Modern Plastics & Polymers - August 2012

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7August 2012 | Modern Plastics & Polymers

oing by the buoyancy seen in the global moulded plastics market

over the recent months, it seems set on a resurgent mode! This holds

especially true when one considers the unparalleled thaw witnessed in

many important end-use application areas from 2008 through 2010.

According to a new market research report by Global Industry Analysts, the global

moulded plastics market (which provides for a wide array of user segments including

construction, automotive, packaging, electrical & electronic appliances and healthcare

products, to name a few) is projected to exceed 155 million tonne by 2017.

The report outlines some of the key demand drivers of this surge as economic

revival, rise in spending power, rapid industrialisation and strong demand from

end-use markets of packaging, construction and food & beverage. From a geographical

perspective, it expects long-term growth stemming from developing markets of Asia,

Eastern and Central Europe and the Middle East.

Not surprisingly, the Asia-Pacific region, backed by strong domestic

markets, would hold the largest share of the world market and is forecast

to rise at the highest Compounded Annual Growth Rate (CAGR)

of 4.6 per cent through 2017, as per the report on moulded plastics.

Standing at the threshold of this crucial milestone is Asia - primarily

driven by the burgeoning economies of India and China - which is

fast becoming the new centre of balance in the global moulded

plastics market. Further, plastics producers from Asia-Pacific

and the Middle East are gaining marketshare as the traditional

leaders in North America, Japan and Western Europe face

increasing pressure from the former in terms of production,

price and placement.

A deeper analysis reveals an emphasis on expanding

the production capabilities in the emerging markets of the

moulded plastic products, with a growing focus on the export

markets. Out of these, the Middle East is likely to garner nearly

half of the new capacity additions during the next five years, and

thus, emerge as the world’s leading supplier of polypropylene.

In brief, amid swift shifting of global production bases to

low-cost Asian countries, increase in foreign investments and rise

in the number of new manufacturing establishments, Asia-Pacific

is all set to ‘mould’ the growth story of the world in the medium-

to long-term period. The question is how much of these India

can leverage.

GAsia-Pacific: The emerging growth ‘moulder’

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

41August 2012 | Modern Plastics & Polymers 41February 2012 | Modern Plastics & Polymers

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

Automation Trends 80 Thermoforming robotic stackers: Key to efficient material handling

Energy Management 84 Hot runner systems: Investing in innovation, harvesting efficiency

Policies & Regulations 88 Import duty on titanium dioxide: Opening trade avenues for Indian industry

Strategy 92 Masterbatch processing units: Preserving quality, preventing contamination

Tips & Tricks 96 Plastic packaging: Steps to boost barrier performance

REGUL AR SECTIONSEditorial ................................. 7News, Views & Analysis ...... 20Technology & Innovation .... 29Technology Transfer ............. 34Projects ................................. 98

41

Tenders ............................... 102Event List........................... 104Book Review ...................... 106List of Products.................. 120List of Advertisers .............. 123

Cover photo courtesy: Novosystems GmbH

Masterbatches and additives .. 42

Quality matters ...................... 44

Plastic pigments ..................... 46

Interface: Chris Wall ............. 48

Roundtable ............................. 52

Special Focus57

Plastics in paints and coatings ................... 58

Powder coating technology .................... 60

Interface:

�Geert Hofman ................................ 64

�G D Barot ...................................... 66

Polymer compounding ........................... 70

BOPP packaging .................................... 74

Case Study ............................................. 78

In Conversation With 38 Raman Trikala

President and MD, Wacker Chemie India Pvt Ltd

Facility Visit 54 Blend Colours Pvt Ltd:

Blending quality with innovation

Insight & OutlookPaints & Coatings

Masterbatches & Additives

Details on pg no. 104

Special Focus: Blow Moulding Insight & Outlook: Plastics in Home Applications

Highlights of Next Edition

80 84


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NEWS, VIEWS & ANALYSIS

20 Modern Plastics & Polymers | August 2012

PolyOne Corporation to expand via ColorMatrix in AfricaColorMatrix, a subsidiary of PolyOne

Corporation and a leading innovator of liquid

colour and additives for plastics, plans to open

a new facility in Africa. The new facility will

be located in the Montague Gardens industrial

precinct in Cape Town, South Africa, and is

expected to open in August 2012. Services

will include sales, technical support and an

on-site colour laboratory for rapid colour

development. The immediate focus of the

operation will be to deepen support for

customers who manufacture products such as

polyethylene terephthalate containers for the

beverage and personal care markets.

“When PolyOne acquired ColorMatrix

last year, we committed to a global ‘invest

to grow’ strategy to add value to our

customers and shareholders. Our new facility

in South Africa illustrates our commitment

to this strategy. While these operations will

initially focus on ColorMatrix products and

services, it affords us an excellent foothold to

leverage other PolyOne businesses and services

in the region in the future,” said Robert M

Patterson, Executive Vice President & Chief

Operating Officer, PolyOne Corporation.

Evolving standards for plastics in food packaging Food Safety and Standards Authority of

India (FSSAI) is working on a mechanism

to evolve standards for plastics used in

packaging domestically

consumed food items

imported f rom abroad.

Dr K Chandramouli,

Chairperson, FSSAI,

said, “Our food exporters

adhere to various stringent

set of rules and regulations

for exporting food, while

we do not stress on similar

stringency on imported food packaging.

Thus, it is imperative to evolve standards for

domestically consumed food, since we have

been having a lackadaisical approach towards

setting standards.”

The FSSAI has issued guidelines for

plastic packaging companies to ensure

higher barrier properties for food items to be

transported over long distances.

R Mathurbootham, Advisor,

Regulatory Affairs, ITC Ltd,

said, “Food packaging safety is

as important for exporters as it is

for importers. We must use the

right labeling technology in food

packaging to prevent piracy and

fraudulence. Plastics used in food

packaging has a wider scope than

metals for safety prerogatives in the form of

labels and bar coding.”

Anwesh Koley

Implementation of on-line particle size analysis

A new white paper from

Malvern Instruments

examines the different

strategies open to those

adopting on-line particle

size analysis, providing

guidance on its design

and implementat ion

and highlighting the

economic & practical

benefits of selecting a

suitable approach to

the project. The proven

ability of on-line particle

size analysis to transform

process control and deliver

substantial economic

benefits has resulted in

its widespread application

across industries.

Typically, the installation

of on-line particle size

analysis involves a number

of steps, including

hardware se lect ion,

process interface design,

automation and integration

within an existing control

platform, validation and

commissioning & control

optimisation. Taking

each project element

in turn, this document

looks at when each might

be handled internally and,

more importantly, where

external support can

be useful.

Americhem applauded for its photochromatic ‘blushing bottle’ technology Americhem Inc, a global provider of custom

colour and additive solutions for polymeric

products, received an honourable mention from

New York-based global materials consultancy

Material ConneXion for its photochromatic

‘blushing bottle’ technology. As one of the

nine companies selected for the third annual

award, the Medium Award for Material of

the Year recognises materials entered into the

library within the last year. This demonstrates

technological innovation and the ability to

positively impact and advance design, industry,

society & the economy.

In 2011, Americhem was selected to

showcase its photochromatic ‘blushing bottle’

technology at Material ConneXion. The

bottle is designed to change colours, or blush,

when exposed to Ultraviolet (UV ) light.

Chosen for the display, a Boston round bottle

changes colours in direct sunlight via a thin

outer layer made of thermoplastic elastomer

that incorporates a UV-sensitive pigment.

Bill Podojil, General Manager - Plastics,

Americhem Inc, said, “We are honoured

to be recognised for this photochromatic

technology. We are dedicated to providing

our customers with technical innovation, and

this award is an example of Americhem’s

innovation in action.”

A m e r i c h e m’s p h o t o c h r o m a t i c

masterbatches can be used on portions

of a package or on the entire package.

Additionally, the technology enables

customers to customise the colours of

each bottle before and after exposure to

UV light.

Anwesh Koley

Dr K Chandramouli



Plastic packaging market to reach $ 28 million by 2014 Considering the growing demand for plastic

packaging, the market is expected to reach $

28 million by 2014. In a conference organised

by Indian Plastics Institute, Ahmedabad,

Pramthesh Pandya, Head-Unit & Business

Development, Parikh Packaging Pvt Ltd,

stated, “The demand for plastic packaging

has increased recently as customers are

shifting from rigid to flexible packaging.

This is because plastics is more cost effective

than conventional materials like glass, metal,

etc and can be easily processed. Also, due to

opening up of lot of untapped areas in food

packaging segment, the demand for plastic

packaging is increasing. The growth in the

pharmaceutical packaging segment has

also given a boost to the plastic packaging

industry.

On the ban on plastics for tobacco

packaging, he said, “This step is taken

by the government to indirectly ban the

usage of tobacco and will not affect the

plastic packaging industry.” He believes

that there is huge potential for plastic

packaging in India, and one should not

say no to plastic packaging, instead find

better solutions to save the environment.

Avani Jain

UNP Polyvalves inaugurates its new plantTo meet the growing demand

of corrosion-free valves, pipes

and pipe fittings manufactured

with advanced engineering

plastics, ie, fluoropolymers &

thermoplastic, UNP Polyvalves

has set up another manufacturing

facility in the Makarpura

Gujarat Industrial Development

Corporation (GIDC), Vadodara,

Gujarat. Urmil Shah, Director,

UNP Polyvalves (India) Pvt

Ltd, said, “We already have two

plants in Makarpura GIDC,

and this is the third plant of

the company. With this, we

aim to increase our production

capacity by 35 per cent. The total

constructed area is about 14,000

sq ft. Considering the space

constraints, the manufacturing

facility will be divided into three

floors, ie, ground plus two floors.”

He added, “The demand for

these types of valves is majorly in

the chemical and petrochemical

segment, as these are mainly

used for corrosive applications

in industries.” The company

has been providing solutions to

almost every leading chemical

and petrochemical giant in India

and is also exporting to other

countries. It has a wide product

range in valves comprising ball,

diaphragm, butterfly, ball check,

foot, sight glass, sampling,

strainers, lined valves, pipes &

fittings, etc.

Avani Jain

BASF unveils Sustainability Report 2011 at panel discussion on Sustainability & Corporate Reporting

For discussions on key issues, challenges

and benefits of sustainability & corporate

reporting and share best practices in

reporting, BASF India conducted a

panel discussion in association with The

Energy and Resources Institute’s Business

Council for Sustainable Development

(TERI BCSD). Prasad Chandran,

Chairman-BASF Companies in India &

Head-Asia, said, “Attracting new investments

in the private sector dependents on

conformance to environmental, social

and governance factors. In this context,

sustainability reporting responds to the

pressing need for improvements in corporate

transparency and helps restore trust in the

private sector.”

At the forum, BASF also published its 2011

sustainability report based on its performance in

three dimensions of sustainability – economic,

environmental and societal. In its third year of

publication, the BASF India Report documents

business highlights, sales and employee figures,

environmental data, social & educational

initiatives undertaken and awards & recognition

achieved in 2011.

Energy-saving recycling solutions

Sikoplast – German plastics recycling

company – has introduced its ‘In-Line

Recycling process, which aims to

achieve material and energy savings

in the plastics processing industry.

An essential element in the Sikoplast

recycling extruder, and a major factor

in its success, is the design of the

conical feed zone in combination with a

single screw.

In standard off-line recycling

extruders, the complete recycling

machine is autarkic, with any

plastic scrap input and an output of

re-granulates. With this extruder,

any grinding process can be saved

and combined with dust elimination.

It offers low investment costs compared

to any off-line execution and up to

50 per cent energy saving. From the

operation point of view, the scrap

portion increases due to no dust and

melting process occurs without oxygen

contact. The arrangement reduces

space requirement and makes any

retrofitting of existing lines possible. It

is also possible to make short switches

over time between various products,

as it directly feeds the melt into the

production extruder.

