“new developments business opportunities in …
TRANSCRIPT
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“NEW DEVELOPMENTS &
BUSINESS OPPORTUNITIESIN IN
ROTOMOULDING”
Product Application & Research CentreRIL & IPCL
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Contents
• Company profile-RIL/ IPCL
• PARC
• International Rotational Moulding Market Scenario
• Indian Rotational Moulding Industry• Indian Rotational Moulding Industry
• Salient Features of Rotomoulding Grades Polyolefins
From Reliance Industries Limited
• Innovative Products
• New Business Opportunities
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Corporate Profile Corporate Profile
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• Manufacture and market internationally competitive Polymers
• Strive to develop the service, technical expertise and creativity toaddress all our customers’ problems and concerns
• Commit to total Customer Satisfaction in terms of Quality & Services forall our products
Our Mission…….
• Ensure sustained Profitability and Growth in our business operations
• Build an organization in line with our continued commitment toexcellence and innovative efforts to stay as market leaders
• Continuously upgrade our product and delivery systems to provide theright product for every customer
Total Customer Satisfaction – a Reliance commitment…
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Reliance Group - BusinessesTextiles
PolyesterPlastics
PetroleumProducts
Oil & Gas
Infrastructure
NarodaPatalganga
Hazira
Materials and energy value chains and infrastructure
HaziraJamnagar
Bombay HighSuiting PSF LLDPE/HDPE LPG Crude Oil Power
Shirting PFY PP Gasoline Natural Gas Telecom
Furnishings POY PVC Naphtha Port
Pillows P. Chips MEG ATF Roads
Fabrics PTA Ethylene Kerosene OFC
PX Propylene Diesel
LAB VCM Petcoke
EO Sulphur
Ducts
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About RIL
• RIL : The fastest growing private sector company
• RIL : Amongst world’s top ten producers inpetrochemicals
• RIL : Gross turnover Rs. 75,518 crores(US$ 17,022 billion) (2003 - 04)
• RIL : First Indian company in Fortune Global 500 list
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Reliance’s Polymer Business
Capacity (KTA) Global Rank
PE 1000 14th
PP 1300 7thPP 1300 7th
Polyolefins 2300 10th
All Polymers 2820 10th
……… Largest PP producer in Asia….
Post IPCL acquisition
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Total Capacity FY2002: 4,200 kTA
500 PVC
GAIL
HPL16%
Others6%
RIL- IPCL – Largest Polymer Producer in India
1160
780 PE
PP
with plans for major expansions
RIL+IPCL
71%
GAIL7%
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About IPCL
• IPCL : Pioneer petrochemical company now managed by
RIL
• IPCL : Heralded the growth of petrochemical industry in
IndiaIndia
• IPCL : Total production of 1 million metric tons of
polymers, synthetic fibres and chemicals
• IPCL : Second largest petrochemicals company in India
in terms of sales, assets, net-worth and profits
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• RIL and IPCL rank amongst tenth largest polymer
producers in the world and caters to approximately
70% of Indian market
About RIL & IPCL
• In PP alone, it has a market share of 85%
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Reliance & IPCL -Manufacturing Facilities
India
Naroda - GujaratTextile manufacturing
Hazira - GujaratPetrochem & Polyester
Jamnagar - GujaratRefinery & Petrochem
IPCL - Baroda, GujaratPetrochem
Strategically located facilities in western India. I N D I A N O C E A N
ARABIANSEA
BAYOF
BENGAL
I N D I A N O C E A N
Patalganga-MahPolyester & Intermediates
Panna Mukta & TaptiOil & Gas
Petrochem & Polyester
IPCL - Gandhar, GujaratPetrochem
IPCL - Nagotahne, MahPetrochem
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IPCL : Polymer Manufacturing Facilities
• IPCL manufacturing locations at :
• Baroda - LDPE / PVC / PP
• Gandhar - PVC / HDPE• Gandhar - PVC / HDPE
• Nagothane - LLDPE / HDPE / MDPE
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PolymersFiber
IntermediatesChemicals
Fibers
Textiles
Reliance Group - Vertical Integration
Ducts
Oil & Gas E & P
Petroleum Refining
Olefins Aromatics
Fully integrated value chain from well head to fabrics.
