modern plastics & polymers - february 2011

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E D I TO R I A L

23February 2011 | Modern Plastics & Polymers

Packaging, in particular flexible packaging, has come a long way in not only creating product differentiation externally but also informing prospective customers about

the content and other relevant details. Some of the visible trends in flexible packaging include down-gauging to conserve energy and costly raw materials, increasing processing speeds as well as higher flexibility and better graphics. At the same time, technological advances are reflected in controlled-atmosphere and modified-atmosphere packaging for a much longer shelf-life of products; novel resins like metallocenes that are stronger and more breathable than traditional films; and convenience features such as zippered bags and specialised closures.

Given the ever-rising demand for well-designed & high quality packaging, especially for food products and other perishable goods, the role of innovative technologies and substrate combinations cannot be over-emphasised. In fact, with the end-users being constantly on the look out for new packaging solutions for FMCG brands, it is imperative for the converters to continually add value in line with the market needs.

As far as the challenges facing this sector are concerned, the energy consumption in producing & transporting packaging, the carbon footprint during manufacturing & use, sustainability and recycling constitute some of the major ones.

However, thanks to recent advancements in technology, the cost differential between packages made out of biodegradable materials and those made from conventional polymers has come down considerably.

The future seems bright with the advent of smart packaging having improved sensory quality & safety control and application of nano technology. The key would be the effectiveness of various ongoing innovation programmes in machinery and materials. For further insight on the fast-evolving flexible packaging scenario, turn to the ‘Sector Watch’.

Polymer compounding, though not new to the industry, offers a quick, easy and economical alternative to realise new grades of plastics meant for varied applications. As per an estimate, there are more than 300 grades of ABS, and 10,000 plus different grades of plastic materials are manufactured using the compounding process. However, the issues at hand include the compatibility and environmental aspects of the additives going into compounds, ways to process materials that are made to degrade, their availability, etc. The ‘Market Trends’ offers a detailed perspective on polymer compounding and allied areas.

A pack of possibilities

Manas R [email protected]

Printed by Mohan Gajria and published by Lakshmi Narasimhan on behalf of Infomedia 18 Limited and printed at Infomedia 18 Ltd, Plot no.3, Sector 7, off Sion-Panvel Road, Nerul, Navi Mumbai 400 706, and published at Infomedia 18 Ltd, ‘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.

14798/2005. Views and opinions expressed in this publication are not necessarily those of Infomedia 18 Ltd. Infomedia 18 Ltd reserves the right to use the information published herein in any manner whatsoever. While every effort has been made to ensure accuracy of the information published in this edition, neither Infomedia 18 Ltd nor any of its employees accept any responsibility for any errors or

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EditorManas R BastiaSenior Features WriterBeverley LewisSenior CorrespondentShivani Mody (Bengaluru)Features WriterKTP Radhika Jinoy (Delhi), Annabel Dsouza, Kymberlee FernandesCorrespondentGeetha Jayaraman (Delhi), Anwesh Koley (Delhi)Copy DeskMarcilin MadathilProducts DeskAbha MishraChief PhotographerMexy XavierPhotographerNeha Mithbawkar, Joshua NavalkarDesignSharad BharekarProductionPravin Koyande, Dnyaneshwar Goythale, Vikas Bobhate, Ravikumar Potdar, Ravi Salian, Sanjay Shelar, Lovey Fernandes, Pukha Dhawan, Varsha Nawathe, Abhay Borkar, Akshata RaneMarketing & BrandingJagruti Shah, Ganesh MahaleCEO-PublishingSandeep KhoslaAssociate Vice PresidentSudhanva Jategaonkar

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Editorial Advisory Board A 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 Patel Chairman, Industrial Products Mfg Co

Vijay Merchant President, Polycraft

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C O N T E N T S

24 Modern Plastics & Polymers | February 2011

Special Supplement

Plastics @ Gujarat

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

Sector Watch : Ancillary Equipment Market Trends : Plastics in Sports & Entertainment

Cover photo courtesy : Bobst India Pvt Ltd

Leaders Speak 42 L K Singh, Managing Director, Fixopan Machines Pvt Ltd

Facility Visit 44 LANXESS India Pvt Ltd: Thrusting forward through sustainability

Sector Watch 48 Flexible packaging: Complete compact solutions

Market Trends 54 Polymer compounding: Reinforcing application-driven materials

Know-How 65 Sustainable design: Integral to mould-making Manoj Mehta, Country Manager - India and SAARC Operations, Dassault Systèmes

SolidWorks Corp

Performance Metrics 68 Welded nylons: Evaluating viable joining technologies Courtesy: BASF SE

IT in Design 74 Digital prototyping: Exploring new dimensions Rajiv Bajaj, Head-Manufacturing, Autodesk India & SAARC

Management Mantras 80 Business growth: Hinging on the right initiative M Hariharan, Director, Savoir Faire Management Consultancy Pvt Ltd

Preview 82 HiTech Manufacturing Show: Growth stays constant

Advertorial 84 Engineering Expo Chennai 2011: Tracking impending opportunities

Report 94 Engineering Expo Indore 2011: Echoing success

48

REGUL AR SECTIONS

Editorial......................... 23

National News............... 26

Asia News ..................... 30

World News................... 35

Tech Updates ................. 38

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Highlights of Next Issue

Details on page no.87, 88, 89, 90, 91, 92

Corrigendum: In the January 2011 issue (Report on Engineering Expo Ahmedabad 2010, page 136), Ashish Sengupta, GM, Atlas Copco was inadvertently misquoted. This is regretted.

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Events Calendar............. 86

Product Update...............98

Product Index............... 114

Advertisers’ List ............ 118

68 74

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N AT I O N A L N E W S


PETROCHEMICALS

IndianOil and LanzaTech sign MoU for fuel grade ethanol technologyIndianOil and LanzaTech, a clean energy technology company, have signed a MoU for collaboration in a technology demonstration that will enable IndianOil to produce fuel grade ethanol. The MoU was signed in New Delhi by Sharat Meshram, Executive Director (Petrochemicals), IndianOil, and Prabhakar Nair, VP (Business Development, Asia Pacific) LanzaTech, in the presence of B M Bansal, Chairman, IndianOil and Dr Jennifer Holmgren, Chief Executive, LanzaTech. IndianOil will evaluate LanzaTech’s proprietary gas fermentation technology in one of its refineries to produce fuel grade ethanol. Dr Holmgren said the collaboration will enable both parties to accelerate techno-economic and feasibility analyses.

LanzaTech, which has key

investment from Khosla Ventures, is already collaborating on several international projects in the steel, coal and chemicals sectors. It has expanded its portfolio from the production of fuel ethanol from non-food renewable resources to include production of 2,3-butanediol (2, 3-BD), a building block used in polymers, plastics and hydrocarbon fuels. India’s crude oil imports are expected to exceed 80 per cent in a few years. India’s biofuels policy aims at increasing the use of alternative renewable fuels produced from sustainable, non-food sources and now requires oil companies to blend up to 5 per cent ethanol with petrol.

BUSINESS EXPANSION

LANXESS adds vibrancy to Jhagadia production unitLANXESS production unit is continuing the expansion of its Indian production site at Jhagadia, Gujarat. The specialty chemicals group broke ground for new

compounding facilities with an initial capacity of 20,000 metric tonne per year. These facilities will start producing the high-tech plastics Durethan (polyamide) and Pocan (polybutylene terephthalate) in the beginning of 2012.

The automotive industry is the largest customer for the semi crystalline products (SCP) business unit, which produces Pocan and Durethan. The Jhagadia site has many geographical advantages for SCP. It is located between two

of India’s largest automotive hubs Pune and New Delhi, which are home to numerous plants operated by the business unit’s customers. Jhagadia is well linked to international ports to ensure a reliable supply of feedstock to the compounding facility.

EXPANSION

Rhodia acquires PI Industries’ engineering plastics business Rhodia announced the signing of a binding agreement to acquire the engineering plastics business of the Indian company PI Industries Ltd. This transaction supports the group’s ambition to increase its share in the Indian polyamide compound market to more than 15 per cent by 2015. François Hincker, President, Rhodia Engineering Plastics,

said, “Rhodia and PI Industries are fully committed to provide the highest level of customer service, product quality and social responsibility. We plan to rapidly expand this activity, with a capacity increase scheduled shortly”.

The transaction includes all the assets used and held by PI Polymer; primarily an industrial facility that employs more than 80 people; with R&D capabilities, customer base and logistics network in India. The completion of the transaction is expected to be finalised by the end of March 2011.

COLLABORATION

RIL, Sibur of Russia in JV for production of butyl rubber in India

Energy and petrochemicals major Reliance Industries Limited (RIL) and Russian petrochemical company Sibur have announced a JV for the production of butyl rubber in India. The announcement was made on the sidelines of the annual summit between PM Manmohan Singh and Russian President Dmitry Medvedev. This facility will have an initial capacity of one million tonne of butyl rubber at RIL’s integrated refining-cum-petrochemical site in Jamnagar, Gujarat, and is expected to be commissioned by 2013.

The estimated investment in the project will be $ 450 million. The plant will initially

produce regular butyl rubber and is expected to manufacture other types of butyl rubber specialities in the future.

Sibur will provide its proprietary technology for butyl rubber polymerisation and finishing, while RIL will supply monomers and provide the JV with world-class infrastructure and utilities. RIL will have a majority stake in the JV. Sibur has unique technologies for the production of synthetic rubber which, in partnership with Reliance, will cater to the growing needs of the Indian tyre industry.

(L-R): Dr Rainier van Roessel,

LANXESS Board Member, Dr Joerg

Strassburger, Country Representative &

Managing Director, LANXESS India

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N AT I O N A L N E W S


DEMAND INCREASE

Plastic output may touch 12.75 MT by 2012According to market analyses by All India Plastics Manufacturers’ Association (AIPMA), plastics production in India will grow by 60 per cent to touch 12.75 million tonne by 2012. Yogesh Shah, President, AIPMA, said “We are expecting the production to grow by 60 per cent in line with the consumpt ion , which will be around 12.75 million tonne by FY 12.” At present, the plastic production as well as the consumption is about eight million tonne. He said, the consumption has grown significantly over the last two decades and India is projected to be number three in plastics usage by 2015.

In finished goods exports, AIPMA expects it to reach $ 5.3 billion this financial year in line with the yearly growth of 15 per cent. India exports plastic finished goods to countries in Africa, Europe and the US. AIPMA is now exploring other overseas markets like China as well. “The plasticsindustry employs about 3.5 million people, which is expected to double in next five years, to keep up with the growth in the sector,” said Shah.

PRODUCT LAUNCH

Dow introduces innovative film resins in India

Dow Chemical International Pvt Ltd (Dow India) has launched a range of innovative film resins for use in food & specialty packaging, industrial & consumer packaging, and health & hygiene applications. This range will meet the demands of film converters

for new materials offering better optics, improved toughness and faster processing opportunities. The new products include developmental DOWLEXTM NG LLDPE resins and ATTANETM NG ultra low density

polyethylene (ULDPE) resins. DOWLEXTM NG LLDPE resins build on the performance credentials of DOWLEX resins by offering greater differentiation opportunities for film converters through better optics, improved down-gauging potential and better processability. ATTANETM NG ULDPE resins are designed with a molecular structure optimised to offer a combination of improved toughness, better optics and enhanced processability.

RECYCLING

CSIR Technofest 2010 unveils technology to produce petrol from plastics Indian Institute of Petroleum, Dehradun, presented a technology in the CSIR Technofest to produce petrol, diesel and LPG from poly bags and plastics. The technology is successful on the semi-pilot level and a small laboratory plant of 5 kg capacity is working on the campus of the institute.

“We use plastics made from PE and PP from the municipal and industrial waste, and recycle it to produce gasoline, diesel, LPG, and petroleum products like benzene, toluene, and xylene. Over 70 per cent of the plastic waste can be used in the process,” said Dr Mahendra Pal, a scientist at the institute. The technology was presented in the energy technical session

organised by CSIR Technofest. The project is being carried out in association with the Gas Authority of India Ltd (GAIL), which will use the technology on a commercial scale in future.

The institute has also developed lubricating oils like gear oil, 2 T engine oil, hydraulic oil, transformer oil, soluble cutting oil, lithium grease, solvent detergent, sugar esters lube oil, etc from vegetable oils like neem, ricebran, kanaja, castor, linseed etc, which are eco-friendly solutions.

LEGISLATION

Polypropylene duty imposed on Oman and Singapore India has imposed an anti-dumping duty of up to

$ 323.5 per tonne of polypropylene, for making woven sacks used for carrying cement, foodgrains, sugar and fertiliser, from Oman, Singapore and Saudi Arabia to

protect the domestic industry from cheap imports. The restrictive duty, which would range from $ 28.49 per tonne to $ 323.5 per tonne, was imposed on

the recommendation of the Directorate General of Anti-Dumping and Allied Duties (DGAD), a notification by the Central Board of Excise and Customs (CBEC) said.

The DGAD, under the Commerce Ministry, found that due to imports of the product from the three nations, the domestic industry suffered ‘material injury,’ it said. The CBEC in the Department of Revenue has imposed the duty for a period of five years. While the Commerce Ministry recommends the duty, the Finance Ministry opposes it.

Anti-dumping duty is a WTO compatible tool that helps to counteract trade distortions due to cheap imports and the consequential injury to the domestic industry.


A S I A N E W S


EXPANSION

Rhodia Polyamide boosting China’s capacityRhodia Polyamide, one of French chemical giant Rhodia SA’s six enterprises, plans to increase the capacity of its Shanghai compounding plant by 40 per cent to stay ahead of the competition in Asia. Speaking to new providers in Shanghai, Frank Laganier, Asia-Pacific Zone Director, Rhodia Polyamide Engineering Plastics, said a capacity boost would help support the rapid growth in

the presently under-supplied market, particularly in auto, home as well as electrical and electronics. About 40 per cent of Rhodia’s global sales of engineering plastics are generated in Asia. Rhodia estimates that Asia will become the largest nylon 6/6 market by 2015 and China’s share in that region will continue to grow.

“It is a no-brainer to keep investing in China,” Laganier added. Demand for engineering plastics in China is growing faster than the overall plastics resin market. Rhodia Polyamide first

entered China in 1995, established a compounding plant in Shanghai in 2006, and added an R&D centre in 2008.

SCHOLARSHIP

Borouge launches fourth scholarship for polymer science and engineering students in China

A leading provider of innovative plastics solutions, Borouge launched its fourth scholarship in China, which provides financial support to high-performing undergraduate students of polymer science and engineering in Yangzhou University by granting

14 selected students with scholarships. Students are selected based on their academic performance each year and among them, one or two will be given an opportunity to get trained at a Borouge location, thereby obtaining hands-on experience in an innovative and dynamic environment.

Located in the heart of Yangzi River Delta, Yangzhou University forms a talent engine for the fast economic growth of the region. The history of the university traces back to over 100 years. It currently hosts 33,900 full-time undergraduate students, 7,200 postgraduate (doctorate and masters) students and 16,000 students of continued education. Yangzhou University is a pioneer in China as an institution of higher learning and is a beacon in China’s university reform.

COLLABORATION

RockTron launches fly ash technology in Asia

UK-based RockTron has signed a deal with Malaysian energy provider, Tenaga Nasional Berhad (TNB) to transform fly ash into materials such as fillers and extenders in polymers, and cementitous substances. RockTron launched its recycled fly ash technology last year. The company extracts high performance fillers from the waste ash produced at coal-fired power stations, using the recovered products in bulk applications and some high performance fillers.

Dato’ Yazid Baba, Chairman, RockTron Asia, said, “As per our estimates there are over six billion tonne of stockpiled fly ash in the world – half of this in Asia. This waste is made up of valuable minerals we have been literally throwing away for decades. Now, thanks to this agreement with TNB, we can start to reclaim, recycle and reuse these minerals.” RockTron launched RockTron Asia in October. Malaysia is the only country that has 2.5 million tonne stored in ash ponds.

INVESTMENT

Plastics likely to ride rails in Asia

The boom in high-speed rail and urban subway systems in Asia is spurring interest among plastics firms hoping to capitalise on the massive building projects.

Governments are clearly investing significant sums: China is building a nationwide network of bullet trains while Taiwan has opened its own high-speed system in recent years. Moreover, cities across the continent from Suzhou to New Delhi are expanding subways and urban rails. This has prompted one of the industry’s shows, the Railway Interiors Expo, to relocate its 2010 edition to Hong Kong, in November, where it attracted European and Japanese plastics suppliers like Bayer Material Science and Teijin Ltd.

Representatives from Yangzhou University, Borouge Board members and management team at Borouge

scholarship signing ceremony, Shanghai

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A S I A N E W S


MARKET TRENDS

Saudi petrochemical exports reach eight-month high

Saudi Arabia’s petrochemical exports reached an eight-month high in November, mainly due to strong demand from China, India and other Asian countries, as per government statistics.

Saudi Arabia, holder of the world’s largest oil reserves, exported 3.54 billion riyals worth ($ 944 million) of petrochemicals that month, the most since March of last year when the value of monthly shipments totalled 3.59 billion riyals, the Department of Statistics and Information noted.

Exports of petrochemicals, plastics and other non-oil products to Asian countries jumped by 9.8 per cent to 3.57 billion riyals in November, the biggest month-to-month increase since March, the data showed. Also, non-oil exports to the EU totalled 1.16 billion riyals, down 0.2 per cent from October.

MARKET FORECAST

Turbulent Q1-2011 for Asia’s polyolefin markets Asia’s polyolefin markets are likely to remain turbulent in Q1-2011 despite recent price hikes, as feedstock costs are fluctuating and future demand remains uncertain, as per ICIS. Producers are also concerned about the rapid rise in crude oil and naphtha prices, which have put margins under pressure.

However, Polyethylene (PE) and Polypropylene (PP) prices rose by $10-50/tonne recently in China, as traders returned to the market after

the New Year holidays. High-Density Polyethylene (HDPE) film-grade prices were higher at $1,230-1,280/tonne (cost & freight) China, linear low-

density PE (LLDPE) was at around $ 1,330-1,380/tonne CFR China, and Low-Density PE (LDPE) was at $ 1,680-1,740/tonne CFR China, Polypropylene (PP) injection-moulding grade prices gained by $ 10-20/tonne to close at $ 1,460-1,500/tonne CFR China during the period.

Since supply of certain grades is tight and buying is happening, price hikes are expected in January. Demand from converters exporting plastic products to the West is said to be good, due to the expectation of a recovery in orders from USA and Europe.

SUSTAINABLE SOLUTION

UAE on track to achieve ‘free of plastic bags’ goalby 2013 Dr Rashid Ahmed Bin Fahad, UAE Minister of Environment & Water, has said the UAE is on track to achieve the goal of becoming free of plastic bags by 2013.

He was speaking at the inauguration of the 10th edition of ArabPlast and Tekno/Tube 2011 at the Dubai International Convention and Exhibition Centre.

Bin Fahad said, “The success of ArabPlast and TeknoTube 2011 exhibitions demonstrates the robustness of the exhibitions industry in the UAE. The UAE and the entire GCC region are on the forefront of countries preserving the environment when it comes to producing plastics. The UAE will be free of plastic bags in 2013. Plastics and petrochemicals companies are adhering to the environment measures we have in place as part of their corporate social responsibility towards the community.”

DEMAND SCENARIO

Spot PET prices end the year on a rising trend as demand picks up in Asia In Asia, spot PET prices ended the year on a rising trend, with predictions that prices will continue to firm up in the days ahead, as per Chemorbis. In addition to finding support from stronger upstream costs, PET sellers are also reporting improved demand inside Asia as beverage manufacturers within the region began ramping up their rates in the final week of 2010 in order to begin preparations for the Chinese New Year holidays, which will begin at the start of February. Converters commented that

they have become more active in the market these days, although they added that they remain hesitant to purchase in large quantities given the uncertain economic environment.

Offers for Korean PET on an FOB Busan basis gained $ 40-60/tonne in the final week of 2010.

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EXPANSION

LANXESS makes first acquisition in Argentina LANXESS is expanding its activities in Latin America. The specialty chemicals company’s wholly-owned subsidiary Rhein Chemie has acquired Argentina-based Darmex SA – a leading manufacturer of release agents and curing bladders for the tyre industry.

With this acquisition, Rhein Chemie will become a leading provider of release agents for rubber products in a highly

fragmented market. It will also acquire Darmex’s bladder technology in Latin America, which is a key production hub for leading tyre manufacturers. Darmex’s production sites are located near Brazil, one of the BRIC nations, in which LANXESS has significantly expanded its presence in the last few years.

“This acquisition enhances Rhein Chemie’s position as an innovative technology provider to the tyre industry and strengthens LANXESS’ standing as the world’s leading synthetic rubber company,” said Dr Rainier van Roessel, Board Member of LANXESS. “Darmex’s highly-reliable products fit perfectly into our strategy of focussing on tailor-made solutions for our customers in growth markets.” Both parties have agreed not to disclose the purchase price.

INNOVATIONVolvic’s sugar-based PET bottle hits the UK Danone-owned water brand Volvic has launched its ‘greener bottle’, made with 25 per cent recycled plastic and 20 per cent plant material.