(L–R): Santhosh Jayaram, Det Norske Veritas AS; Prasad Chandran; Bhaskar Chatterjee, Director General &

CEO, Indian Institute of Corporate Affairs; Annapurna Vancheswaran, Director-Sustainable Development Outreach, TERI; and P D Jose, Associate Professor-

Corporate Strategy & Policy, IIM-Bangalore



Indian SMEs to participate in Canton Fair in China

Despite the sluggish global economy, the vibrant growth opportunities in emerging markets of India and China will be showcased at the Canton Fair – a biannual event – held in Guangzhou,

and is the largest and most comprehensive trade fair in China. It has the broadest distribution of overseas buyers and records an encouraging business turnover from the global industry despite the Euro debt crisis. The previous hosting of Canton Fair in April 2012 attracted over 200,000 buyers and achieved a staggering business turnover of $ 37.9 billion. India’s presence at the fair has been steadily growing with about 9,000 buyers out of a total of 220,000 in the previous edition, which is expected to significantly increase this year. Boosted by China’s promise to open its markets further to foreign goods, and encouraged by the purchasing zeal of Chinese consumers, Indian companies are excited for the prospects of the market. A recently held press conference to introduce the event to the Indian industry was attended by dignitaries and eminent personalities from the corporate world and trade associations,

including Vijay Kalantri, President, All India Association of Industries (AIAI), and Ashish Pednekar, President, Maharashtra Chamber of Commerce, Industry & Agriculture (MACCIA), to name a few.

The 112th edition of the Canton Fair will commence in three phases of five days each – Phase 1 (October 15-19, 2012), Phase 2 (October 23-27, 2012) and Phase 3 (October 31, 2012-November 4, 2012). It will be co-hosted by the Ministry of Commerce, China, and People’s Government of Guangdong Province, and organised by China Foreign Trade Centre. Niu Qingbao, Consul General, Embassy of People’s Republic of China, Mumbai, said, “With the establishment of China-India strategic and cooperative partnership for peace and prosperity, recent years have seen a frequent exchange of high-level friendly visits, resulting in business partnerships.”

Annabel Dsouza

Co-rotating twin-screw extruder by HPMC Hindustan Plastic & Machine Corporation (HPMC) has introduced its co-rotating twin-screw extruder in India. These extruders, mainly used in plastics and polymer applications, have penetrated several different niche markets. Some of their applications are direct compounding, producing masterbatches, plastic alloys, polyvinyl chloride soft cable grade compounding, in-line compounding, natural and wood fibre composites and recycling using side feeder of the co-rotating twin-screw extruder. Calcium carbonate can be filled in the extruder upto 80 per cent and glass fibres can be filled up to 60 per cent without compromising on the quality of end product. This feature reduces the cost of raw material significantly.

In the plastics recycling industry, the use of co-rotating extruders is becoming more of a preferred solution as

compared to traditional technologies (eg, single-screw extruders) in encountering most of the challenges faced by plastics processors. Poonam Kalra, Director, HPMC, said, “These specially designed extruders use a particular degassing and filtering system for treatment of demanding scrap materials that are treated to obtain quality materials ready for new applications. It is a highly efficient machine, as it reduces the cost of production considerably. It has independently controlled vacuum unit, haul-off and cutting unit for each pipe, enabling smooth production of four pipes of different sizes & weight simultaneously.”

Anwesh Koley

Technical Seminar on ‘Advancements in Flexible Packaging’ by IPI

To tap new trends in the flexible packaging segment,

Indian Plastics Institute (IPI)-Ahmedabad Chapter

organised a Technical Seminar on ‘Advancements

in Flexible Packaging’. Rajiv Vastupal, Chairman &

Managing Director, Rajiv Petrochemical Pvt Ltd, was the

Chief Guest for the event, while Rajiv Trivedi, Chairman,

IPI-Ahmedabad Chapter delivered the welcome address.

The speakers presented on various subjects such as

emerging trends/new applications in flexible packaging,

cost-effective blown-film technology, flexible packaging

processes and economy through automation by auxiliary

equipment in blown film. The participants included

students as well as industry associates. Atul H Kanuga,

Vice President, IPI-Mumbai Chapter, and Partner, Sudeep

Industries, said, “The demand for flexible packaging is

increasing and there is a lot of innovation in this field.

We wanted students as well as the industry to become

aware of these.”

Avani Jain

(L-R): Rupen Vikamsey, MD, Orbitz Corporate & Leisure Travels (I) Pvt Ltd; Deng Lizhou, Deputy

General Manager, Personnel Department, China Foreign Trade Centre; Sanjay Bhide, Convenor &

Secretary, Trans Asian Chamber of Commerce & Industry; Niu Qingbao; Suresh Sharma, Vice

President, ICECC; Chandrakant Salunkhe, President, SME Chamber of India; and Liu Guoyu,

Economic and Commercial Counselor, People’s Republic of China, Mumbai

(L-R): Atul H Kanuga; Subodh Goel, Regional Manager-Polymers Business (West Zone), Indian Oil Corporation Ltd; Rajiv Vastupal;

Rajiv Trivedi; Sunil Jain, President, Rajoo Engineers Ltd; Tushar Parikh, Vice Chairman-IPI Ahmedabad Chapter



Anti-microbial masterbatches from Alok Masterbatches Alok Masterbatches Ltd has developed AddNox Tm-Antimicrobial masterbatch that can inhibit microbial growth over plastics and will be effective against Fungi, Yeast, Algae and Bacteria. Applications for this additive include blow-moulded containers of food & pharma packaging, toothbrush handles, medical gloves and face masks, crates, water supply pipes & storage tanks, refrigerator gaskets and sanitary products. The addition level of the same will be 1-1.5 per cent. Such additives in plastics processing have become necessary, as the requirement of safe plastics is increasing.

Antimicrobial masterbatches will help in gaining the confidence of end user and

promote the use of plastics as they provide excellent antimicrobial performance, which has no adverse effects on physical properties and remain effective for the lifetime of the product. Amit Singh, Senior Manager (Business Development), Alok Masterbatches, said, “Such masterbatches protect plastics from microorganisms, eg, bacteria, algae, fungi, mould, etc. These can also be used to protect the polymer surface, such as from staining and degradation by microorganisms, and can be instrumental in providing hygienic & health benefits by controlling or decreasing the amount of microorganisms at the polymer surface.” Generally, end user applications include construction products, consumer/household goods & to medical/healthcare.

Anwesh Koley

Solutia, Sinorgchem and KKPC resolve patent disputeSolutia Inc, Jiangsu Sinorgchem

Technology Co Ltd and Korea

Kumho Petrochemical Co

Ltd (KKPC) have reached a

global settlement to resolve all

disputes among them involving

Solutia’s process patents to

produce 4-Aminodiphenylamine

(4-ADPA), a chemical

intermediate used to make rubber

anti-degradants. Under the terms

of the settlement, Solutia grants

Sinorgchem and KKPC licence

to manufacture 4-ADPA under

Solutia’s patents, which will

expire after 2019. As licensees,

Sinorgchem and KKPC are also

granted certain rights to enforce

those patents. Rich Altice,

President and General Manager,

Technical Specialties Division,

Solutia, said, “The settlement

of these long-standing disputes

is a milestone for Solutia and

its Santoflex anti-degradant

business. We remain committed

to using our innovative

chemistry to provide value to

our customers and shareholders,

as well as to protecting our

intellectual property rights.”

Stephen Choi, Chief

Executive Officer, Sinorgchem,

commented, “We are pleased

to resolve this issue is resolved

and put the dispute behind us.

As a leading rubber additives

producer, we will continue

to use technology to provide

our customers with greener

chemicals.” Further, Sung-

Kyu Lim, Senior Executive

Vice President, KKPC’s Sales

Division, said, “With a focus

on our core values of passion,

innovation, collaboration and

responsibility, we will continue

to take initiative in providing

world-class products & services

to our customers.”

Clariant offers India’s emerging markets sustainability support

Clariant urged India’s colourant and personal

care industries to improve their business

sustainability by considering current trends

and preparing for the future, at Federation of

Indian Chambers of Commerce’s (FICCI’s)

recently concluded ‘Specialty Chemicals

Conclave 2012’ in Mumbai. At the Conclave,

Dr Dileep Wakankar, Head of Product

Stewardship India – Clariant Chemicals

(India) Ltd, delivered a lecture on ‘Pigments

– Regulatory issues’. Besides indicating the

importance of colourants in everyday life,

Dr Wakankar covered the environmental

implications associated with selected

colourants, and gave global illustrations

of regulations affecting food contact &

packaging inks. He briefed the audience

about European, American and Chinese

regulations and outlined differentiation

with India’s current restrictions. “It is only

a matter of time until similar regulations

are enforced in India. To ensure sustained

business, India’s colourant industry needs

to prepare itself for compliance with such

regulations,” said Dr Wakankar.

Lionel Alva

Reifenhauser showcases new blown film lines Reifenhäuser Kiefel Extrusion recently

displayed the latest technology in blown film

extrusion at its state-of-the-art technology

centre in Troisdorf. About 140 visitors from

over 20 countries from DRUPA – the world’s

most important trade show for the printing,

paper and converting industries – attended

the world of complex plastic film technology

and were impressed by the flexibility of the

blown film lines from the new generation of

blown film technology.

Today, DRUPA is not only the leading

forum for the printing industry, but covers

all publishing technologies and processes

in a global context related to the flexible

packaging industry as well. The Düsseldorf

show attracted about 350,000 visitors, most

from the plastics and packaging industries.

The versatility of plastic materials has an

essential influence on packaging technologies,

and the advantages these offer are of great

importance not only for the visual appearance

of food packaging, for example, but are also

indicative of the quality of its content.

Dr Dileep M Wakankar

TECHNOLOGY & INNOVATION


Light-weight polymer alloy for automotive industry A new material combines an ultra-smooth

surface and exceptional dimensional

precision – Panlite AM-9937F, has been

unveiled by Teijin Chemicals – specifically

for automotive applications. This is a

light-weight polymer alloy, which is

a combination of the company’s own

polycarbonate Panlite and polyester resin.

Main features of the material include

flexibility in design, mouldability, high

resistance to corrosion, heat and impact,

and a low linear expansion coefficient.

Automobile manufacturers are provided

with an option to minimise the weight of

components by about 20 per cent with the

new material. Panlite AM-9937F has been

used in the LEXUS HS250h hybrid sedan’s

luggage door garnish.

New moulding machine for packagingKraussMaffei offers MX 650+ model to

meet the specific needs of the packaging

industry in terms of high cavitations

and heavy moulds. Injection rates up to

700 mm/sec are possible, and the machine

satisfies the demands for high flexibility

in mould variant management. The new

machine size extends the clamping force

rating spectrum of the MX Series below

the MX 850, so far the smallest machine.

Optional bracing of the centre platen

on the machine bed relieves pressure on

the tiebars and mould guides when stack

moulds are used. Multi-cavity moulds are

used primarily for screw closures and sealing

caps. Since short cycle times are demanded,

MX 650+ specifically complies with these

demands and offers high performance with

a compact installation area.

The new machine is characterised

by high plasticising capacity and energy

efficiency from the electric screw drive.

HPS-UN plastification, configured

especially for the polyolefins used in the

packaging industry, is said to produce

high specific melting capacities and a

uniformly high melt quality at low melting

temperatures. Thus, dynamic qualities

of the clamping unit are fully exploited

with the processor benefitting from short

cycle times, quality of moulded parts and

long-term production security.

New foam sheet die eliminates spider weld lines

Davis-Standard LLC has

introduced a spiderless foam

sheet die for processing

polystyrene and polyethylene.

