modern plastics & polymers - november 2011

11November 2011 | Modern Plastics & Polymers

ulti-hundred billion dollar rescue plans to prevent sovereign debt

default, highly volatile energy costs and rising demand for financial

inclusion among several strata of society across the globe, irrespective

of the stage of a particular country’s economic prosperity. Are these

mega challenges confronting the world today not exceedingly unprecedented and

were these not almost unthinkable just a few years ago? The idea here is not to

sound like a doomsday prophet, but to recognise the reality of a fast-changing

global phenomenon and, more importantly, mitigate the risks effectively.

Change is not something new for an organisation of any size or industry.

In fact, the progressive ones make that significant difference by managing change

in a sustainable manner. Some of the real-life scenarios range from implementing

new hardware and software to mergers and acquisitions, or relocation of facilities

to adopting processes to do more with less resources.

A few months ago, we also embarked on a similar journey to

‘change’ ourselves, more precisely, our brands, for better. In this

exciting and challenging soul-searching sojourn, we revisited &

thoroughly analysed every practical aspect of our motto of providing

informative empowerment to our audience and not merely publishing

content. Although we have put our best efforts towards perfecting

the products and practices further, we would also submit that

the best practices for managing change are still elusive.

The result is there for you to decipher in this new

avatar of ‘Modern Plastics & Polymers’. From the brand new

sections to focussed features, emphasis has been laid on

ensuring more analytical, in-depth and contemporary first-

hand information. Of course, all these are presented in a

lucid and elegant way, thanks to an optimum combination

of applying mind over matter as well as some of the latest

publishing software available.

Rather than blowing our own trumpet, we will prefer your

valuable feedback on these initiatives. Suffice to say, it will help

us in our constant endeavour to help our audience in terms of

receiving superior value on a sustained basis.

Let there be more info-empowerment towards better decision

making in business. Cheers!

MDonning a new avatar

Editorial Advisory BoardA E Ladhabhoy

Plastics Technologist

Dr Sushil K VermaFormer Director General, CIPET

Dr Swapan K DharaRegional Technical Head,

Basell Polyolefins India Pvt Ltd

Mohan K JainMD, Indoplast & Past President, AIPMA

P P KharasChairman, Ecoplast

Raman M PatelChairman, Industrial Products Mfg Co

Vijay MerchantPresident, Polycraft

Manas R [email protected]

EDITORIAL

CONTENTS

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

Special Focus: Plastics in Electronics / Electrical AppliancesInsight & Outlook : Blow Moulding

Automation Trends

82 Technology index: Process optimisation for boosting efficiency

Energy Management

88 All-electric machines: Energy efficiency par excellence

Policies & Regulations

92 Polymer pricing policy: Maintaining cost-quality equilibrium

Strategy

96 Quantifying quality: Ensuring better business decisions

M Hariharan, Director, Savoir Faire Management Consultancy Pvt Ltd

Tips & Tricks

100 Extrusion techniques: Effective methods for driving profits

Event Preview

114 Engineering Expo Pune 2011: Gateway to exuberant opportunities

Event Report

116 Engineering Expo Rudrapur 2011: Optimising the Northern advantage

REGUL AR SECTIONSEditorial ............................... 11

News, Views & Analysis ...... 28

Technology & Innovation .... 40

Technology Transfer ............ 42

Projects ............................... 106

49

Details on pg no. 108

Event List........................... 108

Book Review ...................... 118

Products .............................. 122

List of Products.................. 137

List of Advertisers .............. 140

Cover photo courtesy : Prasad Group of Companies

Highlights of Next Edition

SPECIAL FOCUS: Polymer Processing

Polymer processing ............... 50

Processing practices .............. 54

Roundtable ........................... 58

Special Focus

63


Plastics in sports applications ..64

Sporting innovations ............ 68

Interface - Anil Kumar ........ 72

Material corner ..................... 74

Injection zone ....................... 78

Insight & Outlook

In Conversation With

46 Atul Dave President, Baumuller India

Facility Visit

60 Plastiblends India Ltd: Colouring the world of plastics



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Business Insights •Technologies•Opportunities

NEWS, VIEWS & ANALYSIS

28 Modern Plastics & Polymers | November 2011

GW Plastics to expand silicones division GW Plastics, a global precision

moulder and contract manufacturer,

has announced the expansion of

its Silicones Division in Royalton,

Vermont, to support the increasing

demand. With an initial investment of

about $ 3 million, GW will commence

work in October 2011 and is planning

for full occupancy by the first quarter

of 2012.

The expansion will allow increased

capacity by creating an additional

15,000 sq ft, scalable up to 25,000 sq ft,

including a new ISO Class 8 clean room

for silicone moulding and assembly. The

initial expansion will be supporting

up to 18 machines. Based on current

projections, GW expects the expansion

to add 25-50 jobs over the next

3-5 years.

Mark Hammond, General Manager,

GW Silicones, commented, “The

expansion of GW Silicones reflects our

commitment to the business and growing

manufacturing jobs in Vermont. It is

encouraging to see that our customers

recognise the value that GW Silicones

is bringing to the market.”

GW Silicones offers highly

automated, precision moulding and

contract assembly services for Liquid

Silicone Rubber (LSR) applications, as

well as internal mould design & build

capabilities.

Shell restarts second CDU at a reduced rate of 75 per cent

Royal Dutch Shell Plc has restarted a

second Crude Distillation Unit (CDU)

at reduced rates at its fire-hit Singapore

refinery, a week after the first was partially

restarted. The 110,000 barrels per day

(bpd) CDU will reach stable operating

levels in 2-3 days, and is expected to

run at a reduced rate of about 75 per

cent. Restart of its distillate-making

hydrocracker is planned at the 500,000

bpd plant within the next 2-3 days.

The CDU operations will facilitate restart

of the 35,000 bpd hydrocracker, which

was shut due to its proximity to the fire

but was undamaged.

With partial operations at the second

CDU, the refinery is currently running at

about 40 per cent, as its largest 210,000-

bpd capacity CDU has been functioning

at about 50 per cent for nearly a week.

A third CDU, of 110,000-bpd capacity,

and some other smaller secondary units

are still shut after the fire that lasted for

more than 30 hours, largely crippling the

capability to deliver clean oil products,

such as gas oil, jet fuel, gasoline and

naphtha. Shell is slowly trying to get the

CDUs and the main secondary units back

up at reduced rates, primarily to yield

products with high margin, eg, base oils

and lubricants, petrochemicals.

DSM Engineering Plastics, RESINEX ink distribution agreement In line with its strategy to deliver

value for existing and new customers

worldwide, DSM Engineering Plastics

has partnered with RESINEX for

distribution in new markets. The move,

which is effective from October 1, 2011,

is designed to strengthen the position of

DSM Engineering Plastics in the Swiss

marketplace, where DSM already has

an ongoing partnership with German

supplier Ter Hell.

According to the company, this

agreement is important for extending

the partnership of DSM and RESINEX.

Swiss customers will benefit f rom

RESINEX’s local presence and

technical structure. This joint approach

will facilitate further growth of DSM

Engineering Plastics in the key Swiss

marketplace. This agreement will make

DSM’s range of world-class products more

easily available throughout Switzerland.

All products will be fully supported by

DSM’s outstanding technical support and

application development programmes,

where necessary.

This distribution agreement is an

important step for RESINEX as well,

following the strategic expansion in

engineering plastics and specialties

product portfolio with well-known

brands from prominent raw material

producers.

SABIC gets country leaders in Europe

SABIC has appointed country leaders

across Europe to ensure that customers

benefit from its global assets as well

as local expertise, and establish closer

cooperation between SABIC’s business

& sales operations in polyolefins,

engineering thermoplastics and chemicals.

Michael Allen was recently appointed as

Country Leader in the UK.

On his appointment, Michael Allen

said, “We will have a unified team that

can provide multi-product customers

with complementary services, eg,

referrals across product lines for

materials, application development and

integrated market intelligence.”

The company has one integrated

office with one Country Leader with

his/her team responsible for the

full product portfolio in Europe. By

bringing everything under one roof,

the company will be well positioned

to provide customers with coordinated

access to the company’s full portfolio

of materials & services and align

service practices to accelerate time

to market.

Michael Allen



BASF to invest in SAP plants in Brazil, China and Malaysia BASF SE, the German-based polymer

manufacturing company, plans to build

Super-Absorbent Polymer (SAP) plants

in Brazil and China, and is considering

the possibility of setting up a similar

plant in Malaysia. SAPs can absorb

and hold up to 500 times their own

weight of liquid, or up to 50 times their

own weight of salty fluids, eg, urine.

The major uses of SAPs are diapers

and adult incontinence & feminine

hygiene products.

The planned facility in Camaçari,

Brazil, will have an annual

capacity of 60,000 Tonne Per Annum

(TPA), and production will likely

begin in late 2014. BASF-YPC Co

Ltd, a 50:50 joint venture between

BASF and Sinopec Ltd will set up

a 60,000-TPA plant in Nanjing,

China, to begin commercial production

in early 2014.

Braskem acquires Dow Chemical’s PP business The leading resin producer, Braskem has

acquired the Polypropylene (PP) business

from the Dow Chemical Company,

which is an important milestone in the

company’s global expansion. The deal was

announced in July 2011 and received the

approval of the European Commission,

Federal Trade Commission and Antitrust

Division of the Justice Department of

the US.

The deal is expected to deliver about

$ 140 million in synergies through a

diversified portfolio, leveraged fixed cost

base & working capital, logistics and

supply optimisation. The assets involved

in the deal include two manufacturing

plants in the US and two in Germany,

with a total annual PP production

capacity of 1.05 million tonne. The two

US manufacturing plants in Freeport and

Seadrift, Texas, will be fully integrated into

Braskem America Inc. The two German

plants in Wesseling and Schkopau will

operate under Braskem Europe GmbH.

Along with the acquisition, Braskem

has made some new appointments.

Mark Nikolich, formerly Vice President

of Commercial and Supply Chain for

Braskem America, has been named Chief

Executive Officer of the new business.

Also, Robert Nadin, General Manager of

Braskem Europe GmbH, formerly Vice

President of Innovation & Technology

for Braskem America, has been appointed

Vice President of Commercial & Supply

Chain for PP in North America.

New hydraulic technology machine by Negri Bossi

Negri Bossi has launched a new hydraulictechnology machine EOS 80 SE. Thismachine sets a new record in terms of compactness, reducing from 5 to 3.5 mthe floor space needed as compared toprevious models.

The extremely compact dimensions of the new EOS line are due to its meticulousdesign. It has two-platen clamping unitsand two cylinder injection units. Thecantilevered clamping system designallows a free open area below the mould, enabling products to be transported in any direction and providing space for placing ancillary equipment. The injection unit slides on two prismatic guides with re-circulating ball bearings and is equippedwith two cylinders directly coupledhydraulically, pulling in tandem during the injection phase and a bi-metallicplasticising barrel, ensuring longer lifewhen processing abrasive materials.

The new machine will come in standardand ‘SE - Smart Energy’ configuration tominimise energy consumption. V Ramesh, Chief Executive Officer, Negri BossiSACMI Engineering (India) Pvt Ltd, said, “The usage of two-platen clamping unit as against the traditional three-platenclamping unit is its uniqueness.” Thisprovides an excellent parallelism betweenthe platens and ensures cleanliness inthe moulding area due to the absence of lubrication oil, making the machine idealfor use in the pharmaceutical, biomedicaland food industry.ff

MachinePoint, Plasgrom SA partner to meet local demand MachinePoint Used Machinery

has entered into the Mexican market

by way of partnership with Plasgrom

SA to work more closely with

the customers and meet the

local demand.

MachinePoint Used Machinery is

the subsidiary of MachinePoint group,

headquartered in Spain, with offices across

all continents. Cesar Rodriguez, Chief

Executive Office, MachinePoint, said,

“Since our inception, Mexico has been

a strategic market for us by the volume

of sales. This local presence is important

to expand our range of services in this

market, including engineering services

& local assemblies, complete plants

and lines.”

According to the company, the

purchase of used machinery remains

a complex process, and it is important

to have a reputable company to

ensure service quality and safety of

the operation. This partnership will

help the company in closely advising

local buyers in the purchase and sale

of machinery used primarily for the

beverage sector.

Rohan Shrikant Shahane, Regional

Director - South East Asia, Machine

Point Consultants SL, informed,

“We not only sell used machines but

also buy them. The Mexican market

offers numerous opportunities for us.

Moreover, we are taking this step since

MachinePoint believes in having a local

language speaker of a country deal with

customers there.”

L-R: Cesar Rodriguez, CEO, MachinePointConsultants SL & David Felix Troche,

Founder, Plasgrom SA



Delhi government plans to ban the use of plastic bags Delhi government has decided to ban the usage and

production of plastic bags in the next two months.

Manufacturers and retailers found selling plastic bags

will be subjected to imprisonment of nearly five years

or a fine of up to ` 1 lakh or both as part of the

initiative towards environment conservation.

According to a draft notification issued by the

centre, “No individual shall be allowed to manufacture,

store, import, sell or transport any type of plastic carry

bags (including that of Polypropylene, nonwoven

fabric-type carry bags) in the National Capital

Territory of Delhi, except for export purposes.” The

Environment Protection Act 1986 has deemed the

storage and sale of plastic bags an offence.

“The plastic packaging industry will be affected

by the ban imposed by the Supreme Court on plastic

packaging. Many packaging companies in this line of

business were forced to close their business operations

after the verdict,” said Sandeep Jain, Director, Hi Tech

Polyflex Private Ltd. While manufacturers have taken

up alternative methods of packaging, this ban has

not penetrated many states. This requires monitoring

of manufacturing facilities and selling outlets in the

2 and 3 tier cities where laws are flouted easily. Only

then, will the ban have a positive impact.

Emmbi Polyarns bags SME Excellence Award Emmbi Polyarns Ltd, one of the

established players in the field of woven

polyethylene and polypropylene product

manufacturing industry, has recently

bagged the SME Excellence Award at

India SME Leadership Summit. The

Summit was held on August 26 in

Mumbai, organised by SME Chamber

of India, and supported by Government

of India.

Many prominent personalities

present at the Summit, including

Virbhadra Singh, Union Minister for

Micro, Small & Medium Enterprises;

Dr Subhir Gokarn, Deputy Governor,

Reserve Bank of India (RBI); Dr Sam

Pitroda, Advisor to Prime Minister on

Public Information, Infrastructure &

Innovation, India. Eminent speakers

from various industries, banks, financial

institutions, government departments,

trade promotion organisations and

management leaders, policy & decision

makers, experts, consultants and other

professionals were invited to share their

thoughts to create leadership qualities

among Small and Medium Enterprises

(SMEs) and young entrepreneurs to

compete in the global market.

Makrand Appalwar, Managing

Director, Emmbi Polyarns Ltd, after

receiving the award, stated, “The

award is an acknowledgement of our

endeavour to excel in this industry,

which is still at a nascent stage in India.

It indicates that our efforts are well

directed. It is also a strong motivator

for us to pursue our goal to be pioneers

in this sector.”

PTT Chemical invests $ 150 million in NatureWorks PTT Chemical Public Company Ltd (PTT Chemical) is investing $ 150 million in NatureWorks LLC. By attracting probably the most advancedbiopolymer processing plant in the worldto Thailand, PTT Chemical has madea significant step in achieving Thailand’sstrategic aim of becoming a regional hubfor green technologies and solutions.

PTT Chemical’s investment supportsNatureWorks’ intent to globalise its Ingeomanufacturing capability by building anew production facility in Thailand, tosupport the Asian customer base anddeliver its commitment to renewablefeedstock diversification. Ingeo offersthe performance of conventional plasticsand fibres with a fraction of greenhousegas emissions and lower non-renewableenergy requirements. Being made fromrenewable plant material, Ingeo hasinherently more stable pricing, in contrast to massive price swings observed in fossil-based polymers.

Makrand Appalwar

Rusnano invests in basalt nanocomposites The global composites industry

holds special significance for the

specialty chemicals and polymers

industry. Moscow-based Rusnano

and UK-based Galen have jointly

invested for setting up production

of composite nanostructured

polymer based on basalt fibre.

The project has a budget of

500 million rouble, of which

Rusnano wi l l co- invest

200 million rouble. Project

planners expect production to

reach 2,500-3,000 tonne by 2016.

Products include shaft lining for

the mining industry; armature,

flexible connectors & rawl plugs

for the construction industry;

composite alluvial drill rods

for oil production; and poles

for street lighting & power

transmission lines.

Alexander Kondrashov,

Managing Director, Rusnano,

said, “Galen is experienced in

developing unique technological

solutions. For example, its

armature for construction of a

single-span bridge in Northern

Ireland or its flexible connectors

for the Passive House in England.

The strict British requirements

for fire resistance of materials

prompted the company’s engineers

to experiment with nanomodifiers

for polymer connectors.”

Basalt plastic armature is as

strong as steel and more durable.

The basalt fibre-based composite

material does not corrode. This

is important for structures that

must operate in high-moisture or

high-salt conditions, particularly

bridge supports. The material is

considerably lighter than steel

(average 70 per cent), simplifying

transportation and saving cost.



Kabra Gloucester showcases first five-layer film plant KAGE is the brand name for film plants

manufactured by Kolsite Group, utilising

the engineering designs and technology of

Gloucester Engineering Co. KAGE lines

are specifically engineered to meet diverse

challenges of the film plant industry, and

the first five-layer fully loaded line is all set

to be delivered to Prropyl Packs Ltd, Kerala.

KAGE plants are designed to produce barrier

film at rates and quality levels that not only

meet the markets requirements, but also

result in enhanced operational efficiency and

higher flexibility for plastics manufacturers.

The five-layer 2,200-mm film line has an

installed capacity of 4,000 tonne/year and

output up to 600 kg/hr. This five-layer

film plant can be used to pack oil, and in

other barrier applications; it is also used for

production of high-quality lamination films.

Prropyl Packs will introduce the barrier

film mainly for oil packaging, vacuum

packaging and packaging that needs

enhanced shelf life. As India has mandated

edible oil to be sold in packaged form only,

barrier film

packaging shall

not only meet

g o v e r n m e n t

standards, but

also improve

the shelf life

of packaged oil

by protecting it

against oxygen

& moisture

and ensuring

its cleanliness.

LANXESS adds capacity in Brazil

Brazil being the world’s fifth largest car maker, with nearly 13 per cent growthin the nation’s automotive industry, LANXESS could not have chosen a more ideal destination for this investment. LANXESS is strengthening its commitment to Brazil with three major

new investments totaling € 30 million ($ 75 million), creating over 100 jobs. The three investments include construction of two new plants at LANXESS’ Porto Feliz site in São Paulo. One is for production of high-tech engineering plastics Durethan and Pocan – used primarily by the automotive industry to make cars lighter and more fuel-efficient.

The new plant will be run by the Semi-Crystalline Products Business Unit (SCP-BU), and will have an initial capacity of 20,000 metric tonne per year. The plant will go on stream by mid-2013. The other new Porto Feliz plant will produce rubber additives, eg, Rhenogran and Rhenoshape curing bladders. Axel C Heitmann, Chairman, LANXESS, commented, “We are making major investments that will ensure that we participate in the current and future success of the Brazilian economy. ”

Italy’s Serioplast invests € 8 million in Poland plant Italian plastics packaging blow moulder

– Serioplast – is investing more than

€ 8 million to construct a new plant

near Lodz, Poland. The group, based in

Dalmine, Italy, recently won a planning

consent to occupy a 4.5-hectare site

in the Kutno area of the Lodz special

economic zone. The new facility will

be operated by the group’s national

subsidiary Serioplast Poland.

In Poland, Serioplast intends to

produce a range of packaging for the

food, pharmaceutical, detergents and

cosmetics industries. The group runs 16

plants in European countries, including

Hungary, Slovakia, Germany, France

and Italy. Serioplast Poland has agreed

to meet a deadline for December 2017

and will employ a workforce of more

than 66 at the new site.

In late 2009, the Italian group, which

blow-moulds bottles and injection-

moulds bottle performs, strengthened

its position in France by taking over

Graham Emballage Plastique of

Meaux. The business changed its name

to Serioplast Meaux and moved the

company base to Langeais, France.

It was at the end of 2008 that Serioplast

launched 6,000-m² production

hall at its Hungarian blow moulding

plant at Nyirbator in the country’s

North East. It has expanded this facility

since then.

Bioplastics market sees rapid global growth The bioplastics market is growing

rapidly, with a 41 per cent Compound

Annual Growth Rate (CAGR) forecast

for 2010-15. This raises the 2010

demand of 571,712 metric tonne

to over 3 million tonne in 2015.

Early adoption of bioplastics and

subsequent interest in the technology

was driven by rising concerns over

environmental issues, particularly

with regard to product disposal and

global warming. Bioplastics includes

recyclable polymers like Polylactic acid,

thermoplastic starch, bio-polyamide

(nylon), Polyhydroxyalkanoate (PHA),

etc, which are synthesised from biomass

and food crops like corn, soybeans and

sugarcane. The high availability of these

crops in the US has led to the country’s

dominance in the market, despite the

fact that in the early stages, European

adoption of bioplastics was higher

than that of the US. Key applications

of bioplastics are automotive, building,

construction, electrical/electronic,

medical and packaging sectors.

Andy Sweetman, Chairman,

European Bioplastics, said, “It is essential

that the issues affecting the bioplastics

industry are recognised and understood

by policymakers since bioeconomy is an

important issue in the European Union

(EU). Bioplastics offer two distinctive

advantages, their renewability and

availability. We must encourage greater

awareness of the bioplastics industry, its

products and their benefits.”

(L-R) Jens Hendrik Fischer, GM - Americas SCP-BU; Guenther Weymans, Head - Technical Rubber

Products-BU; Axel C Heitman, Chairman, LANXESS; Anno Borkowsky, Head - Rhein Chemie; Marcelo

Lacerda, Country Representative, Brazil

Five-layer film plant



Unnati Speciality Films goes green Unnati Speciality Films

(USF) has launched

its first biodegradable

stretch film, in an

attempt to reduce the

impact of waste films

dumped & storage of

the leftovers in the warehouse.

The Ahmedabad-based USF manufactures flexible

packaging films apart from Speciality Packaging Films

has manufactured BioWrap, which is biodegradable &

compostable during 2-4 months under pre-specified

Ultraviolet (UV) conditions. In contrast, a standard

stretch film takes many decades to fully compost. Green

consumers will no longer have to separate out the

stretch film from other items being sent for recycling.

More than 1.5 billion metre of stretch film wrapping

could be used in industries alone every year.

BioWrap contains an additive that initiates

chemical breakdown more quickly and completely in

the presence of oxygen, heat or UV light. These films

shall be available in clear or tinted green. However,

USF believes that choosing BioWrap with a green tint

will help communicate the positive environmental

impact of plastics. This will also help USF’s clients to

differentiate their organisation by being recognised as

a market leader.

Innovations awarded in plastics extrusion With the aim to promote open

innovations in the global plastics

industry, Reifenhäuser had launched

the Extrusioneers Innovation

Contest in April this year. The

company announced the winners

from among over 101 ideas, and

almost 1,000 commentaries have been collected during the competition

in three categories – product, process and machinery.

A jury of external experts and experts from the Reifenhäuser Group

selected the best ideas, the most unconventional idea and the most

valuable participant. The first prize was awarded to the idea Energy

Recovery, which demonstrates a solution for energy recovery to exploit

the great temperature differences in extrusion and is thus relevant in

many areas of extrusion. The second prize went to the idea Exow

Street – a drainage system for streets made of extruded tiles that can

help reduce street damages and improve safety on the streets. The idea

of using nonwoven material in layering artificial turf received the third

prize; it is concerned with construction of artificial turf using nonwoven

material as substrate, which could make artificial turf resemble closely to

the natural ones. Dr Bernd Kunze, member of Reifenhäuser’s corporate

leadership and responsible for innovation management, said, “We are

surprised to see how much time the participants have invested in the

competition and how open and intensively the ideas were discussed. The

occasional unconventional approaches true to the competition motto

‘Thinking outside the box’ have stimulated us to reflect and discuss.”