The bottle has a 38 per cent lower packaging carbon footprint and 16 per cent lower lifecycle footprint than the previous Volvic bottle. The plant material, BioPET, is made from PET produced using

some feedstocks manufactured from fermented and dehydrated sugarcane waste. The resulting bottle

is 100 per cent recyclable, says the firm.

The biomaterial is made in India, using sugarcane molasses. Volvic is also reducing the weight to 15 g from 17 g, and the bottles that are already on sale in France & Germany, are manufactured at the company’s own facilities in France. The firm claims, that this design is part of the plans to reduce the brand’s global carbon footprint by 40 per cent in 2012.

INVESTMENT

Fully equipped multi-process laboratory line The latest addition to an extensive process laboratory, at the world headquarters of Extrusion Dies Industries LLC (EDI), provides opportunities to customers looking for product development or trial runs without tying up with their own commercial-scale production lines.

The expansion at EDI’s Technology Centre consists of a 1.6 metre

extrusion line that can be used for cast film, coating, or lamination and is fully equipped for laboratory-scale single or multi-layer production and web converting. The centre includes a slot die or fluid coating line, a sheet line with six extruders, and other product/process development capabilities. This line has five extruders and can produce single or multi-layer cast film up to 600 mm wide, at thickness ranging from 8 to 125 microns. Speeds for 8 micron

linear low-density polyethylene (LLDPE)/low-density polyethylene (LDPE) film average 229 m (750 feet) per minute.

BUSINESS ENTERPRISE

PolyOne opens innovation centre PolyOne Corporation announced the opening of its new innovation centre in Gaggenau, Germany.

This facility will support applications development for the PolyOne Global Specialty Platform by providing capabilities for development, testing, process optimisation and colour matching. PolyOne has invested over 1 million in this centre.

The centre features an advanced testing laboratory that includes a spectrum of processing and colour matching equipment & computer simulation software. Testing can be conducted for mechanical properties such as modulus, ductility, & strength; physical properties such as density and electrical resistance; & rheological and flammability behaviours. Production-grade processing includes twin-screw extrusion lines for TPEs and engineering materials, a profile extrusion line for quality assessment of TPEs, and injection moulding machines for sample geometries and prototypes. Design collaboration will be supported by injection-moulding simulation software and colour matching software & hardware.

Rainier van Roessel

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W O R L D N E W S


AWARDS

SABIC Innovative Plastics wins award for Ultem* foam SABIC Innovative Plastics won an award in Aviation Week’s first annual Suppliers’ Innovation Challenge competition, recognising new and recent technology developments by tiered suppliers in the aerospace and defence industry. The company’s lightweight, rigid Ultem* polyetherimide (PEI) foam, used as the structural core in multi-layer systems for aviation interior components, won

in the composites category. Ultem* foam can help drive improvements in flame retardancy, fuel economy; lower greenhouse gas emissions; and increase design flexibility helping airlines

achieve their business and sustainability goals. The foam enables aircraft designers to leverage the best-in-class flame, smoke, toxicity performance of Ultem* resin in a form that is 10-20 times lighter than traditional plastic components.

It is an ideal thermoformable core material for composite structures such as luggage bins, galleys and lower wall panels (dado panels). Ultem* foam offers low moisture absorption, excellent energy absorption and low dielectric loss.

INNOVATION

Rhodia launches PA powders for rapid prototyping France-based Rhodia announced the launch of polyamide powders for rapid prototyping and small series manufacturing by selective laser sintering (SLS). This is the first time that PA6 powders are offered for direct part fabrication by SLS, claimed the company. The range will be extended to include PA 66 powders in the near future.

Using SLS, designers and processors can produce complete families of

fully functional prototype parts, said Rhodia, before they cut any metal for tooling. Once the design is validated, they can even use SLS for limited series commercial production.

“With processing properties perfectly adapted to SLS laser sintering – and other fabrication techniques based on addition of layers of powder – this new product range makes these innovative technologies much more accessible than before,” said Jean-Pierre Marchand, Director, Marketing and Innovation, Rhodia’s

Engineering Plastics activities. The part of the rapid prototyping/manufacturing sector using these additive technologies has a current turnover of around 800 million, with a potential estimated to reach 3 billion in 2015.

SUSTAINABLE SOLUTION

Impregnating plastics with CO2 Researchers at the Fraunhofer Institute for Environmental Safety & Energy Technology,

Oberhausen tested how CO2 can be used to impregnate plastics.

At a temperature of 30.1o C and a pressure of 73.8 bar, CO2 goes into

a critical state that gives the gas solvent-like properties. In this state, it can be introduced into polymers, in which dyes, additives, medical compounds and other substances can be dissolved. At 170 bar, pigment in powder-form dissolves completely in the CO2 and then diffuses with the gas into the plastic.The process is suitable for impregnating partially crystalline and amorphous polymers such as nylon, thermoplastic elastomers, thermoplastic polyurethanes, polypropylene and polycarbonate; it cannot be applied to crystalline polymers. The process holds enormous potential as CO2 is non-flammable and inexpensive.

INVESTMENTBorealis announces

17 million PE investment in FinlandEuropean polyolefins producer Borealis is expected to spend 17 million to upgrade its PE2

polyethylene (PE) production capacity at Porvoo, Finland.The upgrade, includes a new ethylene compressor and also an upgrade to the monomer purification line. The Porvoo PE2 plant upgrade is expected to result in a 15 kilo tonne per year increase from the current total 2,40,000 tpa PE production capacity. The Porvoo PE2 plant is Borealis’ demonstration unit for upscaling of the new Borstar PE technologies and for introductionof new PE products.

The facility is a fully integrated petrochemical complex comprising a 6,00,000 tpa cracker for the production of olefins (ethylene, propylene and butadiene), a phenol and aromatics plant, two plants for PE and one for PP. The total polyolefins production capacity amounts to 6,10,000 tpa. Around 70 per cent of Borealis’ production in Finland is exported and mainly used to produce pipes, extrusion coating for steel pipes & packaging, and wire & cable jacketing.


T E C H U P DAT E S


Granulator to target size reduction applicationsWith greater horsepower and features that make it ideal for applications in plastic material testing laboratories, a new small granulator from Dynisco handles a wide variety of parts and scrap efficiently. The granulator is ideal for grinding production plastic parts for material testing and analysis. Also, it allows technicians to granulate lab scrap such as samples from melt-flow tests, rheometer tests, tensile tests and capillary rheometer tests and keeps this material out of the waste stream. It is powered by a 5-hp electric motor, which drives an oversized flywheel to increase rotational momentum

and decrease energy consumption. The slow-speed (200-rpm) rotor has three rotating knives and two stationary bed knives counter-slanted to produce a scissor-like cut. These features help produce a clean, consistent regrind with minimum dust and fines. Along with rotating sidewalls in the 6.5 inch by 8 inch cutting chamber, they also minimise heat generation to prevent the polymer from softening and smearing during granulation. Three different screen sizes are available to produce regrind from 3/16 to 5/16 inch. These screens are reversible for service longevity.

SABIC Innovative Plastics offer conductive resins with greater dimensional stability

SABIC Innovative Plastics has launched a new family of Noryl GTX* resins for the global automotive OEMs. These new conductive blends of polyamide and modified polyphenylene ether cut coefficient of thermal expansion (CTE) by 20-40 per cent compared to previous grades for increased dimensional stability and improved gap & flush management. This gives automotive designers greater freedom to create

high precision body panels, which integrate into existing processes, including higher-heat online painting systems. These high-performance materials also enable system cost reduction and sustainability.

SABIC has utilised this new technology to ensure enhanced conductivity at higher temperatures while maintaining good mechanical properties, including impact strength. Another aesthetic benefit is the perception of robustness in a plastic part, resulting from a 50 per cent improvement in stiffness.

Trelleborg Automotive develops lightweight, hybrid brake pedal Trelleborg Automotive has launched an innovative, lightweight, hybrid brake pedal, which offers s i g n i f i c a n t c o s t - s a v i n g benefits to car manufacturers, while enabling considerable r e d u c t i o n s in CO2 emissions. This design blends glass fibre reinforced plastic and metal, a combination that delivers a weight saving of between 30 and 50 per cent compared to metal brake pedals. The new pedal also enables cost savings as a result of a more efficient production process that ensures faster assembly. The pedal meets the exacting performance specifications required by traditional metal variants currently used by car manufacturers and fulfills the demanding criteria for static & durability performance, including the ability to function under various temperatures.

It is manufactured using a stamping process that is quick and cost-effective. The metal insert is over-moulded at the plastic injection stage, a process using innovative water injection technology to fuse glass fibre reinforced plastic with metal, creating a tubular body and delivering the complete and final assembly in a one-step process. The use of water injection technology to create a complete hollow part along the pedal arm greatly enhances the mechanical behaviour of the hybrid brake pedal.

New preform cooling system for efficient bottle production A Canadian manufacturer of moulding machines, W Amsler Equipment Inc, has developed a unique preform cooling system, which delivers major productivity improvements for manufacturers of PET containers. This uses increased air flow in the oven to reduce the surface temperature of the preform. This results in minimal temperature-differential throughout the preform, thus inducing less stress and creating faster moulding cycles.

The increase in air flow improves production of coloured bottles. It is expected to boost output of PET liquor containers by 13 per cent. The system uses the same heating element (infrared short wave emitters) but replaces the standard reflectors with a plenum (chamber). The air flow through the plenum slots cools each preform directly. It is possible to heat the preforms at a higher temperature while still keeping the outer surface cool.

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T E C H U P DAT E S


Unmatched performance of Stanyl®

Stanyl® is a high-performance polyamide 46 that retains its mechanical properties at high temperatures up to 220°C. It is ideal for extremely high-performance applications, outperforming PPA, PA6T, PA9T and PPS & LCP.

Selecting Stanyl for applications leads to product development with the use of following methods: in metal replacements – Stanyl combines high stiffness with excellent wear resistance at temperatures above 200°C (and for short-term peak temperatures up to 250°C), enabling metal replacement options for a variety of applications. Stanyl provides resistance to wear and low friction and good abrasion resistance for moving parts. Stanyl delivers commercial benefits through reduced cycle time and increased design freedom for industries producing computer and phone components.

Soft seal foam material for mobile applications The High Performance Foams Division of Rogers Corporation has launched a new PORON® ThinStik™ soft seal. This is a highly compressible product for ultra-thin gap filling, LCD gasketing and sealing needs in gaps as thin as 0.1 mm. Rogers’ PORON foam is combined with a pressure-sensitive adhesive layer to enable higher compressibility than traditional laminated adhesive constructions. PORON ThinStik self-adhesive solution material contains fewer incompressible layers as it is manufactured through a unique,

single-step process that combines the adhesive and foam. This process eliminates the additional, incompressible layers of adhesive and PET found in the conventional double-side tape,

providing designers the benefit of more foam-space in a compressible package for the same thickness of final gaskets.

The PORON ThinStik is designed with specifications to ensure a reliable bonding surface to a variety of substrates, with high-quality optical clarity that is tolerant to high temperatures and chemical exposure. Compression force deflection (CFD) testing demonstrates that PORON ThinStik retains over 90 per cent of its original thickness under extreme conditions as compared to the conventional foam with a laminated adhesive.

Productivity boost through adjustable feedblock Extrusion Dies Industries announced the launch of Ultraflow V feedblock, a new system for flat-die co-extrusion that simplifies the fine-tuning of layer thicknesses. This reduces production downtime for structures from the simplest sheet to complex packaging films. Operators can

allow the position to be determined directly by the equilibrium pressure developed by flow from the extruders. For polymers whose interaction at the point of confluence poses the possibility of disrupting the multilayer structure, the adjustable plane can be moved manually to fine-tune polymer flow. The shaft extending from outside the feedblock into the centre of the adjustable planes provides ease of operation. The adjustable planes can be set to varying levels of responsiveness to melt flow pressure. The adjustable plane remains in a fixed position.

Chrome-like reflectivity within a polymer material It is now possible to create a visual appeal with Ampacet’s UltraChrome, which follows the FormulaX LiquidMetals Colors™ line of products. This luxurious mirror-like finish defies the traditional boundaries between polished aluminium, chrome and plastic material. UltraChrome is moulded into the parts to ensure p i e c e - t o - p i e c e uniformity and a sc ra t ch - re s i s tan t finish. The moulded-in finish retains its reflectivity and elegance because the UltraChrome masterbatch is dispersed throughout the parts without compromising on bond strength for laminated parts. As against secondary processes like vacuum metalising and painting, which are easily scratched and chipped, UltraChrome is immune to surface damage. It reduces production-to-market cycle time and lowers costs to a considerable extent since there is no need to outsource finishing or transport products to an off-sight facility for secondary processing. This single-step moulding process eliminates volatile organic compounds (VOC) and carbon emissions that occur during secondary painting operations. This premium reflective UltraChrome masterbatch is available in vibrant and high-end varieties that can be used with polyolefins and other engineered resins. This durable, recyclable, single-step moulding and decorating material takes plastics to a new level of visual presence.


L E A D E R S S P E A K


Emerging trends in the plastics machinery segment in India vis-à-vis the rest of the world… The Indian market, especially the plastic machinery segment, is growing by leaps and bounds. The Indian polymer consumption is expected to double in the next four years, but machinery suppliers in India cannot meet this kind of demand. Hence, I feel that the plastics machinery producers need to go on an expansion spree to meet the growing demand of almost 6-7 million tonne of processing machinery in the next five years. This, of course, is in addition to the upgradation of the machinery. There are a large number of plastic processors, who need to upgrade technologies for achieving better economics, efficient production, optimal utilisation of capacity, and lower energy & fuel costs. Similarly, all the developing countries like breakaway Russian countries, SE Asia, Middle East, South America, Africa, etc, are also witnessing a huge spurt in demand in the polymer industries. Even though the demand is poor in developed nations, the overall growth and demand in the plastics machinery sector is expected to be high globally.

Opportunities in the plastics machinery segment… India offers a plethora of opportunities for machinery suppliers and they need

to leverage these proactively. But as mentioned earlier, the developing nations are witnessing gigantic demands, which exceed all previous records. The machinery sector requires a large amount of manual labour, technology, expertise and experience. In this regard, the Indian machinery sector has adequate labour resources and engineers. Moreover, developed nations are also offering technology solutions, and since these countries are lagging in demand, they are looking towards developing nations. India, China and other developing countries offer good growth opportunities.

Key demand drivers…There is a rapid growth in demand for the upgradation of technology. Today, the world fuel and energy prices have shot up; environmental laws have become more stringent; and infrastructure & labour costs have increased. Hence, all processors have to relook at their costs and upgrade their machinery to stay competitive. Current scenario of the rotational moulding industry in India and globally… The rotomoulding industry is one of the fastest growing in the polymer sector and the industry average growth is said to be around 20 per cent as compared to 15 per cent during the last year. The demand is due to upgradation and

expansion in the industry. This will ensure sustained growth. Moreover, the rotomoulding industry and the suppliers from overseas have been evincing great interest in India. The global scenario in terms of the rotomoulding industry is similar to that of the plastics industry, and there is lot of growth happening in South America, Africa and other developing countries. The developed nations like North America, Europe and Australia are registering negligible growth, but they boast of large processing industries.

Prospects for rotomoulding ancillary market and your plans to tap into the potential... The growth in the rotomoulding industry ancillary market is obviously coinciding with that of the rotomoulding industry. There is an excellent demand for moulds & supporting machineries, and it is a fast growing segment. Sensing the growth prospects, we have expanded and added new high-end & costly machines, imported from the US, UK, etc. We are constructing more manufacturing areas and are planning to take over new factories. The growth in the rotomoulding industry is pegged at 20 per cent currently, which is expected to increase, going forward.

Latest trends in rotational moulding equipment… Technology upgradation is widely

…says L K Singh, Managing Director, Fixopan Machines Pvt Ltd. A veteran in the rotomoulding industry in India, he feels that the sector should come together with a common agenda and move forward. In an interview with Geetha Jayaraman, he talks about the future of this industry.

“The Indian polymer consumption is expected to double in the next four years”

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L E A D E R S S P E A K


embraced in the rotomoulding industry. The requirements for more complex shapes, energy & fuel savings, higher accuracy and special physical properties in the end-products have a strong bearing on the demand. The raw materials are also veering away from the standard 930 density to 940-945 for making stronger tanks. There is a demand for pulverised powders, in-house extrusion & pulverising and special compounded materials for meeting specific needs, especially in automotive parts. A lot of special resins are being witnessed. The special resins also have specific demands in the machinery sector. The machinery suppliers now have to consider provision for automatic operations using PLC, HMI, mould temperature sensors, triple air injection, HMI programs, built-in maintenance programs, trouble shooting and warning systems, processing parameters storage and recall from the PLC memory etc, to name a few.

R&D and innovation... Technology and R&D are the future of the industry. India has an abundance of intelligent and qualified manpower. Generally, innovation is undertaken with a focus towards cost reduction, with a single objective of profit. In the machining sector, especially the organised machining sector, innovation is constantly being undertaken to beat the rising fuel and energy costs. Besides, initiatives like reducing labour, improving efficiency, bringing about changes in equipment are undertaken. The organised sector of plastics machinery in India is small. At the same time, there is a growing requirement for high performing, economical and high quality rotomoulding needs. Thus, R&D plays a critical role in this segment.

Green initiative...The ‘green’ products are indeed important today. We consciously attempt to ensure that the products made by employing our machines create little or no waste. At the design stage, these aspects are

considered. Nowadays, clients also ensure that the manufacturer from whom they buy products follow all standards and specifications.

Prospects for the plastics machinery industry… The future of the plastics machinery sector in India appears positive. India has been lagging behind in consumption. The industry can only go one way and that is ‘up’.

Future plans & strategies of Fixopan...Fixopan has great future plans for meeting the machinery demands in the domestic and international markets, where it is already well-established. The company aims to grow four-fold in machinery manufacturing in the next five to six years. It plans to upgrade the current range of machinery and offer new options in its effort to be among the best companies in the world. Besides the marketing, it is quality and performance, that will help meet the future demands. It is also considering diversification in allied fields in the near future.

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The achievements of Gujarat as an attractive investment destination have been celebrated on a wide scale in

India. The pulsating industries in the Jhagadia commercial district serve as a testimony to the industrial advancements in the state. Located within the Jhagadia Chemical Park is the impressive LANXESS manufacturing and processing complex, spread over an area of 18 hectares. This sprawling campus, along with its infrastructure and technology, stands witness to the many reasons as to why the company is among the leaders in the specialty chemicals business, both globally as well as in India. It ventured into the Indian chemicals industry on February 20, 2004, under the brand Bayer Rubber Chemicals Pvt Ltd. It was subsequently renamed LANXESS India Pvt Ltd on June 30, 2004; and there has been no looking back ever since.

The Jhagadia site was commissioned in March 2010 and offers tremendous

business advantages to LANXESS India. Currently, the LANXESS Jhagadia site has two manufacturing facilities dedicated to rubber chemicals and ion exchange resins. The third will be a compounding unit for semi-crystalline products that will start operations by the beginning of 2012.

Distinguishing technologyTo date, LANXESS has invested 60 million in the Jhagadia site, with a total strength of 300 employees. Much has been said about the company’s contribution through rubber technology to India’s automobile industry. But few know about the technical diligence, meticulous research and stringent quality standards ensured by LANXESS at its rubber chemicals processing unit. Vulkanox® is the flagship product of this unit. LANXESS has been the tyre partner of the Indian automobile sector much before the inception of this plant in March 2010.

Thrusting forward through sustainability

FA C I L I T Y V I S I T

With its initiative to launch another business unit at the production site in Jhagadia, it is evident that LANXESS India is certainly conquering the Indian polymers market and taking giant strides ahead. Annabel Dsouza finds out how LANXESS achieves the daunting task of combining product excellence with sustainability and community welfare.


LANXESS India Pvt Ltd

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On December 3, 2010, the LANXESS Rubber Day was held in New Delhi to discuss key issues pertaining to India’s automotive sector and the likely solutions offered by LANXESS. Indian roads seem to be accident hotspots with the number of sky-rocketing fatalities. High-performance synthetic rubber, rubber chemicals and technical rubber products from LANXESS enable automakers to ensure safer and more efficient radial tyres. These can reduce braking distance by 50 per cent, which can in turn reduce road fatalities by 5 per cent.

The ion exchange resins processing unit was inaugurated on December 2, 2010. It has an annual capacity of 35,000 metric tonne. The Lewatit® resin is used widely in sectors like industrial water treatment, pharmaceuticals, food processing, petrochemicals, semi-conductors and nuclear energy industries.

Pursuing opportunities within the automotives, electrical and

electronics plastics industry, LANXESS recently invested 10 million in a semi-crystalline products (SCP) compounding facility. With an estimated annual capacity of 20,000 metric tonne, this facility will start producing the high-tech plastics Durethan (polyamide) and Pocan (polybutylene terephthalate) by early 2012. It is important to recognise the significant value-addition of these polymers to the design and construction of modern automobiles. The Jhagadia site will strengthen the company’s SCP business in Asia-Pacific by complementing the compounding facility in Wuxi, China. Both these facilities will process an annual capacity of 60,000 metric tonne.

