modern plastics & polymers - july 2012

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7July 2012 | Modern Plastics & Polymers

he famous line of Robert Frost – …And miles to go… – is quite significant

in the current context of India’s economy. Although the country’s

economic progress in recent years has brought about certain changes

in basic infrastructure, there is a clear and critical need for its further

expansion in a fast-phased manner considering the demand dynamics of a burgeoning

populace. Like any other sector, the fate of plastics industry also factors this. Moreover,

there is an ever growing emphasis on sustainable processes and technologies that will

not only meet today’s needs, but also have adequate provisions for tomorrow.

In this scenario, the much-needed scale-up in India can be achieved if both the

public and private sectors join hands through Public Private Partnership (PPP) rather

than trying to individually tackle this imminent challenge of enormous proportion.

Although PPP appears to be a win-win situation for all stakeholders, the key to success

in such projects lies in effectively managing the interests of public and

private sectors across different roles. Also, considering PPP experience

in different sectors, some key implementation aspects of PPP need

to be well-defined and communicated to all concerned parties before

initiating a PPP project.

With fast evolving socio-economic landscapes of India and the

resultant demand drivers pertaining to numerous industrial and

consumer segments, the role of the plastics industry, especially in

devising an optimum life-cycle strategy involving virgin resins,

plastic products and recycled resins, cannot be emphasised

more. Further, since this has a direct bearing on three

key stakeholders – consumers, industrial producers and the

government – applying a PPP concept here seems to have

a promising potential. For a sustainable, standardised and

scalable PPP model in the country, there is a need to have

a futuristic as well as facilitating framework in place, with a

clear mandate of three Ps – people, processes and performance.

Although there is an air of optimism surrounding PPPs in

the country at the moment, a comprehensive analysis calls for its

judicious use in a customised manner as per the need of the particular

sector and circumstances. This will entail clearly demarcating specific

roles, rights and responsibilities; setting precise standards; providing

training to various stakeholders; and fine-tuning the process on a

regular basis to enhance the efficacy of the system. Only time will tell

whether the proposed PPP model will usher in a new growth paradigm

for the plastics industry.

TPPP: Progressive platform for plastics…

Editorial Advisory BoardA E Ladhabhoy

Plastics Technologist

Dr Sushil K Verma Former 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 Bastia [email protected]

EDITORIAL


CONTENTS

45July 2012 | Modern Plastics & Polymers 45February 2012 | Modern Plastics & Polymers

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

Automation Trends 76 PC-based technology: Combining precision with cost-efficiency

Energy Management 80 Extrusion screw design: Energy savings through best-in-class processing

Policies & Regulations 84 Plastic waste management: Need for a holistic regulatory framework

Strategy 88 Operator-friendly machines: An imperative for reducing labour costs

Tips & Tricks 94 Mould maintenance: Steps to a healthy machine life

REGUL AR SECTIONSEditorial ................................. 7News, Views & Analysis ...... 20Technology & Innovation .... 30Technology Transfer ............. 36Projects ................................. 96

45

Tenders ............................... 100Event List........................... 102Book Review ...................... 106List of Products.................. 122List of Advertisers .............. 124

Thermoforming ...................46

Machinery might ..................48

Interface:

�Franco Gornati ..............52

�Vir Singh .......................54

Roundtable ............................56

Special Focus61

Electrical grade plastics .............................. 62

Micromoulding solutions ....................... 64

Interface: Dr Harindu Vyas ................... 69

Polyamide alloy ...................................... 70

Cost information in

project management ............................... 72

Product grade transitions ....................... 74

In Conversation With 40 Nandakumar T

President, Wittmann Battenfeld India Pvt Ltd

Facility Visit 58 Wonderpack - A division of Rajoo Engineers Ltd:

Thermo‘forming’ a mark of success

Insight & OutlookPlastics in Electronic/Electrical Applications

Thermoforming

Details on pg no. 121

Looking For A Specific Product?Searching and sourcing products were never so easy.

Just type MPP (space) Product Nameand send it to 51818

eg. MPP Pump and send it to 51818

Special Focus: Masterbatches & Additives Insight & Outlook: Paints & Coatings

Highlights of Next Edition


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NEWS, VIEWS & ANALYSIS

20 Modern Plastics & Polymers | July 2012

WL Plastics to build new polyethylene pipe plantPolyethylene pipe extruder WL Plastics

Corp plans to build a plant, thus bringing

in jobs to Rapid City, South Dakota USA,

attracted by the Williston Basin oil boom in

Montana and North & South Dakota. Mike

Dahl, Director, WL Plastics, said, “The

company has an option to buy land. The

plant will have a rail spur. We are currently

in the process of designing, and will move

ahead after completing our design and

finalising our budget.”

“By end of summer, we will have a fully

articulated budget. Not only will this create

new jobs, but also enable us to position

ourselves better in the market. This is part of

our long-term market strategy,” added Dahl.

Rapid City would be the seventh plant for

WL Plastics based in Casper, Wyoming,

which has focussed on the energy sector and

grown rapidly besides new sources of oil

& natural gas in the US and Canada. The

company’s sixth plant opened in June, in

Snyder, Texas, a major oil-producing region.

Lionel Alva

Mamata Machinery to start operations at its new facility Gujarat-based Mamata Machinery Pvt

Ltd is in the process of shifting its

operations from the present facility in

Vatva to the new facility in Changodar in

Ahmedabad. The new facility has a total

land area of 36,000 sq m and is much

larger than the previous facility.

Abhijit Deshmukh, Senior Sales

Manager, Mamata Machinery Pvt Ltd,

noted, “The new facility was built

in eight months. The shifting is

being done and the new facility will

be fully operational in few weeks

f rom now. The major reason behind

this shifting of operations to the new

facility was that the old facility was

small and unable to handle large

productions.”

The company specialises in bag-

making and pouch-making machines.

It makes machines for industrial bags

used for packing salt, detergent, shirt,

stationery items, etc, and pouches for

packing hand wash, shampoo, etc, which

utilise sustainable films and not laminates.

Avani Jain

Crude oil prices adversely affect polymer prices

According to a study conducted

by The Associated Chambers of

Commerce and Industry of India

(ASSOCHAM), the international

oil prices and Rupee exchange

rate have been moving in

opposite directions, thus denying

Indian polymer importers the

benefit of drop in rates of crude

oil in the international market.

The study, which analysed the

dynamics of oil prices and India’s

import bill during April 2009-

May 2012, revealed that with

the devaluation of the Indian

Rupee and increase in global crude

oil prices, Indian polymer buyers

have been facing a rise in their

import bills. Yet the oil import

bill in rupee terms largely shows

an increasing trend, which has not

benefited polymer importers on

their prices.

D S Rawat, Secretary General,

ASSOCHAM, said, “The benefits

of lower international prices were

either offset by a faster depreciating

Rupee or a slower appreciating

Rupee, and this could not offset

the negative effect of a sharper rise

in international crude oil prices,

thereby resulting in a higher import

bill. This has a direct impact on the

plastics industry, which is heavily

dependent on crude oil imports.”

Further, the crude oil imports and

its impact on government finances

are dependent on import quantity,

international price of crude oil and

the exchange rate.Anwesh Koley

Rajoo sells its first seven-layer line in South India Rajoo Engineers Ltd –

based in Gujarat – has sold

its first seven-layer blown

film line in the southern

region of India. This is

the third machine of the

same type manufactured

by the company. The first

was sold to Turkey-based

Sahin Plastik-Vakum and

the second to a company

based in northern

India. Khushboo Doshi,

Executive Director, Rajoo

Engineers Ltd, said, “The

machine was launched in

2006. Rajoo is the only

company in India that

has manufactured this type of machine. This

machine is used to manufacture films with

high barrier properties. It takes nearly four

months to make this machine.”

The seven-layer CE-compliant

extrusion system comprises two 60-mm

grooved feed extruders

(for layers A and G),

two 50-mm grooved

feed extruders (C and

E) and three 40-mm

smooth bore extruders

(B, D, F). It is equipped

with a 400-mm die (a

stack-type die made by

Rajoo, with horizontal

melt flow paths) and an

internal bubble cooling

system. The machine

is equipped with

gravimetric feeding and

blending of seven main

components and 11

secondary components.

The blown film extrusion line also

incorporates an automatic film thickness

control system with segmented disc.

Avani Jain

D S Rawat



SABIC invests in Lexan* multiwall sheet capacity in India SABIC Innovative Plastics has opened

a state-of-the-art Lexan* multiwall sheet

production line at its manufacturing

facility in Vadodara, Gujarat, to provide

customers in the country and the

greater Asia with a fast, reliable source

of high-performance materials. The

new line will help meet rising customer

demand in the region for SABIC’s high-

performance Lexan Thermoclear* multiwall

polycarbonate sheet products used for

roofing and glazing in the building &

construction and greenhouse sectors.

“The new Lexan Thermoclear* sheet

line showcases SABIC’s broad portfolio

for almost all regions of the world so

customers can benefit from faster lead

times and expanded supplies to support

commercial & residential construction

projects,” said Sanjiv Vasudeva, South Asia

Sheet and Film Business leader, SABIC

Innovative Plastics.

The expanded Vadodara facility

features world-class quality assurance

processes, including a unique Ultraviolet

(UV )-protective coating system &

cap layer measurement and colour

measurement systems.

Negri Bossi’s outstanding performance at Plast 2012 At Plast 2012 held in Milan,

Negri Bossi showcased new

models of injection moulding

machines, from small tonnage –

the field of application covered

by the all-new EOS units – to the

powerful Bi-Power series capable

of producing large one-step

items. At the event, Negri Bossi

displayed the EOS series, VESTA

full electric series, JANUS 220

SE, CANBIO 430 SE, VECTOR

650 SE and BI-POWER series.

It also exhibited the new full-

electric ELEOS machine and

hybrid VSE 180, of the latest

VSE series.

Silvio Tavecchiav, Managing

Director, Negri Bossi-Sacmi

Group Company, said, “The

focus was on eco-sustainable

solutions since we believe that,

in future, sustainability issues

will gain prominence, and it

would be imperative to develop

machines that provide high

performance, environmental-

friendliness and energy savings.”

He added, “The event was

fruitful for us as we received a

large number of visitors from

Italy, Europe, Africa, Middle

East and Asia, and good response

for all our products, ie, nine

injection moulding machines of

50-1,300 tonne clamping force,

all working with special moulds,

in-mould labeling, silicon devices,

gas injection technology, etc.”

Avani Jain

Sixth symposium for Plastics Processing a huge success

With over 200 visitors and 18 presentations

on ‘New Trends in the plastics industry’, the

sixth Plastics Processing conference held

recently by the KREYENBORG Group in

Muenster, Westphalia, was a major success. The

presenters in the conference included polymer

giants from across the globe. The attendees

received considerable information on the latest

happenings in the polymer industry.

Jörg Auffermann from BASF presented the

fully biodegradable product Ecovio®, which is

made of renewable raw materials, and Ecoflex®,

the familiar BASF biodegradable plastics based

on petrochemicals. Innovations in underwater

pelletising technology were showcased by Frank

Brauer from BKG Bruckmann and Kreyenborg

Granuliertechnik GmbH.

In an interesting presentation,

Dr Thomas Grimm-Bosbach from Seebach

GmbH explained that the polymer industry

is driven by cost pressure (higher throughput,

longer lifetime) and required product quality

through finer filtration of optical quality. He

opined that modern melt filters must fulfill

these requirements. The optimisation of melt

filtration is done by enlarging the filter area,

using the smallest possible unit, adjusting the

filter medium to the customer process as well as

choosing the right filtration technology.

Anwesh Koley

Conair gets new President

Auxiliary equipment manufacturer

Conair Group has promoted Larry

Doyle from Vice President of global

sales and marketing, to President.

Doyle, with a background in plastics

processing machinery, joined Conair six

years ago. His promotion was announced

by Chris Keller, who had held the top

Conair position, while also serving as

President and Chief Executive Officer

of Conair’s parent company, IPEG.

Keller credited Doyle with spearheading

Conair’s Nu-Vu Conair Pvt Ltd joint

venture in India. On Doyle’s promotion,

Keller commented, “He deserves much

of the credit for our remarkable growth

in Asia and Latin America, and has

strengthened our leadership position in

North America.”

Doyle began his career plastics

processing in 1995 as international

sales coordinator for Autojectors Inc, an

Indiana-based maker of vertical moulding

presses. Before joining Conair in 2006,

he was Director of Sales and Marketing

at Demag Plastics Group, now called

Sumitomo (SHI) Demag. Doyle also

implemented a team-marketing approach

in growing industries such as packaging

and medical. He oversaw the launch of a

new upstream extrusion products group

and also initiated a major overhaul of

Conair’s sales organisation.

Larry Doyle



Corvaglia group goes for a face-lift With annual revenues of about CHF

50 million, two branches and 230

staff, the Corvaglia Group has grown

substantially over the last few years. In

order to meet increasingly challenging

requirements and accommodate

both market-specific and internal

developments, Romeo Corvaglia,

Founder, Proprietor and Chairman

of Board of Directors, Corvaglia

Group, had begun restructuring and

remodeling process in 2011, which is

now complete.

Thomas Marder, who had been

on Board of Directors of Corvaglia

Holding since 2009, took on the overall

responsibility for the Corvaglia Group

as Chief Executive Officer (CEO)

in July 2011. With a successful track

record of managing several international

technology companies employing up

to 1,100 staff, he has considerable

experience of designing effective and

efficient processes. This responsibility

was previously managed by Corvaglia,

who will gradually step back from

operational matters. As Chairman of

the Board he will be devoting himself

to strategically important projects, to

which he brings a wealth of knowledge

and technical expertise. The technology

department will now be managed by

Michael Krueger as Chief Technology

Officer.

Peter Kistler will be heading the

newly created ‘Process Improvement’

unit. His team will analyse the internal

processes in an ongoing effort to

integrate operations and refine workflow.

The first steps have been successfully

implemented, increasing output and

efficiency. Moreover, besides his duties

as the Corvaglia Group’s Chief Sales

Officer, Peter Schkoda has taken

over the management of Corvaglia

Closures Eschlikon AG.

The roles and responsibilities of

the other board members remain

unchanged. As Chief Financial

Officer, Simon Weisser is responsible

for financial and personnel matters;

and Bernardo Osés, General

Manager, is responsible for leading

Corvaglia Closures Ixtlahuaca

in Mexico. Corvaglia expects these

structural adjustments to produce

qualitative and quantitative growth in

the long term and is confident of the

company’s excellent position for facing

future challenges.

State boost for SME community In order to reinforce the role of Small and Medium Enterprises (SMEs) in the industrial growth story, the Small and Medium Development Chamber of India (SME Chamber of India) and Maharashtra Industrial and Economic Development Association (MIEDA) had recently organised the annual ‘Maharashtra SME Summit’ in Mumbai. In his inaugural speech, Sachin Ahir, Minister of State for Industry, said, “Though the State receives large foreign direct investment and investment in various sectors, the SME community can benefit by getting emerging business opportunities from various projects. The economic slowdown has adversely affected this sector. Thus, this is the perfect time for the government and banking sector to extend required support to the SME sector to survive this uncertainty.

Government of Maharashtra is in the process of bringing out the industrial policy to give priority to the SME sector.”

Also present at the event was J K Dadoo, Joint Secretary, Department of Commerce, Ministry of Commerce and Industry, Government of India. He highlighted various benefits of antidumping law. Defining the law, he explained that it was structured to protect the domestic industry from uncontrolled flow of foreign goods at prices lower than the domestic goods.

Sumitomo Chemical consolidates its position in India With a presence for over 14 years in India, Sumitomo Chemical enjoys a position of leadership in the Indian Polymethyl Methacrylate (PMMA) market. In order to consolidate and grow further, Sumitomo Chemical– Singapore has aligned with J P Plaschem, Mumbai. J P Group presents a one-stop-shop solution for its customers, thus providing a significant value addition to the business of SUMIPEX PMMA, the acrylic resin from Sumitomo. SUMIPEX PMMA, from Sumitomo Chemical - Japan, is produced by the Sumitomo technology at their wholly owned subsidiary Sumitomo Chemical Singapore at the Singapore plant.

“There is tremendous potential for acrylic in cosmetic packaging. Big companies such as Revlon, Maybelline and ELLE 18, use acrylic for their cosmetic packaging. Since most of these companies have entered India, they will slowly increase the use of acrylic in their product packing. At present, Indian companies such as Lakme and Emami have also begun using small quantities of acrylic in their packaging. This will ensure better aesthetics and be more expensive than normal polymer packaging. It is environmentally sustainable, as it is a recyclable polymer. Also, since the usage is not expected to reach the proportions of Polyethylene or Polypropylene (PE/PP), this will not be harmful in the least,” said M A Bala Gopal, Head-International Business, J P Group.

Lionel Alva

Romeo Corvaglia Thomas Marder Michael Krueger

Sachin Ahir



Foam Supplies Inc to launch India operations Foam Supplies Inc, patent holders of Ecomate blowing agent technology, has set up a subsidiary in India, named Foam Supplies India Pvt Ltd (FSI). The India operations will focus primarily on the distribution of Ecomate in Asia and the Pacific. Ecomate is an affordable non-ozone depleting, and no global warming potential polyurethane foam blowing agent technology based on methyl formate. The launch of this new hub will provide the polyurethane foam industry in the Indian sub-continent and other countries in the region with a steady and more affordable supply of an environment-friendly alternative to ozone-depleting foam-blowing substances.

The success in the use of this

technology has led to investment in

India. The India office will become fully

functional starting January 2013. “Our

company is committed to providing an

easily accessible supply of Ecomate to

its expanding customer base in many

countries, which prompted the launch of

the India operations,” said Todd Keske,

Director - Ecomate Development, FSI.

He added, “This expansion greatly

enhances the ability and speed with

which FSI and its global partners can

supply this ‘green’ product and technology

at a reduced cost. FSI is dedicated to

providing not only the material to foam

manufacturers, but also technical advice

and capacity development services.”

Image makeover for Presto Testing Instruments

With an aim to constantly innovate,

Presto Testing Instruments

has launched a new corporate

logo. Speaking on the occasion,

Gaurav Malhotra, Director,

Presto Group, said, “Through

this new logo, we want to

highlight our organisation’s

commitment to constant

innovation. Upgrading our

products according to the latest

available technology is at the

foref ront of our operating

philosophy.” Commenting on the

features of the new logo, Malhotra

elaborated, “The visual language

used in our logo is a three-

dimensional cube. It represents

Presto’s definition of commitment

and credibility. Its complete,

concise and futuristic shape

showcases our inception into

this niche testing machinery

segment. If we look carefully at

the cube, it is also an extension of

the Presto logo.”

He elaborated, “This cube

structure also represents our work

ethics that are based on stringent

quality checks, while constantly

focussing on dynamic industry

requirements. It showcases our

aim for perfection and constant

innovation to ensure complete

customer satisfaction by providing

safe, cost-effective and competitive

testing.”

Based in New Delhi and

NCR region, the company is the

world’s premier testing equipment

manufacturer. Presto’s products are

endorsed by reputed companies

such as Gap, Honda, Suzuki,

Colgate Palmolive, Cadburys,

Pepsi, Coca Cola, Nestle, Parle, etc.

Anwesh Koley

Solvay’s new centre in India for R&D and technologySolvay has inaugurated its new

Research, Development and Technology

Centre at Savli, India. The Centre will

focus mainly on the development of

high-performance polymers, organic

chemistry, nano-composites and green

chemistry. Housed in a new and high-

performance sustainable building, it will

employ over 200 researchers when fully

operational. The new Centre will tap

the country’s huge innovation talent

potential and carry out open innovation

in collaboration with premier institutes

in India.

Prakash Raman, Managing Director,

Solvay Specialities India Pvt Ltd, said, “This

will enhance the scientific and technical

knowledge of students, as they will learn

about the new technologies employed by

Solvay at their plant and the new Centre.”

The Centre has also established three

fellowships for research in sustainable

chemistry, nanotechnology and polymer

science at the Maharaja Sayajirao

University in Vadodara. The collaboration

between university, research institutes and

business organisations is essential to foster

breakthrough innovations, speed up the

design process and launch new products

in the market.

Kreyenborg group presents innovative technology at ACHEMA 2012

Filtering and conveying of plastic melt, innovative valve technology and pelletising & infrared drying technology are the specialties of the KREYENBORG Group. ACHEMA 2012, which is to be held on June 18-22, 2012, at Franfurt, Germany, will focus on efficient systems. An interesting point for polymer producers is the increasing

trend to replace large area filters in polymer lines by screen changers. This results in numerous advantages, eg, quick change of the filter media or the short residence time of the material in the screen changer. Overall, screen changers can considerably increase the profitability of the complex line.

The new KREYENBORG V-type screen changer with power backflush technology provides for a particularly profitable filtration. Integrated into sensitive extrusion applications, it permits the production of most high-quality products out of polluted input material. Its inimitable backflush system thereby ensures a high screen lifetime and minimal backflush loss.



Breakthrough for Indian scientists in degradable plastics A three-member team of scientists f rom the Institute

of Chemical Technology, Mumbai, have developed an

oxyodegradable polymer by combining plastic granules with a

catalyst, which enables the plastics to break down to smaller

chains under direct sunlight. Although this technology has been

available since quite some time, what differentiates the new

approach is that these smaller chains are eventually consumed

by bacteria present in the soil.

The catalyst works on any type of plastics and facilitates its

oxydegradation, ensuring that it does not pose as a health hazard

or threat to the environment in the long term.

“As the molecular weight declines due to oxydegradation,

this gives the microorganisms access to carbon and hydrogen,

allowing plastics to function as a nutrient for fungi and bacterial,

thus enabling complete degradation,” said R N Jagtap, Head -

Department of Polymer & Surface Engineering, Institute of

Chemical Technology. The efforts made by the research team

for nearly half a decade in a tenacious process of discovery have

finally yielded results. Moreover, the metallic catalysts are not

derived from toxic heavy metals, and the team is in the process

of acquiring a patent for the technology that could revolutionise

how plastics is looked upon at present.

Lionel Alva

New headquarters for Herbold Meckesheim USA Plastics recycling equipment supplier Herbold Meckesheim

USA has tripled its space by moving to a new Rhode

Island (RI) headquarters building. Herbold is moving from

a 5,000-sq ft facility in Smithfield, RI, to a 15,000-sq ft

building in North Smithfield, located a few miles away.

David Lefrancois, President, Herbold Meckesheim USA,

said, “After 16 years in the old place, we had a wish list of

features in the new facility and ensured to build in every

one of them. Our workflow, quality control and inventory

management will all benefit with this change.”

Herbold Meckesheim USA will add a showroom and

also have more space to stock machines & parts. The

machinery is built by parent company Herbold Meckesheim

GmbH in Meckesheim, Germany. Herbold Meckesheim

USA supplies granulators, de-balers, separation tanks,

friction washers, hydro-cyclones, dryers, compactors and

the first wraparound label remover for recycling of post-

consumer polyethylene terephthalate bottles. Lefrancois

added, “Herbold Meckesheim has sold equipment in the

US for about 30 years. Herbold was quick to recognise the

growing popularity of recycling as part of the movement

toward environmental responsibility — the willingness of

consumers to recycle and the growing demand for recycled

content in manufactured products.”

TECHNOLOGY & INNOVATION


Monitoring the moulding system The new CVe monitor f rom

AST Technolog y prov ides

comprehensive reports of an

injection moulding system’s activity

and performance, which may be

transmitted anywhere in the world.

The device features a 2GB flash

drive for storing mould performance

reports, mould drawings, setup sheets

and much more.