The new die is capable of

producing an extensive range

of sheet thickness, width and

density. It is also engineered

to reduce downtime and

maintenance while offering

precision capabilities to

improve quality and efficiency.

The spiderless die eliminates

spider weld lines and provides

a uniform basis weight and

thickness over the entire width

of the sheet, thus eliminating

the need for edge trim. It also

has a unique mechanism to

adjust die-lip gap opening and

closing, enabling the operator

to make modifications during

production without stopping

the sheet line. This control is

enhanced by an external die-lip

concentricity adjustment.

Other features include

streamlined flow channels, upto

three zones of temperature

control, nickel plating on all

wetted surfaces and aluminium

constructed internal and external

air rings. Modular die-lip inserts

allow for easier, inexpensive

replacement of a damaged or

alternative lip die design. A die

lip fast gap allows for quick

cleaning of contaminants. The

company offers die designs

in thicknesses from 0.04 inch

to 0.5 inch, and widths from

24 inch to 120 inch.

Advanced pipe coiling & delivery system from PCT PCT has introduced a unique pipe coiling

and delivery system that provides the

ability to coil pipes PE100 up to DN250

x 250 m without vehicle escorts. PCT’s

well-established Low Ovality Coiling

Technology has been combined with their

newly developed,

unique multi-

trailer road train

design, which

enables pipe

manufac turer s

to de l i ve r

3 x 250 m coils

of DN250 in one

delivery.

The trailer

design also allows free-standing coils or

reels of pipe to be dispensed via the built-

in roller supports. This is only possible

with the use of Low Ovality Technology

coiling machinery that allows the pipe to

be coiled at these tighter bending ratios.

Smaller pipe sizes can also be coiled and

transported, eg, the three trailers would

carry over 1 km of DN180 in three

lengths with less than 5 per cent pipe

ovality occurring. Coils can be unloaded

on-site or alternatively, each trailer can be

dropped at points equal to the pipe coil

length ready

for an on-site

tow vehic le

to lie out.

Either way,

this provides

the ability to

string out and

only make

three butt

welds before

a string of pipe is ready for installation

as compared to having to make

20 times the number of welds if the

same pipe (DN250) is delivered in

12-m stick lengths.

TECHNOLOGY & INNOVATION


Clariant introduces soyabean oil-derived PVC lubricant Licocare SBW11 TP is a chemically

modified wax that offers technical

performance in PVC processing

superior to fatty acid esters or complex

ester mixtures traditionally used for

lubrication. It is suitable for processing

of rigid Polyvinyl Chloride (PVC)

compounds, especially for calcium/

zinc- and tin-stabilised photovoltaic

film & extrusion applications.

The lubricant has several

performance benefits, eg, better

release and anti-sticking property, no

mould deposits due to low volatility

and good compatibility with PVC,

excellent thermal stability ensuring

stable colour, etc. It produces balanced

rheological behaviour in material

and effective performance at low

dosage (0.3-1.0 parts per hundred).

It can also be used as a lubricant in

PVC injection moulding. Here, the

flowability is significantly improved

with less influence on the Vicat

softening temperature than that of

traditional lubricants.

Lybra LGR dosing unit from Piovan

Piovan has launched Lybra LGR – new

masterbatch metering unit for Polyethylene

Terephthalate (PET) applications,

configured for continuous weight-loss

Gravimetric (LG) or Volumetric (LV )

operation. Its distinguishing features are

high level of accuracy, advanced control

and simple user interface. The unit can

accommodate up to two independent

dosing stations, which can even be of

different capacities and be retrofitted

to meet changing production needs.

Each dosing station can be configured

for individual capacities ranging from

1 gm/sec, up to 170 kg/hr. Lybra is equipped

with a 7-inch touchscreen human-machine

interface and is connected to external

supervision systems.

Each dosing station comprises a hopper

containing the granules to be dosed and is

equipped with a proprietary loss-in-weight

control to measure the amount of material

carried by the dosing screw to the PET

mainstream. The dosing auger is available

in three different configurations with single,

dual or triple helical shaft, for controlling

material dosing in low percentages with

high accuracy and repeatability.

New Borealis polypropylene grade Borealis has launched a unique,

high stiffness Polypropylene (PP)

grade Bormod™ BH381MO to

support manufacturers of industrial

pails in meeting their increasing

sustainability and product quality

goals. New heterophasic copolymer

uses Borealis Nucleation Technology

(BNT) to achieve a one-of-a-kind

balance of excellent stiffness, flow

and impact. The PP grade has a

Melt Flow Rate (MFR) of 35, which

behaves like traditional MFR 45

grades. At the same time, its stiffness

level (tensile modulus) of 1,700 MPa

is more than 150 MPa higher than

that of standard MFR 30 grades, yet

with the same impact performance

of softer grades. The higher stiffness

performance is maintained in high-

temperature environments.

The combination of characteristics

allows for lower processing

temperatures and lower injection

pressure including the possibility

to fill more complex parts. It also

supports easier de-moulding. This

creates a spectrum of productivity

and associated environment-related

advantages for converters within a

one-material solution. These include

10-20 per cent reduction in cycle

time, with shorter cooling times,

possibilities of downgauging and

weight reduction, energy & cost

savings through low-temperature

processing and low injection pressures

as well as faster cycles, reduced

carbon footprint from less energy

consumption and good stacking &

drop performance for finished pails

of all sizes.

Monitoring PET quality in real-time in processingProcessing Technologies International has

launched a real-time Intrinsic Viscosity

(IV) monitoring system designed to

deliver better quality assurance and

potentially lower costs for polyethylene

terephthalate sheet production. The

system allows for material formulation

(recycled, virgin or post-consumer) to

be adjusted online in order to maximise

product performance.

The real-time monitoring system is an

invaluable process tool since it identifies

process deviations online so that they can

be corrected to maintain consistent and

efficient production. The IV monitoring

system works from precise measurements

of melt temperature and capillary piping

pressures. These results are benchmarked

against ASTM D4603-86 standard test

method for measuring IV. It claims an

accuracy of ±0.02 decalitre per gram. The

new system offers distinct advantages

over offline solution test methods since

these are time-consuming and slow to

deliver results.

MPP

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WITTE

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 from China offers polyester

production plant, polycondensation plant,

polymerisation line, hot melt adhesive plant

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

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

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

Areas of applicationPolymerisation and fibre lines

Forms of transferTechnology licensing and turnkey

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

Waste plastics conversion This company offers plant technology

for converting non-recyclable waste

plastics into industrial fuel, which is more

sustainable as compared to conventional

industrial fuels such as furnace

oil or light diesel oil. The company

supplies technology to serious

clients who would like to get their

waste plastics tested at a demo plant.

The plant can be custom made for

specific requirements. Municipal bodies,

industries involved in generation of

non-recyclable plastic scrap, plastic

scrap dealers who have access of non-

recyclable cheap plastic scrap and

entrepreneurs are encouraged.

Areas of applicationPlastics scrap recycling for inductrial

fule generation

Forms of transferConsultancy, joint venture, technology

licensing, turnkey

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�� !�"��#�%�'��(� ��)�*��+/5��;�<=�>//+?>>?�JOQ�V�X�Y=�>//+?>>?�JJZZ�V�[��<=��\� ��]��^�� 5��

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

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


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 f rom

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�_�{�_�j��̂��;��^��^�;�_`��<��!�)�zj;;*��^�}�� [_��_�� '�_��<�j��^�� `��z�_�{�_�)}�['j�z*��zj;;�~��< ��j+/��<��(�<`��>�>O��;�<=�>+?>ZQ�?Q��)(��_�*��>+?>ZQ�?Q>�)~�� *��X�Y=�>�+�/O��O/QJ��[��<=��`��]��5��=��5�\_��5��

X��^��_`��<��!��^^�� \<��<��5��_`��<��!J��5�� `�!��_��_�� <�5�;`��^��^�cost platform provided by APCTT for facilitating interaction between buyers and seekers of technologies across the globe. After submitting technology offer or request to this website, you are requested to wait for at least two weeks for receiving a response from a prospective buyer / seeker through this website, before contacting APCTT for further assistance.

Technology Requested

IN CONVERSATION WITH: Raman Tr ikala


…says Raman Trikala, President & Managing Director, Wacker Chemie India Pvt Ltd. With experience gained over two decades in the global specialty chemicals industry, Trikala shares his insights into innovations for the paints and coatings industry in India. In an exclusive conversation with Annabel Dsouza, he emphasises the need for green consciousness in the paints and coatings industry.

“Quality, innovations and expertise are key to long-term success”

IN CONVERSATION WITH: Raman Tr ikala

Raman Tr ikala


What are the growth trends in the paints and coatings industry in India?The Indian paints and coatings industry

is expected to grow strongly with

projected growth rates at double digits

in the next five years. Accordingly,

the demand for high-quality and

state-of-the-art chemicals is also

increasing. Chemical products for

advanced paint and coating applications

are a major growth driver in this industry.

Although these products are currently

just starting to raise their profile in

emerging economies and developing

countries such as India, in the long term,

the additional investment will pay off

due to quality and durability. After all,

quality, innovations and expertise are key

to long-term success – and India is no

exception.

What are the leading innovations in this industry today?The current trend is to develop reliable,

high-quality and high performance

solutions for increasing technological

demands of the future. The importance

of top-quality and cutting-edge base

materials is growing constantly – globally

and in India. While using local raw

materials, it is important to customise

products to local needs as well as the

regional climate. Attention is being

paid to compliance with global codes

of practice, as well as to sustainability,

user-f riendliness and materials’

environment compatibility &

energy-saving potential. Hence, the

industry’s Research and Development

(R&D) is increasingly focussing on

solutions that meet customer needs and

key social responsibilities.

How has been Wacker’s journey in India’s paints & coatings industry?Wacker is not new here. We have

been supplying chemical products to

India since the 1970s. With modest

beginnings, today, we have established a

strong foothold in the Indian paints &

coatings market. The reason is simple;

this sector is increasingly in need of

highly specialised and technologically

sophisticated chemical solutions, and

Wacker is capable of offering these.

We have added a lot of value to

the Indian community by bringing

in chemicals that are used as modern

additives in many applications. We are

also introducing new technologies such

as Vinyl Acetate-Ethylene Copolymers

(VAE). These polymeric binders

enable the formulation of high-quality

interior paints with low odour and

reduced emissions.

A big step was the establishment of

our Technical Center in Mumbai. With

our global network of technical facilities,

we actively participate in drafting and

realising new processing & quality

standards. This is important as industry

needs vary with culture, climate and the

available raw materials. But, given the

growth potential in India, this is just the

beginning. And we are confident that we

can continue to leverage the potential that

India offers.

What are the cost-quality pressures facing this industry in India?On one hand, top-quality and cutting-

edge materials are becoming increasingly

important for India, but demand for

advanced chemical products is influenced

by higher costs involved. Hence, there is

a trade-off here. The focus is now more

on efficiency, durability and quality of

materials. Still, costs always matter. And

here, our VAE products score – the high

price of crude oil and lack of supply

security following the switch from oil

to ethane by American crackers have

prompted many manufacturers to turn

from products based on styrene butadiene

or styrene acrylates to lower-priced VAE

dispersions. This trend will continue in

India as well.

How has this industry evolved towards sustainable manufacturing?Today, the paints and coatings industry is

attaching greater importance to products

& processes that significantly contribute

to sustainability issues such as reducing

emissions, energy efficiency or climate

protection. But this is more than just a

current trend. This is also the basis for

long-term business success.

For instance, environmental and

safety concerns related to interior paints

& indoor emissions are rising globally.

