indian market for specialty packaging films

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“The Indian Market for Specialty Packaging Films – Applications and Opportunities” -Vijay Shankar (Vice President) Mamata Extrusion Systems Pvt. Ltd., India. During International Conference on MULTILAYER PACKAGING FILMS ‘2014 on June 24, ‘2014 at Chicago, Illinois, USA 1 www.mamataextrusion.com

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Page 1: Indian market for specialty packaging films

“The Indian Market for Specialty Packaging Films –

Applications and Opportunities”

-Vijay Shankar (Vice President) Mamata Extrusion Systems Pvt. Ltd., India.

During International Conference on MULTILAYER PACKAGING FILMS ‘2014

onJune 24, ‘2014

atChicago, Illinois, USA

1www.mamataextrusion.com

Page 2: Indian market for specialty packaging films

1. Introduction

2. Indian Market for Plastics and flexible packaging films

3. Applications

4. Opportunities

5. A case study of Edible Oil Packaging Film – Mono to Seven Layer

Contents

2www.mamataextrusion.com

Page 3: Indian market for specialty packaging films

Contents (Contd.)6. Role of Blown Film Technology -

Mono to Co-extrusion Film

7. Role of Indian Packaging Eco-systems – Case Studies

“Eno” Effervescence Powder Sachets

8. Something about Mamata Group 9. Conclusion

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Page 4: Indian market for specialty packaging films

Introduction

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To understand the Indian market for Specialty Packaging Films, we have look into the current consumption of Specialty / Flexible packaging/ non packaging films as Indian market is still driven by COMODITY filmsThe Current Driving forces in Indian market is Lower COST of production/ PRICEThe potential of Indian market is it’s own population of 1.25 B+ @ 18% of world population of 7 B+

Page 5: Indian market for specialty packaging films

Introduction contd…

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According to the recent studies conducted ,the flexible packaging market in India is worth USD 8.5 B @4.35% of global market of USD 195 BThis translates into approx. 2.55 MMT of Flexible Packaging @ 21.6% of Total Plastics consumed as 11.8 MMT in India

Page 6: Indian market for specialty packaging films

Indian market for plastics & flexible packaging films

Packaging films :i. Food Packaging :

Milk PackagingEdible Oil PackagingWater PackagingBread Bags Spices – Whole/ groundedReady to eat Snacks- Nankeens, Potato Chips etc.Chewing Mouth FreshnersHeavy Duty Packing for rice, wheat flour etc.Snack Food : Oriented PP filmStand up pouches

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Page 7: Indian market for specialty packaging films

Film Applications

ii. Non Food Packing :3 Layer film in flexible lami tube -Huge market segment growing rapidlyStrech & Cling Film Shrink FilmLiner BagsInstitution Liner BagsBag in BoxMedical packagingHeavy Duty Sack bags Plastic Granule BagsGrocery Sack bags Agriculture FilmsANTIFOG Films

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Page 8: Indian market for specialty packaging films

Film Applications

ii. Non Packaging :Consumer purchased films and articlesAgriculture and Construction filmsDiaper and Personal Hygiene filmsMulch, Green House filmsSilage bags filmsSurface protection films

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Page 9: Indian market for specialty packaging films

Opportunities – India as manufacturer base for global market

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Global market for flexible packaging material is worth USD 195 billion & growing at a rate of CAGR 3.5% as against 8.5% in India. By this estimate, one can imagine the growth potential of flexible packaging in India in coming days which is tremendous.