Data gathered by the CVe Monitor

includes total operational cycles of

the tool, cycle time recorded over the

life of the tool, cycle time recorded

over the last 25,000 cycles, record of

downtime, proportion of downtime

versus activity and record of mould

maintenance periods. Results can

either be viewed directly on the CVe

Monitor or downloaded via its USB

port for reporting purposes.

New SMP developed from TPU A new Shape Memory Polymer (SMP)

– Desmopan DP 2795A SMP, has

been developed using Thermoplastic

Polyurethane (TPU) by Bayer

MaterialScience and BAM Federal

Institute for Materials Research and

Testing. Components made of this

innovative plastics can be reshaped

and fixed temporarily when heated

to a specific temperature, called

the switching temperature, and the

parts recover to their original shape

without any changes. The switching

temperature of the innovative SMP

is about 40°C. Other benefits offered by

this plastic material include excellent

chemical and abrasion resistance and

flexibility.

Potential applications of Desmopan

DP 2795A SMP include repair of

damaged components by using shrink

tubing, packaging, self-loosening

screws, artificial muscles, remote

temperature sensors and hair dryers.

The TPU material is ideal for food

contact applications and can also be

useful in brand & product protection

applications. BAM has utilised this

material to develop labels with coloured

and engraved Quick Response (QR)

codes. The Desmopan DP 2795A SMP

is free from antihydrolysis agents and

plasticisers.

PolyOne Introduces Smartbatch™ HC Protected by WithStand™ Antimicrobial Technology

PolyOne Corporation has launched

Smartbatch™ HC protected by

WithStand™ Antimicrobial Technology.

This new tailored concentrate

streamlines customers’ production and

enhances end product performance by

delivering both antimicrobial properties

and colourants in a single solution. This

technology enables creating a tailored

solution based on the end application

and specific polymer. This specific

formulation can then be combined with

PolyOne OnColor™ HC colourants to

create the final Smartbatch™ concentrate.

This technology is ideal for applications

in medical device housings, chair rails,

catheters, lab ware, fitness equipment,

surgical tools, etc. It protects these and

other plastic devices used in healthcare

facilities against microbes, eg, bacteria,

fungi and algae as well as degradation,

discolouration & odour caused by these.

Plastics-intensive medical devices in

hospitals and clinics can play a role in

preventing the transmission of microbes

that cause Healthcare Acquired Infections

(HAIs). The facilities have enlisted the

aid of manufacturers to help combat

HAIs. Smartbatch™ HC protected by

WithStand™ Antimicrobial Technology

helps original equipment manufacturers

to meet these customer needs,

while maintaining colour aesthetics,

meeting regulatory requirements and

differentiating their products.

KraussMaffei launches new GX machine series KraussMaffei has introduced new

GX two-platen hydraulic drive

injection moulding machine series.

The machines are equipped with a

modular design, not only to provide

customers with a choice of four

different injection and clamp units,

as well as hydraulic or electric drive

plasticising screw options, but also to

make the machine more suitable for

worldwide production as required.

Krauss Maffei has also raised the

bar in terms of engineering design

and productivity with their new

hydromechanical dual-platen concept

incorporating GuideX and GearX

technologies.

Key features of the new GX

series injection moulding machines

include dry cycle time of 2.3 second;

a choice of 12 injection units offering

a combination of 90 injection

configurations utilising hydraulic

or electric screw drives; potential

energy savings of up to 50 per cent;

unique GuideX platen support guide

shoe; GearX clamp system locks the

machine clamp within the shortest

possible time; accessibility in the GX

housing design of the clamping and

ejection areas and nozzle interface;

as well as clear & easy-to-operate

MC6-19” touchscreen control system.

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TECHNOLOGY & INNOVATION


New locked blow and fill system KHS Corpoplast, Germany, has

introduced its blocked blow moulding

system, a combination blower, filler

and capper unit that can be used in

Polyethylene Terephthalate (PET)

applications. The InnoPET BloFill

blocked system is designed to increase

efficiency and cut costs by filling

in-line after blowing.

The system connects the blower

directly to the filler and capper

unit, cutting out the air conveyer,

bottle rinser and other components.

Instead, a multi-functional star wheel

conveys the bottles from blower to

filler by way of a transfer block. The

block separates the dry blowmoulder

from the wet filler and includes an

airlock with constant air flow. The

base system can be used for water

or other non-carbonated soft drinks

and can make up to 72,000 bottles

per hour. With some modification,

the system can also be used for

carbonated beverage applications and

hot-fill applications at 185-190°F

(85-88°C).

Light guide panels by Arburg

Arburg has developed a hydraulic

compression moulding machine designed

for a 0.5-mm-thick optical application. The

light guide panels are moulded with a thin

optical panel intended for use in tablets and

Thin Film Transistor (TFT) screens, using

Light-Emitting Diode (LED) lighting; also,

the mould cavity does not close completely.

The hydraulic Allrounder 630 S has a

clamping force of 250 tonne and operates

with a two-cavity mould. It maintains a

1-mm gap until the last 50 millisecond of

the process. The mould, in turn, must be

designed so that the cavity is sealed, even

in the partially open state. This process

helps reduce shrinkage and deformation

and can accommodate precise moulding

specifications. The light guide panel features

nearly imperceptible ridging and changes in

thickness at the edges, designed to ‘guide’

LED light from the edges of the panel.

Most tablet panels are lit from behind, but

the light guide panel can be lit from the

edges and maintain even brightness across

the entire surface of the panel.

Sim-pull closures foil tamperers Two all-in-one foil closure solutions

for the food industry have been

launched through a licence agreement

between Dorking-based Bapco

Closures and Aptar. The new Sim-

pull and Trilogy closures both feature

a proprietary Bonded Aluminium-

to-Plastic (BAP) technology, which

claims to provide ease of opening,

built-in tamper-proofing and

excellent seal integrity.

The Sim-pull solution has a flip-

lid design, allowing consumers to

open lids with one hand, according

to Bapco. It is designed for a

diverse range of contents including

snack and granular products such

as nuts, crackers, baking agents and

sweeteners. A variety of ring-pull

configurations enable manufacturers

to tailor the closure to their particular

product specifications. The Trilogy is

a two-piece spout and closure design.

These new solutions meet the

growing demand for re-sealable

closures for on-the-go and at-home

eating. These are perfect for

occasions when customers want

to consume a single portion of food

and save the rest for later. Because

of their ease of opening feature,

Sim-pull and Trilogy are particularly

suitable for elderly consumers

and children.

New LVT eliminates problems in extrusion blow moulding of polyolefinsThe new Liquid Vehicle Technology

(LVT) developed by Clariant

Masterbatches has the capability to

eliminate many of the problems that

have prevented wider use of liquid

colour and additive concentrates in

extrusion blow moulding of polyolefins

(high- and low-density polyethylene

and polypropylene).

Initial testing in monolayer

containers demonstrates that these

highly compatible systems allow for

higher pigment loadings and lower

usage rates, while practically eliminating

past challenges related to screw slippage.

Improved resin compatibility results

in stronger weld lines in the finished

container as evidenced by the scores of

standard burst and compression-loading

tests. The new masterbatches use a

liquid vehicle system that incorporates

suspension aids, and binders have

been incorporated into the new LVT

masterbatches to allow for higher

pigment loadings and, in most cases,

lower usage rates.

Additional components enhance

flow and make for dramatically

faster colour changes. The benefits

of this technology include improved

weld-line strength, better processing

characteristics, faster colour changes

and greater productivity.

TECHNOLOGY TRANSFER


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

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

Technology Offered

Biodegradable polymer The biopolymer nanopartic le

technology is based on cost-effective

biodegradable and biocompatible

polyolefins, copolymer of ethylene

& vinyl acetate and Thermoplastic

Starch (TPS) blend nanocomposites.

These nanocomposites have improved

mechanical properties with zero

moisture content.

Areas of applicationPackaging materials, disposable non-

wovens, hygiene products, consumer

goods, agricultural and horticultural

tools and medical

Forms of transferTechnology licensing

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

in providing consultancy for the

modification of batch-poly plant to

C P plant like polyester plant, polyester

chip or direct spinning.

Areas of applicationChemical fibre and plastics

Forms of transferTurnkey

Pilot plants for small-scale production A Chinese company is interested in

offering small capacity technology for a

wide variety of plants such as polyester

plant, polyester chip or direct spinning.

Areas of applicationChemical fibre and plastics

Forms of transferTurnkey

Plastic light guide fibresA Chinese R&D institute offers to

supply the technology of plastic

lightguide fibres and handicraft articles

made from it. Plastic lightguide fibres

are cylindrical fibers with core-clad

structure made of two highly transparent

polymers, the advantages of which

are excellent light transmission, good

toughness, light weight & easy to

process and use.

Areas of applicationPhotoelectric switches, photosensitive

elements, linear accommodation networks,

short-distance optical communications,

and medical & dental devices

Forms of transferTechnology licensing and equipment supply

Plastic additives processing An Indian company offers pilot

plants for laboratory or small-scale

production purpose. The plant consists

of a spinneret, metering pump, spinning

beam, candle filter, extruder unit,

godet unit, single-screw extruder machine

and melt flow index tester machine.

Areas of applicationPlastics, textiles, etc

Forms of transferSub-contracting, turnkey, etc

Plastic recycling technology This technology uses a mix of synthetic

urea, ammonium carbonate and

ammonia. This chemical mix is used in

the treatment of recycled plastics.

Areas of applicationPlastic compounding and recycling

Forms of transferTechnology licensing

Polyester chip plant A company f rom China offers

polyester production plant,

polycondensation plant, polymerisation

line, hot melt adhesive plant

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

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

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

Areas of applicationPolymerisation and fibre lines

Forms of transferTechnology licensing and turnkey

Processing machinery An Indian plastics processing

machinery manufacturer is offering

screws and barrels for all plastic

extruders. The company also repairs

worn out equipment. The products are

highly energy efficient for washing

and drying all types of recycled plastic

components.

Areas of applicationPlastics, textiles, etc

Forms of transferSub-contracting, turnkey, etc

Recycling PET waste into polyester polyols A Czech Republican company

is offering the technology for recycling

of PET waste (plastic PET

bottles, X-ray films, etc) to produce

polyester polyols. The process

consists of following steps:

Collecting PET waste, sorting out

& shredding collected PET waste,

simple chemical process of glycolysis

& esterification and production

of polyester polyols.

Areas of applicationChemicals industr y: Polyester

polyol is a base material for the

chemistry of polyurethanes, especially

production of polyurethane foams,

which are primarily transferred into

energy saving and insulating materials

Forms of transferTechnology licensing, others

TECHNOLOGY TRANSFER


Share and Solicit TechnologyThe mission of Modern Plastics & Polymers is to spread the technology culture. Here is an opportunity to be a part of this endeavour by sending your technology on offer or technology requirements. If you belong to any of these two categories, you are invited to furnish the techno-commercial details for publication. The write-up needs to be as per the format of this section with information about the particular technology offered or requested, its areas of application and forms of transfer.

Contact: Modern Plastics and Polymers�� !"��#�"�%�'��!��())�)* +��/�;<�)**=>))>�(?O��Q�VX<�)**=>))>�((YY�Q�Z�;<��[��\�� +�

Disposal & recycling of plastic waste A Polish firm seeks the technology

for dry processing of all kinds of

plastic waste or a magnetic processing

method in the electrostatic field. The

technology should allow sorting of all

kinds of plastic materials, hay-silage foils,

PET, HDPE, PVC, etc, by excluding

dangerous waste.

Areas of applicationPlastics industry, waste recycling, waste

management

Forms of transferOthers

Lab-scale non-woven and monofilament plant An Indian company is looking for a

lab-scale, non-woven and monofilament

plant in a single station.

Areas of applicationPlastics


Plastics recycling technologies A Sri Lankan company is seeking

latest plastics recycling technologies

for automatic sorting, washing, metal

detection, granulation process system,

washing plants, crushers, extruders, etc.

Areas of applicationPlastics recycling


Polyacetal resins A Gulf-based organisation wants to

promote projects in the chemicals and

petrochemicals sectors in GCC countries.

It is looking for technology suppliers

for the manufacture of polyacetal resins.

Areas of applicationChemicals/petrochemicals industry

Forms of transferFeasibility study, know-how, equipment,

turnkey plant, joint venture

PP/PET strap processing An Indian company is seeking the

technology for PP and PET strap

processing as well as machinery made

using high-quality raw materials and

parts. It should ensure higher output and

enhance productivity.

Areas of applicationPackaging industry, paper industry, ceramics,

pharmaceutical, industrial components, etc


Recycled PET polyester polyols plant A Poland-based company specialising

in recycled PET polyester polyols

manufacturing is looking for an

alternative proposal of design and

engineering of bigger (approximately

25 ktpa) production plant. It plans to start

with delivering proper, quality recycled PET

flakes in big bags. So, the company needs a

complete package offer for this service.

Areas of applicationPlastics and polymers industry


Road filling materials for road maintenance An Indian company requires the technology

to make materials by transforming waste

plastics, which can gel uniformly with

road materials. This is for filling potholes

in roads. It also needs the know-how

regarding products that are made from

waste plastics, eg, jumble strips, speed

breakers, etc.

Areas of applicationRoad transport


Utilisation of natural rubber in asphalt A Pakistan-based company needs know-

how on utilisation of natural rubber in

modified asphalt covering. It requires

standards and specifications guiding

the use of natural rubber in modified

asphalt; appropriate proportion of natural

rubber in mixture & handling of the

operation; additives needed; and details of

improvement in the asphalt properties by

using natural rubber.

Areas of applicationRubber industry


Information courtesy:� ��"�� ]��"��<� #"� �"�^�� ^_�� =`^"�� /�]^��;�� /"��"� ��"_]�� j"��[�� k�� z�� =� �� {]}�]�`��"�� "�/"��"��/�]^��;�� %�{`//'��{`//�~�;��`=*�� ;��"��z��#�;^��)�)�?��/�;<�)�� =�*?Y?�?�)Y��VX<�)�� =�*? ��?*O(��Z�;<��"�^��\[]��+�"��<��+[]��+�"��V�"��"��"��]^��;��"��"��[;��;��+��]^��;��(��+��"��"��^��"�]��]��;�+�/^��"��]��[;��"��["�_��{`//��"��];��"]��"��"��]^��;��]"��^��;��+��"��]^��;��"��"�"��^��"��"��"��;��"�"�]�_��"��[��"��["��[�]�_��"��"��^"��^��^��"��]��]��APCTT for further assistance.

Technology Requested


…believes Nandakumar T, President, Wittmann Battenfeld India Pvt Ltd. Leading the youngest subsidiary of European machinery manufacturer Wittmann Battenfeld in India, Nandakumar outlines the core requirements of the Indian plastics industry to compete on the global front, in an exclusive conversation with Annabel Dsouza…

“Energy saving is possible throughout the entire system by selecting the right equipment”


IN CONVERSATION WITH: Nandakumar T

Nandakumar T

What are the current growth dynamics for the plastics industry in India?Indian plastics processors are innovative,

dynamic and demanding. They require

technological leadership, together with

outstanding service and short response

times. With this competitive spirit,

the Indian plastics market has grown

consistently over the last few years.

But, the need of the hour is innovative

automation and robotic solutions to keep

pace with global developments. Most

processors are aware that resins represent

a significant percentage of their overall

part-cost, yet they often do not realise the

true cost savings available to them from

efficient handling and control of resins.

Material handling is an area where

many processors are now looking at in

order to reduce their input costs and

improve overall operation without

making a significant capital investment.

Simplification of controls and operation

of equipment is critical for processors

facing a shortage of skilled personnel.

As the Indian plastics industry seeks

energy-efficient equipment to reduce

manufacturing costs, Wittmann

Battenfeld is making a great impact in

delivering low-consumption, high-output

solutions.

How would you describe the journey of Wittmann Battenfeld in India? Wittmann is dedicated to robotic and

automation technology for the Indian

plastics processing machinery market.

After its formal incorporation in

December 2006, Wittmann India was

renamed as Wittmann Battenfeld India

Pvt Ltd, after just one and a half year,

reflecting our broad sales & service

synergy with Wittmann’s acquisition

of Battenfeld in April 2008. Since

then, the Indian company has enjoyed

uninterrupted growth. This does not only

reflect in our marketshare, but also in the

growth of our team in India.

Completing five years in India, we

continue our journey towards being

a complete solutions provider for the

Indian plastics industry. This being our

core strength, we are developing better

solutions for this challenging market to

further strengthen our position.

How can machinery makers overcome cost-quality pressures in India?Not only the size, but requirements for

quality and efficiency are also growing

in the Indian plastics market. At present,

the drive for leading technology is

becoming a major decision factor. Speed,

consistency and energy-efficiency are

the uncontested requirements for every

production unit. As Indian manufacturers

recognise the value of these advantages in

the domestic and export market, quality

scores over price as a key concern of

the globally competitive manufacturer.

Wittmann does not compromise on

quality irrespective of the price factor. Our

cost-competitive solutions are designed

as per manufacturers’ specifications. We

maintain a standard quality policy, thus

strengthening our base in India. We

believe in technology consistency and

transparency across the world through all

our subsidiaries.

What are your current focus areas and future strategy?We are currently the third largest player

in the plastics processing machinery

automation space in terms of market

value. We are expanding our presence in

India through a larger shop floor, which

is likely to begin operations by mid-2012.

We expect a 40-45 per cent jump in

revenue through a well-defined sales and

service network across India. Industry-

wise we are focussing on medical

devices, automotives and white goods

manufacturing. Due to high growth

rates in these industries, and the need

for precision & high productivity, we are

witnessing a rapid shift from conventional

manufacturing to automation & robotics.

As a global player in the plastics

machinery space, Wittmann Battenfeld

is present in all major markets of the

world. But, the Indian subsidiary has also

exported to countries like Uzbekistan,

South East Asia and South Africa.

We remain committed to the Indian

market and are currently establishing a

manless operation factory with one of our

Indian clients.

What are Wittmann’s R&D initiatives in India and globally?We believe in lean production and global

technology to supply the plastics processor

with the best possible technology

at competitive prices. Wittmann’s

Research and Development (R&D) has

increasingly centred on environmental

aspects, with innovations to reduce energy

& oil consumption and noise level by

establishing a true modular concept. Once

these early concepts are decided upon,

we develop the prototype and study its

feasibility in an increasingly competitive

market. Wittmann’s R&D also focusses

on simplification of controls to develop

easy-to-use, open machines thereby

simplifying the shop floor for the operator

and manufacturer. In order to maximise

equipment output and ensure standards

of quality & consistency, processors are

relying more on automation and reducing

dependence on skilled personnel.

When we launched operations

in India, our priority was to adapt

Wittmann’s solutions to Indian conditions

of temperature, humidity and power

supply. Currently, many of the software

R&D projects at the Wittmann tech

centre in Vienna are being developed as

per Indian specifications.

How important is sustainability for plastics processing machinery?Machinery manufacturers play a pivotal role

in making the plastics industry competitive

on the sustainability front. Energy saving is

possible across the entire system by selecting

the right equipment and dimensioning it

as per product analysis, measurements and

readjustment of the process. Wittmann

supports this cause by developing energy-

efficient automation solutions. This needs

creating a culture of energy consciousness.

We have done this by putting the

star rating stickers on our equipment.

We are the only company in the

Indian plastics industry to have this energy

rating sticker.




SPECIAL FOCUS

Thermoforming

45February 2012 | Modern Plastics & Polymers

Thermoforming:

Offering f lexible high-strength solutions ....................................................................................46

Machinery might:

Progress through process optimisation ........................................................................................48

Interface:

�Franco Gornati, MD & CEO, FNC SpA Group - Veripack Solutions India Pvt Ltd ..... 52

�Vir Singh, Proprietor, Sai Thermoformers ............................................................................54

Roundtable:

Is the Indian thermoforming industry ready to compete on a global scale? ..............................56



SPECIAL FOCUS: Thermoforming

With the rapidly rising

price of commodity

polymers, the scenario

in the plastics

market has undergone a change. Many

plastics processors have entered into

thermoforming through acquisition

of companies in this industry in order

to remain a competitive supplier of

containers, particularly to the dairy

market. The reason is orientation strength,

which is achieved by thermoforming

as it is done below the melting point

of the polymer, particularly with

Polypropylene (PP).

Owing to these benefits, it is possible

to produce containers such as those used

for dairy products with much thinner

walls, but having the same compression

strength as their injection moulded

equivalents. S C Dutta, Managing

Director, Shalimar Thermoforming Pvt

Ltd, says, “The thermoforming industry

is flourishing in India. The process finds

wide applications in the day-to-day life,

eg, catering items, food trays/packs, cups

and glasses, beverage containers, bakery

packaging and large industry applications.”

Preference for the processThe customer today demands light-

weight packaging for most of his/her daily

requirements. Thermoforming offers the

advantage of manufacturing thin-walled

products, which help in weight reduction.

Therefore, more and more entrepreneurs

are entering the thermoforming process

industry. An important issue here is that

entrepreneurs consciously manufacture

products from quality/virgin plastics/

polymer to meet the environment norms.

Plastics find various applications in

every day usage. However, in manufacturing

of packaging material or containers, trays

and boxes, PP and Polystyrene (PS) are

fast gaining ground in terms of usage,

while thermoforming is the most widely

used technique for making finished

products. The ongoing development of

new materials, equipment and tooling

technology has enabled thermoforming

to find applications in areas that formerly

utilised paperboard, glass, metal, wood,

Expanded Polystyrene (EPS) foam, etc.

“Compared to other plastics processing

techniques (injection moulding, blow

moulding), thermoforming offers low-

cost tooling, fast, inexpensive prototyping,

shorter production lead times, custom

designs that can be easily modified, thin-

The ability to produce light-weight, cost-effective plastic products without compromising the tensile strength makes thermoforming one of the most sought-after methods and a viable option for plastics processors. Anwesh Koley looks into the latest technologies used in this process to offer high-quality end products.

Offeringflexible

high-strengthsolutions

Courtesy: Shalimar Thermoforming Pvt Ltd


Thermoforming

walled products, demand flexibility and

exceptionally large part capabilities. Thus,

thermoforming facilitates ideas to reality,”

says Dutta.

Application areas Thermoforming is a secondary shaping

process, the primary process being one

that produces the sheet or film. Only

thermoplastics can be thermoformed,

since extruded sheets of thermosetting

or elastomeric polymers are cross-linked

and cannot be softened by reheating.

Common thermoforming plastics are

PS, cellulose acetate and cellulose acetate

butyrate, Acrylonitrile-Butadiene-Styrene

(ABS), Polyvinyl Chloride (PVC), acrylic

(polymethylmethacrylate), polyethylene

and PP.

Mass production with thermoforming

operations is done in the packaging

industry. The starting sheet or film is

rapidly fed through a heating chamber,

which is mechanically formed into the

desired shape. The operations are often

designed to produce multiple parts

with each stroke of the press by using

moulds with multiple punches and

cavities. “In some cases, the extrusion

machine that produces the sheet or film

is located directly upstream from the

thermoforming process, eliminating the

need to reheat the plastics. For optimum

efficiency, the filling process to put the

consumable food item into the container

is placed immediately downstream from

thermoforming,” says Dutta.

Thin film packaging items that

are mass produced by thermoforming

include blister and skin packs. These

offer an attractive way to display certain

commodity products such as cosmetics,

toiletries, small tools and fasteners (nails,

screws, etc). Thermoforming applications

include large parts that can be produced

from thicker sheet stock, eg, covers for

business machines, boat hulls, shower

stalls, diffusers for lights, advertising

displays and signs, bathtubs, toys, etc.

The injection moulding process is

often compared with thermoforming.

