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9April 2012 | Modern Plastics & Polymers
s the Indian economy really in dire straits or are we pressing the
panic button too soon? Union Budget 2012-13, far from taking
any bold step to revitalise the Indian growth engine, turned out to
predominantly prefer the status quo of the current policy regime.
No doubt, it has left a bitter taste even in some of the most optimistic industry
observers, who have been hoping to see some economic acceleration to offset the
India-bound headwinds from Europe.
Call it a missed opportunity or, a cautious approach, this year’s Budget is way
off target from the industry’s expectations in terms of reversing the slowing pace of
growth by virtue of big-ticket reform mechanisms. Rather, the government seems
to have settled for a guarded step towards shoring up weak investment sentiments
and unveiling only a handful of anti-deficit measures comprising a hike in the
service and excise taxes.
That said, the immediate future of the country’s economy does
not seem very bright. According to Moody’s, in the absence of new
policy initiatives, it will take a combination of improved economic
growth, corporate profitability, lower global commodity prices and
exchange rate stability to meet the government’s fiscal deficit target
in 2012-13. In the absence of any elaboration by this Budget on
measures to cap the centre’s subsidy spending to 1.7 per cent
of gross domestic product in the next three years, it further
observes that unless subsidy cuts and fuel price increases
are introduced in the next few months, expenditure targets
are likely to exceed again in fiscal 2012-13.
If that is not all, the budgetary proposal to amend the
Income Tax Act with retrospective effect has, perhaps,
made the biggest dent in the long-term fiscal credibility
of the India story, not only outside but within the country
as well. This has come as a bolt from the blue when the
national economy is pitted against tapering growth on one hand
and growing maturity of Indian manufacturing on the other,
and hence, a rising confidence in higher foreign investment flow
into this domain. Given this scenario, the need of the hour is to
exercise ample jurisprudence and ensure that the Indian growth
juggernaut continues its growth momentum.
IBudget blues
Editorial Advisory BoardA E Ladhabhoy
Plastics Technologist
Dr Sushil K VermaFormer Director General, CIPET
Dr Swapan K DharaRegional Technical Head,
Basell Polyolefins India Pvt Ltd
Mohan K JainMD, Indoplast & Past President, AIPMA
P P KharasChairman, Ecoplast
Raman M PatelChairman, Industrial Products Mfg Co
Vijay MerchantPresident, Polycraft
Manas R [email protected]
EDITORIAL
11April 2012 | Modern Plastics & Polymers
39February 2012 | Modern Plastics & Polymers
CONTENTS
Note: ` stands for Indian rupee, $ stands for US dollar and £ stands for UK pound, unless mentioned otherwise
Special Focus: Rotomoulding Insight & Outlook: Plastics in Building & Construction
28 Post-Budget 2012 Taking cautious steps towards growth
Automation Trends 68 Automatic die changers: Steering the manufacturing might
Energy Management 70 Hybrid machines: Analysing the cost-quality ratio
Policies & Regulations 72 Expansion projects: Achieving economy of scale with industry-friendly policies
Strategy 74 Plastic products recycling: Focussing on the economics angle
Tips & Tricks 78 Purchasing used injection moulding machinery:
Guidelines to strike the right deal
Event Preview 84 Die & Mould India 2012: Gearing up for global opportunities
Event Focus: Chinaplas 2012 86 Event Preview: Heralding unlimited opportunities
88 In the News
90 Product Showcase
Event Report 108 Engineering Expo Aurangabad 2012: Creating yet another success story
REGUL AR SECTIONSEditorial ................................. 9
News, Views & Analysis ...... 20
Technology & Innovation .... 24
Projects ................................. 80
31
Event List............................. 82
Book Review ...................... 111
List of Products.................. 112
List of Advertisers .............. 118
Cover photo courtesy: BASF
Highlights of Next Edition
Injection moulding ................32
Robotics in
injection moulding ................36
PLC-based
moulding techniques .............38
Interface:
Harminder Singh .......42
Helmut Heinson ........44
Roundtable ............................46
Special Focus
51Engineering plastics ................................... 52
Innovation edge ...................................... 56
Interface:
Raju Desai .................................. 58
Shamik Shah .............................. 60
Sanjay Jain.................................. 62
QRST method ....................................... 64
In Conversation With 26 K R Bhuva, CMD, Polymechplast Machines Ltd
Facility Visit 48 Quadrant EPP Surlon India Ltd:
Engineering complete solutions under one roof
Insight &
Outlook
13April 2012 | Modern Plastics & Polymers
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Printed by Mohan Gajria and published by Lakshmi Narasimhan on behalf of Infomedia 18 Ltd.Senior Editor: Manas R BastiaPrinted at Infomedia 18 Ltd, Plot no.3, Sector 7, off Sion-Panvel Road, Nerul, Navi Mumbai 400 706, and published at Infomedia 18 Ltd, ‘A’ Wing, Ruby House, J K Sawant Marg, Dadar (W), Mumbai - 400 028. Modern Plastics & Polymers is registered with the Registrar of Newspapers of India under No. MAHENG / 2008 / 25265. Infomedia 18 Ltd does not take any responsibility for loss or damage incurred or suffered by any subscriber of this magazine as a result of his/her accepting any invitation/offer published in this edition.
Business Insights •Technologies•Opportunities
NEWS, VIEWS & ANALYSIS
20 Modern Plastics & Polymers | April 2012
PVC price rise in Southeast Asia due to soaring demand Polyvinyl Chloride (PVC) has seen prices
hike in Southeast Asian countries with
many regional producers up-adjusting their
local and export offers. Besides the push
from higher input costs, healthy demand
from the region has given sellers real support
to ask for increases. Also, many buyers find
domestic prices more competitive and prefer
to meet their requirements from their local
markets. In Indonesia, local PVC prices
have also gone up by $ 50-70 per tonne.
Sumit Dhingra, Director, Dhingra
Polymers, said, “Now that the demand is
improving and supply appears to remain
limited in line with the tight availability
of Vinyl Chloride Monomer (VCM)
feedstock, the PVC market is likely
to maintain its firm trend for a while.
Demand has improved in the local market,
and we are receiving more inquiries from
buyers.” The industry believes that this
price rise is due to strong local demand
and high feedstock costs, which have also
resulted in a tight supply.
Anwesh Koley
LANXESS to unveil world’s largest Nd-PBR plant in Singapore LANXESS will break ground for
its new Neodymium Polybutadiene
Rubber (Nd-PBR) plant in Singapore
this year. The German specialty
chemicals company will invest about
€ 200 million (SGD 337 million) in a
140,000 metric tonne per annum facility
in Jurong Island Chemical Park. The
facility will be the largest of its kind in
the world and serve the growing market
for ‘Green Tyres’, especially in Asia. The
plant is expected to start up in the first
half of 2015.
Engineering work is on-going.
The company has received all the
necessary internal approvals for the
project. “I am pleased to announce
that it is now full steam ahead for
the second largest investment project
in our company’s history,” commented
Dr Axel C Heitmann, Chairman-
Board of Management, LANXESS. He
added, “This announcement falls in our
company’s Year of ‘Green Mobility’.
The company’s focus on innovation and
technology makes it possible to reduce
rolling resistance in tyres, and thereby
decrease fuel consumption. This is good
news for the consumer as well as the
environment.”
Intercontinental to build compounding plant in India Indian-American joint venture compounder
Intercontinental Polymers Pvt Ltd is
building an engineering resins compounding
plant in Dahag, Gujarat. The plant will
have a production capacity of 44.1 million
pound per year, and is aimed at both the
country’s growing automotive industry and
opportunities to switch conventional metal
products to plastics.
The new facility will be a
tenfold increase in capacity for the
company, which is a joint venture of
Intercontinental Export Import Inc, in
Columbia, and Indian injection moulder,
toolmaker and design house Jyoti Plastic
Works Pvt Ltd.
The factory will target exports
to the US and Europe, where
Jyoti has sales offices, and also India’s
market for moulded parts made from
engineering plastics. “Jyoti is also
planning to build a 100,000-sq ft
mould making facility on the
Khadki campus, targeting export of
tooling to western markets,” said
Raju Desai, Director, Jyoti Plastic
Works Pvt Ltd.
The Dahag plant will have four
twin-screw extrusion lines, with the
equipment likely coming from Western
machinery suppliers because the
company wants to be able to supply
global firms as well.
Anwesh Koley
Dr Axel C Heitmann
Ferromatik Milacron India focusses on futuristic injection moulding solutions
Leading injection moulding machinery
manufacturer Ferromatik Milacron
India (FMI) had exhibited six live
injection moulding machines at
Plastindia 2012. FMI believes that
innovation is the key to future, and the
new machines are built using newer
& advanced technologies such as all-
electric, two-platen servo, hydron servo,
servo pack toggle & hydraulic systems.
Key attractions of these technologies are
precision and energy savings due to servo
technology, Process and Data Analysis
(PDA) & higher speeds with fast cyclic
with multi-cavity mould. The FMI
stall at Plastindia 2012 had the theme
‘One Dream Go Green’, which
emphasised on servo drive of injection
moulding machines and solutions
such as green engagement & green
communication.
Shrish Divgi, Chief Operating Officer,
Ferromatik Milacron India Pvt Ltd, said,
“African countries are really growing,
particularly those in West and East Africa.
These solutions will benefit our domestic
customers as well as plastics industry in
Africa, which is oriented towards the
household and furniture industries. We have
recently observed many upgraded activities in
other sectors as well.” Annabel Dsouza
NEWS, VIEWS & ANALYSIS
22 Modern Plastics & Polymers | April 2012
Vinyl India 2012 to showcase growth prospects in the industry The Indian vinyl chain and chlor-
alkali markets are currently at an
exponential growth curve owing to
robust demand from agriculture, housing
and infrastructure sectors. The vinyl and
chloralkali industry is forecast to cross
$ 8 billion by 2015. In this backdrop, Vinyl
India 2012 brings together industry leaders
and specialists to examine the growth
trends in this industry. Vinyl India 2012
will be held on 12-13, April 2012, at Hotel
Grand Hyatt, Mumbai. Key highlights of
the conference are:
Future potential of PVC in India
Feedstock to polymer
Machinery– compounding, processing
& material handling
Health, safety and environment
Opportunities for China– India
collaboration
PVC innovations in pipe sector
There will be an exclusive dinner speech
on understanding ‘Anti-dumping duty’
by eminent experts from the Commerce
Ministry and the legal fraternity. Some of
the leading industry leaders addressing this
conference will be S S Naik, Senior Vice
President, Reliance Industries Ltd; Dr
Rajiv Kumar, Secretary General, Federation
of Indian Chambers of Commerce and
Industry; and Dr Ranjit Date, President
& Joint Managing Director, Precision
Automation Robotics India Ltd.Annabel Dsouza
KREYENBORG Group invites for 6th ‘plastics processing’ symposium ‘New trends in the plastics
industry’ is an exciting topic
for KREYENBORG Group’s
symposium, which will be
held during May 9-10, 2012,
in Muenster /Westpha l ia ,
Germany. Global competition
in the development of plastic
applications puts companies from
the plastics industry constantly
under pressure to improve their
technical know-how and develop
new solutions.
At the symposium, a panel
of Keynote speakers will give a
hint of the ‘future’, present new
ideas and develop these through
discussions with many key
industry executives. The guest
speakers of the industry will give
a precise idea of the latest trends
in plastics processing in terms of
dosing, compounding, extrusion
or filtration technology. The
symposium will provide insights
into KREYENBORG Group’s
solutions, new developments and
related possibilities for process
technology. Participants can see
demonstrations of the company’s
own laboratory line and participate
in open discussions. Some of the
leading companies participating
in the event include BASF,
Starlinger & Co, Fraunhofer-
Institute, Reifenhäuser Extrusion,
among others.
Negri Bossi appoints Plastigo as distributor in Poland
Negri Bossi has appointed Plastigo as its
exclusive distributor in Poland. Plastigo will
offer six injection moulding machine ranges
made by Negri Bossi. These include Vesta
(a range of full electric machines of 70-
850 tonne), EOS (a hydraulic technology
machine that sets a new record in terms
of compactness), Canbio (a range of fully
digital, hydraulic machines of 55-530
tonne), Canbimat (a range of multi-material
machines with solutions for up to 6 injection
units), Vector (a range of hybrid machines
of 700-1500 tonne) and Janus (a range of
hybrid machines of 160-850 tonne). The
Polish company will also provide warranty
and post-warranty maintenance services for
Negro Bossi’s machines.
“Negri Bossi is one of the most
widely recognised brands in the European
injection moulding machine market.
With the introduction of Negri Bossi’s
injection moulding machines to its product
range, Plastigo aims to target the premium
segment of the Polish plastic injection
moulding market,” said Asteniusz Mysliwiec,
Chief Executive, Asten Group (Plastigo’s
parent company).
Avani Jain
Fabian Spitzner now heads sales and marketing at UNICOR GmbH
The international sales and marketing
operation of UNICOR GmbH of Hassfurt,
Germany, is now headed by a new sales
manager. Fabian Spitzner is the new
marketing director at UNICOR, succeeding
Volker Sprenger.
Spitzner is known in the market as an
expert with extensive experience in corrugated
pipe plants. Until 2010, he was leading the
marketing staff at FRÄNKISCHE in the
machinery division. When the corrugator
operations of FRÄNKISCHE were taken
over by UNICOR, he moved to Hassfurt as
Regional Sales Manager at UNICOR, with
emphasis on the Balkans, Turkey and the
Middle East.
Since January 2012, he is heading
the global marketing of corrugators of
UNICOR GmbH. He has particular
experience in the marketing of
hi-tech corrugators, which UNICOR
manufactures and sells since the machinery
division of FRÄNKISCHE was taken over
by UNICOR.
Fabian Spitzner
TECHNOLOGY & INNOVATION
24 Modern Plastics & Polymers | April 2012
New resin technology from Asahi Kasei Plastics Asahi Kasei Plastics has developed
new resin technologies and capabilities
resulting in new, improved eco-friendly
products.
The Xyron™ PV Grades are Modified
Polyphenylene Ether (mPPE) for solar
panel components. It is compliant for
Underwriters Laboratories Inc (UL)
and International Electrotechnical
Commission (IEC) requirement with
non-halogenated flame-retardants.
These grades carry UL’s 5VA and
V-0 certifications.
The next is Leona™ LG - Polyamide
(PA)66 and PA 66/6I with long glass
fibres for applications requiring high
performance, ie, superior fatigue and
creep resistance, modulus greater than
20 GPa with good surface finish or
flame-retardant grades with excellent
impact strength. The Thermylene® P9 is
a short-glass-fibre polypropylene with
higher temperature resistance for Nylon
alternative. Its applications include air-
intake manifolds and other automotive
under-the-hood automotive components.
This material facilitates weight reduction
strategies of 15 per cent or higher.
Thermylene® P8 is a glass-reinforced
grade with advanced coupling technology
as an alternative to long-glass-fibre
polypropylene. This grade is commonly
used in door modules, motor housings,
sunroof frames, shifter bases, etc.
Clariant introduces pigments for new colour opportunitiesClariant has introduced three azo
pigments that offer new opportunities
for designers and producers of plastic
products in India. The first of the
new pigments is PV Fast Red HGR
– a High-Performance AZO Pigment
with Color Index Pigment Red
(PR) 285. This mid-shade red pigment
displays a high light fastness and
excellent heat stability. Due to its low
warping properties and Food and Drug
Administration (FDA) compliance,
this pigment is suited for food
packaging applications. When used in
combination with PV Fast Yellow HGR
(PY 191), which has similar properties,
it provides new opportunities to match
brilliant, economical orange shades.
New PV Fast Yellow H4G – Color Index
Pigment Yellow (PY) 151 – is a green-
yellow pigment that offers an excellent
alternative to inorganic pigments.
PV Fast Yellow H4G displays high
light fastness and good heat stability.
For producers looking for a bright red
shade of orange, there is PV Fast Orange
H2GL – Color Index Pigment Orange
(PO) 64. This brilliant, pure orange
pigment has excellent overall properties
for colouration of polyolefins, Polyvinyl
Chloride (PVC) as well as polystyrene
and other select polymers. With its
FDA compliance, PV Fast Orange
H2GL opens up numerous possibilities
for applications in food packaging and
consumer goods.
H-PET AE preform manufacturing solution by Husky
Husky’s H-PET All-Electric (AE)
preform manufacturing solution
is a 32-cavity H-PET AE
180 work-cell that produces a
19-gm EcoBase™ preform for a
1 litre still water bottle application.
The H-PET AE system is an
efficient, affordable solution for the
lower volume preform market that
offers customers exceptional value and
a high level of quality. H-PET AE
is an energy-efficient, flexible,
easy-to-use system and has low
maintenance requirements.
As a complete solution,
H-PET AE includes a fully integrated
resin dryer, mould dehumidifier and
a complete work-cell infrastructure
package consisting of both water and
electrical distribution as well as a
mezzanine. Its tight process controls
and accurate mould tolerances,
together with Husky’s EcoBase preform
design, result in preforms that are
up to 2.5 per cent lighter than other
lightweight performs. These features
also allow moulders to benefit from
additional resin savings.
New extruder series by battenfeld-cincinnatibattenfeld-cincinnati has introduced a
new extruder series solEX and twinEX.
The solEX is a series of high-performance
40D single-screw extruders for
Polyethylene (High Density) (PE-HD)
and Polypropylene (PP) pipe extrusion,
and is available in five sizes with screw
diameters in the range of 45-120 mm.
An outstanding feature of these
extruders is high output with low
melt temperature. solEX extruders
are equipped with a powerful, highly
efficient drive train and an optimised
processing unit that enable reduction
of energy consumption by about
15 per cent. The extruders reach such
high throughput levels with excellent
melt homogeneity that the next smaller
diameter machine model can be used to
reach the same performance level as by
conventional 30D extruders.
The twinEX series of parallel twin-
screw extruders consists of four machines
in size range 78-135 mm and is ideal
for the production of pipes and profiles.
The extruders require approximately
15 per cent less specific energy input
with simultaneous increase in output
as compared to other counter-rotating
twin-screw extruders.
IN CONVERSATION WITH: K R Bhuva
26 Modern Plastics & Polymers | April 2012
…opines K R Bhuva, Chairman and Managing Director, Polymechplast Machines Ltd. In an exclusive interaction with Avani Jain, he underlines that quality has taken precedence across all sectors. Besides, he believes that the increasing demand for plastics in the automobile segment will further drive the growth of the injection moulding machinery market.
“Compact and high-speed machines
are the need of the hour”
K R Bhuva
27April 2012 | Modern Plastics & Polymers
What are the key demand drivers influencing the growth of injection moulding machines?The demand for injection
moulding machines is about
7,000 machines per year. Many new
companies are setting up their operations
in India and the existing ones are
expanding their businesses, and this has
given a boost to the industry. In addition,
the growth of the automotive industry
in the country has increased the demand
for injection moulding machines. The
increased usage of plastics in all sectors
such as construction, electrical and
electronics, household, surgical, cosmetics
and packaging has also enhanced the
demand for these machines.
What technological advancements has the industry witnessed over the years?The industry is gradually moving
towards complete automation. Compact
and high-speed machines with reduced
energy consumption have become the
need of the hour and technology is
being developed to ensure the same at a
reasonable price. Over the last 10 years,
the power consumption by machines has
been reduced by more than 50 per cent.
Earlier, the machines came with analog
control but, today, digital controls that
ensure high precision are being used.
How has the machinery quality improved over the years?Today, quality has become the top priority
for all companies, small or large. A decade
ago, the scenario was different, as there
were only few companies and customers
had no choice. But today, with the advent
of several processors in the segment, even
the small companies have to make quality
machines as otherwise their business will
not flourish.
How does Polymechplast achieve sustainability in its operations?Sustainability is an ongoing process. The
world over, industries are making efforts
to reduce their energy consumption and
ensure high production efficiency by
updating their technology on a regular
basis. We are also working towards
reducing the cycle times and power
consumption, while increasing the speed
of machines. The use of servo motors and
efficient controls has helped to a large
extent in this regard. We use variable
displacement pumps and servo motors
in the machines, which reduce energy
consumption considerably. We also try to
avoid environment pollution and improve
waste reduction. We manufacture our
components such that raw materials are
optimally used and nothing goes waste.
What are the challenges faced by the industry?The industry faces a number of challenges.
The first is competition from oversees
manufacturers in terms of volume and
cost. Second, the cost of raw material in
India is continuously increasing, and this
presents a major hurdle for the industry.
Third is the fluctuation in the cost of
petroleum products. Since plastics is made
from petroleum, the rise in petroleum
price makes plastics processing and
consumption expensive, and this, in turn,
affects the machinery manufacturers. A
related cause is the heavy fluctuation
in currency exchange rates, which is
affecting the imports and exports. Further,
government policies are not in favour of
the plastics industry, and hence it faces a
lot of restrictions.
What are the opportunity areas?People are increasingly switching to plastic
products since these are light in weight
but offer the same strength as provided
by other materials such as wood or metal.
Plastics also has an aesthetic value. Thus,
there seems no replacement for plastics
for the next few decades. The increase in
preference for plastic products will boost
the processing machinery industry.
What is your outlook for the overall Indian plastics processing machinery?The future of this sector is bright since
in India, the per capita consumption of
plastics is less as compared to that in
developed countries. Thus, the plastics
industry and its allied machinery
manufacturing industries have a bright
scope in the future.
What are your growth plans for the company?We are currently producing 200-250 sets
per annum and want to expand this to
about 500 machines per year. We are aiming
to produce higher tonnage machines. In
future, we want to manufacture all-electric
machines as well.
How has been your journey so far?My career in this profession has been a
mix of numerous challenges and some
major successes as well. So, overall, my
journey has been quite satisfactory.
What was the toughest business decision you ever made?Leaving the earlier job and entering into
this business was the toughest business
decision I have ever made. We had started
at a small level, but we took that chance
and succeeded.
What are the things you consider while starting something new?You need to check every aspect before
taking a decision, for example, whether
the new venture will be profitable for
your business, will it help sustain your
business in the long run and open new
opportunities in the future.
What is the business etiquette that you value the most?There must be transparency and honesty
in your actions. There is no shortcut to
this. Further, one should always try and be
simplistic in their approach, as this will go a
long way in defining your path of success.
Your message to aspiring and upcoming entrepreneurs in this domain...The aspiring entrepreneurs should take time
in selecting the type of work they want to
do and they should enjoy it. They must love
their work in order to attain success.
Email: [email protected]
POST-BUDGET 2012
28 Modern Plastics & Polymers | April 2012
Taking cautious steps towards growth
The Union Budget 2012 has evoked mixed reactions across the nation’s manufacturing and business fraternity. With emphasis on driving domestic demand and reviving private investment, the Finance Ministry had provided several opportunities for the plastics processing sector. Here are some critical insights into the Budget’s offerings for growth of the plastics industry.
Rajeev Arora, Vice President &
Business Head, Shriram Polytech
This Union Budget can be termed
as neutral. The excise duty has been
increased, but the increase in service tax
will add to industrial expenditure and is
a growth dampener. Growth comes from the
availability of funds, but for manufacturers, a rise in cost
cannot be entirely passed on to the customers. This will
lead to inflation and tighter market dynamics; hence,
both the customer and manufactures will suffer. Our
profit margins will plummet and customers will have to
shell out more.