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CAGR %

Page 10: Indian market for specialty packaging films

Plastic Industry Status Report

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Total Polymer Consumption 2012-13

Thermoplastics + Thermosets

POLYMER 2012-2013 2016-2017 (Estimated)

DEMAND 11.80 MMT 17.60 MMT

CARG 10.70%

Page 11: Indian market for specialty packaging films

Polymer Consumption – Application wise 2012-13

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Page 12: Indian market for specialty packaging films

Total Installed Capacity – Film Plants up to 2012-13

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Up to 2012-13 No of machine installed

Installed Capacity (MMT)

Monolayer Film 9370 1.625

Multilayer 1290 1.050

BOPP 33 0.600

PPTQ Film 2950 0.640

Total 13643 3.915

Page 13: Indian market for specialty packaging films

A Case Study of Edible Oil Packaging Film

- Mono to Nine Layers

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Page 14: Indian market for specialty packaging films

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3664Ghee

3763Butter

3961Vanaspati

5050Palm

8020Groundnut

8416Soybeans

8812Sunflower

946Mustard /Rapeseed

1090Coconut

Unsaturated fatty acidsSaturated fatty acidsProducts

Types of Edible Oil in India and Fatty Acid Composition of Oils / Fats

www.mamataextrusion.comHigher the unsaturation percentage, fast will be the spoilage

Page 15: Indian market for specialty packaging films

Monolayer to 3 Layer Edible Oil Film

Monolayer Structure

No of Layers 01

Polymer 45% LLDPE + 10% HDPE + 10% LDPE + 30% m-LL + 5% MB

% Thickness 100%

Total Thickness 120 Microns ( 4.8 Mil)

Price (USD/kg)* 2.01

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Page 16: Indian market for specialty packaging films

Monolayer to 3 Layer Edible Oil Film

3 Layer Structure

# of Layers 01 (Outer) 2 3 (Inner)

Polymer

45% LLD + 10% HD + 10% LD + 30% m-LL + 5%

MB

75% LLD + 10% HD + 10% LD +

5% MB

60% LLD + 10% LD + 30% m-LL

% Thickness 20% 60% 20%

Total Thickness 100 Microns ( 3.93 Mil)

Price(USD/kg) * 1.95

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Page 17: Indian market for specialty packaging films

Monolayer to 3 Layer Edible Oil FilmBenefits

Distinct skin layers – slip on sealant & non slip on surface

Low COF on inner layers

Chances of least pin holes

Coloured master batch only in middle and outer

Possibilities of using PP, HDPE & PE in desirable blends in different layers

3.42 % SAVING ( USD 0.06 PER KG ) IN RECIPE COST AS COMPARED TO MONO LAYER

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Page 18: Indian market for specialty packaging films

5 Layer Generic Structure - A5 Layer Structure

# of Layers 1 (Outer) 2 3 4 5 (Inner)

Polymer

62% LLD (C4) +

10% LD + 20% m-LL + 8% MB

Tie Poly Amide Tie

60% LLD(C4) + 10% LD + 30% m-LL

% Thickness 38% 6% 12% 6% 38%

Total Thickness 100 Microns ( 3.93 Mil)

Price(USD/kg) * 2.44

BenefitsExcellent Gas Barrier Properties in 5 Layer (Shelf Life up to 3-6 months).

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Page 19: Indian market for specialty packaging films

7 Layer Generic Structure - A7 Layer Structure

# of Layers 1 (Outer) 2 3 4 5 6 7 (Inner)

Polymer

70% LLD (C4) +

10% LD + 20% m-LL

82% LLD (C4) + 10%

LD+8% MB

Tie Poly Amide Tie

82% LLD (C4) + 10%

LD+8% MB

60% LLD(C4) + 10% LD + 30% m-

LL

% Thickness 19% 19% 6% 12% 6% 19% 19%

Total Thickness 100 Microns ( 3.93 Mil)

Price(USD/kg) * 2.41

BenefitsLower Sealant Cost & hence lower over all cost of the film

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Page 20: Indian market for specialty packaging films

5 Layer Generic Structure - B5 Layer Structure

# of Layers 1 (Outer) 2 3 4 5 (Inner)

Polymer

62% LLD (C4) +

10% LD + 20% m-LL + 8% MB

Tie Poly Amide Tie

60% LLD(C4) + 10% LD + 30% m-LL

% Thickness 20% 15% 30% 15% 20%

Total Thickness 100 Microns ( 3.93 Mil)

Price(USD/kg) * 3.05

BenefitsExcellent Gas Barrier Properties in 5 Layer (Shelf Life up to 6 – 12

months).