Staying ahead through R&D Innovation being the backbone of the organisation, LANXESS’ emphasis on R&D is quite logical. In 2009, it set up the new Innovation Group Function to centrally co-ordinate the company’s research and development

Dr Joerg StrassburgerCountry Representative & Managing Director, LANXESS India

We are committed to contribute as a responsible corporate citizen. Our initiatives for the welfare of the community and protection of the environment are integral to our business.





activities, working closely with the 13 business units and their development departments. LANXESS has conducted approximately 160 research and development projects, of which around 125 aimed at developing new products and applications or improving existing ones. The remaining 35 projects concentrated on process technology issues with a view to reducing costs, improving efficiency or increasing capacities. Roughly, 65 per cent of these projects that started in 2009 reached the market or technical implementation stages by the end of 2010. Overall 80 per cent of the projects in LANXESS’ R&D pipeline are ready for market launch within two years. The company has quadrupled the number of new patents registered between 2006 and 2008.

The efforts made by LANXESS have enabled the company to launch itself in numerous verticals across the economy, namely agriculture, pharmaceuticals, textiles, construction & infrastructure, leather, water treatment, etc. However, LANXESS has recently been dedicating much of its resources to strengthen its presence in the plastics automotives segment. Engineering plastics like Durethan and Pocan combine mechanical strength with resistance

to heat, oils and abrasion. These materials are electrical insulators and remain durable for many years under high levels of stress. And they can easily be cast, blown and moulded into any shape or part, under-the-hood and elsewhere. Replacing metals with performance polymers is a global trend that is soon picking up pace in India. Apart from functional advantages, such plastics also offer high levels of safety and reliability. Global automakers like Volkswagen, Toyota and Ford, along with their suppliers as well as domestic producers like Tata and Maruti, are incorporating engineering plastics into their models.

Safety & sustainabilityWith escalating commercial prowess, the environment seems to be at stake. However, defying this decree are the efforts of LANXESS that are directed towards sustainability and social responsibility. Highlighting this aspect of the company, it is worth mentioning that LANXESS India is the recipient of the ‘Green Excellence Award’ at Frost & Sullivan 2010 India Excellence Awards. LANXESS is a strong advocate of sustainable practices implemented in a commercially-viable fashion. Its greenfield investment in Jhagadia follows uniform standards of its plants in Germany, Belgium and China. Dr Joerg Strassburger, Country Representative & Managing Director, LANXESS India, says, “Not just with regard to economy but even with a view to ecology and society, we are committed to contribute as a responsible corporate citizen. Our initiatives for the welfare of the community and protection of the environment are integral to our business.”

The natural gas-based cogeneration plant functions as concrete evidence of the company’s ideals and principles. Apart from the 66 kW power obtained from the GIDC power grid, LANXESS generates almost 80 per cent of its steam and power requirements within its

campus. This cogeneration plant has been installed at an investment of 4 million. This prevents fossil fuel

usage of around 70,000 metric tonne per year while reducing greenhouse emissions by around 95,000 tonne per year. The Jhagadia site also has an internal wastewater treatment system. LANXESS supports the local community by providing nearly a hundred academic scholarships and also collaborating with Teach for India on a programme to bring young and dedicated teachers into the local school system.

The India advantageBesides Jhagadia, LANXESS has production facilities in Nagda, Madhya Pradesh; and Madurai, Tamil Nadu, as well. However, Jhagadia seems to be of strategic importance for many reasons. Reiterating its significance, Rainier van Roessel, LANXESS Board Member, says, “We chose this site in India because it is located between two of India’s largest automotive hubs, Pune and New Delhi, which are home to numerous plants operated by our customers. Excellent links to international ports also ensure a reliable supply of feedstock to the compounding facilities, and fast delivery to clients outside India. The region also has a highly developed legal framework for private enterprise and a strong pool of highly skilled, English-speaking technicians and engineers.”

LANXESS perceives India as a strong partner on its voyage into the high-tech plastics markets of South Asia. The company has declared 2011 as the ‘Year of High-Tech Plastics’, through which it aims at spreading increased awareness to leverage the demand for engineering plastics. By hitching its wagon to the Indian auto market that is expected to grow by seven per cent per annum through 2015, LANXESS hopes to expand all its business units in tune with India’s surging economy.

Rubber chemicals production plant


Flexible packaging is an essential part of modern packaging as it protects, preserves, informs, and creates economical options, which are viable for modern day living. The industry has been attaining robust growth due to the significant advances in laminates and barrier films. Further, flexible packaging is expected to continue its expansion on account of rising consumption of packaged foodstuffs, among other growth drivers. Beverley Lewis provides an insight…

Courtesy: Bobst India Pvt Ltd

S E C TO R WATC H


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Flexible packaging consists of multi-layer laminated sheets of plastics – Polyvinyl Chloride (PVC), Low-Density Polyethylene

(LDPE), High-Density Polyethylene (HDPE), Biaxially-Oriented Polypropylene (BOPP), Biaxially-Oriented Polyethylene Terephthalate (BOPET) – paper, cloth, or metal foils that are used separately or in combination for various packaging applications. Also, there are many different substrates and coatings used to create these packages to produce various levels of barrier protection. The role of flexible packaging material is to give a new face to the product externally and also make customers aware of the content and other relevant information. There are various companies that only manufacture flexible packaging materials and are known to offer well-designed & high quality items to pack various products. Hygiene and seals also play a pivotal role when it comes to food items and other perishable goods. Further, the standard & quality of the material is important and should not react with the content & ingredients of the product. These are some of the challenges faced by the flexible packaging industry.

ChallengesThe converted flexible packaging industry faces the challenge of rising material costs and greater demand for packaging materials of products such as low-fat snacks, which require innovative technologies and substrate combinations to meet packaging needs for freshness. The industry is meeting functional requirements while reducing costs by using thinner gauge materials and increasing processing speeds. Although down-gauging will remain a significant trend, other factors such as flexibility and better graphics will also be important.

Sunil Jain, President, Rajoo Engineers Ltd, says, “Converters, in close collaboration with packaging development experts can help in developing and innovating property & cost-effective packaging formats.

Pan masala in small pouches was the innovation of a converter and not of the pan masala producer. Converters add value by experimenting and suggesting usage of different polymers & substrates and also towards cost-efficiency.”

Technological advances encompass controlled-atmosphere and modified-atmosphere packaging (CAP/MAP), which result in a much longer shelf-life for products such as meat and fruits among others; novel resins such as metallocenes that are stronger and more breathable than traditional films; and convenience features such as zippered bags and specialised closures.

Jay Nair, Business Head, ICM Packaging, states, “In addition to the innovations in the conversion side, even end-users are looking for innovative packaging solutions to enhance their brand appeal. Furthermore, there is never a pause in this continuous cycle of innovations in flexible packaging. Our end-customers are always on the look out for new packaging solutions for their FMCG brands and we as converters have the responsibility to keep moving with the needs of the market.”

Innovating for excellence Flexible packaging is a unique production process, ie, the number of variables required to produce a flexible package is approximately 150. This poses both a challenge and an opportunity for the flexible packaging converters, as they not only have to be aware about all the variables, but also have to use the right options, compatible materials and appropriate combinations to make products, which are superior to each other in their functional attributes. Starting from the types of granules used in extrusion of flat films (Cast Polypropylene Film-CPP, BOPET, BOPP, etc) or blown films (3 layer to 11 layer PE) right up to the finishing processes employed in the pouches (laser cut slots), the permutations & combinations are innumerable. “It is a known fact that in

the global flexible packaging scenario, groups like Amcor and Huhtamaki – PPL have been the leaders in producing innovative packaging on a continuous basis. Hence, the converter can add tremendous value in the development and manufacturing of flexible packaging,” says Avra Mitra, Senior Manager, Bobst India Pvt Ltd.

Also, multilayer blown film (7, 9 and up to 12 layers) gives the converter the flexibility to use combinations of materials to suit various applications. “We at ICM Packaging have invested in a patented technology for making multilayer blown films with Polyvinylidene Chloride (PVDC) as the barrier material. This is the first line of its kind in India. We are working with various customers in India to replace MET PET as a barrier film, and there

Sunil JainPresident, Rajoo Engineers Ltd

A major challenge is to increase the efficiency of consumption of plastics to make flexible packaging more environment-friendly.

Courtesy: Rajoo Engineers LtdThermoforming packaging



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is a possibility to convert traditional 3 ply (PET/MET PET/PE) kind of structures to 2 ply PVDC-based barrier films without affecting the functional properties of the film,” observes Nair.

Machine Direction Orientation (MDO) is another technology that makes it possible to improve the mechanical properties as well as barrier properties in a blown film. MDO films also have high clarity. Another innovative technology includes cast lines. Cast lines generally cast polypropylene and offers impressive transparency & external glossy qualities. It is ideal for packaging snacks and as a sealant film for retorting purposes due to its superb heat sealing characteristic and stabilising dimensions of packaged contents. Going forward, 5-layer cast lines are the latest trends in the flexible packaging market and are likely to capture a significant marketshare.

Market scenario Flexible packaging comprises 26 to 30 per cent of the Indian consumer packaging market. The rest of the consumer packaging market is shared among rigid plastics (18 per cent), printed cartons (15 per cent), glass bottles (10 per cent), metal cans (6 per cent), caps & closures (5 per cent) and other forms of packaging. “With the tremendous growth in the processed food industry, flexible packaging occupies more than 70 per cent of the market share in the food packaging industry. Similarly, in the pharmaceutical sector, with the development of various new materials and methods, flexible packaging has assumed substantial significance due to improved anti-counterfeiting, better shelf-life and cost advantages,” states Mitra.

India’s retail sector is the world’s eighth largest in the world with annual sales of ` 32,500 crore. Rapid growth in grocery & food retailing is being driven by its fast growing 350 million

middle class consumers. Currently, 97 per cent of food retail sales are via family-owned stores, the highest number of retail outlets per capita of any country in the world. Flexible packaging is a preferred form of packaging in organised retail as it is the easiest to transport, the cheapest form of packaging, aesthetically attractive. Moreover, due to the latest developments it is also the most ‘intelligent’ mode of packaging which is able to ‘communicate’ with prospective buyers. Also, with the use of latest techniques like Modified Atmosphere Packaging (MAP) and oxygen scavenging, the shelf life of the packages have increased manyfold. Flexible packages used for liquid packaging like the various packages offered by the world leaders Tetrapak and SIG Combiblok offer shelf-life up to 75–80 months from the date of packaging, which is helpful in this era of retailing. However, in order to maintain sustainable production and consumption, the carbon footprint of the flexible packaging industry needs to be considered.

Green packagingToday, the demand for flexible packaging is greater than ever. As the world population continues to grow, the packaging industry is expected to react to new issues that were never even considered in the past. Concerns such as the energy required to produce & transport packaging, and the environmental impact created during flexible package manufacturing & use did not appear on our radar screen until the last quarter century.

Sanjay Malik SabharwalVice President, Uflex Ltd

Because flexible packages generally conform to the shape of the product, excessive layers of packaging are eliminated. Additionally, less material is needed to create the packages and less fuel to transport the packages.

Jay NairBusiness Head, ICM Packaging

There is never a pause in the continuous cycle of innovations in flexible packaging. Our end-customers are always on the look out for new packaging solutions for their FMCG brands.

Courtesy: Uflex LtdFlexible packaging machinery



S E C TO R WATC H

Flexible packages are produced from lightweight yet durable materials such as paper, plastic film, aluminium foil or any combination of these materials. “Because flexible packages generally conform to the shape of the product, excessive layers of packaging are eliminated. Additionally, less material is needed to create the packages; less fuel is needed to transport the packages; and less landfill space is needed to dispose them,” reveals Sanjay Malik Sabharwal, Vice President, Uflex Ltd.

Moreover, sustainability and recycling of flexible packaging are the two biggest elements of concern. Recylability is a major concern for BOPET-based flexible packaging. This not only leads to added burden on the environment, but is also a big deterrent for maintaining a clean environment. The major challenge for the converters is to use materials like biodegradable polymers so that there is no environmental issue after the package is disposed by its user. Mitra observes, “Environmental pollution from solvents used during the manufacture of flexible packages is not yet regulated in India. Sustainability is of prime importance with regard to regulations on the flexible packaging industry in developed countries, but we do not have any such regulations in India. However, with the new Ministry of Environment and Forests (MoEF) actively campaigning for the reduction of carbon footprints, sustainability will become a focus area in the future.”

Packages made out of biodegradable polymers used to be expensive, but recent advancements in technology have cut down the difference between packages

made out of biodegradable materials and those made from conventional polymers. “A major challenge is to increase the efficiency of consumption of plastics (down-gauging, reducing sizes of packs, etc) to make flexible packaging more environment-friendly,”opines Jain.

Future prospectsThe future growth in flexible packaging is ‘intelligent packaging’. The core function of packaging is to contain, protect & promote the product. With the advent of ‘communicative’ or ‘intelligent’ packaging, the shelf-life of packaged products has increased, but the sustainability of the food has been questioned. Some future advances in active packaging, which is a part of intelligent packaging are, maintenance of quality without food additives and efficient oxygen scavenging. Mitra infers, “Examples of smart packaging include improved control & maintenance of the cold chain, improved sensory quality & safety control and also quality labels as marketing tools. The other future prospects are likely to be the use of nanotechnology in packaging.”

Increasing disposable income levels, and a large working population coupled with the fast developing habits of eating-out or preference for ready-to-cook or ready-to-eat foods are also factors that will contribute to the exponential growth of the flexible packaging industry. “The future focus would be to optimise the shelf-life properties and economise. Increased usage of barrier materials and customised solutions are also future growth prospects. Flexible packaging materials, which today focus primarily on food, will diversify into other sectors – medical, agri-products, pharma, automobiles, engineering, telecom and such growing industries, in the coming years,” asserts Jain.

The flexible packaging sector is undergoing rapid changes due to the fast-evolving market needs. There is considerable research going on and

large investments are being made in machinery and better barrier materials. This sector is also focussing on down-gauging in both flexible & rigid packaging to conserve energy and costly raw materials. “Convenience packaging is the future of the flexible packaging industry. Ready-to-cook foods and other packaged foods are likely to lead to more innovations in the flexible packaging sector, in the near future,” estimates Sabharwal. The flexible packaging industry is likely to continue to grow in double-digit figures in the future. “One of the key reasons for this is that it is cost-effective compared to alternative packaging. Also, in the future, brand marketers will continue to look at innovative flexible packaging solutions to create product differentiation,” claims Nair. Going forward, many businesses involved in the production of consumable products will use flexible packaging as it is a product packaging system that is effective and versatile. It can also help product manufacturers to keep handle on packaging costs.

Avra MitraSenior Manager, Bobst India Pvt Ltd

Examples of smart packaging include improved control & maintenance of the cold chain, improved sensory quality & safety control and also quality labels as marketing tools.

Courtesy: Rajoo Engineers Ltd

Extrusion machinery



M A R K E T T R E N D S

In recent times, compounding has been used to a great extent to make grades of plastics with diverse specifications, because a

variety of plastic materials are required to satisfy a wide range of applications. It is an incredibly expensive proposition to determine and manufacture a new molecule to fit each one of these applications. It is well-known that long fibre reinforcement can increase impact strength in Polypropylene (PP), Polyamide (PA), Polycarbonate (PC), Polyetheretherketone (PEEK) and other polymers. This makes compounding a technology that allows existing processors and entrepreneurs to dream big without worrying about the cost.

Compounding offers a quick, easy and low-cost alternative to discover new grades of plastics. The plastics additives industry has emerged victorious after facing more than five strenuous years of structural market changes, including reduction in margins, swift increases in feedstock prices, product lifecycle maturity, transfer of growth to emerging markets, and regulatory demands.

According to a technical market research report from BCC Research, the global market for plastics additives was worth more than $ 36.2 billion in 2008 and is expected to increase to $ 45.8 billion in 2014, by a CAGR of 4.1 per cent. The market can be categorised into property modifiers,

property stabilisers, property extenders and processing aids. Of these, the property modifiers segment holds the largest share of the market. Following suit are the property stabilisers; and property extenders make up for the third-largest marketshare.

Additives are integral components to plastics and contribute to the success of plastics not only in processability but also in property modification and performance. Although used only 5-7 per cent in terms of weight or about 10 per cent by cost, they provide immense benefits. They make plastics safer, cleaner, tougher and colourful. Additives are sometimes expensive. However, by reducing production costs and increasing the life of products, they result in bringing down overall costs and the use of raw materials.

A ‘mine’ of innovationsMinerals account for a major proportion of the additives used in compounding polymers with a key role as fillers. The minerals’ particle size, shape, surface area, matrix compatibility and dispersion, among others factors, affect the plastics performance. K G Chandan, Technical Director, Technovinyl Polymers India Ltd, says, “Fillers have a role in cost reduction. Functional fillers and nano size minerals are making inroads into polymer compounding, leading to novel composites. Binary

Reinforcing application-driven materials

Polymer compounding

As market potential increases, there is a growing demand for polymers with certain high performance characteristics. To meet this market imperative, polymer compounding has been one of the most sought-after methods, chiefly due to its cost-effectiveness and versatility in applications. Annabel Dsouza and Kymberlee Fernandes zoom in on the material innovations and technological advancements in the compounding industry.Courtesy: BASF

Courtesy: Polykemi AB

Courtesy: Polykemi ABCompounding process for POLYfill HC

A polymer pre-blending station

Market Trends_54-57.indd 54 1/24/2011, 3:29:14 PM



reinforcing is also an innovative concept in designing new-generation mineral filled compounds.”

The main function of a mineral in a thermoplastic is to reduce cost. This is a common misconception, even if it was largely true about 30 years ago. Henrik Eriksson, Development Manager, Polykemi AB, says, “Today, the addition of minerals is mainly done for technical reasons. Many minerals certainly have the apparent benefit of reducing price per kilo even after the compounding cost is taken into the equation, especially calcium carbonates as well as coarser talc and untreated wollastonites.”

However, the more technical mineral additives have a price per volume that is equal or much higher than the volume price for polypropylene. Therefore, if a pure polypropylene is good enough from a mechanical performance point of view for a certain application, it rarely makes sense to consider a filled grade to save money, unless the part can be redesigned to take advantage of the different property profile of the mineral containing the grade.

An apt example would be the finely ground talc that is employed in scratch resistant automotive interior grades, as well as grades for large exterior trim parts, and is often in the same or higher price per volume range as is the polypropylene into which they are mixed. “At the design stage, it is a matter of finding a material with the best price per property, which might very well

be a mineral-reinforced material, but too often people focus on the price per kilo at the design stage and forget all about the impact of density. Many of the sophisticated surface-treated wollastonites are more expensive per volume. Still, the properties offered by these minerals make them attractive for cases where glass fibre reinforcement is over-engineered. Especially for wollastonite, there are some innovative and effective surface treatments available. Surface treatment of talc in only cost-effective in rare cases,” Eriksson adds.

Multifarious technology Globally, more than 30,000 processing units comprising single-screw extruders, internal mixers or dispersive kneaders, reciprocating single-screw extruder (co-kneaders) and twin-screw extruders are currently used for compounding. “Over the years, co-rotating twin-screw extruders have played a dominant role in compounding – used by resin suppliers, proprietary and custom compounders or end-users, making it the most preferred processing equipment,” says Dr Babu Padmanabhan, Founder and MD, STEER Engineering Pvt Ltd.

In India, there is an increasing amount of compounding activity in terms of investment in new equipment and capacity increase. Simon TING, Shanghai Technical Polymers Development Branch, Arkema, observes, “This can be attributed to the ‘mismatch’ between the materials

formulated for the overseas market and the local requirement. Locally designed and developed products are demanding material solutions tailored to their operation specifications. This is one of the key drivers for more local compounding facilities to support the requirement.”

The perpetual trend of trying to get more performance at a lower cost is as influential for the compounders as it is for any other industry. An example of how such challenges are met is a super high-performing, short glass fibre-reinforced polypropylene, with stiffness high enough to compete with significantly more expensive

K G ChandanTechnical Director, Technovinyl Polymers India Ltd

Fillers have a role in cost reduction. Functional fillers and nano size minerals are making inroads into polymer compounding, leading to novel composites.

Courtesy: STEER Engineering Pvt LtdWood ploymerJute composite




PA6 glass fibre-reinforced compounds or even PBT with the same amount of glass fibre.

“In some cases, this material makes it possible to slash costs in half. With this material, Polykemi has enjoyed its major part of commercial successes and is now finding its way into the automotive industry,” asserts Eriksson.

One of the latest innovations is from a Germany-based manufacturer that is producing fibres with completely new performance and longevity characteristics that has propelled the industry into the new age of artificial turf. The company has developed a technology that offers revolutionary fibre with superior performance. It combines the best in polymer technology with the strongest Ultra Violet (UV) inhibitors and a state-of-the-art extrusion process. After years of experimentation, it seems that the perfect formula has been developed. The creation of this new compound will enable to produce a fibre that will resist splitting and reduce degradation caused by the Sun’s UV rays – better than any other fibre the industry has ever known.