However, thermoforming enjoys certain

advantages, which make it the preferred

choice in many applications. Injection

moulding has its limitations when it

comes to size of product and cost of

tooling. A typical injection mould tool

will cost roughly 33 per cent more than

a similar thermoformed tool, and the

margin increases as the parts become

larger. “Injection moulding does not have

a good prototype process, as typically

Stereolithography (SLA) or Selective

Laser Sintering (SLS) parts that are

used for prototyping, which offer limited

comparisons to the actual final product,

can be expensive, and are not of the same

material with which the final product

is made. Thermoforming, on the other

hand, utilises a prototype tool made from

wood or epoxy that can be used to create

several finished parts of the product and

formed from the same material with

which the final product is made,” adds

Dutta. Therefore, many possible design

or fit issues can be caught before going

to production tooling, thus saving time

and money.

Areas to work onThermoforming enjoys many advantages,

but the industry needs to understand

certain fundamental requirements to

ensure steady growth. “An important

concern is that thermoforming

machinery, which is expensive since it is

monopolised by only few manufacturers

who are concerned only up to supplies

and have not considered developing the

skilled workforce to facilitate growth

of the entrepreneurs. The after-sales

service is also not up to the mark, which

should be taken care of by machinery

manufacturers,” believes Dutta. Also,

remote areas and states have difficulties

in terms of technical know-how, logistics,

with delays in after-sales service support,

thus adversely affecting the industry. “A

proper advisory should be issued to the

manufacturers that it is in the interest

of the country to promote and help the

best as well as most efficient utilisation

of machinery available in the country to

avoid wastage of resources,” adds Dutta.

Roadblocks aheadThe key challenge for the thermoforming

sector in India is that the used disposable

plastic and polymer articles are not properly

managed and collected for recycling to

avoid hazardous effects on earth. “The

government, civil society and industry

together must make efforts to create

awareness and pass an ordinance to ensure

scientific disposal of used plastics/polymers

for ensuring environment safety, otherwise

thermoforming sector cannot reach the

desired heights in the coming years, which

would be a huge loss for both the industry

and the society,” opines Dutta.


S C DuttaMD, Shalimar Thermoforming Pvt Ltd

Compared to other plastics processing techniques (injection moulding, blow moulding), thermoforming offers low-cost tooling, fast, inexpensive prototyping, shorter production lead times, custom designs that �� walled products, demand �� large part capabilities.

Courtesy: Shalimar Thermoforming Pvt Ltd

SPECIAL FOCUS: Machiner y might


Courtesy: Sealers India Agencies

Progress through process optimisation

Th e e f f i c i e n c y o f

thermoforming technology

depends on var ied

applications that the process

enjoys. Packaging is an important

area where thermoforming is used.

Thermoformed packaging refers to

a type of retail packaging that uses

thermoforming technology. In this

process, a special type of plastics is

melted to liquid form and frozen to a

brittle, almost glass-like state. This type

of thermoformed packaging is preferred

for various applications and industries,

such as dairy and food packaging, as

well as cold beverage cups.

The thermoforming technology

provides cost-efficiency and high quality

of polymers used in packaging. V Vikram,

Proprietor, Sealers India Agencies, says,

“Thermoformed packaging materials

are stiffer than average packaging,

transparent and provide a barrier against

external flavours or odours, keeping the

food products inside fresh. This feature

keeps the package from smelling like the

food product inside it. This packaging

has anti-fogging characteristics and

resistance to grease & oil.”

Thin- and heavy-gauge thermoformingThin-gauge thermoforming is the

process that uses continuous forming of

roll-fed thermoplastic sheet through an

oven tunnel into a forming station, from

trimming to picking and packaging. This

is a more automated process than heavy

gauge. Thin-gauge is used extensively in

the packaging industry.

The heavy-gauge division of

thermoforming feeds cut thermoplastic

sheets into a machine that carries the sheets

through one or more heating stations to

the forming station for moulding and

then out of the machine. Here, secondary

steps are necessary to trim the finished

part. Trimming includes sawing, routing,

shearing and drilling. “In the early days

The Indian thermoforming industry is embracing new technologies and energy-efficient heating options for the machinery, with more and more organisations becoming aware of the need for energy efficiency. Anwesh Koley highlights some of the techniques that are helping this sector to increase efficiency.

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of heavy-gauge thermoforming, an acrylic

thermoplastic sheet was hung in an oven

to absorb heat. The material was then

stretched over a mould. After allowing

it to cool, it was removed and trimmed.

Drape forming is still used for various

applications in the manufacturing of

many products,” says Vikram.

Vacuum thermoformingThis process utilises heat and suction to

shape the plastic sheet onto the desired

mould. A secondary operation is required

for trimming features such as cutouts and

holes. This technique is best used for large,

light-weight parts or textured or coloured

parts that do not require finishing. It is

easy to create a mould, allowing for quick

turnaround time, and is well suited for

prototyping and short- to medium-run

production of thick-gauge parts. Vacuum

thermoforming provides the solution for

simplification and aesthetics enhancement

for products such as panel covers, trays,

dividers, guards, pans and display cases.

Applications to improve accuracyHeavy-gauge thermoforming is serving all

industries today. New applications include

building and construction products,

products for the electronics industry,

usually replacing injection moulded parts,

and products for the heavy trucking

industry and automotive manufacturing.

In automotive, the matched moulding

system is commonly used for forming

doors, headlining panels, wheel well

openings and closeout panels in the boot.

A variation of drape forming and match

moulding (slip forming) utilises a mould

with a matching plug assist where the

material is free to slip into the mould

configuration. Slip forming is commonly

used in automotive manufacturing for

forming carpeting. “Another important

industry served by heavy-gauge

thermoforming is sanitaryware, which

includes bathtubs, shower tubs and stalls

and wash basins. The materials generally

used are Acrylonitrile Butadiene Styrene

(ABS), vinyl, acrylic and/or acrylic over

an ABS substrate. Some manufacturers

use cell cast acrylic, heating the sheets in

the convection oven and using vacuum to

form the part,” adds Vikram.

Other methods use ABS with

a co-extruded top coat of acrylic.

This is usually formed on standard

thermoforming equipment. The surfaces

are then reinforced with fibreglass (woven

or chopped fibres) or sprayed urethane

foam. A new, recently introduced process

uses thermoformed finished surfaces

with a waffled thermoformed material

back panel, reinforced with cast urethane

foam between the two parts. The

appliance industry uses vacuum forming

to produce interior boxes and door liners

in refrigerators. The common materials

used here are polystyrene and ABS.

The trimmings of refrigerator parts are

moving from massive punch die to five-

axis robotic router trimming.

The industrial pallet industry is

moving rapidly from wood boxes and

pallets to twin-sheet thermoformed

products. The materials used are generally

high-density and high-molecular-weight

polyethylene. The automotive and food

industries have been driving this change

because of the increasing demand for

recyclable containers and pallets. This

represents an excellent opportunity for

plastics and thermoforming.

Thermoforming technology can also be

used if long packaging lines arise as a result

of the output level and many functions.

The principle of the jumbo tray comes into

play here, as a complete array with trays is

formed first. After being formed, this array

is separated into individual trays with a cut

across the film running direction and placed

on a transmodule, which can then move

through the line according to the tasks

to be carried out. “If several transmodules

are lined up for coupled mode, patented

continuous counter-running can be utilised

for picker line operation. Here, products

move through the packaging line from one

side and the packaging materials from the

other side,” says Vikram.

Areas of growthThe highest material growth in

thermoforming sheet is in high-density

and high-molecular-weight polyethylene.

These materials have high impact,

heat, chemical and weather resistance.

Polypropylene is also beginning to

appear in heavy-gauge thermoforming.

In addition, higher temperature, higher

performance engineering materials such

as ABS and polycarbonate are used where

standard polyethylene or polypropylene

do not have sufficient properties.

The heavy-gauge thermoforming

technique has also grown and increased

production & efficiency. It offers better

quality sheet. Precision controls of

the heat and forming cycles at regular

timings ensure better production quality

and final products. “The acceptance of

well-designed, quality built temperature-

controlled forming moulds, which allow

tighter control of part dimensions,

residual internal stress and the ability to

make repeatable parts, have made heavy-

gauge the preferred technique for a

range of thermoforming requirements,”

concludes Vikram.


V VikramProprietor, Sealers India Agencies

The acceptance of well-designed, quality built temperature-controlled forming moulds, which allow tighter control of part dimensions, residual internal stress and ability to make repeatable parts, have made heavy-gauge the preferred technique for various thermoforming requirements.


SPECIAL FOCUS: Inter face - Franco Gornat i

What are the current innovations in the thermoforming industry?The Indian market is currently

witnessing enormous progress, with the

packaging sector moving from basic

formats to more advanced technology.

Today’s customer likes to have the

popular formats of the developed world,

eg, Modified Atmosphere Packaging

(MAP) packaging, vacuum packaging,

etc. Such special packaging formats

have a direct correlation to the

product shelf-life and aesthetic look

of the final pack.

Niche packaging plays a special

role in the retail space and is allowing

packaging manufacturers to compete

with global competitors in terms of best

quality and value-added solutions. Roll-

stock thermoform–fill–seal technology

is one of the most mature packaging

formats widely used in the West

to achieve enhanced shelf-life; this

technology ensures packaged product

integrity and is also combined with

high aesthetics. Generally, the machine

uses two continuous rolls of film, which

would be the lower thermoformable film

and the upper lidding film. The benefits

of this technology are enormous, not

only in terms of enhanced product shelf-

life, but also product integrity, high

convenience factor, high aesthetic quality.

These features ensure that convertors

stay at the top of the market and

have satisfied customers at the end of the

supply chain.

How different is Indian packaging machinery market from other markets across the world?With the type of growth curves that India

is riding on in the food processing sector,

a good demand for high-quality packaging

machines is imminent, which can add

greater value to the packaged product.

In the last decade, we saw the Indian

markets graduating from basic packaging

machinery requirements to value-added

niche packaging. Today, India is attracting

all major global packaging companies

who are now willing to understand the

intricacies of the products and processes.

Moreover, the Indian market is

currently booming, and such a market

requires the use of simpler machines and

applications. One must be prepared to

provide the right solution to customers.

This market is quite different from others

and requires an enormous understanding

of the market dynamics. One needs to

learn the products, processes and its value

addition to the food processor. Veripack

will be looking at the larger picture to

collaborate with the Indian manufacturer

in the long run.

What kinds of challenges are you facing in India?The Indian market is huge, and we are

facing numerous challenges. There are

distinctly different markets within

one big India; further, the market is

extremely price-sensitive, and foreign

technology today is still looked at with

suspicion.

We are gearing up to overcome

these challenges, but we would like be

as close as possible to the markets and

customers. We are trying to understand

them, hear them and also learn with

them. Hence, Veripack must make

efforts to overcome the prevailing

challenges in the Indian market in

order to compete successfully in the

long run.

What Research and Development (R&D) activities are you currently involved in?Our R&D is the key to our success,

and currently, we are carrying out our

R&D activities at our factory. We have

been manufacturing these machines for

more than 50 years, as a result of which

our machine technology has evolved

and matured over the years. Today, we

have worked out numerous advantages

of our machines, making them simple

to operate, ensuring robust and trouble-

free operations. All these provisions have

evolved over the years through good

investments in R&D.


…emphasises Franco Gornati, Managing Director and Chief Executive Officer, FNC SpA Group, the holding company of Veripack Solutions India Pvt Ltd. He highlights the recent innovations in plastics thermoforming and their relevance to the Indian packaging industry, in an exclusive conversation with Annabel Dsouza.

“Niche packaging plays a special role in the retail space”


SPECIAL FOCUS: Inter face - V i r S ingh

How do you see the performance of thermoforming industry in India?The thermoforming industry in India

is witnessing a steady growth as a

result of an increase in application from

the packaging industry. Packaging is

by far the most known application of

thermoforming. This versatile process has

helped modernise several industries such

as automotive, medical, non-conventional

energy sectors and a long list of others.

Thermoformed parts have become

important in two main areas – structural

and functional parts and low-cost, high-

performance packaging applications. The

advantages of thermoforming are the

significantly lower tooling costs and lead

times, as compared to injection moulding

or other closed-cavity methods.

How do you see the progress of this technology in India?The thermoforming industry has

developed despite two fundamental

shortcomings. Many other thermoforming

processes use a resin base in powder or

pellet form. Vacuum forming begins

further down the line with an extruded

plastic sheet, which incurs an additional

process, and therefore, an extra cost to

reach this stage. Generally, a part of the

material is cut away from the formed part,

which, unless reground and recycled, has to

be considered as scrap and accounted for

in expenditure. However, these problems

have been invariably resolved by strict

control of sheet quality and intelligent

mould design to minimise wastage.

What are the advantages of thermoforming over other plastics processing techniques?Thermoforming offers several processing

advantages over other techniques such as

blow moulding, rotational and injection

moulding. The technique requires fairly

low forming pressures, thus enabling the

use of comparatively low-cost tooling

and economical fabrication of relatively

large-sized mouldings, which would be

otherwise cost prohibitive with other

processes. Since the moulds witness

relatively low forces, these can be made

from relatively inexpensive materials and

mould fabrication time kept reasonably

short. This results in comparatively

short lead times. It provides the perfect

solution for prototype and low-quantity

requirements of large parts as well as

medium-size runs utilising multiple

moulds.

What are the challenges facing the sector?Chinese manufacturers are the biggest

threat to us. We follow a single quality

standard, while they have different

product ranges for different consumers.

The customer willing to pay a high

sticker price can opt for a high-quality

product, while the one looking for

quantity and bulk purchase also has his

options, so Indian manufacturers have

little to offer. International customers

prefer Indian machinery, as these are of

better quality, and there is scepticism

regarding the quality of Chinese

products. They produce in bulk, while we

offer quality, and most of our customers

prefer quality. The Chinese lag behind

the Indian manufacturers in terms of

reliability. Domestic consumers do not

even prefer to buy machinery that has

Chinese parts, let alone buying Chinese

machines. Thus, we do not even use

Chinese parts for our machinery.

What are the current key requirements for this sector in India?With cost reduction and competition,

the quality of thermoformed products

is feared to go down. The thickness for

thermoformed products should be set

and made mandatory or else, quality gets

compromised. While growth is expected

in the flexible packaging industry,

consumers are preferring rigid containers,

whose quality can be ensured only by

prescribing a minimum thickness for the

product. Another important factor is the

confidence of investors in the sector. With

rapid implementation of stringent norms

by the Government, new entrepreneurs

are often afraid to venture in this industry

thinking that they might soon have to

look for alternative business avenues.

The fear of ban has been rampant for

quite some time, and this hinders fresh

investment in this sector.


…asserts Vir Singh, Proprietor, Sai Thermoformers. In an exclusive interaction with Anwesh Koley, he explains the current scenario of the thermoforming industry in India and what can be expected from this industry in future.

“Thermoforming offers a fast way to manufacture light-weight products”

SPECIAL FOCUS: Roundtable


Dipak Vyas Director, Neo Pack Enterprises

The thermoforming industry in India is witnessing an upward-moving graph. The demand for light, recyclable, yet rigid, products is on the rise and thermoformed articles enjoy a market that is benefiting from the above characteristics. The plastics and polymer industry has a wide range of applications in the daily life of people, as it has been substituting most items for over a decade, particularly thermoformed catering items such as food trays, packages, cups, glasses, other beverage containers, bakery and sweets packaging, besides other large industry applications.

Thermoforming yields a part with the same aesthetic properties as an injection-moulded part, but at a fraction of the tooling expense involved in injection moulding. In India, there is a constant need to have light-weight packaging, as it offers rigidity and is cost-effective. This renders thermoforming as a better technique. Considering the current requirements of the Indian packaging market, thermoformed products currently made are fit for the international market.

Although thermoforming companies have been successful in catering to the varied requirements of packaging in India, it remains to be seen how well placed domestic companies are to meet the current demands of a market highly influenced by international trends. Anwesh Koley gauges the opinions of some industry experts on the preparedness of the market to compete on a global level.

Ratnesh Kumar Manager, Dr Froeb (I) Pvt Ltd

While the thermoforming industry is growing due to the varied applications it enjoys, new methods have enhanced the quality of finished products. This is due to the increased use of engineering plastics. Earlier, only polypropylene and polystyrene were used, but now polyvinyl chloride is also being used. With the availability of raw materials in the market and increase in competition, manufacturers are forced to offer better quality at affordable prices. Although competition has often hampered our bottom line, it enables us to understand the customer better and makes us aware of the trends in the global market.

However, in te rna t iona l competition in terms of technology is yet to make heavy inroads into the Indian market. As most of the sector is unorganised, our markets are limited primarily to the local demand. This is also because thermoforming technology is still an unexplored area, though it has a lot of scope. With the advent of global competition in India, we can expect domestic players to gear up in terms of quality, which will enhance the scope for the process.

Govind Bhandari Director, Shrink Packaging Systems Pvt Ltd

Although demand for thermoforming machinery is high, competition is increasing both at the domestic and international level. The biggest threat currently is from Chinese manufacturers. We follow a single quality standard, while they have different product ranges for different consumers. The customer willing to pay a higher price can opt for a high-quality product, while the one looking for quantity and bulk purchase also has his options; thus, Indian manufacturers have little to offer. Although international customers prefer Indian machinery, which are of better quality, they are sceptical about the quality of Chinese products.

It remains to be seen how far domestic technology can match up to international standards and the changing customer requirements. While the thermoforming sector faces several challenges, customer demand and global trends have a long way to go in determining the future of this industry. At present, we require more support from the government to be better prepared to face competition from international companies.

The domestic setup for thermoforming is suited for current requirements. However, since packaging is a dynamic market, customers’ tastes keep changing frequently. Hence, thermoformers must adapt quickly to international requirements to retain their marketshare.

Editorial take:

Is the Indian thermoforming industry ready to compete on a global scale?



The Indian plastics processing

industry is witnessing growth

in all verticals. This growth,

coupled with the demand

for light, recyclable yet rigid packaging

solutions, has provided a boost to the

thermoforming machinery segment.

With the rise in their demand from the

packaging industry and recent revolutions

in organised retail, the thermoforming

machinery industry is booming, both

in India and globally. This trend has

led to establishing many manufacturing

companies in the segment, one of the

leaders being Wonderpack, which is a

division of Rajoo Engineers Ltd.

Chandrakant Doshi, Chairman,

Rajoo Engineers Ltd, notes, “The

thermoforming machinery market is

constantly growing in India. Currently,

this technology is used to make cups for

tea and water, but it can also be used

in other segments to make a variety of

products. The key demand driver for the

growth of such machinery is the booming

packaging sector, which consumes almost

50-60 per cent of machines. This demand

will increase in future and be the key

contributor to our growth. Organised

retail will provide a fillip to this industry.”

A humble beginningWonderpack commenced business as

Wonderpack Industries in 1985 at Igatpuri, a

small village in Maharashtra, to manufacture

forming machines. The company grew over

the years and, later, merged with Rajoo

Engineers Ltd in 2010, who were already

present in this segment as one of the key

players; the production facility then shifted

to Rajoo’s premises at Rajkot. Since then,

Rajoo and Wonderpack continue to provide

solutions to the industry, all from a single,

focussed source.

Today, Rajoo caters mainly to

the needs of the packaging industry,

including blister, fast food and cosmetic

packaging. These machines are also used

to make thin- and thick-walled plastic

containers. Khushboo Doshi, Executive

Director, Rajoo Engineers Ltd, says, “The

same technology is also used to make

automotive parts, suitcases & briefcases,

bathtubs, refrigerator liners, door panels,

industrial trays/covers, etc. Thermoformers

manufactured by the company are also

used to make disposable containers, which

constitute a major segment today.”

Product portfolioFrom Rajoo’s portfolio, Dispocon series

thermoformers are sold under the brand

names of Rajoo and Wonderpack. These

machines are developed specifically to

meet highly competitive market demands

for reducing energy consumption, greater

ease of operation, lower maintenance

cost, high-quality output with practically

zero downtime. Rajoo also offers sheet

(foamed polystyrene) extrusion and vacuum

forming systems manufactured in technical

collaboration with Commodore LLC, USA.

State-of-the-art facilityRajoo’s world-class design and manufacturing

facilities span a built-up area of 20,000 sq m

and are located on the outskirts of Rajkot,

Gujarat. Khushboo Doshi notes, “World-

class integrated facilities comprise design

office, machine shops, store house, die shop,

surface treatment shop for nitriding and

hard chrome, one foundry, fabrication shop,

paint shop, assembly shops, testing and/

or quality control shop. The sub-business

FACILIT Y VISIT: Wonderpack – A div is ion of Rajoo Engineers Ltd

With the thermoforming industry in India moving upwards, the demand for such machines in the packaging sector is increasing consistently and who would know it better than Rajoo Engineers Ltd and its division - Wonderpack. Avani Jain investigates the reasons that make the company a leader in this segment.

Thermo‘forming’ a mark of success


units produce hot parts, ie, die, screw,

moulds, etc.”

The state-of-the-art tooling zone

ensures consistently high accuracy levels

in all critical components, and the paint

shop with powder coating facilities has

its own advantages. The huge and well-

equipped assembly shops are partitioned

to accommodate machines of different

dimensions. Highly professional and

skilled craftsmen assemble the lines. The

machines are tested thoroughly as per

Rajoo’s quality standards and customers’

specifications before dispatch. The testing

bay can house over 10 multilayer lines

at a time. The latest entrants to the

Rajoo portfolio are non-woven extrusion

machines, drip irrigation and polyvinyl

chloride/high-density polyethylene pipe

extrusion lines.

R&D initiativesThe company believes in basic and

continuous Research & Development

(R&D). Khushboo Doshi notes, “This

industry always functions on R&D. We also

have our sister concern nearby where we

set up new products, conduct commercial

production, test the technology, designs,

products and then launch these in the

market. These also operate as demo centres

and training grounds for prospective &

existing customers.”

Quality and performance The company is ISO 9001:2008 certified

and the machines conform to CE standards

with regard to safety & operations.

The company’s manufacturing model

comprises a judicious and efficient mix of

outsourcing and in-house manufacturing.

To ensure that the products consistently

live up to and surpass the performance

standards, Rajoo uses the most advanced

machine tools and techniques available

worldwide for stage-wise inspection

of the components & assemblies. Also,

the engineering and manufacturing

departments are integrated through a

digital network to ensure consistency,

reliability and collaboration.

The company’s quality policy is

based on ‘total quality managem0ent’

and world-class manufacturing practices.

Khushboo Doshi notes, “We have

laboratory equipment for testing all

parts of the machines. The machine is

dispatched to the customers only after

completing wet trial and testing. We are in

the process of adopting quality standards

and manufacturing practices employed by

our technical collaborator in Germany

– Hosokawa Alpine – a world leader in

blown film systems. For this purpose,

we send our engineers to Germany for

training and have seen excellent quality

improvements.”

Future growthThe company is way ahead of its competitors

in several aspects. Chandrakant Doshi

avers, “We spend time to understand the

requirements of the customer, and then

provide them with best-quality solutions.

All machines are energy-efficient and of

high quality. We are the forerunners in

providing integrated automated solution

to our customers. We want to continue

growing this way in future as well.” He

concludes, “We are also looking for partners

for technical collaboration or joint venture,

thereby taking thermoforming technology

to the next level.” Photo: Nikhil Patel


Chandrakant DoshiChairman, Rajoo Engineers Ltd

The thermoforming machinery market is constantly growing in India. The key demand driver for the growth of this industry is the booming packaging sector, which consumes almost 50-60 per cent of machines.