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Page 21: Indian market for specialty packaging films

5 Layer to 7 Layer Generic Structure – B17 Layer Structure – Break up PA Layer# of Layers 1

(Outer)2 3 4 5 6 7 (Inner)

Polymer

62% LLD (C4) +

10% LD + 20%

mLL+ 8% MB

Tie Poly Amide Tie Poly

AmideTie

60% LLD(C4) + 10% LD + 30% m-LL

% Thickness 25.5% 7% 14% 7% 14% 7% 25.5%

Total Thickness 100 Microns ( 3.93 Mil)

Price(USD/kg) *

2.91

BenefitsAs 30% Nylon may crack & loose barrier in long run & hence it is

addressed by splitting the Nylon Layer to make structure 7 Layer.Split Nylon layer to 14% &14% to make ~ 30% single layer of Nylon.0.14 USD / KG in 7 layer recipe cost as compared to 5 layer Generic

Structure - A

* SEA CIF Prices

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Page 22: Indian market for specialty packaging films

7 Layer ( Generic Structure – B2)7 Layer Structure – With EVOH

* SEA CIF Prices

# of Layers 1 (Outer) 2 3 4 5 6 7 (Inner)

Polymer

62% LLD (C4) + 10% LD + 20% m-LL+

MB 8%

Tie PA EVOH PA Tie60% LLD(C4) + 10% LD + 30%

m-LL

% Thickness 41% 3% 4% 4% 4% 3% 41%

Total Thickness 100 Microns ( 3.93 Mil)

Price(USD/kg) *

2.55

Benefits EVoH with almost ~ 5 times barrier than Nylon at ~ 2.5 times price, with

capability to have a sandwich layer with Nylon on both sides without Tie layer brings over all price down without compromising on Barrier Properties.

0.36 USD Per kg in recipe cost w.r.t 5 Layer Generic Structure-Awww.mamataextrusion.com 22

Page 23: Indian market for specialty packaging films

9 Layer ( Generic Structure – B2)9 Layer Structure – With EVOH

* SEA CIF Prices

# of Layers

1 (Outer) 2 3 4 5 6 7 (Inner)

Polymer

67% LLD (C4) + 10% LD + 20% m-LL+ MB

3%

90% LLD (C4) + 10%

LD Tie PA EVOH PA Tie

90% LLD (C4) + 10%

LD

57% LLD(C4) + 10% LD + 30% m-LL

% Thickness 20% 21% 3% 4% 4% 4% 3% 21% 20%

Total Thickness 100 Microns ( 3.93 Mil)

Price(USD/kg)

*

2.51

Benefits The sealant layer costs reduced

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Page 24: Indian market for specialty packaging films

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Role of Blown Film Mono to Co-extrusion

Page 25: Indian market for specialty packaging films

Why Co-extrusion Blown Film

As there are still many MONO Layer Blown film lines in market, there is a need to either upgrade / replace them to/ with at least a 3 Layer line.

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Page 26: Indian market for specialty packaging films

Film Properties : Multilayer Vs. Monolayer

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Film property, Unit Monolayer film LDPE

(50 micron)

Multilayer3-layer film LL/LD/LL

(30 micron)

Benefit (%)

Yield Tensile strength MD, MPa 9.5 12.3 + 29.5Yield Tensile strength TD, MPa 9.0 13.0 + 44.0Ultimate Tensile stress MD, MPa 26 28.2 + 8.0Ultimate Tensile stress TD, Mpa 21 27.4 + 30.0Ultimate Elongation MD, % 245 415 + 69.0Ultimate Elongation TD, % 650 745 + 14.6Specular Gloss, % 60 65 + 8.3Tear Resistance MD, g/mil 38 50 + 31.5 Seal ability property Moderate Excellent improved

Note: • All the above figures are merely indicative and for academic intent. They are not a commitment for any offered model of Film Plant and must be discussed in advance. Types of materials and material blends can reduce / enhance the characteristics mentioned above.