The Budget has not addressed the supply side of
the value chain and has taken only fiscal measures. The
Government has to raise funds, but there should be a
balance between the existing factors. The anti-dumping
duty has not been relooked at. Many categories of raw
materials are already under this duty and the industry
will push to include more of them. Overall, the plastics
industry cannot take away any major positive change
from this Budget.
Ashok Goel, President, Plastindia Foundation
Against the backdrop of global economic
and political instability, the Union Budget’s
Gross Domestic Product (GDP) growth
estimate of near 6.9 per cent is good but still
below expectation. But, this consumption-driven
growth may not be sustainable in the long run unless
accompanied by investment-driven growth. The fiscal deficit
target of 5.1 per cent and central subsidies under 2 per cent of
GDP for 2012-13 and the Government’s intentions to further
reduce these have steered clear of populist measures. The
Budget endeavours to shore up investment in infrastructure
with proposals to make more sectors eligible for Viability
Gap Funding under the Public Private Partnership scheme
and include tax-free bonds of ` 60,000 crore to finance
infrastructure projects in 2012-13.
Measures announced to boost infrastructure and
agriculture are good. The consumption of plastics in these
sectors is increasing at fast pace. Further, the Finance
Minister has reiterated the commitment towards Goods and
Services Tax (GST), indicating an early implementation. Its
implementation and harmonisation of the tax structure will
have a positive impact on business, particularly on the plastics
industry, which is currently fragmented. This will encourage
the industry to look for economy of scale.
Rohit Chopra, GM (Polymer Division),
KPL International Ltd
The Union Budget has evoked mixed
reactions in the plastics industry and
overall. While the rise in excise duty will see
a hike in prices, it will increase competition
in the market. This will discourage new players
from entering the polymer industry, particularly the
masterbatch sector, which is currently witnessing a flurry
of new entrants. In India, the regulations regarding
safety standards are not stringent and manufacturers are
also non-chalant towards the health issues of workers.
The Budget should have addressed these concerns.
India lags behind in Research and Development
(R&D), as many unorganised players cannot afford
huge investments. However, the organised players need
to invest more in R&D, and the Government must
create conditions in order to encourage manufacturers
to come up with ideas and techniques for benchmarking
international standards. Such issues have found no
mention in the Budget and the industry will have to
depend on imports for high-grade polymers.
POST-BUDGET 2012
30 Modern Plastics & Polymers | April 2012
Jayesh Mehta, Regional Manager,
Prasad Group
With regard to the plastics industry,
Union Budget 2012 appears rather a
disappointing one, despite expectations
of a more pragmatic approach to foster
the growth of the highly promising plastics
industry. The industry at large will have to tread
cautiously to leverage the implications of the Budget.
This is particularly significant to plastics application
in the capital goods market. Since the current
financial year has failed to depict any impressive
results by key players, the industry has been counting
on fiscal measures. Many of the policies brought
forth by the Budget appear conducive to the growth
of the plastics industry. The provisions of the
Budget by far seem to have prioritised 75 per cent
of the population, while casting aside any of the
requirements of the 25 per cent of the population
keeping in mind that the same class will be
driving the growth opportunities by providing better
employment en masse.
Rajesh Sharma, Business Unit
Director, Closures & Containers,
SACMI Impianti India
The domestic plastics and packaging
industry had hoped for a more
friendly and conducive Budget. There
is a pertinent need to lower and simplify
the existing duty structure on imported
plastics processing and manufacturing machinery,
thereby improving developments across the
manufacturing and engineering sectors. The Budget
should have been formulated with an emphasis
on food and beverage processing. The lack of any
facilitation for this industry will have a direct impact
on the common man who spends a major chunk
of his earnings on food. The revision in direct
taxation is welcome considering the extremely
high inflation rates for all essential items, but it is
partial to certain segments of the population. This
would lead to people having more money in their
pocket and the resulting increase in purchasing
power will fuel the GDP growth and drive the
economy of India.
Injection Moulding
31February 2012 | Modern Plastics & Polymers
Injection moulding:
Driving performance through light-weighting .......................................................................32
Robotics in injection moulding:
Combining precision with safety .............................................................................................36
PLC-based moulding techniques:
Precise control for efficient operations .....................................................................................38
Interface:
Harminder Singh, AGM-Sales & Marketing, Electronica Plastic Machines Ltd ................42
Helmut Heinson, MD-Sales, ARBURG GmbH + Co KG ...................................................44
Roundtable:
Can Indian injection moulding machines compete globally
in terms of energy efficiency? ...................................................................................................46
SPECIAL FOCUS
31April 2012 | Modern Plastics & Polymers
32 Modern Plastics & Polymers | April 2012
SPECIAL FOCUS: In ject ion moulding
Injection moulded parts constitute
70 per cent of the total processed
plastics market. From home
appliances to automotive
components, as well as the construction
industry, injection moulded parts today
are found everywhere. There was a time
when the automotive sector did not favour
the use of plastics for the external and
internal parts. Gradually, the importance
of plastic parts grew as manufacturers
understood the importance of weight
reduction, which enables fuel efficiency.
Intense competition over the years has
witnessed the automobile industry use
more plastics in strategic areas to provide
durability to the vehicle and enhance its
visual appeal.
Conventionally, metal alloys were
synonymous with the auto body exterior
design and manufacturing. But, metal
alloys are susceptible to dents, dings,
stone chips and corrosion. These are
also heavier and more expensive than
plastics. Sumit Kumar, General Manager,
H K Industries, says, “Choosing plastics
for auto body exterior parts allows
manufacturers to adopt modular assembly
practices, lower production costs, improve
energy management, achieve better dent
resistance and use advanced styling
techniques for sleeker, more aerodynamic
exteriors.”
Evolution of injection moulding The moulding process was invented
only a few years after the invention of
plastics. Initially, hand moulding was
used. The moulders had a conventional
screw barrel set-up and external heating
was applied manually. Even the moulds
were opened and closed using the
conventional process. As automation
began, the injection moulding machine
was developed with a circuit installed in
it to regulate the machine. “Hydraulic
systems were developed during this time.
For many years, hydraulic machines were
used by a majority of companies. The
current generation of injection moulding
machines works on servo motors that save
electricity, and hence, cost,” adds Kumar.
Over the years, hydraulic machines
were replaced with Programmable
Logic Controller (PLC) units. Injection
moulding has always been a step ahead
of extrusion in terms of operational
versatility. With injection moulding, all
that is needed is changing the mould to
achieve the desired design. Today, PLC
From bumpers to door panels, light-weight plastics gives cars better mileage and allows designers & engineers the freedom to create innovative concepts that otherwise would not be possible. Anwesh Koley explores the advantages offered by injection moulded plastics, such as heat and chemical resistance, high strength, impact resistance and ease of moulding.
Driving performance through light-weighting
Courtesy: BASF
34 Modern Plastics & Polymers | April 2012
has become mandatory for machines and
servo motors are in vogue as these consume
less electricity. Various safety features have
also been adopted in injection moulding
machines, which regulate the opening
and closing of the mould cavity.
Plastics in automotivesAutomotives is an important market
for plastic resins such as polypropylene,
polyurethane, nylon and other engineering
polymers & thermoplastic polyesters.
Light vehicle applications account for
over 30 per cent of the demand for
each resin. Other resins used include
Acrylonitrile Butadiene Styrene (ABS)
and Poly Vinyl Butyral (PVB). Some
of the typical plastics and composite
applications, processed through injection
moulding, include exterior panels, trim
and bumper fascia, as well as interior
trim panels, window encapsulation,
headlamp housings, manifolds and
valve covers, electronic/electric parts
and components, wiring harnesses,
steering wheels, insulation, dampening
and deadeners, upholstery, mechanical
components, safety glass, etc.
Design flexibilityNew processes enable manufacturers
to reuse scrap plastics and recycle used
plastics cost-effectively. Also, plastic
components weigh about 50 per cent
less than their steel counterparts. This
enables automobile components to be
substantially lighter, while retaining
the needed strength and contributes to
an overall lighter vehicle, and therefore,
fewer emissions & improved gas mileage.
Automobile design engineers face
many constraints while designing with
metal. Low-cost, single-unit production
of large automobile sections, such as a
front grille, is nearly impossible with
metal. “Plastics offers auto engineers
a variety of practical, cost-effective
alternatives and tremendous advantages
over conventional automobile production
materials,” says Kumar.
Automotive safetyThe versatility of plastics allows design
options that produce lighter and safer
vehicles. From concept to reality, injection
moulded parts offer a wide variety of
advantages to customers, eg, a driveshaft
made from plastic composites can help
increase torque as well as passenger safety.
Conventionally made of steel, a driveshaft
transfers power from the transmission
to the rear axle of the vehicle. But, if
the steel driveshaft fails, it can project
shrapnel in all directions and even dig
into the ground, catapulting the vehicle
into the air. Composite driveshafts are
made of carbon and polymer fibre that
is designed to break into small fibre
fragments or ‘broom’ upon failure, posing
little danger. These are light-weight,
require less energy to spin and effectively
increase the amount of power that the
engine can transmit to the wheels.
Fibre-reinforced polymer composite
materials weigh about 50 per cent
less than steel, though according to a
carbon fibre manufacturer, these are
characterised by a higher absorption of
crush energy per kilogram. On impact,
carbon fibres can have four to five times
higher energy absorption than steel or
aluminium. Front-end components made
of these light-weight energy-absorbing
composite materials are specially
designed to fracture in a manner that
utilises impact energy.
Chassis designA chassis is the supporting frame
of a car. It is an especially important
component that gives the car strength
and rigidity and helps increase the
car’s crash-resistance through energy
absorption. Being the skeletal structure
of a vehicle, the moulded plastics offer
the required rigidity for automobiles and,
in the process, helps in significant weight
reduction. Plastics is making inroads into
the chassis market as well. Innovations in
plastics technology have brought about
the development of successful chassis
applications that would not be possible
using any other materials. Many chassis
parts are made with injection moulding.
The chassis ensures low levels of
Noise, Vibration and Harshness (NVH)
in the vehicle. Not only does a reduction
in NVH allow for a more pleasant driving
experience, but by putting less stress on
connecting components, it helps increase
the life span of these components. The
key determinant permitting reduced
levels of NVH is energy absorption. By
having a high level of energy absorption,
NVH levels are lowered, and passenger
protection can be enhanced in the event
of a collision.
The non-metallic alternative Plastics has found remarkable acceptance
as a substitute for metal in transmission
components. Polyetherimide is used
extensively in transmissions for its superior
dimensional, heat and creep performance,
while a single piece of nylon can replace
several steel washers.
A key factor behind the steady growth
of plastics is its recyclability. The use of
large quantities of the same or similar
materials greatly improves the economics
of recycling. As more plastics are used
in automobiles, it is likely to witness
a trend towards increasing recycling
of plastics.
Email: [email protected]
Sumit KumarGeneral Manager, H K Industries
Choosing plastics for auto body exterior parts allows manufacturers to adopt modular assembly practices, lower production costs, improve energy management, achieve better dent resistance and use advanced styling techniques for sleeker, more aerodynamic exteriors.
In ject ion moulding
Combiningwith precision
safety
SPECIAL FOCUS: Robot ics in in ject ion moulding
36 Modern Plastics & Polymers | April 2012
Higher output, lower cost
and energy efficiency have
become the key criteria
in the injection moulding
industry in India. In order to achieve these,
latest technologies need to be adopted
either through process optimisation or
advanced automation. Industry sources in
India show that the injection moulding
market has grown at average annual rates
of 12-15 per cent in the past eight years,
outperforming the overall economy, which
grew at roughly 6 per cent.
Industry projectionsIn India, about 60,000 injection moulding
machines are currently in operation,
serving a wide ambit of sectors. Naveen
Gupta, Senior Branch Manager,
Polymechplast Machines Ltd, says,
“Injection moulding machine sales in India
in 1990 was 2,500-3,000 per year, and
today it stands at about 8,000 machines
a year.” During 2010-11, the demand
for injection moulding across various
plastic processing machines had acquired
70 per cent marketshare.
While extrusion machinery boasted of
23 per cent share, blow moulding had 6 per
cent of the share and other techniques at
1 per cent. Market projections show that
by 2015-16, almost 10,800 injection
moulding machines would be serving the
plastic processing industry across India.
Latest developmentsThe latest advancements in injection
moulding include servo motor for
energy-savings and all-electric machines
replacing hydraulic machines, which
have precise control and are useful
for pharma & automotive products.
Demand is increasing for packaging
that can be simultaneously labeled
during the injection moulding process.
This has resulted in the development of
well-packed In-Mould Labeling (IML)
systems. Besides functional benefits, this
complex process offers potential for cost
reduction.
Along with these, co-injection
and multi-colour injection moulding
techniques are used to create different
designs with Programmable Logic
Controller (PLC)-operated system
to achieve repeatable design patterns
with higher output. Use of robotics
The versatility offered by injection moulding in terms of design and high production output rates makes it the preferred choice of the plastics industry. Anwesh Koley analyses the current trend towards the advanced usage of robotics, which allows complete automation in the moulding process.
Courtesy: EUnited Robotics
Robot ics in in ject ion moulding
37April 2012 | Modern Plastics & Polymers
and automation reduces manpower
and results in consistent output. “The
industry has benefitted from numerous
innovations over the years. From
conventional technology to proportional
technology, production processes in
injection moulding have come a long
way,” says Gupta.
The latest technology used today
in the injection moulding industry is
aimed at developing energy-efficient and
automation-oriented final products. The
equipment within a moulding machine
are now designed to ensure that they are
digitally controlled, more precise, fast,
compact and easily compatible with the
machine controls. Also, manufacturers
are modernising their plants and have
equipped them with latest CNC machines
and other design-oriented software,
which help produce quality products and
compete in the international market.
With the advent of servo control
technology, the normal plastic processing
has become simpler and engineering
plastic processing, which was earlier
considered a difficult process, has become
easier. Metal Injection Moulding (MIM)
and Ceramic Injection Moulding (CIM)
parts can now be found in all areas of life
from the automotive sector to watches,
from dental braces to mobile phones,
from IT equipment to Do-It-Yourself
(DIY) tools and many other areas.
Ensuring higher output at lower costsAdvanced use of robotics ensures a
higher output, but total moulding cost
is low due to lower cost of machine. All
principal modules – the clamping unit,
injection unit, drive, protective covers
and control system – are coordinated and
geared towards efficient production. Even
complex applications are manufactured
at the highest reproducibility level.
Multi-cavity production reduces the
number of machines and manpower with
less energy consumption by servo drive
and hot runner moulds lower cycle time
& ensure zero wastage.
The use of robots adds accuracy
and speed to the injection moulding
process. Injection moulding machines
produce the same results at the same
speed every time. “Robots can keep pace
and improve the efficiency of the entire
system with quick material handling,
effective palletising and few, if any,
errors,” adds Gupta. Industrial robots
add flexibility to the design of plastics
and are used for all types and sizes of
parts, from minute assembly components
to large automotive body pieces. Robots
can be quickly programmed to handle
different products and palletise or place
parts on a conveyor. They can easily
tend to more than one machine at once.
Also, the use of robotics creates a safer
work environment. Typically, workers
are required to work in proximity
to injection moulding machines, to
remove and stack parts repeatedly.
Those removing the parts from an
injection moulding machine are prone
to repetitive movement injuries. Thus,
robots minimise human contact with
the injection moulding machine.
Challenges facedThe primary challenge to the business is
the advent of low-cost Chinese machines.
Often, customers do not understand the
importance of after-sales and service and
opts for Chinese machines. Visibility is
another area of concern. “Even with a
population of about one billion, India
remains essentially unknown to most
moulders from the US. In terms of
gross domestic product per head, India
lags behind almost all countries in Asia,
except Bangladesh,” laments Gupta.
Comparing this with China,
most moulders from the US have
either lost their business to Chinese
imports or considered relocating some
manufacturing to China. The problem
of low-cost products needs to be dealt
with urgency. While India exports bulk
of its products to African markets, China
remains the largest exporter to India.
Also, there is a need to increase the
level of automation within the injection
moulding industry, which would ensure
higher output, lower wastage and greater
production efficiency.
Email: [email protected]
Naveen GuptaSenior Branch Manager, Polymechplast Machines Ltd
Even with a population of about one billion, India remains essentially unknown to most moulders from the US. In terms of gross domestic product per head, India lags behind almost all countries in Asia, except Bangladesh.
Courtesy: EUnited Robotics
38 Modern Plastics & Polymers | April 2012
SPECIAL FOCUS: PLC-based moulding techniqes
Praveen Sharma
As compared to other
developed countries, India
has a wide scope for growth
of the injection moulding
industry. Currently, the usage of plastics
in India is just 5-6 kg per person per
year, whereas in developed countries, this
figure is 14-15 kg per person. Therefore,
this industry has an immense potential
for further growth. On the other hand,
the competition is increasing with each
passing day, which often reduces the
profit margins of companies.
As demand increases for the use of
plastic components produced through
injection moulding machines, the demand
for injection moulding machines also
increases, and this trend has been witnessed
in the last few years. Many companies, both
domestic and international, have expanded
their manufacturing facilities to meet the
increasing demand of customers.
In India, there is still a large segment
in the plastics sector that uses manually
operated or semi-automatic machines.
While majority of the players today
are resorting to a phased conversion of
these machines into modern automatic
Programmable Logic Controller (PLC)-
based machines, there is much scope and
demand for modern and energy-efficient
machines, which provide a host of benefits
to both the processors and end users.
Technological developments With regard to the developments in this
sector, most of the machinery manufacturers
started their journey with manual moulding
or semi-automatic machines. Gradually, the
all-electric machines made their foray into
the market through increased awareness
and changing global trends. This sector
has witnessed numerous advancements in
the field of Research and Development
(R&D). Be it polymers, moulds, injection
moulding machines, auxiliary equipment or
plant automation, manufacturers have been
successful in implementing cost- and energy-
saving mechanisms. Major developments
in this sector are focussed on how to save
energy and bring about innovative design
concepts for the final product.
Today, due to the advancements in
polymer science and engineering plastics,
most of the parts are made from plastics
instead of aluminium, which has resulted
in lower cost and lightweight components
with better durability of the parts. These
components play a major role in the
automobile sector, and thus help improve
fuel efficiency and achieve cost reduction.
The major parts involved in the
injection moulding set-up are the moulds
and auxiliary equipment. At present, with
the availability of latest design software
and modern tool rooms with CAD/CAM
and CNC machining centres, it is easy to
design and manufacture a typical mould
within a short time. With the possibility
to design typical moulds, the moulds are
now available with hot runner, with more
cooling points that lead to shorter cycle
time, better finished final products and
runner-free parts.
The injection moulding machine
manufacturer plays a major role in terms
of product developments for this sector.
The last decade witnessed a number of
From household items to engineering and automobile parts, the acceptability of plastics has risen over the years, yielding positive results for the injection moulding industry. Here is an insight into the demand and scope for energy- and cost-efficient machines that can provide benefits to processors as well as end-users.
Precise control for efficient operations
Energy consumption savings during holding pressure and mould cooling phases in a servo injection moulding machine
40 Modern Plastics & Polymers | April 2012
improvements, with plastic processors frequently upgrading their
technology in this field. In the early 80s, the machines were
equipped with simple hydraulics and electrical control. In the
late 90s, the machines featured some advanced hydraulics such as
variable displacement pumps and microprocessor and, gradually,
PLC was introduced. Today, machine manufacturers emphasise
more on ways to make their machines more energy-efficient.
Aiding this, injection moulding machines currently are made
available with advanced hydraulics, energy-efficient servo motor-
driven pumps and high-speed controllers.
Scope for improvement There is a large scope for improvement in the injection moulding
industry. In India, there are few all-electric machine manufacturers
and only international companies who provide such machines are
present here. These machines have a bright future if the running
cost and maintenance cost are reduced; this would bring many
potential companies in the ambit of all-electric machines.
As a manufacturer of injection moulding machine with
a brand like Euro Series, Hind Machinery emphasises on
manufacturing energy-efficient and low-maintenance machines
that are affordable. These energy-efficient machines save
40-60 per cent of energy as compared to normal injection
moulding machines, which run on simple induction motors. Also,
new-generation machines are equipped with servo motors having
closed-loop hydraulics, as the pressure is sensed by a pressure
transducer, which gives feedback to the frequency drive of the
servo motor. The company has developed a Euro Star Series
(25 and 50 tonne) equipped with a hydraulic clamping unit and
a unique feature of bush-less tie-bars, which eliminates the need
for lubrication. These machines are also environment-friendly and
almost maintenance free. The company manufactures injection
moulding machines – hydraulic and toggle clamping – with
25-400 tonne clamping force. Indian machinery manufacturers
need to have all latest and advanced features and energy-efficient
servo motors, with a reliable controller at an affordable price.
Enhancing productivity and cost-efficiencyThe industry must move towards providing the customer machines
with latest technology with superior features, which are reliable
and low on maintenance. Few such machines are closed-loop
machines, which ensure repeatability with minimum rejection,
energy savings up to 40-60 per cent depending on the moulding
parameters, giving a higher production rate at a lower cost. The
key challenge before the injection moulding industry is competing
globally to upgrade the technology and offer excellent quality &
cost-effective solutions with higher production rate.
Praveen Sharma is
Proprietor of
Hind Machinery Pvt Ltd.
Email: [email protected]
PLC-based moulding techniqes
42 Modern Plastics & Polymers | April 2012
What is the current scenario of the injection moulding industry in India?The injection moulding industry in India
is growing at 14-15 per cent per annum.
This is because the per capita plastics
consumption in India is one of the lowest
in the world. China consumes about
20 kg of plastics per person per year,
while in India it is 5-6 kg. In developed
countries, this figure goes up to 50-60 kg,
with the US being the highest consumer.
These numbers provide a vast scope for
growth of the plastics industry in India.
What are the reasons for growth of injection moulding industry?The acceptability of plastics has increased
with the rising number of industries using
plastics. This has bolstered the growth of
the injection moulding process. With reagrd
to the food packaging industry, packaging
requirements have changed along with
our eating habits. This industry primarily
involves two methods – blow moulding
and injection moulding. These techniques
run parallelly and end-products may
need both; hence, the injection moulding
industry has seen a jump in demand.
What innovations has this industry witnessed?Energy-efficient (eg, servo motor) machines
consume less power. Earlier, we used only
one type of machine and tried to use it
for all major applications, but this did not
yield the required efficiency in terms of
production and energy consumption.
Today, we offer machines with various
applications. At Electronica, we use toggle-
type injection moulding machines (as these
consume less power and ensure faster
production), while many manufacturers are
continuing with hydraulic-type machines.
What are the energy-efficiency standards in the industry?Manufacturers in India have still not
adopted fully automatic machines on a large
scale, as a high availability of manpower
warrants increased involvement of manual
labour. Globally, hydraulic machines have
been almost completely replaced with
automated units, as these require less
manpower. Earlier, power was not a major
concern for most players in the industry,
but with rising infrastructural bottlenecks,
manufacturers have been forced to develop
machines that yield higher output and
ensure energy-efficiency & cost-savings.