LANXESS to produce world’s first bio-based EPDM rubber LANXESS is strengthening its

commitment to produce premium

synthetic rubbers f rom bio-

based raw materials. The German

specialty chemicals company aims

to commercially produce Ethylene-

Propylene-Diene Monomer (EPDM)

from bio-based ethylene – a first in the

world – by the year end.

EPDM is conventionally produced

using the petroleum-based raw

materials ethylene and propylene.

Alternatively, the company plans to

use ethylene derived purely from the

renewable resource sugarcane. This

bio-based form of ethylene is produced

by dehydrating ethanol from Brazilian

sugarcane. Braskem S.A. supply the

bio-based ethylene via pipeline to

LANXESS’ existing EPDM plant in

Triunfo, Brazil. All EPDM grades

will be sold under the brand name

Keltan. “Our company’s ongoing

search for alternatives to fossil fuels

underlines its commitment to reducing

CO2 emissions through sustainable

production,” said Guenther Weymans,

Head-Technical Rubber Products

Business Unit, LANXESS.

Elaborating on the same, Marcelo

Nunes, Director-Renewable Chemicals,

Braskem, said, “LANXESS will

contribute to broaden our portfolio

of renewable chemicals’ clients. This

agreement will bring the benefits of

green ethylene to other important

applications and markets. LANXESS

has extensive automotive experience and

an excellent reputation in this market,

which makes it an ideal partner.”

The Triunfo plant currently

produces 40,000 metric tonne per year

of regular EPDM rubber. It is expected

that the first batches of the product

Keltan Eco will amount to several

hundred metric tonnes.

Plastics firms in Southeast Asia face new challenges Buoyed by the economic growth in

China and India, Southeast Asia’s plastics

industries successfully emerged from the

2009 global recession. But there are major

challenges looming, including inflation, a

slowing world economy and rapidly rising

wages that threaten to prise some of the

former Asian economies out of the ranks of

low-wage countries.

Krianglit Sukcharoensin, President,

Thai Plastics Industries Association, said,

“Plastics firms in Thailand are facing up

to 45 per cent wage increases, both from

government plans to boost minimum

salaries and from market factors like rising

incomes in rural areas. To address the acute

labour shortage, Southeast Asia’s largest

plastics industries, Malaysia and Thailand,

are investing in education & upgrading

efforts. Labour shortages coupled with

energy costs, capacity constraints, rising

commodity & food prices, are threatening

to push inflation beyond control.”

MPP

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No. 34

TECHNOLOGY & INNOVATION


Novopearls micro-granulate to colour thermoplasticsNovosystems has introduced a new

micro-granulate. Marketed under the

name Novopearls, the granulate combines

the best features of liquid colours and

conventional granulate batch material. It

is a solid material with characteristics of

liquid colours, making a higher degree

of colouration possible and offering cost-

savings as compared to conventional

colour batches.

Novopearls micro-granulate fills

the gap between liquid colours and

conventional batch granulate. The

spherical micro-granulate (average

diameter, 450 μm) is a special wax mixture

that can be homogenised with numerous

thermoplastics.

Novopearls is highly pigmented, can s

be mixed together, is dust-free and has

low viscosity. But the real highlight is its

melting point of 85°C. It melts in the

screw faster than the basic plastic material

to be coloured. This ensures rapid, streak-

free homogenisation of the colour and

the plastics. Due to optimally dispersed

pigments in the wax-based granulate,

small amounts of additives (0.1-0.9 per

cent) are needed. Time-savings gained

through quick colour changes gives a high

degree of flexibility to the user.

High-performance UV absorber Tinuvin® 1600 Tinuvin® 1600 is a new Ultraviolet (UV)

absorber that provides extremely long-

lasting UV protection to high-performance

thermoplastics. It exhibits an outstanding

UV absorption capacity, resulting in

minimal loss of optical properties for

stringent weathering requirements.

The product is developed specifically

for long-lasting protection of thin-layer

applications for exteriors and allows

plastic sheets, films & fibres to retain

their mechanical properties, colour and

transparency for extended durations.

It belongs to the class of triazines and

exhibits low volatility, excellent thermal

stability and good substrate compatibility in

various polymeric resins, which allow easy

processing. It imparts superior durability

than conventional UV absorbers of other

chromophores. It extends the durability

and life expectancy of products under

intense UV exposure. It is suited for long-

term outdoor use for up to 20 years.

Tinuvin® 1600 is recommended

for monolithic and multi-wall

Polycarbonate sheets for ultra-high-

durability architectural and automotive

glazing applications; biaxially oriented

Polyethylene Terephthalate (PET) films

for photovoltaics, window films, displays,

protective films & other long-term

applications; Poly(Methyl Methacrylate)

(PMMA) laminations for durable

specialty applications like window profiles,

photovoltaics and demanding construction

applications; PET and polyamide fibres;

styrene acrylonitrile, acrylonitrile styrene

acrylate high-performance plastics

applications, eg, building & construction,

automotive applications, etc.

Capillary Rheology study for injection moulding processes Malvern Instruments has developed

Rosand Capillary Rheometer, which

can measure Pressure–Volume–

Temperature (PVT) characteristics

of compounds and predict their

suitability for use, or help predict

optimum injection moulder settings.

While injection moulding of

samples, it is important to know about

PVT properties of the melt, as some

melts may be more compressible than

others. Generally, a compressible melt

is likely to require higher volume to

fill the mould, but can bleed from the

injection point after moulding, thus

causing the die ‘drool’. Variations in

melt compressibility can result in

convex or concave surfaces of parts

instead of flat surface. This can

cause problems when parts are to be

fitted together. By using the Rosand

Capillary Rheometer, the density of

the hot polymer melt can be used as

an indication to processability when

formulating new injection moulding

compounds.

This rheometer can be used

in conjunction with laboratory

and pilot-scale injection moulders

to formulate high-quality polymer

compounds. PVT testing can

show how to optimise injection

moulding settings, while high-shear

rheometry can simulate the actual

injection process.

REIfill technology saves raw material costs New thermoforming sheet line from

Reifenhäuser Extrusion, equipped with

a REItruder, reduces raw material costs

by more than 40 per cent. The REIfill

technology allows processors to replace up

to 40 per cent of Polypropylene (PP) and

Polystyrene (PS) with mineral fillers, eg,

calcium carbonate, talc, etc.

Besides cost-related aspects, addition

of mineral fillers, according to application

of the end product is also of interest in

terms of product properties, ie, filled PP

and PS films have a greater stiffness than

pure PP and PS films with identical wall

thickness. This is an ideal prerequisite

for manufacture of disposable dishes.

Manufacturers whose products do not

require such enhanced stiffness may

reduce the film thickness, resulting in

further raw material and costs-savings.

Furthermore, filled thermoforming sheets

can be produced in many cases depending

on the end product at increased cycle

rates. The suggested applications include

disposable dishes.

TECHNOLOGY TRANSFER


As part of our endeavour to spread the technology culture,this section provides a means to promote and facilitate exchange of select technologies.

We strive to bring together suppliers of such technologies with suitable users fornegotiations and industrial collaboration.

Technology Offered

Conversion of batch-poly plantto C P plant A company from China is interested

in providing consultancy for the

modification of batch-poly plant to

C P plant like polyester plant, polyester

chip or direct spinning.

Areas of applicationChemical fibre and plastics

Forms of transferTurnkey

Plastic recycling technologies using organic and inorganic compounds An Iranian company offers plastics

recycling technologies using organic

and inorganic compounds. This idea

is based on the principle of water

electrolysis in which sodium chloride is

kept in proximity of turpentine/pine oil

and plastics.

Areas of applicationPlastics recycling

Forms of transferOthers

Plastics recycling technologies An Iranian company is willing to provide

plastic recycling technologies using

urea and ammonium carbonate and

synthetic ammonia.


Forms of transferTechnology licensing

Polyester chip plant A company from China offers polyester

production plant, polycondensation plant,

polymerisation line, hot melt adhesive plant

(500-5,000 tpa), polyester chip plant

(2,000-1,50,000 tpa) and film grade

polyester plant (2,000-1,50,000 tpa).

Areas of applicationPolymerisation and fibre lines

Forms of transferTechnology licensing and turnkey

Pilot plants for small-scale productionC P plant like polyester plant, polyester

chip or direct spinning.

Areas of applicationChemical fibre and plastics

Forms of transferTurnkey

Conversion of batch-poly plant to C Pplant An Indian company offers pilot plants

for laboratory or small-scale production

purpose. The plant consists of a spinneret,

metering pump, spinning beam, candle

filter, extruder unit, godet unit, PP

multifilament plant manufacturer, single-

screw extruder machine or melt flow

index tester machine for masterbatch

industries.

Areas of applicationPlastics, textiles, etc

Forms of transferSub-contracting, turnkey, etc

Rotational moulding of plastics A manufacturer of rotational moulding

machines f rom India offers plant

and machinery for constructing

water storage tanks and other hollow

plastic parts.

Areas of applicationChemical storage tanks, water storage

tanks, material handling trolleys, pallets,

containers, etc


Recycling of PET wastes intopolyester polyolsA Czech Republican company is

offering the technology for recycling

of PET wastes (plastic PET bottles,

X-ray films, etc) to produce polyester

polyols. The process consists of

the following steps: Collection of

PET wastes, sorting out & shredding

of collected PET wastes, simple

chemical process of glycolysis &

esterification, and production of

polyester polyols.

Areas of applicationChemicals industry: Polyester polyol

is a base material for the chemistry

of polyurethanes, especially the

production of polyurethane foams,

which are primarily transferred into

energy saving and insulating materials

Forms of transferTechnology licensing, others

Share Your Technology PropositionsThe mission of Modern Plastics and Polymers is to spread the technology culture. We offer you an opportunity to participate

in this endeavour by publishing the best technology ideas. Technology developers/sellers are invited to furnish the techno-commercial details (with environ-mental benefi ts, if any) for publication in the Technology Transfer column of Modern Plastics and Polymers.

R&D organisations, technical consultancy organisations and individuals assisting small and medium enterprises send therelevant literature, indicating the scope & services and the areas of specifi cation.

Contact: Modern Plastics and PolymersInfomedia 18 Ltd, ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W), Mumbai 400 028.

Tel: 022-3024 5000 l Fax: 022-3003 4499 l Email: [email protected]

TECHNOLOGY TRANSFER


Disposal and recycling of plastics waste A Polish firm seeks the technology for

dry processing of all kinds of plastic

waste or a magnetic processing method

in the electrostatic field. The technology

should allow sorting of all kinds of plastic

materials, hay-silage foils, PET, HDPE,

PVC, etc, by excluding dangerous waste.

Specific technical requirements include

initial cleaning without the use of

water, sorting of all kinds of plastic

materials after cleaning in a closed

system, and a maximum processing

capacity of 10,000 tonne of waste

per annum.

Areas of applicationPlastics industry, waste recycling, waste

management


Lab-scale non-woven andmonofilament plant An Indian company is looking for a lab-

scale, non-woven and monofilament plant

in a single station.

Areas of applicationPlastics


Plastics recycling technologies A Sri Lankan company is seeking the latest

plastics recycling technologies, especially

for automatic sorting, washing, metal

detection, granulation process system,

washing plants, crushers, extruders, etc.



Polyacetal resins A Gulf-based organisation wants to

promote projects in the chemicals and

petrochemicals sectors in GCC countries.

It is looking for technology suppliers

for the manufacture of polyacetal resins.

Areas of applicationChemicals/petrochemicals industry

Forms of transferFeasibility study, know-how, equipment,

turnkey plant, joint venture

PP/PET strap processing An Indian company is seeking the

technology for PP and PET strap

processing.

Areas of applicationPackaging industry


Recycled PET polyester polyols plant A Poland-based company specialising

in recycled PET polyester polyols

manufacturing, is looking for an

alternative proposal of design and

engineering of bigger (approximately

25 ktpa) production plant. It plans to start

with proper quality recycled PET flakes

being delivered in big bags. Hence, the

company needs a complete package offer

for this service.

Areas of applicationPlastics and polymers industry


Information courtesy: Information courtesy: Dr Krishnan S Raghavan, In-Charge,Technology Transfer Services Group, United Nations - Asian and Pacifi c Centre for Transferof Technology (APCTT), APCTT Building , C-2, Qutab Institutional Area, New Delhi 110 016,Tel: 011 - 2696 6509, Fax: 011 - 2685 6274, Email: [email protected], Website: www.apctt.org For more information on technology offers and requests, please log on to www.technology4sme.net and register with your contact details. This is a free of cost platform provided by APCTT forfacilitating interaction between buyers and seekers of technologies across the globe. Aftersubmitting technology offer or request to this website, you are requested to wait for at least twoweeks for receiving a response from a prospective buyer / seeker through this website, beforecontacting APCTT for further assistance.

Technology Requested

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 BastiaSenior Editor

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


“If energy is utilised to its fullest, the cost per piece will decrease steadily”

Highlight the current market trends inthe plastics and polymers industry.The plastics and polymers industry is

growing at a fast pace. Baumuller as a

company concentrates on three processes

– injection moulding, blow moulding and

blown films – since a major portion of our

business comes from these areas. Based

on these basic categories, this industry

has been growing at the rate of 20 per

cent over the last 2-3 years. The plastic

processing machinery industry is expected

to continue growing in a similar fashion

for the next 4-5 years.

Following are the reasons for thisgrowth:Investment in food processing: Food

processing also comprises other agricultural

practices, such as irrigation. Among all

food items like fruits, vegetables, grains,

etc that are produced in India, less than

50 per cent reaches the population. The

remaining go waste and perish due to

lack of proper infrastructure in food

processing segment across India. Realising

this phenomenon, the government is now

offering subsidiaries to ensure that at least

70 per cent of the foodstuffs produced

reaches the population.

We expect growth in the use of plastics

in food processing. This growth would

be not only in food processing, but also

in packaging. Generally, packaged food

comes packed in plastic pouches, bags or

containers. This will result in increased

demand for plastics in this segment.

Another area where plastics are and will

be used in large quantities is irrigation. For

example, Polyvinyl Chloride (PVC) pipes,

rubber pipes and plastic components are

used in drip irrigation.

Retail sector: The growing spending

power of the Indian middle class has led

to an increase in the packed food culture,

and this will continue growing in future.

This will provide an opportunity for

further consumption of plastics in the

form of containers, bottles or films. The

latest trend in plastic packaging in the

retail sector is thermoforming. In this

process, plastic granules are converted

to a film. Thermoformed trays are used

to pack products such as biscuits and

chocolates.

Automobile sector: Car making utilises

various plastic components. These plastic

components are now manufactured in

India for export to developed countries.

What are the latest developments andinnovations in this area?Three areas have seen a number of

developments – energy efficiency, uptime

of machine and quality of product.

In energy, the processes, mainly

injection moulding and, to some extent,

blow moulding, are witnessing new

developments. Energy is an important cost

factor in manufacturing. It constitutes the

second highest cost that a manufacturer

incurs in production. The highest cost

…opines Atul Dave, President, Baumuller India Pvt Ltd. In an exclusive conversation with Vishakha Avachat-Naware, he underlines the importance of the use of plastics in various fields like food processing, retail and automobile. He believes that the use of latest technology & good-quality components in a machine ensures energy efficiency, better uptime and minimal rejections, thereby adding to the cost-efficiency.

Atul Dave


is incurred on raw materials. Processes

like melting, blowing and injecting

require huge amounts of energy. The

biggest concern for those using injection

moulding process is to make optimal use

of the available energy. If technology is

utilised to its fullest, the cost per piece

will steadily decrease.

The second development is the higher

uptime of machine or greater reliability

of the machine. A manufacturer loses out

on man-hours when a machine requires

frequent repairs or in case of shutdown

and maintenance activities.

The reliability of components used

machines depends on the quality of

components used. A well functioning

machine can be achieved using good

quality critical components like valves,

controls, motor, sensors, etc. When the

final product is made as per specifications,

it ensures minimum rejections and

optimum consumption of raw materials.

Automation is a rising trend in this field.

Tell us about Baumuller’s stintin India.In India, Baumuller has recently opened a

facility in Pune. We are greatly dependent

on the plastics sector, so the growth in

this industry has compelled us to expand

our facilities. As Baumuller is a global

company, our shareholders expect us to

provide more services in the Southeast

Asian region. When our customers provide

their products to the Southeast Asian

market, they expect our support in the

form of customer visits, commissioning

and troubleshooting. We provide services

to companies in Southeast Asia and sales

in India.

How has been your journey in this field?After graduating from College of

Engineering, Pune, I wanted to do

something different. In my first job at

Godrej, I opted for the production

department, as I wanted to work on the

shop-floor. Later, in companies like Philips

and Festo, I worked in the field of industrial

automation. Here, I got an opportunity to

work like an entrepreneur and develop

my industry skills. I learnt how to start a

business and got an opportunity to work

with machine manufacturers from the

fields of plastics, packaging & printing. By

the time I joined Baumuller, I had an

in-depth understanding of this field and

its nuances.

What has been the biggest challengepertaining to business decisionsfor you?I have worked in up-market companies

but not in a price-sensitive market. As the

quality, reliability and after-sales service

are good, the price of products is also

high. Our strong technological support

ensures long-term success. The biggest

challenge for me has been to convince

buyers about return on investment, even

though the price of the products is high.

I want to give this matter a thought and

develop a new scheme of effective sales

training for employees.

Who has been the greatestmotivational force in your life?To whom would you attribute your success?I am a keen learner and like to learn

from every person I meet and every new

thing I see. The seniors in my previous

workplaces were very helpful and taught

me a lot. Their teachings at the beginning

of my career have been of great value.

Key demand drivers influencing theIndian plastics industry.The per capita consumption of plastics in

India is about 5 kg. This figure is quite

low when compared to countries such as

China and Brazil, where the consumption

stands at 30 kg and 90 kg, respectively.

Hence, we can confidently say that the

plastics industry will flourish in India in

the coming decade.

How do you see your company’s growth potential in the Indianmarket?The future of our company seems

bright. We envision a 300 per

cent growth in the next 5 years, as

40 per cent of our business comes from

the plastics industry.

Any new technologies at Baumuller?Some of the new technologies at

Baumuller are as follows:

Servo pumps: Servo pump comes as a

package that can be fitted into existing

injection moulding machines, and this

will bring down energy consumption

by 50-60 per cent. The manufacturers

using our machines need not buy a new

machine. They can buy this package and

fit it in their existing machines. The

return on investment can be expected in

6-12 months. Our aim is to introduce

these packages to our existing injection

moulding customers.

Special motors or high-torque

motors: These are highly energy-efficient

motors, which require less maintenance,

are compact and reliable. These motors

are unique and only 2-3 manufacturers

produce them across the world. These

motors are widely used in the plastics

machinery industry in developed countries

– in injection moulding machines,

extruders and blown film lines.

In addition, we are working on

automation solutions like remote

diagnosis through EtherCAT. This will

help in machine support and maintenance

from a remote location without actually

visiting the site and, in the process, saving ,

production man-hours.

What are your expansion and futureplans in India? We are planning to start facilities for sales

and application support in different regions

of the country. By the year end, we will

start operating in New Delhi, Ahmedabad

and Chennai. Apart from this, we will start

some manufacturing facilities in Asia.

What would be your advice to aspiring and upcoming entrepreneurs in thisdomain?The aspiring and upcoming entrepreneurs

must work on improving their skills

through learning, unlearning and

re-learning. With technological

upgradation, one needs to keep pace

with new trends & benefits derived, and

must be able to adopt changes as quickly

as possible.

SPECIAL FOCUS: Polymer Processing

Polymer Processing


Polymer processing:

Riding high on innovative methods ..................................................................50

Processing practices:

Overcoming the bottlenecks ..............................................................................54

Roundtable:

What are the implications of f luctuating

crude oil prices on polymer processing? ............................................................ 58

SPECIAL FOCUS

Courtesy: Georgia Tech Research


When it comes to

p r e p a r a t i o n o f

packaging material or

containers, automotives

& construction, trays and boxes, raw

materials like Polypropylene (PP) and

Polystyrene (PS) are fast gaining ground

in terms of applications in the polymer

processing industry in India. The rising

demand, both domestic and global, has

ensured that manufacturers have their

order books full. Plastic products are

fast replacing metal as the preferred

choice in various industries. This

has led to a flurry of innovations for

the polymer processing industry,

as it has to keep pace with the design

and quality requirements of plastics

manufacturers.

Banking on Research and Development (R&D)With increasing R&D undertaken in

European countries like Germany and

Asian countries like Korea and China,

engineering polymers have promising

growth prospects in the years to come.

High-performance polymer products,

which can replace metal and offer

weight & cost reductions to customers,

while also meeting the functional

requirements of the application, have

excellent growth prospects.

The socio-economic trend of

increasing younger-age working

population has created new avenues

for industrial polymers. Today,

lifestyles are more hectic, dual incomes

are encouraging the emergence of

organised retail, all of which are

opening new application avenues in

packaging. Demand is growing for safe

& hygienic packaging for food, beverages

and medicines. International companies

are approaching these opportunities

with their unique and high-performance

offerings through engineering polymers.

In the medium- to long-term,

companies are looking at opportunities

in the field of defence, renewable

energy & materials (photovoltaics,

bioethanol, bio-butanol, etc) and

renewably sourced materials for

different applications. India is

witnessing heavy investments in

these areas, as there is abundance

of human talent – both skilled

and unskilled.

The Indian plastics industry is witnessing growth in all verticals. This, besides the increasing awareness about the importance of recycling such products, has ensured that not only consumers receive a better finished product, but the environment also breathes a sigh of relief. Anwesh Koley explores the phenomenal changes that have been shaping the Indian plastics processing industry.

Riding high on Riding high on innovative methodsinnovative methods

SPECIAL FOCUS: Polymer processing

Courtesy: Georgia Tech Research


Current industry scenarioCurrently, the polymer processing

industry is witnessing a steady increase in

the number of players driven by growth

and profitability of the sector. “The

Indian plastics industry is growing at the

rate of 12-15 per cent per annum since

the last few years. This means demand of

raw material is growing simultaneously

at the same rate. With regard to the

Indian clientele, people are improving

with technological advancements and

have access to international standards.

But this improvement happens at a

much higher pace for a company that

exports than the one that manufactures

and sells in India,” feels Rajeev Bhatia,

Chief Executive Officer, Premier

Pigments & Chemicals.

“With advancements in machinery,

raw material suppliers have increased

their production with lesser number of

people. Better and consistent material

is available at much competitive

prices than before,” says Sumit Dhingra,

Director, Dhingra Polymers. By 2012,

India is projected to be the third

largest consumer market for plastics,

with a consumption of 12.75 million

Metric Tonne (MT) per annum.

Polymer consumption in India has

historically grown at twice the Gross

Domestic Product (GDP). This growth

is driven by all consuming segments

like automotive, housing, packaging,

agriculture, etc.

An increasing need is felt in

the construction industry to replace

conventional materials with plastics.

“Earlier, wood was the preferred choice

for construction equipment and internal

requirements. Having evolved in their

applications, plastics are fast gaining

ground in this segment as well,” observes

Bhatia. Masterbatch consumption is

projected to increase from 182,000 MT

in 2010 to approximately 255,000 MT

in 2012. This growth can be attributed

to the rise in competition both in the

domestic and international market,

as manufacturers now have access to

global technology and are aware of the

changing demand patterns.

Areas of improvementThe rate of growth witnessed by the

Indian polymer processing industry does

not match up to standards maintained by

China. “The level of R&D undertaken

by China is higher than India. Also,

the government of China is more

friendly towards manufacturers as well

as exporters,” says Dhingra.

While the Indian government has

been taking regular measures towards

making things easier for the polymer

industry, the fluctuating crude oil prices

have had a negative impact on this sector.

“The government should encourage the

use of alternatives to plastics in non-

core areas, as the instability in global

crude oil prices impacts our business,”

says Bhatia.