Hence, high-quality binders based on

VAE are gaining significance. Specific

VAE emulsions are manufactured

without using plasticisers, solvents,

formaldehyde donors or alkylphenol

ethoxylates. Adding to their reduced

environmental impact, VAE emulsions

can fulfill higher application and

performance demands. As a result, these

products pave the way for efficient, high-

quality, low-odour indoor paints, which

is the reason for their current success.

In future, paints and coatings products

not only need technological advances,

but must also address ecological and

sustainability issues to be successful in

the long run.

How do you see the future of paints & coatings in India? What is Wacker’s growth strategy for this market?India is a large and fast growing market.

That is why India is an integral part

of our global expansion strategy. We are

ready to seize these opportunities and

participate in future growth.

Our Mumbai Technical Center with

its training facility, the Wacker Academy,

plays a key role here – highly specialised,

technologically sophisticated chemicals

require profound technical expertise

for the correct use and application.

Altogether, our approach to India is

long-term and strategic.

What has been the most challenging phase of your career and what is your message to the industry?One of the constant challenges has

been to keep up the Wacker competitive

edge and create value in world markets.

I would urge the emerging industry

in India to look at the big picture

of global mega trends and seek

opportunities to create sustainable

value through innovative products and

business models.



SPECIAL FOCUS

Masterbatches & Additives

41February 2012 | Modern Plastics & Polymers

Masterbatches and additives:

Adding vibrance to the plastics growth story ........................................................................................ 42

Quality matters:

Capitalising on product differentiation .................................................................................................. 44

Plastic pigments:

Deciphering the colour dispersion code

Surinder Minocha, Managing Director, Minocha Enterprises Pvt Ltd ............................................. 46

Interface:

Chris Wall, Global Marketing Manager, Dow Corning ..................................................................... 48

Roundtable:

Does Indian masterbatch industry have the required economy-of-scale for the surging demand?....... 52



SPECIAL FOCUS: Masterbatches and addit ives

Loc

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ADDING VIBRANCE PLASTICS GROWTH STORY

to the

Plastics is considered as a

reliable material and preferred

due to its cost-effectiveness,

which makes it an ideal

substitute for many materials. There are

numerous applications of plastics and

its variants. Advancements in new areas

of applications have been more frequent

and consequential. Engineering and

processing technologies have become

more ingenious.

The use of masterbatches for plastic

colour processing, with safer, more

economical and better storage has

ensured better visibility and enhanced

brand appeal for plastics products. V

B Lall, Director, SCJ Plastics Ltd,

says, “In recent years, vendors have

been offering different colours for

the home environment, suitable for

different processing methods of the

masterbatch, allowing processors to

provide more advanced options. The

flexibility of plastics has made it the

leading material. We have also seen

various products such as mug, dustbins

and jugs in vibrant colours. Plastics can

be coloured and used for numerous

purposes and fabricated using many

equipment. Variety and functionality

can be achieved using plastics of

different colours.”

Composition and importanceMasterbatch gives colour to plastics. It

is a concentrated mixture of pigments

formed during the heat process with

a carrier resin. It is then cooled and

cut into a granular shape. Colour

masterbatches are easy to use. Mixing of

a suggested ratio of the batch can give

the desired result. Batches are mixed

according to process requirement of

plastics and the injection mould.

Masterbatches are of many types,

which result in the formation of different

varieties of products. White masterbatches

result in products that are white in colour,

while shine & gloss can be achieved using

chemicals. R K Aggarwal, Managing

Director, Prayag Polytech (Pvt) Ltd,

says, “Plastics with excellent dispersion

and heat resistance can be achieved by

using masterbatches. Injection moulding,

blow moulding, spin dyeing, casting

and foaming are the main uses of

white masterbatches. Products such as

household electronics, packing materials

and houseware are made using white

masterbatches.” Black masterbatches are

used in products that are black in colour.

In order into attain a high degree of

excellence in blackness some chemicals

are mixed to improve the quality. Black

masterbatch render properties such

as high dispersion, Ultraviolet (UV)

protection, blue tone, conductivity and

high loadings. Application areas of

black masterbatches include cast and

blown film, rotomoulding, fibres and

geo-membranes, etc.

Offering variety to plasticsThe substances used to enhance the

property of plastic products are called

filler masterbatches. Transparent filler,

nano filler and calcium carbonate

masterbatches are the three types of

filler masterbatches. The first two have

low effect but enhance the physical

properties of plastic products. Calcium

Plastic manufacturers today have become more competent in terms of production timing and efficiency owing to severe competition on the domestic and global front. Anwesh Koley tracks the latest developments in the masterbatch industry and its significance for plastics processing.

Masterbatches and addit ives


Courtesy: Americhem Inc

carbonate masterbatch is mixed to

maintain the character of the product.

Other masterbatches are used for

different purposes. Masterbatches are

like incentives that increase the quality

of the plastics. Manufacturers consider

the minutest details in the production

of masterbatches in order to meet the

expectations of consumers.

Quality constraintsWhile the variety of masterbatches

available in the market fits the bill for all

plastic colouring requirements, quality is a

major concern. The primary requirement

for the industry is availability of

high-grade polymers. The final plastic

product depends heavily on the quality

of raw materials available with the

manufacturers. “The industry faces an

acute problem of low-quality polymers.

The Indian quality is not at par with

global standards; hence, we have

to import from Europe, especially

Germany,” says Aggarwal. Dependence

on imported polymer has not changed

in the past years, with manufacturers

finding it difficult to look for domestic

options. The industry requires imports

of specific materials such as Polyvinyl

Chloride (PVC), which is in short supply.

The right pricePricing is an important factor

determining the growth of the

polymer industry and, in the long

run, determines the competence of a

country. “The prices of masterbatches

have seen an upward trend in the last

few years due to sharply rising raw

material prices and consolidation of

international raw material suppliers.

Sourcing quality raw material f rom

consistent and reliable suppliers will be

the key in coming years,” says Lall. New

masterbatch players, both domestic

and international, will need to keep

the selling prices competitive, thereby

presenting a challenging market scenario

and reduction in margins. The volume

growth should help sustain most players

but, as in most industries, efficiency and

innovation will be required.

If the present capacity remains

constant, there is a possibility of imports

as well, and this may result in higher

prices. Prices of masterbatches depend

not only on the polymer prices, but also

on the pigment prices, and these have

been increasing steadily. However, with

an increase in demand for masterbatches,

the probability of more manufacturers

jumping into the foray is high. This

will result in an equilibrium price where

the quantity demanded by consumers

(at current price) will equal the quantity

supplied by manufacturers.

The way forwardThe latest technology in plastics helps

in better detection of the material

according to specific requirements.

Some companies have their own

research and development facilities and

those that do not, generally outsource

research activities to achieve a more

customer-centric final output. The latest

technology used in the raw material

production machinery ensures that

more customisation can be achieved

along with higher rigidity.

The latest technology in polymer

processing needs to be supported

with infrastructure. Manufacturers are

willing to innovate and invest in quality

at par with international standards,

but without adequate power and land

availability, expansion plans cannot be

taken forward.


V B LallDirector, SCJ Plastics Ltd

The prices of masterbatches have seen an upward trend in the last few years due to sharply rising raw material prices and consolidation of international raw material suppliers. Sourcing quality raw material from consistent and reliable suppliers will be the key in coming years.

R K AggarwalManaging Director, Prayag Polytech (Pvt) Ltd

The industry faces an acute problem of low-quality polymers. The Indian quality is not at par with global standards; hence, we have to import from Europe, especially Germany.


SPECIAL FOCUS: Qual i ty matters

The polymer industry in India

is expected to see steady

growth in future. Per capita

consumption of polymers is

still low here as compared to developed

nations, which brings with it a latent

opportunity for the sector to grow.

Although crude oil prices have been

a cause of concern as imports tend to

become costly, India is set to become more

self-reliant and grow further to suffice its

domestic demand for polymers. This will

have a direct impact on the masterbatch

industry, as it aids the design versatility

offered by plastic products.

The plastics industry caters to

various sectors where colouring plays

an important role. Rajeev Bhatia, Chief

Executive Officer, Premier Pigments &

Chemicals, says, “Colour differentiates

one product from another. It sends a clear

message about the expected or intended

use of a product. Studies have proven

that a product’s colour and appearance

are key factors in consumers’ purchasing

decisions. This is precisely the role of

masterbatches. Thus, colour has become,

and will continue to be, a critical element

in successful marketing of a product.”

Industry imperativesThe primary requirement for the

industry is availability of high-grade

polymers. The final plastic product

depends heavily on the quality of raw

materials available with manufacturers.

The industry currently faces an acute

problem of availability of low-quality

polymers. The Indian quality is not

up to global standards; hence, Indian

companies have to import from Europe,

especially Germany.

On the quality f ront as well,

consistency is required. Shamik Shah,

Vice President–Sales & Marketing,

Monachem Additives Pvt Ltd, says,

“There is a need to offer customised

solutions based on the performance need

identified at the customer’s end. The

industry must come up with different

solutions for polymer stabilisation,

ultraviolet (UV ) stabilisation,

flame retardancy, improvement of

surface properties, increasing impact

properties, processing and lubrication,

anti-microbial performance, etc.”

Dependence on imported polymer has

not changed in the past years, with

manufacturers facing problems in

domestic options. The industry requires

imports for specific materials such as

PVC, which is in short supply.

Making the right choice An ideal masterbatch for a specific end

use is one whose Melt Flow Index (MFI)

matches as closely as possible with that

of base resin. This is easy with titanium

dioxide-based (white) masterbatches and

some additive masterbatches, but not as

simple with black masterbatch because of

the reinforcing nature described above. If

Of all choices available to processors today for colouring polymers, masterbatches or colour concentrates are overwhelmingly preferred. Masterbatches offer numerous benefits to processors such as competitive operating costs, maximum equipment utilisation and optimal process flexibility. Anwesh Koley scrutinises the colourful world of masterbatches and their advantages.

Capitalising on product differentiation



Qual i ty matters

the masterbatch is to be compounded

into the base polymer using high-shear

mixing equipment such as internal mixer

or twin-screw extruder, it is possible to

choose a fairly low MFI carrier resin and

still achieve excellent incorporation.

Polymer producers generally follow

this practice when making pipe or cable

compounds in order to not affect the

final performance properties of the

compound. “If poor distribution occurs

while simultaneously feeding masterbatch

and resin into an injection moulding or

extrusion process where the shear forces

are slightly lower, the processor can

adjust equipment operation conditions

such as increased back pressure, use of

turbine mixing heads or cavity transfer

mixers at the end of the extruder screw,”

says Bhatia. To maintain output rates, the

processor usually specifies a masterbatch

that is compatible with the base resin

and operating conditions.

MFI of a masterbatch is important

because it indicates the relative ease with

which a masterbatch can be distributed

during a compounding operation

or in injection moulding machines and

film extruders.

Additive masterbatchesBrand manufacturers, designers and

others who work on the colour strategy

should familiarise themselves with

the polymer, surface, wall strength

and manufacturing process. Another

important factor in the development of

a masterbatch is the use of additives to

achieve physical advantages in the end

product. The geometry of the finished

product, the rheological relationship and

the choice of polymer have a significant

influence on the selection of colouring

agent. “Global polymer companies

have advanced market research &

development teams, which work

towards offering innovative solutions to

customers. It is important to internally

conduct market research studies and

identify emerging trends in each industry

at the local, national and global scale,”

adds Shah.

Based on this research, companies

identify plastic additive solutions

through their global knowledge network

and work with key Indian partners by

sharing with them information about

innovative additive solutions and work

together to commercialise it.

Future opportunities The demand for plastics is witnessing

an upward trend around the world

and, with India presenting a wide

scope for expansion, the masterbatch

industry has reasons to cheer.