What challenges does this industry face?Low-priced import from China is a major
threat. Chinese manufacturers receive many
benefits such as subsidies and tax concessions
from their government. No such schemes are
available to Indian manufacturers. Import
of finished products is another concern, as
importers have to pay much more. India is
a price-sensitive and non–quality-conscious
market, where companies are initially
attracted by the low sticker price; quality
considerations arise after the machines are
used over a period. But, Indian companies
offer better after-sales service. The industry
has a bright future, as growth rate is high
and the number of applications of injection
moulding has also increased.
Email: [email protected]
…opines Harminder Singh, AGM-Sales & Marketing, Electronica Plastic Machines Ltd. In a conversation with Anwesh Koley, he highlights the recent trends in the injection moulding industry and challenges of quality and price that are facing companies in India.
“Indian products are recognised for better
durability and after-sales
service”
SPECIAL FOCUS: Inter face - Harminder Singh
44 Modern Plastics & Polymers | April 2012
What are the current trends in the Indian plastics industry?In the Indian market, the technical standards
of products is rising and the requirements
in terms of product quality and efficient
moulded part production are becoming
more competitive. Indian moulders are
realising the benefits of quality over costs
and are demanding high performance
and efficiency. Quality production goes
a long way in enabling Indian processors
to explore global markets through reliable
processes and consistent products. We
have observed demand for the modular
Allrounder injection moulding machine
with its extensive range of robotics and
unique Selogica machine control system.
These solutions are perfectly positioned
to meet ambitious demands in terms of
precision, reproducibility, productivity and
energy efficiency across all sectors.
What innovations have been witnessed in the global arena?Due to the increasing complexity of
applications and rising demand for
customer- & branch-specific production
cells, machine control systems are gaining
increased significance. As the all-important
human-machine interface, automation
solutions must integrate robotic systems as
well as other peripherals and enable simple,
intuitive programming & operation of the
entire injection moulding system. Arburg
continues to develop independently
both the hardware and software of the
Selogica control system, in line with the
principle of ‘Making complex tasks easy’.
The developments in the machine and
control system area from a single source
are coordinated at the appropriate level
of detail.
The aim of developing new-age
injection moulding machines is to
continuously increase the efficiency of
moulded part production. This enables
cost reduction without compromising on
quality. Besides machinery performance
and availability, cycle time is a crucial
determinant. At Arburg, we combine
electric clamping units and generously
dimensioned injection units with position-
regulated screw and hydraulic accumulator
technology. This results in machines that
feature energy savings, high productivity
and short cycle times, making these
perfect for various industries, especially
the packaging sector.
What are Arburg’s initiatives for the injection moulding industry in India?For over 20 years, we have been represented
on the Indian subcontinent through our
trading partner Unimark, with whom we
enjoy a highly successful collaboration.
In India, high-tech injection moulding
machines find applications in various
industries, from disposable syringes and
complex automotive parts to mobile phone
shells, micro-gear wheels and irrigation
systems. Arburg also offers customers
extensive support at the local level, from
sales, through pre-sales and after-sales
service, to consulting on applications
engineering. Arburg ensures that it
provides a uniformly high level of service
competence in India and worldwide.
Email: [email protected]
…opines Helmut Heinson, Managing Director-Sales, ARBURG GmbH + Co KG. In an exclusive interaction with Annabel Dsouza, he assesses the potential for futuristic injection moulding solutions in the exponentially growing Indian plastics industry.
“Indian moulders are realising the benefits of quality over
costs”
SPECIAL FOCUS: Inter face - Helmut Heinson
SPECIAL FOCUS: Roundtable
46 Modern Plastics & Polymers | April 2012
Raj Kumar Director, Micron Hydraulics Pvt Ltd
Injection moulding machines today come with new mechanisms to increase output with precision and also maintain energy efficiency. This can be achieved by retro-fitting injection moulding machine hydraulic systems with Variable Speed Drive (VSD). The hydraulic pump motor of injection moulding machines has an average power draw of 30-80 per cent of rated power before retrofit. Installing a VSD retrofit can save 20-50 per cent of power. The pre-retrofit energy use and percentage reduction in energy consumption after installing VSD are functions of most machine and process parameters. VSD raises the power factor of the hydraulic power motor and decreases the amount of thermal energy generated in the hydraulic fluid, reducing thermal load on cooling water system at the plant. This increases savings by 5-20 per cent more than the conventional hydraulic pump motor. Most injection moulding units use a basic hydraulic system or hydraulically actuated system for the clamping unit. Toggle units are more production efficient, but save less energy.
Injection moulding machines have multiple applications and are available in different configurations. It thus becomes important for these machines to be energy-efficient while performing throughout several stages of the process cycle. Anwesh Koley speaks to some industry experts on the key requirements to assure manufacturers of efficient energy usage of these machines.
Thankur Singh Dhooper Director, Popular Engineers (India)
In injection moulding, while using the latest servo motor technology, the hydraulic and screw drive methods are combined to form a synchronous operation based on complex coordination of parts. This reduces the process time by compound moves of mould open/close during charge cycle and ejection during mould open cycle. Increasing the screw rpm by using a high-output servo motor reduces the charge process time. This ensures significant energy savings by optimising fuel flow and reducing noise levels.
The use of structural innovations in the injection unit improves precision. If an ‘in-line’ architecture is applied to an injection unit, it becomes highly responsive and optimal for precision moulding through stable high-speed injection. This minimises mechanical friction, improves injection conditions and fine control of back pressure. A ‘Quick Barrel Change’ device can also be used, which saves operation time by applying the plug-and-play method. A combination of electronically controlled high-performance and mechanical features offers precise injection for high-quality production.
Sivakumar M Manager, Woojin Selex Co Ltd
New-generation servo motors ensure energy savings and low noise levels in injection moulding machines. Revolutions Per Minute (rpm) control the hydraulic servo pump drive system with AC servo motor, saving significant energy. Moulders can save 65-75 per cent energy with these techniques. High precision stability control is achieved by the closed-loop method of hydraulic servo pump-drive system with servo motor reproducibility. A pressurised operation of servo motor enables high responsiveness of the moulding unit. Low-speed and precision positional control allow precision-enabled protection for metallic patterns. Hydraulic moulding with an integrated system ensures precise timing and lower energy consumption. A servo motor rpm control restricts temperature raise of the hydraulic oil, reducing coolant use by 25 per cent and hydraulic oil use by 15 per cent.
Mould deformation can be minimised by improving the platen, which prevents flashes and reduces thickness variation in products by ensuring uniform surface pressure of installed mould.
While various techniques are used to ensure energy efficiency in injection moulding machines, moulders must select the right equipment to enable precise moulding with efficient production set-up. These steps will ensure product consistency as well as customer satisfaction.
Editorial take:
How can Indian companies raise energy-efficiency of
injection moulding machines?
Email: [email protected]
FACILIT Y VISIT: Quadrant EPP Sur lon India Ltd
48 Modern Plastics & Polymers | April 2012
Engineering plastics is
exceptionally easy to machine
and even a slight modification
in the tools can produce
an outstanding smooth surface finish,
enhancing the aesthetics & performance
of machines. Almost all engineering
plastics are easy to machine, which justify
their use over conventional materials due
to reduced labour time, lower energy cost
and faster component production times.
As a one stop-shop for engineering
plastic components, Quadrant EPP
Surlon India Ltd offers solutions to all
engineering plastics application needs,
from material selection to manufacturing
error-free products through precise
process control. The general and advanced
engineering plastics portfolio developed
over the decade includes the broadest
range of standard and custom shapes
for machining in terms of materials and
dimensions.
Satendra Kumar, Chairman &
Managing Director, Quadrant EPP Surlon
India Ltd, avers, “Our unique polymer
technology extends the performance
boundaries of standard engineering plastics
in machined parts. The extra high levels
of performance improve the productivity,
efficiency, quality and life of equipment
beyond the limits of standard materials.”
The company is ISO 9001-2000 certified
and follows a total quality approach after
careful selection of raw materials.
Quadrant EPP Surlon India Ltd is
a part of Quadrant EPP, a name built
on talent and innovation. The history
of the company is rooted in leading
producers of stock shapes for machining
and fabrication and includes former
Polymer Corporation & Polypenco
companies, Erta and Cestidur, Symalit
Fluoropolymers, DSM Engineering
Plastic Products and, most recently, Poly
Hi Solidur. Now part of the Quadrant
group, a global, diversified, high-tech
plastics processing company, Quadrant
Surlon continues to strengthen its focus
on specialised engineering plastics.
State-of-the-art facilityEstablished in 1994, the company’s
production facility in Sahibabad is
spread over an area of 2,000 sq m. The
company also has a larger manufacturing
plant in Dehradun, spanning an area of
7,000 sq m. The Sahibabad facility is spread
across two floors and offers solutions for
every engineering need. Luv Kumar,
Director, Quadrant EPP Surlon India
Ltd, says, “Our range of materials comply
with Food and Drug Administration
(FDA) and other standards, and are
resistant to various chemicals and solvents,
temperatures & mechanical pressures.
For requirements outside this delivery
programme, we offer custom-designed
stock shapes enhanced with or without
fillers and reinforcements.”
The company boasts of a strong
distribution system and guarantees the
availability of materials across a wide
range of shapes & sizes from the stock.
Optimum dimensional stability of machine
parts is ensured through consistency in
Today, engineering plastics seems to be the perfect solution to demanding engineering applications, while conventional materials are less economical. One of the leaders in engineering plastics for the machinery industry, Quadrant EPP Surlon India Ltd provides world-class solutions to its customers. Anwesh Koley traces the company’s efforts in offering innovation and expertise to its customers.
FACILIT Y VISIT: Quadrant EPP Sur lon India Ltd
Engineeringcomplete solutions
under one roof
manufacturing. The company’s ongoing
investment in production and logistics sites
across the world has resulted in extensive
market development for engineering
plastics. “In India, Quadrant Surlon offers
an exhaustive range of products along
with the manufacturing capabilities. The
company expanded its manufacturing
capabilities to include nylon casting,
extrusion, injection moulding and also
has a state-of-the-art CNC machining
capability,” adds Satendra Kumar.
An illustrious portfolioThe company caters to industries such as
steel, paper and pulp, material handling
and food & beverages. While the company
deals in both advanced and general
engineering plastics, its METALON series
enjoys a wide market appeal due to vast
applications and advantages. “Because
of its successful performance in diverse
engineering applications, Metalon 6 PLA
is the most widely used cast nylon in the
industry, especially as a bearing material.
When used for maintenance requirements
of original equipment manufacturers,
these cast nylons have replaced bronze,
brass, steel, aluminium and other metals,
as well as other plastics, wood & rubber.
Metalon 6 PLA provides higher wear
resistance, high tensile strength and
modulus of elasticity. The low coefficient
of friction, high mechanical strength and
stiffness and other properties make this
series a favourite in the market,” adds
Luv Kumar.
High quality systems Competition is intense in the engineering
plastics market, and the quality of services
and product differentiation is the key
to ensure a steady customer base. “Our
ability to offer reliable products and
service levels are based on Total Quality
Management approach reinforced by
ISO 9001-2000 standards. Quadrant
Surlon meets customer requirements
for consistent quality, performance and
machinability. The company has set the
standard for careful selection of quality
raw materials and resins, leading process
technologies and highest manufacturing
standards,” says Luv Kumar.
Support and service In India, Quadrant Surlon provides
application, technical and production
support as per customer requirements.
“Our teams of technical service,
application development engineers and the
most comprehensive testing laboratories
are based at all major locations in India
and abroad. The mission of our technical
support team is to help equipment
manufacturers, engineers and machinists
in material selection through machining,
for optimum performance, productivity
& cost efficiency,” adds Luv Kumar. The
company is seeking ways to utilise the
available resources and influence to bring
relevant, accessible & affordable plastic-
fibre products to people worldwide.
Rapid market growth At every stage of a project, the company
extends its support with a thorough
evaluation of performance needs and
application environment. The selection
of the appropriate software enables
the company to ensure right material
selection. In India, it is mandatory to
receive prior certifications for materials
and compliance from regulatory agencies.
The company has a dedicated team
to get all these requirements in place.
The market for engineering plastics
is growing repidly and customers are
demanding quality & reliability from
their purchases. “With steady research
and development initiatives, which result
in path-breaking products, Quadrant
Surlon has become a major player in
the industry. We plan to increase our
production facilities beyond the current
limits in order to serve our customers
better,” concludes Luv Kumar.
Email: [email protected]
Satendra KumarChairman & Managing Director
Our unique polymer technology extends the performance boundaries of standard engineering plastics in machined parts. The extra high levels of performance improve the productivity, effi ciency, quality and life of equipment beyond the limits of standard materials.
Quadrant EPP Sur lon India Ltd
49April 2012 | Modern Plastics & Polymers
Material cutting and design
51April 2012 | Modern Plastics & Polymers
Engineering plastics:Offering high-performance capability .................................................................. 52
Innovation edge:Engineering new avenues for plastics ................................................................... 56
Interface:Raju Desai, MD, Compounding Division, Jyoti Group .................................... 58
Shamik Shah, VP-Sales & Marketing, Monachem Additives Pvt Ltd ............ 60
Sanjay Jain, Business Director, DSM Engineering Plastics India ..................... 62
QRST method:A four-step approach for project cost managementM Hariharan, Director, Savoir Faire Management Consultancy Pvt Ltd................ 64
Engineering Plastics
INSIGHT & OUTLOOK
INSIGHT & OUTLOOK: Engineer ing plast ics
52 Modern Plastics & Polymers | April 2012
Courtesy: design mag
The engineering plastics
i n d u s t r y p o s s e s s e s
cons ide rab l e g row th
potential, as untapped
opportunities still exist for metal
replacement in cars and trucks, household
appliances and other applications.
Considering this, the global market
for engineering plastics is projected to
grow at a Compounded Annual Growth
Rate (CAGR) of 9.5 per cent over the
next decade.
In India, the growth is driven by
increasing usage of engineering plastics in
segments such as Electrical & Electronics
(E&E), construction and automotives.
Canon Patel, Managing Director, Loxim
Industries Ltd, says, “The demand for
engineering plastics [excluding Acrylonitrile
Butadiene Styrene (ABS), Polypropylene
(PP) and Polyurethane (PU)] is about
100,000 million tonne per annum in India,
and the demand growth rate is 14 per cent
annually (CAGR for 2009-15).”
Concept of engineering plasticsEngineering plastics exhibits superior
mechanical and thermal properties
over commonly used commodity
plastics. Engineering plastics usually
refers to thermoplastic materials, eg,
ABS, Polycarbonate (PC), Polyamide
(PA), Polybutylene Terephthalate
(PBT), Polyethylene Terephthalate
(PET), Polyphenylene Oxide (PPO),
Polysulphone (PSU), Polyetherketone
(PEK), Polyetheretherketone (PEEK),
polyimide, and many more. Patel
notes, “Engineering plastics is used for
manufacturing household items, circuit
breakers, electrical enclosures, luggage
shells, gears, bushings & bearings, etc. In
the automotive sector, it is used to make
fenders, door panels, instrument panel,
trims, door handles, wheel cover, etc. It is
also used in under-the-hood applications
such as air-intake system, engine cover,
radiator parts, engine oil systems, brake
systems, ignition systems and motors.”
Engineering advantagesAn engineering plastic material is selected
based on its range of enhanced physical
properties. Patel avers, “The key benefits of
engineering plastics are cost-effectiveness,
as these have lower manufacturing cost,
electrical insulation properties, excellent
surface finish, colourability, high production
volume, wide range of mechanical properties
and transparency. These materials are also
corrosion- and chemical-resistant, light
in weight, decorative, paintable, flexible
and soft.”
Engineering plastics offers improved
design flexibility to manufacturers more
than that by metal, glass or wood. A
variety of colour and surface finish can be
achieved to meet the desired aesthetical
and haptical needs. Patel opines, “Plastics
moulding permits more complex shapes
and greater geometry details, which is
not the case with metal stamping.” Other
properties of engineering plastics include
high heat resistance, mechanical strength,
With India becoming an automotive hub and the electronics market witnessing a boom, the demand for engineering plastics in India is increasing. Offering greater flexibility, design freedom, robustness and weight reduction, these are fast replacing other materials. Avani Jain drills deeper into the performance and profitability quotient of engineering plastics.
high-performanceO g
54 Modern Plastics & Polymers | April 2012
rigidity, chemical stability and flame
retardency.
Automotive applications The drivers of change in the automotive
industry are weight reduction, greater
fuel economy and system cost reduction.
Patel notes, “Engineering thermoplastics
are ideal materials to achieve these goals
since their specific gravity is substantially
lower than metals. Thus, these materials
are increasingly replacing metal in key
application areas.” He further adds, “For
automotive applications, higher melting
point and long-term temperature
resistance are required to sustain high
temperatures typically encountered by
components close to the engine. The
excellent heat resistance property of
engineering plastics, such as PA, has
been successful in these areas.”
Polyamide (PA6) and PA66 are
among the most important polymers
by volume in the engineering plastics
market. The excellent strength and
toughness displayed during exposure to
hot, aggressive automotive fluids or hot
air make PAs useful for manufacturing
durable and functional components for
automobiles.
Future trendsEngineering plastic materials are making
inroads in areas where metals once
enjoyed a monopoly. The light-weight
trend that had come from the automobile
industry has spread to the electronics
industry as well, with mobile phones,
pad computer and notebook becoming
more light-weight and smaller. Thus,
light-weight has become the mantra of
success and is defining new horizons
for the engineering plastics industry.
Considering the benefits of engineering
plastics, their demand is expected to rise
globally, driven by the ongoing replacement
of metal parts with high-performance
plastics. The consumption growth of
engineering plastics on an average annual
basis is likely to reach 3 million tonne –
18 per cent of the total demand in 2013.
Email: [email protected]
Canon PatelManaging Director, Loxim Industries Ltd
For automotive applications, higher melting point and long-term temperature resistance are required to sustain high temperatures typically encountered by components close to the engine. The excellent heat resistance property of engineering plastics, such as PA, has been successful in these areas.
Engineer ing plast ics
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InsIght & OutlOOk: Innovat ion edge
56 Modern Plastics & Polymers | April 2012
The industry today is seeking a suitable alternative to conventional materials used in engineering applications.
There is an increased emphasis on constant technological upgradation so as to maintain a consistency with various challenges and demands that the market brings forth while exploring new vistas for material applications. Thus, engineering plastics is acquiring an increasing fervour owing largely to greater flexibility that it offers. Its nature of application is limited only to the imagination of the engineer, while the possibilities are unlimited.
This is mainly because engineering plastics possesses physical characteristics that allow it to perform for prolonged durations in structural applications, over a wide temperature range, under mechanical stress and in unfavourable chemical & physical environments.
The demanding nature of the market has made way for a much sought-after panacea. The various factors contributing to this are an increasing need to upgrade the manufacturing cycle while cutting down on wastage and allowing enhanced recyclability of components. There is a need to reduce raw materials usage,
which is pivotal as a cost-saving exercise for an industry that operates on thin margins and is mostly volume-driven.
Understanding the plastics advantageIn comparison with metal, plastics exhibits better chemical and moisture resistance as well as higher shock & vibration resistance. It is lighter in weight and usually either transparent or at least translucent in thin sections. It has the advantage of sound and vibration absorption and some types of plastics possess greater wear & abrasion resistance than metals. Some plastics, such
Engineering plastics, which is more of a contemporary development and has completely changed the outlook towards plastics, is now challenging the supremacy of metals in conventional engineering applications. Lionel Alva takes a closer look at how engineering plastics is increasingly being regarded as a saviour for engineers today.
InsIght & OutlOOk: Innovat ion edge
Engineeringnew avenues for
plastics
Innovat ion edge
57April 2012 | Modern Plastics & Polymers
as nylons, are self-lubricating. Significantly, one of the most important characteristics of plastics is that it is usually easier to fabricate than metals. Some plastics can also be plated, but a more important property is that plastics can be pigmented in a wide variety of colours. Because of its lighter weight, which gives it an advantage in cost per cubic inch with respect to metal and its easy-to-fabricate characteristic, finished plastics parts are frequently less costly than metal parts.
“Engineering plastics is a modern concept for the industry and yields several advantages in terms of being lighter in weight, self-lubricating, high-end performance similar to metals, etc. It helps modern engineers replace softer metals with these materials in order to ensure infinite possibilities of applications. It also depends on how an engineer can consider and formulate different applications for these materials and put it in the best possible use. Today, India is a small market for engineering plastics as compared to much smaller regions such as Europe; hence, this material has a wide scope. People are increasingly becoming aware of the advantages of this material in the plastics industry and as they are learning, the market is growing. Engineering plastics is viable for the industry in terms of the qualities that it imparts to the equipment it is used in. It may require slightly high initial investment as compared to conventional materials such as metal, but the advantages it gives to the equipment are far greater. Features such as reduced downtime, lower maintenance, higher efficiency and performance of equipment nullify the initial cost,” avers Aditya Tandon, Owner, Classic Polymers and Resins.
Role of fillers, additives and reinforcing agentsPlastics also has certain negative properties. To begin with, plastics is not as strong as metal. In general, it possesses lower heat resistance and is flammable. Plastics is characterised by a much larger thermoexpansion, lower ductility than metals and most types are brittle at low
working temperatures. However, the use of reinforcing additives and fillers has mitigated the disadvantages of conventional plastics, while allowing it to be used in applications that were not considered within the span of plastics used earlier. For example, incorporation of glass fibres into a polyolefin will increase its strength, toughness, rigidity, dimensional stability and heat resistance, putting the reinforced material into an entirely different class as compared to a material that has not been so modified. Other reinforcing agents for plastics include asbestos, which increases strength and heat resistance, and carbon black that increases weather resistance and imparts lubricity & electrical conductivity. Addition of metal powders or metal fibres provides thermal and electrical conductivity to plastics, increases the strength of the material and imparts other desirable properties.
“Reinforcing additives improves the mechanical properties of plastics and reduces the influence of temperature on these properties. This brings new applications within the range for plastics, for example, replacing light metal castings or housings of sheet steel. Fillers and reinforcing additives can modify the properties of plastics within broad limits. There is no sharp distinction between the two terms but, broadly, fillers denote inorganic materials that lower the price of the plastics and may also improve its modulus of elasticity, thermal resistance and surface quality,” avers Sudhir Koli, Deputy General Manager, Bright Autoplast Ltd.
An indispensable matterIn practically all application areas, plastics has come of age like no other material. World production of plastics in 2004 was close to 225 million tonne, a tenfold increase in less than 40 years, and the current rate of increase is about 5 per cent per year. However, unlike metals, all types of plastics fall within a narrow range of specific weights, ie, 0.9-1.5 gm/cm3. This makes plastics indispensable for creating weight-saving designs.
Email: [email protected]
Aditya tandonOwner, Classic Polymers and Resins
Engineering plastics is viable for the industry in terms of the qualities that it imparts to the equipment it is used in. People are increasingly becoming aware of the advantages of this material in the plastics industry and as they are learning, the market is growing.
sudhir koliDeputy General Manager, Bright Autoplast Ltd
Reinforcing additives improves the mechanical properties of plastics and reduces the influence of temperature on these properties. This brings new applications within the range for plastics, for example, replacing light metal castings or housings of sheet steel.