Material outlookWith constant developments in the polymer compounding industry, the characteristics and grades of resins also keep advancing. There are over 300 grades of Acrylonitrile Butadiene Styrene (ABS) alone and more than 10,000 different grades of plastic materials are manufactured using the compounding process. Macro, micro & nano fillers, plasticisers, reinforcements, flame retardants, colourants, carbon black, impact modifiers, lubricants, heat stabilisers, UV stabilisers, antioxidants, organic peroxides blowing agents, anti-microbial agents, and antistatic agents are the most common additives that are compounded. “Other additives include clarifying & cross-linking agents, coupling agents, deodorants, fragrance, nucleating agents, slip & vulcanising agents. These are added separately or in combinations to one or several different

resin types, forming products with unique characteristics suited for myriad applications. Further, these are added in different stages of the process in the form of liquids or solids, either separately or in mixtures to get the required properties in the final compound,” observes Dr Padmanabhan.

As polymer compounding takes centre stage, the demand for polyolefins globally is expected to grow to 132 Million Tonne (MT) by 2013 according to research reports from Applied Market Information. PP constitutes 53 MT and PE is 79 MT of this. Demand has risen the fastest in Asia (excluding Japan) with an annual rate of 10 per cent, with Central and South America at around 6.5 per cent and Europe & NAFTA at 4 per cent. The increase has been double that of the Gross Domestic Product (GDP). The rapid rise in some economies has been due to increased investments, exports and domestic consumption.

While these polymers hold considerable significance, the recent focus has shifted to biodegradable options. Biodegradable plastics are established in the marketplace as alternative materials. Compounding and processing technology is rapidly developing so that these relatively new polymers can be used in a wider range of applications. There are plenty of issues to consider – the compatibility and environmental aspects of the additives going into compounds, ways to process materials that are made to degrade, their availability, etc.

Since the polymer compounding process is rather cost-effective, many small and medium enterprises opt for it, while making their contribution to the environment. Due to availability constraints, Polylactic Acid (PLA) or perhaps bio-based polyolefins, are the only bio-based polymers of real interest for small to medium-sized independent compounders at the moment. Eriksson avers, “It is still a niche market but everyone tries to keep track of the

Dr Babu PadmanabhanFounder and MD,STEER Engineering Pvt Ltd

Co-rotating twin-screw extruders have played a dominant role in compounding – used by resin suppliers; and custom compounders making it the most preferred processing equipment.

Henrik ErikssonDevelopment Manager, Polykemi AB

Today, the addition of minerals is mainly done for technical reasons. Many minerals certainly have the apparent benefit of reducing price per kilo even after the compounding cost is taken into the equation.




most recent developments to be able to join the race once these polymers start making a more considerable impact on the market. Currently, very small amounts of bio-based polymers enter the compounding stage.”

“Bio-based polymers can further reduce weight, increase design freedom, and materials can also be more eco-responsible, fulfilling the renewable, reuse and recycle concept. All these features are providing resin producers additional advantages to convince end-users/OEMs to replace metal and rubber for a more sustainable development,” says TING.

A compound of challenges And while the course to triumph is never smooth, so is the case with the polymer compounding industry. In the compounding industry, Chandan observes, “Rising cost of polymer products; non-organised industry segment, mainly in processing;

unstable marketing dynamics; unhealthy price competition; shortage of raw materials, and the like are some of the major roadblocks.” Independent compounders rely on a stable availability of a wide range of raw materials. Material shortages have posed difficulties for many compounders ever since the industry started to recuperate from the financial crisis.

While addressing the challenges encountered by new applications, it is important to review the steps involved during any compounding, and also the fundamentals to avoid common problems. Efforts are constantly being directed towards upgrading this integral process in plastics processing. The industry is striving to overcome the capital and manpower deficit since the compounding process is one that ensures homogeneity in ingredients through chemical blending.

Simon TINGShanghai Technical Polymers Development Branch, Arkema

Bio-based polymers can further reduce weight, increase design freedom, and materials can also be more eco-responsible, fulfilling the renewable, reuse and recycle concept.


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K N O W- H O W


Manoj Mehta

How would you define sustainability and its role in the mould-making process?Sustainable design consists of a comprehensive, holistic approach to create products and systems that are environmentally-benign, socially-equitable, and economically-viable. Environmentally, it offers obvious or measurable environmental benefits; socially, the design fills the needs of everyone involved in its production, use and disposal or reuse; and economically, it is competitive in the marketplace.

Fuel-efficient cars, solar-heated buildings, clean-burning power plants, recyclable packaging and low-voltage lighting are obvious examples of products that help balance consumer needs with good environmental stewardship. Yet realistically, all products including moulds have the potential to be designed with sustainability in mind, if engineers really think about making products better while using materials that have a positive impact on the environment.

Sustainability is no more just an aspect that is ideal for the mould-making process, but is already an integral part of the process today, given the focus on the environmental impact of moulded parts like in other products at every step in the mould’s existence.

What factors need to be taken into consideration while implementing sustainable design?Some of the factors that organisations including mould makers should take into consideration are as follows:

Minimal material use: Can the wall thickness of a part be changed from half an inch to three-

eighths of an inch without compromising its functionality? (Eg: housing for a wide-screen TV)

Improved material choices: Is there a plastic that was not available ten years ago, which would make this part easier to produce, recycle or transport, at the same cost as before? (Eg: Specify recyclable High-density Polyethylene (HDPE) instead of Acrylonitrile Butadiene Styrene (ABS))Design for ease of disassembly: Can the product be designed to be taken apart, either for repair or selective recycling? (Eg: Use tabs to connect parts, rather than glue)Product reuse or recycling at end of life:Can the product be designed in a modular fashion, so that one part can be replaced to upgrade its function (Eg: Rethink throw-away cell phones by selling a consumer-replaceable slide-in memory/function board)

Minimal energy consumpt ion :Is there a different method or machine for building or operating the system that uses less energy to run? (Eg: Redesign oxygen-flow mask so that it uses lower pressure, less expensive pump system at the consumer end)Manufacture without producing hazardous waste: (Eg: the successful elimination of lead-based solder)

Use of clean technologies as a fundamental mindset: (Eg: Hybrid automotive engines; elimination of lead-based solder)

Integral to mould-makingSustainable design

Sustainability assumes pivotal importance in the design aspect across industries, and particularly in terms of mould-making, it has already become an essential part of the process today. This is on account of the due consideration given to the environmental impact of moulded parts at every step in the mould’s existence. Moreover, all products can be designed sustainably, and moulds are no exception.

Knowhow_65-67.indd 65 1/22/2011, 12:58:14 PM

K N O W- H O W


Why is a new way of thinking so economically important? The demand for natural resources is growing faster than the available supply, driving up their costs, at the same time it is also important to adhere to new environmental directives. Fortunately, small design changes – based on optimised amounts of carefully chosen, modern materials, manufactured with minimal energy/resource usage – generate large ripple effects in the overall sustainable lifecycle, and offer the extra benefit of an improved competitive edge in the global market.

Europe is leading the way towards achieving this change in mindset, having recently proposed an integrated product policy (IPP) that promotes sustainable development. Cyon Research Corporation analysed this approach and the study stated: “At the heart of IPP is the principle that the biggest improvements in environmental impact of products can be made during the design phase (front-of-pipe), rather than through process efficiency, cleaner production, or pollution management (end-of-pipe). The European Union estimates that over 80 per cent of all product-related

environmental impacts are determined during the design phase.”

Consequently, companies that give priority to finding tangible, methodical ways to reduce material costs and improve processes will be leaders in maintaining profit margins.

Could you highlight some of the environmental policies being implemented in the West?While Europe, with its more limited land and resources, leads the way in suggesting and enacting programmes aimed at sustainability, American manufacturers aiming for those markets will have to take heed and comply. A number of EU regulations that are already in place will radically impact the way products are designed and marketed, from cell phones to sports cars.

For example, the Waste of Electrical and Electronic Equipment (WEEE) and End of Life Vehicles (ELV) directives are both based on the principle of extended producer responsibility. WEEE requires that circuit boards must not only be manufactured through non-hazardous processes but also designed

for disassembly, sorting and safe recycling/disposal.

Legally, these rules mean manufacturers must meet the costs of take-back and recycling of their own products. Economically and environmentally, those manufacturers who are smart about designing their products for ease of reclamation should actually reap financial benefits from doing so.

Other directives aimed at reducing energy consumption during both manufacturing and usages are in the early stages of adoption. The Energy Usage Products (EuP) policy imposes energy-use limits on a wide range of products, and even extends to components and sub-assemblies sold as spare parts. Compliance with EuP will be verified through the European CE Marking programme alongside established safety and electromagnetic compatibility standards.

What is the best approach that mould makers should take to ensure sustainability of products?The best option is a lifecycle approach. It is human nature to believe that it is easier to keep things as they are, even against persuasive arguments to the contrary. Often, new products merely reflect a progression of incremental changes based on legacy designs and procedures. Take the example of how a car is assembled: although robotics has played a huge role in the past few decades, the overall assembly process still follows the structure laid down by Henry Ford. Worse yet, steps such as gluing and welding have replaced screwing or bolting in many areas, such that sub-assemblies cannot be opened for repair, but must be trashed and completely replaced.

At the same time, traditional material costs are rushing upwards: the price index for non-manufactured goods rose from less than 70 (representing the actual price when compared to an average value set to 100) in 1995 to more than 170

Cyclonic inertial separator manufactured by Face ModelamentosCourtesy: Dassault Systemes SolidWorks Corporation

Knowhow_65-67.indd 66 1/22/2011, 12:58:31 PM

K N O W- H O W


(a 70 per cent increase over the norm) in 2005. Rising prices for steel and crude oil are also reflected in manufacturing and shipping costs, and yet consumers keep demanding lower prices.

The United States leads the way in product design; in order to maintain this leadership as both economic and social pressures for sustainable design grow stronger, the traditional reluctance to change basic principles can and must fade.

Challenge drives innovation, thus manufacturers the world over, including mould makers, are questioning every piece of plastic they use. Some of the questions that they ask themselves are: How much do the raw materials cost?; How environmentally-benign is the processing and handling?; What energy does it take to use this material?; Is there a material that costs the same but is easier to recycle?; Is there a new material which is so strong that less quantity will suffice to make an existing part with the same durability?

At the same time, many different industry and government groups have developed numerical methods for evaluating the relative environmental impact of different materials, processing, and transport choices. Also, universities such as MIT, are not only looking at energy methods and new design methods, but are creating whole new departments that combine different disciplines for sustainable development.

Can you elaborate on the lifecycle analysis and planning process?Looking at the big picture is a great way to identify specific product design tasks that can be re-evaluated to reduce their contributions to the overall environmental impact. For a product manufacturing process, a Lifecycle Analysis (LCA) identifies the energy and waste (solid, airborne and waterborne) associated with each relevant stage, including raw material extraction; material processing; component manufacturing; assembly & packaging; distribution & purchase; installation & use; maintenance &

upgradation. Last comes the end-of-life factor that involves material recycling; component reuse; product reuse; landfilling; and incineration.

One interesting and timely attempt to quantify such factors for design decisions comes from a partnership between the Industrial Designers Society of America and the US EPA. Their project, called Okala, is currently updating its list of calculated ‘impact’ values for hundreds of materials and processes. For example, one assigns a value of 140 to a product if the material used is aluminium, while switching to the use of ABS plastic (which takes less energy to process in the raw form) brings the impact down to 47.

Mention a few companies that gained tangible benefits from implementing an effective lifecycle policy.Several worldwide companies have already put years of efforts into incorporating some or all the design elements in industries ranging from furniture & flooring to telecommunications and tools. Some examples of these companies are as follows:

IKEA has made a science of the design for its assemble-it-yourself furniture such that the packaging for most pieces comprises flat boxes that stack efficiently in delivery trucks for minimum trip/fuel expenses.

BASF helps automotive manufacturers save time and money with its hybrid UV/thermal coatings that greatly cut back on out-gassing, and thus minimise volatile emissions or possible defects from bubbling during the paint-curing process.

IBM started implementing a formal, ISO 4001 environmental management system across all its global manufacturing & hardware development operations and all its business units more than 10 years ago, building on previous efforts to ensure that environmental considerations are a routine part of all business decisions.

Whirlpool has been named ENERGY STAR® Partner of the Year seven times, and has been internationally recognised for its commitment to environmental packaging, production and design.

BMW’s recycling centre takes new car models and dismantles them, testing the effectiveness of the disassembly process, as some parts are designed for reuse and others for recycling. The group feeds information back to the design centre.

The DeWalt family of industrial power-tools uses a modular design approach such that a single model of rechargeable 14.4-volt battery fits into all the tools in the 14.4-volt product line (eg, drill, power saw, flashlight, etc).

What are some of the lasting benefits of sustainable design?Although there may always be tradeoffs when evaluating the details of sustainable designs, the long-term benefits are undeniable:

Reduced impact on the environment Use of clean technologies for

everyday living, construction and manufacturing activities

Reduced water treatment costs Less waste going to landfills Soil, air and water pollution

prevention Preservation of forests and

biodiversity Reduced climate change Product reuse or recycling at end

of lifeTradeoffs are best analysed with precise software products, whose results can be repeated, shared and evaluated by all departments in an organisation, from design & manufacturing to marketing and transportation. Forward-planning companies are more profitable than reactive, defensive companies, and those that improve their competitive position may also keep jobs from going overseas. Software that enables sustainable design processes at all stages of a product’s lifecycle is a critical tool for successfully operating in today’s design environment.

Manoj Mehta is the Country Manager - India and SAARC Operations, Dassault Systèmes SolidWorks Corporation. Email: [email protected]

Knowhow_65-67.indd 67 1/22/2011, 12:58:41 PM

P E R F O R M A N C E M E T R I C S


Evaluating viable joining technologiesWelded nylons are used in many industrial products, the largest being automotive parts. Various types of welding methods are used for joining and assembling hollow plastic parts. Linear vibration welding (LVW), orbital vibration welding (OVW) and hot plate (H-P) welding methods were deployed for assembling various plastic parts made from similar or dissimilar thermoplastics (including nylon). This is the first of a two part series of the indepth research on welded nylons and the technologies used.

Nylons (polyamides – PA) are high performance s e m i - c r y s t a l l i n e thermoplastics, with a

number of attractive physical, chemical and mechanical (short-term and long-term) properties. Moulded nylon parts are more resistant to fatigue, creep, repeated impact, and challenging chemical environments than the parts made from certain less-durable thermoplastics. There are more than a dozen classes of nylon resins, including PA-6, PA-66, PA-46, PA-12, PA-610, PA-612, etc, and the total number offered by producers worldwide is estimated to be about 1,500.

In recent years, the demand for welded nylons has risen sharply for non-filled, filled and fibre-glass reinforced nylon products for replacing metals (steels and light alloys) and thermosets in the automotive (integrated air induction systems, power train systems, fluid reservoirs and other uses) field. The design of critically stressed plastic components (including welded) requires advanced analysis of structure, noise vibration & harshness (NVH), short-term (including impact) and long-term (creep, fatigue, stress relaxation) strength and life criteria. Reinforced nylon plastics (with 30-35 per cent weight per cent glass-fibre) are typically used in design of air intake manifolds (AIM). Glass/mineral reinforced/filled nylon plastics (40 per cent weight Fibre Glass (GF)/Mineral Fillers (MF) are used in

the design of engine covers. The AIMs, resonators, fluid reservoirs, and many others are hollow parts that may be produced by either lost-core injection moulding process, plastic welding, or welding plus fastening/over-moulding technologies. Worldwide, nearly 80 per cent of air intake manifolds are produced by either a lost-core injection (46 per cent) moulding process or injection moulding followed by linear vibration welding (LVW)(32 per cent). The lost-core process is more capital-intensive compared to plastics welding processes because it involves additional forming, melting and metallic core removing. It is also possible to use the hot plate (H-P) welding and infrared welding technologies for plastic hollow parts. LVW, Orbital Vibration Welding (OVW) and H-P welding equipment and welding tools/nests are not very expensive, and the welding process itself is not too time-consuming. The welding machines are equipped with a data acquisition system that monitors, records & reports the key process parameters.

Differences and similarities of LVW, OVW and H-P welding technologies Different welding methods were used for joining and assembling hollow plastic parts, such as LVW, OVW, H-P, spin (SW), ultrasonic (U/SW), extrusion, infrared (IR), laser (LW) etc. In the past, frictional welding (FW) processes were divided into three groups, ultrasonic,

Welded nylons

Resonator

Air intake manifold

Performance Metrics_68-73.indd 68 1/22/2011, 4:58:06 PM



linear vibration and rotational motion (spin welding). Only five years ago, OVW was introduced. LVW, OVW and H-P methods were utilised in assembling various plastic parts made from two, three or more pieces; moulded, extruded, thermally-formed from similar or dissimilar thermoplastics (including nylon). These joining technologies comprise the following welding phases:

Joined plastic parts placement and gripping in specially designed tools/nests

Materials heated in areas where the joints are to be formed

Local melting in jointed surface areas

Surfaces contacting/pressing together for joining

Cooling in the joint interface and other areas

Welded plastic component removal from welding tool/nest and welding machine

The type of heat generation and heat transfer distinguishes these technologies. The H-P welding method presents an external heating process. The LVW and OVW are an alternative internal heating process using friction. For H-P welding technology, the joined surfaces of thermoplastic parts are melted prior to joining. It permits direct control of the pre-heating and welding temperature during the heating and fusion phases. For LVW and OVW technologies, the temperature in the interface (macro and micro) is a function of processing parameters such as time, clamp-pressure, amplitude, frequency & meltdown, and it also depends on the physical and thermal characteristics of the polymers. Welding temperature in the interface during the LVW and OVW processes is not directly controlled. For optimising LVW processing conditions including temperature in interface of the butt joint, the researchers used advanced thermal imaging infrared method and computerised system during a study.

Orbital vibration welding technology allows motion to be programmed in many ways, and it also provides more freedom

in designing the weld areas. This process avoids some of the hindrances of LVW method – problems with unsupported walls perpendicular to oscillation/vibration direction. The LVW and OVW methods are also based on friction, which uses an electromagnetic drive to create relative motion between two plastic components. The orbital motion ensures that each point surface of the driven plastic part orbits a different point on the butt joint surface of the stationary part. This orbit of motion is continuous and identical for all points on the joint surface. The OVW process operates at lower vibration amplitudes than LVW. Even the pre-assembled or built-in sensitive electronic components are not damaged mechanically or thermally, contrary to other plastic joining methods. For the high performance LVW and OVW joints, the following processing and weld interface parameters are critical:

Vibration frequency: (typically in range from 120 to 240 Hz, nominal) and power

Temperature: In total (part), local and weld interface areas during the melt formation phase; at start and final temperatures at hold/sealing (local cooling) phase

Time: Pre-melt (heating), melting, hold/sealing (cooling)

Clamp pressure (variable in process): Pre-melt; hold/sealing (cooling)

Welding amplitude (variable in process): Pre-melt (heating), melting

Thickness of interface: Of pre-heated and re-melted layer(s); melt collapse/melt-down; final thickness of interface (in local areas)

Direction of oscillation/linear vibrations: Longitudinal, perpendicular to thickness of wall/bead, by angle

Typically, the LVW machines combine all the advantages of vertical or horizontal design for joining of components made from similar or dissimilar plastics. The sizes of the joined parts vary from small (valves, fluid reservoirs, etc) to very

Figure 1: Representative directions of frictional welding: a– LVW (P–weld pressure; 2a–weld amplitude; In–weld interface; R–re-melted layers); b–OVW (1–orbital motion; 2–elliptical motion)

Table 1: Composition (per cent by weight) of the welded and tested nylon plastics

Type of PA Fibre-glass (GF), per cent

by weight

Mineral fillers (MF) per cent by

weight

GF/MF per cent by

weight

Melting point (°C)

Nylon 6 0; 14; 25; 30; 33; 35; 45;

50; 63

40 15 / 25 223

Nylon 66 0; 30; 33; 35 40 16/24 261

66/6 Copolymer

30 - - 238

Nylon 46 30 - - 290

Nylon HTRN 35 - - 300




large (integrated air intake modules, cars cross-beams, etc). When applying LVW technology, one needs to be aware of the following disadvantages:

Weight (of the upper fixture + nested upper part) and design limitations in the sizes of the part placed in upper nest/fixture

Limitations on the weld plane configuration and maximum value of out-of-welded plane angle

Difficulties (to achieve optimised mechanical strength/life performance of joint) in using dissimilar nylon resins with different melt temperatures (of 50°C)

Dimensional limitations (in non-isometric melt distribution in local areas of possible gaps) in reinforced plastics and for non-optimised injection moulding conditions.

For semi-crystalline materials, it is necessary to reach a melt thickness (meltdown) in the range 0.7-1.5 mm. The LVW and OVW processes are less sensitive to dimension

tolerances because both methods are self-adjusting in the contact (weld) areas. It is possible to close a gap up to 5 mm wide, between two joined surfaces with weld clamp pressure. The LVW and OVW technologies are a reliable joining method for injection moulded, blow moulded and extruded thermoplastics and hollow components. It is critical to keep the needed stiffness of the walls in welding directions perpendicular to wall thickness and by angle.