Wonderpack – A div is ion of Rajoo Engineers Ltd

Thermoforming process line Machining of critical components


Electrical grade plastics:Driving potential with low-cost alternatives ....................................................................... 62

Micromoulding solutions:Miniaturising with precision ............................................................................................... 64

Interface:Dr Harindu Vyas, President (Technical & Development), Signet Industries Ltd ............69

Polyamide alloy:Multiple benefits with high-barrier packagingMandar Amrute, Market Development Manager, Arkema India .............................................70

Cost information in project management:Monitoring and regulating cost needsM Hariharan, Director, Savoir Faire Management Consultancy Pvt Ltd .............................. 72

Product grade transitions:Advantages of an automated approachSunil Chaudhari, Country Manager, South Asia Business, Aspen Technology ...........................74

Plastics in Electronic/Electrical Applications

INSIGHT & OUTLOOK


INSIGHT & OUTLOOK: E lectr ical grade plast ics

The low cost of

production, energy-

effic iency and

ability to continually

harness plastic waste, while

offering better malleability and

flexibility than metals, have made

plastics the preferred material

for almost all electrical grade

appliances. The light weight and

high-strength characteristics of

plastics are some of the factors

that affect ease of use, logistics

and performance. These have

been possible due to the polymer

compounding process, which has

expanded the scope of plastics

applications.

Plastics in electronicsThe last decade has seen a

phenomenal growth in the

use of engineering plastics.

Especially, additives that impart

thermal conductivity to plastic

compounds electrically or while

offering antistatic properties are

much sought after. The wider

acceptance of such compounds

in replacing metal (particularly

aluminium) and non-conductive

plastics is evident in their

double-digit annual growth rates

over the last decade. One reason

is the decline in their prices

with increasing applications

in electronics, computers,

medical devices, automotive,

aerospace and appliances. This is

remarkable since plastics by itself

does not offer heat resistance,

durability or high tensile

strength. Additives modify

the properties of plastic resins

during polymer compounding,

making plastics a panacea for

engineering applications.

An example of the

achievements with plastics

and additive blends is the

compounded grade of

Polyphenylene Oxide (PPO)

used in the manufacture of

chassis. A plastic chassis part

for a copier device must meet

multiple service requirements

to be effective. The part must

be rigid and flat while the

paper or plastic tape moves

across the surface. It should

have long-term stability, as any

change in dimension affects

the repeatability and accuracy

of copies. Any medium moving

across a good insulator will

build up static electricity on the

insulator’s surface, which can curl

paper and short out the sensitive

electronic circuit boards. The

plastic chassis, which is a good

insulator, must provide a means

for removing the build-up of

The advent of engineering plastics has brought about a paradigm shift in the possibilities of plastics applications. Lionel Alva assesses the role of performance additives in resins that have facilitated the use of electrical grade plastics as well as their future avenues.

Driving potentialwith low-cost alternatives

Electr ical grade plast ics


static electricity on its surface. The surface

of the part must have dry lubricating

qualities to enable the paper or plastic

tape slide easily across the surface. These

can be achieved with PPO plastic material

compounded with additives.

Thermal properties modification Electrically conductive plastics have

made significant inroads in Electrostatic

Dissipation (ESD) for electronics

packaging and automotive fuel systems

and are growing in both metal replacement

and safety applications, eg, Explosive

Atmosphere (ATEX) environments.

The range of application has broadened

to include silicon-wafer storage boxes,

thermoformed trays for electronic

components, storage and transport

containers, air-cleaner parts, conveyors

as well as protective films, foils & bags.

Unlike conventional migrating antistats

used in packaging, ESD applications

require longer-term protection and/or

lower resistivity. These are better served

by ‘permanent’ antistats such as carbon

black, carbon and metal fibres and

nanomaterials. These additives must show

rapid charge dissipation and cleanroom

compatibility & and low outgassing.

Carbon black compounds and

concentrates offer a good price-

performance ratio and account for a

major portion of conductive plastics.

But, although carbon black is effective in

adding electrical conductivity, its adverse

effects on mechanical properties is a

drawback.

One of the fastest growing areas for

conductive plastics is metal replacement

for weight reduction. Among the most

widely used heat-conductive additives

are graphite fibres and ceramics such

as aluminium nitride and boron nitride.

“Computer, automotive, appliance

and aerospace markets are welcoming

thermally conductive plastic compounds

for transferring heat away from sensitive

electronic components. These are

increasingly specified for heat exchangers,

heat sinks, heat pipes, electronic

interfaces, housings and transformers.

The emergence of energy-efficient light-

emitting diode lighting is also fast turning

into a major growth area. Most specialty

compounders have added some thermally

conductive materials to their portfolios,

aimed primarily at metal replacement.

These offer lighter weight and good

chemical resistance, making them an

excellent alternative to metal heat

exchangers that are susceptible to failure

due to corrosion,” avers Aditya Tandon,

Director, Classic Polymers.

Possibilities and limitations Thermally conductive compounds are

generally not considered to be direct

replacements for metals, but open up a

range of new opportunities for ‘thermal

management’ applications. Parts moulded

from this new generation of materials

can replace metals and ceramics in some

applications, while non-conductive plastics

in others. Uses include custom-moulded

heat sinks on circuit boards, as well as

tubing for heat exchangers in appliances,

lighting, telecommunication devices and

industrial equipment used in corrosive

environments. Heat sinks often involve

plastics overmoulded on a metal heat

pipe. Lighting applications also include

reflectors, laser-diode encapsulation and

fluorescent ballasts.

In temperature sensors such as

thermistors, thermally conductive plastic

encapsulation improves the response of the

temperature sensor. Thermally conductive

compounds are also used to encapsulate

small motors and motor bobbins. The

heat-transfer requirements of ever-

smaller and more power-consuming

electronics have opened the door for

this new generation of cooling materials.

While unfilled thermoplastics have a

thermal conductivity of about 0.2 Watt/

meter-Kelvin (W/mK), most thermally

conductive plastic compounds typically

have 10-50 times higher conductivity, ie,

1-10 W/mK.

Electrifying prospects Ensuring that electronics, lighting and

car engines remain cool are some of

the new roles for thermoplastics that

have been formulated to replace metal

or ceramic. Packing more powerful

microelectronics into ever smaller spaces

would not be possible without heat

sinks and heat spreaders moulded from

new thermally conductive thermoplastic

compounds. In the Indian context, this

provides a tremendous opportunity

for Indian plastics processors to

tap a lucrative market with enormous

business potential.


Aditya TandonDirector, Classic Polymers

Most specialty compounders have added some thermally conductive materials to their portfolios, aimed primarily at metal replacement. These offer lighter weight and good chemical resistance, making them an excellent alternative to metal heat exchangers that are susceptible to failure due to corrosion.


INSIGHT & OUTLOOK: Micromoulding solut ions

Micromoulding technique

is used to make extremely

small-sized parts of

electronic products.

These parts are measured in micron.

Micromoulding has opened the door to

manufacturing tiny parts relatively easily

at a lower cost and higher speed, and

has thus increased profitability through

material conservation as less resin is

used to create more parts. Amit Mahant,

Director, PK Plastic International Pvt Ltd,

notes, “Micromoulding is a specialised,

precision injection moulding technique

specifically for moulding micro-miniature

electronic components.”

Micromoulding is designed specifically

for producing the smallest components,

typically, with component weights less

than 0.25 gm and even smaller. It has

many advantages, eg, greater accuracy

in finished parts. Its major application

includes plug connectors. Since the

process is designed for smaller parts, few

mould cavities are used in micromoulding.

Thus, the accuracy and reliability exceed

those of conventional moulding. New and

unconventional part geometries are also

possible using micromoulding. Material

choices for micromoulded components

range from commodity olefins and

polypropylene to exotic, high-heat

materials. Generally, in micromoulding,

part weight is 0.001 gm or lesser and part

size is 0.075-inch of diameter or smaller.

Machining parametersIn moulding of electronic components,

micromoulding can offer a range of cost-

effective alternatives for components that

are small, complex and require high-

precision tolerances. Mahant notes, “The

one big reason for companies using this

technology is the cost savings it incurs.

That is because the time taken to mould

a component is a fraction of the time

taken to machine a component. Another

reason is that designers generally do not

want to have the possibility of entry

of foreign matter into their electronic

devices. Micromoulding eliminates

the potential failure mode of having

particulates left after machining. It also

gives more freedom to designers to

introduce intricate features in products,

thereby enhancing their ability to create

more innovative products.”

He adds, “As the trend for smaller

components becomes greater in the

Electrical & Electronic (E&E) industry,

micromoulding can make it easier to

machine complex geometries. In addition,

this technology offers solutions to some

common manufacturing issues specifically

pertaining to the electronic device field,

which has embraced micromoulding as

a key enabling technology for making

micro-electronic components.”

Basket of offerings Micromoulding solution offers numerous

benefits in the moulding of electronic

components. “It can be an excellent

low-cost alternative to machining.

Further, small parts require high-speed

automation to maintain part consistency,

complex, tight tolerance and flash-free

moulding, which can be only achieved

by micromoulding process. In a nutshell,

micro-injection moulding is a lower

cost solution, leads to dimensionally

stable production process and causes no

particle contamination; further, complex

geometries can be achieved through this

process. It uses alternative resins or fillers

to improve mechanical and/or electrical

properties, leading to better surface finish,”

notes Mahant. Some other benefits

include reduced tool sizes, increased part

accuracy, improved cycle times, reduced

part cost and defined colours.

Moulding successControl of the mould design and build

process is essential to the success of

any micromoulding project. Four key

factors contribute to the success of any

micromoulding project, ie, mould tool

design & fabrication, micromoulding

equipment used, the quality of inspection

equipment used and the business

With electronic products becoming smaller and portable, the plastic components inside them are constantly expanding in performance but shrinking in size. Avani Jain analyses the micromoulding technique used for moulding tiny electronic plastic components at higher speeds and lower costs.

MINIATURISINGprecisionwith

Micromoulding solut ions

strategy. Mahant asserts, “These variables

are critical for obtaining a specific

micromoulded component, yet individuals

sourcing micromoulded components

commonly overlook one or more of them.

Attempts to micromould components

using conventional moulding equipment

often fail due to various reasons.

Therefore, a buyer must have adequate

understanding of the mould tooling and

the capabilities of the equipment being

utilised, to be able to make an informed

decision on whether the micromoulder

can provide a successful product.”

Conventional injection moulding

machine has a high shot size relative to the

barrel capacity. Mahant notes, “If plastic

resin is left in the screw for an extended

period, it will affect the mechanical

properties of the plastic resin. The

conventional machine screw, depending

on size, can carry several hundred shots

of material in the injection barrel. This is

important since many conversions use high-

performance plastics in their applications.

These high-performance plastic resins

have a high degree of thermal degradation.

One way in which moulders try to alleviate

this problem is by increasing the number

of cavities in the mould to increase the

shot size. This resolves the issue with the

shot weight. The machine specifically

designed for micromoulding process

addresses the issues of melt cushion size,

speed and pressure.”

He elaborates, “The last factor to

consider, and one that is often overlooked,

is the quality inspection equipment.

Buyers must verify whether the

suppliers have the capability

to measure micromoulded

components. For visual

inspection, a microscope

(0–50X) is needed. For first-

piece inspection, optical

measurement inspection

systems are suitable

(0–200X), which can handle

most of the work. For in-process

inspection, the micromoulder should

have a camera inspection system

incorporated in the injection moulding

equipment. In combination with a robot,

the equipment continuously provides

100 per cent visual inspection. This ensures

that the moulded component has been

inspected and separated correctly from

rejects. Otherwise, an operator would have

to perform a manual in-process inspection.”

Future trendsAt present, micromoulding machines have

plunger injection, programmable controls,

built-in gate cutters and needle valves.

Mahant avers, “In future, these machines

will see new developments in the form

of small screws (14-16 mm), high-speed

injection up to 700-750 mm/sec, low

injection volume and shot size of 1.0 gm

or smaller and development of two-stage

machines, ie, screw or plunger type.”

He further adds, “The use of all-

electric micromoulding machines for

moulding electronic components offers

various benefits along with precision and

accuracy. These can lead to energy savings

up to 80 per cent, helping to achieve

accuracy and repeatability. In future, the

machines will make use of tie bar-less

mould-clamping structure, which will

result in much larger mould space and can

be equivalent to wide platen style. The

machine will come with direct lock-ball

screw with cross head to ensure accuracy

and stable clamping and lead to equalised

force on the mould. The machines will

also incorporate mechanical ejector with

servo control for enhancing machine

efficiency.”

A positive outlookThe increasing complexity of contemporary

electronic appliances has resulted in

more components per appliance. This

has increased the pressure on injection

moulders to constantly upgrade machines

to meet specialised requirements. The

added features demand more part strength

and miniaturisation, which has increased

the demand for micromoulding solutions.

Due to various benefits offered by

micromoulding solutions, their demand in

moulding electronic compounds and in the

E&E industry will continue to increase in

the future.


Amit MahantDirector, PK Plastic International Pvt Ltd

The use of all-electric micromoulding machines for moulding electronic components offers �� precision and accuracy. These can lead to energy savings up to 80 per cent, helping to achieve accuracy and repeatability.


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INSIGHT & OUTLOOK: Inter face - Dr Har indu Vyas

How is the demand for engineering plastics in E&E sector?Plastics in E&E applications cover

the third largest plastics market in the

world. Without plastics, some of the

electronic or electrical applications

would not be practically possible or be

very expensive. In E&E applications,

the contribution of thermoplastics is

75 per cent; thermoset, 15 per cent;

polymer composite, 9 per cent; and

others 1 per cent.

Insulation is the most important

property required by the material

used in the E&E sector. The

materials conventionally used for

these applications are wood, ceramic

composites, polymer composites and

engineering plastics. Wood and ceramic

composites have some drawbacks in

comparison to engineering plastics, eg,

high weight, brittle nature and high

moisture absorption. To overcome these

drawbacks, presently, manufacturers are

using engineering plastics in the E&E

industry. Thus, the demand for these

plastics has increased. Also, engineering

plastics are easily processable in injection

moulding machines, with excellent

flame resistance and dimensional

stability. These have excellent electrical

properties, eg, dielectric strength,

insulation resistance, arc resistance,

comparative tracking index, and

properties for glow wire test & ball

pressure test, etc. Thus, the demand

of engineering plastics is continuously

increasing in the E&E sector.

What are the major usages of engineering plastics in E&E sector? Engineering plastics have wide

applications in the E&E sector. These

are used in electronic applications,

eg, CEE connectors, single-socket

outlet, plug socket set, connection

unit, Printed Circuit Board (PCB),

electrical accessories, etc. Presently,

engineering plastics are well accepted

in optical cable application and its

parts, microwave parts, switchgear

application, telecommunication, low

voltage application, etc. Electronic

instruments used in medical diagnosis

are unimaginable without using

engineering plastics. Thus, the

application of engineering plastics in

the electronics sector is fast increasing.

What are the recent trends in the sector? The use of engineering plastics in

the electronics sector includes PCB,

switchgear applications, high-dielectric

application, excellent arcing resistance,

etc. Light-Emitting Diode (LED),

which utilises engineering plastics, is one

of the excellent innovations used across

the world. Engineering plastics are

also used in solar panels. Thus, almost

90 per cent of the E&E sector uses

engineering plastics.

What are the leading innovations in the sector? Research is underway to find new

applications of engineering plastics in

the E&E sector. Some of the leading

innovations in this sector include nano-

filler engineering plastic compounds

to replace ceramics or thermoplastics

in E&E applications, flame-retardant

engineering plastics, high-dielectric

strength polymer blends, etc. In

Europe, Restriction of Hazardous

Substances (RoHS) in electrical and

electronic equipment and Waste

Electrical and Electronic Equipment

(WEEE) directives mandate that flame

resistance be achieved without the use

of halogenated components, one of the

favoured areas of research.

What are the future trends in engineering plastics in the E&E sector? Nano-plastic composite, clay composite,

carbon fibre composite are the future

of E&E sector. The demand for

these materials will increase in the

E&E sector, due to their numerous

advantages. Depending on the

electronics application, plastics is

chosen for its rigidity or flexibility,

toughness/durability, resistance to low

or high voltage and electrical insulation

or conductive properties. Ease of

fabrication into complex shapes is

also a requirement. Thus, in terms

of usage of engineering plastics

in the E&E sector, polycarbonate,

acrylonitrile-butadiene-styrene, Nylon,

thermoplastic polyester, polyphenylene

oxide, fluoropolymers, polyacetal,

polysulphones, etc, will be the future of

this industry.


…opines Dr Harindu Vyas, President (Technical & Development), Signet Industries Ltd. In a conversation with Avani Jain, he highlights the growth and demand for engineering plastics in the Electrical & Electronics (E&E) sector and underlines the recent trends & innovations making headway.

“The demand for engineering plastics is continuously rising in the E&E sector”

INSIGHT & OUTLOOK: Polyamide al loy


Mandar Amrute

Polyamides are known for

their outstanding mechanical

properties, tensile strength

and abrasion properties. One

of the most common problems with the

polyamide family is its property of water

absorption. Polyolefins, on the other hand,

have good hydrolysis properties with the

ease of processing on standard plastic melt

processing machines. In general, polyamides

are observed to be incompatible with

polyolefins. Therefore, polyamide alloy is

a Polyamide (PA) 6- or PA66-based alloy

with polyolefin, which offers the benefits of

combined properties from polyamides and

polyolefins. Orgalloy® – a type of polyamide

alloy – is based on a patented technology,

which ensures homogeneous mixing and

ease of processing, combining the benefits

of both polyolefins and polyamides. This

technology also ensures consistency in the

product, thus resulting in improved and

consistent performance of the final product.

Low moisture uptake resulting in

retention of mechanical and

electrical properties

Excellent dimensional stability

Easy to process on standard

processing machines

Good chemical resistance

Low density

Good recyclability [Polypropylene

(PP), Polyethylene (PE), PA, etc)]

Light in weight as compared to

PA6 and PA6/6; it is clearly visible

to difference in density of these

materials resulting in low-weight final

component

Excellent barrier properties against

polar and non-polar gases and solvents

Multilayer film packaging A layered structure is usually used in

multilayer film packaging for food items.

Polyamide has been the material of

choice for the barrier layer since long. In

multilayer packaging, PA is often used

when an enhanced barrier function is

required, due to its unique combination

of features:

Mechanical strength

Excellent impact, puncture resistance

and tear resistance

High transparency

Thermal stability

High oxygen barrier

High aroma barrier

Easy thermoformability

As a barrier material, PA does much more

than just preventing oxygen migration

into the package, which helps slows

down spoiling or discolouration of the

packaged material (eg, meat, cheese fruit

juice packages). It also provides a barrier

to aroma molecules, which helps prevent

loss of aroma from the packaged material,

as well as delays contamination of the

package's environment by the aroma

material. Some examples of packages

where aroma conservation is necessary are

spices, fruit juice, detergents, toothpaste,

etc. Also, herbicides, pesticides and

fungicides may require a barrier material,

such as Nylon, to prevent migration of

the active, potentially harmful ingredient

as well as the organic solvent into the

environment during storage. As an

additional feature, a well-designed barrier

material will not absorb flavour or aroma

constituents from the packaged item.

Advantages and applications Polyamides are impermeable to non-polar

An excellent barrier material, polyamide offers features such as reducing oxygen migration into the package, which helps delay spoiling of the packaged material. One such polyamide alloy is Orgalloy®. The properties, processing methods and some of the key applications of Orgalloy® in the packaging sector is outlined here.

Multiple benefits with high-barrier packaging

PA6 and Polyolefin incompatibles blend

Orgalloy®PA6-based allloy

Polyolefins

Tie layer

Nylon layer

Tie layer

Polyolefins

Five-layer multilayer film structure

Comparative permeability values

MediumConditions

(on 25-μm films)Units

Polyamide

alloyPE PP PA6

Water 75% RH @ 25oC

g/m2/24 h

60 3 7 400

Methanol 60% RH @ 20oC 1,000 20 4 4,600

Ethanol 60% RH @ 20oC 100 10 0.8 600

Oxygen 0% RH @ 25oCcm3/

m2/24 h90 3,000 4,200 50

CO2 75% RH @ 25oC

g/m2/24 h

290 9,000 9,500 160

Pentane 60% RH @ 20oC 0.4 8,000 30,000 7

Octane 60% RH @ 20oC 2.4 520 420 6

White

spirit60% RH @ 20oC 0.4 1,000 500 2

Chloroform 60% RH @ 20oC 800 13,400 14,400 300

A barrier to polar liquids

A barrier to gases

A barrier to aromatics:

styrene toluene

Polyamide al loy


solvents and gases (eg, hydrocarbons,

oxygen), but, unlike polyolefins, these have

poor barrier to polar solvents, eg, water

and alcohol. Polyamide alloy combines

the advantages of both polyolefins and

polyamides, with simultaneous barrier

to polar and non-polar solvents

& gases.

Another advantage of

polyamide alloy is the ease

of processing on machines

designed for polyolefins.

Polyamide alloy can be used

to produce three-layer barrier

films without using tie layer

on the same machine designed

for polyolefins, as polyamide

alloy has good bonding with

polyethylene. Polyamide alloy

features good weldability at

production speeds normally

achieved with PE. Thus, the

excellent barrier properties,

mechanical properties, ease of

processing and low sensitivity

to moisture of polyamide alloy

make it suitable for packaging

applications such as cosmetics

packaging, industrial packaging

films, agricultural barrier films

and food packaging films

& containers.

Providing a unique barrier In the field of barrier packaging,

polyamide alloy is a unique

material that can bring about

various changes without

changing anything on one's

standard machine. Apart

from mechanical properties,

low moisture pick-up and

dimensional stability, this alloy

has a lot to offer in packaging

& films where low permeation

properties are required. Ease of

processing on standard extrusion

and injection machines designed

for polyolefins is an added

advantage. Hence, polyamide

alloy can be an ideal material for

any application that demands

barrier properties.

Mandar Amrute is Market

Development Manager with

Arkema India Branch office.

Email: mandar.amrute@

arkema.com

Arkema is a French chemical company mainly operating in industrial chemicals and specialty polymers such as Polyamide–11/12 and PVDF. Polyamide alloy is marketed by Arkema under the brand name of Orgalloy®.

INSIGHT & OUTLOOK: Cost informat ion in project management


M Hariharan

V arious methods are used in management of project cost and schedule concerns. One of these is ‘Cost Information

Need’. In cost management, there is only ‘A’ Cost, and no ‘The’ Cost, which depends on the requirement. Cost information requirements for a project may vary according to the stage of a project.

Project cost information needs These include cost estimation at

conception stage, cost budgeting at planning stage, cost analysis and cost tracking during execution stage and compliance requirement.

Compliance takes precedence Similar to manufacturing firms, in project firms also, formal cost analysis is restricted to compliance. Compliance should be properly maintained. But, a common mistake is to use it mindlessly for other requirements. Project companies generally believe that

Enterprise Resource Planning (ERP) can track their costs well. But, although it is satisfactory for compliance and cost control, configuring ERP to meet only compliance requirements undermines its potential.

Cross-disciplinary costing cell In some project companies, cost estimation is an exclusive club of engineers, while cost reporting through execution is the domain of accountants. Here, a Cross Disciplinary Costing

Monitoring and regulating cost needsThe previous two articles (Apr ’12 and June ’12) dealt with project cost control on the basis of the QRST pattern and the S-Curve & 4D Grid. This article focusses on cost information needs of project cost management.

Detailing and grammar of cost numbers, which depend on the stage of a project

Stage of project Detailing required Grammar of information

Project conception stage

Assessing project viability;Participating in tender;Funds requirement planning

Macro-level information based on rough order of magnitude; planning horizon is longer, so detailing is difficult. But, with long experience in such projects, micro-level details can be achieved.

Future cost information. What will be the cost?