58 Modern Plastics & Polymers | April 2012
INSIGHT & OUTLOOK: Inter face - Raju Desai
How has engineering plastics helped design more innovative products? Plastics is perhaps the most versatile and
cost-effective material known to man. At
Jyoti, while dealing with customers, we
check the application areas and work to
formulate a product for their application
requirements. This demands a great
degree of Research and Development
(R&D), and these efforts of the industry
have helped plastics achieve a ubiquitous
presence today. Of course, the use of fillers,
reinforcing agents and additives confer the
core material characteristics that provide
unprecedented opportunities for creating
innovative products.
What critical applications are driving the demand for engineering plastics in diverse fields?
Any application that uses metals can
easily be considered as a critical area
that can use plastics. A good example
for the use of plastics and that has
changed the scenario of the industry is
parts for submersible pumps, which were
conventionally made from gunmetal and
cast iron; the process involved a lengthy
and arduous manufacturing process that
required several steps such as machining
and sandblasting. Even in aerospace,
plastics is used to a large extent while
allowing for body structure considerations
that were not possible earlier for high-
performance parts. All industries, from
mining and railways to construction, use
engineering plastics since these offer
several advantages such as improving
performance and longevity over their
conventional counterparts.
How commercially viable is engineering plastics in India from a manufacturer’s perspective?In the Indian context, plastics pose
two advantages from a manufacturer’s
perspective. The first is that the demand
for engineering plastics is growing and
is stronger than in any other part of
the world. Also, the domestic market
potential still remains untapped. The
engineering plastics being produced
in India is viable for the industry in
terms of the advantages it yields to the
equipment that it is put into. While it
may have a slightly higher investment
initially, its advantages to the equipment
in terms of lower downtime, better
lubrication, higher efficiency and
performance make up for the slightly
higher investment cost.
What R&D initiatives have you undertaken with regard to engineering plastics?We have a one-stop shop right from
design, engineering analysis, assembly
and supply. We have in-house capabilities
for product development and product &
stress analysis. We are, perhaps, the only
company specialised in designing plastics.
Recently, we had developed low-cost
computer parts for Bharat Electronics,
which came to be known as the lowest
cost tablet PC in the world. Jyoti Plastics
has also won a Plasticon Gold Award
this year for the most innovative product
design where the assembly line required
three assembly parts and converted these
three into one complete part by using
injection moulding, which shortened the
manufacturing cycle considerably.
Email: [email protected]
…states Raju Desai, Managing Director, Compounding Division, Jyoti Group. In an interaction with Lionel Alva, he highlights processing trends in engineering plastics while sharing his vision on the role of plastics in setting the stage to establish India as a major world player.
“The domestic market potential still remains untapped”
60 Modern Plastics & Polymers | April 2012
INSIGHT & OUTLOOK: Inter face - Shamik Shah
What is the demand for additives in the Indian plastics industry?The demand for plastic additives is
increasing in India. This growth is directly
proportional to the extent of innovation
happening within the plastic processing
industry; government regulations; global
standards [eg, fire retardant standards,
Restriction Of Hazardous Substances
(ROHS), Food and Drug Administration
(FDA), environmental standards, etc]; and
dissemination of knowledge of various
performances that plastic additives offer
to all users of plastics, including the final
consumer.
What are the current trends in the industry?Today, a plastic processor is keen to
gain more knowledge of innovative
plastic additives such as anti-microbial,
anti-scratch and halogen-free flame-
retardants. Another trend is forming
partnership between an additive supplier
and a compounder/masterbatcher. The
plastic additive supplier brings in the
knowledge of plastic additives and the
compounder brings his processing skills.
Yet another trend is the entry of foreign
additive processors into Indian markets,
which introduces global quality standards
in the Indian plastics industry.
What are some of the innovations in this segment? Numerous innovations are taking place
across all industries, thus increasing demand
for plastic additives. In the automotive
sector, several innovations are happening for
developing anti-scratch applications, light-
weight solutions and improving impact
resistance. Stabilisation for medium- and
high-voltage cables and metal deactivation
solutions are some innovations happening
in the wire & cable industry. The packaging
industry continuously demands better
aesthetics, increased shelf-life of food
products, etc. The infrastructure sector
requires chlorine-resistant solutions for
Polyethylene (PE) pipes. In the households
sector, innovations are happening to
improve aesthetics, surface and mechanical
properties, which are replacing Bisphenol
A (BPA)-based Polycarbonate (PC) with
Polypropylene (PP) for baby bottles and
other similar items. Similarly, numerous
innovations are happening in the agricultural
and medical sector, driving the demand for
plastic additives.
What are the challenges faced by the industry?Some of the challenges faced by this industry
include fluctuating price of additives,
compliance with international standards
entering the Indian market, which are
pushing the Indian plastic processors to use
specific additives. Despite the challenges,
there are opportunities for growth of the
industry as well. There is an aggressive
scalable growth potential of additives in
the Indian market, as many areas remain
untapped. Plastic additives can be used
across different industries. There is a strong
opportunity for plastic additive suppliers
and masterbatchers/compounders to work
together for developing new markets.
What are your growth plans for the company?We want to build on our core strengths,
which are to offer the widest range of
plastic additives solutions from a single
source, quality products with consistency
and high performance from leading
brand manufacturers across the world,
quality service in terms of response time,
application support and R&D. Currently,
the company offers solutions for
improving processing and flow to ensure
cost reduction, improving mechanical
and surface properties, halogenated
& non-halogenated flame-retardant
solutions for various polymers, heat &
Ultraviolet (UV) stabilisation solutions
for improving the usage life of plastics,
phenol-free stabilisation for PP fibres,
nonylphenol-free liquid antioxidant for
improved colour & gas fade performance,
stabilisation solutions for medium- &
high-voltage XLPE cables, solutions
to reduce breakage of PP totes & bins
for retailers, reduction of water carry
over for PP/PE tapes used in Flexible
Intermediate Bulk Container (FIBC) and
polyvinyl chloride replacement solutions
for the medical industry.
Email: [email protected]
…opines Shamik Shah, Vice President–Sales & Marketing, Monachem Additives Pvt Ltd. In an exclusive conversation with Avani Jain, he states that plastic additives confer a unique innovative edge to a plastic processor for differentiating his products in the market place.
“Plastic additives can be used across different industries”
62 Modern Plastics & Polymers | April 2012
INSIGHT & OUTLOOK: Inter face - Sanjay Jain
What are the current application dynamics for engineering plastics in India?The current application dynamics
for engineering plastics are driven by
the end-use market, which includes
automotive, electrical and electronics
and general industry. Applications in the
automotive industry arise from entry of
existing applications in new car models
and conversion of complex metal parts to
plastics for higher fuel efficiency, weight
down, improving Noise-Vibration-and-
Harshness (NVH) performance and
overall system cost reduction. Applications
in the electrical and electronics industry
are driven by use of less hazardous
materials & replacement of conventional
materials such as thermosets.
What are the latest innovations in the world of engineering polymers? New ideas and innovations in engineering
polymers are the result of increased
awareness in major end-markets for
‘Green’ materials – for example, bio-based
polymers and halogen-free flame retardant
compounds. Bio-based polymers are
partly based on renewable raw materials.
The raw materials are not oil-based, but
produced from vegetable sources or by
fermentation. Some bio-based polymers
can also be biodegradable. EcoPaXX™
developed by DSM is an example of
innovative green high-performance
plastics. EcoPaXX is carbon neutral, as
CO2 generated in the production process
is compensated by absorption in the
growth process. It has been well received
by many global automotive Original
Equipment Manufacturers (OEMs) and
is being evaluated by all major OEMs.
Another example is the Arnitel® Eco
– a high-performance Thermoplastic
Co-Polyester (TPC) partially made from
renewable resources, in which rapeseed oil
is used instead of mineral oil.
How cost competitive is engineering plastics for the Indian market?The Indian engineering plastics market
has been using materials ranging from
high-performance materials such as
polyether ether ketone, Stanyl Polyamide
(PA)46 and polyethylenimine to
more commoditised materials such as
polyoxymethylene. Thus, engineering
plastics with various price points are
finding a place in the competitive
Indian market. The challenge is not with
engineering plastics being cost competitive,
but has more to do with having the right
capability to identify, design and develop
applications that create real value for all
in the business chain as compared to the
incumbent solution and deliver total lower
cost of ownership.
How does DSM assess sustainable performance of engineering plastics?Engineering plastics is a recyclable
material. The extent of recycling depends
on various factors, including its end-use.
As far as engineering plastics is concerned,
the use of renewable/halogen-free raw
materials is not sufficient to make a
product ‘green’, but the sustainability of
the product must also be assessed. DSM
has commissioned Life Cycle Assessment
(LCA) of its products to prove that their
new solutions are indeed reducing the
impact on the environment. For example,
to assess its reduction in greenhouse
gases, Arnitel Eco was measured against
classic co-polyesters using a so-called
‘cradle-to-grave’ LCA. The study was
carried out in accordance with ISO
14040/14044 standards. The IPCC 2007,
GWP 100a method was used to quantify
the global warming potential of Arnitel
Eco as compared to classic co-polyesters.
The international norm to measure
renewability is ASTM D6866. This
norm uses the difference in isotopes of
new carbon from plants and old carbon
from oil to calculate the renewable carbon
content.
Email: [email protected]
…believes Sanjay Jain, Business Director, DSM Engineering Plastics India. In this exclusive interaction with Annabel Dsouza, he traces the trend of innovations, cost efficiency and sustainability of engineering plastics in India.
“Engineering plastics are finding place in the competitive Indian market”
INSIGHT & OUTLOOK: QRST method
64 Modern Plastics & Polymers | April 2012
M Hariharan
Today, any individual handling a project can be found talking about cost over-runs, budget over-runs, time over-runs.
Why do most people face such problems? Is there no solution for these problems? In project management, the first question that arises is how to complete the project on time, but one fails to understand the cost impact of this over-run on the overall profit of the firm. Here, Project Cost Management (PCM) comes into picture.
Purpose of PCMEnsuring that the plan is in place and tracking & minimising the deviations from the plan is critical for preventing or minimising cost over-runs. Thus, project cost control must ensure the following:
Identifying early trends of cost variances on Quantity-Rate-Specification-Time (QRST) basis
for timely corrective actions Projection of estimated cost to
completion as per study of trends & technical analysis
Suggest corrective actions to minimise cost over-runs, manage review & final decision
Analyse costs incurred on each construction contract package
Levels of PCMPCM requires three ingredients to be effective:
Cost budgeting: It means estimating costs of resources needed to complete project activities and allocating overall cost estimate to individual work activities
Actual cost tracking: It involves capturing actual costs incurred at the Work Breakdown Structure (WBS) level when it incurs (not approximation of cost incurred across WBS elements)
Cost control: It includes tracking changes to the project budget, identifying
trends and ensuring on-time at-cost completion
Cost drivers The reasons for deviations in the actual project cost from the budget are Quantity, Rate, Specification and Time (QRST):Q: Implication on cost due to change in quantity from change in design and scope, extra work not specified in the contract, rework due to modification at post-installation, incorrect installation, failure of installation & designR: Implication on cost due to change in rate caused by statutory variations, tax structure, inflation, demand & supplyS: Implication on cost due to change in specification in terms of materials, physical design, quality characteristics & safety standardsT: Implication on cost due to time factors – delay resulting in idle time of resources and crashing of activities
Earned Value Management (EVM)EVM manages project cost on an on-going basis by measuring project performance related to three variables:
Budgeted Cost of Work Scheduled (BCWS) [Planned Value (PV)]:
Physical work to be done, including the estimated value of this work
BCWS to be completed on an activity or WBS component up to a given point in time
Budgeted Cost of Work Performed (BCWP) [Earned Value (EV)]:
Physical work actually accomplished, including estimated value of this work
A four-step approach management
for project cost In any project by a company, the actual costs generally exceed the estimated costs and schedule, as a result of which budget takes a backseat. Cost management is the bottom line for any company’s projects. Here is an outline of the QRST method for minimising deviations in the expected cost over-runs.
Earned value graph
66 Modern Plastics & Polymers | April 2012
Budgeted cost for work actually completed on schedule or WBS component during a given time
Actual Cost of Work Performed (ACWP) [Actual Cost (AC)]:
Actual costs incurred to accomplish the earned value
Total cost incurred in completing work on schedule or WBS component in a given period. This must correspond in definition and coverage to that budgeted for BCWS & BCWP
Performance metrics for EVM EVM uses the following key performance metrics to manage project costs:
Cost Variance (CV): Indicates if the work accomplished using labour and materials costs more or less than was planned in the project (measured as BCWP minus ACWP)
Schedule Variance (SV): Overall assessment in monetary terms of the progress of work packages in the project scheduled to date (measured as BCWP minus BCWS)
Cost Performance Index (CPI): Measures cost efficiency of work done to date. CPI<1 indicates cost over-run and CPI>1 indicates that the costs are within budget (calculated as BCWP/ACWP)
Schedule Performance Index (SPI): Measures scheduling efficiency and predicts completion date. It is used with CPI for projecting project completion status. SPI <1 indicates that the project is behind schedule and SCI>1 indicates that the project is ahead of schedule (calculated as BCWP/BCWS).
Prediction metrics of EVM For a project manager, it is critical to have a mechanism that pre-empts the cost and schedule over-run to plan its completion on schedule. EVM uses two metrics for this – Estimate At Completion (EAC) and Estimate To Complete (ETC). EAC is a forecast of most likely total project costs based on project performance and risk quantification. EAC is measured as ACWP plus ETC. ETC is a forecast of additional costs that will be incurred in future. This is calculated by considering future cost trends and corrective actions to be taken to manage EAC.
Triggers for cost over-runsCost over-runs triggered at different phases of a project:
Proposal phase (failure to understand customer requirements, unrealistic appraisal of in-house capabilities, underestimating time requirements)
Planning phase (omissions, inaccuracy of work breakdown structure, misinterpretation of information, use of wrong estimating techniques, failure to identify and concentrate on major cost elements, failure to assess & provide for risks)
Negotiation phase (forcing a speedy compromise, procurement ceiling costs, negotiation team that must ‘win this one’)
Contractual phase (contractual discrepancies, difference in statement of work and request for proposal requirements, difference in proposal & project teams)
Design phase (accepting customer requests without management approval, problems in customer communication channels, data items & design review meetings)
Production phase (excessive material costs, unacceptable specifications, manufacturing and engineering disagreement)
Recovery actions for PCMOn the basis of EVM, project cost management has to manage ETC to ensure that EAC is within acceptable limits. Some recovery actions that can be taken are as follows:
Push for compliance- Try and maintain original plan and do not accept potential changes
Recover in later tasks- Future plans must reflect in the project schedule
Add resources- Get additional help, consider potential increase in project expenditure and possibility of diminishing returns when adding resources
Accept substitutions- When something is unavailable or expected to be late, substitute a comparable item and consider any potential effects on performance
Use alternative work methods- Find an expedient way to complete the work and check its impact on cost & schedule
Accept partial deliverables- Delivering only some of the items may keep the project moving forward
Offer incentives- Offer bonus or other inducements to improve performance
Renegotiate cost and schedule targets- Extend deadline or increase budget
Reduce scope- Reduce quality and performance requirements of deliverables to reduce the work required, but all stakeholders must agree on this course of action
In a nutshellPCM must influence the factors affecting cost baseline; ensure that requested changes are agreed upon; manage the changes; monitor cost performance to detect variances from cost baseline; record all changes against cost baseline; prevent incorrect, inappropriate or unapproved changes from being included in the reported cost or resource usage; and work to bring expected cost over-runs within acceptable limits.
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 helps organisations to improve their profitability by aligning their people and processes to customer value and articulate the bottomline impact using the cost excellence (CE©) model. Email: [email protected]
QRST method
uantity
QRST of cost variations
ate
pecification
ime
Q
R
S
T
AUTOMATION TRENDS: Automatic d ie changers
The high cost of initial
design in terms of time,
money and marketshare is
well understood. With the
die-making process at the helm of the
manufacturing process, due care must be
taken to ensure its smooth functioning.
Another key reason is that many plants
in India still do not take an integrated
approach to invest in modernisation.
The focus, instead, is on the production
capacity of machines. A more systemised
approach that would help streamline the
production process is often neglected
due to focus on the production capacity
of machines.
However, industrial paradigms
strongly depict how the profitability
of investing in reducing setup times
allows for a remarkable 70-90 per cent
savings potential over conventional,
completely manual methods for making
moulds and dies. Thus, it is crucial
that manufacturers work to reduce this
set-up time in order to stay ahead of the
competition. Since most engineering
thermoplastic parts are fabricated
by injection moulding, the use of an
automatic die changer for such machines
will enhance the quality and consistency
in high-output plastics processing. But,
to achieve this, the designer must have
a keen understanding of the overall
manufacturing process.
Need of the hourConsidering the competition in the
industry, the emphasis has increased
on a standardised approach that utilises
just-in-time inventory techniques for
production. Also, lead times are crucial
to the success of an organisation,
and greater pre- and post-production
planning is required. With the
Indian plastics industry being largely
fragmented and driven by Small and
Medium Enterprises (SMEs), this
provides a significant challenge since
there is little scope for error in this
era of cut-throat competition driven
by complete enterprise solutions. Thus,
there is a pertinent need to develop
techniques that can improve lead times
and enhance quality & consistency in
production. A quick die-change system
is perhaps the most crucial aspect of
a paradigm shift in the manufacturing
approach.
Anand Kshatriya, Manager-New
Product Development, Renata Precision
Components Pvt Ltd, emphasises,
“Automatic die changers are the need
of the hour that focus on consistency
of output by making a process cleaner
and saving valuable time. With rising
industrial standards, the injection
moulding process is expected to deliver
the highest output at the lowest
possible cost. Automatic die changers
can considerably reduce the downtime
of machines while changing the mould,
and with minimum possible labour
involvement. Changing die in less than
three minutes is practically possible,
this increases the total output of the
machine and is integral to the highly
competitive Indian scenario. This will
allow for standardisation of moulds for
particular machines, and hence ensure
better control on manufacturing.” He
further adds, “Hydraulic and hydro-
magnetic automatic die changers
facilitate controlling the entire clamping
mechanism with one button, and are
manufacturing
The ever-evolving nature of the plastics industry is driving technological sophistication, with automation being a key ingredient for a more streamlined manufacturing process. Lionel Alva highlights the changing dynamics of plastics manufacturing, the significant role of automatic die changers for injection moulding machines and their effect on the plastics processing.
might
AUTOMATION TRENDS: Automatic d ie changers
68 Modern Plastics & Polymers | April 2012
Steering the
Automatic d ie changers
69April 2012 | Modern Plastics & Polymers
more convenient and technologically
advanced than conventional mechanisms.
This will improve the quality of output
due largely to mechanised manufacturing
systems with quality checks in place.
With implementation on a trial basis
started by medium- to large-scale
industries, this flawless system with a
quick changeover aimed at cost reduction
would be the driving force behind
the popularity of such systems in the
near future.”
Design considerations Melting the plastic material and injecting
it into the mould are the functions of
the plastifying and injection system.
The rate of injection and pressure
achieved in the mould are controlled
by the machine hydraulic system.
Injection pressures are in the range of
35-138 MPa (5,000-20,000 psi). The
melt temperature varies between a low
value of 205°C (400°F) for acetal resins
to a high value of about 300°C (570°F)
for some of the glass-reinforced nylon
and Polyethylene Terephthalate (PET)
thermoplastic polyester resins.
Vinod Sutariya, Head of Department
- Marketing, Indo German Tool Room,
Ahmedabad, avers, “The automobile
industry and heavy parts manufacturers are
among the key users of this technology. It
bears relevance especially with engineering
plastics where the mould weight is higher
and production lead time is important.
The role of an injection moulding machine
manufacturer is important in this regard
since machines have to be designed in
accordance to specifications provided by
the customer.”
Various design considerations for
Quick Mould Change (QMC) system
are as under:
Size of the machine (tonnage) and
machine & moulds
Mould fixed and moving side-platen
thickness must be standardised
Direction of the mould change could
be vertical or horizontal
Rail construction
Mould positioning slot and mould
plate chamfering
Two systems for QMC – hydraulic
clamp-type and magnetic machine
platen-type – as well as machine &
mould design
Hydraulic circuit design for QMC
and weight & size of the mould – for
selection of mould clamping device
If pressure drops, the system can add
pressure automatically and become
interlocked with the machine to
avoid mould damage
Adjustable height range of machine
Mould positioning slot
An important point is that the moulding
cycle can be as short as two seconds or as
long as several minutes, with one part to
several dozen products ejected each time
the mould opens. The cycle time can
be limited by heat transfer capabilities
of the mould, except when machine
dry cycle or plastifying capabilities
are limiting.
Time saved is money savedA quick die-change system could be a
game changer for plastics manufacturers,
especially those involved in manufacturing
of engineering plastics. The foreseeable
advantages are apparent both in the
long term and short term since it leads
to a considerable reduction in
manufacturing cycles, giving room
to manufacturers to respond quickly
to client needs. It will provide them
with an opportunity to survive in an
unfavourable economy with periodic
changes in demand. While the initial
cost of such an automation process
may be high, it is more than offset by
the significant advantages it offers to
the manufacturer where profit is the
key to survival in a largely volume-
driven market. Also, a standardisation
of the process would reduce the need
for constant maintenance at every
stage of the manufacturing cycle while
improving on the quality and consistency
of production. While it may not
be something as a drastic as re-inventing
the wheel, automatic die changers
are of great significance for an
assembly line.
Email: [email protected]
Anand KshatriyaManager - New Product Development, Renata Precision Components Pvt Ltd
The injection moulding process is expected to deliver the highest output at the lowest possible cost. Automatic die changers can considerably reduce the downtime of machines while changing the mould, and with minimum possible labour involvement.
Vinod SutariyaHead of Department - Marketing, Indo German Tool Room, Ahmedabad
The automobile industry and heavy parts manufacturers are among the key users of this technology. It bears relevance especially with engineering plastics where the mould weight is higher and production lead time is important.
ENERGY MANAGEMENT: Hybr id machines
70 Modern Plastics & Polymers | April 2012
The Indian injection moulding
machinery industry is
incessantly setting up
new highs year over year,
thanks to the increased ability of Indian
machinery suppliers to accommodate into
their machines enhanced technologies
available across the world. An injection
moulding machine can be classified into
following types – hydraulic, mechanical,
electric and hybrid. Of these, hybrid
injection moulding machines are gaining
prominence due to the benefits these
provide to customers.
Types of machinesOstensibly, the predominant type available
in the market is the hybrid injection
moulding machine. The mechanical
machines use the toggle-type system
for building up tonnage on the clamp
side of the machine. The electric or all-
electric injection moulding machines are
new in the market but are becoming
popular due to their energy efficiency,
greater cleanliness, quick start-up, better
repeatability and noiseless operations.
But, the cost of these machines is higher
by 50-200 per cent than the conventional
hydraulic systems. The fourth type
– hybrid injection moulding machine –
combines the best features of hybrid and
electric systems. Amit Mahant, Director,
PK Plastic International Pvt Ltd, notes,
“It is predicted that by the end of 2012,
as many as 20-25 per cent of all installed
machines would be all-electric or hybrid
machines, concentrating in the 50- to
500-tonne range.”