The following key processing and weld interface parameters are important for the performance of H-P welded butt joints:

Temperature: At the heating element/plate; in local areas of materials or interface at joining; in material(s) diffusion phase; start and final temperatures at hold/sealing (local cooling) phase

Time: Pre-melt, during melting & hold/sealing (cooling)

Clamp pressure (variable in process): Pre-melt and during hold/sealing (cooling)

Thickness of interface/distance: Of pre-heated and re-melted layer(s); melt collapse (at joint sealing phase); final thickness of the interface (in local areas)

For H-P welding, it is important to achieve a sufficient and consistent through-thickness and local material heating during the pre-melt phase. For the semi-crystalline materials, the requirements include:

Meltdown of about 30 per cent of the wall thickness (for a wall thickness less than 4 mm)

Sealing distance/joining displacement of approximately 60 to 80 per cent of above mentioned melt thickness (or about 18-24 per cent of a wall thickness)

Hot-plate/tool temperature (for semi-crystalline plastics application) should be equal to the melting peak, + 70°C.

The H-P technology is a reliable joining method for injection moulded, blow moulded and extruded thermoplastics and hollow components. Typically, H-P machines have all the advantages of horizontal or vertical design. These include welds of small and big components (ie gas tanks), long/large diameter gas pipes made from similar plastics. When applying the H-P methods, one needs to be aware of the following disadvantages:

Design limitations in plane configuration of the joint surfaces; position tolerance (centering capability for non-stiff applications – flexible walls, etc)

Dimensional limitations (in non-isometric melt distribution in local areas of possible gaps) in reinforced plastics that are dimensionally unstable, and for non-optimised moulding conditions; limitations on optimising clamp-force pressure (in case of welding of small components)

Figure 2: Similarities and differences of electromagnetic driving systemsa–LVW; b–OVW; 1–Electromagnet; 2–Welded part; 3–Upper tooling (Table); 4–Lower tooling (Table)

Table 2: Welding/processing parameters for LVW and OVW technologies

Processing parameters Linear vibration (LVW) Orbital vibration (OVW)

Weld amplitude, mm 1.02 ~ 1.80 0.6 ~ 1.50

Frequency (nominal), Hz 240 190

Melt-down, mm 0.5 ~ 5.0 0.5 ~ 2.0

Hold/sealing/cooling time, sec 2 ~ 10 2 ~ 10

Maximum clamp force, kN 3.6 0.5

Driven platen fixture weight, kg 2 2

Direction of vibration/ oscillation

Longitudinal; perpendicular to thickness; by angle

Orbital; elliptical longitudinal




Welded materials and joints The thermoplastics used in the investigation mentioned here comprise heat stabilised nylon 6 and nylon 66 (for nylon 46, 66/6 copolymer and high temperature resistance nylon-HTRN, limited data for LVW technology only) pigmented black (BK), typical for automotive under-the-hood components.

Table 1 mentions the level of fibre-glass (GF) reinforcement, mineral fillers (MF) loading (per cent by weight) of the materials. It also lists melting points of these resins. Melting points may vary because methods of measurement, oligomer contents, additives, reinforcements, fillers and crystalline forms can alter the result.

Mechanical tests procedure In quality control and performance evaluation of the welded components and plagues, tensile test and burst test methods were usually applied. The tensile strength of welded joints or specimens is a key parameter for the material selection, component design, joint performance evaluation and welding optimisation. However, as of now, the standards for defining LVW, OVW, and H-P butt joint strength are not available. At the same time, most of the plastic weld performance data have been obtained by testing the tensile strength of welded butt joints. The tensile test results are also important for joint design evaluation and improvement, along with new materials development for welded parts. For mechanical performance evaluation of weld (by tensile strength criteria), the researchers used AIM butt joint design, consisting of two beads 4 mm & 6.25 mm thickness welded together, following injection moulded rectangle plague measuring:

100 (or 150) mm × 65 mm × 6.25 mm 100 (or 150) mm × 65 mm × 4 mm

Sizes (length × width) of the welded plagues are: 100 (or 150) mm × 125 mm (approximately).

The test data was obtained from rectangle tensile specimens (10 mm width, 125 mm length), cut and machined from above mentioned welded plagues (150/100 mm × 125 mm). For each LVW or H-P processing condition, a minimum of five specimens were tested using ISO 527 procedures. In most applications, the weld flash/bead is not removed. In this study, weld flash was machined off prior to a tensile test. The tensile specimen, which has a uniform butt weld at middle length, is then subjected to constant displacement/strain rate. The specimen is loaded until it fails. All tensile test results were used for performance optimisation. Samples with high tensile strength were selected to perform the morphology analysis in the weld zone (interface).

LVW process optimisation: Time-temperature profile One of the most important parameters affecting the performance of welded joints is the temperature during joining process. An advanced method of thermal imaging (infrared) was applied in




the study referred here to analyse the temperature changes during the welding process. For the temperature detection in welding process, Thermovision 900® Series System (FSI/AGEMA infrared) was employed. The infrared camera continuously monitored the temperature distribution in overall and local areas. The computer electronically labelled on-time gates images according to the duration of time between sending and receiving a pulse.

The software then converted these thermal pictures into series of thermal wave images, which might also detect possible material or welding defects at various depths below the surface. During the welding, heating and melting of the same thermoplastics proceeded symmetrically. This process will be not the same, when joined components of dissimilar materials are moulded. Because of differences in thermal properties, one material may melt at a faster range. Sometimes, one of the materials may not even reach melting point/temperature at the joint interface.

The time-dependent temperature distribution and melt propagation in the weld interface (at five local areas with the same size) was measured during the LVW process. The results were obtained at various longitudinal welding conditions (amplitude-pressure-meltdown), at vibration welding frequency of 210 Hz for the similar or dissimilar nylon 6 and nylon 66 that were non-filled, filled, or reinforced.

The second plastic pre-heating phase is too short for the heat to penetrate through all interface areas; an additional 4-6 seconds are needed for this purpose. The distribution of weld temperature in local areas was not isochronous; it was dependent on the flatness of welded surfaces, nest design and heat transfer out of interface by the melted flush. Similar time-temperature data may also be obtained for the H-P technology. These temperatures were not affected by the reinforcement under optimised welding conditions. The reinforcement, however, was changing the heat transfer processes.

For nylon 66 plastics, the coefficient of thermal conductivity may double with glass-reinforcement in the range of 0 to 40 weight per cent. The temperatures of the nylon weld-melt (weight per cent 33 GF) at the steady state were in the ranges above melt temperature of plastics.

When the LVW machine is shut off, the weld penetration continues to increase because the clamp pressure causes the molten interface to flow until it solidifies. During the shutting off phase, the interface temperature has a tendency to increase (for 40°C on average). The maximum temperature of the joint interface was equal to the melting point of welded polymers or blends + (85-90°C). The results in this study are slightly different from the data for the H-P technology. These differences may reflect the difference in the methods, calibration, measurement procedures, and effects observed & analysed during this investigation.

Acknowledgements Support provided by Branson Ultrasonics Corporation, Bielomatik Inc and FSI/AGEMA Infrared Systems is gratefully acknowledged. Special thanks go to Shaul Aharoni for knowledge, and to Chris Roth and Nanying Jia for help in preparing this study for publishing. Their contributions are greatly appreciated.

References 1. Michel Costes, Jean-Bruno Monteil,

“Trends in Plastics Used for the Construction of European Cars – An Analysis Based on PLASTICAR, A Specialized Benchmarking Tool”, SAE’99 Technical Paper Series - Plastics: Components, Processes, and Technology (SP-1410), 5 p.

2. Kevin Edwards, Paul D Daly, “Plastic Intake Manifolds – Geometric Growth for 7 Years”, SAE’98 Technical Paper Series - Plastics: Components, Processes, and Technology (SP-1315), 8 p.

3. “Increased Options for Manifold Moulding”, British Plastics & Rubbers, February 1999, pp. 64-66.

4. Melvin I Kohan, “Nylon Plastics

Handbook”, Hanser Publisher, New York, 1995, 631 p.

5. Shaul M. Aharoni, “n-Nylons: Their Synthesis, Structure, and Properties”, John Wiley & Sons, New York, 1997, 598 p.

6. “Vibration-Welded Manifolds Coming on Strong”, Injection Molding, January 1999, pp. 41-44.

7. D Grewell, A. Benatar, “An Application Comparison of Orbital and Linear Vibration Welding of Thermoplastics”, ANTEC’99, SPE Conference Proceedings, Vol. 1, 1000 p.

8. “Seek But Don’t Destroy”, Machine Design, March 1996, pp. 60-63.

9. V Kagan, “Joining of Nylon Based Plastic Components: Vibration and Hot Plate Welding Technologies”, ANTEC’99, SPE Conference Proceedings, Vol. 1, pp.1349-1359.

10. H Potente, M Uebbing and E. Lewandowski, “The Vibration Welding of Polyamide 66”, Journal of Thermoplastic Composite Materials, Vol. 6, January 1993, pp. 2-17.

11. V Kagan, “Vibration Welding of Glass-Fibre-Reinforced Polyamide Plastics”, Kunststoffe plastic europe, Vol 87, December 1997, pp. 1804-1807.

12. H Potente, A Brubel, “Welding Behaviour of Filled and Reinforced Thermoplastics with Hot-Plate Welding”, ANTEC’98, SPE Conference Proceedings, Vol. 1, pp. 1062-1066.

Note: The information submitted in this publication is based on BASF’s current knowledge and experience. In view of the many factors that may affect processing and application, these data do not relieve processors of the responsibility of carrying out their own tests and experiments; neither do they imply any legally binding assurance of certain properties or of suitability for a specific purpose. It is the responsibility of those to whom BASF supplies their products to ensure that all proprietary rights and existing laws & legislations are observed.Courtesy: BASF SE


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Exploring new dimensionsDigital prototyping

Digital prototyping provides a new approach to plastic product design and is revolutionising the way companies design, manufacture and market their products. It has unleashed a new wave of design ideas, materials, processes in the arena of plastic product development, thereby offering a competitive advantage to companies.

Rajiv Bajaj

The ability of manufacturers to deliver low-cost, better performing products to more consumers than ever before,

over the past 25-50 years, has brought about a sea change the world over. Today, there is an unprecedented amount of innovation being witnessed

throughout manufacturing processes for new product development. The never-ending efforts for increased revenues and margins aggressively drive companies to continuously evaluate their activities and processes. This has revolutionised the processes for designing, engineering, manufacturing and marketing continually with the development of


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a plethora of new design ideas & materials as well as novel manufacturing methodologies & processes, new distribution methods, and increasing amounts of regulation. This holds true in the development of plastic products as well.

From consumer to industrial & commercial products, plastics are used in virtually every industrial sector and continue to replace other materials. Relatively low-cost, flexible, strong, durable, light and increasingly sustainable plastics are broadly integrated into the current lifestyle and make a major, irreplaceable contribution to almost all product areas.

Today, digital prototyping is paving the path for companies to effectively design, manufacture and market their products. The availability of various sophisticated tools for digital prototyping is changing people’s perceptions of what is achievable and possible during product development.

Challenges Currently, innovation is functioning as a growth driver, offering value as well as a competitive advantage. However, the digital tools used to design, engineer and manufacture products are based on a paradigm shift introduced in the market, a quarter of a century ago.

The concept of parametric modelling gained momentum a few years ago. And now companies have adopted it into their processes, which has resulted in some significant improvements to product development and manufacturing processes. Parametric modelling is a feasible idea, particularly for engineers. The concept of being able to closely control a design, based on known parameters, is extremely comforting. From an engineering perspective, this is beneficial. However, from an innovation perspective, it is far from ideal. The ability to examine new ideas demands a high degree of freedom to explore.

Design For Manufacture (DFM) is a pragmatic idea, which is well-established in the industry. There are numerous other, similar examples where sometimes unknown downstream requirements drive design intent and development. Although parametric modelling provides a framework to capture rules that can govern design intent, it does not actually provide some of the guidlines, leaving that to the expertise of the user. However, assuming that there is value in these processes, why is it so difficult to link manufacturing considerations to detailed engineering design?

The same is true when it comes to the performance of a product. The idea that digital simulation can help improve a product is also well-established. However, simulation must be capable of creating geometry and driving design intent from the outset, and not as an afterthought.

If all this were not enough, parametric modelling, as it has been introduced in most systems, will not particularly be ideal for engineers either. Parametric modelling expects that engineers developing these models are geometric CAD experts.

Inventor tooling software

Autodesk® Inventor® tooling software automates key aspects of the design of injection moulds for plastic parts. This enables companies to create and validate complete mould designs, reduce errors and improve mould performance. The design of plastic injection moulds can be streamlined with easy-to-use mould design features that work directly from Inventor 3D models of plastic parts. In addition, full association to the Inventor digital model can help ensure that any changes to the model are automatically reflected in the mould design.


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What is really needed is a tool that enables them to focus on engineering – something that adheres to the needs of the engineers and designers, rather than IT, computing orgeometric theory.

Transforming ideas into engineering realityCompanies that are able to manage the transition from a great idea through to engineering are more effective in their ability to deliver innovative and differentiated products to the market that meet the expectations of their customers. Best-in-class companies are aware of the importance of conceptual design to their processes. A research outlined that best-in-class companies are 2.5 times as likely to capture best practices around the development of digital conceptual models as their lagging counterparts. Clearly, it is important to be able to drive detailed engineering considerations directly from design concepts.

Industrial designers and engineers are driven by fundamentally different principles. On one hand, freedom of thought and creativity unbounded by traditional considerations are pivotal to success. On the other, the application of indisputable laws of physics and practicality govern the process of development and manufacturing. This fundamental difference is inherent in a majority of traditional

applications that have been used to drive design and engineering. Key to the product development process, the industry-leading and award-winning industrial design tools are now more closely integrated to engineering processes than they have ever been possible before. As a result, design integrity is closely maintained and companies are able to drive conceptual design ideas through to engineering and onto manufacturing.

Autodesk® Inventor® software offers one of the closest integrations of industrial design and engineering available today. As the concept evolves, engineers can incorporate changes from the industrial design team with ease. This allows companies to efficiently design plastic parts that are ready for manufacture. The Inventor software provides integrated, free-form shape and parametric modelling within the Inventor environment. This unique suite of capabilities allows engineers and designers to easily create free-form, organic models, without the need for detailed surfacing expertise or complex CAD modelling experience. In a highly dynamic and free-form modelling environment, users can create and derive complex organic shapes simply by pulling and pushing geometry to create the shape they need, easily and intuitively. They can also control all command inputs

right at the point of application, directly affecting geometry. Moreover, the software enables an uninterrupted design workflow.

For customers, this new paradigm opens the doors to some new ways of working that are driving some significant improvements to their processes and workflows. With the introduction of these capabilities, various companies are able to realise creative and imaginative shapes, without the need for expensive training or expertise. These revolutionary tools are allowing a new generation of engineers and designers to directly create innovative and differentiated conceptual models that will help make their products stand out on the shelf.

Realistic visualisation For the vast majority of companies, effective product visualisation is an important consideration right across the product development process. The key lies in getting customers’ input at the beginning of the development process and adding value at the end of the process & digital visualisation. This proves a significant boon in helping convey product idea and value.

Traditionally, however, digital product visualisation has been considered part of the engineering process, with visualisation resulting automatically from engineering activities in CAD systems. In addition, these traditional systems have also provided a rather idealistic level of product visualisation, where everything about the model is a perfect representation. Best-in-class companies, however, treat this aspect of their processes much more seriously, putting a high degree of focus and attention into ensuring that their ideas, concepts and products are seen in the best light possible. This has led to a significant shift in the way in which companies are able to engage with their customers.

Tool design and production


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In addition to engineering, sales and marketing, organisations are now reaping benefits from being able to visualise their products in a realistic, dynamic and interactive environments; where the value their products bring to their customers can easily be conveyed.

The progressive nature of engineeringEngineering is a critical phase of the new product introduction processes. It is the time when expensive commitments to manufacturing processes, tooling and equipment are made, which are typically responsible for around two-third of the cost associated with new product development and introduction. With this level of commitment, it is critical that product engineering is able to incorporate manufacturing considerations as early as possible in the engineering and design process.

In today’s environment, most of the traditional design and engineering systems have been developed with the simple aim of geometric modelling in mind. Focussed on the creation of geometry, many of these tools demand that those who use them are familiar with, and often have great expertise in geometric detail. In turn, engineers using these systems have had to abstract their engineering needs and embed them into these systems manually.

Support collaborationCoupled with these technical requirements is a need to support collaboration between the systems being used for product development. Increasingly, innovative business models across all industries are demanding that the different groups involved in product development share their design information.

Efficient collaboration is becoming increasingly critical to a manufacturer’s success. However, most of the traditional systems have

only recently begun to embrace the idea of heterogeneous, or multi-CAD, development environments. The ideal solution is one that is focussed on ensuring that customers are able to streamline their collaboration efforts by exchanging data with other systems, allowing them to accept and supply data in their customers’ preferred format.

Tool design and production In majority of the processes employed during the production of plastic parts, tool design occupies a key juncture between engineering and manufacturing. Similar to directly influencing factors like quality & cost, tool design has a large impact on downstream product profitability. Many companies are, therefore, closely focussed on realising productivity and efficiency to keep costs low.

Automatic creation of tooling design information for moulds has been a long-time aspiration. The practical reality is that design associated with moulds is a complex issue. This is particularly apparent, given the demands of today’s designs that are driving increasingly complex mould designs. While there are several discrete design issues that need to be manually addressed throughout the mould process, there remains a high degree of automation that can be applied to many, often more mind-numbing aspects of tool design.

Digital simulation Digital simulation is another key aspect of the digital prototyping process. As indicated by a research firm, digital simulation grants the power to move some of the most expensive and time-consuming aspects of the engineering process away from physical prototyping and into the fast, cheap and safe simulation of electronic/digital prototyping. Unfortunately, simulation tools have traditionally required the user to have advanced knowledge and expertise. As a result,

the tools have been used primarily by analysts and engineering simulation experts. In addition, these simulation tools have been, at best, loosely integrated into design and engineering applications. All of this meant, for example, that part and tool designers had to wait for key inputs that could drive changes to their models.

A large number of tools available for digital prototyping are wholly focussed on ensuring that simulation can be used to drive decisions in a more timely manner. Companies are aiming at delivering, and making attainable, digital simulation tools endowed with next generation simulation capabilities for engineers and designers. This allows them to drive detailed engineering considerations, without requiring detailed and specialised knowledge as with most dedicated simulation packages.

Functioning as an enablerPlastics have become an irreplaceable part of modern product development and function as a critical enabler to overcome many design and development challenges. However, based on a computing paradigm that was revolutionary a quarter of a century ago, the vast majority of tools currently in use for digital plastic product design and manufacture have not kept pace with the rapid innovations occurring in many other areas of this fast-moving industry. In order to realise business opportunities and optimise efficiency, new approaches enabling better product development in an easier and affordable manner are the need of the hour.

Rajiv Bajaj heads the manufacturing division at Autodesk India and SAARC. His responsibilities involve consolidation and growth

of the Autodesk products across various verticals in the manufacturing segment.Email: [email protected]


Business growth

Initiatives aim at preventing or correcting problem areas at every level, be it personal or business. All those who take initiatives move in the right direction in terms of achieving their respective goals. However, the catch lies in deciding on the best solution, its appropriateness and feasibility. Read on…

M Hariharan

Ivaguely remember a definition of a long sentence. “A long sentence is one, which starts slowly, uncertain of its terminus, and after the initial

hesitancies it gathers momentum, meanders for a while and when it becomes apparent that the movement is not towards any specific destination, that long sentence comes to an abrupt halt with a full stop.”

There is a variation to this definition when companies undertake initiatives. They do not start slowly, but with lot of fanfare. There are initial resistances not necessarily hesitancies. It does gather momentum but meanders for a while. Then some other initiative crops up and this initiative drops off. There are many

reasons for this endemic malaise and some of them are mentioned below:

Desperate measuresInitiatives are triggered by the desperation to address a current problem. It may not even be a problem but a symptom. Companies end up selecting the wrong tool and trying it out to counter the ‘so-called’ problem. The solution naturally fails and the initiative gets dismissed. The personnel subsequently start blaming the tool (first of all calling an initiative as a tool itself is inappropriate), the consultants, or worse even the employees.

Fashion statementThe boss attends a conference, picks up some ideas about a few ‘tools’. He/she believes that if everyone is trying this

Hinging on the right initiative

M A N A G E M E N T M A N T R A S


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out, there is something about this tool. Everyone is doing Six Sigma, Kaizen, Lean, re-engineering (the fad of the early 90s), so the boss feels that his company should also follow suit. Initially, a few baby steps are taken, and an auditor is called to certify these initiatives. The company boasts, “We have been following the 5S for last 8 years” (repeating 1S and 2S five times is not 5S).

Just before the 5S auditor arrives, 1S and 2S are undertaken on a feverish pitch, thereby stopping production.

Overzealous consultantsThe science of dialectics, logic and reasoning, Tarka Sastra, proposes ‘nahi ninda nyay’ to support one’s theory, wherein one’s view is glorified. But that does not mean that the other views are flawed. But unfortunately, in business consultancy, the mantra is ‘evam ninda nyay’; ridicule the other methodologies to glorify one particular methodology.