With increased demand, masterbatch

manufacturers will strive to use up

their present capacities. If the present

capacity remains constant, there is a

possibility of imports as well, which

may result in price hike. The price

of masterbatches depends not only

on the polymer prices, but also on

the pigment prices, and this has been

increasing steadily. However, with the

increase in demand for masterbatches,

the probability of more manufacturers

jumping into the foray is high. This

will result in equilibrium price where

the quantity demanded by consumers

(at current price) will equal the quantity

supplied by manufacturers.

Creating a vibrant futureThe pace of innovations in the polymer

industry is commendable; however, it

requires support from the government

as well as international policies and

prices. Also, the increase in applications

for polymers has encouraged R&D

by manufacturers, thereby increasing

competence globally. However, the

Indian polymer industry has shown

enthusiasm towards adoption of latest

technologies; moreover, exposure to

international standards & quality has

ensured that plastics find applications

in more and more areas, which were

earlier dominated by metal & wood.

Rajeev BhatiaChief Executive Offi cer,Premier Pigments & Chemicals

The government should encourage the use of alternatives to plastics in non-core areas, as the instability in global crude oil prices impacts our business.

Sumit DhingraDirector, Dhingra Polymers

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

Polymer processing

SPECIAL FOCUS: Processing pract ices


The consumption of Indian

polymer products is on the

rise. “Polymer consumption

is expected to double in

the next three years, as products by

Indian manufacturers are well priced

as compared to those by European

manufacturers,” says R K Aggarwal,

Managing Director, Prayag Polytech

(Pvt) Ltd. While earlier, manufacturers

were skeptical towards using the latest

technology, this trend has given way to

extensive Research and Development

(R&D) in the field of polymers,

resulting in the advent of the latest

machinery in the country. The industry

is now gearing up towards reducing

the pollution caused by the plastics

industry. A number of machines have

been developed, which produce less

wastage and help in reprocessing of

the waste. Manufacturers now ensure

that the waste they produce is either

disposed properly or can be recycled.

Quality issuesThe primary requirement for the industry

is availability of high-grade polymers.

The final plastic product depends

heavily on the quality of raw materials

available with manufacturers. Amit Puri,

Director, Alok Masterbatches, says, “We

face an acute problem of low-quality

polymers for the industry. The Indian

quality is not up to global standards;

hence, we have to import from Europe,

particularly, Germany.” Dependence on

imported polymers has not changed

in the past years, with manufacturers

having difficulty in finding options

in the domestic market. The industry

requires imports for specific materials

such as Polyvinyl Chloride (PVC),

which is in short supply. This is because

India has a net shortage of PVC and

only few large-scale players manufacture

this raw material.

Space constraintsAnother constraint for manufacturers

is availability of land. At times,

expansion plans of companies get

stalled due to lack of infrastructure and

land availability. Most manufacturers

operate in small areas and often do

not have adequate space to implement

any measures towards achieving green

productivity norms. “Even after going

ahead with our expansion plans, we are

unable to achieve the desired levels of

efficiency as we are handicapped for

space of operation. Acquiring land

The Indian polymer processing industry has well adapted to changes in the global market. It is now moving towards evolving as a major global player, as the international plastics fraternity is noticing the high quality standards followed in India. But, the enthusiastic expansion plans of companies in the polymer industry are replete with challenges that hinder smooth working for manufacturers. Anwesh Koley analyses some of these obstacles and how to prevent these.

Overcoming the bottlenecks

Illu

stra

tion

: Sha

rad

Bha

reka

r


is often a cumbersome procedure,”

informs Aggarwal. European polymer

manufacturers operate on a much larger

scale than their Indian counterparts.

Need for more powerInf rastructure problems remain

persistent for the sector, as power

availability is scarce in many

areas, affecting the timeliness for

manufacturers. “In terms of energy

conservation in plastics production, the

availability of power is a major concern

for plastics producers. The steps

required for implementation of green

manufacturing and renewal of energy

have not been seriously implemented

in the industry till date. A major reason

for this is that this implementation is

costly and if it does not yield adequate

returns, it is not worth carrying out,”

says Aggarwal.

Fluctuations in power supply hamper

the regular operations of a polymer

company, as a number of high-end

equipment depend on the steady flow

of electricity. While manufacturers have

done their part in ensuring continuous

flow of power in production units, there

are larger problems that need to be

addressed in the long run. “In India, the

Transmission and Distribution (T&D)

losses are high; hence, the final power

reaching our manufacturing units is low

as compared to the stipulated power on

the grid,” says Aggarwal.

Pricing it rightPrice is an important factor determining

growth of the polymer industry

and in the long run determines the

competence of a country. “The prices of

masterbatches have been on an upsurge

for the last few years due to a sharp rise

in raw material prices and consolidation

of international raw material suppliers.

Sourcing quality raw material f rom

consistent and reliable suppliers will

be the key in the coming years,” says

Puri. New masterbatch players, both

domestic & international, will need

to keep the selling prices competitive,

thereby presenting a challenging market

scenario and reduction in margins.

The volume growth should help

sustain most players but, as in most

industries, efficiency and innovation

will be required.

Role of the governmentThe government does not have specific

policies for the polymer industry

and, while this has not hindered

manufacturers form reaping profits,

a policy support in some areas could

make a difference. “The government

needs to have a clear understanding of

polymers and their applications. This

will help manufacturers, as the customer

will better understand the quality of the

product,” feels Puri.

Even for polymer machinery

manufacturers, advancements in plastics

technology provide scope to adopt

internationally accepted standards and

higher consumer satisfaction. “New

resins, additives and fillers are entering

the market, which can enhance the

material properties without causing much

change in the price. As compared to the

conventional single-screw machine, twin-

screw extruders and gravimetric feeders

have taken a lead with higher output,

better quality and less involvement of

people,” says Aggarwal.

The latest technology in plastics

helps in better detection of the material

according to specific requirements.

Most companies have their own R&D

facilities and those that do not, generally

outsource research activities to achieve

a more customer-centric final output.

The latest technology used in the raw

material production machinery ensures

that more customisation can be achieved

along with higher rigidity.

Rising above the challengeThe latest technology in polymer

processing needs to be supported well with

adequate infrastructure. Manufacturers

are willing to innovate and bring quality

up to international standards, but without

adequate power and land availability,

it is difficult to take the expansion

plans forward.

R K AggarwalManaging Director,Prayag Polytech (Pvt) Ltd

As compared to the conventional single-screw machine, twin-screw extruders and gravimetric feeders have taken a lead with higher output, better quality and less involvement of people.

Amit PuriDirector, Alok Masterbatches

The government needs to have a clear understanding of polymers and their applications. This will help manufacturers, as the customer will better understand the quality of the product.

Processing pract ices

SPECIAL FOCUS: Roundtable


Neeraj Garg,Partner, Suruchi Industries

While the Indian market saw price

reduction by major producers, the

Polypropylene (PP) price across

Asia has fallen persistently, as most

end-users and distributors bought

raw materials on a short-term basis

fearing that prices would fall amid

weak demand in future.

Concerns of further tightening

of credit measures in China have

dampened the buying interest for

petrochemical raw materials in the

country, and a sluggish buyer sentiment

has spread in the Southeast Asian

market. Domestic demand is slowing,

with buyers deferring purchase

decisions in anticipation of further

fall in crude prices, further lowering

polymer prices. Most players had

suffered during global slowdown. The

price protection scheme had helped

buyers make a purchase decision and

offered a sense of security towards a

further price decline. Manufacturers

expect stability in the near future, or

else polymer manufacturers will have

difficulty sustaining businesses.

The plastics industry depends heavily on the supply of crude oil for manufacturing polymers, which serve as raw materials. However, fluctuations in global crude oil prices have not gone down well with the industry, with a direct impact on the prices of polymers, and thereby the final plastic product. Anwesh Koley gauges the opinion of some of the industry experts about the impact of this price fluctuation on the plastics industry.

What What are theare the implications implications ofof fluctuating fluctuating crudecrude oil oil

prices prices onon polymer processing?polymer processing?

Vir Singh, Proprietor, Sai Thermoformers

Polymer grades may differ as per

usage, but plastics manufacturers

have to deal with price fluctuations,

which often cannot be passed on to

the end consumer. Currently, the

crude oil prices have plummeted,

leading to a drastic decline in naphtha

prices globally. While crude oil prices

have come down to $ 86-88 a barrel,

naphtha prices are at $ 860-870 per

tonne. This is as against a high of $

110-115 per barrel for crude, which

had propelled naphtha prices to touch

$ 1,000 per tonne some time earlier.

As people become aware of

hazardous chemicals, the plastics

industry is using products that are

lead- & benzene-free and chemically

friendly. Although not many

manufacturers produce such products,

people today are willing to spend extra

for the same. Rcently, the demand for

eco-friendly plastic products has risen

85-90 per cent. This is a comforting

factor for the polymer industry, as

otherwise global fluctuations in crude

oil prices would have resulted in

closure of many manufacturing units.

Sumit Kumar, Marketing Head, H K Industries

The domestic polymer industry has

shown resilience in the face of global

fluctuations and Indian polymer

manufacturers have slashed prices of

Linear Low Density Polyethylene

(LLDPE) by ` 1.50-2 per kg across`variants. This price decrease is only

for LLDPE and not other polymers.

LLDPE is a popular variant of

polyethylene, produced at low

temperature and used to make plastic

bags & sheets, plastic & stretch wraps,

toys, lids, pipes, containers, covering of

cables, etc. It finds application in regular

items, and hence price reduction may

result in a lower-priced final product.

Fluctuations across the polymers

range have been a regular phenomenon,

as domestic players do not have a role

in determining crude oil prices. Price

stability remains a key factor for the

future of the polymer industry and has

a direct impact on the price of plastic

products. Gradually, manufacturers

should move towards alternatives, as

crude oil is a non-renewable source and

its supply is limited.

Regulating crude oil prices is an immense challenge given the demand-supply mismatch across the globe. While polymer manufacturersneed to effectively deal with price volatility, broadbasing of raw material alternatives will considerably mitigate the risks.

Editorial take:

FACILIT Y VISIT: Plast ib lends India Ltd


The growth of India’s plastics

industry is closely linked

with the phenomenal rise

in applications and products

across various sectors of the economy.

The resultant increase in demographic

dynamics and disposable incomes has

driven the Fast Moving Consumer

Goods (FMCG) sector to new heights.

Consequently, packaging has emerged

as one of the chief applications of the

plastics processing industry. In keeping

with today’s high-end specifications for

retail packaging, the Indian convertor

relies heavily on specialty masterbatches

and additives to enhance performance

and profitability of common plastics.

Masterbatch industryThe masterbatch market in India has

been growing at a rate of 15 per cent

in the last few years, driven by demand

from end-user segments, primarily

plastic packaging, plastic products and

cables & pipes.

Among the market leaders in the

masterbatches and additives segment,

Plastiblends India Ltd has created a

niche for itself through value-added

services and a diversified product

portfolio in the Indian plastics scenario.

Founded in 1991 as a brainwave of the

Kolsite Group, Plastiblends India Ltd

has evolved as one of India’s largest

manufacturers and exporters of plastics

masterbatches & additive compounds.

By closely aligning its business model

to the demands and developments of the

nation’s plastics industry, Plastiblends

has emerged as a leading player, with a

60 per cent marketshare in the organised

masterbatch segment and an overall

marketshare of 12 per cent. The company

has been registering a Compound Annual

Growth Rate (CAGR) of nearly 30 per

cent for the last two years.

Manufacturing mightThe Indian masterbatches industry has

a total capacity of 350,000 Tonne Per

Annum (TPA), comprising organised

(25 per cent of capacity) and unorganised

(75 per cent) players. Since the process

of manufacturing masterbatches is less

capital- and technology-intensive, there

are more players in the unorganised

segment. In a highly competitive

industry such as this, Plastiblends sets

comparatively high standards of product

quality and price competitiveness.

Located about 200 km away from

Mumbai, the company’s Daman facility

has a capacity of about 50,000 TPA.

Spread over an area of 45,000 sq m,

this facility processes bulk of Plastiblends’

product offerings in the market, eg,

varieties & grades of white, black, colour

and additive masterbatches. Besides

processing 4,000 tonne of material per

month, the company maintains an

inventory of more than 7,000 tonne at

any given time. These figures indicate

a manufacturing might that is tough

to compete with in the masterbatch

Masterbatches are the secret ingredients that make all the difference to the processability and functionality of a polymer. In this regard, Plastiblends India has created a niche for itself through value-added services and a diversified product portfolio. Annabel Dsouza traces the company’s growth ambitions through an in-depth look at its best-in-class manufacturing practices.

world of plasticsColouring the

Impressive product portfolio

White masterbatch processingPhoto: Joshua NavalkarPh J h N lk

Plast ib lends India Ltd


segment. Ramesh Dumbre, Vice President

- Marketing, Plastiblends India Ltd, says,

“After fine-tuning our production and

commercial operations for more than a

decade, Plastiblends can today boast of

a quick turnaround time and high levels

of efficiency without compromising on

product quality and consistency. ”

With 24 dedicated compounding lines

operating at an average capacity of 10-15

tonne, the company has clearly segregated

its products as a precaution against cross-

contamination. Plastiblends’ production

system includes twin-screw extruder

lines, high-speed continuous mixer lines,

computerised gravimetric feeding systems

and process control systems. Plastiblends

attributes much of its success to its close

association with the machinery excellence

of Kabra Extrusiontechnik (KET), part

of the Kolsite Group. Dumbre explains,

“In order to provide tailor-made solutions

to the market, we have to design our

machinery accordingly. As KET is our

partner for in-house machinery, it is

easier for us to launch new processing

lines and upgrade the existing ones.

This ensures faster delivery to customers

and has helped us to gain the higher

market share.”

Quality controlBeing an ISO 9001:2008 certified

company, Plastiblends ensures that all

its production batches are subjected to

processability tests for a wide range of

critical performance properties. One of

the crucial advantages of Plastiblends’

masterbatches is the high dispersion

and pigment loading properties that

result in significant cost savings and

process efficiency. The company

conducts stringent simulated tests for

specific functions like weatherability and

stress tests important for performance

of the plastics product in actual use.

The facility is well equipped

with an extensive and accurate

inventory management system to

closely monitor the company ’s

shop-floor to market production cycle.

These best-in-class manufacturing

practices have given the company an

edge not only for domestic demand,

but also in an expanding export market.

Plastiblends exports over 30 per cent

of its capacity to 45 countries, mainly

in Latin America, Africa and Europe.

Hence, quality assurance is integral to

the company’s production operations.

Dumbre highlights, “Over the years,

we have designed our in-house quality

checks and practices to ensure that

all our products meet the properties

specified by customers. We understand

the product’s process and application

requirements and run our products

in small batches before scaling-up

operations, thereby ensuring 100 per

cent results.”

Research and Development (R&D)The company’s commitment to product

quality and consistency is reflected in its

R&D operations for which Plastiblends

has a Department of Scientific and

Industrial Research (DSIR)-approved

in-house R&D unit. The R&D centre

undertakes independent as well as

customer-specific projects. In the

moulding segment, the company is

developing additives for automotive

interiors and other such applications.

Sustainability, efficiency andgrowthProcess sustainability and efficiency is

crucial to Plastiblends’ functions and

growth as a dominant player in the

Indian plastics industry. The company

has made conscious efforts to reduce

utilities and enhance machinery output.

The company is on an accelerated

growth drive, with a recently established

facility at Roorkee, which has a capacity

of 10,000 tonne. Dumbre concludes,

“With increased efficiency and business

integration, we hope to raise the bar

for additive and masterbatch processing

in India.”

Ramesh DumbreVice President - Marketing

Masterbatch processing is not a globally standardised procedure and every supplier has to defi ne its own standards.

High output compounding lines

Operator-friendly technology

Dies for injection mouldingPhoto: Joshua NavalkarPh t J h N lk


Plastics in Sports & Entertainment

INSIGHT & OUTLOOK


Plastics in sports applications:

Outmanoeuvring the competition .....................................................................64

Sporting innovations:

Packing a punch for profitability ......................................................................68

Interface - Anil Kumar:

Managing Director, Great Sports Infra ............................................................72

Material corner:

Transparent polyamide with a clear advantage ................................................. 74

Injection zone:

Performance monitoring in real time ................................................................78

T

India’s emergence as an important player in the high-performance polymer market accurately corresponds with the growing investments in the world of competitive sport. From football to Formula One,

analyses the challenges and opportunities in plastics application in sports equipment industry.

Outmanoeuvring the competition

INSIGHT & OUTLOOK: P last ics in spor ts appl icat ions

64


Expanding application portfolioThanks to plastics, athletic equipment can

be literally ‘tailor-made’ to meet the most

diverse requirements. As desired, such

applications can offer thermal insulation

for winter sports or can be breathable

for track and field events. When used in

specialised swimwear today, performance

polymers create smooth flowing surfaces.

It would be not an exaggeration to say that

the top sports performances of today would

not have been possible without plastics.

High-strength polymers are ideal materials

for high-performance athletic shoes and

equipment. Exceptional compression and

fatigue resistance make these polymers

the best choice for outsoles where high

strength and support are needed at low

density. A wide variety of polymers offer

excellent performance at low density.

Ideal for outsoles, these block copolymer

resins offer resilience to repeated stress,

besides unmatched resistance to distortion

and deformation. Polyamides also offer

superior protection from scratches and

scrapes caused by aggressive use of high-

performance sports equipment. Their UV

resistance maintains transparency & colour

clarity, and being resistant to salt, salt water

& a host of chemicals, these polyamides

keep equipment glossy and looking new

season after season.

Properties like shock absorbance in

sports equipment improve control and

increase vigour in sports. Resins have the

capability to absorb shocks and vibrations

normally experienced in applications like

tennis racquets. As polymeric resins do

not stiffen at low temperatures, snow shoe

deckings made with such resins retain their

mechanical properties and resilience under

frigid conditions (-40°C). Premium golf

balls also exploit polymeric resin capabilities

like excellent compressive strength and high

resistance to deformation. In various core

technologies, these resins offer excellent

resistance to permanent deformation,

which can improve distance & ball flight.

Innovation indexOne comes across various grades of

thermoplastics just about everywhere in

sports applications. These materials give

an impressive demonstration of their

fitness in the world of sports shoes.

These resins are particularly used in

manufacturing of soles and heel taps by

injection moulding. The unique selling

points of these resins are their high

abrasion resistance and elasticity as well as

good resilience & flexural strength. Due to

their rigidity and toughness, these resins

are especially suitable for the shells of ski

boots & inline skates. Soles and studs

of football shoes – and also other sport

shoes – have one thing in common; they

have to undergo rigorous use everyday.

We have, therefore, developed a range of

new grades of Thermoplastic Polyurethane

(TPU) with a 30 per cent lower abrasion

loss than standard TPU grades. The parts

manufactured from these can be readily

de-moulded even at high wall thicknesses,

enabling economical production with

short cycle times.

On the right trackAn ideal track surface can help athletes

to achieve ungained heights, while also

preventing injuries. Having the right

surface can easily make a difference of

tenths of a second while running and a

difference of centimetres when jumping.

Innovative sports surfaces provide safe

& productive conditions for training and

competition.

Modern athletic track surfaces made

of PU are installed by pouring in situ

onto a level asphalt substrate. Installing an

athletic track with these resins is a stepwise

procedure and result in a three-layered

finished system having a total thickness of

about 14 mm. First, qualified application

experts apply a specially designed PU

levelling coating onto the absolutely level

asphalt substrate and sprinkle it while still

fluid along with an excess of synthetic

rubber granules [Ethylene Propylene Diene

Monomer (EPDM)]. The coating sets

overnight and binds the rubber granules

in direct contact with the substrate. This

process is repeated to create a second layer.

These two lower layers of the system are

designed to minimise the risks of injury

for athletes. Minute air chambers both in

the PU and granules provide the most

stress-free conditions for athletes’ joints

and have shock-absorbing properties.

The hardness and elasticity of PU can

be precisely adjusted by modifying the

individual component formulation, thereby

imparting aesthetic and safety features to

the surface.

The India advantageCurrently, India is witnessing a boost

in terms of ideas and opportunities for

high-end applications of sports-grade

polymers. Hebbar concludes, “Globally,

there seems to be a resurgence in

the reinforced plastics industry. India

has never been a strong contender

in this area due to a lack of investment

in research & development for composite

design, engineering and processing

technology. However, as the competitive

and professional parameters have risen in

the world of sports, there is a significant

opportunity to move into the higher value-

added and higher margin-driven composite

sporting goods industry. The availability

situation with fibres and resins is also set to

improve, and this will provide a fillip to the

Indian industry.”

Akhil HebbarCountry Manager,Zoltek Corporation

With the ability to offer weight reduction, excellent strength & stiffness, corrosion resistance and excellent fatigue properties, carbon fi bres are increasingly becoming the material of choice for fi bre-reinforced plastics.

Plast ics in spor ts appl icat ions

INSIGHT & OUTLOOK: Spor t ing innovat ions


Packing a punch for profitabilityIn a challenging application like sports equipment, properties such as strength, toughness and weight ratio go a long way in building brand equity and profitability for processors and manufacturers. Annabel Dsouza identifies the accurate moulding and tooling strategies for some of the daunting applications in the sports equipment industry.

Plastics has long been known

for its impressive mechanical,

optical, electrical and thermal

properties. Features such as

strength, toughness and weight ratios

have led to polymers successfully replacing

conventional materials in sports. High-

performance polymers form an integral

part of equipment used today. Polymeric

materials, fibres and coatings contribute

directly to improvements in performance

and are vital in safety applications.

Innovations in action In recent times, polymer science and

technology have improved effectiveness

and performance of winter sports gear.

It can also help protect participants

from sports injuries, assist in repairing

damage in both participants &

equipment. With advancements in

polymer science, the sports equipment

industry is also demanding efficient

moulding, tooling and machinery

standards in order to implement material

innovations.

In a challenging application like

sports equipment, these properties go

a long way in building brand equity

and profitability for the processors and

manufacturers. Today’s sports merchandise

industry manufactures specific products

for dedicated applications (eg, running,

skiing, snowboarding, etc), which has

led to introduction of products with

integrated functions by using innovative

plastics grades. There have also been

developments in unique manufacturing

practices through innovative tooling and

machining technology.

Today, the tool and die fabrication

technology in plastic injection moulding

is one of the fastest growing industries in

the world. Plastics is now used in almost

all applications, ranging from household

articles to space travel, transportation

to packing, medicine to toys and from

bridge building to sports. The injection

moulding

moulding

material i

forcing it

mould cavity. The desired shape

of the plastics is achieved by

cooling in thermoplastic or by

chemical reaction for thermosetting.

Accuracy of designMould design and fabrication is a

costly and high-technology process,

as it uses science-based Computer-

Aided Engineering (CAE) software to

analyse and simulate the plastic parts

and Computer-Aided Design (CAD)

software to design the complicated

plastic product. It also uses Computer-

Aided Manufacturing (CAM) to

perform programming fabrication to run

a Computer Numeric Control (CNC)

machine for milling or latch. This

design module provides the designer

with necessary information to allow

Cou

rtes

y: C

alla

way

Precision moulding for sports helmets

for environmental process, design and

end-use effects to achieve an efficient,

functional part design in the shortest

possible time.

Advancements in computer

technology have led to an increasingly

favourable power-to-cost ratio for

computers. Hence, this advantageous

and costly technology will improve

productivity & process consistency.

Thus, for this fast-growing industry,

new technologies are vital to ensure

that this technology reaches perfection.

CAE is the assistant for processing and

calculation of the plastic material flow

inside the injection mould.

The most important first step in

designing a plastic part is to define

properly and completely the environment

in which the part will operate. Properties

of plastic materials are substantially

altered by temperature changes, chemicals

and applied stress. These environmental

effects must be defined on the basis of

both short and long term, depending on

the application. Considering the high

stress and rough environment in which

sports equipment are used, it is important

to determine the extent to which

properties, and thereby the performance,

of the part will be affected. If a part is to

be subjected to temperature changes in

the end-use, it is not enough to define

the maximum temperature to which the

part will be exposed. The total time for

which the part will be at that temperature

during the design life of the device must

also be calculated. The same applies to

stress resulting from the applied load. If

the stress is applied intermittently, the

time when it is applied and frequency of

occurrence are crucial.