Identifying the merits The hybrid machines combine features of
both the electric and hydraulic machines.
Mahant says, “These features include
hybrid clamping design with electric
servo motor, core pull, part ejection and
carriage movement powered by a gas
accumulator & variable-volume hydraulic
pump.” As compared to conventional
hydraulic machines, hybrid machines
are better in many ways. Mahant notes,
“These are noiseless and can save power
by 25-30 per cent, which depends on
product cycle to cycle. Also, compared to
electric machines, these cut down energy
consumption significantly, thus reducing
operating costs & addressing some of the
associated environmental concerns.”
Hybrid injection moulding
machines ensure low cycle times and
are environment-friendly. Mahant notes,
“The servo drive in the hybrid machines
help increase energy efficiency, leading
to smaller footprint and low operational
costs. Servo drive when idle, during the
cooling time, does not consume energy, ie,
it saves the flushing energy. Moreover, the
amount of energy needed for oil cooling
is lower in hybrid machines.”
Eliminating the demeritsHybrid injection moulding machines also
suffer from certain limitations. Mahant
notes, “Their merits are less when
compared to electric machines. The electric
machines are quieter, faster and have
higher accuracy than hydraulic machines.
Contamination and oil maintenance is not
a problem with electric machines. Further,
in case of hybrid machines, manufacturer
has to take care of the servo drive against
dust and contamination. Also, these
require an in-built voltage stabiliser to
prevent fluctuations in power ratings.”
The cost factorWith regard to the cost of hybrid
machines, Mahant says, “At present, hybrid
injection moulding machines are costlier
than conventional hydraulic machines
by 35-40 per cent. The cost of these
machines is 20-25 per cent lower than
all-electric injection moulding machines.
Injection moulding has been the preferred processing technology for part manufacturing that requires high output and accuracy. Of the various types available in this segment, hybrid injection moulding machines are gaining wide acceptance due to a number of reasons. Avani Jain assesses the cost-quality ratio of these machines.
Hybr id machines
71April 2012 | Modern Plastics & Polymers
The main reasons for this are servo
drives, variance in machine specifications
by manufacturers and application-based
machine models.” He adds, “In future, the
price can be reduced by making available
different types of servo drives and
manufacturing more number of machines.
Other factors may also affect the market
for hybrid injection moulding machines
in the future.”
Future projections The future trends for improving the
quality and reducing the cost of hybrid
machines will include multiple factors.
“The performance and quality of
machines can be improved by using more
electric servo drives, greaseless tie bars,
etc. Hybrid machines need to have two
or three servo drive to eliminate more
number of hydraulic systems, oil tanks
or reservoirs. Greaseless tie bars will
help eliminate part contaminations,”
suggests Mahant.
In future, hybrid machines will face
tough competition from the all-electric
machines. The only disadvantage with
electric machines at present is that these
are costly and only few companies in
India are manufacturing these machines.
Further, these machines cannot go beyond
a certain tonnage such as 100-140 tonne,
and thus are not suited for large-scale
productions. In such a scenario, the hybrid
injection moulding machines can win the
competition, as these are better than the
conventional hydraulic machines and less
costly than all-electric injection moulding
machines.
Thus, both all-electric and hybrid
injection moulding machines will find
major applications in the automotive,
agriculture, electrical & electronic,
packaging and medical sectors because
of their energy-saving claims. In today’s
competitive world, machines with higher
output and lower power consumption
per unit of output will be the winners.
Thus, the industry must be proactive in
bridging the technology gap in high-end
processing machines and processes.
Email: [email protected]
Amit MahantDirector, PK Plastic International Pvt Ltd
The performance and quality of machines can be improved by using more electric servo drives, greaseless tie bars, etc. Hybrid machines need to have two or three servo drive to eliminate more number of hydraulic systems, oil tanks or reservoirs. Greaseless tie bars will help eliminate part contaminations.
POLICIES & REGULATIONS: Expansion projects
72 Modern Plastics & Polymers | April 2012
The rapidly expanding sphere of influence of the plastics industry within a short span of time has deeply impacted
key economic sectors in India, such as agriculture, infrastructure, healthcare and consumer goods. But, the nature of this growth is subjective and the core competence of the Indian plastics industry as a whole is questionable since the future of the industry seems uncertain.
All seems to be going well for India’s plastics industry, whose remarkable growth has outpaced the country’s Gross Domestic Product (GDP). It has emerged as a ` 85,000-crore industry, employing directly and indirectly over four million people and has achieved an export turnover
of ` 13,000 crore. In contrast, per capita consumption of plastics in India is among the lowest in the world, and the industry lies fragmented and largely driven by Small and Medium Enterprises (SMEs) that lack the necessary technological prowess to compete globally. Much needs to be done to consolidate the industry’s prospects to help it acquire its true potential.
On an expansion driveThe forecast for the plastics industry seems to be positive, with unprecedented opportunities in both domestic and international market. Credit Rating and Information Services of India Ltd (CRISIL) states that the world
trade in plastics is expected to reach 140 Million Metric Tonne (MMT) by end of 2012, providing a lucrative opportunity for India. However, considering its meagre 1.5 per cent share in world export volumes, the country is not well equipped to capture this opportunity. The Indian plastics industry needs to strengthen capacity, upgrade facilities, improve productivity and increase use of critical plastics applications. This will facilitate economy of scale, allowing industries to adopt better technology and waste management strategies while enhancing quality & consistency in production. In this regard, India is performing well, as 60 per cent of plastics here is recycled as compared to the world average of 20-25 per cent.
Uday Shah, Managing Director, Star Technocrates Pvt Ltd, says, “Some crucial factors to consider while undertaking expansion projects include demand from the local customer base and export potential. Having the new site located close to a well-connected port significantly reduces the cost of internal logistics and enables new production to be market-ready & sustainable.” He adds, “Another factor is the use of latest technology. With the Indian plastics industry competing on the global scale in terms of products and solutions, one must invest in state-of-the-art manufacturing technology & practices. Technology is critical in plastics processing and enables long-term returns on initial investment. Break-even period varies with the type of expansion, so manufacturers must be cautious while planning expansions.”
In this era of many astonishing industrial developments, probably no industry has undergone such rapid growth and development as the plastics industry. In order to consolidate their presence in a growing market, industry players are planning major expansion drives. Lionel Alva and Annabel Dsouza highlight some critical factors prompting the industry to raise the stakes.
Achieving economy of scalewith
industry-friendly policies
Expansion projects
73April 2012 | Modern Plastics & Polymers
Tapping domestic potentialWhile every government report on the plastics industry has emphasised the need for a facilitative policy to foster growth for this industry, little has been seen in terms of initiative. The Indian plastics industry faces several handicaps such as cost of capital, feedstock, electricity and local taxes & tariffs as compared to producers in the US, Europe and other parts of Asia. Today, India has the lowest import duties in the world even though producers here do not enjoy any competitive advantage in raw material, capital cost, energy or other conversion cost.
Saudi Arabia has emerged as a major producer of plastic raw materials due to huge advantage in feedstock, which costs one-tenth of current prices elsewhere in the world, and the country levies 12.5 per cent import duty on polymers to protect its industry. In contrast, India, with no significant advantage in the cost of feedstock, energy or capital levies 5 per cent import duty on polymers. Here, import duty on polymers is lower than in the US, European Union, China, Malaysia
and other Asian countries. Further, Government of India is aggressively pursuing Free Trade Agreement (FTA) with many of these countries and trading blocs proposing to bring import duty to zero. This move will further deteriorate the position of Indian producers, taking away the employment opportunities offered by the industry.
It is necessary to break away from the bureaucracy and the government must bring forth initiatives to boost the development of this sector. Despite globalisation, the domestic market for manufacturing has not acquired the support it needs. A greater awareness is required as there is a lot of misinformation, due to which a facilitative policy regime for growth has not been established yet. There is a need to tap the tremendous demand in the domestic market. The plastics industry has grown despite tough conditions, and a favourable policy will position it such that India can establish itself as a major world player.
Email: [email protected]
Email: [email protected]
Uday ShahManaging Director, Star Technocrates Pvt Ltd
With the Indian plastics industry competing on the global scale in terms of products and solutions, one must invest in state-of-the-art manufacturing technology & practices. Technology is critical in plastics processing and enables long-term returns on initial investment.
STRATEGY: P last ic products recycl ing
74 Modern Plastics & Polymers | April 2012
Plastics finds immense applications in nearly all verticals of the manufacturing industry – from automotives to
packaging. But, the industry is realising the vast opportunities offered by recycled plastics. In India, about 3.6 million tonne of plastics is recycled every year. The major types of plastics recycled include Polyethylene (PE), Polypropylene (PP), Polyethylene Terephthalate (PET), Polyvinyl Chloride (PVC), Acrylonitrile-Butadiene-Styrene (ABS), Polystyrene (PS), Nylon, Polycarbonate
(PC), High-Impact Polystyrene (HIPS), Poly(Methyl Methacrylate) (PMMA) and other engineering plastics.
Current trendsNot many companies are involved in recycling of plastic products. K M Shah, Managing Director, NU-VU Conair Pvt Ltd, notes, “Recycled plastic products find usage in definite market segments. Recycled plastics cannot be used in all industries, such as food and medical industries.” However, there are various sectors in which innovative use of
recycled plastics will offer more benefits than normal plastics.
Application areasPlastic bags can be recycled and reused further. Recycled plastics can be used in various areas, such as in making artificial goods and road construction. At present, recycled plastics finds maximum usage in the artificial goods industry. Its use in road construction is a relatively new concept, which is slowly growing in India.
The advantage of using plastic waste in road construction is noteworthy, as it does not need employing new and/or costly high-tech machinery. It improves the performance of the road and helps it last longer, thus solving the problem of disposal of harmful plastic waste. Apart from channelising waste material towards building the nation’s infrastructure, roads made from recycled plastics have enhanced longevity and overall performance. The cost of plastic road construction may be slightly higher than that of conventional methods. But this should not be a deterrent to adoption of the technology, as the benefits are significantly higher than the cost. Recycling or reuse of materials for road construction can have direct and indirect economic benefits. It also reduces transportation and production costs since materials are reused.
In packaging, recycled PET (rPET) sheets can be effectively used for pharma and blister packaging. The increased usage of PET bottles has resulted in high availability of PET bottle flakes, and this is bound to grow further. The rPET sheets can be converted into products such as carpet fibre, strapping, moulding compounds
With increasing focus on sustainable development, the plastics industry is making efforts to recycle plastics. Recycled plastic products have many applications and offer a cost-effective solution across industries. Avani Jain analyses the profitability quotient attached to this business.
Focussing on the economics angle
76 Modern Plastics & Polymers | April 2012
and non-food containers. Recycled PET is accepted as the preferred material due to its numerous superior properties that include crystal-like clarity and sparkle, toughness, lightweight, good gas barrier, etc. It is also resistant to solvents as well as corrosion, besides being recyclable and regrindable.
Cost factorEvery process has a cost involved but that must be justified. Shah says, “Recycling of plastics is a cost-effective solution, which needs to be developed in a better way. It gives an edge to convertors in today’s competitive market. There are certain areas where recycled plastics in tolerable percentage can be used effectively. This can make the products cost-effective.”
Recycling of plastic products is definitely a profitable business but a few points must be taken into consideration. If plastics is recycled using correct technologies and machines, then the end product will be of good quality and yield good margins to manufacturers. Manufacturers are gradually identifying the advantages of recycling plastic products and, in future, this industry will see a progressive growth.
Smart strategies Many companies have taken up the task of recycling plastic products and are also reusing them. Bharat Mistry, Partner, Ash Win Engineers, avers, “We manufacture machines that recycle plastic wastes. For example, the entire plastic tanks are cut into small pieces by a scrap cutter, and these pieces are fed into a solid granulator where their size is further reduced to 10 mm. These are then put into a recycling extruder in which fine plastic granules are obtained; these granules are used to make entirely new product. Therefore, we are not only making the machine, but also reusing the plastic waste.” He further adds, “This is profitable because we do not have to buy fresh plastics and can make products from the available resources. But, customers are not showing much interest in such products, and hence their perception needs to be changed.”
Many companies are developing new technologies that enable efficient recycling of plastic products. Shah says, “We manufacture machinery (auxiliary equipment) that can help processors in regrinding their plastic materials. We are also directly involved in recycling of plastic wastes. The main waste at our unit is injection and blow moulding screws. These are ground by our granulators and reused further.”
Future trendsIn the near future, recycled plastics materials are expected to be increasingly used in road construction. As a result, India will have strong, durable and eco-friendly roads, which will solve the problems associated with plastic wastes. Going further, this will improve the environment while also creating a source of income.
Much has been said about recycling of plastics, but integration of conventional waste management methods with commercial viability requires skills and technologies. Shah notes, “One must select the right method with all precautions and appropriate machinery for building profitability through efficient recycling of plastic products. There are numerous applications for recycled plastics, such as road constructions and buildings. Thus, in the time to come, there will be many companies taking interest in this area.”
The trend is setting in, but this industry is still at a nascent stage. Further, unlike foreign countries, companies in India still consider it as a secondary task and do not employ proper technologies for recycling of plastic products. Thus, in order to build profitability through recycling of plastic products, companies need to invest in latest technologies and trends.
Taking into consideration the ongoing efforts by various companies, the goal of the plastics industry is to become more environment-f riendly in the future. Further, with the latest machinery and methods making inroads to the country, the recycling industry will reach new heights and recycled plastics will see maximum application in various industries.
Email: [email protected]
K M ShahManaging Director, NU-VU Conair Pvt Ltd
One must select the right method with all precautions and appropriate machinery for building profi tability through effi cient recycling of plastic products. There are numerous applications for recycled plastics, such as road constructions and buildings.
Plast ic products recycl ing
Bharat MistryPartner, Ash Win Engineers
We manufacture machines that recycle plastic wastes. This is profi table because we do not have to buy fresh plastics and can make products from the available resources. But, customers are not showing much interest in such products, and hence their perception needs to be changed.
TIPS & TRICKS: Purchasing used in ject ion moulding machiner y
78 Modern Plastics & Polymers | April 2012
Injection moulding is one of the most preferred methods in plastic processing. Hence, with the rise in demand for injection moulded parts, the market for used injection moulding machines is also on the rise. Anwesh Koley explores various points that must be considered before purchasing a used injection moulding machine.
Guidelines to strike the right dealAnwesh Koley
With the anti-dumping duties levied on Chinese plast ics in ject ion moulding machines,
buyers in India are now looking for used plastics injection moulding
machines, considering the lead times of domestic machine manufacturers being more than two month. This leads to processors turning to used plastics injection moulding machines, which are readily available at 45-50 per cent of the price of the new machine. To provide market processors with high-quality
used machines at affordable prices, the secondary market for injection moulding machines has seen a host of improvements over the years.
Email: [email protected]
(With inputs from Rohan Shahane,
Regional Director – South East Asia,
MachinePoint Group)
Following are some points to consider before purchasing used plastics injection moulding machines:
Used machinery offered for sale should be properly checked and inspected in terms of functionality and condition, especially the electrical parts, by the buyers to ensure that they get what they pay for. This proves beneficial in terms of productivity and saving money for a company that is unable to invest a huge amount.
In most injection moulding machines, under most circumstances, the hydraulic oil pumped to run the machine is not used but dumped back into tank through a relief valve. A valve is the hydraulic equivalent of a mechanical brake, which converts energy to heat. Thus, while purchasing used injection moulding machine, the hydraulic oil around the valve should be checked to avoid congestion.
While choosing a used injection moulding machine, one must consider the different forms of power available. Although hydraulic machinery is the most conventional, a hybrid equipment can increase energy efficiency, strength and accuracy. In the early stages of development of business, a used device is more cost-efficient and gives time to familiarise the company with the product’s advantages.
The condition of the screw/barrel assembly and mould components must be inspected, as often, the machines do not undergo regular maintenance or service contracts by original equipment manufacturers. Each equipment used in an injection moulding machinery has specific applications. The buyer must have a thorough knowledge of the usage of a component in the mould machinery.
Used machinery is usually not warranted; hence, one must know the extent of refurbishment and the actual state of the machinery. One should find out about the state of maintenance and look for worn out parts. It is advisable to insist on a test run and be alert for signs of machine ill-health such as unusual vibrations or noise.
Installing AC drive systems on the right injection moulding machine can yield remarkable results. But, it is not easy without the right combination of equipment and experience to determine if a system is justified in a given situation. Thus, before buying a used machine, one must ensure that the AC drive has long cooling time and an integrated electrical system.
PROJECTS
80 Modern Plastics & Polymers | April 2012
Chlorinated Polyvinyl Chloride (CPVC) Lubrizol CorporationProject typeNew facilityProject 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, GujaratProject cost` 1,175 crore ($ 245 million)Implementation stageProposed
Contact details:
Aant Pant
Lubrizol India Pvt Ltd
9/3, Thane Belapur Road, Turbhe
Navi Mumbai - 400705
Tel: 022-27672568-74
Fax: 022-27632407
Email: [email protected]
Composites processing CarburesProject typeNew facilityProject 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, USAProject cost$ 6.5 million (€ 4.9 million)Implementation stagePlanning
Contact details:
Carbures USA
5, Hercules Way
Donaldson Center Airport
Greenville
South Carolina - 29605
Tel: +1-864-593 3934
Email: [email protected]
Plastic additives BASFProject typeNew facilityProject 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 opportunities presented by the countries of 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 locationBahrainProject costNot knownImplementation stage
Planning
Contact details:
Reinhold Lutz
BASF Bahrain
PO Box 18696
Al Seef, Bahrain
Tel: +973-17585251
Fax: +973-17583400
Email: [email protected]
Polysilicon Punj LloydProject typeNew contractProject 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 Tonne 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, QatarProject cost$ 1 billion approxImplementation stagePlanning
Contact details:
Punj Lloyd House
17-18 Nehru Place
New Delhi - 110019
Tel: 011-26466105
Fax: 011-26427812
Email: [email protected]
New projects and expansion activities are the barometers of industrial growth. These also present business opportunities to service providers like consultants, contractors, plant & equipment suppliers and others down the value chain. This feature will keep you updated with vital information regarding new projects and capacity expansions being planned by companies in the plastics, polymers and allied industries.
EVENT LIST
82 Modern Plastics & Polymers | April 2012
Vinyl India 2012This conference is dedicated to the surging vinyl and chlor alkali sectors of the Indian chemical industry. This event will witness industry leaders sharing their perspectives on the current scope and future potential of PVC applications, feedstock availability and pricing as well as trends in health, safety and environment; April 12-13, 2012, at Hotel Grand Hyatt, Mumbai
For details contact: Nidhi Verma
ElitePlus Business Services Pvt Ltd
61, Radheya, 14th Road, Plot 359
Khar (W), Mumbai 400052
Tel: 022-26000556/26000555
Mob: 09322335560
Fax: 022-26000556
Email: [email protected]
Website: www.eliteplus.co.in
Die & Mould India 2012With plastics processing scaling new heights in India, the die & mould industry is of particular significance to plastic parts manufacturing. This event will focus on tooling, CAD/CAM solutions, rapid prototyping & modeling, moulding machine/die casting machine, texturising, gauges, die spotting, etc; April 19-22, 2012; at Bombay Exhibition Centre, Mumbai
For details contact: Tool & Gauge Manufacturers Association
of India (TAGMA)
A-33, Nandjyot Industrial Estate
Safed Pool, A K Road
Mumbai - 400 072
Tel: 022-28526876/28508976
Fax: 022-28503273
Email: [email protected]
Website: www.tagmaindia.org
Packplus South 2012This will be an opportunity to focus on the emerging opportunities in the fast industrializing markets of South India. This event will emphasize on plastics packaging applications through its latest trends and technologies, especially by SMEs; July 6-9, 2012; at Hyderabad International Trade Exposition Centre (HITEX), Hyderabad
For details contact: Prateek Kaushik
Print Packaging Pvt Ltd
E-6, 1st Floor
Lajpat Nagar 2
New Delhi, India
Tel: 011-2981 2833/2981
2934/2981 2834
Mob: 09313011029
Fax: 011-4172 2130
Email: www.print-packaging.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; April 18-21, 2012;
at Shanghai New International Expo
Centre, PR China
For details contact:
Lillian Tse
Adsale Exhibition Services Limited
6th Floor, 321 Java Road
North Point
Hong Kong
Tel: +852 2516 3374
Fax: +852 2516 5024
Email: [email protected]
Website: www.chinaplasonline.com
PLAST 2012Among the world’s leading markets for
plastics processing machinery, Italy is at the
forefront of technology and innovations.
This event will highlight machines for
foam, reactive and reinforced resins,
laboratory control & test equipment,
ancillary equipment, raw materials,
acrylics, polyamides, polyolefinics,
styrenes, vinylics, thermoplastic polyesters,
masterbatches, fillers, reinforcements,
additives, etc; May 8-12, 2012; at Fiera
Milano, Milan, Italy
For details contact:
Promaplast
Centro Direzionale Milanofiori
Palazzo F/3 - 20090 Assago
Milan, Italy
Tel: +39 02 8228371
Fax: +39 02 57512490
Email: [email protected]
Website: www.plastonline.org
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. The 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
For details contact:
AIPMA House
A-52, Street No. 1
MIDC Marol
Andheri (E), Mumbai - 400 093
Tel: 022-28217324/25, 28352511
Fax: 022-28216390
Email: off [email protected]
Website: www.plastivisionarabia.org
International
The information published in this section is as per the details furnished by the
respective organiser. In any case, it does not represent the views of
Business Insights •Technologies•Opportunities
National
EVENT PREVIEW: Die & Mould India 2012
84 Modern Plastics & Polymers | April 2012
With the global tooling
industry progressing
towards high-tech
solutions across all
applications, the 8th edition of Die &
Mould India will expose Indian tool
rooms to global standards of quality
and consistency, thus keeping pace with
higher growth rates in the manufacturing
sector. Organised by Tool & Gauge
Manufacturers Association of India
(TAGMA), Die & Mould India 2012
will be held from April 19-22, 2012, at
Bombay Exhibition Centre, Mumbai.
P N Surendranath, Executive Director,
TAGMA, says, “Tool rooms today are
under tremendous pressure from shrinking
budgets and production cycle times. The
solution lies in a concerted team effort
of software technologists, tool-cutting
engineers, machinery manufacturers,
CAD/CAM solution providers, etc. Die
and mould technology covers the entire
manufacturing sector from the largest
to the smallest application, beginning
with dimensional research, prototype
development and production. Indian
tool rooms are currently under pressure
from Original Equipment Manufacturers
(OEMs), who demand faster product
turnover at competitive prices.”
Tapping the plastics potentialIndian tool rooms are increasingly focussing
on plastic moulding due to a healthy
growth with rising demand for high-
quality plastics. This is further led on by a
surge in demand for high surface finish and
precision moulds with shorter moulding
cycles to achieve optimum productivity
& quality. The key considerations for
moulding machines are tonnage, clearance
between platen, injection pressure, distance
between tie bars, height of closed mould,
height of fully open mould, etc.