Project planning stage

Project cost baseline for cost control Micro-level detailing using parametric modeling or bottom-up estimation is critical. Resource and cost details at Work Breakdown Structure (WBS) level are required for cost budgeting. For short-term projects, this will be same as in the conception stage. But, for long-term projects, such as infrastructure, detailing must be done for a shorter time horizon.

Near future cost information.

Project execution stage

Cash planning for short-term requirement

Projects typically require cash outlay on daily, weekly and monthly bases. This must happen at the site. For this, a detailed cost estimation with time schedule for disbursement is needed. This estimation will be at the level of cost elements, eg, salary, travel, etc.

Near future cost information.

Actual cost tracing for cost control Cost detailing at WBS level is required. Cost classified as direct and indirect, variable & fixed is critical for effective cost control. This requires detailed analysis.

Immediate past cost. What was the cost?

Cost analysis for decision making during execution

During execution, site incharge takes many spot decisions. Project head takes decisions for course correction. Cost analysis is detailed at a micro level. Cost estimate numbers used for tendering, cost estimates used for budget and actual cost numbers captured in the system are of limited use for this. One must look beyond the formal cost information system to cull out the information required for this purpose.

Near future and immediate past cost.

Milestone billing for cost plus projects

Direct costs captured at WBS level plus indirect costs apportioned to the stage (including Administration costs) are relevant.

Past cost information. Cost rates based on the agreement.

Compliance requirement

Costing of project work in progress for accounting

Cost tracing as per the accepted rules of accounting principles and cost accounting report. Includes only site cost and not administrative costs.

Past cost information.

Cost informat ion in project management


Cell of Engineers, Accountants and IT team is required to help in various stages of the project. The team should be trained for estimation of techniques, cost analysis, IT capability, engineering and operations management. The Cell is responsible

for cost estimation for tendering, project viability and funds planning; cost budgeting for project cost baseline; providing inputs for decision-making during execution; cost tracking & deviation reporting for cost control; and inputs for milestone billing.

Resolving cost conflicts Distinct departments like engineering, estimating, project monitoring and costing working in silos are not of much help. Most inter-departmental conflicts in project companies arise from cost conflicts. Thus, understanding the uniqueness of cost information needs for projects is critical for their on-time, at-cost completion.

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]

Flowchart depicting cost information needs in a project

Cost estimation at project conception stage

Compliance requirement

Cost analysis and cost tracking during

project execution stage

Cost budgeting at project planning

(for execution) stage

Cost information for projects

INSIGHT & OUTLOOK: Product grade transi t ions


Sunil Chaudhari

Typically, during a downturn,

most processing companies

tend to shift their priorities

away from maximising

throughput to minimising waste and

reducing energy consumption as a means

to increase return on investment. This

change in focus thus leads to a stronger

emphasis on the safety parameter.

The experience of several polymer

production plants is a case in point. In

these plants, in particular, as also in other

specialty chemicals facilities, processes

are constantly changing, as they run

on a fixed set of operating conditions.

Companies continuously produce

various products with different densities,

viscosities and material properties.

One of the key environmental

challenges that organisations face is that

each grade transition produces many

tonnes of off-specification material. It is

frequently difficult, or even impossible,

to sell these intermediate grade products

at a premium rate. While blending

and recycling techniques are available

in this eventuality, which are more

environment-friendly, these cost energy

and such products thus manufactured will

probably invariably have to be dumped

into landfills. There are associated safety

implications as well. Carrying out a

transition from one product grade to

another is one of the most safety-critical

operations in a chemical plant.

A harmonised approachUntil recently, no commercially available

technologies were available to support

automation and optimisation of product

grade transitions. Minimising the

waste created by the transition from

one grade to another is something that

Advanced Process Control (APC) can

now help with, thanks to the innovative

use of non-linear as opposed to linear

control and advancements in procedural

automation technology.

Nevertheless, it is not only the

development of the process that is

important here, but equally important

is orchestration of the functions of the

controller and having a technology that

can coordinate and provide synchronised

sequencing logic to some of the manual

processes in the plant. For instance,

AspenTech’s clients have witnessed

considerable success in this area. We

have been able to achieve an average of

50 per cent reduction in transition waste

for them, with some clients significantly

exceeding this value.

This is a relatively recent but hugely

significant breakthrough. Handing over

the product grade transition process to

an automated controller has never been

taken lightly by operators who have

historically not been fully convinced

of the safety credentials of automated

processes. Therefore, for many years,

while APC was being widely deployed

across ethylene and refining plants, it

was not extensively used in the polymer

industry. Since the collaboration was

complex between what the automated

controller needed to do and what

operators were required to do, both on

the plant and in the control room, it

was not deemed safe to use the APC

Rising emphasis on productivity and safety in companies, particularly during crisis, has resulted in the need for an approach that could reduce energy consumption and enhance return on investment. Manufacturers, therefore, need to automate their processes and operations to attain these objectives as well as enhance productivity and profitability.

Advantages of an automated approach

Product grade transi t ions


technology. For instance, AspenTech has managed to

tackle such problems by using a combination of sequencing

technology and non-linear control.

Over the past few years, the use of this method has become

an expectation with companies in the sector. If a polymer

company requires an advanced process control, then it expects

the solution to optimise its product grade transitions. Polymer

companies have moved on from being concerned only about the

safety of handing over a process to a remote controller towards a

situation where they recognise this as the right approach.

Working in tandemThis paradigm shift has been driven by polymer companies

themselves. In the earliest days of APC, vendors have tried

to push a certain technology as being a solution rather than

listening to their customers’ requirements.

For example, they initially tried to promote the standard

version of APC, though it did not work. Later, they shifted

their focus to consider the viability of neural networks as a

potential solution. Again, the sales pitch was unsuccessful,

primarily because the ability of this technology to deliver

precise predictions about product grade transitions can often

be unreliable.

Ultimately, vendors realised that the best approach was to

work painstakingly with polymer companies in order to develop

safe as well as reliable modelling and controller technology

that closely fitted their business objectives of reducing waste

not just in transitions, but also during in-grade product runs.

Being able to manage this process has further environmental

benefits because the ‘off-spec waste’ created by the latter process

would either have to be reprocessed, with all attendant energy

implications, or scrapped. The key was to gain knowledge and

proofs of concepts and ensure that business needs were driving

the technology development rather than vice versa.

Futuristic solutionsThis meticulous approach has ultimately borne fruit. Polymer

companies today no longer have to be concerned about

environmental and safety issues surrounding product grade

transitions. They can now be confident about the resolution

of the problems. Moreover, manual techniques combined with

high-quality sequencing technology and non-linear controls

have provided them with the solution that they have been

seeking for many years.

Sunil Chaudhari is Country Manager for

South Asia business of Aspen Technology.

He leads the company’s core sector businesses

in engineering, construction, energy and chemicals.

His experience includes leading business units,

operations, project management, consultancy, business

development and plant automation commissioning.


AUTOMATION TRENDS: PC-based technology

The advancements in computer

technology and development

of artificial intelligence has

made it possible to greatly

reduce the cost and lead times in the

design & manufacture of injection moulds.

This is due to the optimisation of the

overall manufacturing process. However,

understanding the intricacies of injection

mould design is highly complex. This

is because injection moulding imbibes

several sub-designs related to various

components of the mould, and thus needs

an absolutely keen understanding of the

overall manufacturing process.

Design considerationsMould design affects the productivity,

mould maintenance cost, manufacturability

of mould and quality of the moulded

part. Until now, most of the work in

mould design has been directed towards

application of expert systems, knowledge-

based systems and artificial intelligence to

eliminate or supplement the vast amount

of human expertise required in the

conventional design process. A number of

studies have also been done on improving

the design of specific components of an

injection mould.

The design principles of cavity layout

and patterns of mould design can be

presented easily in a knowledge-based

design system. This helps build an effective

system to address the complexities.

Current practice for injection mould

design, especially cavity layout design,

depends largely on designers’ experiences

and knowledge. Therefore, one can

use knowledge engineering, artificial

intelligence and intelligent design

techniques for generating accurately and

efficiently an acceptable cavity layout

design in an injection mould.

The criteria to select a suitable

layout pattern for design depend on

working environments, conditions and

requirements of customer and are based

on a designer’s skills & experience.

Intelligent design techniques should

be used in systems designed for such

situations, especially for routine or

innovative design. Design of an injection

mould mainly involves considering

the design of the certain elements or

sub-systems such as mould type, number

of cavities, runner system, ejector system,

cooling system, venting and mounting

mechanism.

One cannot realistically expect a

designer to keep close scrutiny on all

design parameters. However, one must

understand that cavity design and

layout are the key factors affecting all

other activities. Application of advanced

knowledge based techniques to assist

the designer in cavity layout and

design enables effective creation and

development of a capable computer-aided

injection mould design & manufacturing

system. “A fully integrated Enterprise

Resource Planning (ERP) system

should be used to enhance quality and

consistency in production. Especially, in

high-volume production, monitoring of

Injection moulding is a widely used method for plastics processing and the technique & its applications have been refined over the years. Lionel Alva assesses how computer-aided technology has put the injection moulding process among the top techniques used in contemporary plastics manufacturing.


Combining precision with cost-efficiency


PC-based technology

the entire manufacturing process without

the aid of technology is an arduous

task. A keen understanding of various

injection moulding parameters as well

as a pre- and post-production analysis

can help develop a highly effective ERP

system,” avers Gaurav Bansal, Director,

Kiran Consultants Pvt Ltd.

Challenges in IndiaA key problem in India is investment,

infrastructure and availability. The

market is largely driven by Small and

Medium Enterprises (SMEs) who do not

possess the economies of scale that larger

manufactures have. Thus, adoption of

new technology becomes a major problem

since it does not justify the return on

investment for manufacturers. However,

with recent technological developments,

an ERP solution can be acquired at a

much lower and affordable cost. This will

greatly enhance the competitiveness of

manufacturers in the Indian scenario.

“In the Indian scenario, many SMEs

view ERP systems as cost-prohibitive.

Also, having an effective ERP system for

the entire manufacturing process would

require an approximate investment of

` 30-40 lakh, which many manufacturers

are not willing to make. Better awareness

is required regarding the advantages of

ERP solutions, and it is important to

consolidate the growth of the plastics

industry in India. We also provide training

to employees since a full-time operator

is needed to monitor manufacturing

activity,” observes Bansal.

Impact on qualityA healthy mix of cutting-edge hardware

and sophisticated software enables the

creation of a highly integrated approach

to injection moulding manufacturing.

Since injection moulding is used for

manufacturing of a wide variety of parts,

the software must adapt easily to new

applications. Further, optimisation of the

material used ensures minimal wastage in

various stages of production.

Computer-assisted technology is

designed to optimise the machinery

parameters, including process stabilisation,

shortened cycle times and production

efficiencies, which are most critical

to zero-defect medical, automotive,

electrical component, optical & liquid

silicone rubber plastics injection moulding

operations. Conventional injection

moulding machinery optimisation

involves time-consuming, manual

trial-and-error adjustments of relevant

parameters until all quality targets are

met. During this phase, user experience

with similar parts, materials and injection

moulding machinery is critical. Online

process optimisation (ie, during active

production) is even more complex, as

each parameter change can mean new

machinery setting modifications, cycle

time data recording and moulded parts

measurements.

“Our injection moulding systems

consist of Programmable Logic

Controllers (PLC), precise machining

tools, temperature regulators and several

highly advanced features that help in

complete automation of the injection

moulding process. While being an

expensive proposition, the use of CAD

has helped enhance the quality of our

volume-driven manufacturing, while

reducing energy costs,” avers Hiren Bhatt,

Proprietor, Sai Shakti Plastotech.

Facilitating industry needsIn the context of an injection moulding

manufacturing facility, ERP may be

used to facilitate on time delivery,

eliminating unnecessary downtime, and

ensure compliance with industry &

government standards. A critical benefit

is the ability to track and trace products

across the supply chain. This is especially

important for medical, safety and military

applications. A product failure in the

field can be isolated according to lot

number and a replacement or repair can

be pushed to all customers affected, thus

allowing the manufacturer to proactively

solve problems before they impact a large

number of customers. Hence, in today’s

fast-paced business environment, an ERP

system is critical for the competitiveness

of industries.


Gaurav BansalDirector, Kiran Consultants Pvt Ltd

Hiren BhattProprietor, Sai Shakti Plastotech

In high-volume production, monitoring of the entire manufacturing process without the aid of technology is an arduous task. A keen understanding of various injection moulding parameters as well as a pre- and post-production analysis can help develop a highly effective ERP system.

Our injection moulding systems consist of Programmable Logic Controllers (PLC), precise machining tools, temperature regulators and several highly advanced features that help in complete automation of the injection moulding process.

Extrusion can be seen as not

only a final forming process,

but also as an intermediate

process for other processing

techniques such as film blowing and

injection & blow moulding. The efficient

operation of extrusion screws used

in the extruder is, therefore, the most

essential aspect of the plastics processing

industry, as these perform various tasks

that enable manufacturers to achieve

the desired results. Screws can be used

for a plethora of applications such as

conveying the polymer, mixing, shearing,

compressing, degassing or heating

the polymer through convection and

many others.

Jaymin Pithwa, Director, Konark

Plastomech Pvt Ltd, notes, “For ensuring

maximum energy efficiency, the machine

designs have changed drastically over the

years. Every company involved in plastics

extrusion is trying to adopt strategies to

produce maximum at a lesser energy

cost. A good extrusion screw design

technology can help achieve the objective

of reducing the energy consumption to a

large extent. Further, with each passing

day, the companies are developing

new technologies that can minimise

mechanical losses.”

The core matter The extrusion process is highly dependent

on electricity, and most of the energy used

is directly related to machine operation.

Various steps can be taken to reduce

energy consumption of the extruder

in plastic extrusion processes. The

heart of the extruder is extruder screw.

This is a long cylinder with a helical

flight wrapped around it. The screw is

important because it mostly determines

the conveying, heating, melting and

mixing of the plastic materials. The

stability of the process and quality of the

extruded product depend on the screw

design. The screw rotates in a cylinder

that fits closely around it.

Extrusion screws perform four

main functions – consistent feeding of

the resin or axial forwarding, uniform

melting of the resin, steady consistent

pumping of the melt and homogeneous

mixing of the melt pool. Constraints

like head pressure, throughput rate and

product quality determine proper screw

design for applications. These points

must be considered while designing the

extrusion screws.

Types of screwsThe field of extrusion screws has

undergone tremendous development

over the past decade. The screw used

in extrusion processes can be classified

in different ways. These can either be

classified based on their methods of

working or the functions they perform.

Screws may also be classified based

on the types of materials for which

these are most suitable. Screws can be

classified as single-stage or multi-stage

(non- vented or vented) screws; simple

Courtesy: STEER Engineering Pvt Ltd

An efficient screw design technology helps reduce considerably the energy consumed during the plastics extrusion process. With the industry continuously working on modifying the screw geometry and design, Avani Jain analyses the role and benefits of a good extrusion screw design technology in reducing energy consumption.

Energy savings through best-in-class processing

ENERGY MANAGEMENT: Extrusion screw design



Extrusion screw design

conveying screws or barrier screws

or mixing screws and screws for low-

viscosity polymers, medium viscosity

polymers & high viscosity polymers.

Some other modes of classifications

could be single-flight or multi-flight

screws; screws for smooth-bore extruders

or grooved-feed extruders; screws for the

primary extruder of foam extrusion lines

and screws for the secondary extruder

of foam extrusion lines (cooling screws).

They may also be classified as melt-fed

screws or plasticising (solid fed) screws.

Barrier-type screw designs are most

widely used in the extrusion industry and

help in achieving energy efficiency. The

advantages derived from well-designed

barrier screws are improved rate, lower

melt temperature and improved melt

quality. Barrier screws, due to their

mechanism of melting, produce higher

internal pressures through the barrier

section helping to increase the melting

of material. In contrast, general-purpose

screws do not produce as high internal

pressures at the end of the transition

section as do barrier screws. Primarily,

barrier screws are designed so as to

increase the throughput in single-

screw extruders and improve the melt

quality. Twin screws also help in process

optimisation. These are well known

for their ability to offer optimisation,

efficiency and flexibility in processing

tasks such as mixing, compounding or

reactions between polymeric materials.

Energy consumptionA high percentage of the total energy

requirement (up to 30 per cent) for

moulding and extrusion equipment

is used to plasticise material. Screw

design is the most important feature

on extrusion machines. Screw design

technology is constantly evolving and

the processors are always involved in

gauging the appropriate screw diameter,

geometry and length-to-diameter ratio

appropriate to a specific material and

plasticising rate.

Energy savings of 20-30 per cent are

claimed in some instances. If the rate

of machine use is high and production

demands are predictable, a screw

replacement may be warranted. Screws

and barrels should be checked every five

to six months. Worn screws must be

replaced or repaired as the payback is

quick (ie, a few weeks).

Fixing the screw designPoor screw design is a common cause

of overheating of plastics and is usually

the reason why barrel cooling is needed.

Operations where multiple extruder

zones are cooled at 100 per cent are

inherently inefficient. Pithwa notes,

“The most energy-efficient extrusion

operations are those where most of the

heat is supplied by the extruder screw,

with only a small amount of heating by

the barrel and die heaters and without

the need for cooling of the extruder.”

The best solution to overheating

caused by poor screw design is to

change the screw geometry. If an

extruder with poor screw design runs at

0.25 kWh/kg and with a good screw

design at 0.20 kWh/kg, the energy savings

will be $ 36,000/year at $ 0.10/kWh and

a throughput of 1,000 kg/hr running

24 hr/day and 300 days/year. Thus, a

well-designed extruder screw can recover

the costs faster. It also offers various

benefits such as lower melt temperatures,

less degradation of the plastics, better

physical properties in the extruded

product, better product appearance and

consistency.

Thus, irrespective of the age of

the machine, it is essential to get the

right extruder for the job and the screw

diameter & design should be checked

to ascertain that they are appropriate

for the polymer product. Pithwa notes,

“One must decide on the screw design

and diameter right at the design stage. A

well-designed extruder screw can cover

up for the high prices relatively quickly,

based only on reduced energy cost.”

The right design With energy management concerns

rising worldwide, the companies in future

will have to adopt various other measures

for decreasing their energy consumption

in plastics extrusion process. For this, the

first step is to get the extruder right. If

the extruder runs at optimum conditions,

the need for downstream cooling and

calibration will be minimised. To achieve

this, deciding on the appropriate screw

design right at the design stage will be

beneficial. Thus, the companies need to

increasingly adopt strategies to ensure a

good screw design technology that helps

minimise energy consumption. The

ideal screws will fulfill the performance

criterion to deliver maximum output for

the available motor power with minimum

frictional heat generation. Ideally, there

should be no need for barrel cooling.

These two criteria ensure that energy

consumption remains at the lowest.

These are only some of the steps for

reducing energy consumption through

extrusion screw design technology. But,

a complete extrusion process has several

other components that consume large

amounts of energy, such as dryer, resin

conveying system, water-cooling and

circulation system. Various steps should be

taken to reduce the energy consumption

of these components as well.


Jaymin PithwaDirector, Konark Plastomech Pvt Ltd

One must decide on the screw design and diameter right at the design stage.A good extrusion screw design technology can help achieve the objective of reducing the energy consumption to a large extent.

POLICIES & REGULATIONS: P last ic waste management


The ability of India to become a major world player in all aspects depends greatly on how well it uses its most

abundant resource – its population. The huge population of the country as well as the economic developments have created numerous issues, one of which is waste disposal – particularly non-biodegradable plastic waste. The emergence of supermarkets and mall culture has brought to the fore increasing utilisation and ubiquitous applications of plastics, right from packaging food stuff and electronics to automobiles & construction. Since any threat to public health must be viewed with urgency, there is a pertinent need to understand effective waste disposal methods to ensure sustainable and healthy growth in India.

Since the Indian industry is still in the initial stages of the retail and consumer revolution, it is possible to bring in a tenable policy and regulatory framework for the management of plastic waste.

The most effective way to do this is to make a concerted effort at all levels, by including the Government, the plastics industry and even the consumers to some extent. Thus, there is a need to build better awareness and promote responsible behaviour on part of plastics manufacturers as well as those concerned with the plastics industry. With the help of an effective strategy, the country would be able to achieve a manufacturing consonance to ensure that the promise that this industry holds does not get affected. It would also lead to an amenable environment

for industrial growth, which is the need of the hour, considering India’s below average performance during this fiscal quarter.

Key challengesPlastic waste forms a significant part of the total Municipal Solid Waste (MSW). It is estimated that approximately 10,000 Tonne Per Day (TPD) of plastic waste is generated in the country, ie, 9 per cent of 1.20 lakh TPD of MSW. The plastic waste constitutes two major category of plastics – thermoplastics and thermoset plastics. Thermoplastics constitutes 80 per cent and thermoset, about 20 per cent of total post-consumer plastic waste generated in India. Thermoplastics are recyclable plastics, eg, Polyethylene Terephthalate (PET), Low-Density Polyethylene (LDPE), Polyvinyl Chloride (PVC), High-Density Polyethylene (HDPE), Polypropylene (PP) and Polystyrene (PS). Thermoset plastics are alkyd, epoxy, ester, melamine formaldehyde, phenolic formaldehyde, silicon, urea formaldehyde, polyurethane and metalised & multilayer plastics. The environmental hazards resulting from the mismanagement of plastic waste include the following aspects:

Littered plastics spoils the beauty of cities and chokes drains, making public places filthy

Burning of garbage containing plastics emits polluting gases and causes respiratory diseases

Garbage mixed with plastics interferes in waste processing facilities and may cause difficulties in landfill operations

Recycling industries operating in non-conforming areas result in unhygienic conditions

A growing population and vibrant economy brings with it the issue of increasing waste. Since plastic waste is considered hazardous to public health, Lionel Alva assesses the importance of having a strong regulatory framework to manage this waste.

Need for a holistic regulatory framework

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Plast ic waste management


“In terms of post-consumer waste, especially with flexible packaging (eg, heavily printed, multilayer/laminated/vacuum metalised pouches), currently, there is no efficient and professional waste disposal system in India. The challenges arise at various levels, since there are no sorting methods available at source, which results in waste disposed at an individual’s convenience,” avers Deepak V Mehta, Partner, Leevams Inc. He adds, “The advent of malls, super stores, mega stores, etc, in every city and town will further increase the use of convenient flexible packaging, while the waste disposal system will further deteriorate. Effective means of waste collection, disposal and recycling is the only resort to respect the growing consumption rates.”

Need for regulations Plastic waste is recycled in India in an unorganised way. Almost 60 per cent of the plastic waste collected and segregated is recycled back into materials for further processing into consumer products, while the remaining is left unutilised. Regulations and legislations are being enforced in two states of India, viz, Haryana and Himachal Pradesh, while a National Plastic Waste Management Council Task Force has been set up by the Ministry of Environment & Forests, Government of India, in association with Department of Petroleum and Chemicals, Ministry of Urban Affairs, Municipal Corporation of Delhi and various groups/associations of plastics manufacturers. There is scope for recycling/management of plastic waste as an organised activity in India. Mehta says, “Plastic Waste (Management and Handling) Rules, 2011, has certainly come into force; however, its understanding and implementation in the true sense will take time considering the diverse spread of the industry and huge population of the nation. The real effect can only be seen after the move is made in the right spirit and perspective.”

At present, no penalties are imposed on plastics manufacturers for improper handling of plastic waste. This move would help improve the image of the plastics industry by making it more environmentally responsible, thus setting

a landmark precedent that would actually improve its prospects in India.

The National Plastic Waste Management Council Task Force has recommended a strategy and action programme for Plastic Waste Management in India. The Ministry of Environment and Forests, Government of India, has issued criteria for labeling plastic products as environment-friendly under its ‘Ecomark’ Scheme, in association with the Bureau of Indian Standards (BIS). One of the requirements for plastic products is that the material used for packaging should be recyclable or biodegradable. The BIS has issued specific criteria for recycling of plastic waste while providing instructions on how waste should be classified and collected; further, there is a will and desire among Government bodies as well as Non-Government Organisations (NGOs) to make the existing guidelines stringent.