Emphasis on innovationToday’s moulding technology needs to

consider the growing range of composites

that are making waves in the world

of sports equipment manufacturing.

Nanocomposite materials are being

used in squash and badminton racquets,

baseball bats, hockey sticks, snowboards,

skis, fishing rods & poles, golf balls &

clubs, etc. Philippe Michaud, Global

Technology & Innovation Director,

Huntsman Advanced Materials,

emphasises, “The main advantages

of using nanotechnology in sports are

improved mechanical and damping

properties. Enormous investments have

thus been made to utilise the potential

of nanomaterials for sporting excellence.

Today, nanotechnology represents a small,

but fast growing, part of the composites

market for sports goods.”

Smart solutions in the consumer

sports segment reflect general trends in

engineering plastics manufacture. Besides

strength and flexibility of the polymer,

manufacturers are enhancing user-friendly

electronic features digital clocks and pulse

monitors as training aids for professional

& amateur athletes. The moulding and

tooling methodology has been designed

such that plastics is not merely the material

used in a helmet, but also compatible with

other value-added products.

Research focusThe conceptual design of plastic parts is

based on the need of the plastic processor.

For sports equipment, part is designed in

a changeable insert mould base. The use

of one mould base will reduce the cost

and time taken for manufacturing. In the

mould-making industry, accuracy and

tolerance are important issues; thus, the

use of CAD/CAM will enhance quality

of work in mould design and reduce

number of errors in manufacturing. From

the analysis simulation, it is important

to obtain information results such as

fill time, injection pressure and pressure

drop. With this result, users can avoid

defects of plastics in actual injection,

eg, sink mark, hesitation, air traps and

overpacking. The analysis will also help

mould designers to design a perfect

mould with minimum modifications and

reduce mould setup time.

Sporting excellenceSince long, sports goods manufacturers

have been using system integrators

for developing products that combine

microelectronics, plastics and ceramics

in new smart functional applications. In

order to develop value-added products

and applications for the sporting

community, manufacturers have developed

virtual tools and applications that offer

consumers entirely new experiences.

All these will provide engineers and

designers with direct feedback on how

consumers use their products.

Philippe MichaudGlobal Technology & InnovationDirector, Huntsman Advanced Materials

The main advantages of using nanotechnology in sports are improved mechanical and damping properties. Enormous investments have thus been made to utilise the potential of nanomaterials for sporting excellence.

Spor t ing innovat ions



INSIGHT & OUTLOOK: Inter face - Ani l Kumar

What are the key performance requirements from polymer sportssurfaces?Synthetic turf is a unique application of

common plastics such as Polyethylene

(PE) and Polypropylene (PP). The

overall material design & usage is such

that it replicates the properties and

visual aesthetics of natural grass field.

However, polymer surfaces have several

advantages over natural grass. This is

significant in the context of sports as

artificial (polymer) turf does not require

watering or any other kind of intensive

maintenance. It offers unlimited usage

and all-weather playability. The key

parameters for artificial turf are softness

and flexibility, low f riction, high

resilience, Ultraviolet (UV) resistance

and fire-retardance.

Apart from these basic properties,

there are other applications of polymer

surfaces in modular (interlocking) sports

tiles. These exhibit other important

performance criteria such as grip on the

surface, sports load-bearing and shock

absorption of the underlay.

How is this market evolving in India? What are the demanddrivers?The last 10-15 years have witnessed

a complete paradigm shift. There has

been a dramatic increase in the number

of sports infrastructure projects, and

this is primarily due to the increased

awareness in the general population.

Unlike a few years ago, it is not

uncommon for every new residential

project, school, corporate campus,

large hotel or a facility to have at least

some basic sports infrastructure. One

of the key drivers is also that the sports

surfaces should ideally be maintenance-

free. In order to meet the high standards

set by international governing bodies

like the International Federation of

Association Football (FIFA) and

International Basketball Federation

(FIBA), plastics score high on this

factor. Overall, there is definitely an

evolving sports culture in the country,

but this definition does not include

cricket fans watching matches on their

television screens.

What are the safety and performance standards used to formulate plasticsfor sports applications?Different sports bodies have evolved

standards that define performance

& safety standards in sports surfaces,

irrespective of whether they are

natural or plastic based. Some examples

include American Society for Testing

and Materials (ASTM) in the US

and other European standards. These

parameters broadly measure various

performance aspects, eg, friction, shock

absorption, breaking strength, melting

temperature, human & environmental

hazards, etc.

Where do you see the scope for research and innovation in thecoming years? Tracing the path of polymer surfaces,

AstroTurf introduced this innovationf

almost 40 years ago. FieldTurf

continued to expand the application

portfolio almost 20 years ago. From

the perspective of sports, research

should focus on all other types of

sports that can benefit from the use of

plastics. Apart f rom maintenance

advantages, plastics considerably reduces

the use of natural resources involved

in sports (eg, reducing water consumption

for watering natural sports turf ).

Polymer surfaces can also be used

to convert any unutilised areas into

productive areas. Any reduction in

the cost is always welcome, and this

encourages widespread acceptance of

new innovations. From an environmental

perspective, utilisation of every discarded

plastic wrapper, cover, bag, bottle, etc,

can be recycled and used to create

new products.

…believes Anil Kumar, Managing Director, Great Sports Infra. Unlimited possibilities of plastics application in sports along with an increasing interest in sports in India have spurred investments in sports infrastructure. He elaborates on the evolving sports equipment market and the future scope of plastics use in various sports equipment in an interaction with Annabel Dsouza.

“There is an evolving sports culture in the

country”

INSIGHT & OUTLOOK: Mater ia l corner


Mandar Amrute

According to the history of

polymers, Poly(Methyl

Methacrylate) (PMMA)

is considered as one of

the oldest polymers, developed in

the late 1920s. Polycarbonate was

commercialised by General Electric

in 1950. Various other specialised

transparent materials were developed

later and, today, this process still

continues.

Polyamide - 12 is one such

transparent material discussed here

and, for simplicity, it will hereafter be

referred to as clear polyamide.

Polymers and propertiesMost transparent materials belong to

the amorphous family of thermoplastics.

Polymers can either be amorphous

or partially crystalline, depending on

their molecular structure and conditions

of formation of solid phase. A

polymer is considered semi-crystalline

when it develops a detectable crystalline

phase in its structure. Crystalline and

amorphous polymers are distinguished

by different properties, most evident of

which is light transmission: crystalline

polymers are opaque, whereas

amorphous polymers are transparent.

This thumb rule is applicable

in general, though there are exceptions,

eg, Polyethylene Terephthalate

(PET). Table 1 presents the key

properties of amorphous and semi-

crystalline materials.

Clear polyamideThe polyamide family offers various

mechanical properties. These properties

Several transparent engineering polymers are available in the market today, most of which fall in the amorphous family and offer desired characteristics for standard end-use applications. Polyamide-12–based transparent Nylon is one such material, which is more dynamic and offers many advantages over existing conventional transparent plastics for demanding applications. Here we explore some of the key properties of transparent Polyamide-12, its application, processing and advantages.

Table 1: Polymer properties and morphology relationship

Property Crystalline Amorphous

Light transmission High None to low

Solvent resistance High Low

Lubricity High Low

Dimensional stability High Low

Mould shrinkage High Low

Resistance to dynamic fatigue High Low

Facility to form high-strength fibres High None

Thermal expansion coefficient High Low

Melting temperature Sharp Absent

Dependence of properties on temperature High Low

Transparent polyamide with a clear advantage


are further enhanced in Polyamide

- 12/11, in terms of robustness

and excellent chemical resistance.

Capitalising on these properties, clear

polyamide was developed to offer

properties offered by the Polyamide -

12 family, with an additional benefit in

the form of transparency. Today, clear

polyamide is available in various forms,

some of which are semi-aromatic and

cycloaliphatic amorphous polyamide.

The second-generation (cycloaliphatic)

clear polyamide offers better

transparency over the first-generation

(semi-aromatic) clear polyamide.

Key properties of clear polyamide are

as follows:

1. Excellent flexibility, which provides

design of freedom

2. Outstanding optical properties and

transparency

3. Good chemical resistance

4. Good ultraviolet resistance

5. Excellent processability

6. Light in weight

7. Good mechanical properties

Table 2 presents general mechanical

and physical properties of clear

polyamide.

AdvantagesRazor sharp clarity: Clear polyamide

is more transparent than any general

glass and polycarbonate at any

thickness. This increases the possibility

of its varied applications where high

transparency is a critical criterion.

Ultra l ight-weight: When

compared with glass, clear polyamide

is definitely lighter; moreover, it is

the lightest transparent polymer.

It is lighter than polycarbonate by

approximately 20 per cent. This

helps in reducing the weight of

end product, faster processing and

energy savings.

Maximum flexibility: Clear

polyamide is the most flexible material

in the transparent materials family. This

property gives long-lasting endurance,

excellent shape recovery and vibration

dampening characteristics to the

end product.

Easy processing: Clear polyamide

has a broader processing window, which

makes its processing easier and reduces

probability of material degradation.

Its excellent thermal resistance

helps in processing even if the

material is left in the barrel at

280-290°C for 1-2 hour, and will

not get oxidised. Its improved flow

helps in processing, especially in the

packing stage. This reduces shrinkage

bubbles. Overall, faster processing

is achieved with a reduction in cycle

time of up to 20 per cent, as well as

energy savings.

Processing of clear polyamideClear polyamide is easy to process

on conventional polyamide injection

moulding machines as well as extrusion

and blow moulding machines.

Similar to most of the polyamide

family members, clear polyamide

must be pre-dried before using on

the machine. Generally, a sealed bag

can be used directly; however, if it

is open and remains open for more

than 2 hour, it should be vacuum

dried in a dehumidifier. The

recommended drying conditions are

70-90°C for 4-6 hour. Care must

be taken with purging for this material

before running it on the machine, since

if a barrel is not purged thoroughly,

the transparency of the end product

may be affected. Standard purging

compounds available in the market

can be used with High-Density

Polyethylene (HDPE).

ApplicationsClear polyamide is used in optical

lenses, sunglasses, safety lenses

and Three-Dimensional (3D)

glasses due to its excellent flexibility

and transparency. It is the preferred

choice of material for optical

fibre cable due to its anti-termite

property. Owing to its mechanical

properties and chemical resistance,

clear polyamide is used in diesel water

separators, air separation filters and

hydraulic filters. Also, due to its light

weight and excellent transparency,

it is used in many other industrial

applications, eg, electronic housing &

covers, consumer goods and automotive

applications.

Mandar Amrute is Market

Development Manager with

Arkema India Branch office.

Email: mandar.amrute@

arkema.com

Courtesy: Arkema & Biobased edge: Clear Polyamide is sold by Arkema under the brand name Rilsan Clear®. Arkema is a French Chemical Company offering products like vinyl compounds, industrial chemicals and specialty chemicals. Arkema is a leader in bio-based Polyamide - 11, with an experience of over 50 years.

Table 2: General mechanical and physical properties of clear polyamide

Standard Unit Clear polyamide

Density ISO R1183D g/cm3 0.99

HDT under the load of 0.45 MPa ISO 75 °C 125

Glass transition temperature ISO 11357 °C 145

Hardness ISO 868 Shore D 81

Water absorption at equilibrium ISO 62 % 1.1

AT 23°C and 50% RH

Charpy impact ISO 179 / 1eU

Unnotched at 23°C ISO 179 / 1eU kJ/m2 NB

Unnotched at -40°C ISO 179 / 1eU kJ/m2 NB

Tensile strength modulus ISO 527 MPa 1420

Flexural modulus ISO 178 MPa 1360

Mater ia l corner

INSIGHT & OUTLOOK: In ject ion zone


Y R Anand

Over the past decade, many

injection moulding and

general manufacturing shops

have rapidly increased in

their capacity and number of machines

on the shop-floor. To an extent, it is easy

to manually track machine performance,

material planning, maintenance schedule,

inventory management and many

other functions.

Beyond a point (eg, when number of

machines cross 20), this process becomes

more complex. Typically, most of these

shops will have several auxiliary items

like dryers, colouring devices and mould

temperature controllers. Often there will

be other processes also, eg, ultrasonic

welding, extrusion, blow moulding and

painting. All these require a complex

management system to produce parts in

the most cost-effective manner. Most

companies implement ERP systems to

manage an enterprise. As ERP systems

generally do not relate to actual machine

performance or behaviour, it is important

to seek solutions for managing complex

injection machine-oriented manufacturing

units to merge the two.

An online management system can be a

Manufacturing Execution System (MES).

Some of its critical objectives are:

Reduced machine stops (long &

short stops)

Reduced cycle time, increased speed

Reduced scrap by real-time quality

control

Optimised scheduling, machine and

mould maintenance

Improved decision support

Reduced human resource &

paperwork

Improved logistics

Management reports

Management solutions in real-timeThe major function of such a system

is to record machine behaviour directly

online and transfer the data to a central

database. This should allow manipulation

of data to satisfy various functions within

the company. It should provide a link to

the company-wide planning system for

direct information flow. Consequently,

a complete vertical integration – from

machines to material planning, purchasing

and sales – can be achieved seamlessly.

In today’s globalised world, production

is distributed, and it is almost essential to

have worldwide access to production data

from any site. There should be a central

management of part, mould and material

master data, with real-time production

planning (without waste) by online

acquisition of:

Order progress

Machine status

Process parameters

Alarms

Manual data entries could result in multiplet

errors. This is completely eliminated by

online data acquisition. Many injection

moulding machine manufacturers offer

their own systems to cater to these needs.

Such a system does not require additional

external hardware for collecting and

transferring data to a server. Another

advantage of using such systems from

a machine supplier is the ability to

optimise the production process through

a central server.

Performance monitoringin real time

With injection moulding shops adding machines, the need to monitor their performance has become increasingly important. The use of conventional methods like manual tracking and Kanban are slated to soon reach their limits. Thus, here are some other options that can be used for online performance tracking in real time.

Figure 1: Concept of a complete MESCourtesy: BarcoVision


But, manufacturers will face limitations

if multiple brands of machines are present

in a shop and also while integrating other

manufacturing machines to same systems.

Currently, several vendors can supply complete

solutions with external data collection modules

to integrate a complete injection machine-

oriented manufacturing plant.

Data managementFigure 1 shows a typical layout with

different types of plastics production

machines with data collection modules

and their routing to different aspects of

production management.

Through these programmes, a database

is built for the following elements:

Calendar (working days, shift times)

Products (technical data)

Moulds

Machine operators (direct personnel)

Machine data & production counters

Machine groups (work centres,

machine types)

Production orders

Stop cause reasons (table per machine type)

Reject causes (table per machine type)

Maintenance counter definitions

Such systems should generate real-time

information with a graphical overview of the

plant layout displayed. Each pictogram on

the screen represents a machine and contains

information concerning speed, production,

efficiency, etc. Exceptions have been colour

coded to attract instantly the users’ attention.

From the filter window, a specific filter set

can be selected, which will display only

machines that correspond with that filter,

eg, all stopped and slow-running machines.

A mouse click on a specific machine opens a

window with required details for the selected

machine. This window can be configured as

per user specifications and includes textual

& graphical information.

A typical system such as this offers

users a broad range of information:

Efficiency of machine, quality, cavity

efficiency, speed, cycle time

Overall Equipment Effectiveness

(OEE), Mean Time Between Failures

(MTBF), Mean Time To Repair

(MTTR) calculations

Run time and downtime analysis

(eg, Pareto Analysis)

Production counts

Reject or defect analysis

Automatically detected stop analysis

Manual stop declaration analysis

Problem machine detection

Maintenance status for mould & machine

Such systems can help schedule the shop-

floor with the following:

Real-time graphical plan board

Drag & drop to assign orders to

machines and re-schedule orders

Order splitting options

Automatic check for mould availability

and resolve conflicts

Planning machine & mould

maintenance

Calculation of required operators

Tool change forecast report with

machine mould conflict resolution

Support for family moulding

Support for frames & inserts

(Option)

They system should auto flag for:

Low efficiency

Stop time & number of stops

Remaining time (quantity) till job ends

For a good monitoring systemBesides machines and moulds, auxiliary

resources like robots, chillers, regrinders

and packers may be needed to make a

product. Thus, a good system must be able

to support management and scheduling of

these resources by availability and assign

resource needs per product or production

counters per resource & maintenance

counters. Generally, they will check

resource availability in real-time when

planning a job and should warn the

planner in case of possible problems. Such

systems must be able to communicate with

different types of ERP systems, which

will be running or planned for general

management.

More advanced systems can

incorporate quality systems and preventive

maintenance systems. Here, a system by a

machine manufacturer would offer greater

access to the machine control system.

Thus, organised moulding shops should

invest in a good MES to attain benefits

from their shop-floors, minimise scrap

and maximise efficiencies.

Y R Anand holds a bachelor’s

degree in Mechanical

Engineering from University

of Mysore and a master’s

degree in Production

Engineering from IIT, Kharagpur. He worked

for a little over 9 years in manufacturing

industries in Mumbai. Since 1980, he

has been a partner in UNIMARK. The

company sells and services machines in

plastics processing, tooling industry, micro-

electronics and wire mesh welding industry.


Figure 2: A typical server view Courtesy: BarcoVision

In ject ion zone

82 Modern Plastics & Polymers

The plastics compounding industry is facing an escalating need to supply

an ever wider variety of specialty products within the shortest possible

time. This results in an increasing demand for frequent formula changes

in masterbatches and additive mix manufacturing. Today’s compounding

plants focus on single polymer production in large volumes, and in a continuous

mode. With the growing need for variety, the demand for customised, rather

than universal masterbatches, has increased and given rise to higher degrees of

automation throughout the plastics supply chain. Sunil Chaudhari, President

& Chief Executive Officer, Zylog Plastalloys Pvt Ltd, says, “Improving the

process through automation helps an organisation perform better on customer

delivery reliability, productivity, machine utilisation and improvement of

machine uptime. This helps optimise manpower across the manufacturing

direct processes, thus minimising waste across processes such as non-

value-added activities, sequential process operations, time & motion study

of process, work in progress inventory, waiting time, over production

and defects.”

Role in compounding industryBesides increasing process efficiency and product consistency, automation

technology is empowering today’s plastics processor by bringing down labour

costs and utilities investment. Specialist compounding companies are faced with

increasing quality challenges, driven by users who issue tighter specifications.

New medical applications, high-end car coatings and bulletproof polycarbonates

are only a few examples of the high demands in specialty compounding. At the

same time, the quantity per process unit reduces. This presents a significant burden

Process optimisation for boosting efficiency

As the Indian plastic processing industry battles higher operating costs while delivering cutting-edge solutions, automation technology offers a wide range of benefits like reduced

material consumption and energy management. Annabel Dsouza takes a closer look at automation solutions that drive performance and profitability for the plastics industry.

82 Modern Plastics & Polymers 1111er 201

Courtesy: Siem

ens

ATION TRENDS:AUTOMA Technology index

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on a manually operated plant where the

human factor must be constantly managed

to minimise risk of errors. Increasing the

automation levels of existing machinery

enables instant changeover times of

operators by way of applying the Single

Minute Exchange of Dies (SMED). These

smart manufacturing methods, when

correctly applied, bring benefits that far

outweigh the apparent savings of manual

tasks or outsourcing operations.

In today’s dynamic and volatile

business environment, a company’s focus

has shifted from ‘quality’ to ‘competitive

quality’. With ever-changing customer

requirements, quality is no more a

competitive weapon and processors strive

to deliver top quality at competitive

pricing. What separates an organisation

from others is in how better it is from

its competitors. The need of the hour is

to constantly challenge the status quo to

improve the present performance. The

ultimate key to success in any business

enterprise is customer satisfaction. Business

process automation makes an organisation

successful in the long term, not only by

meeting customer expectations but also

by exceeding them, and hence beating

competition by increasing marketshare.

Chaudhari says, “Automation of

production processes helps the organisation

to minimise activities in terms of on-line

inspection, monitoring, proper utilisation

of resources, infrastructure, minimising

spillage, startup and process scrap,

improving process accuracy and product

quality. It enables plant utilisation by way

of addition of quality software to monitor

& control statistical process control,

measurement system analysis, effective

quality management system tools in place,

eg, Kaizen, continual improvements,

Poka-Yoke, lean manufacturing quality

tools/software, etc.”

Taking one step beyond process

automation, most players in the

compounding industry have automatic

material handling systems at the inbound

stage, whereas outbound logistical activities

are manual in the Indian scenario. Adding

material handling equipment improves

personnel productivity, housekeeping,

response time to customer and easier

handling of emergency activities in terms

of customer delivery reliability.

Material wastage reductionWith operating costs escalating globally,

waste reduction is another important

advantage of automation systems.

Following are some of the immediate

benefits of automation technology with

regard to waste minimisation in plastics

processing plants:

Overproduction: Mixing additives

in large quantities than ordered, as

cleaning is a challenge

Waiting: Operators and expensive

machinery standing idle, eg, due to

cleaning activity or awaiting quality

check analysis results

Inventory: Customer requirements

for rapid and next-day delivery

resulting in huge finished goods and

intermediate goods storage

Defects: Rework for human error or

pigment colour problems discovered

after value is added (extrusion)

Transporting: Additional transporting

to & from inventor storage and

between processes to meet variations

in client demands

Over processing: Technology

selected on worst case scenarios and

applied to the whole, as opposed to

applying sufficient technology for the

application

Motion: Unnecessary movement of

people and product between processes

due to poor process flow or additional

motion caused by poor plant layout

The actual and potential cost associated

with waste is enormous, leading to higher

prices and reduced profitability. Moving

the wasteful process to a low-cost practice

is not a long-term solution. Smarter

manufacturing without generating waste

is the key to sustainable profitability.

Indian automation standardsThe Indian plastics industry is highly

fragmented with large numbers of small-

scale manufacturers. Thus, the overall

automation standards in Indian processors

are at the first basic level as compared to

global standards followed in the plastics

industry. Hence, acceptability of high-end

automation solutions to increase profitability

depends on improving financial resource

capabilities and building awareness on lean

manufacturing. Chaudhari says, “Currently, a

high standard of automation is restricted to

medium- or large-scale industries, especially

with industries having joint ventures or

collaborations with multinational companies.

Implementation of automatic machinery is

on an accelerated pace with medium- and

large-scale processing industries.”

Continuing the success storyWith conscious efforts to keep pace with

global competition through a booming

export market, the automation story in

India is set to continue. International

competition and quality awareness, coupled

with customer involvement and increasing

supplier capabilities, will go a long way in

bringing automation solutions to Indian

shores. But, Chaudhari suggests, “The

need of the hour is that process automation

equipment manufacturers must provide low-

cost excellent automation solutions with

innovative ideas to Indian manufacturers

currently operating at competitive pricing

with thinner margins.”

Sunil ChaudhariPresident & Chief Executive Offi cer,Zylog Plastalloys Pvt Ltd

Process automation equipment manufacturers must provide low-cost excellent automation solutions with innovative ideas to Indian manufacturers currently operating at competitive pricing with thinner margins.

Technology index

ENERGY MANAGEMENT: Al l -e lectr ic machines


The cost of energy hascost of energy has

conventionally been between

4 and 5 per cent of the cost

of a moulding, but this is

increasing rapidly with rising energy

prices. To remain competitive, a business

must have an effective energy management

process. Thus, the focus is more on

energy efficiency, which has led to

popularisation of electric injection

moulding machines.

Earlier, hydraulic injection moulding

machines ruled the market, but with

the advancements in technology, various

new developments are now taking place.

Currently, all-electric machines are

making inroads into the Indian market,

with a 4-5 per cent share of total injection

moulding machinery sales. Their demand

is expected to increase in the near

future due to their energy efficiency,

greater cleanliness, quick start-up, better

repeatability and noiseless operations.