The injection mould manufacturing
process includes machining of steel plates,
converting flats and rounds to core/cavity
inserts and other critical parts with
Computer Numerical Control (CNC)
milling, CNC Electrical Discharge
Machining (EDM), CNC wirecut, etc.
Reducing the amount of metal used,
wall thickness of plastic products and
improving efficiency of the final product,
all require continued efforts.
Concurrent eventDie & Mould India offers a complete
range of technologies for plastics injection
moulding, hot runner systems and latest
automation & measuring solutions. Being
the biggest die & mould focussed event,
the exhibition leaves no stone unturned in
consistently meeting the expectations of both
exhibitors and visitors. Many international
and national exhibitors will present modern
technology and solutions, helping industry
professionals connect, network and explore
business prospects with market leaders.
Email: [email protected]
Over the years, Die & Mould India has emerged as a leading platform that represents the aspirations and concerns of Indian tool rooms. As the tooling industry strives for global standards of excellence, Annabel Dsouza unveils the potential of Die & Mould India 2012 and the opportunities awaiting the industry.
Gearing up for global opportunities
In a nutshell What: Die & Mould India 2012 When: April 19-22, 2012 Where: Bombay Exhibition
Centre, Mumbai Net exhibition space: 20,000 sq m No of visitors: 30,000+ No of exhibitors: 300+ Key exhibitor range: Press tools
& gauges, hot runner systems, CAD/CAM system, accessories for machine tools, etc
85April 2012 | Modern Plastics & Polymers
EVENT FOCUS: Chinaplas 2012
85
Chinaplas 2012
Event Preview: Heralding unlimited opportunities ........................................................................................................................................ 86
In the News ........................................................................................................................................................................ 88
Product Showcase ............................................................................................................................................................ 90
Now in its 26th edition, Chinaplas has established itself among the foremost trade shows in the world and is one of the most sought-after events in Asia. This edition also promises to demonstrate technology and concepts that will set the pace for a definitive growth of the region’s plastics industry. Here are some of the highlights to watch out for.
Heralding unlimited opportunitiesEVENT PREVIEW: Chinaplas 2012
86 Modern Plastics & Polymers | April 2012
Lionel Alva
As it marks the beginning of a new epoch in the success
story of the plastics industry, Chinaplas 2012, to be
held during April 18-21, 2012, in Shanghai, will be
of great interest to the latent observer and especially
those associated with the plastics industry. The event promises to
provide a unique opportunity to understand the varied pan–Asian
plastics industry with experts envisaging robust growth trends.
As per industry statistics, consumption of plastics is expected
to reach 297.5 million tonne by 2015. This growth is largely
driven by the booming market in the Asia-Pacific region,
with China and India being the key players. The event
will highlight the key factors spurring the unprecedented
growth of the plastics industry, such as development of
new-age plastic materials, new applications while also
addressing environmental concerns, which are changing
the outlook towards plastics.
The event, being held at the Shanghai New
International Expo Centre, will serve as a gateway to
enter Asia’s growing plastics industry for the trade
and industry associations from across the world.
While allowing established players to consolidate
their presence on a global stage, the event will
provide them with new avenues for growth and
help discover novel applications and also acquire
a greater cognisance of trends that are driving
the industry today.
Sustainability effortsThe previous edition depicted an unprecedented
interest in environment-friendly plastics such as
bioplastics and biodegradable plastics. With growing
environmental concerns worldwide, there is an increasing
emphasis on ‘green’ technologies such as bioplastics
processing and recyclable solutions. This edition has
increased the space allotted to the bioplastics zone by
40 per cent in order to provide an impetus to and
recognise the enormous potential that bioplastics has
for the market today. Concurrent with Chinaplas
2012, the fourth International Conference on
Bioplastics and Applications will be held, which
will provide an in-depth focus on this segment.
World’s leading bioplastics suppliers will
display their products at the event. Some of the
Chinaplas 2012
87April 2012 | Modern Plastics & Polymers
renowned exhibitors in this field include
Cardia, Danisco, Ecomann, Esun, Hisun,
Kingfa, Mirel Plastics, NatureWorks, Nuvia
and Demag. Overseas and Chinese plastics
associations will continue to support the
conferences, which are expected to reach
over 70 sessions this year.
The organiser of Chinaplas, Stanley
Chu, Chairman-Adsale Exhibition
Services Ltd, asserts, “The complicated and
changing global economic situation will
bring new challenges to China’s economy.
Today, enterprises are perplexed by
shortage of labour and electricity in China,
and elimination of backward production
capacity due to the growing pressure of
energy-savings. Chinaplas 2012 will display
products such as robot hands, energy-saving
servo motors, all-electric injection moulding
machines and bioplastics materials, which
will offer solutions to address the problems
of environmental protection, raw material
shortage & new recycling technologies.”
Exploring growth avenuesBesides the growing demand from the
automobile, mining, chemical, construction
and agricultural industries, the Asia-Pacific
(APAC) market is propelled by trends
such as globalisation and demand for
durable products. With rapid urbanisation
taking place in the region and lucrative
opportunities offered by the APAC market,
the plastics sector is set to grow by leaps
and bounds in the future. The growth of
the plastics industry is attributed largely to
a steady rise in engineering plastics, which
has been at the forefront of innovation
and technological development.
A concurrent event ‘Future Zone’ will
be held to display creativity in plastics
applications. Its first part, ‘Nurturing Our
Future’ programme, is for university students
and experts from the automotive, plastics
& rubber industries to combine plastics
& rubber applications and technology to
create a new design for ‘Future Car’. The
second part, ‘Premium Design Gallery’,
will showcase new products from local
and overseas companies, which fall in the
categories of future transportation vehicle,
appliances, architecture and packaging.
Surmising event expectationsWhile tracing the phenomenal rise of the
Asian plastics industry, the event is expected
to gain attention from companies the world
over and focus on ‘green innovation’ that
will lead to a paradigm shift in plastics
concepts. With advancements in plastic
material science and mounting demand
for product innovation through high-
performance polymers, the global plastics
industry is expected to flourish further.
Email: [email protected]
Event spotlight Recognised as the second biggest
event in the world
Estimated to attract more than
100,000 trade visitors
100+ group of buyer
delegations expected
Exhibition area of
over 200,000 sq m
Over 2,600 international
exhibitors
IN THE NEWS
88 Modern Plastics & Polymers | April 2012
LANXESS emphasises on ‘Green Mobility’ LANXESS will display a series of its
latest technologies and environment-
friendly products under the theme of
‘Green Mobility’ at Chinaplas 2012
– a renowned trade fair in the field of
plastics and rubber in Asia.
The company will highlight its
premium products predominantly used in
the electronics, automotive, construction
and plastics coating industries. It will
display its engineering plastics for the
automotive industry with a range of
Durethan® polyamides and Pocan®
polysters, which exhibit features such as
high load resistance, halogen-free flame,
flame retardancy and good flowablility.
LANXESS’s subsidiary Rhein
Chemie (RCH) will exhibit its new
additive BioAdimide™. This additive
enables production of renewable bio-
based polymers for durable applications
with low environment impact.
The company’s line of customised
range of inorganic pigments for colouring
plastics Bayferrox® and Colortherm®
will also be featured. These pigments
impart features such as ease of dispersion,
high thermal stability, excellent weather
stability, light-fastness, making these an
optimal choice for eco-friendly colouring
of plastics.
Chinaplas 2012 to focus on energy-efficient LED solutions
Solutions and materials dedicated to
the lighting industry, particularly Light
Emitting Diode (LED) applications,
will be the focus at Chinaplas 2012.
Lighting consumes about
20 per cent of China’s overall electricity
supply, making power supply tight.
Reducing power consumption in
lighting is a significant step by China
for saving power. LED, due to its
energy-efficient and environment-
friendly features, is expected to flourish
in the lighting industry.
Generally, plastics and rubber
composites are used for LED production,
eg, polybutylene terephthalate,
polymethyl methacrylate, polyethylene,
silicone rubber, polycarbonate, glass fibre-
reinforced epoxy, etc. According to Gong
Xiaozhi, Secretary General-Shanghai
Illumination Electric Appliance
Trade Association, “Applications of
plastics and rubber in the lighting
industry are expected to grow by
15-20 per cent annually in China.
Materials for encapsulation, light
reflection, diffusion, dodging,
heat dissipation, production of
lens, etc, will be in great demand,
offering the plastics and rubber industry
an opportunity for further growth.”
Theme at Chinaplas 2012: The future is in plastics and rubberAimed at uniting the direction of
industry development and building an
effective platform to assist the industry in
implementing the green concept, Chinaplas
2012 actively aligns itself with the rapid
development of China’s plastics & rubber
industries by showcasing advanced
products, technologies and solutions from
local & overseas, under a new theme ‘The
future is in plastics and rubber’.
A concurrent event ‘Future Zone’
is being organised to display unlimited
creativity on plastics applications. The
first part of this event, ‘Nurturing
Our Future’, programme aims for a
collaboration between university students
and experts from the automotive, plastics
& rubber industries to combine plastics
& rubber applications, technology and
innovations to create a brand new
design of ‘Future Car’. The second
part, ‘Premium Design Gallery’, will
feature a series of unique designs of
various plastic end-products. Kingfa
Sci & Tech Co Ltd, DuPont Titanium
Technologies (Shanghai) Co Ltd and
Bayer MaterialScience will display
products in the automotive, electronics &
electrical appliances as well as packaging
categories. Plastics and Rubber Processing
Machinery and Moulds Manufacturers
Association (ASSOCOMAPLAST)
will also showcase Italian designed
plastic products.
Key buyers from auto industry to visit Chinaplas 2012 Chinaplas 2012 signals a strong
relationship of the plastics and
automotive industries with many
renowned buyers from the automobile
and auto components industry joining
the event. The automotive industry is
enthusiastically supporting the drive
towards efficient energy-saving measures
and sustainable growth, resulting in
faster development of plastics and
rubber machines & equipment as well
as the mould industries. Advanced
moulding techniques combined with
injection moulding machinery and
hot runner systems, featuring high-
precision, efficient, energy-saving and
environment-f riendly designs will
have a significant effect on research
and development & manufacturing
processes. Some of the key buyers from
automobile and auto parts industry have
registered for Chinaplas 2012, including
BMW, Honda, Great Wall Motor, TE
Connectivity and Yanfeng Visteon.
An event ‘Future Zone’ will be held
concurrent to Chinaplas. It includes a
‘Nurturing Our Future’ competition for
which students have been invited to
submit their designs combining plastic
and rubber applications, technology
& innovation to build a brand new
‘Future Car’.
IN THE NEWS
89April 2012 | Modern Plastics & Polymers
Key buyers from E&E industry register for Chinaplas 2012 The rapid development of
Electronics and Electrical
(E&E) industry has increased
demand for plastics and rubber.
Offering advantages such as
low density, light weight, high
chemical corrosion resistance,
high insulation, flexible design
and high recyclability, with
the market trend towards
high-performance, safe and
sustainably developed eco-
friendly materials, plastics and
its numerous applications have
become a major development
in the E&E industry. Followed
by popularity of personal
intelligent telecommunications
devices, the application of
transparent and electrically
conductive thin film used on
touch panels is expanding.
Many renowned buyers
from the E&E industry have
registered for Chinaplas 2012,
eg, Philips, BYD, Panasonic,
Schneider Electric, Mitsubishi
and Samsung. The event will
display a wide range of plastic
materials used in the E&E
industry, including Light-
Emitting Device (LED)
applications. Plastics and rubber
composites are used for LED
production, eg, polybutylene
terephthalate, polymethyl
methacrylate, polyethylene,
silicone rubber, polycarbonate,
epoxy resins, glass fibre-
reinforced epoxy, etc.
W&H emphasises green and clean extrusion & converting technologies At Chinaplas 2012, German-based Windmöller & Hölscher
(W&H) will display solutions for packaging production with
efficient use of energy and raw materials. The company’s
VAREX universal blown film line operates on one of the
lowest specific energy consumption levels in the industry.
With 0.3–0.35 kW/kg, VAREX is about 30 per cent more
energy-efficient than its closest competitor. The individual
components of the line are optimally tuned to each other to
deliver an absolutely constant bubble circumference. When
producing flat film, this eliminates the need for trimming
the film, resulting in significant savings in material and
energy for reprocessing.
Each VAREX line features OPTIFIL P, the innovative
thickness profile control system. Better film gauge with
lower thickness tolerance permits production of thinner
films without compromising mechanical strength, resulting
in substantial savings of plastic resin during film extrusion.
Its automation module, EASY-CHANGE eliminates the
need to stop the line for size changes, saving about 100 kg of
resin per changeover. PROFILE BOOSTER quickly narrows
down film thickness tolerances after line start-up, reducing
by 60 per cent the time needed to reach full production
levels through waste reduction.
PRODUCTS SHOWCASE
90 Modern Plastics & Polymers | April 2012
This section provides information about the national and international products available in the market
Co-extrusion blown film machineThe new water
cooling downstream
3-layer co-extrusion
blown film machine
is equipped with
water cooling
system, 360-degree
oscillating nip
roller device, EPC
and auto-tension
controller winder. This machine is suitable for production of food
packaging, zipper bags, chips, PP+PE+PP film, PE+PP+PE, PP film,
PE film, etc. Material composition is two layers of A+B structure and
three layers of A+B+C or A+B+A. The die head is made of high-
quality alloy steel with nitride and quenching treatments to make
sure non-transformed of material under high temperature. Flow
channels are hard chrome-plated and highly polished & treated. The
PE+PP+PE film has clear and transparent look.
Chyi Yang Industrial Co Ltd
Taoyuan County - Taiwan
Tel: +886-3-3288686
Email: [email protected]
Website: www.cymw.com.tw
Injection moulding machine
The EN series injection moulding machine is available in the range
of 30-3500 tonne and offers different demands in wide production
requirements. Not only servo motor, but to apply energy-savings on
the hydraulic system, cooling system and heater system, makes the
total energy saving rate much higher than the machines only with
servo motor. The new energy-saving injection moulding machines
save about 78 per cent consumption.
Enaiviv Machinery Industrial Co Ltd
Tainan City - Taiwan
Tel: +886-6-2544328
Email: [email protected]
Website: www.enaiviv.com.tw
Thermoplastic elastomersEverlon compounds
are high-performance
thermoplastic elastomers
designed specifically
for the production of
moulded and extruded
products on conventional
thermoplastic processing
equipment and do not
require vulcanisation. It
can be seen in numerous
processing techniques
in which it is used, such as injection moulding, blow moulding,
compression moulding, extrusion, etc. In all these processes, Everlon
scrap is recycled without loss of its physical properties.
Ever Polymer Co Ltd
Taoyuan - Taiwan
Tel: +886-3-3125717
Email: [email protected]
Website: www.everlon.com.tw
GearboxThe Sun Lung gearbox
adopts pioneer energy-
saving greasy chipping
adsorption installation
design. It has features
such as greasy
chipping clearance
under machinery
operation, no need to
stop the production
line, best transmission efficiency & high-torque and sufficient safety
coefficient design, precision of gear grinding up to DIN 1~3 grade,
operation noise is below 80 dB, forced lubrication and built-in
the cooling & filter system ensure excellent hear dissipation,
top-quality SKF bearings to be selected, incorporated with
Japanese NOK oil seals, seats being special treatment ensures
longer durability, diversified output orientation design, CE & TUV
certificated, achieved Germany, Japan, Taiwan, China and other
worldwide patents.
Sun Lung Gear Works Co Ltd
Tainan City - Taiwan
Tel: +886-6-2639969
Email: [email protected]
Website: www.slgear.com.tw
Booth No:
E6 K05
Booth No:
N4 M31
Booth No:
E6 J21Booth No:
E6 M61
PRODUCTS SHOWCASE
92 Modern Plastics & Polymers | April 2012
Thermoplastic elastomer compoundsPhoenix transparent Thermoplastic
Elastomer (TPE) compounds
are developed for transcending
current standards. Styrenic Block
Copolymer (SBC) compounds offer
classic water clear transparency and
softness. These fulfill users’ pursuit of aesthetic and attractive
products, but at the same time, without compromising on quality
and performance. State-of-the-art compounding technology offers
maximum diversity of features. Though it is used for direct injection
moulding, extrusion or blow moulding, this product family is
capable of satisfying users’ requirements. Compounded with SBC
compounds, the Phoenix transparent TPE compounds contribute
varied performance and properties.
Phon Tech Industrial Company
Youlin County - Taiwan
Tel: +886-5-5574567
Email: [email protected]
Website: www.phon-tech.com.tw
Eco-friendly synthetic rubberThe eco-friendly synthetic rubber (SSBR)
reduces not only the consumption of gasoline,
but also the emission of waste gas. The
property of SSBR differs from the traditional
rubber and is customised according to the
processing and application demands. SSBR
is mainly used in energy-conserving (low
rolling resistance), high-performance and all-
season tyres. The tyre reduces fuel consumption and carbon dioxide
emission in line with environment protection concerns, and provide
added value to end-users.
TSRC Corporation
Taipei City - Taiwan
Tel: +886-2-37016000
Email: [email protected]
Website: www.tsrc.com.tw
High-torque gearboxThe TST series super high-
torque gearbox is a co-rotating
twin-screw extruder gearbox.
This gearbox is used for twin-
screw extruders starting from a
centre distance between screws of
21.5 mm up to a centre distance
between output shafts 116 mm. The new system of torque distribution
has enabled the company to increase considerably the output speed
and also the density of the transmissible torque. The TST gearbox
is available in the range starting with a centre distance of 21.5-116
mm. This gearbox is developed by featuring excellent compactness.
Also, for this series, the axial thrust is supported by an axial roller-
type swivel thrust-bearing of the 294-E series, coupled with thrust
bearings assembled in tandem.
Zambello Riduttori Group
Milan - Italy
Tel: +39-331-307616
Email: [email protected]
Website: www.zambello.it
Co-extrusion blown film lineThe three-layer co-extrusion blown film
line has Ø250-mm die with production
output of 450 kg/hr. It has a continuous
type loss in weight gravimetric dosing
unit (German-made) and auto thickness
profile control (auto air ring) air ring
height adjustable, high-efficiency cooling
and high output rate (German-made).
The IBC computer control system is of
US-make. This line has a 360-degree thickness profile measurement with
oscillating rail of Germany-make along with width measurement also of
German-make. The co-extrusion blow film line has horizontal oscillating
take-up unit and back-to-back automatic surface-type winding unit.
Kung Hsing Plastic Machinery Co Ltd
Chia Yi - Taiwan
Tel: +886-5-2374466
Email: [email protected]
Website: www.kunghsing.com.tw
Booth No:
E6 K27
Booth No:
C7 A29
Booth No:
E2 C61
Booth No:
N3 E31
Extruder and cutting machineThe EDC-08-05 multi-
layer extruder and cutting
machine is used in co-
extrusion systems for
combining different types
of materials. Therefore, the
characters of single layer tube cannot compete with the complex
characters of co-extrusion tube, such as glossy surface, extensive
colour combination, excellent barrier property, scratch and dust-free,
etc. Moreover, the extrusion linear speed of EDC-08-05 is 10 m/min
for ø35 mm tube (EDC-16-05: 20 m/min), and cutting speed is 100
pcs/min (EDC-16-05: 200 pcs/min). The EDC-08-05 can produce
tube diameter range of ø16 to 60 mm and easy-to-change tooling in
different sizes of tube produced.
Bonmart Enterprise Corp
New Taipei City - Taiwan
Tel: +886-2-22994281
Email: [email protected]
Website: www.bonmart.com.tw
Booth No:
E6 Q31
PRODUCTS SHOWCASE
94 Modern Plastics & Polymers | April 2012
Mould-temperature controller and chillerThe mould temperature
controller and special
custom-made chiller are
new products that include
cold-hot all-in-one mould
temperature controller, die-
casting mould temperature
controller, quick-cooling &
heating mould temperature
controller, two machines
in one water circulation
temperature controller, and
rubber/high temperature/
roller mould temperature
controller. These machines are intended for processes such as plastic
injection moulding, extrusion moulding, blow moulding, chemical
industry, dye-casting, reaction axe rubber tyre, rubber vulcanisation,
electric wire, calendar, printing, ban-burying and other related
industries.
Weichi Enterprise Co Ltd
Guangzhou - China
Tel: +86-020-36850626
Email: [email protected]
Website: www.weichigz.com
Booth No:
E6 L41
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2012
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Special Projects
Ruby House,1st FloorJ K Sawant MargDadar (W), Mumbai 400 028INDIA
INFOMEDIA 18 LIMITED
PRODUCTS SHOWCASE
98 Modern Plastics & Polymers | April 2012
Quick mould change systemThe complete
s i n g l e - s o u r c e
system solutions
available include
Quick Mould
Change (QMC)
and Quick Die
Change (QDC)
systems for plastic
injection moulding
industry and for
metal stamping
applications. Magnetic Clamping Systems (MCS) are used for
injection moulds and dies. Mono-coupler, manual and automatic
multi-coupler systems are for general industry use. Mould and
die rotation units, die splitters and other tool handling & storage
equipment are also offered.
EAS Mould & Die Change Systems Co Ltd
Wujiang City - China
Tel: +86-512-63093091
Email: [email protected]
Website: www.easchangesystems.com
Pellet screening systemSuper Platon is the latest generation of
pellet screening system for plastics industry.
This system detects black spots or off-
colour contaminants as small as 0.1 mm in
a pellet stream by using four high-resolution
line sensor cameras. The Super Platon is
installed inline or offline after a vibratory
sizing screener to detect and remove
defective pellets.
Kubota Corporation
Shanghai City - China
Tel: +86-21-63298843
Email: [email protected]
Website: www.keisoku.kubota.ne.jp/chinese/
Engineering plasticsE n g i n e e r i n g
plastics are
based on
Polyamides (PA
6 and 6.6) and
Po l y b u t y l e n e
Terephthalate
(PBT) that are
available under
the brands
Durethan and Pocan. Durethan and Pocan high-tech plastics are
enablers for greener mobility. These replace metal parts with
lightweight plastic, thus offering excellent fuel savings and carbon
emission solutions to the automotive industry. Apart from the
automotive segment, also available is a variety of offerings for high-
tech plastics solutions apt for a wide range of industries.
Lanxess Chemical (China) Co Ltd
Shanghai - China
Tel: +86-021-61096666
Email: [email protected]
Website: www.lanxess.com
Hot runner system mould
Some characteristics of the Moki patent hot runner system mould
include short cycle time (shortest time up to 3.2 sec with advanced
blowing technology), high productivity and good stability. It is suitable
for lightweight and extra-thin (thinnest up to 0.3 mm) disposable
products. Other features are wastes reducing, production cost lowering,
high stability of finished products and low defect rate, and strong
mould structure, floating structure, thin finished products, average
thickness, stable quality and long life of mould.
Mo Chyi Enterprise Co Ltd
Changhua County - Taiwan
Tel: +886-4-7354681
Email: [email protected]
Website: www.food-mold.com
Extrusion machineThe LIN-90II-TS is
a performance-based
machine designed
to accommodate
large containers with
outstanding cycle time.