However, while formulating Indian standard specifications for various plastic products used for critical applications such as plastic piping system, water-storage tanks and packaging for food articles, a clause is included, which reads – ‘No recycled plastic waste shall be used’. The Ministry of Environment and Forest in association with BIS has carried out an exercise to include the use of recycled plastic waste where appropriate in the manufacture of plastic products, and this should be specified accordingly in the relevant Indian waste disposal guidelines.

Preventing wastagePlastic waste has several facets involving various stages where waste occurs, and it is important to bring about an effective strategy to deal with different types of waste. Recycled polymers are finding new avenues for application. If the waste is not handled in an effective manner, then it could lead to a serious situation. The implications of bringing in better regulations would ensure that plastics manufacturers utilise waste in a proper manner. Alternative strategies such as the use of non-recyclable waste for roads and power generation can also be explored, which could lead to innovative methods for waste management while enhancing the prospects for the industry in the global arena.


Deepak V MehtaPartner, Leevams Inc

Plastic Waste (Management and Handling) Rules, 2011, has certainly come into force; however, its understanding and implementation in the true sense will take time considering the diverse spread of the industry and huge population of the nation.

The Indian plastics processing machinery industry is incessantly setting up new highs

year over year, due to the enhanced ability of Indian machinery suppliers to accommodate innovative technology. Evolved over the years, the plastics processing industry has seen some major innovations recently, which have a long-term impact on the functioning of machines. With overall cost reduction including labour costs and quality improvement as the main driving forces, the plastics processing industry offers a comprehensive choice of technologies and application techniques.

Some of the major trends for increasing the operating efficiency and reducing costs in all sectors of the plastics processing machinery segment such as injection moulding, blow moulding and extrusion include the use of Supervisory Control And Data Acquisition (SCADA) system, Programmable Logic Controller (PLC) and PC-based control systems.

Praveen Sharma, Proprietor, Hind Machineries, notes, “Today, customers want highly

automatic and synchronised systems to improve their product quality & efficiency and reduce overall costs. Although priced slightly higher, these machines are high in demand, as they help reduce the overhead cost of manufacturers, thus eliminating the need to employ a large number of workers to perform common tasks.”

User-friendly machineryThe main aim of the control system for any equipment in the plastics industry is to provide a simple, but powerful user interface. Its function must be intuitive and easy-to-use; further, depending on the familiarity level of the user, the complexity of the functions can increase. Currently, machines with PC-based control systems are the most operator-friendly machines available in the market. PC-based automation includes a PC platform with Windows operating system. It ensures a host of benefits to the plastics industry, ranging from higher quality parts, through improved equipment uptime, faster cycle time and more predictable production flow to reduce employee turnover. A PC-based system solution offers a style of operation similar to desktop PC applications, which any individual can use today. This has a direct impact on the human-operator performance considering the rules of behavioural science.

Further, software such as colourful Graphical User Interface (GUI) can be installed on PCs, which not only makes machine operations interesting and motivating for operators, but also shortens the learning curve for them. Thus, machine operations become more enjoyable at the shopfloor.

Controllers speakIn a PC-based system, at the press of a button, the set-up person can select a completely different procedure or adopt its function to the required procedure. The ‘simple view’ wide selections of tried-and-tested standard procedures are available to the operator in the controller for different automation applications. The set-up person does not require any programming know-how; he/she can simply select a procedure and adopt the process sequences to the requirements demanded by changing variants. All the settings necessary for a sequence (position, speed

With growing emphasis on automation and demand for operator-friendly machines in the plastics processing segment, many companies in the country are employing machines with PC-based automation or control systems. Avani Jain finds out how the use of such machines helps in reducing the labour costs.

An imperative for reducing labour costs

STRATEGY: Operator- f r iendly machines


Location courtesy: Parikh Packaging Pvt LtdPhoto: Aamir Quadri

Operator- f r iendly machines


Praveen SharmaProprietor, Hind Machineries

Although priced slightly higher, these machines are high in demand, as these help reduce the overhead cost of companies, thus eliminating the need to employ a large number of workers to perform the tasks.

and time) are displayed on a clearly arranged setting page. Commands to be inserted are simply selected from an extensive functions list and placed at the desired point in the sequence. Pressing the symbols in the sequence editor immediately calls up the respective screen page on which the parameters can be set. Even complex sequences can be quickly configured. An operator able to create

movement sequences for linear robots can thus learn to program articulated arm robots within minimum time. Thus, all tasks can be performed by just clicking the button, reducing the need of labour for performing each task manually.

The ‘soft’ware touchOne of the key benefits of process control system based on PC technology is ease of use because the software is running on a familiar platform, and that makes it cost-effective as well. An operator can be trained to use a well-designed touchscreen control system in a few hours. And because these systems are software based, these are more powerful and flexible. PC-based systems are inherently user-friendly and operation can be very intuitive. The biggest convenience for users is the ability to see the ‘big picture.’ Instead of viewing process conditions in isolation, this type of system allows users to readily view data from all equipment from a single, central monitoring station and view that data over time via trending screens.

Human Machine Interface (HMI)Today, machines with PC-based controls come equipped with HMI, which is operator-friendly and easily accessible for process parameters. It provides excellent troubleshooting guidelines, along with the help and alarm menu pages. It has several features: functionally oriented screen

layouts; process parameter monitoring in real-time and feeding value on absolute basis; simple & pictorial diagrams to enable operator understanding; auto temperature and profile selection for homogenous melt from the first shot; extruder over-run for uninterrupted auto cycle; auto heating start, shut down and standby to save time & energy during operation; intrusion insert moulding, gas-assisted interface, core pulling, etc for multitasking utilisation; auto purging for smooth shutdown; mould cooling, mould gate option, sprue break, nozzle shut-off valve, cold slug remove, etc for various applications; as well as smart input/output for uninterrupted production.

Reducing labour dependenceAt present, the controls use microprocessor-controlled high-speed PLC systems, which also help reduce labour cost. Sharma says, “The PLC systems help in reducing labour costs to a large extent, as only one skilled personnel is required to set the parameter once and then the operations can be repeated automatically, thereby minimising manual labour.” Hence, machines with PC-based controls can reduce the labour cost of the company considerably.

Future trendsThe plastics processing industry is in the midst of a transformation in terms of machine construction and system engineering, leading to development of versatile and innovative control technology.

Further, despite increasing complexity, the user-friendliness of the systems and processes not only need to be maintained, but also improved. The operator must only be confronted with a central operating concept and user interface. Therefore, control systems that facilitate integration of peripherals, a uniform operating concept, simple programming and clear representation of complex processes with all important parameters, a high degree of process reliability and comprehensive motoring functions for quality assurance are required to increase the user-friendliness of the machine, which, in turn, will lead to reduction of labour costs.


Location courtesy: Plastiblends India LtdPhoto: Joshua Navalkar

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TIPS & TRICKS: Mould maintenance


Regular maintenance can prolong a mould’s life, reduce interruptions, and hence save time, money and problems in the long run. Anwesh Koley lists some pointers that are a must for ensuring proper functioning of plastics machinery through regular maintenance of moulds.

healthy machine lifeto a

Plastics moulding machineryare the most important of all processing equipment, as mould quality is directly

related to the merits of the quality of products. Moreover, as the importance

of the mould during the processing of plastics is high and involves a high cost to the company, these should be paid special attention. Therefore, it is important to spruce up the quality of moulds as well as

their maintenance in order to increase the life of the machinery and ensure seamless output quality.

Email: [email protected] inputs from: Gaurav Anand,

Director, AB Diachem Systems Pvt Ltd

Following are some of the pointers for ensuring regular mould maintenance:

Aluminium or soft tools suffer wear and tear faster than tools made of steel. Plastic materials having fillers are abrasive and wash away the mould steel after some cycles. Plastics with high melt temperature expose the mould to more heat and increase wear. Some materials emit excess residue or corrosive gasses, resulting in the need for regular mould cleaning.

Preventive maintenance should be done every time the mould goes into operation and every time it comes out of the press. Inspection must note small problems and have the repair done. This type of maintenance should be performed by a lead operator in the tool room after about 20,000 cycles, 10 production days or at the end of a production run, whichever comes first.

Use soft or treated water in cooling systems. Blowing out or draining the tool when it is pulled from the machine will enhance its life. Avoid excessive clamp pressures, high injection pressures and over-packing or flashing the mould. The press should not be operated such that the mould is rapidly jerked open and closed, and the appropriate components should be well lubricated.

Extreme care should be taken not to crash the mould closed or close up on partially ejected parts. Seal the work area and mould storage area from the external environment. Moulds with intricate mechanisms or parts requiring unusually high tolerances will require more maintenance than a simple open-and-shut mould, making a low tolerance part.

All components determined and authorised to be replaced should be removed and new components constructed and installed in accordance to the original designs, if previously certified spare components are not available. Worn leader pins, bushings and all bearing moving surfaces such as wear plates and wedge blocks, should be checked for wear and replaced or repaired as required.

In-house tool abuse should be reduced by having a clean operation using well maintained machines and the right tools. One should avoid the use of hard tools such as screw drivers, hammers, punches and knives on any moulding surface, parting or shutoff surface. Use soft tooling like rubber mallets, punches and pliers made from plastics, copper or brass to avoid damaging the mould.

Steps

PROJECTS


Butyl rubberReliance Industries LtdProject typeProduction Project newsReliance Industries (RIL) will form a joint venture with Russian company SIBUR, Eastern Europe’s biggest petrochemicals producer, to manufacture 100,000 tonne of butyl rubber per year in Jamnagar, at an investment of ` 2,250 croreProject locationJamnagar, GujaratProject cost` 2,250 croreImplementation stageOngoing

Contact details:Reliance Industries Ltd (RIL)Makers Chambers – IVNariman PointMumbai - 400021 Tel: 022-22785000Email: [email protected]

EthyleneIndian Oil Corporation Ltd (IOCL)Project typeNew facilityProject newsIndian Oil has several petrochemical projects at an early stage of development. The company is contemplating a 1.1-Million Metric Tonne (MMT)/year ethylene plant at Paradip on the east coast of India, adjacent to a 15-MMT/year oil refinery, for completion by 2017-18. The cracker, currently in the feasibility study phase, would use naphtha and FCC off-gases as feedstock. Indian Oil has not yet configured the downstream slate of products but may include polyolefins, glycols and specialties such as ethylene propylene diene-monomer rubber.Project locationParadip, OrissaProject cost$ 4 billionImplementation stagePlanning

Contact details:R RamakrishnanBusiness Development (Ref ineries & Pipelines)Indian Oil BhavanNo 1, Sri Aurobindo MargYusuf Sarai, New Delhi - 110016Tel: 011-26524707Email: [email protected]

Ethylene Reliance Industries LtdProject typeNew facilityProject newsReliance will build an ethylene plant that will crack refinery off-gases and construct downstream units at Jamnagar by 2015. The cracker will be designed to produce 1.4 Million Metric Tonne (MMT)/year of ethylene and 200,000 MMT/year of propylene. Downstream units will include two new Polyethylene (PE) lines and an Ethylene Glycol (EG) plant. The PE lines will be designed to produce 400,000 MMT/year of Low-Density PE (LDPE) and 500,000-600,000 MMT/year of Linear LDPE or High-Density PE (LLDPE-HDPE). The EG plant will have capacity for 700,000 MMT/year.Project locationJamnagar, GujaratProject costApproximately $10 billionImplementation stagePlanning

Contact details:Reliance Industries Ltd (RIL)Makers Chambers – IVNariman Point, Mumbai - 400021 Tel: 022-22785000 Email: [email protected]

Packaging product upgradationKanpur PlastipackProject typeExpansionProject newsFlexible intermediate bulk container manufacturer Kanpur Plastipack is set to expand its operations, with a project

cost of ` 21,500 million. It plans to upgrade the product range of the company and consolidate production, now split into three-four locations.Project locationKanpur, Uttar PradeshProject cost` 21,500 millionImplementation stageConstruction

Contact details:Kanpur PlastipackD19-20, Panki Industrial AreaPO Udyog Nagar Kanpur - 208022 Tel: 0512-2691113Fax: 0512-2691117Email: [email protected]

PetrochemicalsMangalore Refineries and Petrochemicals Ltd (MRPL)Project typeNew facilityProject newsMajorly owned by ONGC, MRPL is venturing into petrochemicals using refinery feedstock at Mangalore. The Mangalore refinery, with throughput capacity of about 12 Million Metric Tonne (MMT)/year is being expanded to 15 MMT/year next month. MRPL, as part of the expansion, is entering the polypropylene business with a 440,000 MMT/year, Novolen-process plant that is due onstream in November.Project locationMangalore, KarnatakaProject costUnknownImplementation stagePlanning

Contact details:Mangalore Ref ineries and Petrochemicals LtdPO Kuthethoor, Via Katipalla Mangalore - 575030Tel: 0824-2270400Fax: 0824-2271404Email: [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.

PROJECTS


Plastic furniture manufacturing unitNilkamal Crates and Binds Pvt LtdProject typeExpansionProject newsLeading plastics and moulded furniture manufacturer Nilkamal will set up a new manufacturing unit at Jammu shortly, as part of its ` 1,500 million expansion plan in the next three years.Project locationJammu, IndiaProject cost` 1,500 millionImplementation stageOngoing

Contact details:Nilkamal Crates and Binds Pvt Ltd77/78, Nilkamal HouseRoad No 13/14, MIDC Andheri (E)Tel: 022-26818888Fax: 022-268361369Email: [email protected]

Polypropylene HPCL Mittal Energy LtdProject typeNew facilityProject newsHMEL, a JV between Hindustan Petroleum and Mittal Energy Investment Singapore, a Lakshmi Mittal Group company, is close to completing construction of a 500,000 Million Metric Tonne (MMT)/year polypropylene plant at Bathinda. It is being built adjacent to HMEL’s 9 MMT/year refinery.Project locationBathinda, PunjabProject cost$ 4 billion Implementation stagePlanning

Contact details:HPCL–Mittal Energy LtdINOX Towers, Sector 16 A, Plot No 17Noida – 201301, Uttar PradeshTel: 0120-4634500 Fax: 0120-4271940 Email: [email protected]

Rubber manufacturingMadras Rubber Factory (MRF)Project typeConstructionProject newsMadras Rubber Factory (MRF), one of India’s leading tyre makers, expects to get possession of 500 acre at Tiruchirapalli, Tamil Nadu, where it plans to invest $ 252 million (` 10 billion) to set up a new facility.Project locationTiruchirapalli, Tamil NaduProject cost$ 252 millionImplementation stageOngoing

Contact details:Madras Rubber Factory (MRF)110 E/20 North Bypass Road Tirunelveli 627 003Tel: 0462-2573805/2582634Fax: 0462-2573805Email: [email protected]

Tyre manufacturingApollo Tyres Ltd Project typeExpansionProject newsApollo Tyres plans to invest around € 400 million (over ` 2,500 crore) to set up two new facilities in East Europe and Brazil in the next 3-4 years, as it aims to expand its global footprint. The company, which currently has an European subsidiary — Apollo Vredestein, is also keeping its options open to acquire a tyre firm in the Latin American market to start its operations there.Project locationBrazilProject cost€ 400 millionImplementation stageOngoing

Contact details:Apollo Tyres Ltd603/604 Janki BuildingOff Veera Desai Road, Andheri (W) Mumbai - 400 078Tel: 022-26730834 Email: [email protected],

Tyre manufacturingApollo Tyres LtdProject typeExpansionProject newsTyre maker Apollo Tyres (ATL) is set to expand its operations through a greenfield project in Tamil Nadu. The 135-acre facility is to come up at the Oragadam Industrial Park promoted by the State Industries Promotion Corporation of Tamil Nadu (SIPCOT) near Kanchipuram on the Chennai-Bangalore route.Project locationTamil NaduProject cost` 5,000 millionImplementation stagePlanning

Contact details:Apollo Tyres LtdApollo House, 7 Institutional AreaSector 32, Gurgaon Haryana - 122001Tel: 0124-2383002-18Email: [email protected]

Tyre plantRuia Group Project typeNew facilityProject newsThe Ruia group-led Dunlop India Ltd would set up a ` 4,500 million green-field tyre plant in Guwahati, and market imported products under the Dunlop brand.Project locationGuwahati, AssamProject cost` 4,500 millionImplementation stageConstruction

Contact details:Ruia Centre46 Syed Amir Ali AvenueKolkata - 700017Tel: 033-22894747Fax: 033-22893463Email: [email protected]

TENDERS

Latest Popular Tenders brought to you by www.tendersinfo.com


PVC overhead tank with steel structureOrg : Oil and Natural Gas Corporation Ltd (ONGC)TRN : 11509966Desc : Providing PVC overhead tank with steel structure at workshop area BOD : 3 July, 2012Loc : Ankleshwar, Gujarat, IndiaBT : Domestic competitive bidding Supply of plastic bags on R C basisOrg : Central Medical Store OrganizationTRN : 11499458Desc : Supply of plastic bags on R C basisBOD : 3 July, 2012Loc : IndiaBT : Domestic competitive bidding Polipro insulating sleeve Org : Singareni Collieries Company Ltd (SCCL)TRN : 11509771Desc : Procurement of polipro insulating sleeve for area workshop, BHPBOD : 5 July, 2012Loc : IndiaBT : Domestic competitive bidding Supply of various packing materials/ consumables and providing service for co-packing of ice cream varietiesOrg : Mother DairyTRN : 11452095Desc : Supply of various packing materials/ consumables and providing service for co-packing of ice cream varietiesBOD : 5 July, 2012Loc : IndiaBT : Domestic competitive bidding Supply of self adhesive kapton tapeOrg : Central RailwayTRN : 11332654Desc : Supply of self adhesive kapton tapeBOD : 6 July, 2012Loc : IndiaBT : Domestic competitive bidding Multilayered cross laminated polyethylene film of 70 GSMOrg : Bharat Heavy Electricals Ltd (BHEL)TRN : 11424200Desc : Multilayered cross laminated polyethylene film of 70 GSM

BOD : 7 July, 2012Loc : IndiaBT : Domestic competitive bidding

Laboratory chemicals plastic ware filter aidsOrg : Central Salt and Marine Chemicals Research Institute (CSIR)TRN : 11559605Desc : laboratory chemicals plastic ware filter aidsBOD : 10 July, 2012Loc : IndiaBT : Domestic competitive bidding Supply of PVC flexible ductOrg : South Eastern Coalfields Ltd (SECL)TRN : 11445503Desc : Supply of PVC flexible ductBOD : 10 July, 2012Loc : IndiaBT : Domestic competitive bidding Procurement of plastic watch boxOrg : HMT LtdTRN : 11499573Desc : procurement of plastic watch boxBOD : 11 July, 2012Loc : IndiaBT : Domestic competitive bidding

Supply of PVC GI and HDPE pipes of various sizesOrg : Kerala Water Authority (KWA)TRN : 11491120Desc : Supply of PVC GI and HDPE pipes of various sizesBOD : 12 July, 2012Loc : IndiaBT : Domestic competitive bidding High intensity grade retro-reflective film-red Org : East Central Railway TRN : 11464425Desc : High intensity grade retro-reflective film-red BOD : 13 July, 2012Loc : IndiaBT : Domestic competitive bidding : Polypropylene ropeOrg : Ministry of DefenceTRN : 11571001Desc : Polypropylene rope


TENDERS



Org: Organisation’s name, TRN: Tendersinfo Ref No, Desc: Description, BOD: Bid Opening Date, Loc: Location, BT: Bidding Type.

Information courtesy: Tendersinfo.com

1, Arch Gold, Next to MTNL Exchange, Poisar, S V Road, Kandivali (W), Mumbai - 400 067, Maharashtra, India

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BOD : 13 July, 2012Loc : IndiaBT : Domestic competitive bidding

Rope polypropylene 3 std Og 24 mm diaOrg : Army Ordnance CorpsTRN : 11560275Desc : Rope polypropylene 3 std Og 24 mm diaBOD : 13 July, 2012Loc : IndiaBT : Domestic competitive bidding

Supply and delivery of cratesOrg : Dairy Development CorporationTRN : 11407319Desc : Supply and delivery of cratesBOD : 13 July, 2012Loc : IndiaBT : Domestic competitive bidding

Supply of HDPE at BNP DewasOrg : Security Printing and Minting Corporation of India LtdTRN : 11585319Desc : Supply of HDPE at BNP DewasBOD : 13 July, 2012Loc : IndiaBT : Domestic competitive bidding

Procurement of coconut oil bottlesOrg : Karnataka Soaps and Detergents LtdTRN : 11562518Desc : Procurement of coconut oil bottles with cap-50mlBOD : 16 July, 2012Loc : JapanBT : International competitive bidding

Microcellular injection moulding machineOrg : Akita Prefectural GovernmentTRN : 11409196Desc : Microcellular injection moulding machineBOD : 17 July, 2012Loc : JapanBT : International competitive bidding

Purchase of raw material & packing materialOrg : Haryana State Cooperative Supply and Marketing Federation LtdTRN : 11531422Desc : Purchase of raw material & packing material required for manufacturing animal feedsBOD : 17 July, 2012Loc : IndiaBT : Domestic competitive bidding

Supply of HDPE bagsOrg : Bharatiya Reserve Bank Note Mudran Pvt Ltd (BRBNMPL)TRN : 11518385Desc : Supply of HDPE bagsBOD : 17 July, 2012Loc : IndiaBT : Domestic competitive bidding

Supply of 100 L sigma blade mixer with bottom screwOrg : Defence Research & Development Establishment (DRDE)TRN : 11231375Desc : Supply of 100 L sigma blade mixer with bottom screwBOD : 18 July, 2012Loc : IndiaBT : Domestic competitive bidding

Rubber mixing millOrg : Naval Materials Research Laboratory (NMRL)TRN : 11584405Desc : Heavy duty rubber mixing mill (of roll size 10x24)and rubber dispersion kneader BOD : 19 July, 2012Loc : IndiaBT : Domestic competitive bidding

Supply of final packing tubeOrg : Ordnance FactoryTRN : 11423105Desc : Supply of final packing tubeBOD : 24 July, 2012Loc : IndiaBT : Domestic competitive bidding


EVENT LIST


India Chem 2012As the Indian industry is soaring

in terms of commodity plastics and

engineering polymers, this event will

highlight the specialty polymers,

fine chemicals, agro plastics,

masterbatches, pigments, additives, etc,

with emphasis on sustainable processing

and effluent management; October 4-6,

2012; at Bombay Exhibition Centre,

Mumbai

For details contact:

Vishal Ganju

FICCI Mumbai

33/B, Krisnamai Building

Pochakanwala Road, Worli

Mumbai – 400030

Tel: 022-2496 8000, 2496 6633-39

Fax: 022-2496 6631/32

Email: vishal.ganju@f icci.com

Website: www.indiachemgujarat.com

Ind plastThis is an initiative to promote India as a

leading producer of plastics and specialty

polymers on the global platform. The

event will also facilitate interaction

and international investments in the

domestic market; October 5-8, 2012; at

Science City Ground, Kolkata


Vishal Ganju

FICCI Mumbai

33/B, Krisnamai Building

Pochakanwala Road, Worli

Mumbai – 400030

Tel: 022-24968000, 24966633-39

Fax: 022-24966631/32

Email: vishal.ganju@f icci.com

Website: www.indiachemgujarat.com

Plast Expo 2012This is a unique opportunity

for exhibitors to develop a direct

relationship with their clients.