A plethora of consultants carrying one or two methodologies in hand reminds one of the village fairs where in one corner, a guy sells ‘Activity-based costings’ that claims to offer clarity on costs’; another vendor next to him yells “SAP is the way to manage one’s data and have clarity not only on costs but also all business processes”. If someone goes further down the aisle,

he/she will find two vendors sitting next to each other and selling ‘Balanced Score Card (BSC) and Economic Value Added or (EVA)’. Unless one links people to a strategy, one cannot have a

successful business (BSC). In another instance, unless one measures the bottom-line impact of individual divisions, one cannot align the goal

(EVA). Then there will be a horde of disparate vendors selling Kaizen, 5S, Six Sigma and Lean strategies to drive business. They refer to these as disparate, as they claim that their way of doing it is the right way and the only way. One can find these vendors claiming that “I have received training on Six Sigma at Motorola itself”; “I was trained under a Sensei from Japan”, among other self-praises. A few consultants sell ‘Theory of Constraints’, claiming that it can offer a cure for all ailments; and worse, if one does not adopt it, he/she will be in trouble. Then there are the

evangelical Lean consultants supposed to look at the holistic view of business, but rarely so.

In this melee, the hapless businessman is confused and ends up taking the initiative that has been proffered by the most convincing seller.

Myopic view of the initiativeEvery methodology focusses on one key theme. Abraham Maslow, a renowned psychologist, said, “If the only tool you have is a hammer, you tend to see every problem as a nail.” Maslow’s observation was spot on. It is not uncommon to see people claiming “if you follow ‘XYZ’ methodology, everything is taken care of”. For example, 5S’ focus is to bring in stability that will enable other improvement initiatives. Total productive maintenance (TPM) aims at improving the reliability and availability of the equipment. Six Sigma addresses process capability. Activity-based costing is a cost measurement mechanism trying to articulate the resource consumption more scientifically. So the ‘XYZ’ can be replaced with any such initiatives deemed fit for an organisation’s growth.

Lack of preparedness of the organisationOften, initiatives are undertaken without understanding the preparedness for the same. ERP implementation is a classic case. Organisations without any great culture of data capture end up wasting their time and resources, hoping the initiative will ease up all the problems they face. The shop floor is in a mess, but organisations claim to follow Six Sigma. Six Sigma calls for a huge amount of data gathering and analysis. If the right amount of data gathering is not possible in the gemba (Japanese term meaning the ‘actual place’ or ‘real place’), one cannot pursue a great Six Sigma initiative.

Viewing an initiative as a toolEvery initiative has prerequisites and preparedness; needs champions to take it forward and ultimately should become a part of the performance measure. Instead, perceiving an initiative as a tool will only lead to short-term focus of benefits of the tools and not the long-term focus for achieving sustainable improvement.

ConclusionThe aim of any business is to create value for the customer. Hence, a company needs to align the purpose, ie, the process has to be in sync with the intent. The employees must align the process to purpose and vice versa. Moreover, initiatives and methods are essential to ensure that this alignment is as seamless as possible. Only then businesses can prosper. Choosing the method, therefore, is the first critical step. And once the purpose of the method is decided, the method follows.

M Hariharan practises consultancy in the field of cost management, lean thinking, constraint management, management control system

and business excellence as Founder Director at Savoir Faire Management Services. Email: [email protected]

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P R E V I E W


Shibani Gharat

There are very few moments that carry the magnitude to change the course of history. The opening up of the Indian economy in

1991 was one such defining moment. Globalisation not only shaped the entire Indian economy but also formed the silver lining for the industry in India.

It encouraged exports and increased productivity by employing comparative advantages that could be achieved through exposure to foreign competition, enhanced technical development and access to economies of scale. The positioning of domestic and foreign prices helped generate industrial efficiency, increase exports and reduce forced idleness of resources, abolish monopoly profits & allow optimum resource allocation in the economy.

Globalisation has indeed helped India in many ways. Manufacturing is one of the industries that has benefited the most from liberalisation.

“Since 1991, the Indian economy opened up to witness an inflow of FDI in several sectors and less export-import regulations. These factors provided access to international markets and contributed to the technological development in the country. The corresponding development of globalisation in the Indian manufacturing sector helped drive the growth of several industry verticals like IT and hardware, telecommunication hardware, automobile,

pharmaceutical, biotechnology, infrastructure, electronic, electrical, textiles, etc,” says Sudhanva Jategaonkar, Associate Vice President – B2B Publishing, Infomedia 18, a Network 18 Group company.

Manufacturing backboneToday, the manufacturing industry forms the backbone of the Indian economy. It has not only helped the overall productivity and employment, but has also played a vital role in strengthening several other sectors. The Indian manufacturing sector is successfully competing in the global marketplace and has been registering high growth year-on-year basis since the 1990s.

“Today, the kind of innovations that the Indian manufacturing industry is witnessing was unimaginable around 20 years back. Almost, every day there is a new product, machine or service launched. The buyers are really spoilt for choice,” says Jategaonkar.

HiTech Manufacturing Show, organised by Network 18, is one of the largest tradeshows in the country that showcases pioneering solutions in engineering and manufacturing.

HiTech Material Handling Show and HiTech Automation are two concurrent shows under the same umbrella. HiTech Manufacturing will help bring all players from these two major industry verticals under one comprehensive roof. This event will display the best in terms of cutting-edge technologies and innovations

that will help shape the future of the industry in India.

From plastics & packaging machines to IT & software, automation systems, instrumentation & controls, machine tools & accessories, hydraulics & pneumatics, electrical & electronics, and material handling equipment storage systems, the entire industry will converge to showcase their innovations on this unique platform.

Envisioning the futureThe trade show will have several product launches, live demonstrations, dedicated zones/areas for various industries that will help those participating in the show on a long-term basis. “The manufacturing industry in India is bound to experience a revolution named HiTech. If the Indian manufacturing has evolved since 1991 to the stature of a gigantic player in the world arena, HiTech Manufacturing Show intends to take the country to the position of a leader. It will not just help the exhibitors in terms of quality business visitors, but also enrich them with an experience of a lifetime,” says Jategaonkar.

With this show, the entire spectrum of the manufacturing industry in India will be spectators to a plethora of exhilarating developments, which in turn will help several businesses grow beyond measure.

HiTech Manufacturing Show is all set to give shape to a robust manufacturing future for a country that has seen this industry grow from strength to strength, year-on-year since 1990.

Following the initiation of free market principles in 1991, India witnessed a fast-paced economic growth. There was an upsurge in foreign investment and competition. These resulted in technological innovations and business growth in the country. Manufacturing and exports boomed. Tapping this potential of the gigantic Indian manufacturing segment is the HiTech Manufacturing Show that will aid the industry to sustain its growth spiral.

Growth stays constantHiTech Manufacturing Show

Mumbai

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Shibani Gharat

Tamil Nadu has been successful in attracting massive investments since time immemorial. Today, it is one of the premier

Foreign Direct Investment (FDI) destinations in India. The investors have capitalised on the strategic location of its capital city – Chennai – which today wears the crown of the undisputed leader, as far as industrial presence is concerned.

The region remains unarguably the epicentre of investments. Today, it boasts of being a hub for several industry verticals. From IT to automotives, logistics & material handling to textiles & apparels, medicines to petrochemicals, Chennai plays host to several industry domains.

Presence of industry bigwigsSeveral software companies like Accenture, Cognizant Technology Solutions, CSC, EDS, HCL, HP, IBM, Infosys, Satyam, Sun Microsystems, Symantec, TCS, Verizon, Wipro, US Technology Resources, etc, have development centres in Chennai. The city has also surfaced as an electronic manufacturing hub with MNCs like Samsung, Nokia, Motorola, Cisco, Dell, Siemens, Sony-Ericsson, Flextronics and Foxconn setting up manufacturing units in the 250-acre Sriperumbudur electronics SEZ. Ericsson and Alcatel have R&D facilities in the region. Besides, R&D facility for Texas Instruments and semiconductor companies like SPEL and Tessolve are in the pipeline.

A large chunk of the Indian automotive industry is based in Chennai. Almost 30 per cent of India’s automobile industry and 35 per cent of its auto ancillary industry is based in and around this region. Further, several global automotive companies such as Ford, BMW, Hyundai, Mitsubishi, TVS, Ashok Leyland, Nissan-Renault, Caterpillar, Royal Enfield, TI Cycles, MRF, etc have manufacturing plants in the same area. Various petrochemical companies like Chennai Petro Chemicals Ltd (Manali Refinery), Manali Petrochemicals, Petro Araldite and other pharmaceuticals companies such as Orchid Pharmaceuticals are situated on the outskirts of Chennai.

The presence of big names from the industry provides the local industry an opportunity to grow. Participating in an industry exhibition is the perfect way to showcase technology, exchange ideas, and meet & interact with customers as well as competitors. “Exhibitions provide an opportunity to interact with business buyers, understand their expectations and develop innovative technologies,” says S Sriram, National Sales Manager, Boge Compressed Air Systems. Boge manufactures a range of oil-lubricated & oil-free screw and

piston compressors. The company has participated in all the four cities of Engineering Expo.

According to S Prabhakar, Marketing Representative, Bois Technologies, “This is the fourth time we are participating in Engineering Expo Chennai. In the previous years, the event has been a good experience and helped us generate a lot of leads.”

Along with SMEs, Engineering Expo Chennai will see participation of some of the renowned names from the industry. Atlas Copco India, FEIN Power Tools, Tussor Machine Tools, Trelleborg Sealing Solutions, Pathak Machines International, Nilkamal Ltd, Emtex Machinery, Boge Compressors, Toshnitek, Sri Yantra Engineering, Rittal India, etc and several other major manufacturing industry players will be participating in Engineering Expo Chennai.

Excellent connectivityChennai is well-connected through major roads such as Oragadam Industrial Corridor Road, East Coast Road, NH-44, NH-45, a major seaport, railway station and also has an international airport. The road and rail network provides great connectivity

Chennai has emerged as a hot destination for investments from across the globe. Availability of educated manpower, robust infrastructure, and accessibility via different modes of transport are some of the deciding factors that have made the city the destination for several companies from various industry verticals. Trade shows like Engineering Expo have proved to be platforms of growth for the industry to come together under one roof, and hence help induce the growth of trade & commerce in the region.

Engineering Expo Chennai 2011

Tracking impending opportunities

A large chunk of the Indian automotive industry is based in Chennai. The presence

of big names from the industry at the Expo provides the local industry an

opportunity to grow.

Advertorial_Eng expo_84-85.indd 84 1/22/2011, 6:03:10 PM

to major cities like Bengaluru & Mumbai and several other major western & northern cities. Waterways connect Chennai with many countries in Asia and beyond.

This has also led to several Indian logistics players such as DHL, Realtime Logistics, Shri Kailash Logistics to set up their respective logistics hubs in this region. “There are several regions in India that have grown into major industrial hubs owing to massive investments from domestic as well as international players. But Chennai has an advantage over other regions. It owes its strategic advantage to an established infrastructure and excellent multimodal connectivity, a huge manufacturing presence, demand base and supplier presence,” avers Sudhanva Jategaonkar, Associate Vice President – B2B Publishing, Infomedia 18, a Network 18 Group company, and the organiser of Engineering Expo Chennai.

Adequate government supportThe Government of Tamil Nadu has been promoting industrial growth through various initiatives to make the state a hub for manufacturing. Currently, the state ranks third in

terms of development of SEZs in the country. The various places where SEZs are being set up in Tamil Nadu are Hosur, Tuticorin, Ennore, Tirunelveli and Vandalur. The government has realised that the future investments will be centred around the emerging industrial centres.

“SEZ helps in economic and industrial development of the state. It also helps in bringing investments and creating employment & business opportunities for the locals. The government is making efforts in the right direction to help the industry prosper,” states Jategaonkar.

The two leading agencies of the state – the Tamil Nadu Industrial Development Corporation (TIDCO) and the State Industries Promotion Corporation of Tamil Nadu (SIPCOT) – that help sustain industrial growth of the state are now looking at the need to support industrial growth with the formation of planned urban infrastructure.

India’s largest show on engineering & manufacturingEngineering Expo is one of India’s largest SME gatherings. Every year, it boasts of profuse industry participation from various verticals, some of which include machine tools & accessories, process machinery & equipment, material handling equipment, hydraulics & pneumatics, automation & instrumentation, electrical & electronics, IT products & services, light & medium engineering, safety & security, packaging machinery, etc.

Considered to be one of the most preferred platforms to grow business by the 1,000+ companies that participated in Engineering Expo in the previous editions, this year’s Expo promises more business than ever before.

Showcasing some of the pioneering engineering solutions and technologies for the visitors, Engineering Expo Chennai has participation from a variety of industry verticals.

“Initiatives like Engineering Expo in the past have proved to be principal platforms for this thriving industry to grow beyond measure. Exhibition and trade shows have been utilised as an effective medium to generate business leads, and launch new products & services. Engineering Expo has helped several SMEs in this region to spread awareness about their businesses,” says Jategaonkar.

The investment pipeline for Chennai is indeed robust, and many prospective investors are eyeing the region closely. Platforms such as Engineering Expo help foster trade and commerce in the region.

Engineering Expo is an ideal medium through which several businesses can reach out and spread awareness to these prospective investors about their products. Indeed, the Expo proves to be a perfect combination of a vast range of exhibitors, spacious venue, state-of-the-art amenities and a humongous visitor turnout – the most crucial factor for any exhibitor.

Chennai | 11-13 Mar, 2011

Engineering Expo, organised by Infomedia 18 Ltd, is one of the biggest events in the country dedicated to the engineering industry. The 2009-10 edition witnessed business transactions worth over ` 150 crore. Launched in Ahmedabad in 2002, the event today boasts of a huge visitor turnout. The Expo is a preferred destination for SMEs and manufacturing & engineering companies to transact, network, tie-up and exchange ideas for the growth the industry.

After flagging off Engineering Expo 2010-11 in three cities – Pune, Ahmedabad and Indore – this season of the Expo will conclude with Engineering Expo Chennai.

Considered to be one of the most preferred platforms to grow business

by the 1,000+ companies that participatedin Engineering Expo in the previous editions,

this year’s Expo promises more businessthan ever before.

Advertorial_Eng expo_84-85.indd 85 1/22/2011, 6:03:21 PM

E V E N T S C A L E N DA R


Indian Medical Devices & Plastics Disposables Industry 2011This conference will focus on the medical polymers processing and device manufacturing industry. It will highlight the technology, research, market developments and regulations within this sector, February 11-12, 2011; at the Ahmedabad Management Association Complex, Ahmedabad

For details contact:DL PandyaClassic Computer ServicesB-4, Mandir Apartment, Jodhpur Char RastaSatellite RoadAhmedabad - 380 015Tel: 079-2674 0611Mob: 098254 57563Email: [email protected]/[email protected]: www.imdiconferences.com

International Conference & Exhibition on Reinforced PlasticsThis bi-annual event of the Indian fibreglass reinforced plastics industry will provide an ideal opportunity for the global composites industry to focus its attention on India through interaction with raw materials processors, tools & accessories suppliers and end-users; March 02-04, 2011; at Bombay Exhibition Centre, Mumbai

For details contact:Dr A SelvamFRP Institute Ekkattuthangal, Chennai - 600 097Tel: 044-2225 0359/22251502Mob: 098414 26644, Fax: 044-2225 0349

Email: [email protected]: www.icerpshow.com

PU TECH 2011This exhibition and conference will bring together raw material producers, equipment suppliers & end-users under one roof to provide a comprehensive interaction of technology and industry; March 09-11, 2011; at the India Expo Centre, Greater Noida, New Delhi

For details contact:Ramamurthy KSecretary General, IPuAFlat 7, III Floor, Shakthi MahalCIT Colony, Mylapore, Chennai - 600004Tel: 044-2499 5923, Fax: 044-2499 5923Email: [email protected]: www.putechindia.com

PLASTAVENUES Summit 2011The first edition of PlastAvenues Summit 2011 aims to further build green plastics & sustainability in India, and help the plastics fraternity leverage the potential in this segment. The sessions will include opportunities in biopolymers and biodegradables, plastics waste management etc; March 18, 2011; at Novotel, Juhu, Mumbai

For details contact:Sundeep NadkarniHead – Conference DevelopmentTex Centre Premises, 2nd floorHDFC Compound, Chandivali, Andheri (E)Mumbai - 400072Tel: 022 42081715, Mobile: 09819559459E-mail: [email protected]: www.plastavenuesummit.com

Plastex CaspianThis is an international trade exhibition for raw materials, equipment, plastics & rubber production and processing technologies. This is the 1st edition of the show; May 25-27, 2011; at the International Exhibition Centre, Pune

For details contact:GiMA International Exhibition Group GmbHMathias Lauk, CEOLübeck Str 128 D-22087 Hamburg Tel: +49 (0)40 2 35 24-0 Fax: +49 (0)40 2 35 24-400 E-mail: [email protected] Website: www.gima.de

Eastern Plastic & Rubber ExpoThis exhibition is expected to be the platform for modern machinery, materials, and accessories segments; to understand their need and demands. The four-day international exhibition will showcase the entire spectrum of products, latest trends, technology, equipment and services in its chosen sector; June 16-19, 2011; at TBA, Kolkata

For details contact:Nayan Dhayani, DirectorD -43 Clover Centre, 7- Moledina Road Camp, Pune Tel: 020 40068318/32911450Mob: 09371025233, Fax: 020 26054870E-mail: [email protected]: www.vnbindia.com

PET+Drink TECH ASIA 2011The fifth edition of this international exhibition and seminar will showcase the entire spectrum of products, latest trends, technology, equipment and services in PET, drinks and liquid processing, filling & packaging related sector; August 27-29, 2011; at Milan Mela Exhibition Centre, Kolkata

For details contact:SK BhardwajScf 172-A, First Floor Grain Market Sector-26 ChandigarhTel: 0172 2795067Mob: 09216129027E-mail: [email protected]/ [email protected]

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:

Infomedia 18 Ltd, Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028.

Tel: 022-3003 4649/51 Fax: 022-3003 4499 •Email: [email protected]

Chennai Tamil Nadu Mar 11-13, 2011Chennai Trade Centre

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Plastech West 2011This international exhibition and conference will serve as a project-acceleration resource with new technology, machinery & materials for increased efficiency and reduced costs & wastes; February 8-10, 2011; at Anaheim Convention Centre, Anaheim, California, USA

For details contact:Canon Communications LLCLos AngelesCalifornia, USATel: +1 (310) 445-4200Fax: +1 (310) 445-4299Email: [email protected]: www.canontradeshows.com

Plastec South 2011This will be a platform for plastics industry professionals to explore the best products, technologies and services in the global plastics industry. It will focus on the primary processing machinery, CAD/CAM/CAE solutions, materials, mould components, handling/logistics, etc; March 16-17, 2011; at Orange County Convention Centre, Orlando, Florida, USA

For details contact:UBM Canon11444 W. Olympic BoulevardLos AngelesCalifornia-90064-1549Tel: 310/445-4200Fax: 310/996-9499Email: [email protected]: www.PLASTECsouth.com

Asia Masterbatch 2011This programme will cover a number of areas like raw material, machinery, market trends and customer developments to provide an international forum for all companies involved in the Asian masterbatch business; March 28-30, 2011; at Swissotel The Stamford, Singapore

For details contact:Adele BrownSenior Conference OrganiserApplied Market ResearchBristol, United KingdomTel: +44 (0) 117 924 9442Fax: +44(0)117 989 2128Email: [email protected]: www.amiplastics.com

European Coatings Show 2011The European Coatings Show featuring adhesives, sealants and construction chemicals is one of the leading exhibitions for the international paints industry held every two years. The aim of this exhibition is to bring together all coating professionals under one roof; March 29-31, 2011; at Exhibition Centre, Nürnberg, Germany

For details contact:NürnbergMesse GmbHMessezentrum, Nürnberg, GermanyTel: +49 (0) 9 11. 86 06-0Fax: +49 (0) 9 11. 86 06-82 28Website: www.european-coatingsshow.comEmail: [email protected]

Polymers in Photovoltaics 2011This conference will bring together top materials experts, module component and manufacturers to discuss the best materials and manufacturing technologies for the solar industry. It is an opportunity to network with a range of professionals who work with and produce photovoltaic systems worldwide; April 12-14, 2011; at Maritim Hotel, Cologne, Germany

For details contact:Dr Sally HumphreysBusiness Development ManagerApplied Market Information Ltd AMI House45-47 Stokes Croft Bristol United Kingdom

Tel: +44 117 924 9442 Fax: +44 (0) 117 311 1534Email: [email protected]: www2.amiplastics.com

Bangla Plast 2011This international fair seeks to explore the latest inventions & research for the plastics industry. It will suit entrepreneurs in the Indian subcontinent to consolidate and strengthen their business opportunities globally; April 20-23, 2011; at Bangabandhu International Conference Centre, Dhaka, Bangladesh For details contact:KMG Business Technology AhmedabadGujarat, IndiaTel: 079 26851511/079 3241 0602Fax: +91 79 2685 1716Email: [email protected]: www.kmgindia.com

Interplas 2011This international event is aimed at showcasing the European polymer industry. It will feature the latest machinery & equipment for processing and converting polymers; September 27-29, 2011; NEC, Birmingham, United Kingdom

For details contact:Jenna ReidPlastics Multimedia Communications LtdUnit 2, Chowley Oak LaneTattenhall CheshireUnited KingdomTel: +44 (0) 1829 770037 Fax: +44 (0) 1829 770047 Email: [email protected] Website: www.britishplasticsshow.com

International

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

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

Business Insights •Technologies•Opportunities

Events Calender_86-93.indd 93 1/22/2011, 1:09:13 PM

Prasenjit Chakraborty

The business dynamics of every economy and market keeps evolving continuously as a large number of manufacturers enter the market,

thereby enhancing competition and raising the standards. The intense competitive environment calls for a networking platform that not only connects the buyer and seller but also enables them to seal envious business deals.