Applications for masterbatches will see

an increase in the automotive sector

with anti-scratch applications, thereby

making the final product lighter and

improve its impact resistance & soft

touch functions.

Even the agricultural sector

will benefit f rom better light

stabilisation requirements for agro-

films. Chlorine-resistant solutions

for polyethylene films will aid

inf rastructural needs. Improving

aesthetics in household appliances as

well as enhancing surface and mechanical

properties, replacing Bisphenol A-based

polycarbonate with polypropylene for

baby bottles, etc will ensure that the

common man gets more from regular

plastic products.


Rajeev Bhatiaj`��^�[Y�_��^{�_��Premier Pigments & Chemicals

Studies have long proven that a product’s colour and appearance are key factors in consumers’ purchasing decisions. Thus, colour has become, and will continue to be, a critical element in successful marketing of a product.

Shamik Shah��_��z�� '�<��Monachem Additives Pvt Ltd

Global polymer companies have advanced market research & development teams, which work towards offering innovative solutions to customers. It is important to internally conduct market research studies and identify emerging trends in each industry at the local, national and global scale.



SPECIAL FOCUS: P last ic p igments

Surinder Minocha

In a brilliantly coloured plastic object

under high magnification, the colour

observed is not continuous, but made

up of many tiny coloured dots, each dot

representing a pigment particle. Normally,

the eye sees the aggregate colour. The

problem encountered in using pigments is

that particles tend to clump together to form

specks or agglomerates.

Unfortunately, although a speck can

be made up of hundreds of individual

particles, it contributes no more to the

final colour than it does to one of the

ultimate particles. If the speck becomes

big enough to be seen with the naked eye,

it could result in a rejected piece. Thus,

to use pigments efficiently with maximum

value, perfect dispersion is a must.

Pigment dispersion The separation of pigment particles in

a plastic medium is called dispersion.

Achieving a perfect dispersion is the beauty

of colour on one hand and economy on

the other. The better dispersed a pigment

is, the less the amount needed to colour a

given job. Most colours are obtained from

more than one pigment.

All particles of each pigment must

be perfectly dispersed. If one pigment is

developed more efficiently than another,

the colour will be inappropriate. Perfect

dispersion is essential for masterbatches

due to the high colourant loading of

this method. This is because, in use,

the concentrate is diluted many times

and under varying conditions. Pigment

dispersion must be perfect, so that despite

dilution, the colours remain true and the

pigments do not agglomerate.

The differentiating factorThe pigment level is vastly increased, by

20-200 times. This multiple is a colour

concentrate. It is a reservoir of perfectly

dispersed colour-matched colourants. It

has multiple colouring powers. It readily

gives up its colouring power to colour a

much larger quantity of plastic material.

The requisite amount of natural material

is mixed with the concentrate. This is

put through a screw-based machine, and

the product is uniformly coloured and

matched. This allows the fabricator to

compound and colour products without

running an in-house colour laboratory.

Masterbatches can also be filled with

glass, talc, rubber, stabilisers, slip agents,

foaming agents, flame retardants, antistats,

etc. But the principle remains the same.

The concentrate manufacturer disperses

the desired component in vast excess. The

moulder or extruder acquires a reservoir

of the materials needed.

Dispersion and distributionDispersion refers to the process of

creating the concentrate. For example,

it is the green concentrate consisting

of a white, yellow and green pigment,

Pigments are highly coloured bodies available as minute particles. For colouring thermoplastics, pigments are dispersed in a plastic medium. Perfect dispersion of pigments is required to achieve the perfect colour. Here is how masterbatch processors can create aesthetically coloured plastics for product differentiation.

dispersion codethe colour


P last ic p igments

plus the matrix. The colour concentrate

producer must thoroughly mix these

pigments with the plastic base, and each

particle of colour must be completely

encapsulated in plastics. If dispersion

is incomplete, a defect may arise in

the finished part, resulting in a streak

of individual colourants (green, white

or yellow). Such defects are difficult

to correct at the process level, and the

concentrate should be returned to the

producer for correction. However, before

taking this action, one must determine

whether the specks or streaks are

inherent in the concentrate and are not

dirt specks or oil stains.

Distribution refers to the process

operation (moulder or extruder) in which

the concentrates and matrix material are

thoroughly mixed to form a uniform

colour. Failure to melt evenly and mix

completely will show up as a series

of light & dark areas in the finished

part. This is a common problem and

the solution lies in maximum use of

the screw. The basic principle is early

melting of the screw contents, thereby

utilising maximum length of the screw

for colour mixing.

Step one: The crucial step is

increasing heat in the feed zone. The

changes needed are not substantial, and

the heat should be raised gradually by

25-50°F. The objective is to bring the

temperature of the rear feed zone above

that of the rest of the machine. Because

only the feed zone temperature is raised,

it is possible to frequently decrease the

overall temperature of the machine.

Step two: Decrease the screw return

speed along the cooling portion of the

cycle as much as possible. Target screw

speed should be 40-60 rpm. These two

steps should solve the greatest portion of

distribution problems. One should also

consider the following:

The machine should have an

initial inspection to ensure proper

working of all areas

A heater may be defective

A thermocouple may be displaced,

giving erroneous readings

Usually, a minimum dwell time in a

machine is needed for the plastic material

and the concentrate to be plasticised and

mixed. Occasionally, following problems

may be encountered:

High cavity volume

The cycle is too short, and the time in

the cylinder is inadequate

In such extreme cases, it may be necessary

to transfer the mould to a larger machine

with greater plasticising capacity or

increase the cycle time. In some cases,

the concentrate producer can supply the

concentrate in a smaller pellet size, thus

improving the ratio of concentrate pellets

to plastic pellets. Close synergy between

masterbatch producer and processor

eliminates potential distribution problems

or identify them in the sampling stages in

order to take corrective action.

Surinder Minocha is

Managing Director of

Minocha Enterprises Pvt Ltd.


SPECIAL FOCUS: Inter face - Chr is Wal l

…asserts Chris Wall, Global Marketing Manager, Dow Corning, while emphasising the importance of masterbatches and additives in plastics applications. In an interaction with Lionel Alva, he focusses on how India is a major market for the plastics industry and is expected to record high growth figures.

“Additives may seem expensive, but they provide value for money”


What are the key market trends for the additives and masterbatches

market in India? Dow Corning sees India as

a key market, since India is

expected to witness maximum

growth in additives and

masterbatches at a double-

digit compounded annual

growth rate for the next

few years, driven mainly by

automotive and construction

industries. The per capita

consumption in India is one-

fifth or one-tenth of the global

average. One of the biggest segments in

India is agriculture.

What are the recent innovations in this sector?The plastics industry is currently witnessing an

unprecedented change. With the pressure on

natural resources as well as cost reduction, plastics

is seen as the most efficient solution to tackle

these global challenges. Plastics is gaining pace in

terms of sustainability, as compared to standard/

traditional materials. Its carbon footprint is the

lowest in most cases. In applications such as

green energy, eg, solar panels or wind turbines,

plastics offer ever-improving material properties.

Light-Emitting Diode (LED) is another example

where plastics enables weight saving, durability

and versatility. Plastics has revolutionised the

field of medicine, contributing to a reduction

in medical costs, infectious disease and pain

management.

How do additives and masterbatches help develop halogen-free plastics? What are their advantages?Halogen-free flame retardant solutions are in

demand today more than ever. The additives

commonly used today for flame retardance such

as halogens, phosphorous and nitrogen-based

compounds & hydrates – come at a cost, whether

it is mechanical, environmental or financial

performance. Designers must balance flame-

retardant properties, mechanical properties,

regulatory requirements and public perception for

various applications & markets. Many industry

players are looking for new ways to meet these

varied needs without making compromises. Dow

Corning’s plastics and composite additives can

help in optimising this balance by providing

better flame-retardant and smoke-suppression

performance, while maintaining or improving

mechanical properties.

How do additives and masterbatches contribute to a sustainable plastics industry?Without additives, plastics would not be as safe,

clean, tough and colourful as it is today. Additives

may seem expensive but they actually enable

reduction in production costs and make products

last longer, thus providing value for money.

They help the industry save money and preserve

the world’s raw material reserves. Additives

have the capability to turn basic polymers

into useful plastics.

What are the challenges for the additives and masterbatches industry in India? And, what is its future outlook?The priority for the plastics industry is to

work on its image to ensure that it is clearly

positioned as providing solutions to some of

the world’s biggest challenges. The second

challenge will be to make a smooth transition

from a highly fragmented compounding industry

towards a more consolidated structure. Despite

the challenges, this industry has a bright future

and is in a unique position to make our life

simpler, safer and more sustainable.


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SPECIAL FOCUS: Roundtable


Anik Patel Director, Add Plast

India has the capability to produce masterbatches that meet international standards of quality. At present, we do not have the required large-scale capacity due to lack of investment and several other factors. There are a few players who can do so, but they are few and far between. However, when it comes to quality, it is possible to acquire high-grade masterbatches at the local level. It is expected that in the next few years, there will be a sea change in the availability of additives and masterbatches for the domestic market.

There is an urgent need to attract investors, and the government can also help by creating a favourable atmosphere for investment. Masterbatches and additives constitute a fast growing market, and it is also important to keep pace with innovations; moreover, once economies-of-scale are achieved, it would be possible to tap into new areas of application that fits local needs.

While the plastics industry has grown by leaps and bounds in recent years, it is in a unique situation where demand outpaces supply and masterbatch manufacturers find it challenging to keep pace with market requirements. Lionel Alva assesses how various industry players are gearing up for such scale-related challenges.

Parag Parikh Director, Universal Colorant Company

There has been a surge in domestic

demand and tremendous opportunities

are available for domestic masterbatch

producers. While capacity exists with

some big organisations at the domestic

level, quality does not conform to

international standards, thus creating

barriers for domestic producers.

There is heavy reliance on imports

and with surging exchange rates in

recent years, there is a need to look at

viable options within the country. The

industry is making efforts to ramp

up production capacity and enhance

quality for renewed interest in

domestic production. Contamination

issues must be addressed before

production is ramped up. This is vital

for the plastics industry as a whole and

also for enhancing core production

competency with new avenues for

plastics being explored in several

unconventional areas of application

such as the construction industry.

The rise in raw material costs has also

deeply affected the competency of the

Indian masterbatch market.

Nitin Nemade Director, Tushar Polymers & Tradings

Several problems prevent the widespread facilitation of plants for managing large capacity production. Problems in infrastructure and power supply, lacklustre quality of Indian masterbatches and fluctuating prices across manufacturers make it difficult for the industry to remain competitive at the domestic level. Thermoforming, blow moulding and extrusion sectors are major consumers of masterbatches, and it is important that local masterbatch manufacturers focus on quality to acquire the confidence of major players in this segment. Currently, we do not have the economies-of-scale to cater to large manufacturers or fulfill demand in the local context. This is a necessary step to ensure commercial viability and healthy growth of the polymer industry. However, with an optimistic outlook, India is set for a paradigm shift in terms of possibilities in the local context since there is a visible cognisance among local masterbatch manufacturers to bring production on par with international standards.

While the Indian plastics industry is witnessing a surge in growth prospects, it is imperative that the capacity to develop raw material be created indigenously. This is because in the long run, a weaker rupee might significantly impact the plastics industry’s prospects,

especially in international trade.

Editorial take:

Does Indian masterbatch industry have the required economy-of-scale

for the surging demand?



The rapid strides taken by the

Indian plastics industry have

necessitated global standards

of quality and innovation.

Masterbatches are essential ingredients

for the plastics processing industry,

which is growing at a rate twice as much

as national Gross Domestic Product

(GDP). With progressive demographics

and increased consumption patterns,

plastics is making inroads into the

manufacturing sector to boost production

at competitive costs.