Hydraulic versus electric injectionHydraulic versumoulding machinesThe basic difference between the two is

the use of servo motors in electric injection

moulding machines as against the use of

pumps in hydraulic injection moulding

machines. Rohan Shrikant Shahane,

Regional Director - South East Asia,

Machine Point Consultants SL, says,

“Energy consumption in different injection

moulding machines depends on how the

drives are powered. The product type, size

and material can be a large contributor to

the difference in energy consumption. A

conventional hydraulic machine uses one

or more pumps as a central unit to drive

the machine. Two of the most wasteful

aspects of a hydraulic machine are the

architecture of the system and the wasted

pump power when there is no demand. In

contrast, all-electric machines reduce losses

by using high-speed servo motors to drive

injection moulding processes.” All-electric

injection moulding machines are said to

have the potential to reduce energy costs

for moulding by 30-60 per cent, depending

on the moulding and the machine.

The plus pointsAll-electric machines have several

advantages over hydraulic machines.

“The servo motor used in an electric

machine only drives the shaft required for

the moulding process, creating a direct

exchange of energy and ensuring less

energy consumption. Also, a substantial

reduction is seen in maintenance cost, as

the electric machine eliminates the need

for hydraulic oil, obviating the need to

store, dispose, maintain and cool the oil.

All-electric machines eliminate the need

for cooling the hydraulic system, besides

the associated equipment requirements

and energy use. A shorter product cycle

makes these more productive than the

hydraulic machines. All-electric machines

Rising energy prices is a crucial issue with the plastic processing industry. As a result, the need to monitor and reduce energy consumption has become more important than ever. This has given rise to new developments in the injection moulding industry, like all-electric injection moulding machines. Avani Jain analyses the effectiveness of these machines in achieving energy efficiency.

par excellence

Energyefficiency


produce less noise as it does not have

pumps. The plumbing piping to the

plant can be greatly reduced for new

construction. Moreover, these machines

are more precise and good for repetitive

operations,” notes Shahane.

All-electric machines allow machine

movements to be integrated directly with

the control system. This greatly improves

machine set-up, adjustment and process

control. These machines use less water,

and, depending on the product, water

consumption can be reduced by up to 65

per cent. Generally, all-electric machines

require less maintenance as compared to

hydraulic machines. Overall, all-electric

machines have a relatively lower risk of

failure and are easy to maintain than

conventional machines. Thus, all-electric

machines can significantly reduce energy

consumption and production cost for

many mouldings. These machines are used

in applications that require high precision,

eg, engineering and pharmaceutical

applications.

Demerits Despite the many advantages of all-

electric machines, these do have certain

disadvantages, which might hamper

their demand. Shahane observes, “The

market barrier of accepting all-electric

machines is the cost differential between

hydraulic and all-electric machines, which

is almost 40 per cent. However, of late,

this price has declined by 10-20 per cent.

Although all-electric injection mouldings

exhibit superior efficiency in the plastics

manufacturing process, these cannot be

used in applications that require high

speed and high clamping forces.”

Demand scenarioThe higher cost of electric injection

moulding machines than the conventional

hydraulic systems limits their usage. V

Ramesh, Chief Executive Officer, Negri

Bossi SACMI Engineering (India) Pvt

Ltd, says, “Of the total injection moulding

machinery market in India, electric

injection moulding machine constitutes

only a small percentage. As compared to

India, the demand for all-electric injection

moulding machine is high in other

countries like Japan where 90 per cent

of the machines are injection moulding

machines. As a result, the governments in

these countries have subsidised the price

of these machines for end-users.”

Adding to this, Shahane says, “In

India, people prefer to buy machines

that are less costly and bear the high

maintenance cost throughout the year.

Although the capital investment in

electric injection moulding machine

appear to be huge in the beginning, there

are no further costs involved with them.

Thus, despite being energy efficient, the

scope of these machines in the Indian

market seems limited at present.” he

continues, “But with the growth in auto,

medical and electric & electronic sectors,

the investment in all-electric machines

is expected to increase. This growth will

be fuelled by productivity improvement

initiatives due to manpower shortage, wage

inflation and higher power availability.”

New technologies for greater efficienciesWith the rising focus on energy

management, companies are looking

beyond electric injection moulding

machines. “For this purpose, new machines

like the Canbio VS series with electro-

hydraulic system comprising servo-driven

motor and variable displacement pump are

produced by Negri Bossi,” says Ramesh.

Through complete digital control, Canbio

VS provides high moulding accuracy and

improved repeatability of the moulded

parts. The use of digital variable

displacement pumps with integrated

electronic control of pressure and speed

permits higher energy savings.

“These machines are close to electric

injection moulding machines and can

save more energy & other costs. This

gives them an advantage over electric

injection moulding machines, which are

expensive and have certain limitations,”

details Ramesh. Thus, in future, energy

management concerns are expected to rise

further and machines with higher output

and lower power consumption per unit

will lure customers worldwide.

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

All-electric machines eliminate the need for cooling the hydraulic system, besides the associated equipment requirements and energy use. A shorter product cycle makes these more productive than the hydraulic machines.

V RameshChief Executive Offi cer, Negri Bossi SACMI Engineering (India) Pvt Ltd

As compared to India, the demand for all-electric injection moulding machine is high in other countries like Japan where 90 per cent of the machines are injection moulding machines.

Al l -e lectr ic machines

POLICIES & REGULATIONS: Polymer pr ic ing pol icy


Polymers constitute an integralpart of the plastics industry.Over the years, the market for plastic polymers has grown and

so have the numbers of players in thisarena. Demand for raw materials is onthe rise and producers have stood up tothe challenge.

Where we standBy 2012, India is projected to be the thirdlargest consumer market for plastics, withconsumption of 12.75 million Metric

Tonne (MT) per annum. Rajiv Arora, Vice President & Business Head - Shriram PolyTech, says, “Polymer consumption in India has historically grown at twice the Gross Domestic Product (GDP) rate. This growth is driven by all consuming segments such as automotive, housing, packaging and even agriculture.”

In addition to polymers, masterbatch consumption is projected to increase from182,000 MT (2010) to approximately 255,000 MT (2012). This growth can be attributed to the rise in competition,

both domestically and internationally, asmanufacturers now have access to globaltechnology and are aware of the changing demand patterns. This rise in productionand consumption has helped existing players to expand and new manufacturersto establish themselves.

Future avenuesPolymer manufacturers will strive toexhaust their present capacities withincreased demand. If the present trendcontinues, there is a possibility of importsas well, and this may result in higher prices. “Prices of masterbatches aredependent not only on polymer prices,but also on pigment prices, and these havebeen increasing steadily. However, withan increase in demand for masterbatches,there is a high probability of moremanufacturers jumping into the foray,”says Parag Parikh, Partner, UniversalColorant Company. This will result inan equilibrium price where the quantity demanded by consumers (at current price) will equal the quantity supplied by manufacturers (at current price). Overall,with the rise in consumption of plasticsin India, many new avenues will openfor manufacturers and an increase incompetition will only result in better quality of final products.

The Indian plastics industry is growing at the rate of 12-15 per cent per annumsince the last few years. With this growth,the demand for the raw material isgrowing simultaneously at the same rate.“At present, a manufacturer is well awareof the quality of his product, cleanliness

The growing consumption of plastics in India is putting a pressure on raw material supplies, thus increasing the possibility of raw material imports. This will, in turn, result in price hike of raw materials, which would trickle down to the end product. Anwesh Koley finds out how government could play a significant role by regulating price rise and helping companies maintain product quality.

equilibriumMaintaining cost-quality


of his production area as well as need for developing a new look for his end products,” adds Parikh.

People in India are improving with technological advancements and have access to international standards. But, this improvement happens at a higher pace for a company that exports than the one that manufactures and sells in India. The prices of masterbatches have seen an upward trend for the last few years due to soaring raw material prices and consolidation of international raw materialsuppliers. Sourcing quality raw material from consistent and reliable suppliers will be the key in the coming years.

Policy changes requiredThe polymer fraternity has been seeking government support on various issues. “We have requested the government to fix customs duty on polymers to a level equalto the customs duty imposed on inputs of major producers of crude & naphtha. This would force indigenous producers to maintain stable domestic prices and alsokeep the price levels in parallel with the international levels,” says Parikh.

As a result of continuous follow-up, the customs duty on polymer imports has been steadily reduced from the earlier highlevel of 25 per cent to the current level of 5 per cent. “Manufacturers seek elimination of this protection from the government; major producers do not need it, as they operate through world-class plants equipped with the latest technology,” says Bhatia.

What is in store for masterbatches?Along with conventional masterbatches,the future of additive masterbatch is equally bright. The development of highly productive machines has opened up new horizons for masterbatch application. Moreover, plastics is widely used as a first immediate replacement of metal, paper, etc. This has created a compulsion for development of new blends (composite plastics) for the plastics industry.

The market for masterbatches is showing robust growth, as there is sufficient supply and availability of materials. The next year will be challenging for polymer producers and the entire polymer market; further growth will happen as

many large-scale players are developing a number of capacities near their plants.New players, both domestic & international, will keep the selling pricescompetitive; hence, a challenging market scenario and reduction in margins is likely.The volume growth should help sustainmost players, but as in most industries,efficiency and innovation is and willbe required.

Looking forwardThe Indian plastics industry has a hugemarket potential and is gradually on itsway to prosperity. This potentiality of themarket has been constantly encouraging entrepreneurs to invest in this industry.Entrepreneurs are making all efforts toprovide high-quality plastic products,to make it a booming industry. Themasterbatch business in India is slated tobenefit the most from the rise in plasticsconsumption. Masterbatch, which is anadvanced polymer, forms 75-80 per cent of the raw materials used in the plasticsindustry, and hence will witness a parallelrise in demand as India becomes the thirdlargest consumer of plastics by 2012.

This is mainly because more andmore manufacturers are turning toadvanced polymers on account of enhanced consistency in the performanceand elimination of pollution problems.“Silicon masterbatches find applications inmanufacture of Polyethylene (PE) ductsfor optical fibres. This could generateadditional business of almost 1,500-2,000tonne per year. Growth of masterbatchesis also expected to be higher, as polymer manufacturers are resorting more tothe use of the masterbatch systeminstead of direct addition of additives,”believes Arora.

On the road to successThe growth in the plastics sector hasalways exceeded the GDP growth ratein the country and, with the increase indemand, manufacturers on global as wellas domestic levels need to increase their production capacities. However, as growthpropels production, new avenues to meet additional demand will surface. Hence,with adequate government support,there is huge scope for manufacturers togrow further

Rajiv AroraVice President & Business Head,Shriram PolyTech

Growth of masterbatches is also expected to be higher, as polymer manufacturers are resorting more to the use of the masterbatch system instead of direct addition of additives.

Parag ParikhPartner, Universal Colorant Company

Prices of masterbatches are dependent not only on polymer prices, but also on pigment prices, and these have been increasing steadily. However, with an increase in demand for masterbatches, there is a high probability of more manufacturers jumping into the foray.

Polymer pr ic ing pol icy

STRATEGY: Quant i fy ing qual i ty


M Hariharan

Organisations embark on myriad quality initiatives. Many of these initiatives have emerged from Japan

– 5S, Kaizen, Quality Circles, Total Quality Management (TQM), Total Productive Maintenance (TPM), etc – and a few from the West, Six Sigma being the most popular one. It is often observed that ideas of improvement are rejected by financial controllers, as no perceptible improvement is visible in the bottom line; moreover, some times, the bottom line declines after an initiative.

K Ramakrishna (adjunct Professor of SP Jain Institute Management and Research) – a renowned expert in Project Financing – has developed a modified version of DuPont chart. Using

this model as a base, and applying to it the principles of activity based costing, Savoir faire has created a model for quantifying the benefits of operations initiatives (quality initiatives or supply chain initiatives).

DuPont chartDuPont chart of ratios is a popular and useful model for measuring profitability performance (Figure 1). This chart was developed by Frank Donaldson Brown (1885-1965), a financial executive and corporate director with DuPont and General Motors.

This model is useful for analysing the performance on three parameters, viz, operating efficiency [Profit After Tax (PAT)/sales], efficiency of asset usage (sales/total assets) and efficiency of financial leverage (total assets/net worth). This is till date a popular

model, widely used and appropriate for understanding the overall performance of an enterprise. However, to further analyse the operations performance one needs to go into a micro level.

K Ramakrishna’s model The model deve loped by K Ramakrishna is a modified version of DuPont chart (Figure 2). This model differentiates between the areas under the control of finance and operations. This model is extended to develop a methodology to address key impact areas of operations.

Factors affecting the three operations ratioContribution/sales ratio: This is the popular profit-volume ratio and signifies the direct profitability of the product. Three factors impact this ratio, namely,

The theory of constraints is a generally followed concept today, where improvements everywhere may not necessarily lead to overall improvement. Most organisations have taken initiatives such as Six Sigma, 5S, single minute exchange of die, autonomous maintenance, cycle time reduction, single piece flow, milk run and cross docking, to ensure long-term profits. Here we take a look at some of the basic tenets of quantification of performance to maximise quality.

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change in variable cost per unit, change in selling price per unit and change in product mix. Any action taken by an operation that impacts these three factors will affect this ratio.

Profit Before Interest and Tax (PBIT)/contribution: This is the popular margin of safety and signifies two issues: (a) How safe is one's business? (b) How well is one utilising the fixed cost resource. Besides the three factors listed for the profit volume ratio, two more factors affect this ratio – change in fixed cost and change in sales volume. Any action taken by an operation that has an impact on these five factors will affect this ratio.

Sales/Capital Employed (CE): This is the popular asset turnover ratio, which signifies how well one’s assets (fixed assets and working capital) are utilised. Of the five factors that affect the margin of safety, three factors impact this ratio, eg, sales volume, sales mix and sales price. Apart from these three, one’s decision on fixed asset and change in working capital will affect this ratio. Any action taken by an operation that affects these five factors will impact this ratio.

Operations triggers of the bottom lineThe seven triggers of the three ratios can be grouped under sales, expenses and investment.

Sales triggers: Sales price, sales volume and sales mix are the three sales factors that trigger the bottom line.

Cost triggers: Change in variable cost and change in fixed cost will affect the bottom line. In other words, any process improvement that releases fixed cost capacity will not result in short-term cost reduction.

Investment triggers: Change in working capital and decision on fixed asset are the two triggers. Any action that releases the capacity of fixed assets will help hold over the investment to a later date.

Savoir faire model for quantification of operations and quality measuresNot all results of operations and quality will lead to cost reduction and asset reduction. It may result in reducing tomorrow’s cost and today’s investment. The Savoir faire model for quantification traces the actions of operations to these seven triggers of bottom line. This model uses an activity-based approach to understand the financial reaction of the actions. The model follows a four-stage approach:

Stage 1: Identifying the activities pre- and post-implementation of the initiative

Stage 2: Identifying the resources required pre- and post-implementation of the initiative

Stage 3: Comparing the resources required pre- and post-implementation of the initiative

Stage 4: Tracing the impact of changes to the seven triggers of bottom line

Stage 5: Quantification of benefits/costs of initiatives

Quantifying quality measures Initiatives cannot be justified simply based on intellectual satisfaction levels attained. Initiatives should help organisations improve their profitability for a sustained period. At the same time, one cannot expect the initiatives to derive benefits within only a few months. Hence, a model to quantify today’s costs and tomorrow’s benefit is critical for a sustainable initiative. Ultimately, for every action, there is a financial reaction.

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. Savoir Faire develops cost information systems to support pricing, outsourcing and control decisions using the cost excellence (CE©) model. Email: [email protected]

Quant i fy ing qual i ty

Goal of a business enterprise: Maximising investor’s wealth

Sales(-) Cost of sales (variable cost, fixed cost incl depreciation)= Profit before interest and tax(-) Long-term interest= Profit before tax(-) Taxation = Profit after tax (PAT)

Fixed asset+ Working capital= Capital employed

Net worth (ie, capital plus

reserves)+ Long-term debt= Capital employed

PAT

Sales

Total assets

Net worth

PAT

Net worth

Sales

Total assets

Figure 1: DuPont chart

Goal of a business enterprise: Maximising investor’s wealth

Sales(-) Variable cost = Contribution (-) Fixed cost incl depreciation = Profit Before Interest and Tax (PBIT) (-) Long-term interest = Profit Before Tax (PBT) (-) Taxation = Profit Before Tax (PAT)

PAT

NW

Figure 2: K Ramakrishna’s model

Finance

Operation

PAT

PBIT

PBT (1-T)

PBIT(1 + D/E)

PBIT

Capital employed

Contribution

Sales

PBIT

Contribution

Sales

Capital employed

CE

NW

X X

X

X

X X

TIPS & TRICKS: Extrusion techniques


Blown film extrusion is one of the most common methods of film manufacture. The process involves extrusion of a plastic material through a circular die, followed by ‘bubble-like’ expansion. The advantages of making films with this process are ability to produce flat & gusseted tubing in a single operation and regulating the width & thickness of film by regulating volume of air in the bubble and output of the extruder.

In the plastics industry, using the right technique to manufacture the desired end product is of prime importance. Plastic extrusion techniques have evolved with time and manufacturers are constantly figuring out ways to improve productivity and ensure seamless processing. Here are some tips on how to achieve quality products in an efficient way.

Effective methods for driving

profits

Anwesh Koley

Extrusion is the process o f fo rc ing mol ten plastics under pressure through a shaped die

to produce a product with a specific cross-section. This method is used to manufacture a wide range of plastic products and can be applied to shorter products cut to length, such as piping, or continuous

length products, such as plastic sheeting. Plastic extrusion can be highly automated, resulting in nearly continuous and consistent production, and the level of automation depends on the quality of equipment.

There are a number of ways to achieve consistent quality in extruded products:

Sheet extrusion method is used for making plastics sheets, where converts plastic pellets or powder are converted to plastic sheets by extrusion through a flat die. These sheets can then be made into rolls, cut into specific lengths or made directly into finished products via in-line thermoformers. The means of production is a sheet extrusion line.

Jacketing extrusion is the process of extruding plastics as a coating over another product, particularly wires. This requires plastics to be flexible and able to withstand current flow & temperature fluctuations. Plastic insulation can be extruded over a single conductor or a bundle of wires. Different materials can be used for this purpose depending on the application.

Screw extrusion is the technique of manufacturing most thermoplastics. Screw extruders involve single or multiple screws. Currently, twin-screw applications are also used, depending on temperature requirements. A drawback to most extrusion operations is that dimensional tolerances are relatively high, ranging up to 10 per cent of the workpiece.

The oldest form of extruder used was the ram extruder, which is still in vogue. In a ram extruder, instead of extrusion screw, a ram or plunger is used. This is used to produce profiles, sleeves, rod, block, tubing, lining sheet bars, etc. It is effective for specific materials like polytetrafluoroethylene, which cannot be extruded successfully by using a screw extruder.

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PROJECTS


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

Chlorinated Polyvinyl Chloride (CPVC) Lubrizol Corporation

Project typeNew facility

Project newsLubrizol Corporation has proposed

to set up a ` 1,175-crore Chlorinated

Polyvinyl Chloride (CPVC) industrial

unit in a joint venture at Dahej Gujarat

Industrial Development Corporation

(GIDC), Bharuch, Gujarat. The

construction of the unit will start in

January 2013 and the production by

October 2014. CPVC products have

great demand in South-East Asia,

Middle East and Africa. Considering

the investor-friendly and transparent

policies and best infrastructural facilities

in Gujarat, the company has chosen the

state for setting up this unit.

Project locationDahej, Gujarat

Project cost` 1,175 crore ($ 245 million)

Implementation stageProposed

Contact details:Aant PantLubrizol India Pvt Ltd9/3, Thane Belapur RoadTurbheNavi Mumbai-400705 Tel: 022-27672568-74Fax: 022-27632407Email: [email protected]

Polysilicon Punj Lloyd

Project typeNew contract

Project newsPunj Lloyd has bagged an Engineering,

Procurement and Construction (EPC)

contract to set up Qatar’s first plant

for manufacture of polysilicon, the raw

material used to build solar cells. The

contract has been awarded by Qatar Solar

Technologies (QSTec) and is scheduled

to be commissioned by mid-2013. The

EPC contract awarded to the Indian

conglomerate involves the establishment

of 4,000 tonnes per annum (TPA) of

polysilicon manufacturing capacity. The

total envisaged capacity of the plant is

8,000 TPA of high-purity solar grade

polysilicon at an investment of $ 1 billion.

The work under the contract involves

residual basic engineering & design,

detailed engineering, procurement,

supply, manufacturing, construction and

commissioning, among others.

Project locationRas Laffan Industrial City, Qatar

Project cost$ 1 billion approx

Implementation stagePlanning

Contact details:Punj Lloyd House17-18 Nehru PlaceNew Delhi - 110019Tel: +91 11 2646 6105Fax: +91 11 2642 7812Email: [email protected]

Composites Processing Carbures


Project newsSpain-based Carbures plans to invest

$ 6.5 million to build a composites

manufacturing plant in Greenville,

USA. The company selected the

location in part due to its proximity

to potential customers like Lockheed,

Boeing, Proterra and BMW. Processes

will include hand layup, resin transfer

moulding and automated tape layup.

Construction of the facility will begin

shortly, and Carbures plans to have the

facility online in the second quarter of

2012. It will employ 50 people.

Project locationGreenville, USA

Project cost$ 6.5 million (€ 4.9 million)


Contact details:Carbures USA 5, Hercules WayDonaldson Center AirportGreenvilleSouth Carolina-29605 Tel: (+1) 864 593 3934Email: [email protected]

Plastic additivesBASF


Project newsBASF has broken ground on a

previously announced multi-million

dollar plastic additives facility at the

Bahrain International Investment Park,

with production of Customer Specific

Antioxidant Blends (CSB) to start in 2012.

The company said that the investment

was spurred by a supply agreement with

Astra Polymer, the Damman, Saudi

Arabia based supplier of masterbatch,

additives, and compounds, as well as the

opportunities presented by the countries

of the Gulf Cooperation Council (GCC),

which represent one of the fastest growing

sectors of polyolefin production worldwide.

The new operation will become one

of the world’s largest CSB plants

with an annual capacity of about

16,000 metric tonne.