In such a scenario, a trade fair should offer all promotional benefits that a manufacturer looks for. In this direction, the third edition of Engineering Expo Indore, held from January 07-10, 2011, at Poddar Plaza, Gandhi Hall,

delivered the promised prospects. It proved to be one of the most successful shows held in Indore in recent times. Besides being extremely effective, the Expo provided participants with a cost-effective means to promote their products on a wider platform to a serious set of buyers.

Abundant opportunitiesEngineering Expo Indore 2011 witnessed participation from over 270 exhibitors, including some of the leading engineering companies such as Siemens, Havells, S&T Engineers, Atlas Copco (India), Guhring India, Kirloskar Oil Engines, Nilkamal, Godrej & Boyce, etc. The exhibitors used this platform to fruitfully showcase

their latest product offerings to esteemed customers and visitors present at the event.

The inauguration ceremony was attended by a galaxy of industry leaders namely Ashok Jaiswal, President, Association of Industries, MP; Gautam Kothari, President, Pithampur Audhyogik Sangathan; Omprakash Gupta, President, Madhya Pradesh Electric Merchants and Contractors Association, and many other dignitaries across industries. Addressing the gathering, Jaiswal said, “With the proactive support of the State Government, MP is taking rapid strides on the industrial front. In this scenario, the exhibition provided a much-needed momentum to accelerate the growth prospects of the industries.”

One of the major highlights of this Expo included the visit of Kailash Vijayvargiya, Minister of Industries, Government of Madhya Pradesh. He took keen interest in the exhibition and visited different pavilions. Commenting on the Expo, the minister said, “Engineering Expo is an excellent platform for the industry. It has an important role in uplifting the industrial scenario of MP.”

He further added, “The Expo met several requirements of new entrepreneurs by providing them a chance to interact with a plethora of new companies, and learn about different products & technologies showcased at the event. It is a good platform for facilitating growth in the manufacturing sector of MP.” The minister was accompanied by dignitaries from the government as well as several industry associations.

The growth facilitator

Kailash Vijayvargiya, Minister of Industries, MP, during his

visit at the Expo

Modern Plastics & Polymers | February 201194

R E P O R T R E P O R T

Setting an inspirational benchmark for itself, the recently held third edition of Engineering Expo Indore surpassed its previous records. The event marked the presence of more than 270 exhibitors and generated business worth ` 65.24 crore. In the backdrop of rapid industrial growth in Madhya Pradesh (MP), the Expo played a catalytic role in providing further boost to the manufacturing fraternity in and around the region.

Engineering Expo Indore 2011

Echoing success

PostShowReport-Indore.indd 94 1/22/2011 6:11:56 PM

He further added, “The products displayed at the Expo will enable manufacturers to upgrade their existing technology. I hope the organisers will continue their zeal in the years to come. The Expo is beneficial to the manufacturing fraternity, visitors as well as the industrial segments of Madhya Pradesh.”

Echoing similar sentiments, Kothari stated, “The exhibition is the manifestation of MP’s growth in the engineering segment. The participation of reputed brands across categories clearly narrates the success of Engineering Expo Indore. It also spells the bright future of industrial growth in the state.” He pointed out, “The technology displayed at Indore Expo will help manufacturers reduce production cost. It also acts as a platform for educating industries located in this region.”

Highlighting the investment scenario in the state, Kothari informed that Pithampur area, known as the automobile hub, has been on an expansion spree. Hence, there is a continous surge of investments being witnessed in this region. Putting things into perspective, Kothari concluded that the Engineering Expo is best placed to provide further momentum to this growth. Meanwhile, Gupta lauded the organisers for segmentation of pavilions, which helped the visitors in finding the right products in less time.

Generating crucial leadsIn the backdrop of the state’s rapid industrial growth, Engineering Expo emerged as an ideal platform for companies to showcase their latest products. Atanu Sengupta, Area Manager – Power Tool Division,

Bosch, said, “The atmosphere here was quite professional. Irrespective of whether the exhibitors were big or small, they professionally managed their stalls. It clearly indicates that they highly value this exhibition and consider it a serious platform for enhancing their business.”

Seconding the view, Ajay Jain, Sales Engineer – Madhya Pradesh, BIPICO Industries (Tools), said, “After the Engineering Expo Indore 2010 edition, the business of our company grew by 10-15 per cent in MP.” The Expo served myriad purposes for exhibitors; some utilised this platform to launch new products, others attempted to garner new information about companies.

Finolex Cables is a case in point. “Many do not know that Finolex also manufactures a complete range of switches and compact fluorescent lamps (CFLs). During the event, our major focus was on switches and CFLs, so that people are aware of these products. Engineering Expo serves as the right place for deciphering the information,” explained Gopal Halwasiya, Engineer - Sales, Finolex Cables. The participants, exhibitors and visitors alike, believed that the rapid pace of industrial growth, coupled with emerging sectors like cement and power in MP is all set to add to the grandeur and significance of Engineering Expo Indore in times to come.

With proactive support from the State Government, the industrial scenario in MP is rapidly changing. A closer look reveals that soya, chemical and food machinery segments are flourishing in western MP, while automobile and other engineering sectors are at the forefront in eastern Madhya Pradesh, especially Indore and its surrounding areas. However, there are ample growth opportunities in other sectors as well, as the state has natural wealth in the form of limestone, coal, soya, cotton, bauxite, iron ore, silica, etc. Therefore, the state has a strong industrial base in sectors like textile, cement, steel, soya processing, etc. “The State Government is attracting investments by organising summits and offering tax benefits to entrepreneurs who plan to invest in the state,” stated Ashok Jaiswal, President, Association of Industries, MP. The positivity incidentally is also indicative of the fact that in future, Engineering Expo Indore will play a greater role in boosting the industrial growth of the region.

Opportunities calling...

Guest of honour Omprakash Gupta, President, Madhya Pradesh Electric Merchants and Contractors Association (second from left); Gautam Kothari, President, Pithampur Audhyogik Sangathan, and Ashok Jaiswal, President, Association of Industries, Madhya Pradesh lighting the traditional lamp at the inaugural function of Engineering Expo Indore

Third edition of Engineering Expo Indore attracted 19,732 visitors


Modern Plastics & Polymers | February 2011 95


The launch pad

Ashish Sinha, Assistant GM, Godrej Material Handling, Godrej & Boyce Mfg CoIndore is the commercial capital of MP, with a number of industries coming up in Pithampur, Dewas, etc. The industry is growing and this is the right platform to display our products. At the Expo, we have received quality enquiries from the visitors. We have also launched upgraded models of forklift trucks at this exhibition.

Yogesh Bagora, Assistant Manager – Sales & Marketing, NilkamalWe have a complete range of material handling and storage systems. We launched the steel dustbin in MP at this exhibition. This is the only exhibition in the state where one can exhibit engineering products.

Rajesh Joshi, Assistant GM, Havells India Engineering Expo is the best platform for reaching the target audience in Indore and surrounding areas. Recently, we have introduced (in India) geysers that are protected with earth leakage circuit breaker, which were displayed for the first time in MP through this Expo. The response was fantastic.

Sulabh Muchhal, Director, A-One Electrical AgenciesThis year, the response is much better than the last edition. Overwhelmed by the response we received last year, we booked the entire row in a pavilion. At the Expo, we launched HT Solutions product.

Exhibitors’ experience Rahul Yadav, Assistant Manager – Sales, Rittal IndiaI was amazed by the number of visitors and enquiries received on the first day itself. Being an MNC, we generally take part in exhibitions organised in metro cities. We are participating in Engineering Expo Indore for the first time. And I must say, on a regional level, we never thought of receiving such a wonderful response. Through this exhibition, we had an opportunity to meet SME customers in and around Indore.

Ajay Mehta, MD, Arihant Bearing Services Due to several constraints, small entrepreneurs cannot reach every customer. The Expo provided the perfect platform for customers to meet entrepreneurs and vice-versa.

Rajesh Godse, Director, Reliable TerrestrialsWe always believed that this exhibition is a good platform for launching new products. We have more scope when a unit expands. If rapid growth of industries is any indication, the exhibition will grow manifold from its present status. We are satisfied with the kind of arrangement and the response generated here.

Sunil Mahajan, Area Sales Manager – MP, Black & Decker IndiaEngineering Expo is a good platform to participate. The plus point of the exhibition was the opportunity offered to meet entrepreneurs from neighbouring states, who participated in the event.

7,177Total business

leads generated 86,000 kgTotal machinery movement at the venue




250+ exhibitors


Elated first timers Raj Kumar Jain, Branch Manager, Legrand (India) The exhibition has proved to be beneficial for one and all present here. Most importantly, only serious participants were present, which brightened the business prospects. At our stall, we displayed three new products. We consider this as the right platform to introduce our products to the target audience.

Manoj Pugaliya, Director, Kan Power Rubber IndustriesThe exhibition is much better than what I had expected. The enquiries are from across all industry segments, which will facilitate the growth of our business.

Rajul Gandhi, Director, Seion Watertech Though I was a bit apprehensive on the first day, Engineering Expo Indore turned out to be a fantastic exhibition overall. I must say, we were at the right place to enhance our business prospects.

M B Unjhawala, Managing Director, MGMT Tools & HardwareThis is the first exhibition we have participated in, since we started manufacturing six months back. I firmly believe that the automobile sector will drive the growth of the industrial scenario in MP. The exhibition will help us to penetrate the market. We displayed tool cabinets and trolleys, which are mainly used in the automobile industry.

Visitors’ views Mushtak Ali, Vice President, Wire & Wire Products Association, Indore I regularly visit exhibitions in Delhi and Mumbai, and I feel that the standard of Engineering Expo Indore is high. If the same standard is maintained, then we need not have to explore avenues outside the region to seek new types of machines.

Yogesh Mantri, Managing Director, AGECOThe exhibition was much better than what I expected. The display range was vast, which covered almost the entire gamut of the industry. This exhibition provided the latest information about new products and technology, thereby it generated huge interest from exhibitors and visitors alike.

Kumar M Desai, Director, Omega ElevatorsI have come all the way from Ahmedabad to seek some electronic automation products and machine tools. The trade fair covered the entire range of engineering products. Regional players will benefit tremendously from this exhibition.

Manish Kumar Jain, Business Manager, Tata SteelManufacturers, be it small-scale or large-scale, have displayed their products, thus offering a number of options to select from. We were looking for some galvanised products, which we managed to source from the Expo.

87%Exhibitors happy

with quality of

visitors

76%Exhibitors willing to participate in the next edition




Business of over ` 65.24 crore 19,759+ Visitors


P R O D U C T U P DAT E


and give proportional analogue output (0 to 10V or 4-20 mA). It has unsurpassed performance due to Complementary Metal-Oxide-semiconductor (CMOS) technology, offset and hysteresis free, it has excellent accuracy and reproducibility even below 10 Pa, fully calibrated and temperature compensated, not sensitive to the mounting orientation, sensor continuously monitors differential pressure between two ports, integrated circuit converts differential pressure to electrical signal (0-10V Or 4-20mA), optional micro controller based circuit available for future up gradation to connect with Supervisory Control & Data Acqusition (SCADA) on Modbus protocol, conditioning/control circuit can be supplied in enclosure (IP-66). This device can communicate on different communication protocol ie Modbus, RS232, and RS485 etc. Katlax differential pressure transducers are available with various measuring ranges that starts from -0.5 mbar to 100 mbar. This is applicable in variable air volume systems (VAV), heating, ventilating and air conditioning (HVAC), filter pressure drop, fan/ventilator control, duct air flow measurements, room/cabin pressure control, burner control, CPAP equipment, sleep apnea monitors, air handling units, textile air engineering and pharmaceutical industry.

Katlax Enterprises Pvt LtdGandhinagar - GujaratTel: 02764-286 784 - 85Fax: 02764–286 793Email: [email protected]

Cable tray fixing tiesNovoflex offers cable tray fixing ties. These are specially designed to provide a convenient method of fixing cables to perforated cable trays. Supplied as a one piece tie, the two sections can easily be pulled apart and

fixed on either side of the trays, thus eliminating the need to access the rear of the tray. It has a tensile strength of minimum 55 kg. The ties can withstand temperatures ranging from 25ºC to +85ºC. They are available in standard colours of natural white and black.

Novoflex Marketing Pvt Ltd Kolkata - West BengalTel: 09903163634 Fax: 033-2229 7814Email: [email protected]

Hot runner controller Yudo Hot Runner India offers CW991. This is an advance multi channel, high precision hot runner temperature controller equipped with a personal computer for temperature control. Its features consists of high precision (0.01 deg c); multi zone (maximum 120 zones); tele-control; easy use with HMI; data management (easy to store and manage files in folders); self diagnostics; with various alarms; in-built sequential timer (optional); remote control (optional); elegant design and easy to move on caster.

Yudo Hot Runner India Pvt Ltd Thane - MaharashtraTel: 0250-245 1155 - 56Fax: 0250-245 1158Email: [email protected]

Differential pressure transducerKatlax Enterprises offers differential pressure transducer (DPT). The transducer measures pressure differences between two points

Ultrasonic horns & fixturesNevik Ultrasonics offers ultrasonic horns for plastic (and metal) welders. This focus helps deliver excellent solutions for ultrasonic plastic assembly applications. Solutions are based on a wide range of standard tools to custom-engineered, high wear resistant

and long life tools. Custom engineered horns are based on finite element analysis. These are available in aluminium, steel or titanium alloy based on its application. Fixtures play an important role in successful welding applications. The company has engineered fixtures in aluminum and special epoxy materials, with features for quick changeover, easy multiple alignment for large parts, as well as to eliminate any marking on the plastic components.

Nevik Ultrasonics Nashik - MaharashtraTel: 0250- 235 1935Mob: 09320269883Email: [email protected]

Product Update_98-108.indd 98 1/22/2011, 5:37:14 PM



Blown film lineKabra Extrusiontechnik offers a blown film line. The three-layer blown film line has 2 x 55 mm grooved feed extruders and a 65 mm extruder for the outer layer. The outer extruder is connected with European PIB liquid injection pump. The plant is equipped with a 300 mm Kabraflex die head and cooling ring. The film is wound on a back to back dual station load-cell controlled duplex winder with latest design, which ensures uniform film tension during the entire operation. The monolayer film plant with liquid PIB technology are being used for producing stretch cling film. The advanced PIB technology imparts stickiness to the cling film helping it to effectively cling to the product to be wrapped.

Kabra Extrusiontechnik LtdMumbai - MaharashtraTel: 022-2673 4822-25 Fax: 022-2673 5041Email: [email protected]

Extruder for producing oriented sheetMalik Engineers offers extrusion line for producing oriented sheet from nylon. The nylon oriented sheet is mainly used in the manufacture of power transmission belting, as inner, load-bearing tensile member between outer rubber layers. The application demands very high tensile strength for the nylon sheet (tensile member). To produce this nylon material in granule or pellet form, it is first melted inside a single screw extruder which is electrically heated and conveys the melted material, continuously forward through a T-die which extrudes a flat, thick sheet. The thick sheet is continuously drawn away by the chilling rollers set (3 rolls) in S-fashion, led by roller conveyor and wound on a suitable winder. The sheet thus produced is not oriented in the extrusion stage. Later, the sheet produced in stage-1 is reheated between set of feeding & pulling rollers. This is done in the orientation oven, placed between feeding rollers and stretching rollers stand. The unit is offered in a standard size of 65 mm screw size (extruder) with output capacity of 40 Kgs/hour and oriented sheet width up to 320mm.

Malik EngineersThane - MaharashtraTel: 0250-239 0839, Fax: 022-2883 0751Email: [email protected]




Plastic brightner/shinerPlast Fine Polymers offers plastic brightners/shiners/whitener for natural transparent, colours and milky-white end-products. This is used for adding clarity and gloss finish to natural transparent

polymers. It gives shining and bright finish colours to end products. This brightner/whitener removes yellowness and dullness from the end-products and makes it super milky-white. This product is used in virgin, second, dull natural or milky white sutli, ropes, twine, reprocess granules, High-density Polyethylene, Low-density Polyethylene, Polyvinyl Chloride (HDPE-LDPE-PVC) pipes & profiles, box strap, PET jars, spoon, container, carry bags, liners, sheet, yarns and other end products. One of the main advantages of this product is that it saves excess use of white pigments and titanium dioxide for opaque end products.

Plast Fine Polymers Ahmedabad - GujaratTel: 079-6524 2332Mob: 09825587152Email: [email protected]




DC motorsNBE Motors offers DC motors, that are used in applications wherever variable speed control drives are used. The speed control of DC motors by armature control or field control at constants torque helps in constant continuous operation. The V-weld imparts heavy strength to the yoke. Armature laminations are of high-quality electrical grade steel. The commutator is made from silver-copper-alloy. Electrolytic copper segments are insulated from one another with mica. Riser connections are TIG welded. The armature windings are impregnated with synthetic resin and are baked at a designed temperature to give complete protection against damage from moisture, acids and alkalis. The main poles are made from thick laminations (GI sheet). For ventilation the motor is equipped with screen protected drip proof (SPDP) & is totally enclosed. External force cooling is provided with the blower-mounted motor.

NBE Motors Pvt LtdAhmedabad - GujaratTel: 079-2274 0467Fax: 079-2274 1196Email: [email protected]

Biodegradable additivesAVI Additives offers Bio Add range of biodegradable additives. Heat, oxygen and sunlight are used to cause degradation benefits. Its flame retardant masterbatches are used for engineering and commodity plastics. AVI Additives also offers colour masterbatches & special effect masterbatches; filler masterbatches for raffia, blown film & moulding; performance additives leading

to biodegradation. This adheres to new legal requirements, reduces waste, has ecological and economical, biodegradable additives & flame retardants; polymer blends, colours for enineering polymers & recycled plastics. With a palette of 10,000 colours and more being added, it can provide with a complete spectrum of colours for the entire industry.

AVI Additives Pvt LtdHyderabad - Andhra PradeshTel: 40-2355 0551-2-3Email: [email protected]




Cast film lineBakubhai Ambalal offers cast film line manufactured by SML Maschinengesellschaft. It is provided with a material feeding dosing system, extrusion unit, chill roll unit, thickness measuring unit, corona unit, edge trim

re-feeding system, winder and control system. This system is used for feeding materials using a pneumatic system.

The extrusion unit comprises of extruders equipped with barrier screws and are driven by water cooled AC-drives with increased power for higher output and improved melt quality. The chill roll unit is used for the adjustment of length and height, while the thickness measuring unit is used for the regulation of automatic die, which operates with a radioactive KR-85 sensor. In the edge trim re-feeding system, the first edge trim cutting is arranged upstream of the corona treatment unit to avoid damage to silicon treatment rollers. The second edge trim cutting is arranged upstream of the winder. All the trims are sucked to a mill and then to a vertical scraptruder that feeds the flakes directly to the feed opening of the main extruder.

The cast film line comes with three different winders that are specially developed for winding the CPP-film - one is a horizontal sliding winder, while the other two include turret winders. In addition, the system is equipped with a clear alarm menu, recipe administration, and a short-time & long-time trend system.

Bakubhai AmbalalMumbai - MaharashtraTel: 022-2579 1702, Fax: 022-2579 1713Email: [email protected]

EPS cup making machineNeejtech India offers EPS cup making machine manufactured by Thermoware B V.

This machine is available in both vertical and horizontal Expanded Polystyrene (EPS)

production machines for manufacturing cups, containers, tubs and meat trays. It has a capacity to produce 6,400 cups/hr. Its features include guaranteed cycle time, efficient pneumatic control, user-friendly electronics, etc. The advantage of this machine is that disposable trays, plates, containers, etc, can be made easily by changing the mould. This machine is used for manufacturing drinking cups for hot & cold drinks, ice cream cups, etc.