Imparting value Masterbatches are used to impart colour

and various special properties to products

manufactured from plastics. Although

the cost and volume of masterbatches

in the final plastic product is low, they

are an integral component of the final

compound and are important for attaining

the desired properties of the required

application. The masterbatch market

in India has been growing at a rate of

15 per cent in the last few years, driven

by demand from end-user segments, eg,

packaging, automotives, irrigation, etc.

Among key manufacturers of additives

and masterbatches in India, Blend

Colours Pvt Ltd has served the domestic

plastics industry with a wide variety of

products and services driven by a culture

of quality, commitment and consistency.

Incorporated as a member of the

erstwhile Shree Group of Companies in

1998-99, Blend Colours has emerged

as an important player in South India’s

plastics processing scenario. The company

began with an initial capacity of

300 Million Tonne Per Annum (MTPA)

and, today, it boasts of a total capacity of

14,000 MTPA spanning two

manufacturing facilities in the Kattedan

and Mankhal regions of Hyderabad. This

is symbolic of the strong growth synergy

between Blend Colours and the nation’s

plastics industry.

Manufacturing mightBlend Colours currently operates seven

compounding lines with automated

twin-screw extruders dedicated to black,

white and colour masterbatches. With

continuous focus on the industry’s

application requirements, the company

has evolved into a well recognised

manufacturer, supplier and exporter

of colour masterbatches and specialty

additives. Today, the company also boasts

of India’s highest installed capacity for

black masterbatches at 5,000 MTPA.

As ISO 9001:2000 certified processor

of masterbatches, Blend Colours

observes high standards of quality

assurance and authentication.

Sharad Rathi, Director, Blend

Colours Pvt Ltd, avers, “As part of our

continuous efforts to bring innovative

and sophisticated products to the market,

we consider Research and Development

(R&D) as an integral function to our

overall growth strategy. Developing new

products to meet the changing needs of

customer base is an ongoing mission and

our unmatched experience and application

know-how ensures that Blend Colours

remains at the forefront of product

development for this industry in India.”

Commitment to qualityThe experience and expertise of Blend

Colours in assuring some of the most

challenging customer requirements stem

The global plastics industry has conquered new heights of excellence through the power of performance additives and masterbatches. Bringing global innovations to Indian shores, Blend Colours Pvt Ltd has carved a niche for itself in terms of quality innovations and customer focus. Annabel Dsouza traces the company’s progress towards growth and excellence.

Blending quality with innovation

FACILIT Y VISIT: B lend Colours Pvt Ltd


from its commitment towards best-

in-class manufacturing practices and

stringent quality control processes. The

company ensures that it maintains its

products’ consistency in each supply. The

quality control procedures begin with

random testing of incoming raw materials

such as pigments, additives and minerals

to final output consisting of masterbatches.

The pigments and additives are selected

with utmost care keeping in mind

end-use performance and process

conditions to achieve the best results.

Rathi asserts, “Every product batch

is tested thoroughly on the parameters

of dispersion, Melt-Flow Index (MFI),

density, carbon/filler content, opacity,

whiteness, gloss, etc, as well as specific

tests like impact and tensile strength for

specific applications. We commit ourselves

to producing quality masterbatches

and compounds for all applications,

consistently and on time, bearing

in mind our customers’ benefit and

our brand equity.”

Focus on R&DProduct obsolescence is a common

feature in additives and masterbatches;

hence, product innovation is the master

key to future growth. Focus on R&D

has enabled Blend Colours to introduce

new solutions apart from manufacturing

more than 300 grades of masterbatches.

Higher consumption trends combined

with the need for constant innovation is

driving Blend Colours to develop more

sophisticated products for small-scale

plastics processors, thereby enhancing

market competitiveness. Beside its

expertise in colour matching, Blend

Colours draws on its long experience of

application knowledge to customise its

products and solve common processing

challenges. The company strives to achieve

global standards in all R&D projects, with

special focus on the following parameters:

Match standards with international

requirements

Make dispersion perfectly suitable for

end use application

Maintain batch-to-batch consistency

and quality

Prompt customer service for colour

matching

Rathi elaborates, “With significant

strides in the domestic market, we are

now focussing on the surging export

potential. We are among the top 10 largest

processors of additives and masterbatches

in the Indian industry. While commodity

products such as black, white and coloured

masterbatches have always been our key

strength, we are increasingly focussing on

specialty applications such as automotives

and non-woven fibres, etc to compete in

global markets.”

Expansion plansIn the near future, Blend Colours hopes

to introduce two new compounding lines

and expand existing capacities to 30,000

MTPA. Rathi concludes, “Although

economies of scale are critical to achieve

growth targets in an increasingly

competitive global plastics industry, we

would like to differentiate our strategy

by unflinching commitment to quality

and innovation. We are looking at global

machinery suppliers and technical partners

to gain a truly commercial edge in the

export market. We are among the most

cost-competitive players in the Indian

market, offering quality solutions at

costs that are 10-15 per cent lower

than the largest players in the country.

Although we want to take our cost

competence to the world market, we are

committed towards creating a culture

of quality and excellence in the global

plastics industry.” Photo: Suresh Vengapally


Sharad RathiDirector

�� the domestic market, we are now focussing on the surging export potential. We are looking at global machinery suppliers and technical partners to gain a truly commercial edge in the export market.

R&D in action

Focus on quality and consistencyCompounding process line

Blend Colours Pvt Ltd


Plastics in paints and coatings:Painting a sustainable future ......................................................................................................... 58

Powder coating technology:Engineering a smooth surface finish ............................................................................................ 60

Interface: Geert Hofman, General Manager, Performance Additives (Worldwide), Akzo Nobel ......64

G D Barot, Chairman and Managing Director, Gunjan Paints Ltd .................................. 66

Polymer compounding:Precision through innovationSatish Padmanabhan, Global CEO, STEER Engineering Pvt Ltd ................................................. 70

BOPP packaging:New-age material solutionAshish Kothavade, Senior Manager-Business Development, Plastiblends India Ltd ...........................74

Case Study:Virtual designing for enhanced productivityCourtesy: Autodesk Inc ..................................................................................................................... 78

Paints & Coatings

INSIGHT & OUTLOOK

INSIGHT & OUTLOOK: P last ics in paints and coat ings

Organic solvents are widely

used in the industry today

in a number of processes.

Typically, the metal

coating industry uses trichloroethylene,

xylene, Methyl Ethyl Ketone (MEK)

and white spirit, mainly in paints and

for cleaning & thinning processes.

These and other organic solvents

lead to emission of Volatile Organic

Compound (VOC) vapours. This is

primarily because VOCs create a low

level of air pollution and are a health

hazard, while affecting crops and

natural vegetation and also because

they contribute to global warming. At

present, the levels of these VOCs in

the atmosphere are a cause of much

concern, making it imperative to look

for eco-friendly and viable alternatives.

Solvent-based paint processes are known

to create air and water pollutants, and

water-borne coatings produce hazardous

waste. The air pollutants contribute to

photochemical smog.

Plastic resins in solvent-based paintsThere are two ways to reduce pollution

– by installing expensive equipment to

treat pollutants or by eliminating the

source of pollutants. The second method

is clearly more pragmatic. Equipment

installed merely to prevent the discharge

of pollutants to the environment

represents an extra expense, which

does not contribute to profitability at

all. Production processes that minimise

the production of pollutants at their

source are a more positive solution and

less expensive in the long run. However,

the paints and coatings industry

is looking for alternative, more

eco-friendly solutions to reduce or

eliminate VOC emissions from solvent-

based coatings.

Paint is of two types – acrylic latex,

often called latex paint, and oil-based

paint called alkyd paint. Acrylic latex

paint is essentially made from water and

an acrylic resin binder. Oil-based paint

most often uses a hydrocarbon-based

solvent as an alkyd resin. All paints

are composed of a solid (or binder)

and a vehicle. Acrylic latex paint uses

acrylic resin as the binder and water

as the vehicle. The binder in acrylic

latex paints binds various pigments and

water to form a film that covers the

paint surface. Binders are the major

components that provide the paint with

its application properties. Conventional

solvent-based paints consist of a surface-

coating material – generally a pigment

with a binder resin – dissolved in an

organic solvent. Typical conventional

paints contain 60-80 per cent solvent

(720-960 gm VOCs/litre of coating), ie,

20-40 per cent coating solids by weight.

During application and drying of

the paint, solvent evaporates from the

coating leaving a durable, pigmented

coating on the surface of the metal.

PAINTING a sustainable future High performance demands of industrial paints and coatings have increased the use of solvent-based paints, which have high Volatile Organic Compound (VOC) emission rates. Lionel Alva assesses how plastic resins have helped reduce VOC emissions of paints, while providing performance similar to solvent-based paints.


Courtesy: Wacker Chemie AG


Plast ics in paints and coat ings


The paint is dried either by drying in

ambient air or by stoving. Increasing

concerns about the impact of chemicals

on health and the environment are

being translated into strict legislation

that may have significant impact on the

use and disposal of plastics, particularly

those used in electrical and electronic

equipment. Original Equipment

Manufacturers (OEMs) and their

moulders & extruders must carefully

look at emerging legislations around the

world to ensure compliance.

Fortunately, innovative plastics are

currently available as alternatives to

companies that are facing regulatory

restrictions. The use of pigmented

resins instead of paint can reduce VOC

emissions and lower production costs,

while providing new design options.

Acrylic latex paint, often advertised

as 100 per cent acrylic latex, is a

water-based paint and is generally

considered as the highest quality.

Other resins used in latex paint include

styrene, epoxy and polyvinyl acetate.

Of the acrylic latex paints available,

vinylacrylic latex paints are the most

popular. The acrylic used as binder in

acrylic latex paint is a type of synthetic

polymer or plastics. A number of

synthetic polymers are used for various

applications. However, latex paints

use only one polymer – elastomer. As

the name implies, elastomers are quite

flexible – or elastic – and give acrylic

latex paints their dry flexibility.

Challenges facedThe long-term growth prospects of

the paints and coatings market in

India are healthy with the optimism

of the Gross Domestic Product (GDP)

growth bouncing back to the levels of

7-7.5 per cent, growing demand

in Tier-II and Tier-III markets

as well as the substantial middle-

class households with increasing

disposable income and willingness for

discretionary expenditure. India has one

of the lowest per capita consumption

of paint (less than a litre), indicating

a huge opportunity, as compared

to the per capita consumption to

20 litre in developed economies.

Renewed investment in infrastructure

and growth in industries such as auto, oil

& natural gas, marine and construction

will provide an impetus to the paint &

coatings industry.

“The increase in energy and

feedstock costs is the biggest challenge

and a potential hurdle to growth in this

industry. Paints and coatings are raw

material intensive, with raw material

accounting for 60 per cent of net sales.

High cost and erratic availability of raw

materials is a massive challenge. Most of

the raw materials are petroleum-based

and vulnerable to rise in crude prices.

This coupled with currency devaluation

of 13-14 per cent compared to last year,

is shrinking the margin, with companies

barely being able to pass on the increase

in cost to the customer,” avers M R

Shankar, Purchasing Manager, India &

South Asia, Akzo Nobel India Ltd.

Another external challenge

is the remote possibility of the

macro-economic situation of the

country not being corrected and the

GDP growth slippage not witnessing a

reversal in the short term as well as the

continuously diminishing demand.

Sustainable solutionsConsidering how the focus is increasing

on environment sustainability, plastic

resins allow for creation of high-quality

solvent-based paints, while reducing the

threat of high VOC emission rates. This

is indicative of the industrial paints &

coating industry viewing plastics as a

long-term solution towards creating

high-performance paints & coatings.