It will be an interactive platform to

display raw materials, chemicals and

auxiliaries, equipment & services,

moulds, dies, etc; October 7-10, 2012;

at Rajkot Race Course Ground, Rajkot,

Gujarat


Brijesh Purohit

Saurashtra Plastic

Manufacturers Association, ‘Laxman’,

3rd Floor, Paramount Hall Bhutkhana

Chowk, Rajkot – 360 002, Gujarat

Tel: 0281-2228802, Mob: 09426249072

Fax: 0281-2223798


Website: www.plasticmanufacturer.org

PLEXPOINDIA 2013In its 6th edition, PLEXPOINDIA offers

a platform where the Indian plastics

industry can showcase its machinery

and equipment expertise. This event will

bring together manufacturers, dealers,

traders, suppliers of raw materials,

machinery & equipment, ancillary

equipments, testing equipments,

chemicals & additives to consolidate

the growth of the plastics industry in

India; January 8-13, 2013; at Mahatma

Mandir, Gandhinagar, Gujarat


Archana Kansara

Gujarat State Plastics Manufacturers

Association

7th Floor, Span Trade Centre,

Near Paldi Char Rasta, Ellisbridge,

Ahmedabad-380 006.

Tel: 079-26579204 /26578227

Fax: 079- 2657 9204 Mob: 9925017136


Website: www.plexpoindia.com

PlastAsia 2013The fourth edition of this exhibition

will be among the highly anticipated

launch pad for the plastics industry, and

will take off amid an era of renewed

optimism in Asia. This is an excellent

platform to build business alliances and

increase channels to expand opportunities

in the dynamically expanding plastics

industry; February 15-18, 2013; at

Palace Grounds, Bengaluru


Vilma Pereira

No 25, 3rd Floor, 8th Main Road

Vasanthnagar, Bengaluru – 560 052

Tel: 080 4330401, Mob: 09480944213

Fax: 080 22352772


Website: www.plastasia2013.com

National

India’s premier industrial trade fair on products and technologies related to Machine Tools, Hydraulics & Pneumatics, Process Machinery & Equipment, Automation Instrumentation, Packaging & Auxiliaries, IT Products, Electrical & Electronics, Material Handling and Safety Equipment.

For details contact:Infomedia 18 Ltd,

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EVENT LIST


PLASTEX 2012This is an important international trade

fair dedicated to the plastics machinery,

components, raw materials and chemicals

in the Middle East and North Africa.

It will present products and services,

technologies & innovations for global trade

markets. It is an international meeting-

place for worldwide suppliers and regional

manufacturers; September 6-9, 2012;

at Cairo International Convention &

Exhibition Centre, Nasr City, Egypt


Ahmed Mostafa

41 Street No 269, New Maadi, Cairo, Egypt

Tel: +202-2753 8401, Fax: +202-2753 8323


Website: www.plastex-online.com

Taipeiplas 2012This biennial trade show is well positioned to

attract the global plastics industry with exciting

opportunities in the Far East and South East

Asia. Taiwan is ranked the world’s fifth largest

producer and fourth largest exporter in plastics

& rubber processing machinery. With quality

design and competitive price, Taipeiplas

2012 is the global sourcing hub for plastics

& rubber processing machinery; September

21-25, 2012; at Nangang Exhibition Hall

Taipei World Trade Center, Taiwan


Taiwan External Trade Development Council

(TAITRA)

333 Keelung Road

Section 1, 5-7 Floor, Taipei 11003, Taiwan

Tel: +886 (2) 2725-5200

Fax: +886 (2) 2757-6245


Website: www.taipeiplas.com.tw

FAKUMA 2012This international trade fair for plastics

processing is celebrating its 30th anniversary. It

will show plastics advantages in conservation

of resources, lightweight design engineering

and energy efficiency. It will provide the

industry with opportunities for futuristic

manufacturing solutions; October 16-20,

2012; at Friedrichshafen Exhibition Centre,

Germany


P E Schall GmbH & Co KG

Messeunternehmen, Gustav-Werner-Straße 6

D-72636 Frickenhausen

Tel: +49-70259 2060, Fax: +49-70259 2066


Website: www.fakuma-messe.de

Composites Engineering Show 2012Building on the success of its previous

editions, this show will bring together more

designers, engineers, technicians, materials

specialists, procurement & management

teams from the global composites industry.

It will highlight the latest developments in

engineering composites and their applications

in automotives, oil & gas, construction and

consumer goods manufacturing; November

7-8, 2012; at NEC, Birmingham, United

Kingdom


Ian Stone

Leading Edge Events & Media Ltd

4 The Mews, 53 High Street, Hampton Hill,

TW12 1ND, United Kingdom

Tel: +44 (0) 208 783 3574

Mob: +44 (0) 790 857 6050


Webiste: www.compositesexhibition.com

Thermoplastic Elastomers 2012In its 15th edition, this international

conference is a great opportunity to

network with leaders in the surging global

thermoplastics industry. From medical

applications to automotives and consumer

durables, this event will highlight the

current & furute trends in thermoplastics

applications; November 13-14, 2012; at

Berlin Exhibition Centre, Germany


Smithers Rapra

Shawbury, Shrewsbury, Shropshire

SY4 4NR, United Kingdom

Tel: +44-01939 250383

Fax: +44-01939 251118


Website: www.smithersrapra.com

Plast Eurasia 2012This trade show plays an important part

in the expansion of plastics industry to

new markets and influences machinery

& technology investments. This event

will witness some leading innovations in

precision plastics moulding and recycling;

November 29 – December 2 2012; at Tüyap

Fair Convention and Congress Center,

Istanbul, Turkey


Tamer Güzelaydin

E – 5 Karayolu Üzeri, Gürpınar Kavşağı

34500 Büyükçekmece, Istanbul, Turkey

Tel: +90-212 8671100, Fax: +90-212 8869399


Website: www.plasteurasia.com

Arabplast 2013This exhibition and conference is among

the leading trade shows for the global

petrochemicals & plastics processing

industry. The petrochemical industry

in the GCC region has become a major

investment opportunity for the Gulf

countries as they become the world’s largest

source of polyethylene and polypropylene;

January 7-10, 2013; at Dubai International

Convention & Exhibition Centre, UAE


Jeen Joshua

Al Fajer Information & Services

PO Box 11183, Dubai, United Arab Emirates

Tel: +9714 340 6888

Fax :+9714 340 3608


Website: www.arabplast.info

International

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BOOK REVIEW


Epoxy polymers are considered as mature polymers since the fundamental knowledge of these thermosetting polymers has been well established during the 1970s and 1980s. The industry, however, continued developing new formulations, processing techniques and applications in the areas of adhesives, coatings & composites, which extend to sectors such as building, electronics, sports goods, automobile and aircraft among others. Towards the end of 1990s, the world had begun to recognise the word ‘nano’, and this book covers the new work done with nanoclays, Polyhedral Oligomeric Silsesquioxanes (POSS), block co-polymers and carbon nanotubes. Serious readers from the industry and students can benefit from this exhaustive compilation.

The book has a chapter on ‘Green Chemistry’ describing different monomers derived from various natural products that are now available commercially. It also has a chapter on thermoplastic epoxies, which can be processed like thermoplastics and cured like thermosets. There is a good inclusion of advanced functional materials such as self-healing, shape memory and transparent opaque transitions with formulations based on epoxy polymers.

EPOXY POLYMERSEditors : Jean-Pierre Pascault and Roberto J J WilliamsPrice : ` 6,595

Polymers are the building blocks of a vast number of natural and synthetic raw materials, which when mixed together and with other materials produce a variety of products such as plastics and resin-based articles, adhesives and many other coating formulations.

Three basic mechanisms, either alone or in combination, can be present in mixing processes. This book briefly describes the mixing equipment and the process where mixing is achieved by a combination of shear and circulation. Blade mixers achieve the mixing by kneading the material continuously, tearing, folding and compressing it between heavy rotating blades. The blades are available in various designs, but are commonly Z-shaped, and while rotating their paths, overlap or cross to achieve the required degree of mixing.

The book gives a view of high-pressure laminates, which play an important role in engineering industries. Other important features include in great detail the high-pressure laminates and copper-clad laminates that are used as printed circuit boards. The topics covered at length in this book are remarkable, such as the use of paints, additives such as anti-oxidant, surfactants, anti-foams, fungicides and curing catalysts. This book is excellent for the library for general information on plastics and resin compositions and even demands space on the shelf of industries even remotely related.

PLASTICS AND RESIN COMPOSITIONS

Avaliable at: Wisdom Book Distributors, Hornby Building, 1st floor, 174, D N Road, Mumbai 400 001 /�;<�)**=**)O�(( (�??>�� Y� �Q�/�;��X<�)**=**)>�()� �Q�Z�;<��^��\_��;+]��

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Reviewer: Arvind S Athalye, Founder & CEO, Arvind Athalye Technology Transfer Pvt Ltd

Reviewer: Dr Yatish B Vasudeo, President, BY INNOVATIONS Consultancy (I) Pvt Ltd

Editor : W Gordon SimpsonPrice : ` 7,275

PRODUCTS



Just type MPP (space) Product Name and send it to 51818eg. MPP Moulding and send it to 51818

In-mould labelling systemThe In-Mould Labelling

(IML) system has following

advantages: reduced costs,

promoting hygienic production,

increas ing decorat ive

possibilities, offering resistance

to heat & scratching, reducing

in-house container inventory &

overhead costs, better strain

& squeeze resistance, improved

sidewall strength and shelf-life. Application areas are injection

moulding IML for cups & containers, thermoforming IML, blow

moulding IML and BDA (blister decorating applications) for

thermoformed PET/PVC blister packaging.

Neejtech India

Ahmedabad - Gujarat

Tel: 079-26561312


Website: www.neejtech.com

Strapping band extruding line

The JC-ST series strapping band extrusion line has a wide range of

production capability from 80 kg/hr up to 400 kg/hr and low energy

consumption. JC-ST series strapping band extrusion line is merged

with JC-ST/PP and JC-ST/PET series. The JC-ST/PP series

conceived for making polypropylene straps. The extruder available

in diameter 65-120 mm for 2-, 4-, 6-, up to 8-strap extrusion. The

JC-ST/PET series extruder is available in diameter 85-120 mm for

2-, 4-, up to 8-strap extrusion.

Jenn Chong Plastics Machinery Works Co Ltd

Tai Pao City - Taiwan

Tel: 886-5-2376175

Mob: 09414195707


Website: www.jennchong.com.twSafety light curtainThe safety light curtain is an

opto-electronic device in the

form of an invisible wall, which

detects any unintentional

movement across it and

signals for use in activation of

protective circuits. This curtain

is mainly used for safety of

the machine operator. The

safety light curtain is used as

an alternative or addition to

mechanical safety system and other form of traditional machine guards.

It is placed between an operator and the machine so that if the operator

puts any part of his body into the machine unintentionally, then some

of the optical beams get interrupted and the receiver generates a trigger

signal for the controller section to stop the machine.

Katlax Enterprises Pvt Ltd

Gandhinagar - Gujarat

Tel: 02764-286784


Website: www.katlax.com

Plate moulding machine The DISA MATCH

20/24 horizontal flaskless

match plate moulding

machine is designed

and manufactured to

deliver high capacity of

160 un-cored mould/hr.

It is more precise with

maximum machine-

related mismatch

guarantee of 0.15 mm.

The automatic core setter (CSE) ensures repeatable and automatic

core setting. Quick match plate changer (QMC) enables easy and fast

pattern change.

DISA India Ltd

Bengaluru - Karnataka

Tel: 080-40201400


Website: www.wheelabratorgroup.com

PRODUCTS


Additive feedersTrueFeed gravimetric feeder units are simple to install and use, extremely accurate and economical. These colour and additive feeders deliver accurate feeding rates on the basis of continuous loss in weight metering technology with closed loop control of the feeding speed. These can be used in injection moulding, extrusion and blow moulding processes. It reduces material cost, increase productivity and has unbeatable accuracy.

Nu-Vu Conair Pvt LtdAhmedabad - GujaratTel: 079-32985993, 25841181Mob: 09423677084 Email: [email protected] Website: www.conairgroup.com

MasterbatchesA 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: +886-2-82094051Mob: 09930137484Email: [email protected]: www.npc-color.com.tw

Plastics machinery A broad range of plastics machinery is offered. These include PE stretch film and cling film whole plant, 2/3/5-layer co-extrusion blown film machine, PE/PP fi lm extruder, PE/PVC shrinkable film making machine, PE waterproof sheet

extrusion machine, PP pearl ribbon making machine, plastic bag flexographic printing machine, plastic bag making machine, sealing and cutting machine as well as waste plastics recycling and pelletising machine.

Chyi Yang Industrial Co LtdTaoyuan County - TaiwanTel: +886-3-3288686Email: [email protected]: www.cymw.com.tw

Bag making machine

The polypropylene woven bag making machine comes with cutting and sewing machine and printing machine. These machines are highly durable, of good quality and enable efficient operation. These 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

Injection moulding machine The two-platen injection moulding machine is available in 850-3,500 tonne range. It occupies less space and is provided with four sets of hydraulic cylinders, which are on the moveable platen instead of

fixed platen. The design not only ensures precise and accurate clamping force, but also gives large space for the operator to work on the fixed platen. Mould-open position is more accurate. The tie bars and hydraulic cylinder pistons are isolated. There is no need to dismantle hydraulic cylinders and no risk of damaging seals while changing tie bars. Changing tie bars are much easier.

Jon Wai Machinery Works Co LtdTaipei - TaiwanTel: +886-2-25954867Email: [email protected]: www.jonwai.com

PRODUCTS


Hot runner systemsMastip hot-half-hot runner system is

used in plastic moulding. It is also used

for manufacturing electrical, electronics,

packaging, automobiles, white goods and

consumer products. The key feature of the

system is that it removes the hassles of

assembly and ensures smooth start-up, reduces

time-span of mould manufacturing to parts

production. The hot halfs are engineered to

international standards and pre-sales liaison

with mould manufacturer makes hot half installation in the mould

convenient and easy.

Madhu Machines & Systems Pvt Ltd

Vadodara - Gujarat

Tel: 0265-2353886/2321104


AC drivesThe Vacon 20 series incorporates a built-

in Programmable Logic Controller (PLC)

functionality, which conforms to the

IEC61131-3 standard. In addition, the

functionality can be extended via optional

modules, including field bus cards and tools

for easy parameter copying from one unit to

another. Efficient volume manufacturing is possible as these are fast to

install and easy to set up. Also, the products can be modified and tailored

to the needs of the customer.

Vacon Drives & Controls Pvt Ltd

Chennai - Tamil Nadu

Tel: 044-24490024


Website: www.vacon.com

Swing-arm robotThe SS series swing-arm robot is useful for use

in injection moulding machine. It is designed

for rapid and precise removal of sprue & runner

from the injection moulding machine and placing

them in the granulator for recycling. This robot is

suitable for injection moulding machines under

250T clamp force. Swing-arm robots are equipped

with various useful mechanisms in arm, swing,

kick stroke and base.

Shini Plastics Technologies (India) Pvt Ltd

Dist Thane - Maharashtra

Tel: 0250-3021132


Website: www.shini.com

PRODUCTS


Injection moulding machineThe Niigata all-

electric horizontal

i n j e c t i o n

m o u l d i n g

machine in the

range of 50-1,000

tonne and the

vertical injection

moulding machine

in the range of 30-150 tonne. Shot size (PS) ranges from 20 to 4,550 gm.

This all-electric machine is generally known as green machine because

it saves more than 60 per cent power consumption than a hydraulic/

toggle machine of similar size. The machine is free from oil, and hence

does not create pollution. It ensures enhanced accuracy and reliability,

and also provides great cost savings and contributes to environmental

preservation. The machine is ideally suitable for medical, automotive,

pharmaceutical-healthcare and packaging moulding segment of

the industry.

Neejtech India

Ahmedabad - Gujarat

Tel: 079-26561312

Mob: 09825040231


Website: www.neejtech.com

PRODUCTS


Wood plastic composites

Wood Plastic Composites (WPC) are thermo-plastically processible

materials made from wood and plastics (PP, PE, PVC, PS, ABS)

for use in building, furniture, automotive, consumer goods, housing

industry, etc. In order to operate under optimum function, upstream

and downstream equipment are designed for the best matched with the

extrusion line. For further improvement the output of extrusion line,

each processing device and computer-controlled possibility (eg, PLC,

PC base) is recommended perfectly to suit different users’ demand.

Plastic injection moulding machineThe PET-LINE

is based on the

platform with 3,500

kN clamping force

covering moulds

with 48-128 cavities.

This machine offers

solution to cope with

the rising demand

from the food & beverage industry. Numerous optimisations such as

the simplified product removal and after cooling unit or the increased

injection pressure to shorten the cycle time make the PET-LINE an

economical system solution for production of PET preforms.

Netstal-Maschinen AG

Naefels - Switzerland

Tel: +41-55-6186111


Website: www.netstal.com

Extrusion machine The LIN-90II-TS is

a performance-based

machine designed

to accommodate

large containers with

outstanding cycle time.

It produces containers

from PE/PP & PVC/PTEG of capacity 200 ml to 4L, and productivity

reaches 4,500 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

Tel: +852-852-27411312


Website: www.akei.com.hk

Engineering plastics Engineering plastics

are based on Polyamide

(PA6 and PA6.6)

and Polybutylene

Terephthalate (PBT)

that are available

under brands

Durethan and Pocan.

Durethan and Pocan

high-tech plastics are enablers of green mobility. These replace metal

parts with lightweight plastics, thus offering excellent fuel saving and

carbon emission solutions to the automotive industry. Aside 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) Company Ltd

Shanghai - China

Tel: +86-21-61096666


Website: www.lanxess.com

Extruder and cutting machine The EDC-08-05

multi-layer extruder

and cutting machine

is used in co-extrusion

systems for combining

different materials.

Thus, characteristics

of single-layer tube

cannot compete with the complex characteristics of co-extrusion

tube, eg, 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 tube with diameter 35 mm

(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

in the of 16-60 mm and has easy to change tooling in tubes of

different sizes. In addition, tubes made by EDC-08-05 can be used

on pesticide container, toothpaste, side window, multi-colour, long-

preservation cosmetics, etc.

Bonmart Enterprise Corp

New Taipei City - Taiwan

Tel: +886-2-22994281


Website: www.bonmart.com.tw

Intype Enterprise Co LtdTainan, Taiwan

Mob: 09769220221


Website: www.intype.com.tw

PRODUCTS


Libratherm Instruments Pvt Ltd

Mumbai - Maharashtra

Tel: 022-28963823


Website: www.libratherm.com

In-mould labelling equipment Supreme 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 following

features: electrostatic and vacuum, easy to understand, durability,

low defects rate, low-cost & simple maintenance, simultaneously

available machine for variant shape containers, suitable for different

label options, etc.

Supreme Technic Package Co Ltd

Kalol - Taiwan

Tel: +886-7-6141505


Website: www.emdpack.com.tw

Thermoplastic elastomers Everlon 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 is used in numerous

processing techniques, eg, 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


Website: www.everlon.com.tw

Hydrogen gas detection systemThis hydrogen gas detection

system is used for detection

of hydrogen gas. It uses a

3-status technology, which

displays in terms of low/

medium/high concentration.

It has selectable slide switch

for audio & visual built-

in solid state buzzer. The system has the facility to function five gas

detectors with independent alarm latching facility, potential free N.O/

N.C contact and recorder output. The system is equipped with 4-wire

technology and maturity timer.

Subtronics (India) Pvt Ltd


Tel: 022-24224461


Website: www.subtronicsindia.com

Temperature control systemThe 2-16 zone control

panel for hot runner

temperature control

system is widely used

in plastic injection

moulding. Panels are

designed taking into

consideration all required controlling and safety features to accurately

maintain the desired temperature of all the zones. The main

components of the control panel include model PID-723 temperature

controller, LTC-16 SCR-based heater power regulator, HMC-8

heater monitoring card, PWM-4 pulse width modulation card and

other panel accessories.

PRODUCTS


Thermoplastic elastomer compounds Phoenix transparent

thermoplastic elastomer

compounds are developed

for transcending current

standards. SBC compounds

offers classic water clear

transparency and softness.

It fulfills users’ pursuit of

aesthetic looking and attractive products, but, at the same time, without

compromising quality and performance. State-of-the-art compounding

Hot runner controller The 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


Website: www.arico.com.tw

Hot runner system mould Some of the

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 most suitable

for lightweight and extra-thin (thinnest up to 0.3 mm) disposable

products. Other features are waste reduction, low production cost,

high stability of finished products and low defects rate; and strong

mould structure, floating structure, thin finished products, average

thickness, stable quality and long mould life.

Mo Chyi Enterprise Co Ltd

Changhua County - Taiwan

Tel: +886-4-7354681


Website: www.food-mold.com

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

styrenic block copolymers compounds (SEBS compounds, SEPS

compounds, SBS, SIS), Phoenix transparent TPE compounds yield

varied performance and properties.

Phon Tech Industrial Company

Youlin County - Taiwan

Tel: +886-5-5574567


Website: www.phon-tech.com.tw

Thermoplastic elastomers The thermoplastic 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 the thermoplastic

elastomers are suitable for use particularly in the sanitary and drinking

water sector.

Kraiburg TPE

Wadhwan - Germany

Tel: +49-8638-9810278

Mob: 09821136685


Website: www.kraiburg-tpe.com

Cup forming machine The thermorunner KTR 5 speed cup

forming machine combines intelligent

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 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. Coordinated multi-axis movements: fast and precise.

Kiefel GmbH

Freilassing - Germany

Tel: +49-8654-78182


Website: www.kiefel.de

PRODUCTS


Breath analyser with printerIt detects alcohol in the breath and gives

an audio-visual indication. It has 3-status

technology which includes bright graphic

display, easy & quick testing, reading latching,

non-volatile memory, password protected

critical menu settings, subject sample blow

indicator, print readings with data & time,

user selectable multiple number of prints

for evidential record documentation, etc.

The instrument is housed in a robust

plastic enclosure.

Subtronics (India) Pvt Ltd


Tel: 022-2422 4461


Website: www.subtronicsindia.com

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 also provides

added value to end-users.

TSRC Corporation

Taipei City - Taiwan

Tel: +886-2-37016000


Website: www.tsrc.com.tw

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


Website: www.keisoku.kubota.ne.jp/chinese

PRODUCTS


Vacuum dryerThe Orient vacuum dryer consists of a conical cylinder provided with a jacket for hot water, steam or oil heating. The indirect heating process is carried out under vacuum, while

recovery of solvent is possible by conducting the vapour-generated drying operation. The dryer rotates, and a rapid & thorough intermixing of the entire batch brings every particle in contact, repeatedly with the heated surface for more rapid heat conduction. The heat efficiency of the drying system is two times greater than the ordinary dryer.

Toshniwal Systems & Instruments pvt ltdChennai - Tamil NaduTel: 044-26445626Email: [email protected] Website: www.toshniwal.net

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 - ItalyTel: +39-0331-307616Email: [email protected]: www.zambello.it

Centrifugal air blower and fanThe high-effic iency centrifugal air blower and fan can handle air/hot flow gases/corrosive gases/dust/fibre/powder materials, etc. These are available for impeller mounted and motor shaft/direct coupled/V-belt drive. The impeller has a backward/back inclined/forward curves

type design. The blower and fan are designed in single-stage/multi-stage/DWDI type depending upon the required specification. These have capacity ranging from 100 m³/hr to 3,00,000 m³/hr and pressure up to 2,500 mm WG.