Neejtech IndiaAhmedabad - GujaratTel: 079-2656 1312, Mob: 09825040231Email: [email protected]




Thermoplastic compoundVideojet Technologies offers laser marking systems. The 'Videojet 7210 (10 W) and 7310 (20 W)' pulsed fibre lasers are compact, versatile and low-maintenance solid-state marking systems. These are

perfect for Direct Parts Marking (DPM) and Unique Identification (UID) applications on metals, plastics and other hard-to-mark materials in aerospace, automotives, electronics, medical devices and tools markets. These machines have the smallest available standard & high resolution scan heads, with straight-out or right angle beam exits. Optional high resolution scan heads offer exceptionally large marking areas, and extra wide mark fields for high speed mark-on-the-fly applications. No PC is required for stand-alone operation, which saves space and increases reliability & versatility for broad application range. These laser coding systems are clean to operate, have low consumable cost, and are suitable for industries with high processing requirements. These deliver laser marking on almost any material, giving a wide range of application options.

Videojet Technologies (I) Pvt LtdNavi Mumbai - MaharashtraTel: 022 - 2778 0678, 3298 1209Fax: 022-2778 0674Mob: 9920227957Email: [email protected]

Mr L. R. KatratManaging Director - CEOKatlax Enterprises Pvt. Ltd.

“We have been a regular advertiser of our products in

leading publications such as SEARCH, Modern Machine

Tools and Modern Plastics & Polymers of Infomedia 18

Ltd. We are associated with the publication house for

more than 12 years and are utilising these magazines to

promote our products aggressively and receiving good

response.”

[email protected]




Control valveForbes Marshall offers Ecotrol, control valve, which is a robust, compact and lightweight control valve with a pneumatically operated, easy field-reversible multi-spring diaphragm actuator and a sturdy, pipeless and vibration resistant mounted digital positioner. It is also available with an optional handwheel. Tubeless mounting, with the digital positioner and with the option of bi-directional communication is the key feature of this control valve. Auxiliary energy is utilised by employing pneumatic multi-spring diaphragm actuator with the option of permanent spring case ventilation. It is designed according to American National Standards Institute (ANSI), with standardised trims. The prevention of leakage and bypass leakage is by a limited compressive load acting on both encapsulated gaskets. It is used in oil & gas, chemical & petrochemical, pharmaceuticals, distillery & food, fertiliser, steel & metal, power, etc.

Forbes Marshall Pvt Ltd Pune - MaharashtraTel: 020-2714 5595Fax: 020-2714 7413/7593

Rheometers with simulation softwareMalvern Aimil Instruments offers Rosand range of capillary rheometers, bundled with Windows™ based simulation software Flowmaster™ developed by Compuplast. These bench-top and floor-standing rheometers measure the flow properties of polymers with market-leading precision, providing a sound basis for the construction of truly representative process models. The simulation software makes it easy to use the data to simulate extrusion, and other polymer processing operations, cutting the requirement for expensive, time-consuming pilot scale trials. The rheometers provide the requisite material data to the simulation software so that the latter can develop a simulation that accurately reflects process behaviour. The simulation software allows accurate representation of the complete die or screw extrusion process, including cooling, a suite of module options in simplifying plant specific model development.

Malvern Aimil Instruments Pvt LtdNavi Mumbai - MaharashtraTel: 022-3918 3596Fax: 022-3918 3562Mob: 9867368075Email: [email protected]




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

Moulding automation systemsNeejtech India offers moulding automation systems for small single injection moulding machines and large automation & networking

in-line assembly systems for two or three injection moulding machines manufactured by Hekuma. The functions performed by the systems include high speed take out, insertion of labels or metal parts or re-insertion of substrate for second shot, ultrasonic welding (of filters and assembled parts), heat staking (of filters), swaging, leak-test, label application, assembly processes, stacking, flow wrapping, automated packaging in any configuration, etc. The company also offers customised & standardised moulding automation systems for dedicated products (eg petri dishes).

Neejtech IndiaAhmedabad - GujaratTel: 079-2656 1312Mob: 09825040231Email: [email protected]


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 3000 words, while that of a product write-up should not exceed 200 words.

The articles should preferably reach us in soft copy (either E-mail or a CD). The text should be in

MS Word format and images in 300 DPI resolution & JPG format.

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

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

particular issue and an honorarium cheque.

Published by Infomedia 18 Ltd, ‘Modern Plastics & Polymers’ is the leading monthly magazine exclusively

meant for producers and user fraternities of the plastics industry. Well supported by a national readership

of over 80,000 and our strong network of 26 branch offices across India, this magazine reaches out to

key decision makers among the Indian manufacturers of plastics products, machinery and allied sectors.

Brought out in association with Hong Kong-based Ringier Trade Media Ltd (one of the world’s largest trade

publishing houses with more than 200 special interest titles and offices in every major country), it ensures

that advertisers are able to promote their products and services across the globe at no extra cost.

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

Thanking you,

Yours sincerely,

An invite that rewards as well...

Manas R BastiaEditor

Infomedia 18 Limited‘A’ Wing, Ruby House,J K Sawant Marg, Dadar (W)Mumbai 400 028India

T +91 22 3024 5000F +91 22 3003 4499E [email protected] www.infomedia18.in

D +91 22 3003 4669


Product Index_113-117.indd 113 1/25/2011, 5:27:11 PM

P R O D U C T I N D E X


1 Accumeter................................ 53

2 Additive masterbatches ................. 22

3 Additives...................................... 99

4 Air bubble film plant .................. 101

5 Air bubble sheet plant .............. 6, 77

6 Air cooled sealers ........................ 43

7 Air treatment................................ 12

8 Air-conditioner parts...................FGF

9 Air-conditioning equipment and

compressor’s spare parts ......... 113

10 Ammonia liquid chillers ................ 21

11 Auto dosing and mixing system..... 75

12 Auto vacuum loader .................... 75

13 Automation system ....................... 31

14 Banking services..................... 103

15 Biodegradable additives ............. 102

16 Biodegradable masterbatches ....... 22

17 Black masterbatches............... 22, 99

18 Blenders ...............................83, FIC

19 Blending unit .............................FGF

20 Blow moulding machine control.... 19

21 Blow moulding machines.............. 39

22 Blower series ............................... 31

23 Blown film line........................... 100

24 Bulk milk cooler........................... 21

25 Butterfly valve .............................. 21

26 Cable tray fixing ties ................ 98

27 Cast film line ...................6, 77, 103

28 Central material conveying system ...75

29 Chemicals ................................... 15

30 Cinpres gas injection.................. 105

31 Clean room applications ................ 8

32 Cluster facia ..............................FGF

33 CNC.......................................... BIC

34 CNC vertical machining centres.... 51

35 Co-extrusion blown film plant ......... 6

36 Co-extrusion die ............................ 6

37 Colour additives .......................... 99

38 Colour masterbatches ......22, 33, 99

39 Compact chiller ........................... 13

40 Complex multipart assembly ........... 9

41 Compounds................................. 99

42 Compressed air loader................. 53

43 Connectors................................FGF

44 Control valve............................. 106

45 Cooling tower.............................. 12

46 Counters & power supplies ............. 5

47 Crusher ....................................... 75

48 Dairy machinery....................... 21

49 DC motors ................................ 102

50 Dehumidified air dryer................FGF

51 Dehumidified dryers .................... FIC

52 Dehumidifying dryers.............. 13, 75

53 Differential pressure transducer ..... 98

54 Digital panel meter ...................... 10

55 Door trims.................................FGF

56 Dosing & mixing system ............... 31

57 Dryers ......................................... 53

58 Drying & dehumidifying ................ 31

59 Drymax dryers............................. FIC

60 Drymax pet-dehumidified dryers ... FIC

61 Dyestuffs...................................... 16

62 Electric injection moulding

machine gearboxes ................. 7

63 Encoders ....................................... 5

64 Engineering products.................... 15

65 Entrepreneur magazine................. 20

66 EPS cup making machine ........... 103

67 Exhibition - Engineering

Expo.............................87, 89, 91

68 Exhibition - HiTech Manufacturing

Show ........................................ 59

69 Exhibition - Plast Avenues

Summit 2011.......................... 104

70 Extruder for producing oriented

sheet ...................................... 100

71 Extruder machine ......................... 37

72 Extrusion coating lamination

plant..................................... 6, 77

73 Extrusion dies............................. 101

74 Extrusion machineries ................... 25

75 Feeding & conveying system .... 31

76 Filler compounds ......................... 99

77 Film extrusion lines..................... 102

78 Financial services ....................... 103

79 Flame retardant masterbatches ..... 22

80 Flame retardants.......................... 99

81 Fully automatic strapping plant ..... 77

82 Gas & water assisted moulding

technology........................... 105

83 Gear motor ........................... 14, 29

84 Gear pumps.............................. 101

85 Gearbox................................ 14, 29

86 Geared & flexible couplings ......... 14

87 Gearless extruders ....................... 71

88 Gears ......................................... 14

89 Granulating & recycling system..... 31

90 Granulators ..........................13, FIC

91 Gravimetric blender ..................... 13

92 HDPE pipe plant ........................ 6

93 Head & tail lamps......................FGF

94 Heart valve frames...........34, 63, 64

95 Heating & cooling........................ 31

96 High cavitations ............................. 8

97 High-speed heater cooler mixers

and spares.............................. 101

98 High-speed mixer......................... 37

99 HM/HDPE/LDPE/LLDPE ................ 77

100 Hopper dryer ............................... 75

101 Hopper loader............................. 13

102 Horizontal machining centre ........ BIC

103 Hot air dryer........................13, FGF

104 Hot runner controller.................... 98

105 Hot runner system........................ 31

106 IML technique ............................ 8

107 Induction sealing machine........... 43

108 Industrial control & sensing devices..5

109 Industrial coolers.......................... 12

110 Injection molds ............................ 45

111 Injection moulding machine..............

112 Ink adhesion................................ 43

113 Invertor/variable frequency drives.... 5

114 Knobs & switches ................... FGF

115 Lab mixer............................... 101

116 Label adhesion ............................ 43

117 Large-flow water heaters............... 31

Sr No Product Pg No Sr No Product Pg No Sr No Product Pg No

To know more about the products in this magazine, refer to our ‘Product Index’ or write to us at [email protected] or call us at +91-22-3003 4685 or fax us at +91-22-3003 4499

and we will send your enquiries to the advertisers directly to help you source better.


P R O D U C T I N D E X


118 Lathes ........................................ BIC

119 Level controllers ............................. 5

120 Loader ....................................... FIC

121 Masterbatch feeder .................. 75

122 Masterbatches ....................... 22, 99

123 Material dryers............................. 83

124 Material storage .......................... 13

125 Measuring & monitoring relay ....... 5

126 Medical moulds ............................. 8

127 Milky polymers........................... 107

128 Milling centres ............................ BIC

129 Monolayer blown film lines...........BC

130 Monolayer blown film plant ............ 6

131 Motion controls ............................. 5

132 Mould temperature controller ....... 13

133 Moulding....................................... 8

134 Moulding automation..................... 9

135 Moulding automation systems..... 107

136 Moulds........................................ 37

137 MTC .......................................... FIC

138 Multi-component moulds................ 8

139 Multi-layer blown film lines ...........BC

140 Multi-layer blown film plant ...... 6, 77

141 Multi-station ................................ 45

142 Natural polymers ................... 107

143 Neat resin ................................... 16

144 New liquid loss in weight feeder . 107

145 Online b2b marketplace .. 79, 114

146 Paper & allied chemicals .... 15, 16

147 Paperless recorder........................ 10

148 Parallel & right angle axes

gearboxes ................................... 7

149 PET box strapping plant................ 77

150 PET mastermatches ...................... 22

151 PET recycling plant......................... 6

152 Photo electric sensors..................... 5

153 Pipe making ................................ 45

154 Pipe shredder .............................. 53

155 Plastic brightner/shiner ....... 101, 107

156 Plastic compounds ....................... 99

157 Plastic tinopol ............................ 107

158 Plastic whitener .......................... 107

159 Plate heat exchanger.................... 21

160 Plug valve ................................... 21

161 Pneumatic valve ........................... 21

162 Polymer allies product .................. 15

163 Polyurethane exhibition................. 18

164 PP glass-filled compounds ............ 22

165 PP mineral-filled compounds......... 22

166 PP TQ plant ................................ 77

167 PP/ HDPE-semi-automatic strapping

plant......................................... 77

168 PP/HDPE rafffia tape lines ............ 77

169 PP/HDPE/PET box strapping plant ... 6

170 PP/HDPE/PET monofilament plant... 6

171 PP/TQ film plant............................ 6

172 PPRP powder ............................. 107

173 Precision moulding.....................FGF

174 Process controllers........................ 10

175 Process tanks ............................... 21

176 Procurement & auditing servicing ...15

177 Programmable logic controllers....... 5

178 Programmable terminals................. 5

179 Proximity sensors ............................ 5

180 Pulveriser ..................................... 37

181 Pump & technology.................... 119

182 Quick connectors ..................... 47

183 Quick mould change system......... 47

184 Raffia tape lines ......................... 6

185 Rail tankers.................................. 21

186 Refrigerant pumps ........................ 21

187 Refrigeration ................................ 21

188 Refrigeration compressors ........... 113

189 RFID ............................................. 5

190 Rheometers with simulation

software.................................. 106

191 Robot systems .............................. 17

192 Robotics ..................................... FIC

193 Rock-n-roll machine ..................... 37

194 Rotary automatic hot colour

marking machines ..................... 57

195 Rotary cutters .............................. BIC

196 Safety light curtains.................... 5

197 Screw compressor ........................ 21

198 Sealers ........................................ 43

199 Secon & dull polymers ............... 107

200 Segmented barrels .................... 101

201 Single-mill pulveriser .................... 37

202 Single-screw and barrel ............. 101

203 Single-screw extruder gearboxes ..... 7

204 Smart Logistics Leadership Series ...117

205 SME finance .............................. 103

206 Spiral-cum-helical gearbox ........... 14

207 Stack moulds ................................. 8

208 Strand pelletiser ......................... 107

209 Surface treatment......................... 43

210 Switching relays ............................. 5

211 Synthetic string plant ..................... 6

212 System solution ............................ 31

213 Tanks & silos ............................ 21

214 Technical moulds ........................... 8

215 Temperature controllers ............ 5, 10

216 Thermoforming & PS foam ...........BC

217 Thermoplastic alloys..................... 16

218 Thermoplastic compounds ....16, 105

219 Three-arm bi-axial rotomoulding

machine ................................... 37

220 Timers ........................................... 5

221 TPE/TPU compounds.................... 22

222 TPU masterbatches....................... 33

223 Twin-screw co-rotating

extruders .......................34, 63, 64

224 Twin mill pulveriser....................... 37

225 Twin-screw elements .........34, 63, 64

226 Twin-screw extruder gearboxes ........ 7

227 Twin-screw extruders.........34, 63, 64

228 Twin-screw feeders ..................... 107

229 Ultrasonic flowmeter ................ 10

230 Ultrasonic horns & fixtures ............ 98

231 Universal masterbatches ............... 22

232 UV & PU masterbatches ............... 22

233 Vacuum forming machine ........ BC

234 Vacuum loader ..........................FGF

235 Vacuum receiver .......................... 53

236 Vertical machining centre ............ BIC

237 Vibro screens ............................... 37

238 Virgin polymers .......................... 107

239 Vision sensors ................................ 5

240 Weigh belt feeder .................. 107

241 WFR........................................... FIC

242 White masterbatches .............. 22, 99

243 Wire-EDM ................................... 51

244 Worm gear.................................. 14

Product Pg No Product Pg No Product Pg No

SOURCE PROCESS PLANT MACHINERY & EQUIPMENT @www.engg-expo.com


A DV E R T I S E R S ’ L I S T


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

Our consistent advertisers

ACS Auxiliaries India Pvt Ltd 53

T: +91-20-40147575

E: [email protected]

W: www.aecinternet.com

Aeromec Mktg Co 57

T: +91-250-2454915


W: www.aeromec.in

Allied Solution I Pvt Ltd 39

T: +91-22-42210100


W: www.alliedsolutions.com

Alok Masterbatches Ltd 33

T: +91-11-41612244


W: www.alokmasterbatches.com

Avi Additives Pvt Ltd 99

T: +91-40- 23550551/2/3/4


W: www.aviadditives.com

Beckoff Automation Pvt Ltd 19

T: +91-20-40004800


W: www.beckhoff.co.in

Blend Colours Pvt Ltd 22

T: +91-40-2436 1499


W: www.blendcolours.com

Disha Technologies 73

T: +91-11-45635747


W: www.dishatech.co.in

Elecon Engineering Company Limited 14

T: +91-2692-236469


W: www.elecon.com

Electronica Plastic Machiners Ltd 71

T: +91-20-22922029


Enercon Industries Corporations 43

T: +91-09600344430 / 91-4344 244303


W: www.enerconaciapacific.com

Engineering Expo 87, 89, 91

T: +91-09920401226


W: www.engg-expo.com

Entrepreneur 20

Fu Chun Shin Machinery Manufacture 58

T: +886-6-595-0688


W: www.fcs.com.tw

Gem Equipments Ltd 12

T: +91-422-3267800


W: www.gemindia.com

Goodie International Pvt Ltd 119

T: +91-11-41613643


W: www.goodiesons.com

Haas Automation India Pvt Ltd .BIC

T: +91-20-32935433


W: www.HaasCNC.com

Hitech Manufacturing Show 59

T: +91-09820373804


Ice Asia Pvt Ltd 107

T: +91-22-24443703


W: www.ice-asia.com

IDMC Limited 21

T: +91-2692-225399


W: www.idmc.coop

India Mart Intermesh Ltd 79, 114

T: +1800 - 200 - 4444


W: www.indiamart.com

Indian Polyurethane Association 18

T: +91-44-24995923


W: www.pu-india.org

Ink Business Media Pvt Ltd 104

T: +91-22-42081715


W: www.inkbusinessmedia.com

Jon Wai Machinery Works Co Ltd 45

T: +886-2-2595-4867


W: www.jonwai.com.tw

K P L International Ltd 15

T: +91-11-43606200


W: www.kplintl.com

Kabra Extrusion Technik Ltd 25

T: +91-22-26734822


W: www.kolsite.com

Konark Plastomech Pvt Ltd 77

T: +91-79-22891670


W: www.konarkplastomech.com

L & T Plastics Machinery Ltd .FGF

T: +91-44-26812000


W: www.larsentoubro.com

Lan Marketing Pvt Ltd 101

T: +91-22-27893645


W: www.maag.com

Livewire 115

T: +91-22-30245000


Ad Index_118-120.indd 118 1/24/2011, 2:34:35 PM

Ad Index_118-120.indd 119 1/24/2011, 2:34:45 PM

A DV E R T I S E R S ’ L I S T


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

Our consistent advertisers

Loxim Industries Limited 16

T: +91-2717-308000


W: www.loxim.com

N A Corporation 37

T: +91-79-25840374


W: www.naroto.com

Neejtech India (Braunform) 8

T: +91-79-26561312


W: www.neejtech.com

Neejtech India (Hekuma) 9

T: +91-79-26561312


W: www.neejtech.com

Neejtech India (Niigata) 27

T: +91-9909974224


Nu-Vu Conair Pvt Ltd 13

T: +91-79-25841181


W: www.conairgroup.com

Ocean Extrusions 6

T: +91-79-22902200


W: www.oceanextrusions.com

Omron Automation Pvt Ltd 5

T: +91-80-40726400


W: www.omron-ap.com

Plas Alliance Ltd 102

T: +886-5-2217-005


W: www.pal-plas.com

Plast Fine Polymers 107

T: +91-79-65242332


W: www.plastfine.com

Premium Transmission Ltd 29

T: +91-20-27488886

W: www.premiumtransmission.com

Procon Technologies Pvt Ltd 10

T: +91-79-27492566


W: www.procon.co.in

Rajoo Engineers Ltd .BC

T: +91-28272 52701/2


W: www.rajoo.com

S&T Engineers 51

T: +91-422-2590810


W: www.stengineers.com

Sacmi Engineering India Pvt Ltd 11

T: +91-2717-250397


W: www.negribossi.com

Sea Bird Refrigeration Pvt Ltd 113

T: +91-11-22155684


W: www.amoking.com

Shini Plastics Technologies I Pvt Ltd 31

T: +91-250-3021166


W: www.shini.com

Shree Radhekrishna Extrusions Pvt Ltd 101

T: +91-79-25842509


W: www.radhekrishnaexports.com

Smart Logistics 117

T: +91-22-30034650


Spark Technologies 105

T: +91-09444069967


W: www.cinpres.com

Standard Chartered Bank 103

T: +91-22-39401616


W: www.standardchartered.co.in

Steer Engineering Pvt Ltd 34, 63, 64

T: +91-80-23723309


W: www.steerworld.com

Toshiba Machine (India) Pvt Ltd 41

T: +91-11-43291111


W: www.toshiba-machine.co.jp

Unimark (Arburg Gmbh) 17

T: +91-22-25506712


W: www.unimark.in

Unimark (Maguire) 83

T: +91-22-25506712


W: www.unimark.in

Unimark (Staubli Faverges Sca) 47

T: +91-22-25506712


W: www.unimark.in

Wittmann Battenfld India Pvt Ltd .FIC

T: +91-44-42077009


W: www.wittmann-group.com

Yann Bang Electrical Machinery Co Ltd 75

T: +886-4-2271-6999

E: [email protected]; [email protected]

W: www.yannbang.com

Zambello Riduttori Group 7

T: +39-0331-307-616


W: www.zambello.it

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