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Page 27: Indian market for specialty packaging films

The output rates of individual layers in a multilayer die are very much lower than for equivalent size of single layer die. The results in reduced shear rate and longer resistance time in the die spirals, leading to better homogeneity and additional relaxation of melt. Hence, the inherent benefits of Co-extrusion is improvement of film quality.

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Why Co-extrusion Blown Film

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FILM QUALITY

Page 28: Indian market for specialty packaging films

Ultimately there will be no need of any MONO Layer as 3 Layer will be able to offer a BETTER & CHEAPER solutions as it can now produce films using all PEs (LDPE/LLDPE/mLLDPE/HDPE etc.) & PPs (Homo as well Co- Polymer) through an ENGEENIRED STRUCTURE in a 3 Layer Blown Film Line.

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Why Co-extrusion Blown Film

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Present Future

Page 29: Indian market for specialty packaging films

This trend will need a joint co-operation with Machine manufacturers, Resin manufacturers & film producers to ADD VALUE to the whole process in phased manner.

29www.mamataextrusion.com

Page 30: Indian market for specialty packaging films

Future Trends in Co-Extrusion

The SLIM packaging ahead will force the Industry to control the RESOURCE by producing thinner & thinner films without compromising the core properties. A film today of say 1 mil (25 micron) will have to be down gauged to ultimately be of 12- 15 microns. To achieve this, we will have to develop very high line speed based Post Extrusion Equipment.

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Low Speed PEEs

High Speed PEEs1 mil (25 microns)

0.5 mil (12-15 microns)

Film Thickness Blown Film LinePost Extrusion Equipment (PEEs)

Page 31: Indian market for specialty packaging films

Looking into the future concerns globally to be kept this EARTH as GREEN as possible, we need to produce 100% recyclable flexible packaging laminates. This means we will have to produce blown films to replace existing non- recyclable substrates like PET, BOPP etc. Hence, there is a need to produce the blown film which could be having HIGH CLARITY & HIGH STIFNESS using say Homo Polymer PP blend in core & LL/mLL/LD blends in skins as usual to get a Double FROST line based film.

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Future Trends in Co-Extrusion

Page 32: Indian market for specialty packaging films

Future Trends of Co-Extrusion

This film needs to be further processed for Double Bubble/ Triple Bubble operations for highest possible across the width strength due to higher BUR. The film has to pass further through MDO (Machine Direction Orientation) process for enhance machine direction strength to enable film be running at very high line speed during printing with negligible STRTCHING. All the above processes has been achieved by Industry very successfully on individual operation base. Now the need of the hour is to marry them all together which is a challenging mile stone ahead. The reverse printed Blown film will then be laminated with another Blown film as sealant layer to offer recyclable LAMINATES.

32www.mamataextrusion.com

Page 33: Indian market for specialty packaging films

Role of Indian Packaging Eco-friendly system – i. ENO Sachets

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Page 34: Indian market for specialty packaging films

Eno Pouches – Eco Friendly System

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Earlier Present

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Page 35: Indian market for specialty packaging films

Something about Mamata Group

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Page 36: Indian market for specialty packaging films

Mamata Group

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The Flagship company of the GroupThe Flagship company of the Group

A Fully owned subsidiary of Mamata A Fully owned subsidiary of Mamata to make Multi layer Blown Film Line Systems and elements

A Green Field Project A Green Field Project to propogate Usage of Solar Thermal Energy for Purpose of Cooling & Heating applications.