This means that the paints and coatings

industry in India is all set to witness

a paradigm shift, while furthering the

avenues of innovation with paints and

coatings. The use of plastic resins will

also enable reduction of costs, thus

creating a win-win situation for the

industry that has borne the repercussions

of creating products that would be a

hazard to the environment.


M R ShankarPurchasing Manager, India & South Asia, Akzo Nobel India Ltd

Most of the raw materials are petroleum-based and vulnerable to rise in crude prices. This coupled with currency devaluation of 13-14 per cent compared to last year, is shrinking the margin, with companies barely being able to pass on the increase in cost to the customer.



INSIGHT & OUTLOOK: Powder coat ing technology

Courtesy: Universal Colorant Company

Powder coating is a type of

coating that is applied as a

free-flowing, dry powder, and

is the latest surface finishing

technique commonly used today. Unlike

conventional liquid paint, powder coating

does not need a solvent to keep binder

and fillers together in liquid form. This

method was first used in 1967 in Australia.

It is the technique of applying dry paint

to a part. Technology advancements in

powder coating have spurred growth in

the industry. End-users are increasingly

using powder for reasons of economy,

ecology and high-end performance.

Coating advantages The reason for increased growth and

popularity of powder coating is that

it generates low Volatile Organic

Compounds (VOCs) and delivers high-

performance coatings. High performance

is fortified by the use of additives in

powder coating formulations. Additives

increase the service life of the coating by

reducing the effects of Ultraviolet (UV)

damage, providing better temperature

stability and improving corrosion

resistance. In addition, the usage of

engineering thermoplastics enhances

performance and sustainability.

Canon Patel, Managing Director,

Loxim Industries Ltd, notes, “Typically,

engineering plastics are chosen for

their broad range of enhanced physical

properties, ie, they are highly impact

resistant and polyamides are highly

resistant to abrasion. The key benefits of

engineering plastics are cost-effectiveness,

as they have a lower manufacturing

cost, corrosion/chemical resistant, light

weight (lower density), excellent surface

finish (no secondary operations required),

colourability (by addition of pigments/

dyes), aesthetic, paintable, flexible & soft.”

Other properties of engineering

plastics include high heat resistance,

mechanical strength, rigidity, chemical

stability and flame retardance. Patel

notes, “The mechanical properties

of engineering plastics, which enable

their wide usage in various industries,

particularly powder coating industry,

include specific strength and stiffness,

high impact, durability, surface finish

and high-heat performance (strength

& stiffness at elevated temperatures).”

The electrical properties include surface

and flame resistance.

Engineering thermoplastics in powder coating technologyThere are two common ways of applying

powder coating - electrostatic spray and

fluidised bed powder coating - the latter

is the original powder coating technique.

Fluidised bed powder coating is still the

primary technique used for application of

engineering thermoplastic powders. Several

other processes have been developed,

but they are used infrequently. These

include flame spraying, spraying with a

plasma gun, airless hot spray and coating

by electophoretic deposition. The most

common application for powder coatings

is for covering industrial metal parts to

protect them from corrosion and chemical

etching, thereby increasing durability.

There are two types of powder

coatings – engineering thermoplastics

and thermosetting polymers. Engineering

As the coating industry worldwide grows rapidly, companies are fast adopting new materials such as engineering plastics to enhance efficiency and appeal. Avani Jain discusses the benefits of using engineering plastics in powder coating technology for enhancing performance and sustainability.

ENGINEERING A SMOOTH SURFACE FINISHA SMOOTH SURFACE

Powder coat ing technology

thermoplastic powder coatings melt and

flow upon applying heat, but continue

to have the same chemical composition

after these cool and solidify. Engineering

thermoplastic powders exhibit excellent

chemical resistance, toughness and

flexibility. These are applied mainly by

the fluidised bed application technique,

in which heated parts are dipped into a

vat where the powders are fluidised by air

and used in many thick-film applications.

These are generally applied to a surface

that has been preheated to a temperature

significantly higher than the melting

point of the powder. As an engineering

thermoplastic powder material is applied

to the hot surface it will melt and fusion

bond to the surface and then flow out into

a strong, continuous film. Upon cooling,

the film develops its physical properties.

Dr Harindu Vyas, President (Technical

& Development), Signet Industries Ltd,

says, “The most important property of

engineering plastics that make them so

useful in powder coating technology

is that these can easily withstand

atmospheric changes and moisture. They

possess good lubrication properties. These

are the main reasons for their use in

coating of metal parts, eg, Teflon coating.”

He adds, “Engineering plastics are used

for various purposes including powder

coating of water turbines in order to avoid

siltation, which cuts the metal parts. Thus,

polymeric coating is done to avoid such

problems. This enhances the life of the

part that is powder coated, thus increasing

sustainability and performance.”

Types of engineering thermoplastics Nylon powder-coating materials are

the most commonly used engineering

thermoplastic powders. Acrylic powder is

also used where decorative requirements

and resistance to ultraviolet rays from

sunlight for a longer period of time is

critical. Many critical automotive trim

components are coated with acrylic powder.

Even urethane powder coatings feature

characteristics of excellent gloss retention

and long-term resistance to humidity and

corrosion in thin-film applications. Its

typical applications include agricultural

equipment, air conditioners, construction

equipment, electrical enclosures, garden

equipment, lawn furniture, light fixtures,

office furniture, recreational equipment,

under-hood automotive as well as wheels

& rims.

Future trendsIn India, a robust, long-term growth in

industrial coatings is expected, as emphasis

has increased on manufacturing of

high-tech products such as automobiles,

locomotives, passenger and military

aircrafts, consumer electronics and other

technology-driven products. This has

led to higher consumption of specialised

industrial coatings, including powder

coating technology in the country.

Further, the future of the powder

coating industry is bright also due to

the boom in construction segment.

With the resurgence in automotive and

consumer durable industries, the Indian

powder coating and paint industry is

heading towards an exciting phase of

growth and profitability. Therefore,

going forward, a better focus on supply

chain or distribution mechanism backed

by aggressive promotion will drive the

fortunes of the Indian powder coating

and paints industry like never before.

The growth in the powder coating

industry has directly impacted the

engineering plastics segment in the

country. The consumption growth of

engineering plastics on an average annual

basis is likely to reach 3 million tonne,

which is 18 per cent of the total demand

in 2013. Looking at the benefits offered

by engineering plastics in powder coating

technology, their demand is expected to

rise globally.

Email: avani.jain@infomedia18.

Canon PatelManaging Director, Loxim Industries Ltd

Dr Harindu VyasPresident (Technical & Development), Signet Industries Ltd

The mechanical properties of engineering plastics, which enable their usage in various industries, particularly powder coating industry, �� and stiffness, high impact, �� high-heat performance.

The most important property of engineering plastics that make them so useful in the powder coating technology is that these can easily withstand atmospheric changes and moisture. They possess good lubrication properties.


Courtesy: AkzoNobel


INSIGHT & OUTLOOK: Inter face - Geer t Hofman

What is the role of resins in the paints and coatings industry?Resins perform several essential

functions such as rheology modification,

setting, controlling, spraying and

splatter resistance; setting control

on vertical surfaces and leveling on

horizontal surfaces; water retention for

solvent-based paints, etc. Cellulose ether

is a cost-effective specialty additive used in

both interior and exterior architectural &

decorative coatings. Cellulose ether–based

products can thicken aqueous solutions and

control flow properties with economical

advantages. Other advantages are:

Excellent thickening and stabilising

agent, leading to in-can stability,

brushability, leveling & customer

appeal

Superior water retention, leading to

longer open-time, which has become

more critical with strict regulations

for Volatile Organic Compounds

(VOCs)

Excellent price performance

Easy dispersion and quick dissolution,

making paint processing fast & easy

Improved performance in spattering

behaviour, adhesion and colour float

resistance

What are the recent innovations in polymer technology for paints and coatings applications?One of the innovations is cellulose ether

technology, which possesses higher

tensile strength, better colour resistance,

pigments used improve paint finish.

Cellulose ether is made from natural

resources that are completely renewable.

It is manufactured by reaction of purified

cellulose with alkylating reagents under

heterogeneous conditions, usually in

the presence of a base, typically sodium

hydroxide, and an inert diluent. We have

modified these core properties, which

induce better tensile resistance. Thickness

of pigments used in cellulose ether must

strike the right balance.

What is the difference between water-based and solvent-based paints? Water-based paints emit low VOCs as

compared to solvent-based paints. Water-

based paints are used extensively for

both interior and exterior surfaces, while

solvent-based paints are used in general,

non-masonry type applications. Since

cellulose ether has strong water retention

properties, it is used predominantly in

water-based paints.

What technologies are used to produce cellulose ethers? Cellulose fibres are converted into a

valuable cellulose derivative, which is easily

marketable with additional properties.

Two most important technologies are

used to produce cellulose ethers: first is

reacting cellulose with monochloro acetic

acid, resulting in carboxy methyl cellulose.

Second is reacting cellulose with ethylene

oxide which is the leading technology for

producing cellulose ether. For the latter,

AkzoNobel has a substantial sustainability

edge over its competitors by using more

environmental friendly process.

What are your Research and Development (R&D) initiatives for this industry?Our R&D initiatives focus on

reducing the carbon footprint for our

customers. We not only work on paint

formulations, but also on improving the

quality of substrates on which paints

are applied, since poor plastering of

walls due to sub-optimum quality of

cement or gypsum, or seepage of water

through walls, negatively affects paint

performance.


…asserts Geert Hofman, General Manager, Performance Additives (Worldwide), AkzoNobel. Besides highlighting the technology advancements and consumer requirements of the paints & coatings industry in an interaction with Lionel Alva, he delineates some of the measures to make this industry even more sustainable.

“Our R&D initiatives focus on reducing carbon footprint”


INSIGHT & OUTLOOK: Inter face - G D Barot

How is the paints and coatings industry faring in India? The growth rate of paints and coatings

industry has been 10-12 per cent since

the last few years. This reduced to 7-8

per cent during the economic slowdown,

but the demand is still good with the

increasing awareness about this industry

and more people demanding decorative

paints for various purposes. The major

usage of decorative paints is in the

construction industry, as people today

paint their houses almost every year.

In case of industrial paints, there is

good demand because companies want

protection from rusting and corrosion.

Further, the moist climate in India and

high humidity level increases the demand

for paints, especially anti-corrosive

paints. The demand for industrial

paints in the automotive segments is

increasing by 10-12 per cent since last

two years. This trend is seen in Gujarat,

particularly as many foreign companies

in automotive segment are entering

the State owing to attractive schemes

offered by the Government, and this

has greatly enhanced the demand for

industrial paints.

With regard to the specialised

category in the segment, ie, powder

coating technology, the demand for paints

has increased due to various reasons. For

example, earlier, people used synthetic

enamels for painting metal parts, but

these had shorter life, ie, lasting for only

2-3 years as against powder coating,

which has longer life and remains the

same for 10-15 years. Despite remarkable

growth trends, the paints and coating

industry may see a slower growth rate

at present due to fall in the real estate

segment and slower industrial growth in

the times of economic uncertainty.

What are the recent market trends?Today, customers have become quality

conscious and even a slight variation in

shade is not acceptable to them. The

industry has also become technologically

advanced with multinationals coming

from China, Sweden, etc. Further,

the demand for low-temperature-

cured coating is increasing as it helps

in reducing energy needs. These days,

people are also moving towards quick

drying paints as against slow drying

paints since these yield good results.

Another trend is that people are buying

products from Small and Medium

Enterprises (SMEs) in this segment as

they find their products economical and

of good quality.

What are the R&D initiatives of your company?In the industrial paints segment, we

are going to launch floor coating with

longer life and inorganic zinc silicate

coating later this year. In the decorative

paints segment, we are coming up

with a luxurious paint that will be

named as ‘Beauty Queen.’ This product

will have an excellent surface finish,

smoothness and shine.