It produces from 200
ml to 4L of PE/PP and PVC/PTEG, and the productivity reaches
4500 pc/hr and 860 pc/hr, respectively. To ensure quality, mechanical
and electrical components from leading brands are used for this
machine.
Akei Plastic-Machine Mfy Ltd
Hong Kong - Hong Kong
Tel: +852-+852-27411312
Email: [email protected]
Booth No:
E3 S41
Booth No:
E5 D07
Booth No:
E3 Q31
Booth No:
W5 B41
Booth No:
N1 E01
PRODUCTS SHOWCASE
100 Modern Plastics & Polymers | April 2012
Multi-rotation section extruderThe Multi-
R o t a t i o n
Section (MRS)
extruder is ideal
for processing
of PET-r. It
permits the
processing of
PET without pre-drying, but by using a simple water ring vacuum
system to process the PET to a high-quality product. This is achieved
by means of its unique and patented processing section. Based on a
conventional single-screw extruder, MRS is a drum containing eight
satellite single screws, driven by a ring gear and pinion transmission.
The devolatilising performance is 50 times greater than that of a
conventional single-screw extruder, and this is at a vacuum of only
25-40 mbar.
Gneuss Kunststofftechnik GmbH
Bad Oeynhausen - Germany
Tel: +49-5731-5731530710
Email: [email protected]
Website: www.gneuss.de
Injection moulding machineThe new model
CLF-230AE all-
electric injection
moulding machine
is equipped with
advanced Siemens
(Germany) servo
drive and servo control system, which offer superior performance,
including high-speed, accuracy, quiet, clean and energy saving. This
is in addition to the innovation multi-functional technology with
multi-axis and multi-tasking control providing high-cycle, high-
output, high-stability and automotive moulding process. The model
CLF-230AE has high price-performance rate and wide application
range on the worldwide parts market.
Chuan Lih Fa Machinery Works Co Ltd
Tainan Hsien - Taiwan
Tel: +886-6-2532111
Email: [email protected]
Website: www.clf.com.tw
Plastic injection moulding machineThe PET-LINE is based
on the platform with
3500 kN clamping force
covering moulds with 48-
128 cavities. This machine
offers solution to cope
with the rising demand
from the beverages and
foodstuffs industry. Numerous optimisations such as the simplified
product removal and aftercooling unit or the increased injection
pressure to shorten the cycle time make the PET-LINE a economical
system solution for production of PET preforms.
Netstal-Maschinen AG
Naefels - Switzerland
Tel: +41-55-6186111
Email: [email protected]
Website: www.netstal.com
Wood plastic composites
The Wood Plastic Composites (WPC) are thermo-plastically processible
materials made from wood and plastics (PP, PE, PVC, PS, ABS) for use
in building, furniture, automotive, consumer goods, housing industry,
etc. In order to operate under optimum function, upstream and
downstream equipments are designed for the best matched with the
extrusion line. For further improving the output of extrusion line, each
processing device and computer-controlled possibility (eg, PLC, PC
base) is recommended perfectly to suit different users’ demand.
Intype Enterprise Co Ltd
Tainan - Taiwan
Tel: +886-6-2614196
Email: [email protected]
Website: www.intype.com.tw
In-mould labelling systemThe new A-Pack Inmold
Labeling (IML) system
has vacuum and static label
absorbing, which reduces
the cycle time and saves
total production cost. The
A-Pack IML turnkey
solution is applied to all kinds of beverage and food package, such
as tea, coffee, juice, water, yogurt and dairy product. It consists of
four components including FCS AF series, hi-speed hybrid close
loop injection moulding machine, hot-runner mold, robot, product
stacking system and label inserting system. Also provided is a
customised label for the turnkey solution.
Fu Chun Shin Machinery Manufacture Co Ltd
Tainan County - Taiwan
Tel: +886-6-5950688
Email: [email protected]
Website: www.fcs.com.tw
Booth No:
E6 B41
Booth No:
E1 C17
Booth No:
E1 J01
Booth No:
E6 E41
Booth No:
K11
PRODUCTS SHOWCASE
102 Modern Plastics & Polymers | April 2012
Specialty chemicalsThe Millad NX 8000 offers
important sustainability
benefits enabling PP to be
processed at significantly lower
temperatures versus standard
clarified PP. The superior
clarifying performance enables
broader use of PP, a low-
density, easily recycled plastic, to replace less-sustainable materials
in packaging, household and food storage applications. Hyperform
HPN nucleating agent for polyolefins is a family of high-speed
nucleating agents, which allow for faster crystallisation rates,
improved processing and higher throughputs. Hyperform HPR
synthetic reinforcing agents for polypropylene improve mechanical
properties, while reducing part weight as compared to traditionally
filled automotive compounds.
Milliken Asia Pte Ltd
Singapore
Tel: +65-65931319
Email: [email protected]
Website: www.millikenchemical.com
In-mould labelling equipmentSupreme in-mould labelling
(IML) equipment is reliable
and sustainable. The IML
equipment is offered on
turnkey basis to customers.
This label supply machine,
integrated with technology
knowledge, has features like
both electrostatic and vacuum, easy understanding, durable quality,
low abnormal, cost-down and simple maintenance, simultaneously
available machine for containers with varied shapes, suitable for
different label options, etc.
Supreme Technic Package Co Ltd
Kalol - Taiwan
Tel: +886-7-6141505
Email: [email protected]
Website: www.emdpack.com.tw
Robotic automationThe Sepro Robotique S5
line of high-performance
robots features fast, precise
servo-driven robots,
including three different
models to serve injection
moulding machines in the
range of 30-800 tonne. The S5 line of robots is developed with longer
strokes and larger payload capacities than units of comparable size in
Sepro’s earlier Generation 4 (G4) range. There are three models in
this series. All S5 robots are equipped with the top-of-the-line Sepro
Visual 2 controller as standard equipment. At its core is a high-speed
PLC, featuring scan rates as fast at 100 millisecond.
Demag Plastics Machinery (Ningbo) Co Ltd
Zhejiang - China
Tel: +86-574-86181500
Email: [email protected]
Website: www.sumitomo-shi-demag.eu
T-shirt bag-making machineThe automatic
electronic T-
shirt bag-making
machine (4-lines)
comes with auto
punching. Model
P-30S-2×4+SS is
specially designed for mass production of T-shirt bags. The high
speed is up to 500 pieces/minute. Four sets of independent film-
feeding motors can keep film feeding smoothly. Conveyor pad delivers
the finished bags in pile according to priority. The performance of the
machine is stable and reliable.
Daidan Machinery Co Ltd
Foshan City - China
Tel: +86-0757-28396777
Email: [email protected]
Website: www.daidan.cn
Screws and barrelsA full series of screws and
barrels applied for various
extruding machines and
plastic injection moulding
machines are offered. Also
designed and manufactured
are screws with special alloys
and special flight geometry
to meet specific customer
applications. Solutions to help customers solve extruding and
injection moulding problems are also offered. The extra large screw
and barrel manufacturing capabilities include screw dia x length 450
mm x 8,000 mm, and barrel hole dia x length 450 mm x 8,000 mm.
Nan Yun Industrial Co Ltd
Tainan Hsien - Taiwan
Tel: +886-6-2017773
Email: [email protected]
Website: www.nyi.com.tw
Booth No:
E2 J41
Booth No:
E6 P01
Booth No:
N5 S01
Booth No:
E6 L25
Booth No:
N2 M41
PRODUCTS SHOWCASE
104 Modern Plastics & Polymers | April 2012
Thermoplastic elastomersThermoplastic elastomers are intended
for applications in the consumer, medical,
industrial or automotive sector. These
thermoplastic elastomers offer optimal
adhesion properties on materials, such as
PA (nylon), ABS or ABS/PC and ensure
excellent elastic recovery. The new DW
compounds (drinking water series) are
offered for the first time. These satisfy the
most important European drinking water
standards. Due to their smooth, dirt- and
limescale-repellent surface, thermoplastic elastomers are suitable for
use particularly in the sanitary and drinking water sector.
Kraiburg TPE
Wadhwan - Germany
Tel: +49-8638-9810278
Email: [email protected]
Website: www.kraiburg-tpe.com
Water heaterThe model STM-MW water heater
is used to heat up the mould and
maintain constant temperature.
High-temperature water from the
mould is returned to the cooling tank
and cooled by direct cooling. It is
then pressurised by the high-pressure
pump, sent to the heating tank and
finally to the mould with a constant
temperature. The water heater adopts magnetic pump instead of
mechanical pump to reduce the leakage of media water and it employs
brand-new controller, which ensures stable temperature controlling
and abundant expandable function.
Shini Plastics Technologies Inc
New Taipei City - Taiwan
Tel: +886-2-26809119
Email: [email protected]
Website: www.shini.com
Cup forming machineThe thermorunner KTR 5
speed cup forming machine
combines intell igent
technology, perfect quality
and optimum production
rates with low costs. This
high-speed machine is used
for producing drinking cups
from PET material and features perfect integration of a new
innovative inline stacking system. With the integration of the new
inline stacking system, BEST 78/40, Kiefel also sets new trends
when it comes to automation. Also future-oriented, the video control
system, Simotion is supplied by Siemens. An integrated system for
positioning control and SPS directly at the drive system ensures
minimum cycle times and best functional results. Co-ordinated
multi-axis movements are fast and precise.
Kiefel GmbH
Freilassing - Germany
Tel: +49-8654-78182
Email: [email protected]
Website: www.kiefel.de
Blow moulding machineThe complete XBLOW X07 series
with platen widths of 350-700 mm
is offered. The new single- and
double-station machine is available
with all-electric (EBLOW) as well
as hydraulic (HYBLOW) drives.
No modifications are required to
Hot runner controllerThe TC5200 multi-cavity hot runner controller
features a 12~60 point temperature combination
control and multi-machine networking. Maintenance
operations are simplified with its modularised device
design and requirement-based configuration. The
GUI based user interface, along with its adjustable
perspective angle, is easy for fast adoption in multi-
points control. The RS485 communication function
enables users to setup multiple controls at once to
simplify the required operations. The built-in and
practical current sensor and indicator functions
benefit various applications, especially automotive
industry, bottle billet injection and medical supplies, by realising the
concept of one-stop control.
Arico Technology Co Ltd
Tainan County - Taiwan
Tel: +886-2-29101266
Email: [email protected]
Website: www.arico.com.tw
use existing Bekum customer blow moulds on these machines.
Continuity of the machine operation, apart from certain extended
capabilities is taken into consideration. The machine platens are
designed for good accessibility and ease-of-maintenance.
Bekum Maschinenfabriken GmbH
Berlin - Germany
Tel: +49-30-74900
Email: [email protected]
Website: www.bekum.de
Booth No:
N1 S01
Booth No:
E1 B51
Booth No:
E1 G41
Booth No:
E4 M71
Booth No:
E2 P61 & W4 J41
products showcase
106 Modern plastics & polymers | April 2012
The information published in this section is as per the details furnished by the respective manufacturer/
distributor. In any case, it does not represent the views of
Business Insights •Technologies•Opportunities
Blow moulding machine
These blow moulding machines are targeted to produce plastic containers such as bottles, drums, tanks and other types of containers with volume ranging from 20 ml to 220 ltr. Available is a continuous type the blow moulding machine is used for containers below 25 ltr. The accumulator die head type-blow moulding machine is used for containers above 25 ltr. Chen Way Machinery Co LtdTainan City - TaiwanTel: +886-6-2434077Email: [email protected] Website: www.chenway.com.tw
T-shirt bag making machine
Bag making machineThe PP woven bag making machine comes with cutting and sewing machine and printing machine. This machine is highly durable, of good quality and enables efficient operation. The machines are easy to operate and enable customers to achieve desired quantity.
Rey Long Machinery Co Ltd Dou-Liu City - TaiwanTel: +886-5-5571565Email: [email protected]: www.reylong.com.tw
Masterbatches
A wide range of masterbatches are available along with colouring solutions. The product range includes universal plastic masterbatches, specialised ABS/PC/PET/PA masterbatches, grain/wooden/marble/metallic effect masterbatches, phosphorescent/fluorescent/pearl/golden, silver series masterbatches, shelly-shining effect series/UV masterbatches, halogen-free masterbatches, frosted white masterbatches and high-gloss black masterbatches.
New Particle Chemical Colors CorpTaoyuan County -TaiwanTel: +886-2-82094051, Email: [email protected]: www.npc-color.com.tw
Booth No:
N4 M39
Booth No:
e6 t73
Booth No:
e6 t41
Booth No:
e6 d61 & w5 p43
The high-speed T-shirt bag making machine (model ST-88/ST-88) is computer-controlled in the whole process. From film roll to final bag, there is one process flow, while the servo motor, as standard attachment, makes it easy to adjust the bag length and the production speed. Component self-testing function is available. Automatic film feeding, coordination is free from tension adjustment. The machine automatically stops when there is a problem or jam.
Cosmo Machinery Co LtdTaipei Hsien - TaiwanTel: +886-2-26806116Email: [email protected] Website: www.cosmo886.com.tw
EVENT REPORT: Engineer ing Expo Aurangabad 2012
108 Modern Plastics & Polymers | April 2012
Nishi Rath
In this era of ‘glocalisation’ where
every leading company is trying to
establish its footprint in regional
markets and create a stronghold,
sensing the pulse of customers is one
of the old and most powerful adages.
In order to explore the tremendous
opportunities to get established in
regional markets, trade shows play
a critical role. Known for organising
multi-location trade shows, Engineering
Expo is a brand to reckon with. Keeping
up with its rich tradition and fresh vigour
& enthusiasm, the maiden edition of
Engineering Expo Aurangabad portrayed
the poised locational advantages to
the manufacturing community. The
latest edition of Engineering Expo,
an established trade show from the
stable of Network 18, with support
from Aurangabad Industrial Suppliers
Association (AISA), held f rom
February 17-20, 2012, turned out to
be a huge success in terms of its quest
towards bringing out the message to the
entire Indian manufacturing fraternity
of an emerging manufacturing hub –
Aurangabad.
One of India’s largest
mu l t i - l o c a t i on S ma l l and
Medium Enterpr i se (SME)
gatherings, Engineering Expo
has become a definitive place for
Indian as well as foreign companies
to exhibit their products & services
and interact with buyers & sellers.
According to the industry, the Expo is
an ideal platform for companies to foster
growth through reach and awareness to
their right target audience. And
Engineering Expo Aurangabad
provided a perfect platform for SMEs
and manufacturing & engineering
companies to exchange ideas.
Expo takes off on a high noteDignitaries including Mukund Kulkarni,
President, Chamber of Marathawada
Industries and Agriculture (CMIA),
and Managing Director, Expert Group
Solutions; Millind Kelkar, Owner, Grind
Master; Jayant Soni, President, AISA;
Ravindra Naidu, Joint President, Birla
Precision Technologies; Sunil Daga,
Senior Vice President-Business Banking,
Kotak Mahindra Bank, along with
Sudhanva Jategaonkar, Associate Vice
President, Infomedia 18, were present at
the Expo’s inauguration function.
The maiden edition of Engineering Expo held at Aurangabad was a runaway hit among the growing manufacturing and general engineering sector, as well as small and medium enterprises based in and around the historical city. The Expo had a positive impact on the developing manufacturing industry in Aurangabad and is poised to come back with more offerings and opportunities for the exhibitors and visitors in the next edition.
Creating yet anothersuccess story
AURANGABADFebruary 17-20, 2012Ayodhya Nagari Ground
Dignitaries unveiling the Exhibitors’ Directory during the inauguration ceremony of Engineering Expo Aurangabad
Engineer ing Expo Aurangabad 2012
109April 2012 | Modern Plastics & Polymers
Elaborating on how Engineering
Expo is all set to offer a fillip to the
trade prospects of Aurangabad, Naidu
said, “This is one of the largest SME
gatherings in Aurangabad. As we all
know the potential this place has, this
Expo comes across as a catalyst that will
further boost its growth. It is a matter of
pride for Aurangabad. Earlier, it was only
known as a historic city; but now, it is
also known as an automobile hub.”
Complementing Naidu’s views,
Soni, co-organiser, added, “We were
looking for a platform in Aurangabad and
now, with Engineering Expo, we found
the best and one of the most preferred
platforms. This Expo has brought a show
of international standard to the doorstep
of users. The small and medium business
units will reap a lot of benefits from
the Expo.”
Offering a financial perspective,
Virat Diwanji, Executive Vice President
& Head-Branch Banking, Kotak
Mahindra Bank, said, “We are delighted
to be associated with Engineering Expo.
SMEs are the backbone of India’s
economy. The sector has played a critical
role in achieving wide measures of
industrial growth, and is instrumental in
generating large-scale employment across
the country. We, at Kotak Mahindra
Bank, believe that with the right mix
of capital, technology and innovative
ideas, SMEs have the potential to push
India’s growth to the next level. Our
customised business solutions, backed
with customer-friendly service, are
designed to meet the challenges and
growing requirements of this sector.”
Opening a new account at AurangabadThe latest edition of Engineering Expo
highlighted the potential that a new
and developing place like Aurangabad
has to offer. The fast-paced industrial
growth in Aurangabad will not only
improve the employment avenues, but
will also raise the standard of living in
this city, opined Kulkarni. He added,
“A trade show like Engineering Expo is
vital for the competitiveness of industry,
especially for SMEs.”
Offering an organiser’s perspective
on the choice of a new location
for organising Engineering Expo,
Jategaonkar said, “Engineering Expo
has come a long way by becoming one
of India’s largest multi-location trade
shows (other places include Ahmedabad,
Chennai, Indore, Pune, Rudrapur and,
now, Aurangabad). Over the years, it
has successfully delivered its goal of
becoming a preferred destination for
SMEs, manufacturing and engineering
companies to connect, transact &
leverage ideas to foster the growth of
organisations as well as that of the
industry at large.”
Exhibitors attract audience Engineering Expo Aurangabad boasted of
huge industry participation from various
manufacturing areas, including machine
tools & accessories, material handling
equipment, hydraulics and pneumatics,
automation & instrumentation, light and
medium engineering, safety & security
and packaging machinery, among others.
Elaborating on the excellent
response generated at Engineering Expo
Aurangabad, S J Gijare, GM – Equipment
Division, CTR Manufacturing India,
articulated, “Engineering Expo has helped
the SME sector, which is fast growing
in Aurangabad, in finding potential
customers. We showcased some of our
best products here and even received
good response. CTR already has a
strong presence in the segment and by
participating in this Expo, we want to
retain that position in the years to come.”
Discussing the scope Aurangabad offers,
Aniket Nanajkar, Profit Centre Manager-
Mechanical Division, Phoenix Mecano,
250+ exhibitors
18,013+ visitors
1,00,000 kg machinery moved
17,000+ business leads generated
6,250+ products displayed
1,00,000 sq ft exhibition area
` 70 core+ business transaction
Quick Stats: Engineering Expo Aurangabad
Endurance TechnologiesVarroc EngineeringForbes & CompanyLarsen & ToubroNRB BearingsVideoconWiproCrompton GreavesBajaj Auto
Delegations who visited the Expo…
Panel discussion on shifting status from ‘Why Aurangabad’ to ‘Why not Aurangabad’The panel discussion was organised by Infomedia 18 in association with Aurangabad Industrial Suppliers Association prior to the Expo. The endeavour was a part of its value additions intended to bring the manufacturing and dealer community of Aurangabad to discuss critical issues related to the growth of the region, with an aim to position Aurangabad and the surroundinig areas as the most sought-after manufacturing hub.SME Meet: An informal discussion on the pain and gain areas of SMEsA large gathering of SMEs shared their pain and gain areas of working in and around Aurangabad. Some of the major issues discussed during the meet included banking and government policies, availability & procurement of land, which deters expansion, and, most importantly, the shortage of skilled labour in & around the region. The major solutions that were arrived at include amendments in regulatory laws and a clear exit policy to change the product line.
Prelude to Engineering Expo Aurangabad
EVENT REPORT: Engineer ing Expo Aurangabad 2012
110 Modern Plastics & Polymers | April 2012
explained, “Engineering Expo has provided us a good platform to
understand the market demands here. We were delighted to find
potential customers visiting our stall at the Expo.”
Visitors in aweThe responses from visitors were encouraging as well. Most visitors
emphasised that more such events should be organised in future.
“Engineering Expo provided companies an excellent platform to
know more about new technologies. It helped local manufacturers
meet global standards. The Expo was well-organised and garnered
huge success among visitors. Trade shows of this stature will
help this growing manufacturing hub,” said Satish Adsul, AGM-
Corporate Purchase, Endurance Technologies (Casting Division).
Rajesh Baheti, DGM-Corp Materials & VEPL-Head, Varroc
Engineering, who was also present at the Expo, visited stalls and
interacted with various exhibitors. “In its first edition itself, the
Expo has become a huge success. We saw various companies
showcasing their best products and solutions here. This will
definitely help the SMEs located in and around Aurangabad.
Considering the fact that Aurangabad is developing, organising
such events will definitely boost the growth prospects of this
region,” Baheti added.
Engineering Expo Aurangabad also attracted overseas visitors.
Russell Small, Sales Manager, Asia-Pacific, Precision Polymer
Engineering, England, was in Aurangabad mainly to attend the
Expo. “I saw some of the best automation products displayed
here by quality exhibitors. Such trade shows can be helpful for a
developing place like Aurangabad,” he exclaimed.
Promising times aheadWith various other companies looking forward to investing in
Aurangabad, the region is set to witness further growth over the
coming years. The huge turnout at the Expo is proof enough of
the increasing awareness among local businessmen about new
technologies and their value-added benefits. With an optimistic
outlook, Jategaonkar asserted, “As we look forward to making
further value additions for an even better experience and reach
to the target audience, we welcome large, medium & small
industries in the manufacturing and servicing sectors to be
a part of the Expo in its exciting journey.” With this huge
success, Engineering Expo is slated to make it even bigger
in the next edition, with more promising opportunities to be
tapped and more areas to be covered.
Email: [email protected]
Guests of honour assesing futuristic technology
BOOK REVIEW
111April 2012 | Modern Plastics & Polymers
Screw extruders are the major processing machines for thermoplastic products such as polyethylene films. The most common and widely used products include pipes, sheets, films, monofilaments, monoaxially oriented tapes (raffia), box strapping and compounding. This is a comprehensive volume on twin-screw extrusion technology and twin-screw & modified extrusion lines. It gives detailed views on screw geometry, various screw configurations, co-rotating screws, intermeshing co-rotating twin-screw extruders, modular intermeshing co-rotating twin-screw extruders with right- and left-handed screw elements, modular intermeshing co-rotating twin-screw extruders. It also covers variations such as intermeshing counter rotating screw, flow visualisation studies of intermeshing counter-rotating twin-screw extruders, which only few technical individuals would have studied, understood and applied.
The book presents the technology, flow mechanisms and dispersive mixing, which involve the break-up of particle agromerates and droplets of dispersed melt phases. It covers a wide range of variations in twin-screw extrusion lines and, hence, will be a good reference not only for processing of polyvinyl chloride, but also for manufacturers of masterbatches and compounds. This book is recommended for manufacturers of extrusion lines, research and development groups and enterprising processors wishing to explore non-conventional segments of extrusion.