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About PARC About PARC -- RILRIL
Total TechnologyTotal TechnologyTotal Technology
&
Business Solution Provider !
Total Technology
&
Business Solution Provider !
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PARC
Established in 1990 , this centre committed to deliver value
addition to polymer business by
� Providing technical service,
� Constant product up gradation and
� Market development
With the sole objective of total customer satisfaction
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• Between business enterprises and their vendors
• Converting basic needs into commercially viable
technology
• Helping produce useful products
WE believe in building strategic relationships
Research Institutions
Polymer Processors
End Users Machinery Manufacturers
PARC
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Bureau of Indian Standards -Representations
• Plastics Containers PCD 21
• Test Method on plastics Containers
PCD 21.1
• Crates for Veg. & Fruits PCD 21.P1
• Method of testing of Plastics PCD 23
• Cement & fertilisers TX 23
• Textile Materials Polyolefins TX23
• Polyethylene Pipes CED 50
Member of 18 committees
• Food Packaging PCD 12.12
• Thermoplastics PCD 12.3
• Moulded Luggage PCD 12 P2
• Recycling PCD 12.17
• Plasticizers PCD 12.10
• Multilayer Films PCD 12.16
• Polyethylene Pipes CED 50
• UPVC pipes CED 50
• PVC CED 50
• Irrigation and Farm Drainage FADC 54
• Sprinkler Irrigation FADC 35-P!
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PARC
• Doctorates
• Polymer Engineers
Biggest asset - People
• Polymer Engineers
• Industrial Designers
• Polymer Chemists
• Technicians
Total Manpower : 43
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Presentations
Houston
- SPO ‘97
Vancouver
ISO TC/61
London
- PVC ‘98
China
-PPS
Germany
- PE ‘97
Netherland
- PPS-15
Japan
- PPS-14
Antec 2001
Addcon
2003
PPS 20
- SPO ‘97
Singapore
- WCC
Delhi
Polymer’99
International conferences
National conferences
Presentations to OEMs
Customer Meet
Enviormental Meetings
Papers published - 75
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PARC Facilities
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ROTOMOULDING MARKETS
NORTH AMERICA MARKET:
�U.S. rotational mouldingmarket place is unique inso far as fully 20% of itsannual output consists of
O t h e r s
2 0 %T o y s
2 0 %
annual output consists oftoys(Little Tikes and Step 2)
�Agricultural and industrialtanks are the secondlargest market for NorthAmerica.
T a n k s
2 0 %
R e c r e a t i o n a l
P d t s
2 0 %
A u t o m o t i v e
2 0 %
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ROTOMOULDING MARKETS
EUROPEAN MARKET :
�European moulders areinvolved in design conceptsand products.
�The largest segment is the
Leisure Time
5%
Toys
6%
Others
11% Automobile
18%
�The largest segment is thefood and agriculture marketat 32%.
�In Europe, the rotationalmoulding industry makes theprocess fit the desireddesign.
�In North America, however,the trend is to make thedesign fit the process.
Material
Handling
10%
Food &
Agriculture
32%
Lawn &
Garden
10%
Highway
8%
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ROTOMOULDING MARKETS
SOUTH AFRICA MARKET :
� It is estimated that there are 40
companies involved in rotational
moulding. Tanks dominate the
market (56%), although a very
broad range of products are
Others
4%
Leisure
5%Mining
2%Industrial
7%
Material
Handling
8%
broad range of products are
manufactured.
�The need for building products
such as septic tanks has been a
big driving force.
�The mining industry and the
expanding automotive sector
has also created a demand for
higher performance of
rotomoulded products.
Construction
12%Tanks
56%
Automobile
6%
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ROTOMOULDING MARKETS
INDIAN MARKET :
� Over 150 rotomoulders
� Annual consumption about 35,000 MTA
� 85% fo the market is Water
Others
15%
� 85% fo the market is Water storage tanks
� Rotomoulders have initiated developments in various industries like Automotives, Diary, Material handling .