Project locationBahrain

Project costNot known


Contact details:Reinhold LutzBASF BahrainP.O. Box 18696Al Seef, BahrainTel: +973 - 17585251 Fax: +973 - 17583400

EVENT LIST


POLY INDIA 2011This international exhibition and conference

will highlight the use of advanced plastics

& polymers in automobile, aviation,

telecommunication and other emerging

areas; November 9-11, 2011; at Hyderabad

International Trade Expositions Ltd

(HITEX), Hyderabad

For details contact:

Manoj Mehta

FICCI

Federation House, Tansen Marg

New Delhi - 110001

Tel: 011 23738760-70, Fax: 011 23320714,

23721504, Mob: 09891098772


Website: www.ficci.com

CONVEXPOThis exhibition will showcase the latest

plastic films, packaging & printing

machinery, tapes/plastic pallets,

warehousing equipment, bag making

machinery, material handling equipment,

etc; November 23-27, 2011; at University

Grounds, Ahmedabad


B Swaminathan

Smart Expos

T-6, Agarwal Court - K G Plaza

41-44, General Patters Road, Chennai

Tel: 044 28603086, Fax: 044 28604261

Mob: 09789095247


Website: www.smartexpos.in

Industrial Automation-India The event will bring latest trends and

technology in automation, energy and

power transmission closer to the Indian

traders; December 6-9, 2011; at Bangalore

International Exhibition Centre,

Bengaluru


Hannover Milano Fairs India Pvt ltd

603/604, Samarpan Complex, New Link

Road, Chakala, Next to Mirador Hotel

Andheri (E), Mumabi - 400 099

Tel: 022 4005 0681-82

Fax: 022 4005 0683


Website: www.hmf-india.com

Plastindia 2012This is the premier exhibition of the Indian

plastics industry. It will once again prove to

be a strategic meeting point for all large

and small players from the global arena;

February 1-6, 2012; at Pragati Maidan,

New Delhi


Plastindia Foundation

401, Landmark B, Suren Road,

Off Andheri Kurla Road,

Andheri (East), Mumbai - 400093

Tel: 022 26832911, Fax: 022 26845861


Website: www.plastindia.org

Intelpack 2012This exhibition will showcase various

technology and converting applications for

the future of plastics packaging. Visitors

will find innovations & solutions to make

their business more efficient and profitable;

February 23-25, 2012; at Bombay Exhibition

Centre, Mumbai


113, New Sonal Link Industrial Estate

Building No 2, Link Road

Malad (W)

Mumbai - 400 064

Tel: 022 28803977/28803978

Fax: 022 28819008


Website: www.intelexpo.com

Indian Medical Devices Conference 2011This event will focus on the growing range

of applications and oppotunities in the

Indian medical manufacturing industry;

March 23-24, 2012; at Ahmedabad

Management Association (AMA)

Complex, Ahmedabad


D L Pandya

Classic Computer Services

B-4, Mandir Apt

Opp P & T Colony

Jodhpur Char Rasta, Satellite Road

Ahmedabad - 380 015

Tel: 079 26740611

Fax: 079 26754867

Mob: 09825457563

E-mail: [email protected] / dlpandya gmail.com

Website: www.imdiconferences.com

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,

Infomedia 18 Ltd, Ruby House, 1st Floor, J K Sawant Marg, Dadar (W), Mumbai 400 028. Tel: 022 3003 4651 • Fax: 022 3003 4499 • Email: [email protected] • Web: www.engg-expo.com

PuneMaharashtra

Nov 18-21, 2011Auto Cluster Exhibition Centre,

Pimpri-Chinchwad

IndoreMadhya Pradesh

Jan 6-9, 2012Poddar Plaza, Nr Gandhi Hall

ChennaiTamil Nadu

Dec 8-11, 2011Chennai Trade Centre,

Nandambakkam

AurangabadMaharashtra

Feb 17-20, 2012Garware Stadium, Chik-

kalthana

EVENT LIST


IPCC 2012The International Paint, Coatings and

Chemicals Exhibition has a special

significance since the Middle East is

the world’s fastest growing chemicals

and petrochemicals market. The region’s

booming construction sector is renewing

the demand for raw materials and

propelling business for the processing

industries; Decermber 28-31, 2011;

at Tehran Permanent Fairground,

Tehran, Iran


Banian Omid Company

Apt.7, 4th floor, No 2212, Near Park Saie Gas

Station, Vali-e-Asr Avenue, Tehran, Iran

Tel: +98 (21) 88720005-7

Fax: +98 (21) 88710252

Email: nfo@ ipcc.ir/[email protected]

Website: www.ipcc.ir

Polyester and PET Chain 2012The 16th annual polyester world congress

brings together industry leaders from around

the world to focus on the new technology,

product and application directions needed

to sustain growth and maintain profitability

as markets recover worldwide; February 14-

16, 2012; at Swissôtel, Zurich, Switzerland


Nicole Morris

MBS Polymer Events

A unit of Chemical Business Media

110 William Street, 11th Floor

New York, NY 10038

Tel: 1-212-621-4978, Fax: 1-212-621-4970


Website: www.mbspolymer.com

Plastica 2012This is a biennial exhibition that aims at

presenting the new developments, trends

and technologies in plastics and rubber

processing. Raw materials, petrochemicals,

polymers, resins, mixtures, special chemicals,

additives, masterbatches, semi-finished and

finished polymers, processing machines,

moulds, ancillary equipment, etc will be

exhitbited; February 17-20, 2012; at Athens

Metropolitan Expo, Athens, Greece


3EK Organization of Exhibitions

L. Pentelis 28 152, 35 Vrilissia, Hellas, Greece

Tel: +30 (210) 8056205/207/208

Fax: +30 (210) 8056209


Website: www.plastica-expo.gr

JEC Europe 2012JEC is a composite industry organisation

dedicated to developing products and

services for its customers and for the

composite industry. This conference will

address the booming composites market’s

requirements of raw materials and

automation solutions. It will be a meeting

ground for the scientific community, R&D

professionals across Europe; March 27-29,

2012; at Porte de Versailles, Paris, France


Guillaume Vouioux

Journals and Exhibitions

25 boulevard de l’Amiral Bruix

Paris-75116, France

Tel: +33 1 58 36 15 07, Fax: +33 1 58 36 15 19

Website: www.jeccomposites.com

Chinaplas 2012This edition of Chinaplas will continue the

legacy of bringing solutions to the global

plastics industry while highlighting the

opportunities within Asia. The exhibition

will showcase the most innovative and

advanced plastics and rubber machinery

and raw materials in the coming future;

April 18-21, 2012; at Shanghai New

International Expo Centre, PR China


Lillian Tse

Adsale Exhibition Services Limited

6th Floor, 321 Java Road

North Point, Hong Kong

Tel: (852) 2516 3374, Fax: (852) 2516 5024


Website: www.chinaplasonline.com

Plastivision Arabia 2012While serving as an international platform

for the Indian plastics industry, this

exhibition will facilitate business prospects

for all major global players in the region.

This event will promote opportunities and

provide exposure to manufacturers of raw

material & machinery, auxiliary equipment,

pigments & additives, dies & moulds, etc;

May 14-17, 2012; at Expo Centre Sharjah,

United Arab Emirates


AIPMA House

A-52, Street No. 1, MIDC Marol,

Andheri (E)

Mumbai - 400 093

Tel: +91 22 28217324 / 25, 28352511

Fax +91 22 28216390

Email [email protected]

Website: www.plastivisionarabia.org

Argenplás 2012While focussing on the latest in plastics

technology and value-added innovations,

this event will serve myriad business interests

through a highly qualified segmented

audience of OEMs and distributors. It will

be a good opportunity to ideate and network

with the best minds in the region’s polymer

industry; June 18-22, 2012; at Centro Costa

Salguero, Buenos Aires, Argentina


Emma Fiorentino

Argentine Chamber of the Plastics Industry

J Salguero 1939

Buenos Aires

1425, Argentina

Tel: 54-11-4821-9603

Fax: 54-11-4826-5480


Website: www.argenplas.com.ar

International

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

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



Swapnil Pillai

Western India is the

WWsecond-largest consumer WWgoods market after the WWnorthern market. VariousWWdevelopmental policies and initiatives

have resulted in the emergence of Pune

as a preferred choice for manufacturing

companies to establish their base in the

region. The proximity to Nhava Sheva

port and the presence of huge supplier

base are some of the key investment

drivers for this region. The bustling

industrial hub of Pimpri-Chinchwad has

seen many MNCs setting up their base

here to leverage on the Small & Medium

Enterprise (SME) advantage.

Pune occupies an important place

in production as well as export of

cutting-edge engineering solutions.

Satish Joshi, Director, Micro Supreme

Auto Industries (I) Pvt Ltd, says,

“Pune offers good transportation and

logistics support, and has comparatively

less union troubles. These factors have

resulted in the creation of a positive

environment, suitable for high growth

rate and capital investment.” As per

the latest figures released by the Auto

Component Manufacturers Association

(ACMA), Pune has 53 large companies

with a collective turnover of $ 1,400

million, and exports worth $ 235 million.

Additionally, there are about 7,000 auto

ancillary units in and around Pune.

Gateway to exuberant opportunitiesThe industrial hub of Pune is gearing up to witness the mélange of latest technologies and innovative products at the highly awaited engineering congregation, Engineering Expo Pune. To be held from November 18-21, 2011, at Auto Cluster Exhibition Centre, Pimpri, the event will reinforce itself as a leading platform for companies to reach out to the target audience and display their manufacturing prowess. It will also enable the business fraternity to collaborate with companies and find right partners and solutions.

PUNENov 18-21, 2011Auto Cluster Exhibition Centre

225+ Exhibitors

15,000+ Expected visitors

15,000+ Products on display

Spread over more than

45,000 sq ft

Expected business worth more than

` 55 crore

ENGINEERING EXPO PUNE STATS


According to S J Gijare, General

Manager - Handling Equipment

Division, CTR Manufacturing Industries

Ltd, “Pune was home to many ‘start-

up’ SMEs in the 1960s and 1970s,

with hi-tech products that met the

requirements of defence establishments

and some large private companies.

The last decade has witnessed a high

growth in the SME sector with thousands

of such units coming up and

adopting latest manufacturing and

management techniques.”

Engineering Expo Pune, being

organised by Infomedia 18 Ltd, is a

testimony to the rising significance of

Pune in the Indian industrial landscape.

Milan Supanekar, Proprietor, Welding

Technologies India, observes, “Pune is

a preferred manufacturing destination

for automobile as well as engineering

companies. This has a favourable impact on

the development of the SME sector here.

Thus, the business environment for SMEs

is favourable.”

Leveraging the legacyEngineering Expo enjoys wide media

coverage and leaves no stone unturned

in consistently meeting the expectations

of both exhibitors & visitors alike. The

previous edition of the event generated

business worth ` 47 crore and more than`6,038 business leads. This has reinforced

the faith of exhibitors in the event, which

is evident from the fact that this year’s

edition was fully booked two months

in advance. Referring to the event as a

gateway to Pune’s industrial opportunity,

Prasanna Kulkarni, Business Manager -

Industrial Air, Atlas Copco (India) Ltd,

says, “Engineering Expo provides an

excellent platform to interact and touch

base with the customers. It enables us

to not only showcase our products but

also provide live demonstrations. This

interactive forum provides companies a

chance to display their products and discuss

the latest happenings in the industry.

Western region is one of the important

markets and companies will utilise the

Engineering Expo as a platform to create

a brand that comes first in the mind

of the customer and is synonymous

with quality.”

Elaborating further on the crucial role

played by Engineering Expo in enhancing

business prospects, Prashant Wani,

Proprietor, Shende Sales Corporation,

states, “The Expo has carved a niche for

itself among professionals, and thereby

attracts quality visitors. This enables us to

reach a wide base of customers and generate

high amount of business.” S Chandra

Sekar, Senior Manager - Western Region,

S & T Engineers (P) Ltd, feels that the

event enables exhibitors to forge new

relations with decision makers from the

SME sector and corporate houses, who

are regular visitors at the event. “It helps

us to connect with our existing customers

as well as meet prospective clients, besides

showcasing our new range of products. It

gives us the opportunity to identify and

interact with decision makers from various

big & small companies,” he adds.

More in storeThe sixth edition of the event aims at

empowering the visitors with latest

technology. Companies can use this Expo

to reinstall customers’ confidence and

loyalty in the brand & take advantage of

new opportunities. As Engineering Expo

Pune continues its success saga, an ebullient

Sandeep Khosla, Chief Executive Officer

- Publishing, Infomedia 18 Ltd, puts this

in perspective, “Engineering Expo has

come a long way today by becoming one of

India’s largest multi-location (other places

include Ahmedabad, Chennai, Indore,

Rudrapur and Aurangabad) SME meeting

points. Over the years, it has successfully

achieved its goal of being a preferred

destination for SMEs and manufacturing

& engineering companies to connect,

transact and leverage ideas to foster growth

of individual organisations as well

as that of the industry at large. As

we look forward with further value-

additions for even better experience and

reach to the target audience, we welcome

large, medium & small industries

in the manufacturing and servicing sector

to be a part of the Expo in this

exciting journey.”

Gijare, who feels that Engineering

Expo plays a vital role in bridging the

gap between business stakeholders,

says, “The event enables manufacturers

and traders from Maharashtra

and other states to showcase their

products and services, thereby gaining

brand recognition & additional customers.

Also, many visitors to these exhibitions,

particularly in the SME segment,

have gained appropriate knowledge

and solutions to meet their specific

requirements.”

With the Indian industry poised

to maintain the high growth

momentum in the coming years,

expectations are high about an upbeat

investment environment in Pune. This

spells excellent business opportunities for

the manufacturing sector to scale new

heights, and Engineering Expo Pune would

act as a catalyst towards this end.

Engineer ing Expo Pune 2011

EVENT REPORT: Engineer ing Expo Rudrapur 2011


Arindam Ghosh

New-age realities spring some

unwritten guiding principles.

In the boundaryless market

reality, it is critical for

companies to establish a strong base

in the local markets. This guiding

principle take a different dimension

when multinational corporations have

to establish a local connect and client

base while keeping their gaze fixed on

the global trend. To combat such critical

needs, many skillfully crafted ‘meet your

customers’ or ‘showcase your innovations’

platforms are created. But when it is a

veteran brand like Engineering Expo

and an opportune location like Rudrapur,

the scope and extent of such platforms

multiply manifold.

The latest edition of the Engineering

Expo, an established trade show brand

of Infomedia 18 Ltd, turned out to be

a huge success in terms of its quest

towards bringing out the message to the

entire Indian manufacturing fraternity

of a new and emerging manufacturing

hub – Rudrapur – located in the state of

Uttarakhand.

With the aim of highlighting India’s

new manufacturing hub situated in

the northern belt, it indeed helped the

fraternity to come together and created

a conducive business environment for

manufacturers to network, showcase and

build brands & business, all under one

enabling roof. Vikas G Patil, Incharge –

Customer Care, Ratnaparkhi Electronics

India, one of the exhibitors at the event,

substantiated this fact. “We have been

participating in Engineering Expo since

the past 4-5 years and we are grateful

that Infomedia 18 Ltd. has given us this

opportunity to participate and display our

machines at Engineering Expo Rudrapur.

Engineering Expo takes place in areas

where new industries are coming up

and I hope that Infomedia 18 Ltd keeps

searching for new & lucrative places so

that we can also reach there and showcase

our machines,” he added.

The inaugural function of the Expo

saw the attendance of Chief Guest Tilak

Raj Behar, MLA, Rudrapur; along with

the Guest of Honour, Darbara Singh,

President, Kumaun Garhwal Chamber

of Commerce and Industry (KGCCI) –

Uttarakhand; Meena Sharma, Chairman,

Rudrapur Municipality; and Anil Sharma,

Lawyer; in the presence of Sudhanva

Jategaonkar, Associate Vice President,

Infomedia 18 Ltd. The guests highlighted

the need to tap the potential of this region

and offer a fillip to the industries here by

providing them a conducive networking

environment and state-of-the-art products

& services. “Rudrapur has been emerging

as an industrial destination for companies,

and Uttarakhand is garnering benefits

from this growth. I am sure that events

such as Engineering Expo will further

substantiate the importance of Rudrapur

as a major industrial hub. The expanse

of products & technologies on display at

the event will offer a whole new gamut

Optimising the northern advantageThe ‘Think Global… Act Local’ anthem got another anecdote. With major multinational manufacturing and general engineering companies participating in & visiting the maiden edition of Engineering Expo Rudrapur, this northern stronghold got a befitting partner. With many promises delivered and many made, the Expo concluded with a promise to come back next year with more offerings and opportunities for the participating & visiting companies.

RUDRAPURSept 23-26, 2011Gandhi Park

Engineer ing Expo Rudrapur 2011


of opportunities for existing companies

as well as pave the way for the growth

of prospective companies in the region,”

Behar pointed out.

Rudrapur shining The latest edition of Engineering Expo

turned out to be an eye opener of sorts.

It highlighted the potential that new

manufacturer-f riendly regions like

Rudrapur in northern India have to offer

to manufacturers. Elaborating further on

the same, Singh opined, “There are many

reasons why big manufacturing companies

are setting up their plants in Rudrapur.

Apart from the fact that the region is

highly adaptable, the state government is

supportive and offers manufacturers a slew

of industry-friendly policies. Companies

wanting to set up base here can have

access to skilled manpower and resources.

In addition, proximity to Delhi is one of

the biggest advantages that this region

offers investors.”

Commenting from the organiser’s

perspective on the choice of a new

location for organising Engineering

Expo, Jategaonkar explained, “Going by

the customers’ feedback, we selected Rudrapur

as our next destination. We are committed

to work closely with the Government of

Uttarakhand in furthering industrial growth of

the state and that is the intent of

launching the Rudrapur edition of

Engineering Expo.”

Setting up manufacturing facilities in

the Tier II and Tier III cities is the new

mantra for all big manufacturing companies

in India. Cities like Pune, Nagpur and

Indore are slowly and steadily finding space

in the investment and expansion plans of

the big companies as they provide easy

access to land, labour & logistics expertise,

strategic geographical locations, etc.

Led by manufacturing biggies, Rudrapur

is fast emerging as a leading investment

destination in the northern belt of

the country.

Exhibitors positive on thenew editionHeld during September 23-26, 2011,

Engineering Expo Rudrapur boasted

of profuse industry participation from

diversified manufacturing spaces, which

included machine tools & accessories,

process machinery and equipment,

material handling equipment, hydraulics

& pneumatics, automation and

instrumentation, electrical & electronics,

light and medium engineering, safety &

security, packaging machinery, etc, from

all over the country. Substantiating this,

Patil stated, “The business generated

has been quite good. A lot of potential

customers had visited our stall. Based on

the enquiries I received, if things work

out, about 30-40 per cent of my business

will come from Rudrapur.”

On how he plans to cash in on the

lucrative opportunities that Rudrapur

offers, T N Gopinath, Director – Technical

& Marketing, Suyog Rubber India, one

of the exhibitors at the event, explained,

“There are a number of auto companies

as well as engineering companies in

Rudrapur. We are located in Haridwar, as

we are suppliers to Mahindra, who are our

primary customers in Uttarakhand. Having

said that we would like to develop business

in Rudrapur, as it offers a potentially

bigger business opportunity in comparison

to Hardwar.”

Highlighting the healthy relationship,

which Infomedia 18 Ltd shares with

the exhibitors, Arun Nene, Manager

– Channel Support, Jyoti CNC

Automation, one of the exhibitors at

the event, averred, “Our relationship

with Infomedia 18 has brought us

to Rudrapur.”

Responding to the question as to

whether Engineering Expo Rudrapur

fulfilled its promises, Michael A Martyr,

Sr General Manager, Trident Precision

International, said, “The event has

certainly exceeded my expectations. I see

a huge potential in Rudrapur.”

Satisfied visitorsThe responses from visitors were quite

encouraging as well. They highlighted

that such events should be organised

more often in future. “The expo was

highly informative. More events like

these should be organised here,” opined

Joginder Singh, Managing Partner,

J K Industries, and further added, “The event

met my expectations, and it has been able

to meet some of my business requirements

as well.”

Another visitor, Papu Prasad Sharma,

Manager – Electrical, Teracom, averred,

“The event was well organised and the

product spread was good.”

Commenting on the potential that

events like Engineering Expo hold,

Martyr said, “Such exhibitions provide

food for thought and opportunities to

learn besides offering the opportunity to

become a service provider to companies

looking out for vendors or suppliers.

I find a lot of potential in expos such

as this.”

Taking a step ahead and carrying

this growth momentum forward,

the next edition of the Engineering

Expo will be organised in Ahmedabad

this month.

223 Exhibitors

5,260 Visitors

15,000+ Products displayed

` 11.25 crore Business generated

1,25,000 sq ft Exhibition area

77,000 kg Machinery moved

50 Cities participated

ENGINEERING EXPO RUDRAPUR AT A GLANCE

118 Modern Plastics & Polymers

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PRODUCTS


This section provides information about the national and international products available in the market

Extruders

Steer Engineering offers Mega series co-rotating twin-screw extruders

that offer complete interchangeability of parts and high levels of

compatibility with other extruder lines. The processing challenges

are met by an optimal energy-saving screw geometry, appropriate

use of special materials and specific treatments, a robust gearbox,

modern drive systems and state-of-the-art automation. All of these

are supported by user-friendly configuration management software.

These extruders feature cycloidal spline profile with shafts, which

are proof-tested at 125 per cent rated torque. Major applications

are in fibre-grade polyesters, polyethylene masterbatches, polymer

blends automotive compounds, short fibre-reinforced thermoplastic

compounds and in many other specialised applications. The twin-

screw extruders are available in laboratory, pilot-plant and production

models in various sizes, capable of outputs in excess of several

thousand kilograms per hour.

Steer Engineering Pvt Ltd

Bengaluru - Karnataka

Tel: 080-2372 3309, Fax: 080-2372 3307


Injection moulding machinesAllied Solutions

offers injection

moulding machines

that are available in

a wide range of 25-

1,600 T clamping

force. The injection and clamping force are controlled by linear

transducer. These have a five-point toggle clamping system. The

variable piston pump system enables 35-45 per cent energy savings.

It comes with hydraulic motor and high torque control and low

speed with six-stage injection speed and pressure control and

four-stage holding pressure. The injection moulding machines are

available with melt decompression, bi-metallic screw and barrels.

The hydraulic components are sourced from Vickers, Rexroth,

Yuken and Tokmias.

Allied Solutions India Pvt Ltd

Mumbai - Maharashtra

Tel: 022-4221 0100

Fax: 022-2557 6234


Plastic raw materialsAVI Additives offers

various plastic raw

materials. Necessary

inf rastructure and

equipment are provided

to come up with suitable

compounding solutions for

the plastic and polymers

industry. Other products

consists of: plastic masterbatches, plastic compounds, calcium-

filled polypropylene, tale-filled polyethylene, colour masterbatch,

fluroscent masterbatch, afterglow masterbatch, performance additives,

engineering compounds, flame retardants and alloy.

AVI Additives Pvt Ltd

Hyderabad - Andhra Pradesh

Tel: 40-2355 0551/ 2/ 3


GranulatorsYudo Hot Runner

India offers an efficient

range of granulators

for different types

of materials and

products. The capacity

starts from 20 kg/h to

400 kg/h with low and

high speed of crushing.

These granulators are

available with various

options like titanium-

coated blade, strong

2-axis crushing blades. These are easy to move with a handle, easy to

check blade through transparent window with CE certified controller.

The granulators are compact in size and have elegant design. These

are also easy to adjust the size of particles by changing a screen,

crushed pieces of size 4-10 mm.

Yudo Hot Runner India Pvt Ltd

Thane -Maharashtra

Tel: 0250-245 1155 / 56

Fax: 0250-245 1158


PRODUCTS


Hopper dryersShini Plastics Technologies

(India) offers Euro hopper dryers

(SHD-U series) that adopt hot

air down-blowing design and use

stainless steel material hoppers

to avoid contamination. With

this design, these can be used

with honeycomb dehumidifiers

to dry engineering plastics. The

capacities range from 20-8,000

litre with air-tight material

cleaning doors. Features of these

dryers include: innovative design with sleek appearance; hot air

down-blowing pipe to ensure even distribution of hot air to

maintain a steady temperature in the hopper & increase drying

efficiency; all air & material contact surfaces are made from stainless

steel; microprocessor used for accurate temperature control; double

overheat protection ensure reliable operation; provided with digital

PID temperature control with LED display; and equipped with main

power switch & control switch.

Shini Plastics Technologies (India) Pvt Ltd


Tel: 0250-302 1125/36, Fax: 0250-302 1100


PRODUCTS


Rotomoulding machinesN A Corporation offers Rock-

N-Roll model rotomoulding

machines that are used to

produce the smaller to large size

hollow products of capacity up to

40,000 litre. These machines are

made from heavy mild steel and

tripodal supporting structure with

all required accessories. Heavy-

duty gearboxes are provided for

suitable drives. The machines are

provided with AC variable motors for smooth working of major and

minor axis. Features include: easy & comfortable machine operating

function through digital control & display panel; operator can easily

adjust the burners for effective flame control & low consumption

of fuel; gas burner's constructions are robust & simple; trouble-free

working; and flexibility to convert from gas-fired to diesel oil-fired

system. The moulding processes are fully visual to the operator so

the monitoring of the products during process leads lesser chances of

product rejection.