Vacunair Engineering Co Pvt LtdAhmedabad - GujaratTel: 079-22910771-3, Mob: 09824036375 Email: [email protected]: www.vacunair.com

In-mould labelling system The new A-Pack In-Mould 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, eg, tea, coffee, juice, water, yoghurt, dairy products, etc. It

consists of four components including FCS AF series, hi-speed hybrid close loop injection moulding machine, hot-runner mould, robot, product stacking system and label inserting system. Also provided is a customised label for turnkey solution.

Fu Chun Shin Machinery Manufacture Co Ltd Tainan County - TaiwanTel: +886-6-5950688Email: [email protected] Website: www.fcs.com.tw

Screws and barrelsA full series of screws and barrels applied for various extruding machines and plastic injection moulding machines is 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 diameter x length 450 mm x 8,000 mm, and barrel hole diameter x length 450 mm x 8,000 mm.

Nan Yun Industrial Co LtdTainan Hsien - TaiwanTel: +886-6-2017773Email: [email protected] Website: www.nyi.com.tw

PRODUCTS


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

��

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. 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


Website: www.shini.com

Injection moulding machines The product range of these injection moulding

machine includes mould makers, A/C, HVAC parts/

components, auto parts/components, OA furniture,

3C parts/components, plastic houseware, etc.

Aplus Molds & Plastics Co Ltd

Tainan - Taiwan

Tel: +886-2-27235390


Website: www.chenlueng.com

PVC perforated cable trayShital rigid PVC perforated cable tray is

an ideal replacement to MS tray. It is not

affected by any corrosive chemicals and

is waterproof. The tray is UV stabilised

to resist ultraviolet rays of the sun, and

hence is used outside for a prolonged period. The PVC cable tray is

available in widths in the range of 50-500 mm, with flange heights

of 25, 50 and 75 mm and standard length of 2.9 m. It is light-weight

and maintenance-free. The cable tray is joined by socketed jointing

system, which means no coupler plates incorporated.

Supreme Electroplast Industries


Tel: 022-28873428, Mob: 09820306252


Website: www.supshitl.com

Reduction gearbox and geared motorThe new ZPE series for driving single-

screw extruders is effectively complete, as

it begins with the smallest gearbox size

of 100 (suitable for single-screw extruders

with screw diameter of 25/30 mm) and

reaches size 630 (suitable for big single-

screw extruders with screw diameter of 250/300 mm). High quality is a

typical feature of this new range. This refers to all toothed gears, which are

manufactured and checked with utmost precision.

Zambello Riduttori Group

Milano - Italy

Tel: +39-331-307616


Website: www.zambello.it

TPE foaming materialsThe TPE foaming materials meet

international environmental standards. These

are comfortable to touch with conforming

physical characteristics. The foaming

materials have optimised vulcanisation

resulting in excellent flexibility and anti-spreading. These have excellent

electro-insulation compounds and contain durability for better acid and

alkali resistance. The materials are non-toxic, odourless and harmless to

the environment & human body. These can meet the individual demands

for customers.

Microcell Composite Company

Tainan County - Taiwan

Tel: +886-6-2641352


Website: www.microcell.com.tw

Air-cooled compressorA unique range of air-cooled compressors is

offered for industries that demand oil-free air

at their application point. The non-lubricated

compressor offers advantages of low energy

consumption and low running costs. The air-

cooled design eliminates the need for water cooling systems, thereby

saving industrial water costs. Two-stage air-cooled aftercooler has a

0.25 kW single-phase motor driving a cooling fan. This eliminates the

need for cooling towers, water circulation pumps and the associated

piping, thus reducing the initial investment. This also reduces the

installed power.

Elgi Equipments Ltd

Coimbatore - Tamil Nadu

Tel: 0422-2589326, Mob: 09790039326


Website: www.elgi.com

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LIST OF PRODUCTS


AC drives..........................................................109, 111

Acoustic enclosure ............................................................ 49

Additive feeders.............................................................. 108

Additive masterbatches .................................................... 31

Air audits blowers .............................................................. 4

Air bubble sheet plant ...................................................... 99

Air chiller ......................................................................... 23

Air rings ............................................................................. 3

Air-cooled compressor ................................................... 118

Automation ...................................................................... 77

Automation system ........................................................ 103

Bag making machine ............................................... 108

Baking .............................................................................. 29

Barrels............................................................................. 128

Blenders ........................................................................ 3, 17

Biodegradable additive ..................................................... 33

Black masterbatches ......................................................... 31

Blow moulding machines ................................................. 18

Blower series .................................................................. 103

Blown film extrusion systems ........................................ BC

Blown flim systems ............................................................ 3

Bottle testing equipment .................................................. 89

Box series wormgear units ............................................... 33

Brake motor ..................................................................... 33

Breath analyser with printer........................................... 115

Bubble ................................................................................ 3

Cast film line .............................................................99

Centrifugal air blower and fan ...................................... 116

Circular weaving looms .................................................... 60

Circular weaving machine ................................................ 12

Clean room applications .................................................. 35

Cleaning ovens ............................................................... 128

Co-extruded sheets and telecom cables ........................... 67

Color masterbatches ................................................... 13, 31

Compact chiller ........................................................ 23, 125

Compressed air dryer ....................................................... 91

Compressors ....................................................................... 4

Conical twin-screw extruder ...................................... 14, 21

Continuous screen changers ........................................... 128

Controllers .......................................................................... 3

Conveyor .................................................................... 25, 77

CPVC pipes ................................................................. 8, 19

Crystalliser.................................................................. 25, 91

Cup forming machine .................................................... 114

Curing .............................................................................. 29

Cutting and stitching machine ........................................ 12

Dehumidified air dryer ........................................23, 125

Dehumidifying dryer ........................................................ 65

Delphi three-phase motor ................................................ 33

Dosing & blending .......................................................... 77

Dosing & mixing ........................................................... 103

Dosing & mixing units .................................................... 25

Double shaft gearbox ....................................................... 44

Dry van pump .................................................................. 49

Dry-break couplings ........................................................... 4

Drying .................................................................. 25, 29, 77

Drying & dehumidifying ............................................... 103

Duracon (POM) ...........................................................BIC

Duranex (PBT) .............................................................BIC

Dyestuffs .......................................................................... 68

Eco-friendly synthetic rubber ................................... 115

Ejectors ............................................................................... 4

Electric injection moulding machine gearboxes................. 5

Engineering plastics ....................................................... 112

Extruder and cutting machine ....................................... 112

Extruder feeding systems ............................................... 113

Extruder machine ................................................... 3, 37, 79

Extrusion ........................................................................ BC

Extrusion coating lamination plant .................................. 99

Extrusion coating lines (lamination ant).......................... 12

Extrusion dies..................................................................... 6

Extrusion lamination machines ........................................ 81

Extrusion lamination plants ............................................. 81

Extrusion machine ......................................................... 112

Extrusion pumps .............................................................. 50

Extrusion systems ........................................................... BC

Extrusion tape stretching machines ................................. 81

Extrusion tape stretching plants ...................................... 81

Feeding & conveying ..........................................91, 103

Film dies ............................................................................. 3

Flame-retardant masterbatches ........................................ 31

Fortron (PPS) ................................................................BIC

Fueling systems .................................................................. 4

Fully automatic strapping plant ....................................... 99

Gearbox ............................................................... 44, 86

Gear pump ....................................................... 50, 113, 128

Geared motor ................................................................... 86

Gears ................................................................................ 44

Granulating & recycling ................................................ 103

Granulator .......................................................... 23, 91, 125

Gravimetric blender ....................................................... 125

Grinder ............................................................................. 23

HDPE woven sack manufacturing plants ...................81

Heart valve frame....................................................... 26, 42

Heat transfer rolls .......................................................... 128

Heating & cooling ................................................... 77, 103

Heating solutions ............................................................. 29

Helical inline geared motors / reducers ........................... 86

Helical speed reducer ....................................................... 44

High cavitations ............................................................... 35

High-performance screws .............................................. 128

High-precision hydraulic clamping

injection moulding machine ............................................. 53

High-speed mixer ...................................................... 37, 79

High-torque gearbox ...................................................... 116

HM/HDPE/IDPE/IIDPE ............................................. 99

Hopper dryer .................................................................... 23

Hopper loader .......................................................... 23, 125

Hot air dryer ............................................................ 65, 125

Hot runner controller ..................................................... 114

Hot runner system ................................................. 103, 109

Hot runner system mould .............................................. 114

Hydrogen gas detection system...................................... 113

I-fix gauge controls ..................................................... 3

IMl technique .................................................................. 35

Infrared dryer ................................................................. 113

Injection moulding

machine ...........................15, 53, 93, 97, 105, 108, 111, 118

Inline drip tubing ............................................................. 19

Inline shaft mounted helical geared motors / reducers ... 86

In-mould labelling equipment ....................................... 113

In-mould labelling system ...................................... 107, 116

Insert moulding machines ................................................ 18

Internal bubbles cooling systems ....................................... 3

Jumbo bag manufacturing machines ...........................81

Jumbo blown film plant ................................................... 60

Lamination plant for tarpaulin ...................................60

Large flow water heaters ................................................ 103

Loading arms ..................................................................... 4

Manual & hydraulic screen changers ........................ 128

Masterbatches..................................................... 31, 67, 108

Material dryers ................................................................. 17

Material storage ............................................................. 125

Material testing instrument ............................................. 89

Medical moulds ................................................................ 35

Product Pg No Product Pg No Product Pg No

FGF - Front Gate Fold, FIC - Front Inside Cover, BIC - Back Inside Cover, BGF - Back Gate Fold, BC - Back Cover


Just type MPP (space) Product Name and send it to 51818eg. MPP Moulding and send it to 51818

LIST OF PRODUCTS


MFRS of injection moulding machines .......................... 18

Milky polymers .............................................................. 115

Mould changing systems .................................................. 71

Mould temperature controllers ........................................ 65

Mono and multilayer sheet line ....................................... 12

Monofilament line ........................................................... 12

Monofilament plant for PP/HDPE ropes & twine ........ 60

Monolayer blown film .................................................. 8, 19

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

Motor ............................................................................... 33

Mould temperature controller .................................. 23, 125

Moulding .......................................................................... 35

Multi-component moulds ................................................ 35

Multilayer cast film line ................................................... 12

Multilayer blown film .................................................. 8, 19

Multilayer blown film line ........................................12, BC

Multilayer blown film plants ............................................ 99

Multilayer co-extrusion sheet line .................................... 16

Natural polymers ..................................................... 115

Neat resin ......................................................................... 68

Optic sheet extrusion line ..........................................16

Oscillating haul-off ............................................................ 3

Paper chemicals .........................................................68

Paper lamination plant ..................................................... 60

Parallel & right angle axes gearboxes ................................ 5

Parallel shaft helical gearbox ............................................ 44

Pellet screening system ................................................... 115

Pelletisers ........................................................................ 128

PET bottle testing equipment ......................................... 89

PET box strapping plant ................................................. 99

PET masterbatches .......................................................... 31

PET perform dedicated machine..................................... 55

PET sheet extrusion......................................................... 16

PET/PE washing line ...................................................... 12

Pipe extrusion line for PVC/PPR/PE ............................. 97

Planetary gearboxes .......................................................... 44

Plastic brightener ........................................................... 115

Plastic conveyor belt ......................................................... 37

Plastic injection moulding machine ............................... 112

Plastic masterbatches ....................................................... 85

Plastic processing machines ............................................. 12

Plastic sheet extrusion plants ........................................... 81

Plastic textile and machinery ........................................... 73

Plastic tinopol ................................................................ 115

Plastic whitener .............................................................. 115

Plastics machinery .......................................................... 108

Plate moulding machine ................................................ 107

Polymer conveyer belt ...................................................... 23

Polymer vales .................................................................. 113

Polyolefin pipes ............................................................ 8, 19

PP glass-filled compounds ............................................... 31

PP mineral-filled compounds .......................................... 31

PP TQ plant .................................................................... 99

PP woven sack manufacturing machines ......................... 81

PP/HDPE rafffia tape lines ............................................. 99

PP/HDPE semi-automatic strapping plant .................... 99

PP-R pipes ................................................................... 8, 19

PPRP powder ................................................................. 115

Priming valves .................................................................... 4

Printing and cutting / rewinding machines ..................... 12

Pulveriser .................................................................... 37, 79

Pump ............................................................................ 4, 49

PVC compounds .............................................................. 67

PVC foam core pipes ................................................... 8, 19

PVC kisan pipe plant ....................................................... 60

PVC mixer cooler......................................................... 8, 19

PVC palletising lines .................................................... 8, 19

PVC perforated cable tray.............................................. 118

PVC pipes .................................................................... 8, 19

PVC profile lines .......................................................... 8, 19

Quick die change system ............................................71

Quick mould change system ............................................ 71

Recycling ...................................................................77

Recycling lines.................................................................. 12

Reducer ............................................................................ 33

Reduction gearbox and geared motor ............................ 118

Reprocessing plant ........................................................... 60

Resin dehumidifier ........................................................... 91

Right-angled helical bevel geared motors / reducers ....... 86

Robot system .................................................................... 23

Robotics .......................................................................... 109

Roots blower .................................................................... 49

Rotary automatic hot colour marking machines .............. 83

Round table carousels....................................................... 37

Safety access equipment .............................................. 4

Safety light curtain ......................................................... 107

Sandwich BOPP lamination ............................................ 81

Screen changer ............................................................... 113

Screws ................................................................................. 3

Screws and barrels .......................................................... 116

Seals ................................................................................ 115

Secon & dull polymers................................................... 115

Servo energy saving machine ........................................... 55

Shaft-mounted speed reducers ......................................... 44

Shut-off nozzles ............................................................. 128

Single mill pulveriser .................................................. 37, 79

Single-screw extruder gearboxes ........................................ 5

Single-screw extruder plant ........................................ 14, 21

Single-shaft extruder gearbox .......................................... 44

Software for central monitoring....................................... 91

Special silos .................................................................... 113

Sprockets .......................................................................... 44

Stabilisers ........................................................................... 3

Stack moulds .................................................................... 35

Storage tank equipment ..................................................... 4

Strapping band extruding line ....................................... 107

Stretch blow moulding ..................................................... 18

SV power-cooled motor ................................................... 33

Swing-arm robot ............................................................ 109

System solution .............................................................. 103

Tank truck equipment ................................................. 4

Tape stretching line with inverter driven cheese winders 12

Tarpaulin manufacturing machines .................................. 81

Technical moulds ............................................................. 35

Temperature control system ........................................... 113

Testing instruments .......................................................... 89

Thermoformers .............................................................. BC

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

Thermoplastic alloys ........................................................ 68

Thermoplastic compounds ............................................... 68

Thermoplastic elastomer compounds............................. 114

Thermoplastic elastomers ....................................... 113, 114

Thermoplastic polyurethanes ........................................... 57

Thick & wide plastic sheet extrusion line ....................... 16

Three-arm biaxial rotomoulding machine ................. 37, 79

Topas (COC) ................................................................BIC

TPE foaming materials .................................................. 118

TPE/TPU compounds ..................................................... 31

TPU masterbatches .......................................................... 13

Transmissions & PTOS ..................................................... 4

Twin-screw co-rotating extruder .......................... 26, 42, 95

Twin-screw element ............................................. 26, 42, 95

Twin-screw extruder ............................................. 26, 42, 95

Twin-mill pulveriser ................................................... 37, 79

Twin-screw extruder gearboxes .......................................... 5

Twin-screw extrusion line .......................................... 14, 21

Two-colour cane plant ..................................................... 60

Two-layer blown film ................................................... 8, 19

Underwater pelletising systems ................................. 113

Universal masterbatches ................................................... 31

Universal quick mixer ..................................................... 113

UV & PU masterbatches ................................................. 31

Vacuum booster pump ................................................49

Vacuum dryer ........................................................... 65, 116

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

Vacuum pumps & systems ................................................. 4

Vacuum system ................................................................. 49

Variable displacement pump energy-saving machine ...... 55

Vario speed variators ........................................................ 33

Vectra (LCP) .................................................................BIC

Vibro screens .............................................................. 37, 79

Virgin polymers .............................................................. 115

Volumetric dosing unit ..................................................... 91

Water chiller ..............................................................91

Water heater ................................................................... 118

Water jetting ...................................................................... 4

White masterbatches ........................................................ 31

Winders ............................................................................ 60

Wood plastic composites ................................................ 112

Worm reducer gearbox ..................................................... 44

Worm reducers ................................................................. 44

Wovensack tape plant for PP/HDPE ............................. 60

Product Pg No Product Pg No Product Pg No

FGF - Front Gate Fold, FIC - Front Inside Cover, BIC - Back Inside Cover, BGF - Back Gate Fold, BC - Back Cover

LIST OF ADVERTISERS


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

Our consistent advertisers

Aerodry Plastics Automation Pvt Ltd ........ 77

T: +91-120 4766777

E: [email protected]

W: www.aerodry.com

Aeromec Marketing Co Pvt Ltd ................ 83

T: +91-250-2454915


W: www.aeromec.in

Alok Masterbatches Ltd ............................ 13

T: +91_011-41612244


W: www.alokmasterbatches.com

Ask Me ...................................................110

T: +91-3555 5555

E: twitter.com/AskMe_35555555

W: www.facebook.com/AskMe.infomedia18

Blend Colours Pvt Ltd .............................. 31

T: +91-40-2436 1499 / 2436 0887


W: www.blendcolours.com

Boge Compressed Air System ................... 32

T: +91-44-43009610


W: www.boge.in

Dongguan Alfa Automation

Machinery Limited ..................................109

T: 86-769-8318-0326


W: www.alfarobot.com

Everest Blower Systems ............................ 49

T: +91-11-45457777


W: www.everestblowers.com

Ferromatik Milacron India Pvt Ltd ........... 23

T: +91-79-25890081


W: www.milacronindia.com

Forwell Precision Machinery Co., Ltd. ...... 71

T: 886-4-834-5196


W: www.forwell.com

Gardner Denver Engineered

Products (I) Pvt Ltd .................................... 4

T: +91-79-40089312


W: www.gardnerdenver.com

Gujarat Machinery Pvt Ltd ....................... 81

T: +91-79-29295988


W: www.gujaratmachinery.com

Hindustan Plastic And Machine

Corporation ........................................ 14, 21

T: + 91-011-25473361


W: www.hindustanplastics.com

Hindustan Syringes & Medical

Devices Ltd .............................................111

T: +91-0129-4289000


W: www.hmdhealthcare.com

Ingeco Gears Pvt. Ltd. .................................. 44

T: +91-2717-651551


W: www.ingecogears.com

J P Extrusiontech Limited......................... 12

T: +91-2646-222163


W: www.jpextrusiontech.com

Jing Cheng Mold Machinery Co., Ltd ......... 6

T: 86-576-8461-0001


W: www.jc-times.com

Kabra Extrusion Technik Ltd .................8, 19

T: +91-22-2673 4822


W: www.kolsite.com

Konark Plastomech Pvt Ltd ...................... 99

T: +91-79-22891670


W: www.konarkplastomech.com

Kreyenborg Group ...................................113

T: 49-251-214-050


W: www.kreyenborg-group.com

Larsen & Toubro Ltd ............................... 39

T: +91-22-6752 5656


W: www.larsentoubro.com

Litel Infrared Systems Pvt Ltd .................. 29

T: +91-20-66300639


W: www.litelir.com

Lohia Starlinger Ltd. ................................ 73

T: +91-011-30641770


W: www.lohiagroup.com

Loxim Industries Limited ......................... 68

T: +91-2717-308000


W: www.loxim.com

Lubrizol Advanced Materials

India Pvt Ltd ............................................ 57

T: +91-22-66027800


Mamata Extrusion Systems Pvt Ltd ............ 3

T: +91-79-66309800


W: www.mamata.com

Matsui Technologies India Ltd. ................ 65

T: +91-0120-4243862


Motan-Colortronic Plastics

Machinery (India) Pvt Ltd ........................ 25

T: +91 - 044-22472423


W: www.motan.com

N.A. Corporation ..................................... 79

T: +91-79-25840374


W: www.naroto.com

Neejtech India (Niigata) .......................... 15

T: +91-9909974224


W: www.niigataindia.com

Neejtech India (Braun) ............................ 35

T: +91-79-26561312


W: www.neejtech.com

COC - Cover on Cover, FGF - Front Gate Fold, FIC - Front Inside Cover, BIC - Back Inside Cover, BC - Back Cover

LIST OF ADVERTISERS


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

Our consistent advertisers

Nu-Vu Conair Pvt Ltd .............................125

T: +91-9376783206


W: www.conairgroup.com

Piovan India Pvt Ltd ................................ 91

T: +91-22-27782367


W: www.piovan.com

Plast Fine Polymers .................................115

T: +91-79-65242332


W: www.plastfine.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

Power Build Ltd ....................................... 86

T: +91-2692-231070


W: www.pbl.co.in

Prasad Gwk Cooltech Pvt Ltd ................... 37

T: +91-79-25830112


W: www.prasadgroup.com

Prayag Polytech Pvt Ltd ............................ 85

T: +91-011-47262000


W: www.prayagmb.com

Presto Stantest Pvt Ltd ............................. 89

T: 0129-4085000


W: www.prestogroup.com

R R Plast Extrusions Pvt Ltd .................... 16

T: +91-22-42461500

E: Email:[email protected]

W: www.rrplast.com

Rajoo Engineers Ltd ................................BC

T: +91-2827-252701


W: www.rajoo.com

Remica Platics Machinery Manufactur ..... 60

T: +91-79-25712741


W: www.remicaplastics.com

Rotomotive Powerdrives India Ltd. ........... 33

T: +91-2692-230430


W: www.rotomotive.com

Sacmi Engineering India Pvt Ltd .............105

T: +91-7600003968


W: www.negribossi.com

Scj Plastics Ltd ......................................... 67

T: +91-011-25439950


W: www.scjindia.com

Shende Sales Corporation ........................115

T: +91-020-24488005


W: www.shendesales.com

Shini Plastics Technologies I Pvt L ..........103

T: +91-250-3021166


W: www.shini.com

Specific Engineering ................................ 95

T: +91-265-2646871


W: www.specificgroup.com

Sri Sai Plasto Tech ................................... 55

T: +91-44-42994365


W: www.srisaiplastotech.com

Steer Engineering Pvt Ltd ................... 26, 27

T: +91-80-23723309


W: www.steerworld.com

Steer Engineering Pvt Ltd ................... 42, 43

T: +91-80-23723309


W: www.steerworld.com

Supermac Machinery ................................ 53

T: +91-9998040433


W: www.supermacmachinery.com

Suresh Engineering Works ....................... 75

T: +91-731-2527872


W: www.sureshengg.com

Taiwan Association Of

Machinery Industry (Tami) ....................... 10

T: 886-2-2349-4666


W: www.tami.org

Toshiba Machine (India) Pvt Ltd. ............. 93

T: +91-011-43291111


W: www.toshiba-machine.co.jp

Unimark ( Maguire) .................................. 17

T: +91-22-25506712


W: www.unimark.in

Vacon Drives ..........................................111

T: +91-44-24490024


W: www.vacon.com

Windsor Machines Limited ...................... 97

T: +91-79-25841591


W: www.windsormachines.com

Witte Pumps & Technologies ...................... 50

T: +91-11-41613643


W: www.witte-pumps.de

Wittmann Battenfeld India Pvt Ltd ........FIC

T: +91-44-42077009


Xaloy Asia (Thailand)Ltd. .......................128

T: +91-79-40327380


W: www.xaloy.com

Zambello Riduttori Group ......................... 5

T: 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

Mod

ern

Pla

stics & P

olym

ers

July 2

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Reg No: MH/MR/WEST/234/2012-2014 RNI No: MAHENG / 2008 / 25265 Licence to Post at Mumbai Patrika Channel Sorting Office, 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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modern plastics & polymers - july 2012

Documents

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