Twin Screw Extrusion: Technology and PrinciplesAuthors : James L White and Eung K KimPrice : ` 9,093
Additives manufacturing is a comparatively young technology, and since a long time, almost no efforts were made for standardisation except some preliminary work in Germany in the early 1990s. In 2009, the American Society of Mechanical Engineers (ASME) in cooperation with the American Society of Testing Materials (ASTM) started developing standards for all plastics and related products. Following this, most countries, including the UK, Germany and India, began developing such standards.
With rapid growth in the production and usage of plastics in various end-uses from home appliances to highly sophisticated and critical components covering a broad spectrum of end products, the need for standardisation was evident. With wider usage and acceptance of plastics in almost all fields, from consumer products to highly critical, precise and engineering components as well as healthcare & medical devices, the need arose for developing customised polymers by using specialty plastics and additives.
This book includes a wide spectrum of additives for all polymers manufactured today for meeting specific end-use performance requirements. It gives an exhaustive coverage of rapid tooling and additive manufacturing processes, focussing on industrial components including automobile parts. The book covers all technical aspects of additives manufacturing. It is recommended for progressive plastics processing units as well as research and development groups.
Understanding Additive ManufacturingAuthor : Andreas GebhardtPrice : ` 4,893
Avaliable at: SCI-TECH Books & Periodicals, 414, Janki Centre, Veera Desai Road, Andheri (W), Mumbai 400 053Tel: 022-2673 5260/6697 0507 • Telefax: 022-2673 5424/2673 5260 • Email: [email protected]
Reviewer: Arvind S Athalye, Founder & CEO, Arvind Athalye Technology Transfer Pvt Ltd
LIST OF PRODUCTS
112 Modern Plastics & Polymers | April 2012
1 Accumulator high-speed injection machine ......992 Additive masterbatches ....................................COC3 Additives ............................................................... 234 Adhesives ............................................................ 1215 Air audits blower................................................... 396 Air chiller .............................................................. 257 Air-conditioner parts ........................................FGF8 Ammonia liquid chiller ....................................... 1079 Automation panel ................................................. 9710 Automation system ............................................... 8311 Automation ........................................................... 4312 Bag making machine .................................40, 10613 Barrel screw ........................................................... 1914 Bed knives ............................................................. 5515 Bio-degradable additives ................................. 23, 4516 Bio-degradable masterbatches..........................COC17 Black masterbatches ...................................COC, 2318 Blender ................................................... FIC, 21, 9319 Blending unit ....................................................FGF20 Blow moulding machine ....................... 18, 104, 10621 Blower ................................................................... 8322 Blown film extrusion system ............................... BC23 Bottle testing equipment ..................................... 12024 Bulk milk cooler .................................................. 10725 Butterfly valve ..................................................... 10726 CASI products ...............................................12127 Chiller ................................................................. 11028 Circular weaving loom ........................................ 12229 Circular weaving machine ..................................... 1430 Cleanroom applications......................................... 1531 Cluster facia ......................................................FGF32 CNC vertical machining centers ................... 67, 7933 Co-extrusion blown film line ................................ 9234 Co-extrusion blown film machine ........................ 9035 Colour additives .................................................... 2336 Colour mark sensor ............................................... 9737 Colour masterbatches ................................. 23, COC38 Compact chiller ..................................................... 2539 Compound injection moulding machine .............. 9940 Compounds ........................................................... 2341 Compressor ........................................................... 3942 Conductive compounds ....................................COC43 Conical twin-screw extruder ........................... 59, 6144 Connector .........................................................FGF45 Control system ...................................................... 9746 Conveying system ................................................. 4347 C-PVC pipe .................................................... 10, 1748 Crane control system ............................................ 9749 Cup forming machine ......................................... 10450 Cutting and stitching machine ............................. 1451 Cyclic olefin copolymer .....................................BIC52 Dairy machinery ............................................10753 Dehumidified air dryer .................FGF, FIC, 25, 4754 Die face cutter ....................................................... 5555 Die plate ................................................................ 5556 Digital panel meter ............................................... 1257 Digital temperature controller ............................ 10558 Door trim ..........................................................FGF59 Dosing and blending machine .............................. 4360 Dosing and mixing machine ................................. 8361 Drive ............................................................. 41, 10562 Dry-break coupling ............................................... 3963 Dryer .................................................................. FIC64 Drying and dehumidifying system ....................... 8365 Drying system ....................................................... 4366 Dual channel with modbus ................................. 10567 Dye stuff ............................................................... 7568 Dynamic controller ............................................. 10569 Eco-friendly synthetic rubber ...........................9270 Ejector ................................................................... 3971 Elastomer refinery and petrochemicals ............... 12172 Electric injection moulding machine gearbox ........ 773 Electrical panel ...................................................... 9774 Engineering plastics .............................................. 9875 Exhibition - Plastivision Arabia-2012 .................. 5076 Extruder and cutting machine .............................. 9277 Extruder machine ............................................ 33, 3578 Extruder screw ...................................................... 5579 Extrusion coating line ........................................... 14
80 Extrusion lamination machine ............................ 10381 Extrusion lamination plant ................................. 10382 Extrusion machine ................................................ 9883 Extrusion system ................................................. BC84 Extrusion tape stretching machine ..................... 10385 Extrusion tape stretching plant ........................... 10386 Extrusion ............................................................. BC87 Feed roll machine ............................................5588 Feeding and conveying system .............................. 8389 Filler compound .................................................... 2390 Film cutter ............................................................. 5591 Flame-retardant components ................................ 2392 Flexo printing machine ......................................... 4093 Fluorescent ............................................................ 7594 Four-axis shaft gearbox ......................................... 9495 Fueling system....................................................... 3996 Gearbox for injection machine .........................9497 Gearbox for plastic extruder ................................. 9498 Gearbox ................................................................. 9099 Granulating and recycling system ......................... 83100 Granulator blade ................................................... 55101 Granulator .................................................... FIC, 25102 Green purified gearbox ......................................... 94103 Grinder .................................................................. 25104 HDPE woven sack manufacturing plant .........103105 Head lamp and tail lamp ..................................FGF106 Heart valve frame ............................... 71, 73, 87, 98107 Heating and cooling system............................ 43, 83108 High-cavitation system ......................................... 15109 High-speed mixer ........................................... 33, 35110 High-speed precise injection moulding machine . 99111 High-speed rotogravure printing machine ........... 40112 High-torque gearbox ............................................. 92113 Hopper dryer......................................................... 25114 Hopper loader ....................................................... 25115 Hot runner controller.......................................... 104116 Hot runner system mould ..................................... 98117 Hot-air dryer .......................................FGF, FIC, 47118 Hot-runner system ................................................ 83119 Hot-runner temperature controller ....................... 97120 Hydraulic injection moulding machine ................ 99121 IML technique ................................................15122 Industrial automation .......................................... 101123 Infrared heater ...................................................... 97124 Injection moulding machine ......................................
FGF, 18, 29, 65, 90, 99, 100, 115, 116, 117, 119125 Inks ..................................................................... 121126 In-line drip irrigation plant .................................. 30127 Inline drip tubing system ................................ 10, 17128 In-mould labeling and
injection moulding machine ................................. 99129 In-mould labelling equipment ............................ 102130 In-mould labelling system .................................. 100131 Insert machine ...................................................... 18132 Instrumentation and control ................................. 97133 Jumbo bag manufacturing machine ................103134 Jumbo blown film plant ...................................... 122135 Knobs and switches ......................................FGF136 Lamination machine ........................................40137 Lamination plant for tarpaulin ........................... 122138 Large flow water heater ........................................ 83139 Liquid crystaline lymer ......................................BIC140 Loader ................................................................ FIC141 Loading arms ........................................................ 39142 Masterbatches and plastic compounds ............121143 Masterbatches ............................................... 23, 106144 Material dryer system ..................................... 21, 93145 Material testing instruments ............................... 120146 Medical mould ...................................................... 15147 Melt pressure transducer ....................................... 97148 Mono- and multi-layer sheet line ......................... 14149 Mono-filament line ............................................... 14150 Mono-filament plant........................................... 122151 Monolayer blown film line ................................. BC152 Mono-layer blown film ................................... 10, 17153 Mould temperature controller ......................... 25, 47154 Moulding machine ................................................ 15155 Moulds ............................................................ 33, 35156 Mould-temperature controller and chiller ............ 94
157 MTC .................................................................. FIC158 Multi-component mould ...................................... 15159 Multi-layer blown film line............................BC, 14160 Multi-layer blown film .................................... 10, 17161 Multi-layer cast film line ...................................... 14162 Multi-layer co-extrusion sheet line ....................... 16163 Multi-rotation section extruder .......................... 100164 Napkin dies .....................................................55165 Neat resin .............................................................. 75166 Oil cooler ......................................................110167 Optic sheet extrusion line ..................................... 16168 Optical brightener ............................................COC169 Panel cooler ...................................................110170 Paper chemicals ..................................................... 75171 Paper lamination plant ........................................ 122172 Paperless recorder .................................................. 12173 Parallel and right-angle axes gearbox ..................... 7174 Pellet screening system.......................................... 98175 Pelletiser parts ....................................................... 55176 Pelletisers ............................................................... 55177 PET bottle testing equipment ............................ 120178 PET dehumidified dryer .................................... FIC179 PET perform dedicated machine ......................... 63180 PET sheet extrusion machine ............................... 16181 PET/PE washing line ........................................... 14182 Pharmaceuticals and cosmetics ........................... 121183 Pipe extrusion line for PVC/PPR/PE ................ 119184 Plastic board production system ............................. 8185 Plastic compounds ................................................ 23186 Plastic conveyor belt ............................................. 33187 Plastic injection machine ...................................... 94188 Plastic injection moulding machine .................... 100189 Plastic masterbatches ............................................ 53190 Plastic moulding machine ................................... 121191 Plastic processing machine.................................... 14192 Plastic processing machinery ancillaries and spare 19193 Plastic sheet extrusion plant ............................... 103194 Plastic textile and machinery ................................ 77195 Plastics machinery ............................................... 106196 Plate heat exchanger ........................................... 107197 Plug valve ............................................................ 107198 Plybutylene terepthalate .....................................BIC199 Pneumatic valve .................................................. 107200 Polymer conveyer belt ........................................... 25201 Polyolefin pipes ............................................... 10, 17202 Polyphenylene sulfide .........................................BIC203 PP woven sack manufacturing machines ............ 103204 Pplyacetal copolymer .........................................BIC205 PP-R pipe ....................................................... 10, 17206 Precision gear ........................................................ 94207 Precision machine ............................................. FGF208 Pre-form injection moulding machine .................. 99209 Presses ..................................................................... 8210 Priming valve ........................................................ 39211 Printing and cutting/rewinding machine .............. 14212 Printing press .......................................................... 8213 Process controller .................................................. 12214 Process tank ........................................................ 107215 Profile controller ................................................. 105216 Programmable logic controller ............................ 105217 Pulveriser disc ....................................................... 55218 Pulveriser ......................................................... 33, 35219 Pumps ................................................................... 39220 PVC foam core pipe ....................................... 10, 17221 PVC mixer cooler ........................................... 10, 17222 PVC palletising line ........................................ 10, 17223 PVC pipe plant ................................................... 122224 PVC pipes ....................................................... 10, 17225 PVC products...................................................... 121226 PVC profile line .............................................. 10, 17227 Quick mould change system .............................98228 Rail tanker.....................................................107229 Recycled polymer .................................................. 23230 Recycling line ........................................................ 14231 Recycling machine ................................................ 40232 Recycling system ................................................... 43233 Refrigerant pump ................................................ 107234 Refrigeration system ........................................... 107235 Reprocessing plant .............................................. 122
Sl No Product Pg No Sl No Product Pg No Sl No Product Pg No
FGF - Front Gate Fold, FIC - Front Inside Cover, BIC - Back Inside Cover, BGF - Back Gate Fold, BC - Back Cover
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LIST OF PRODUCTS
116 Modern Plastics & Polymers | April 2012
236 Rigid injection moulding machine .......................................................................99237 Robot system ................................................................................................... 25, 65238 Robot ................................................................................................................. FIC239 Robotic automation.............................................................................................102240 Rock-n-roll machine ....................................................................................... 33, 35241 Rotary automatic hot colour marking machine ....................................................91242 Rotary cutter .........................................................................................................55243 Rotary dies ............................................................................................................55244 Rotogravure printing machine ..............................................................................40245 Round table carrousel ...........................................................................................33246 Safety access equipment .............................................................................. 39247 Sandwich BOPP lamination ...............................................................................103248 Screw compressor ................................................................................................107249 Screws and barrels ...............................................................................................102250 Screws ...................................................................................................................19251 Sealants ...............................................................................................................121252 Sensors ..................................................................................................................97253 Servo drive ............................................................................................................97254 Servo energy saving machine ................................................................................63255 Sheet calendering line .............................................................................................8256 Side sealing-bag making machine ........................................................................40257 Single mill pulveriser ...................................................................................... 33, 35258 Single screw extruder gearbox .................................................................................7259 Single screw extruder plant .............................................................................. 59,61260 Slitting machine ....................................................................................................40261 Speciality chemicals ............................................................................................102262 Stack moulds .........................................................................................................15263 Storage tank equipment ........................................................................................39264 Stretch blow moulding machine ...........................................................................18265 Switching device ...................................................................................................97266 System solutions ....................................................................................................83267 Tank truck equipment................................................................................. 39268 Tanks and silos ....................................................................................................107269 Tape stretching line...............................................................................................14270 Tarpaulin manufacturing machine ......................................................................103271 Technical moulds ..................................................................................................15272 Temperature controller ................................................................................... 12,105273 Testing instruments .............................................................................................120274 Thermoformers ................................................................................................... BC275 Thermoforming and PS foam ............................................................................ BC276 Thermoforming machine .................................................................................... BC277 Thermoplastic alloys .............................................................................................75278 Thermoplastic compound .....................................................................................75279 Thermoplastic elastomer compounds ...................................................................92280 Thermoplastic elastomers ............................................................................. 90, 104281 Thermoplastic polyurethanes ................................................................................81282 Thermoset ...........................................................................................................121283 Thick and wide plastic sheet extrusion line..........................................................16284 Three arm bi-axial roto machine .................................................................... 33, 35285 Three axis shaft gearbox .......................................................................................94286 Transmissions and PTOs ......................................................................................39287 T-shirt bag-making machine ...................................................................... 102, 106288 Twin mill pulveriser ........................................................................................ 33, 35289 Twin-screw co-rotating extruder......................................................... 71, 73, 87, 89290 Twin-screw element ............................................................................ 71, 73, 87, 89291 Twin-screw extruder gearbox ..................................................................................7292 Twin-screw extruder ........................................................................... 71, 73, 87, 89293 Twin-screw extrusion line ............................................................................... 59, 61294 Two color cane plant...........................................................................................122295 Two-layer blown film ...................................................................................... 10, 17296 Two-platen injection moulding machine ..............................................................99297 Ultrasonic flow meter.................................................................................. 12298 Universal controller .............................................................................................105299 UV stabiliser .....................................................................................................COC300 Vacuum dryer.............................................................................................. 47301 Vacuum forming machine ................................................................................... BC302 Vacuum loader ...................................................................................................FGF303 Vacuum pump and system ....................................................................................39304 Variable displacement pump energy-saving machine ...........................................63305 Vertical machining centre .....................................................................................99306 Vibroscreen ..................................................................................................... 33, 35307 Warehouse ....................................................................................................8308 Water heater ........................................................................................................104309 Water jetting machine...........................................................................................39310 WFR .................................................................................................................. FIC311 White masterbatch.....................................................................................COC, 23312 Winders...............................................................................................................122313 Wire EDM ..................................................................................................... 67, 69314 Wood plastic composites .....................................................................................100315 Woven sack tape plant for PP/HDPE ...............................................................122
Sl No Product Pg No
FGF - Front Gate Fold, FIC - Front Inside Cover, BIC - Back Inside Cover, BGF
- Back Gate Fold, BC - Back Cover
LIST OF ADVERTISERS
118 Modern Plastics & Polymers | April 2012
Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No
Our consistent advertisers
Adroit Control Engineers ............................. 97
T: +91-011-47600700
W: www.adroitcontrol.com
Aerodry Plastics Automation Pvt Ltd ............ 43
T: +91-120-4766777
W: www.aerodry.com
Aeromec Marketing Co Pvt Ltd .................... 91
T: +91-250-2454915
W: www.aeromec.in
AVI Additives Pvt Ltd .................................. 23
T: +91-40-23550551/2/3/4
W: www.aviadditives.com
Boge Compressed Air System ....................... 45
T: +91-44-43009610
W: www.boge.in
Bombay Hydrolic India ................................. 94
T: +91-161-2494216
Bonfiglioli Transmissions (Pvt) Ltd .............. 41
T: +91-44-43009610
W: www.bonfiglioli.com
Expo Centre Sharjah .................................... 50
T: +971-6-5770000
W: www.plastivision.ae
Ferromatik Milaon India Pvt Ltd .................. 25
T: +91-79-25890081
W: www.milacronindia.com
Freeze Tech Equipments Pvt Ltd .................110
T: +91-44-42152387
W: www.freezetechequip.com
Gardner Denver Engineered
Product India Pvt Ltd ................................... 39
T: +91-79-40089312
W: www.gardnerdenver.com
Glaves Corporation ...................................... 55
T: +91-141-2460324, +91-9983330808
E: [email protected], [email protected]
W: www.glaves.biz
Gujarat Machinery Pvt Ltd ..........................103
T: +91-79-29295988
W: www.gujaratmachinery.com
Hindustan Plastic And
Machine Corporation .............................. 59, 61
T: +91-11-25473361
W: www.hindustanplastics.com
Huarong Plastic Machinery Co Ltd .............. 99
T: +91-9825739634
W: www.huarong.com.tw
IDMC Limited ...........................................107
T: +91-2692-225399
W: www.idmc.coop
Ishan International ....................................... 40
T: +91-9737992000
W: www.ishan-intl.com
J.P. Extrusiontech Ltd ................................... 14
T: +91-2646-222163
W: www.jpextrusiontech.com
Kabra Extrusion Technik Ltd ................... 10, 17
T: +91-22-2673 4822
W: www.kolsite.com
L & T Plastics Machinery Ltd .................. FGF
T: +91-44-26812000
W: www.larsentoubro.com
Larsen & Toubro Ltd ..................................101
T: +91-22-6752 5656
W: www.larsentoubro.com
Lohia Starlinger Ltd ..................................... 77
T: +91-11-30641770
W: www.lohiagroup.com
Loxim Industries Limited ............................. 75
T: +91-2717-308000
W: www.loxim.com
Lubrizol Advanced Materials India Pvt Ltd .. 81
T: +91-22-66027800
W: www.estane.com
Matsui Technologies India Ltd ..................... 47
T: +91-120-4243862
Mifa Systems ...............................................105
T: +91-79-26870825
W: www.mifasystems.com
Mona Chem Additives Pvt Ltd ....................121
T: +91-261-2894847
W: www.monachem.com
Mould Master .............................................. 67
T: +91-422-4502171
W: www.moldmasters.com
N.A. Corporation ......................................... 35
T: +91-79-25840374
W: www.naroto.com
Neejtech India (Niigata) ............................... 29
T: +91-9909974224
W: www.niigataindia.com
Neejtech India(Braun) .................................. 15
T: +91-79-26561312
W: www.neejtech.com
Plastiblends India Ltd ..............................COC
T: +91-22-67205200
W: www.plastiblendsindia.com
Poly Mechplast Machines Ltd ....................... 18
T: +91-265-2631211
W: www.polymachplast.com
Polyplastics Marketing (India) Pvt ............. BIC
T: +91-22-67587668
W: www.polyplastics.com
Prasad Koch Technik Pvt Ltd ....................... 33
T: +91-79-25830112
W: www.prasadgroup.com
Prayag Polytech Pvt Ltd ............................... 53
T: +91-11-47262000
W: www.prayagmb.com
Presto Stantest Pvt Ltd ................................120
T: +91-129-4085000
W: www.prestogroup.com
Procon Technologies Pvt Ltd ........................ 12
T: +91-79-27492566
W: www.procon.co.in
R R Plast ..................................................... 16
T: +91-22-42461500
E: Email:[email protected]
W: www.rrplast.com
COC - Cover on Cover, FGF - Front Gate Fold, FIC - Front Inside Cover, BIC - Back Inside Cover, BC - Back Cover
LIST OF ADVERTISERS
120 Modern Plastics & Polymers | April 2012
Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No Advertiser’s Name & Contact Details Pg No
Our consistent advertisers
Rajoo Engineers Ltd....................................BC
T: +91-2827-252701E: [email protected]: www.rajoo.com
Remica Platics Machinery Manufactur ........122
T: +91-79-25712741E: [email protected]: www.remicaplastics.com
S&T Engineers ............................................ 79
T: +91-422-2590810E: [email protected]: www.stengineers.com
Sacmi Engineering India Pvt Ltd .................115
T: +91-7600003968E: [email protected]: www.negribossi.com
Sanity International ..................................... 19
T: +91-79-65227458E: [email protected]: www.sanityindia.com
Shanghai Forward Machinery Co. Ltd ............ 8
T: +9186-21-5990-8899E: [email protected]: www.forwardsh.com
Shini Plastics Technologies I Pvt Ltd ............ 83
T: +91-250-3021166E: [email protected]: www.shini.com
Shuenn Jaan Machinery Co. Ltd ..................116
T: +91-886-6-233-9590
E: www.soongiant.com.tw
W: www.soongiant.com.tw
Sri Sai Plasto Tech ....................................... 63
T: +91-44-42994365
W: www.srisaiplastotech.com
Steer Engineering Pvt Ltd ............ 71, 73, 87, 89
T: +91-91-80-23723309
W: www.steerworld.com
Sun Lung Gear Works Co. Ltd ..................... 94
T: +91-886-6-263-9969
W: www.slgear.com.tw
Suresh Engineering Works ........................... 30
T: +91-731-2527872
W: www.sureshengg.com
Toshiba Machine (India) Pvt Ltd .................117
T: +91-11-43291111
W: www.toshiba-machine.co.jp
Unimark (Maguire) ....................................... 93
T: +91-22-25506712
W: www.unimark.in
Unimark (Arburg Gmbh) .............................. 21
T: +91-22-25506712
W: www.unimark.in
Unimark (Staubli Faverges Sca) .................... 65
T: +91-22-25506712
W: www.unimark.in
Windsor Machines Ltd ................................119
T: +91-79-25841591
W: www.windsormachines.com
Wittmann Battenfeld India Pvt Ltd ............FIC
T: +91-44-42077009
W: www.wittmann-group.com
Zambello Riduttori S. R.I. .............................. 7
T: +91-39-0331-307-616
W: www.zambello.it
COC - Cover on Cover, FGF - Front Gate Fold, FIC - Front Inside Cover, BIC - Back Inside Cover, BC - Back Cover
Reg No: MH/MR/WEST/234/2012-2014 RNI No: MAHENG / 2008 / 25265 Licence to Post at Mumbai Patrika Channel Sorting Offi ce, Mumbai GPO., Mumbai 400 001.
Date Of Posting 1st & 2nd Of Every Month / English & Monthly.Date Of Publication: 28th Of Every Month.
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