N A Corporation

Ahmedabad - Gujarat

Tel: 079-2584 0374/1821, Fax: 079-2584 0809


Reclosable packing productsSVP Packing Industry

offers series of flexible

reclosable packing

products and solutions

that are tailor-made

as per customers'

requirements. The

product range consists of PP & PE ziplock bags, PP & PE zipper

profiles, PP & PE slider bags and biodegradable ziplock bags. Various

salient features of special low sealing temperature zippers are that

these are manufactured from advanced polyolefin/specialty polymers;

seal with laminates at a very low temperature; increase machine speed

by 20 per cent; reduce wrinkles on films due to low temperature

requirement; avoid delamination as temperature required is very low;

and have good bonding between zipper and laminates. The latest

development is soft seal zipper. It crushes at a very low temperature

and pressure. Soft seal zipper does not leave gaps or pins-holes on

side sealing pouches and is good for hydroscopic material, pharma

products, etc.

SVP Packing Industry Pvt Ltd


Tel: 022-2494 5116 / 17 / 6635 1516 / 17

Fax: 022-2494 5118


PRODUCTS


PVC pipe threading machinesVikrant Special Machines offers

PVC pipe threading machines

(model WPD2E & WPD4E)

complete with tangential diehead

and chaser holders, motors and

DOL starter. These machines

are used for cutting external

thread on PVC pipes by chasing

method. HSS Tangential chasers

are used as cutters. BSP, Metric, BSPT, NPT, BSW, threads can be

cut on this machine depending on the type of chasers. The PVC

pipe threading machines are designed to give maximum efficiency

and reliable performance under the most severe conditions of service

with minimum maintenance cost. These machines range from ½" to

2.0" and 2½" to 4.0" and are highly suitable & productive machines.

This further ensures high durability and effective performance

due to which these are high on demand in the national and

international market.

Vikrant Special Machines Pvt Ltd

Kolkata - West Bengal

Tel: 033-2551 3070

Fax: 033-2337 7053

Mob: 98307 06056


PRODUCTS


Injection moulding machinesMultiplas Enginery Co

offers injection moulding

machines for a wide range

of applications. The vertical

injection V-series of injection

moulding machines feature

up/down clamping for easy

insertion and enhanced safety,

while allowing for wider

operation area on four sides

of the machine. Lead frame

device can be equipped to

make insert moulding process

automatic. Multi-mould

option can be selected to improve productivity, for quality control and

efficiency, while the vertical structure of the machine and its flexible

arrangement of wires and pipes allow easy assembly, disassembly and

maintenance. The injection moulding machines occupy less floor

space. The 2/3-colour process saves time and improves efficiency.

Multiplas Enginery Co, Ltd

Gueishan - Taiwan

Tel: 886-3-3180090

Fax: 886-3-3974598


Liquid-ring vacuum pumpsAcmevac Sales offers liquid

ring vacuum pumps that find

applications in vacuum distillation,

drying, concentration, degassing,

crystallisation, gas evacuation,

gas conveying & compression,

etc, in chemicals, drugs, food,

beverage, sugar, fertiliser, paper,

metallurgy and allied process

industries. These vacuum pumps

are available in both single and double stage with capacities ranging

from 10 CFM to 4000 CFM and ultimate vacuum up to 720 mm

Hg. The sophistically designed pumps are silent in operation with

the result that the silencer is totally eliminated. Mechanical shaft

seal design ensures adequate protection to the expensive shaft and

provides ease of maintenance. This leads to minimal time required

for servicing, thereby cutting down time to the barest minimum.

The liquid ring vacuum pumps are rugged in design, reliable in

performance and easy to maintain.

Acmevac Sales Pvt Ltd


Tel: 022-2837 5837

Fax: 022-2836 4977, Mob: 092233 88105


PRODUCTS


Grain effect masterbatchesNew Partic le

Chemical Colors

Corp offers grain

effect masterbatches

that have colourful

flow patterns based on

differences in melting

temperature between

masterbatches and

plastic resins. These

masterbatches are applicable for ABS, PP, PS, HIPS, PE, PMMA

materials. There is no need to change the injection or extrusion

machines as these can be processed as normal with temperature

and pressure setting control. Also offered are standard colours and

customised formula for clients.

New Particle Chemical Colors Corp

Taoyuan County - Taiwan

Tel: +886-2-8209 4051

Fax: +886-2-8209 4053


Injection moulding machinesNeejtech India offers world-class all-electric

horizontal injection moulding machines from

Niigata Machine Techno Co Ltd, Japan. These

injection moulding machines are available in the

range of 50-1,000 tonne and vertical IMM in the

range of 30-150 tonne. Shot size (PS) is in the

range of 20-4,550 g. These all-electric machines are

generally known as green machines because these

save more than 60 per cent power consumption

than similar size Hydraulic/toggle machines. The

machines are absolutely free from oil and therefore

do not create pollution. Due to no oil use the

machines reduce maintenance and repair costs of

hydraulic system. These machines ensure enhanced

accuracy and reliability, and also provide great

cost-savings and contribute to the environmental

preservation. The injection moulding machines

are ideally suitable for medical, automotive,

pharmaceutical, healthcare and packaging moulding

segments of the industry. These machines run silent

and without vibrations. These are precise as there is

no deviation through oil viscosity, compressibility,

through drifting hydraulic valve action time. By

switching over from hydraulic to electric injection

moulding machines, one can save greater cost on

power consumption, cooling water consumption,

hydraulic oil elimination, as well as housekeeping

and maintenance cost. This will increase uptime

and decrease material wastage.

Neejtech India

Ahmedabad - Gujarat

Tel: 079-2656 1312, Mob: 098250 40231


PRODUCTS


PVC clear colour filmsAll India Plastics

manufactures and

offers PVC clear

colour films in

thickness ranging

from 50 micron to

100 micron. These

films are available

in various colours,

like blue, green, orange, red, yellow, etc. The PVC clear colour films

find applications in Polaroid glasses, 3D glasses, top covers for

halogen lights, etc.

All India Plastics

Mumbai - Maharastra

Tel: 022-2342 8096

Fax: 022-2344 8151


Humidity & temperature transmittersKatlax Enterprises offers

RH and temperature

transmitters that are

available with X’Bee

wireless connectivity.

These instruments

use ASIC chip as an

RH & temperature

measurement devices.

X’bee is a low-cost,

low-power, wireless

mesh network standard.

The low cost allows

the technology to be widely deployed in wireless control and

monitoring applications. The instruments have an accuracy of

0.6 per cent for temperature and 3 per cent for RH. Range of the

devices is 0-100 per cent RH and 0-100°C. These units have a local

7-segment display and transmit 0-10 V DC/4-

20 mA. They can control two temperature (lower & higher)

and two humidity (%RH lower & higher) setpoints.

The units are available with various supply voltage options, ie,

230 V AC/12 V DC/24 V DC, etc. These have a range of

up to 50-60 metre indoor and 1 km for outdoor application. The

humidity and temperature transmitters are widely used in cleanroom

application.

Katlax Enterprises Pvt Ltd

Gandhinagar - Gujarat

Tel: 02764-286 784

Fax: 02764–286 793

Mob: 097245 06614


PRODUCTS


Quick mould change systemsMadhu Machines & Systems offers

electromagnetic quick mould change

(QMC) systems from EMT, Hong

Kong, for injection moulding machines.

These QMC systems can be supplied

for machines up to 3000-tonne

capacity. Major areas of applications

are in the following: automotive,

motorcycles, home appliances, electrical & electronics, packaging,

consumer products, etc. Important features of the electromagnetic

plate of QMC are: most efficient QMC to replace conventional

hydraulic clamp; compatible with any machine & considerable mould;

easy installation & setup for minimum machine downtime; permanent

magnetic force: powerful, reliable & safety; uniform & flexible; and

clean & power saving. QMC can be easily interfaced with main

machine control and supplied for various special applications, like

side loading & oversize mould, rotating system, large moulds for

automotive, etc. The QMC systems help processors to introduce

automation in mould change operation and increase mould-up time,

while ensuring safety of operation and operators.

Madhu Machines & Systems Pvt Ltd

Vadodara - Gujarat

Tel: 0265-235 3886/232 1104, Fax: 0265-233 4278


PRODUCTS


Colour marking machinesAeromec Marketing Co offers

rotary automatic hot colour (hot

embossing) sequential colour

marking machines that are

designed to mark in colour in

all types of polyethylene pipes,

rigid PVC pipes and sections

during extrusion process. These

machines require power only for

heating. Model AMC-210 can

mark from 10 mm to 315 mm

outside diameter of pipes. The

marking is done at every one

metre on the pipes/sections by

using pantorgraphed brass/SS stereos fixed on the heater body.

Stereos are heated by using electronic percentage differential circuit,

which adjusts the temperature. The machines are designed to colour-

mark by adjust using a coloured polyester tape placed between the

stereos and the pipes/sections to be marked. Option of periodical

marking can be given with special electronic equipment and an

apparatus with pneumatic working. Periodical marking can be set

up to three digits. Other models available are: automatic sequential

counter with 3- or 4-digits and up to 7-digit coder (hand-operated)

colour marking machines.

Aeromec Marketing Co Pvt Ltd

Thane - Maharashtra

Tel: 0250 245 4915 / 3896, Fax: 0250-245 5579


Gripper systemsNeejtech India offers world-class gripper

systems from Gimatic SPA, Italy. Gimatic

manufactures pneumatic components for

plastics and handling like grippers, rotary

actuators, linear actuators and pick-&-

place for many industries. Dynamism,

flexibility and fast reaction time are all

factors that distinguish our company.

The company regularly produces and implements innovative ideas

of which it is rightly proud. All Gimatic products are covered with

patents. Some of the features include: specifically developed profiles,

high flexibility at a reasonable price, each point of the part is attainable,

ready-to-use as per design, more than 200 patented products,

customised applications, dynamic & flexible, etc. The grippers are

used in robots as end arm in industries, eg, automotive, packaging,

medical, etc.

Neejtech India

Ahmedabad - Gujarat

Tel: 079-2656 1312, Mob: 098250 40231


PRODUCTS


Crystallising systemsWith the increased use of PET in plastic

processing, the efficient use of amorphous

regrind material is critical. A Conair

crystallising system allows one to convert

amorphous PET to a crystalline state

that then can be dried. The drying can

occur at elevated temperatures to obtain

low moisture levels without the fear

of agglomeration. The Conair crystallising

systems consist of a high-temperature

heat source, an insulated hopper

with an agitator and a rotary discharge

valve. These can be easily integrated

with other material handling

equipment. Salient features include: continuous, automatic

operation; configuration to meet users' needs; agitating

hopper prevents agglomeration; and safe design, convenient

clean out, etc.

Nu-Vu Conair Pvt Ltd

Ahmedabad - Gujarat

Tel: 079-3298 5993, 2584 1181

Fax: 09377483203 / 204 / 205

Mob: 093767 83206


PRODUCTS


Additive masterbatchesBlend Colours offers various kinds of additive

masterbatches that have desired properties for

end users. Their additive masterbatch range

includes: UV stabiliser, antistatic, conductive,

slip, anti-block, Polymer Processing Aid (PPA),

dessicant, flame-reardant, purging compound,

antimicrobial, anti-oxidants and foaming agents.

Blend Colours Pvt Ltd

Hyderabad - Andhra Pradesh

Tel: 040 -2436 1499/ 2436 0887

Fax: 040-2436 0894

Bag making machinesPlas Alliance offers

PL42BFWFA-V+SL4 roll-

to-roll bag making machines.

The Garbag bag on the roll

machines (BFWFA-V+SL

series) combines full automatic production to multi-tracks roll.

There is no need to wait or to manually operate to change roller. The

BFWFA-V+SL series bag making machines can supply side slitting

seal to get multi-tracks roll to roll at the same time and good output

condition. These machines use the heavy-duty unwind up to 1,000

mm diameter bobbin. The bag making machines take less space, cost

less and have many more advantages.

Plas Alliance Ltd

Chia-Yi Hsien - Taiwan

Tel: +886-5-221 7005, Fax: +886-5-221 1929


PVC pipe extrusion unitsMalik Engineers offer rigid Polyvinyl

chloride (PVC) pipe extrusion units

for producing pipes for water supply,

irrigation and electrical conduits. The

unit includes a single-screw extruder

fitted with die for PVC pipe, vacuum

tank fitted with sizer, water tank, caterpiller take-off, motorised cutting

device and seperate control panel for complete machine. The extruder is

fitted with nitrided and hard chrome-plated screw & barrel set, DC main

drive, gearbox, pulleys, heaters, die, etc. In operation, the PVC dry blend

compound is fed into the extruder, where it is heated, melted and forced

out of the annular die in the form of hot hollow pipe. This passes through

vacuum sizing chamber for proper size as per the OD of pipe desired,

and then through the water tank where the pipe is cooled. The pipe thus

produced is passed through caterpiller unit, which maintains the pipe

straight as it passes through the line, and finally through the cutter where

desired lengths are cut. The control panel is fitted with controls for the

DC motors of extruder, caterpiller and precision electronic solid state

controllers for accurate control of the process temperature and safety

devices.These machines are manufactured in screw sizes of 40 mm, 45

mm, 50 mm, 65 mm, 75 mm and 90 mm.

Malik Engineers

Thane - Maharashtra

Tel: 0250-239 0839, Fax: 022-2883 0751


Gravure proofing machinesGraphic (India) offers JM Heaford’s

SCOF gravure proofing machine. The

open fronted design ensures fast cylinder

loading for greater productivity, with

additional space around the cylinder for

ease of operation. The moving rail and

fixed drum design helps consistently print high quality, in register, proofs.

The low open fronted rail with load platform and easy lift system ensures

that smaller cylinders can be loaded by hand and the design of the load

platform and register camera position allows for larger cylinder loading by

crane. Processing times vary by user, but it can handle up to 10 cylinders

per hour including one substrate change. It incorporates a larger drum,

which gives longer proof length and the higher proofing speed improves

ink transfer from fine cells. A range of smaller detailed modifications

such as addition of a quick change doctor blade, have also been made.

The machines are used by both printing companies and cylinder

engraving service houses for checking cylinder quality, separations, text

and register, producing production quality proofs for customer approval,

in-house development work and staff training purposes.

Graphic (India)


Tel: 022-2261 3151/ 6147, Fax: 022-2262 5300


Cartridge heatersPratik Heat Products offers cartridge

heaters. The heating conductor grade

NiCr 80:20 is uniformly wound over the

supporting core that is located centrally

in a SS-304 tube and the inner space

is packed with particularly chosen high-purity magnesium oxide.

The unit is compressed, thereby converting the core, powder and

conductor into a homogenous mass. The base of the heater is welded

with a disc washer to avoid contamination. These products are used

in marking & sealing machinery, medical & laboratory apparatus, hot

runner bushings, packaging industry and shoe making industry. These

cartridge heaters are CE certified.

Pratik Heat Products Pvt Ltd


Tel: 022-2920 0183

Fax: 022-2925 4309

Mob: 09004388444


PRODUCTS


Lab extrudersNeoplast Engineering offers fully

instrumented single-screw &

twin-screw laboratory extruders with integrated

data acquisition PLC. This machine can be

attached to various downstream equipment for

carrying out a variety of tests like extrudability

of polymers, studying the problems occurring in R&D as well as in

practical applications. It is provided with manifold screws, die heads and

downstream equipment to fulfil all kinds of extrusion tasks. The sample

material is plastified under practice-oriented conditions and extruded

through die-head. All measuring values such as torque, melt pressure,

and melt temperature are recorded continuously and represented in

the form of tables & graphs parallel to the running test. The extruder

frame is mounted on four caster wheels with level screw arrangement

for fixing it rigidly on the floor. The main motor with AC variable

frequency drive and detachable keyboard are fitted with this extruder.

For attaching various tools, the barrel flange is provided with hinge-type

arrangement for its quick opening, dismantling and screw cleaning. Since

the maximum output is just 5 kg/hr, it prevents wastage of expensive

material under testing. The maximum processing temperature is up to

40°C, which can be controlled by auto tune-type and dual-display PID

temperature controllers.

Neoplast Engineering Pvt Ltd

Ahmedabad - Gujarat

Tel: 079-2583 0602/1185, Fax: 079-2583 5298


CodersProcess Instrumentation and Controls

offers 'Sparsh' coder. It is used to print

various statutory information like batch

number, date of manufacturing, expiry date,

prices and any other information on various

packing like tins, container, cartons, lids, stickers, laminated flexible

pouches & films, metal containers, etc. It is a small compact intermittent

motion reciprocating contact coder with an ink cartridge enclosed in a

sealed container to give a constant amount of PIC fast drying coding

ink. It is specially used for high-speed coding application viz self-

sticker labelling and multi-tracking line, FFS, blister pack and strip

pack machine. Its compact design makes it easy to install where space

is limited. It can be mounted in any angle, vertical, horizontal or side

mounting. Due to separate ink cartridge, it avoids film contamination

and keeps the printing area clean. It is a versatile controller, which consist

of in-built cyclic timer and five different input modules to achieve or

optimise printing speeds up to 180-200 impressions per minute with

easy operation. It also runs through external inputs.

Process Instrumentation & Controls

Vadodara - Gujarat

Tel: 0265-235 7228, 232 0756, Fax: 0265-235 5429


PRODUCTS


Desiccant dryersAtlas Copco Compressor Sales offers

energy-efficient 'CDX 120-1050' desiccant

dryers. Features include low pressure drop

and almost negligible power consumption.

Reliable performance of the dryers is

achieved by massive desiccant overfill, wide

desiccant chambers, low air speed design

and proper selection of the desiccant. Wide

desiccant vessels and optimised flow have

reduced the pressure drop to as little as 0.25 bar for smaller dryers.

Routine maintenance has been made fast, clean and as simple as

possible. Changing the desiccant takes just a few minutes, as the

it can be removed and replaced without disconnecting the dryer

from the compressor. Standard pressure dew point performance is

-40ºC (with activated alumina as desiccant), for more demanding

applications -70ºC pressure dew point is available as an option (with

molecular sieves). Each dryer of the 'CDX 120-1050' range can

operate in 4-16 bar working pressure. Each dryer is also suitable for

both G and NPT connection.

Atlas Copco Compressor Sales

Pune - Maharashtra

Tel: 020-3985 2316, 3985 2318, Fax: 020-2714 5948


Laser displacement sensorsBanner Engineering offers triangulation

laser displacement sensors for non-

contact height or thickness measurement

of a wide variety of materials such as

sheetmetal, wood, ceramic, paper,

plastic, rubber, foam and baking

dough. These sensors provide precise measurement of distance,

web thickness and alignment. Applications include hot parts,

machined parts, semiconductors & PCBs, shiny or reflective

parts and soft or sticky parts. There are three models in the

series, with measurement ranges of 25-35 mm, 60-100 mm and

100-200 mm. Thickness is measured by two sensors mounted

at either side of the target that automatically synchronise with

one another. Up to 32 sensors can be easily combined in a mixed

measurement network of multi-track displacement or thickness

sensors. The dedicated software application included with each

sensor allows easy set up, configuration and software accommodates

data logging and monitoring for statistical process control. Output

communication is via simultaneous 4-20 mA (16 bit D/A) and RS-

485 serial connection.

Banner Engineering India Pvt Ltd

Pune - Maharashtra

Tel: 020-6640 5624, Fax: 020-6640 5623,

Mob: 93223 39208


Dispensing systemsAM Spa offers ‘Servo-Flo® 801-HV’VV

positive-displacement, two-component

meter-mix dispensing system manufactured

by Sealant Equipment & Engineering. It is

designed to apply small precision beads

and small metered shots of precisely mixed

resins and provides longer bead lengths

and/or an increased quantity of metered

shots. The servo-motor design provides

consistent and repeatable bead profiles

and a change of flow rate during the

dispense cycle. The fixed-ratio design improves production rates,

product quality and reduces manufacturing costs in micro-dispensing

applications. This dispensing system is designed to provide a variety

of preset material-dispensing profiles and dispense results ranging

from 0.2 cc to 18 cc at 1:1 ratio. It can dispense precisely mixed

materials for different part configurations in batch or random

processes. It can be preset to vary the flow rate during dispensing in

automated, indexing, XYZ-motion and robotic processes. The control

accepts operator preset material profiles or electronic commands from

the automation.

AM Spa


Tel: 022-2648 9074, Mob: 98339 32265


GearboxesZambello riduttori Group offers

gearboxes for electric injection

moulding machines. Its MNP3

is upgraded series from MHP3,

which is mainly shorter than the

bell connected with motor, and

becomes more compact overall. In

addition, the new MNP3 series

gearboxes are equipped with

new cooling plate system up to

size MNP3-280. The innovative

cooling plate solution is entirely

made of aluminium and provided

with internal channels used for

water circulation. The plate is fitted directly to the cast-iron housing

of the gearbox, which offers excellent efficiency and long life. In

order to provide a complete solution for customers, the company also

supplies the high-performance motor made by Oemer SpA.

Zambello riduttori Group

Milan - Italy

Tel: +39-0331-307 616

Fax: +39-0331-309 577


PRODUCTS



Injection moulding machinesJon Wai Machinery Work offers

Centre Force extra large-size toggle-

type injection moulding machine.

This CF-series fits a centre force and

external-acting five-point double toggle

clamping to give long efficiency and

reliable movement. These machines

with large inner tie-rod distance and

thickened platen can minimise toggle

pressure, lower deformation and increase structure rigidity and

reliability. To optimise the production need, the CF-series is used for

different types of material and different design of screws. The CF-

series are used in automotives, housewares, electronics, appliances and

furniture, for any specific demand on production machinery.

Jon Wai Machinery Work Co Ltd

Kunshan - Taiwan

Tel: +86-512 5766 6123-7,

Fax: +86-512 5793 2889


TPE foaming materialsMicrocell Composite

Company (MCC)

offers TPE foaming

materials. These are

comfortable to touch,

with conforming

physical characteristics

and do not involve

vulcanisation, which

results in excellent flexibility and anti-spreading. These contain

electro-insulation compounds and have excellent durability for

better acid & alkali resistance. These foaming materials are

non-toxic, odourless and harmless to the environment and

human body. These meet international environmental standards

as well. The wastes generates are completely recyclable and

reusable. These can meet individual demands for customers

with their adjustable materials. These find usage in shoes,

sports equipment, semiconductors, building construction, toys,

medical treatment, stereos and products of anti-percussion in

the information industry.

Microcell Composite Company

Tainan County - Taiwan

Tel: +886-6-264 1352, Fax: +886-6-249 1692


Blow moulding machinesChen Way Machinery Co offers

the ABL series blow moulding

machines. These are particularly

used for producing Jerry can/

drum tank/large articles. These

machines can be combined with

some accessory equipment to

increase the efficiency and expand functions, such as after cooling

unit/auto deflashing unit. The die head can stock the melting resin

and purge the material for blowing, and its design includes two-

heart flow channels. This can make welding line-free to increase the

strength of production. The tie bar-less clamping unit consists of the

stiff structure frame and guiding devices that ensure deflection-free

advantage. Also, the device with precision rack gear of both sides

enables synchronised movement of plates. The blow pin unit is

designed for production calibrating that will be suited for different

demand of customers.

Chen Way Machinery Co Ltd

Tainan Hsien - Taiwan

Tel: +886-6-243-4077

Fax: +886-6-243-4071


Servo driven robotsShini Plastics Technologies’ ST3

series are specially designed robots for

small manufacturing plants. These can

quickly and accurately remove finished

products from the mould and place in

desired location, and can be equipped

with special jig for plug-in module assignments. It is suitable for large

hot runner mould users. Based on the stoke of the arms, there are three

models (STM1-900-1600DT, STM1-1100-1800DT, STM1-1300-

2000DT) available for use with plastic injection moulding machine

200T, 300T, 450T and under 650T. The series has European style

streamline, beam, crosswise and vertical arms. It uses servo motor, and

with high-precision steel wire belts, cooperates with linear guides to

achieve maximum stretching and faster running. Sucker and gripper

work with gear rack and gear wheel, which are cylinder driven. External

oleo-strut and proximity switch are present in the limit position of the

arms that remove products, which has accuracy limit & sucker with a

protection device. Customers can adjust the parameters according to

their needs. Electrical support uses the enable move design, and is easy

to install and maintain. The machine has an intelligent controller and

is man-machine interface friendly, easy to operate, has self-diagnostic

function as well as triggers alarm for trouble and its cause.