Water Tanks
85%
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� The process comprises of the following :
• Loading the resin in the mould
• Heating fusion of the resin
ROTATIONAL MOULDING PROCESS
• Heating fusion of the resin
• Cooling and unloading the mould
� Unlike other processes, no pressure is involved and
the plastic material is heated / melted and cooled in
the mould.
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• Flexibility.
• Moulds inexpensive. Less lead time.
• Moulds of quite different size and shapes may be run
simultaneously on the same equipment.
ADVANTAGES OF ROTATIONAL MOULDING
simultaneously on the same equipment.
• Articles with undercuts and intricate contours can be
produced
• No weldlines or sprue marks
• wall thickness uniformity
• Inserts can be easily incorporated
• surface textures such as wood grain, leather grain etc. can
be achieved with comparative ease
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ATTRIBUTES OF HOLLOW PARTS PROCESSES
Rotational Moulding Extrusion Blow
Moulding
Twin-Sheet
Thermo - forming
Shape complexity 10 8 7
Maximum size 10 5 8
Manimum size 10 9 7
Thickness uniformity 10 6 5
Moulded-in inserts 10 4 1Moulded-in inserts 10 4 1
Material choice 6 8 10
Material scrap factor 10 8 6
Material cost 8 10 6
Machine cost 10 7 9
Mould cost 10 7 9
Labour input 6 10 7
Production rate 7 10 8
10 = Best or most common, 5 = Worth considering, 0 = Normally not done
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PLASTICS IN ROTATIONAL MOULDING INDUSTRY
• Polyolefins (mainly PE) dominate the market
• Readily converted from
granules to the powder form
• Stability to withstand
long heating period
Others
5%
LLDPE
61%
LDPE
2%PVC
13%XLPE
8%
HDPE
11%
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• Liquid, fine powder or small pallet
• Optimal processing performance
• Proper stabilization
RESIN REQUIREMENTS
• Proper stabilization
• Good physical properties
• Impact
• ESCR
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EMERGING APPLICATIONS
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RECLAIR O35042
�Reclair ER-19 is a Octene Conomoer based medium
density Polyethylene grade designed for Rotational
Moulding applications with optimum loading of UV
Stabilizer
�Processing similar to Butene grades
�Excellent toughness and ESCR.
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OCTENE ADVANTAGES
TYPICAL PROPERTIES
Property Unit Test Method ValueProperty Unit Test Method Value
Butene Octene
Tensile Strength at Yield M Pa ASTM D368 14 15
Flexural Modulus M Pa ASTM D790 480 500
Izod Impact Strength J/m ASTM D256 144 650
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Indothene LL 36RA045
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Reclair O35042
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� automotive components,
� fuel tanks,
� underground tanks (septic tanks, manholes)
� insulated crates
APPLICATIONS ( O 35042)
� insulated crates
� pallets.
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WHY POLYPROPYLENE (PP) ?
In order to expand into new markets, the rotational moulding
industry needs materials offering good surface hardness and high
temperature stability.
• Excellent chemical resistance
• Autoclavable
• High heat distortion
• Better stiffness
• Better abrasion resistance.
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TYPES OF POLYPROPYLENE (PP)
•Three basic types of PP :
• HOMOPOLYMERS :• Fibres, carpet backing, caps etc.
• RANDOM COPOLYMERS :• RANDOM COPOLYMERS :• Clarity, house wares,• Clear / see through
applications
• IMPACT COMOPOLYMERS :• Automotive, bumpers,• Luggage
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POLYPROPYLENE (PP) AS A ROTATIONAL MOULDING RESIN
• Toughness is a very major
requirement for Rotomoulded
products.
• Due to inherently low stiffness of • Due to inherently low stiffness of
LLDPE, Polypropylene is considered.
• With the advent of high activity
catalyst technology, PP impact
copolymers exhibit an excellent
property balance of stiffness to
impact resistance.
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• Parts requiring autoclaving / sterilization
• Medical bio-technology
APPLICATIONS ( PP)
• High temperature applications
• Housings of appliances -
• Automotives, Furniture.
