferably reach us in soft copy (either E-mail or a CD). The text should be in MS Word format and images in 300 DPI resolution & JPG format.
The fi nal decision regarding the selection and publication of the articles shall rest solely with ‘Modern Plastics & Polymers’. Authors whose articles are published will be sent
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a complimentary copy of that particular edition. Published by Network18 Media & Investments Ltd, ‘Modern Plastics & Polymers’ is one of the leading monthly magazines exclusively meant for producers and user fraternities of the plastics industry. Well supported by a national readership of over 80,000 and our strong network of 26 branch offices across India, this magazine reaches out to key decision makers among the Indian manufacturers of plastics products, machinery and allied sectors. Brought out in association with Hong Kong-based Ringier Trade Media Ltd (one of the world’s largest
An invite that rewards as well...
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