Shini Plastics Technologies (Dongguan) Inc

Taipei - Taiwan

Tel: +86-769-8111 6600, Fax: +86-769-8111 6611


LIST OF PRODUCT


1 AC motor .....................................r 37

2 Additive.............................................55

3 Additive masterbatch ......10, 132,COC

4 Air bubble sheet plant ......................t 91

5 Air treatment system ........................77

6 Air-conditioner part......................t FGF

7 Ammonia liquid chiller.....................r 29

8 Auto dosing and mixing system .......43

9 Automotive gripper...........................r 45

10 Auto vacuum loader..........................r 43

11 Automatic leak testing machine .......93

12 Auxiliary equipment..........................22

13 Axial flow fan..................................131

14 Bag making machine ...................132

15 Barrel..............................................BIC

16 Barrel screw.....................................w 123

17 BBL/KEC flame proof motor ..........r 37

18 Bed knife...........................................73

19 Biodegradable additive......................55

20 Biodegradable masterbatch ..........COC

21 Black masterbatch ............10, 55, COC

22 Blender..................................... 25, FIC

23 Blending unit ................................t FGF

24 Blow moulding machine ............93,136

25 Blower & fan ..................................131

26 Blown film extrusion system ........... BC

27 Boiler...............................................r 121

28 Brake motor ......................................r 37

29 Brine chiller ....................................r 125

30 Bulk milk cooler ...............................r 29

31 Butterfly valve ...................................29

32 Calorifer .....................................r 121

33 Cartridge heater ..............................r 132

34 Cast film line ....................................91

35 Central material conveying system ...43

36 Centrifugal air blower.....................r 131

37 Circular weaving loom ......................48

38 Circular weaving machine .................14

39 Clean room application.....................31

40 Cleaning oven ................................BIC

41 Cluster facia ..................................FGF

42 CNC vertical machining centre ........81

43 Coder ..............................................r 133

44 Colour additive .................................55

45 Colour marking machine ................130

46 Colour masterbatch......10,33,55, COC

47 Compound ........................................55

48 Compressed air dryer......................r 107

49 Compressed air system .......................8

50 Compressor .................................r 8, 131

51 Compressor air chiller................r 18,143

52 Conductive compound .....................coc

53 Conical twin-screw extruder.............r 53

54 Connector .....................................r FGF

55 Continuous screen changer............r BIC

56 Conveying blower ...........................r 131

57 Coolant pipe .....................................87

58 Cooling pad ....................................121

59 Cooling tower ...........................r 77, 121

60 Counter & power supply ....................y 7

61 CPVC pipe .................................12; 19

62 Crane duty motor .............................r 37

63 Crusher .............................................r 43

64 Crystalliser ......................................r 107

65 Crystallising system ........................131

66 Cutting and stitching machine .........14

67 Dairy machinery...........................y 29

68 DC motor .........................................r 37

69 Dehumidified air dryer .................r FGF

70 Dehumidified dryer............ FIC, 39, 43

71 Desiccant dryer ...............................r 134

72 Digital panel meter ...........................r 16

Sl No Product Pg No Sl No Product Pg No Sl 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 4684 or fax us at +91-22-3003 4499

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

LIST OF PRODUCT


73 Digital temperature controller ..........r 97

74 Dispensing system ..........................134

75 Door trim ......................................FGF

76 Double shaft gearbox ................99, 124

77 Drive .................................................97

78 Drymax air-hot dryer.....................FIC

79 Drymax dryer.................................r FIC

80 Drymax pet-dehumidified dryer....r FIC

81 Dual channel with modbus...............97

82 Dust collector system ......................131

83 Dyestuff.............................................ff 34

84 Dynamic controller ...........................r 97

85 Electric injection moulding machine 9

86 Electric solution ................................89

87 Encoder...............................................r 7

88 Exhibition -

Engineering Expo ............... 83,105,112

89 Exhibition - Imtex Forming 2012..104

90 Exhibition - Poly India 2011 ..........144

91 Extruder ..........................................r 122

92 Extruder machine .......................23, 35

93 Extrusion ......................................... BC

94 Extrusion coating lamination plant ..t 91

95 Extrusion coating line ......................14

96 Extrusion machinery.........................y 69

97 Extrusion pump ..............................135

98 Extrusion system ............................. BC

99 Feeding & conveying system ........107

100 Filler compound................................55

101 Finger gripper ...................................r 45

102 Flame retardant.................................t 55

103 Flame retardant masterbatch ............10

104 Flange mounting b5/b35 motor .......37

105 Fluid..................................................26

106 Fluorescent........................................t 34

107 Fuel burner......................................r 131

108 Fully automatic strapping plant ........t 91

109 Gear.................................r 26, 99, 124

110 Gear motor ...........................r 26, 62, 65

111 Gear pump..............................135,BIC

112 Gearbox.................. 26, 62, 99, 124,134

113 Geared & flexible coupling...............g 26

114 Geared motor....................................r 37

115 Grain effect masterbatch ................127

116 Granulator.......................r 107,122, FIC

117 Gravure proofing machine ..............132

118 Gripper system..........................45, 130

119 Head lamp & tail lamp ..............FGF

120 Heart valve frame .............................27

121 Heat transfer roll ...........................BIC

122 Helical gearbox .................................65

123 Helical inline geared motor/reducer... 62

124 Helical speed reducer................r 99, 124

125 High cavitation .................................31

126 High-performance screw ...............w BIC

127 High-pressure reciprocating

air-compressors ...............................129

128 High-speed mixer ...............r 23, 35, 125

129 HM/HDPE/IDPE/IIDPE ..............91

130 Hopper dryer .............................r 43,123

131 Hot air dryer...........................r 39, FGF

132 Humidity & temperature

transmitter.......................................r 128

133 IML technique ............................. 31

134 Industrial automation ........................85

135 Industrial control & sensing device ....7

136 Industrial cooler ................................r 77

137 Industrial cooling system ................125

138 Injection and blow

moulding machine .....................18,143

139 Injection mould...............................123

140 Injection moulding machine

..17,71, 95, 121,122,126,127,133,136, FGF

141 Injection moulding-general .....123, 126

142 Injection

moulding - multi-component .........t 123

143 Injection moulding - vertical ..........123

144 Inline drip irrigation plant..............t 128

145 Inline drip tubing........................g 12, 19

146 Inline shaft mounted

helical geared motor..........................r 62

147 Intuitive display-revolutionary

user interface .....................................57

148 Invertor/variable frequency drive ........7

149 Jumbo blown film plant ................t 48

150 Knob & switch ..........................FGF

151 Lab extruder................................r 133

152 Lamination plant for tarpaulin .........48

153 Laser displacement sensor ..............r 134

154 Level controller ...................................r 7

155 Liquid ring vacuum pump......126, 131

156 Loader............................................r FIC

157 M a n u a l & h y d r a u l i c

screen changer...........................r BIC

158 Masterbatch ................................10, 55

159 Masterbatch feeder ...........................r 43

160 Material dryer ...................................r 25

161 Measuring & monitoring

relay for 1ph/3ph ................................7

162 Medical mould ..................................31

163 Metal detector & separator.............r 113

164 Mould sweat protector...............r 18,143

165 Mould temperature controller...........r 39

166 Moulding ..........................................g 31

167 Mono and multilayer sheet line ........14

168 Monofilament line ............................14

169 Monofilament plant .........................48

170 Monolayer blown film .................12,19

171 Monolayer blown film line ............. BC

172 Motion control....................................7

173 Motor................................................r 37

174 Mould .........................................23, 35

175 Mould changing system ..................127

176 Mould clamp .....................................22

177 MTC ..............................................FIC

178 Multi-component mould ..................31

179 Multilayer blown film ..................12,19

180 Multilayer blown film line ........ 14, BC

181 Multilayer blown film plant..............t 91

182 Multilayer co-extrusion

sheet line ...................................75, 141

183 Multistage centrifugal air blower....r 131

184 Multi-station ...................................123

185 NPE 2012 .................................... 20

186 Oil/coolant cooler .......................r 125

187 Oil/gas firing equipment.................131

188 Online B2B marketplace ...........51,139

189 Optic sheet extrusion line.........75, 141

190 Optical brightner .........................r COC

191 Panel air-conditioner...................r 125

192 Paper chemical ..................................34

193 Paper lamination plant......................t 48

194 Paperless recorder..............................16

195 Parallel & right angle axes gearbox ....9

196 Parallel shaft helical gearbox .............99

197 Patented diffusion bonded transducer 57r

198 Pelletiser .........................................r BIC

199 Pelletiser - dry cut strand type .........73

200 PET bottling compressor................129

201 PET box strapping plant ..................t 91

202 PET masterbatch..............................10

203 PET perform dedicated machine .....41

204 PET sheet ................................75, 141

205 PET/PE washing line.......................14

206 Photoelectric sensor ............................r 7

207 Pipeline ...........................................121

208 Pipe making ....................................g 123

209 Planetary gearbox......................99, 124

210 Plastic compound..............................55

211 Plastic conveyor belt .........................t 35

212 Plastic extrusion machinery ............y 125

213 Plastic injection

moulding machine .............. 21, 22, 131

214 Plastic processing machine ........14,123

215 Plastic raw material .........................122

216 Plastic scrap grinder........................r 125

217 Plastic textile and machinery ............y 59

218 Plastivision Arabia 2012 ...................24

219 Plate heat exchanger .........................r 29

220 Plug valve ..........................................29

221 Pneumatic conveying system ..........131

222 Pneumatic valve ................................29

223 Polyolefin pipe .............................12,19

224 Portable loader ................................r 131

225 PP glass-filled compound .................10

226 PP mineral-filled compound ............10

227 PP/HDPE - semi-

automatic strapping plant .................t 91

228 Precision moulding .......................g FGF

229 Pressure guage ...................................87


LIST OF PRODUCT


FIC - Front Inside Cover, BIC - Back Inside Cover, BC - Back Cover

230 Printing and

cutting/rewinding machine ...............14

231 Process controller ..............................r 16

232 Process tank ......................................k 29

233 Profile controller ...............................r 97

234 Programmable logic controller.......r 7,97

235 Programmable terminal.......................7

236 Proximity sensor..................................r 7

237 PU tube.............................................87

238 Pulveriser.....................................r 23, 35

239 Pump ...............................................131

240 Pumping filtering unit

vacuum pump ..................................131

241 Push fitting .......................................g 87

242 PVC clear colour film .....................128

243 PVC flexible braided hose ................87

244 PVC foam core pipes...................12,19

245 PVC mixer cooler .......................r 12, 19

246 PVC palletising line .....................12,19

247 PVC pipe ............................ 12, 19, 121

248 PVC pipe extrusion unit.................t 132

249 PVC pipe plant .................................t 48

250 PVC pipe threading machine .........125

251 PVC profile line ..........................12, 19

252 Quick connector..........................r 103

253 Quick die change system ................127

254 Quick mould

change system .................. 103, 127,129

255 Rail tanker ...................................r 29

256 Reclosable packing product ............t 124

257 Recycled polymer..............................r 55

258 Recycling line ....................................14

259 Redefining high-end

disc performance ...............................57

260 Refrigerant pump..............................29

261 Refrigeration .....................................29

262 Reprocessing plant ............................t 48

263 Resin .................................................34

264 Resin dehumidifier..........................r 107

265 RFID...................................................7

266 Right-angled helical

bevel-geared motor ...........................r 62

267 Right-angled helical

worm-geared motor ..........................r 62

268 Robot .....................................t 130, FIC

269 Rock-n-roll machine...................23, 35

270 Rotary automatic hot

colour marking machine .................111

271 Rotary cutter .....................................r 73

272 Rotomoulding machine ..................124

273 Round table carrousel .......................35

274 Safety light curtain ......................... 7

275 Screw...............................................w 123

276 Screw compressor..............................r 29

277 Self-adhesive tape ...........................129

278 Servo driven robot ..........................t 136

279 Servo energy saving machine ............41

280 Shaft mounted speed reducer ...r 99, 124

281 Shut off nozel ................................BIC

282 Side channel blower........................r 131

283 Single-/two-stage

reciprocating air-compressor ...........r 129

284 Single mill pulveriser ..................r 23, 35

285 Single-screw extruder gearbox ............9

286 Single-screw extruder plant ..............t 53

287 Single-shaft extruder gearbox ...99, 124

288 Software for central monitoring .....g 107

289 Solenoid valve ...................................87

290 Spare .................................................73

291 Spare twin-screw barrel set.............t 137

292 Special refrigeration equipment......t 125

293 Spiral cum helical gearbox ................26

294 Sprinkler system ..............................121

295 Sprocket ....................................t 99, 124

296 Sprue picker ......................................r 45

297 Stack moulds .....................................31

298 Switching relay....................................y 7

299 Tank & silo .................................. 29

300 Tape line ...........................................91

301 Tape stretching line with inverter ...14

302 Technical mould................................31

303 Temperature controller............r 7, 16, 97

304 Thermoformer ................................r BC

305 Thermoforming & PS foam ........... BC

306 Thermoplastic alloy...........................y 34

307 Thermoplastic compound .................34

308 Thick & wide plastic

sheet extrusion line ...................75, 141

309 Three-arm bi-axial

rotomoulding machine ................23, 35

310 Timer ..................................................r 7

311 TPE foaming materials ..................136

312 TPE/TPU compound.......................10

313 TPU masterbatch..............................33

314 Trim handling system .....................131

315 Twin-screw co-rotating extruder ......r 27

316 Twin-screw element..........................t 27

317 Twin-screw extruder .........................r 27

318 Twin-mill pulveriser....................r 23, 35

319 Twin-screw extruder gearbox..............9

320 Twin-screw extrusion line .................53

321 Twin-screw extrusion

plant machinery ..............................y 137

322 Two-colour cane plant ......................t 48

323 Two-layer blown film ..................12, 19

324 Two-stage reciprocating

air-compressor.................................r 129

325 Ultrasonic flow meter ...................r 16

326 Universal controller ...........................r 97

327 Universal masterbatch .......................10

328 UV stabiliser ................................r COC

329 Vaccum cup .................................. 45

330 Vacuum dryer ....................................r 39

331 Vacuum forming machine............... BC

332 Vacuum loader ..............................r FGF

333 Vane damper ...................................r 131

334 Variable displacement

pump energy-saving machine ...........41

335 Ventilator....................................................r 129

336 Vibro screen ...........................................23, 35

337 Vision sensor ..................................................r 7

338 Volometric dosing unit...............................t 107

339 Walk-away automation ................. 57

340 Water chiller...............................................125

341 Water-cooled reciprocating

air-compressor ............................................r 129

342 Water ring vacuum pump ..........................131

343 Water chiller...............................................107

344 Welding gun ...............................................121

345 WFR .........................................................R FIC

346 White masterbatch ......................10, 55, COC

347 Winder .........................................................r 48

348 Wire EDM ..................................................81

349 Worm gear....................................................26

350 Worm reducer ......................................r 99, 124

351 Worm reducer gearbox .........................99, 124

352 Wovensack tape plant for PP/HDPE ..........48


Looking for a specifi c product?We will fi nd the product for you. Just type MPD (space) Name of the Product and send it to 51818

eg, MPD (space) xxxx and send it to 51818.

LIST OF ADVERTISERS


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

Our consistent advertisers

COMPLETE ENGINEERING UNDER ONE ROOF @www.engg-expo.com

yAB Diachem Systems Pvt Ltd 121

T: +91-11-25155456E: [email protected]: www.scalewatcher.in

gAeromec Marketing Co Pvt Ltd 111

T: +91-250-2454915E: [email protected]: www.aeromec.in

Alok Masterbatches Ltd 33

T: +91-11-41612244E: [email protected]: www.alokmasterbatches.com

Avi Additives Pvt Ltd 55

T: +91-40- 23550551/2/3/4E: [email protected]: www.aviadditives.com

B J S Engineers 137

T: +91-09832926696E: [email protected]: www.bjsengg.comj gg

Battenfeld-Cincinnati Austria Gmbh 69

T: +91-098207 01960E: [email protected]: www.battenfeld-cincinnati.com

Blend Colours Pvt Ltd 10

T: +91-40-24361499E: [email protected]: www.blendcolours.com

g p yBoge Compressed Air System 8

T: +91-44-43009610E: [email protected]: www.boge.in

pD & M Enterprises 22

T: +91-44-42184295E: [email protected]: www.dmeindia.net

ggDongguan Alfa Automation Machinery Limited 130

T: +86-769-8318-0326E: [email protected]: www.alfarobot.com

g g p yElecon Engineering Company Limited 26

T: +91-2692-236469E: [email protected]: www.elecon.com

Electronica Plastic Machiners Ltd 133

T: +91-22-32531959E: [email protected]

Engineering Expo 83, 105, 112

T: +91-09819552270E: [email protected]: www.engg-expo.com

Expo Centre Sharjah 24

T: +91-22-67778849

E: [email protected]

W: www.plastivisionarabia.org

Exxonmobil Chemical Asia Pacific 67, 79

T: +86-10-5965-7385


W: www.exxonmobilchemical.com

FICCI 144

T: +91-11-23738760


W: www.poly-india.in

yForwell Precision Machinery Co Ltd 127

T: +886-4-834-5196


W: www.forwell.com

Fu Chun Shin Machinery

Manufacture Co Ltd 126

T: +886-6-595-0688


W: www.fcs.com.tw

q pGem Equipments Ltd 77

T: +91-422-3267800


W: www.gemindia.com

pGlaves Corporation 73

T: +91-141-2460324


W: www.glaves.biz

Hinds Machineries 131

T: +91-124-28124921


pHindustan Plastic And Machine Corporation 53

T: +91-11-25724865


W: www.hindustanplastics.com

IDMC Limited 29

T: +91-2692-225399


W: www.idmc.coop

IndiaMART InterMESH Ltd 51, 139

T: +1800-200-4444 / 91-120-3911000


W: www.indiamart.com

Indian Machine Tool Mfg. Association 104

W: www.imtex.in

gIngeco Gears Pvt Ltd 99

T: +91-2717-651551


W: www.ingecogears.com

J.P. Extrusiontech Limited 14

T: +91-2646-222163E: [email protected]: www.jpextrusiontech.com

gJagmohan Pla-Mach Pvt Ltd 93

T: +91-22-25955678E: [email protected]: www.jagmohan.com

yJon Wai Machinery Works Co Ltd 123

T: +886-2-2595-4867E: [email protected]

W: www.jonwai.com.tw

Kabra Extrusion Technik Ltd 12, 19

T: +91-22-2673 4822


W: www.kolsite.com

Konark Plastomech Pvt Ltd 91

T: +91-79-22891670


W: www.konarkplastomech.com

jKotra & Woojin Selex Co Ltd 21

T: +91-9941342299


W: www.woojinselex.com

yL & T Plastics Machinery Ltd FGF

T: +91-44-26812000


W: www.larsentoubro.com

Larsen & Toubro Ltd 85

T: +91-22-6752 5656


W: www.larsentoubro.com

gLohia Starlinger Ltd 59

T: +91-11-30641770


W: www.lohiagroup.com

Loxim Industries Limited 34

T: +91-2717-308000


W: www.loxim.com

yMadhu Machines & Systems Pvt Ltd 18, 143

T: +91-265-2353886


W: www.madhu-group.com

gMatsui Technologies India Ltd 39

T: +91-120-4243862


yMifa Systems 97

T: +91-79-26870825


W: www.mifasystems.comww

FIC - Front Inside Cover, BIC - Back Inside Cover, BC - Back Cover

LIST OF ADVERTISERS


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

Mold - Masters T gechnologies Pvt Ltd 89TT

T: +91-422-4502171


W: www.moldmasters.com

pN.A. Corporation 23

T: +91-79-25840374


W: www.naroto.com

jNeejtech India (Braun) 31

T: +91-79-26561312


W: www.braunform.com

jNeejtech India (Gimatic) 45

T: +91-79-26561312


W: www.neejtech.com

j gNeejtech India (Niigata) 17

T: +91-9909974224


W: www.niigataindia.com

Omron Automation Pvt. Ltd. 7

T: +91-80-40726400


W: www.omron-ap.com

yPanchal Machinery 124

T: +91-79-25620953


W: www.panchalmachinery.in

Piovan India Pvt Ltd 107

T: +91-22-28560450


W: www.piovan.comp

Plast India Foundation 109

T: +91-22-26832911


W: www.plastindia.org

Plastiblends India Ltd COC

T: +91-22-67205200


W: www.plastiblendsindia.com

Power Build Ltd 62

T: +91-2692-231070


W: www.pbl.co.in

Prasad Gwk Cooltech Pvt Ltd 35

T: +91-79-25830112


W: www.prasadgroup.com

Premium Transmission Ltd 65

T: +91-20-66314100

W: www.premiumtransmission.com

gProcon Technologies Pvt Ltd 16

T: +91-79-27492566


W: www.procon.co.in

R R Plast Extrusions Pvt Ltd 75, 141

T: +91-22-42461500


W: www.rrplast.com

j g gRaj Engineering Works 125

T: +91-20-65104541


W: www.rajengg.net

j gRajoo Engineers Ltd BC

T: +91-2827-252701


W: www.rajoo.com

yRemica Plastics Machinery Manufacture 48

T: +91-79-25712741


W: www.remicaplastics.com

gS&T Engineers 81

T: +91-422-2590810


W: www.stengineers.com

p gS+S Separation And Sorting

Technology Gmbh 113

T: +91-20-26741012


W: www.se-so-tec.com

g gSacmi Engineering India Pvt Ltd 95

T: +91-7600003968


W: www.negribossi.com

Saimona Air-Mech Pvt Ltd 129

T: +91-79-22870666


W: www.saimona.com

Samson Extrusion Ind Pvt Ltd 87

T: +91-22-23436320


W: www.samson-grp.com

ySanity International 123

T: +91-79-65227458


W: www.sanityindia.comy

Society Of Plastics Industry - NPE2012 20

W: www.npe.org

Sreelakshmi Traders 129

T: +91-44-24343343


W: www.sreelakshmitraders.com

Sri Sai Plasto Tech 41

T: +91-44-42994365


W: www.srisaiplastotech.com

g gSteer Engineering Pvt Ltd 27

T: +91-80-23723309


W: www.sww teerworld.com

gSuresh Engi gneering Works 128

T: +91-731-2527872


W: www.sureshengg.comgg

TA Instruments-Thermal Analysis 57

T: +91-80-23194177


W: www.tainstruments.com

The Indian Electric Co 37

T: +91-20-24474303


W: www.indianelectric.com

Toshiba Machine (India) Pvt Ltd 71

T: +91-11-43291111


W: www.toshiba-machine.co.jp

gUnimark (Maguire) 25

T: +91-22-25506712


W: www.unimark.in

gUnimark (Staubli Faverges Sca) 103

T: +91-22-25506712


W: www.unimark.in

Vacunair Engineering Co Pvt Ltd 131

T: +91-79-22910771


W: www.vacunair.com

Werner Finley Pvt Ltd 125

T: +91-80-23289889


W: www.wernerfinley.com

p gWitte Pumps & Technologies 135

T: +91-11-41613643


W: www.witte-pumps.de

Wittmann Battenfeld India Pvt Ltd FIC

T: +91-44-42077009


W: www.wittmann-group.com

yXaloy Asia (Thailand) Ltd BIC

T: +91-79-27541971


W: www.xaloy.com

g yYann Bang Electrical Machinery Co Ltd 43

T: +886-4-2271-6999


W: www.yannbang.com

pZambello Riduttori Group 9

T: +39-0331-307-616


W: www.zambello.it

Reg No: MH / MR / WEST / 234 // 2009 – 2011 RNI No: MAHENG / 2008 / 25265Licence to Post at Mumbai Patrika Channel Sorting Offi ce, Mumbai GPO., Mumbai 400 001.

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

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