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VALUE ADDITION FROM RECLAIR LLDPE
• FR compounds for Rotational Applications
• Crosslinkable LLDPE for achanced performance
• Value addition -PE Foamed products
• Tailor-made compounds for niche markets
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FR compounds for Rotational Moulding
• Requirements-
-Antistatic properties
-V-0 rating, UL -94
• FR compounds for different
flammability ratings as per UL 94 .
• Applications: Defence, Packaging,
Dust-bins, Automotive.
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CROSSLINKABLE LLDPE
• Alters performance of base resin
- Increase Service temperature
- Improvement in ESCR- Improvement in ESCR
- Increase in Toughness.
• Applications: fuel tanks,
Chemical tanks
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CROSSLINKABLE LLDPE
� Crosslinked materials showed encouraging results
Property Unit Reclair R35042 Crosslinked R35042
Tensile Mpa 16 17Tensile Mpa 16 17
Elongation % 260 210
Flexural MPa 710 740
Mod.
Izod Impact J/m 60 240
ESCR hrs 50 >400
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PE- FOAMED PRODUCTS
• Reduce Weight -Strength ratio
• Improve Rigidity
• Thermal insulation
-Eliminate post-moulding-Eliminate post-moulding
-Better bonding ( Skin& core)
-Ease Recyclable
• Applications: Insulated
containers,Automotive components
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PE- FOAMED PRODUCTS
• In-house trials have given
encouraging results
-Consistent & uniform cell
structurestructure
-Increase in rigidity
-Good insulation
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PE - FOAMED PRODUCTS0
• Development of insulation containers for fishery Industry
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TAILOR- MADE COMPOUNDS FOR NICHE MARKETS
• Development of compound for Automotivecompound to match Impact - Rigidity balance.
• Compound was designed as per the requirements ofthe End user.
• In-house trials were conducted to evaluate• In-house trials were conducted to evaluate
- Process ability
- Product properties
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UNDERGROUND ROTOMOULDED MANHOLE
Manhole Developed for RelianceTelecom junctions.
Total weight of the product is
100 Kgs, as compared to the
conventional Concretemanhole of 7 tons.
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TESTING OF THE MANHOLE STRUCTURE
• The manhole was installed underground and soil wascompacted around the structure.
• The pre-fabricated concrete frame and lid weighing1.2 tonnes was placed on the Manhole.
• Various vehicles were moved on this Manhole assembly, tosimulate actual loading conditions.simulate actual loading conditions.
• This test was carried out with different soilconditions.(Compacted, loosely packed, Dry / Wet.)
• The various Vehicles tried were :
» LMV(Car) 1.5 Tonnes
» HYDRA 4.0 Tonnes
» HMV(Truck) 10.0 Tonnes
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TESTING OF ROTOMOULDED (UNDERGROUND) MANHOLE.
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UNDERGROUND SHELTERS
Underground Shelter for
Defence from
Reclair LLDPE
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Visualisation On ID Software
ROTOMOULDED BUS STOP SHELTER AT JAMNAGAR
• For visualising the concepts, Industrial Design(ID) Software is used.
• ID Software are highly useful for developing new products since designing can be totally freeform based without any basis of dimensions
• Here, standard mannequins (life sized human dummies) are available to check/design ‘Ergonomics’ (Human factors viz.. Access, reach, comfort etc).
Left : the approved concept Right: Same shelter visualised for Cycle stands
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FEA - Finite Element Analysis
•Any creative concept should ultimately meet certain performance conditions
•Loads applied on the model for testing and modifying the design
ROTOMOULDED BUS STOP SHELTER AT JAMNAGAR
and modifying the design
Top left: Meshing, boundary conditions applied
Bottom : Test results are displayed as colored plots with values on scale
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Actual Product
ROTOMOULDED BUS STOP SHELTER AT JAMNAGAR
Reliance Industries Limited - PARC
won the Plasticon Award 2000 for the above
rotomoulded product
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POTENTIAL APPLICATIONS
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POTENTIAL APPLICATIONS: (AUTOMOTIVES/ APPLIANCES)
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POTENTIAL APPLICATIONS
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APPLICATIONS
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APPLICATIONS
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New Development Support from RIL
� Development of new grades.
� Technical assistance- Application development.
� Customer support- Testing and Processing .
� Coordinate with OEMs and nodal agencies for
approvals.