Engineering & Marketing Arm of Mamata Engineering & Marketing Arm of Mamata Machinery Machinery in USA at ILLINOIS & FLORIDA

Page 37: Indian market for specialty packaging films

How we started:

In 1989, MAMATA MACHINERY introduced a unique concept in Bag Making Machines. Mamata was one of the very few companies in the world to have offered Microprocessor controlled Machines at that time.

Mamata has been exporting it’s product historically, Infact, Mamata exported it’s 1st machine in 1990 itself.

Mamata has developed Machines which are specifically targeted for the markets of Europe and United states of America.

Mamata introduced Vega series Machines in Europe in 1998 and introduced Machines in USA in 2003.

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Bag making machines

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Page 38: Indian market for specialty packaging films

Where we are today:

Today, Mamata has significant presence in USA. Mamata USA Inc. was formed and became operational in 2003 to service USA, Canada and Central South American Markets.

With over 3000 Machines in more than 75 countries, Mamata Machinery Pvt. Ltd. Has emerged as one of the Leading companies in this field Globally.

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Page 39: Indian market for specialty packaging films

Fastest System in world for Zip inserted Wicket Bags.

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Bag making machines

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Page 40: Indian market for specialty packaging films

Fastest system in world for making Flower Sleeve / Bags

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Bag making machines

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Page 41: Indian market for specialty packaging films

Fastest system in the world for making slider zipper pouches

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Bag making machines

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Page 42: Indian market for specialty packaging films

More than

110 machines supplied to USA in 100 months.

300 machines running in Europe.

200 machines supplied to South Afirca.

800 machines supplied to rest of African Countries.

Undisputed leadership in Indian market with more than 1000 machines

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Bag making machines

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Page 43: Indian market for specialty packaging films

Manufactured based on design from Klockner, Germany.

Basic design was based on clutch and brake technology for indexing. Sealing jaw movement was cam driven.

We changed film indexing and sealing jaw movement in line with our design philosophy with servo technology.

First machine became ready for commercial sale in ‘2000.

Since then we have sold 13 machines for applications to pack powders / liquids.

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Packaging machines

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Page 44: Indian market for specialty packaging films

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M-200 HFFS Pouch MachineSetting New Standards in Pouch Making

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Page 45: Indian market for specialty packaging films

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MAMATA ENTERPRISES INC.

MONTGOMERY, ILLINOISwww.mamataextrusion.com

Page 46: Indian market for specialty packaging films

Facilities / Locations…

Head Office & Manufacturing facility at:

Ahmedabad, Gujarat, INDIA

Pre-sales & After sales service centre &

showroom:

Montgomery, IL-60538 USA.

Agent Network in:

Over 15 countries in…

Europe

Middle East

Far East

Africa www.mamataextrusion.com 46

Page 47: Indian market for specialty packaging films

Blown film lines

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MES has dedicated facility of 140,000 Sqr. Feet. For Assy. and testing of Blown Film Line

With Canadian technology platform, we manufacture -Blown Film Lines of 1000 mm to

3000 mm width, output range from 120 kg/hr to 1000 kg/hr. Basic 3 Layer Lines & State-of-the

art, Fully Automated Lines with Internal Bubble Cooling Systems for higher output and critical applications.

Page 48: Indian market for specialty packaging films

Conclusion

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PE-PE laminate for bulk packaging applicationPE-PE laminate for environment /recyclability-  major thrust by MNC globallyAs can be seen, monolayer is not a market but a phase in many part of the world as ultimately any monolayer has to upgrade itself into co-ex with 2 0r 3 layer to go away from the problems of Pin Holes, Strength Properties / Process ability /down gauging and finally cost per square meter of Film. With recent advance in Die Design and Air Ring designs, Co-Extrusion Blown Films have far more benefits in terms of cost savings with optimum film properties by varying layer ratios in range of 1:2:1 and can go up to 1:5:1 and even up to 1:8:1.

Page 49: Indian market for specialty packaging films

Thank You…

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