What are the challenges and opportunities faced by the industry?The major challenge before this industry

is fluctuating prices of raw materials.

The rise in crude oil prices is impacting

the refineries and they are forced to

increase their prices, which is impacting

this industry. Unfavourable government

policies in terms of high Value-Added

Tax (VAT) and Excise Duty are also

major concerns for the industry. The

Excise Duty is 12-15 per cent and VAT

is almost the same. The industry is forced

to pay both taxes and this creates cost

pressures. Further, there are no subsidies

or benefits provided to the small-scale

industries in this segment. That is a

huge challenge for SMEs. Also, there is

cut-throat competition in the segment,

not only because of the various local

players but also due to the entry of

multinationals in the country. At present,

the industry is also facing problem due

to market slowdown. But, despite the

challenges, the future of the industry is

bright as the consumption of paints and

coatings is increasing in India day by

day.

On the future outlook of the Indian paints and coating industry...The demand for decorative paints in

the construction segment will definitely

increase. With the growth of the

industries in Gujarat, the demand for

industrial paints will also increase

steadily.


…opines G D Barot, Chairman & Managing Director, Gunjan Paints Ltd. In a conversation with Avani Jain, he highlights the growth and demand for decorative and industrial paints in the country, as well as the recent trends & challenges faced by the industry.

“Future of this industry is bright as the consumption is increasing”

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TOSHIBA

INSIGHT & OUTLOOK: Polymer compounding


Satish Padmanabhan

Polymer compounding is an

environment-friendly process

due to the source of the raw

material that it uses to make

Polyvinyl Chloride (PVC) resin. Salt is

used to create the resin, and this involves

the process of compounding.

While designing central drying

stations, energy management is a priority.

For example, a heat exchanger is employed

in the regeneration process for its desiccant

beds. This ensures that energy from hot,

humid outgoing air can be recovered and

used to heat the incoming air. Closed-

loop cooling systems, used in the cooling

phase of regeneration, conserves energy

by preventing the absorption of moisture

before the bed switches over to drying.

Since PVC pipes last for decades,

they are used in one of the most common

applications of compounding and cost less

for recycling in the long run. Compounding

is used to create light-weight materials

that are easily transportable per truck load

than metal pipes. Thus, lesser fuel is used

in transportation of the material.

Latest innovations and technologiesThe gradual shift from kneaders to

co-rotating twin-screw extruders with

high output leads to a reduction in power

consumption without compromising

effective and efficient dispersion &

distribution of constituents that make

up the compound. The latest innovation

in the compounding machinery industry

is the control over the residence time

and its distribution. Throughput per

litre per hour has been increased from

100-150 kg per litre per hour to over

400 kg per litre per hour.

Features such as quick material change to reduce downtime, lowest possible usage of expensive raw materials through precision feeds and obtaining high-grade polymers in a single mass, make compounding the preferred choice for plastics processors. Thus, polymer compounding has emerged as an efficient processing technique for the plastics industry.

Precisionthrough

innovation

Courtesy: Certech ASBL


Currently, equipment such as

two-roll mills, Banbury mixers, continuous

mixers, kneaders and co-rotating

twin-screw extruders are used

in compounding. The individual

requirements are die face cutting,

underwater pelletisation and strand

pelletisation, Sioplast technology for

polyethylene power cables, conical and

parallel counter-rotating extrusion

systems for PVC dry blends into pipes

and profiles. The industry is moving

towards the use of automation to

overcome problems associated with

human resources and skills. Human

machine interface and integration of all

upstream and downstream equipment is

paving the way for improved productivity

and reduced wastage.

Evolution of compounding processCombining of a base plastics resin

with colours, modifiers, additive,

reinforcements, fillers or other polymers

is carried out in over 3,000 plants globally.

This is because 55 million metric tonne of

plastic materials, constituting roughly half

of the plastics consumed in the world, are

not used as base resin. The compounding

process is employed to convert raw

polymer or base resin to desired plastics

that is more effective, uniform and can be

used in varied applications.

The product made from such

a compound also has improved

characteristics such as better performance,

lower costs, ease of manufacturing and

more attractive appearance. Over 300

grades of Acrylonitrile-Butadiene-

Styrene (ABS) and more than 10,000

different grades of plastic materials are

manufactured using the compounding

process. Plasticisers, reinforcements,

flame retardants, colourants, carbon

black, impact modifiers, lubricants, heat

stabilisers, UV stabilisers, antioxidants,

organic peroxides, blowing agents,

antimicrobial agents, antistatic agents as

well as macro, micro and nano fillers are

some of the most common additives that

are compounded.

Other additives include clarifying

agents, cross-linking agents, coupling

agents, deodorants, fragrance, nucleating

agents, slip agents and vulcanising

agents. These are added separately or in

combination with one or several different

resin types forming products with

unique characteristics suited for myriad

applications. Further, these are added in

different stages of the process in the form

of liquids or solids, either separately or in

mixtures to achieve the required properties

in the final compound.

Compounding extrusion process mixes

one or more polymers with additives to

yield plastic compounds. The feeds may

be pellets, powder and/or liquids, but the

product is usually in pellet form, to be

used in other plastic-forming processes

such as extrusion and injection moulding.

Machine size varies from tiny

laboratory machines to the biggest

extruders in the industry, running as much

as 20 tonne per hour. Usually twin-screw

extruders are preferred because they give

better mixing at lower melt temperatures.

Most of these have screws and barrels

made up of smaller segments (mixing,

conveying, venting and additive feeding)

so that the design can be changed to meet

the production and product needs. Single-

screw extruders can also be used for

compounding, especially with appropriate

screw design and static mixers after the

screw. Selection of the components to be

mixed (eg, viscosities, additive carriers) is

as important as the equipment.

Globally, over 30,000 processing

units comprising single-screw extruders,

internal mixers or dispersive kneaders,

reciprocating single-screw extruder

(co-kneaders) and twin-screw extruders

are currently used for compounding.

Over the years, co-rotating twin-screw

extruders have played a dominant role in

compounding – used by resin suppliers,

proprietary and custom compounders

or end-users, thus making it the most

preferred processing equipment. This

dominance is due to some clear advantages

of co-rotating twin-screw extruders over

other process equipment.

Research initiativesBackward integration into critical

extruder parts and associated Research

and Development (R&D) in metallurgy

to withstand wear and corrosion is the

latest in terms of research witnessed by the

compounding industry. With its patented

elements, companies have paved the way

for most applications that were limited

by feed to be now limited by torque.

The R&D initiatives have led to narrow

residence time, resulting in the ability

to process sensitive materials. Processing

companies have addressed fatigue caused

due to high throughputs. Vacuum side

stuffer technology introduced in the

market has resulted in continuous

production without stoppages for

cleaning the blocked vents and preventing

wastage of material.

Industry challengesLack of academic study in developing

compounds based on low-cost fillers and

agro-based fibres as reinforcement is a

problem. Inadequate experience and lack

of facilities to develop composites for

strategic requirements, such as bullet-

proof vests and aerodynamic parts, result

in loss of man-hours and resources for

the industry. It is necessary to develop

the required facilities to support

technical requirements of compounding

without loss of productivity and energy

efficiency.

Satish Padmanabhan

is Global Chief Executive

Officer at STEER Engineering

Pvt Ltd. Email: satish@

steerworld.com

Advantages of co-rotating twin-screw extruders

�Narrow residence time distribution

�Lowest operating cost due to reduction of process steps

�Maximum process control due to continuous addition of material in various sequences without human intervention

�High levels of melting and mixing ability (dispersive, distributive and pure kneading)

Polymer compounding


Ashish Kothavade

About 30 years ago, Biaxially

Oriented Polypropylene

(BOPP) was introduced as

a supplement to cellophane,

but only recently this material has become

the most preferred material for functional

flexible packaging. The term biaxially

oriented means that the polypropylene

film is stretched in both the Machine

Direction (MD) and Cross Direction

(CD). Because of its superior strength at

low gauges, flatness, clarity and excellent

printability, BOPP has become the

material of choice for flexible packaging.

Processing practicesBOPP can be manufactured as heat-

sealable or non–heat-sealable material

and in both cases produced as white

opaque, pearl lustre or clear transparent

films. Certain additives improve its

properties related to slip, blocking,

modifying the heat-seal temperature

and anti-static requirements. The basic

BOPP manufacturing plant comprises

compounding, feeding, extrusion, casting,

orientation, gauging, winding, recycling,

corona treatment and profile control

systems. The main line plant is imported,

while auxiliary equipment and utilities are

indigenously obtained.

Packing in the advantagesToday, technological advancements have

created a practical and efficient outlook

among people, which also includes

their choice of product packaging. The

improvements in people’s economic

welfare have stimulated the demand for

more hygienic and aesthetic packaging

to attract consumers. Due to stiff

competition, packaging is no longer just

a supporting element in the distribution

of goods, but determines marketing

success, particularly for consumer goods.

Thus, there has been a shift in the role of

packaging. Plastic film, especially BOPP,

is becoming a popular alternative material

for the flexible packaging industry. BOPP

film is not only more cost-efficient than

other materials, such as cellophane film,

kraft paper and aluminium, but also

has greater resistance to pull and shock,

temperature changes and gas penetration.

BOPP film has an advantage in

terms of its physical appearance owing

to technological advancements in flexible

packaging and rotogravure printing.

Owing to its unique features, BOPP film

is the most popular plastic film for use

in flexible packaging as a substitute for

cellophane film. It is more attractive and

resistant to humidity. It is produced in

plain and special film forms. BOPP film

Besides supporting goods transportation and distribution, plastics packaging has become a significant factor determining marketing success, particularly in the consumer goods segment. With Biaxially Oriented Polypropylene (BOPP) being a preferred packaging material today, here are some interesting insights into the advantages as well as future prospects of BOPP film in the Indian packaging industry.

New-agematerial solution

INSIGHT & OUTLOOK: BOPP packaging


is used for packaging of various products,

including food products, cigarette and

adhesive tape. By function, six types of

BOPP film are available – plain, heat

sealable, white pearlescent, metallisable/

metalised and Polyvinylidene Chloride

(PVDC)-coated films. Currently,

the demand for BOPP film in food

packaging is growing due to the rapid

strides in the country’s food processing

industries such as instant noodles, snack

foods and biscuits. About 55 per cent

of the national BOPP film production

is used for packaging of food products.

The cigarette industry uses BOPP film

in significant quantities, accounting for

about 16 per cent of the national BOPP

film production.

Other industries contributing to the

growth of the BOPP film industry in

India include adhesive tape, album and

lamination. The strong demand for BOPP

film has encouraged investors to enter the

BOPP film industry, as indicated by the

existing investment plans in the industry.

Types of BOPPVarious grades of BOPP are available

today. Following are the characteristics

and application areas of these grades:

Transparent and opaque non–heat-

sealable film: This grade of film is

generally used in conjunction with wax-

coated paper. Non–heat-sealable films are

used for pressure-sensitive tapes, overlay

in print lamination, as release agents in

decorative laminates and, most importantly,

in lamination with other substrates selected

to add sealability and other characteristics.

The use of an opaque film further reduces

light penetration and protects the products

against Ultraviolet (UV) radiation.

Transparent, heat-sealable film:

This grade of film is mostly used to

pack snack products, either alone or as

a laminate with other films. This film

is manufactured in combination with

several materials such as Ethylene-

Propylene (EP) copolymers and broad

seal-range polymers. This grade of

BOPP is the most economical and

widely used film.

Opaque, heat-sealable film:

Generally, opaque films are white

pigmented to act as a light barrier. The

opacity of the film can be up to 80-90 per

cent, thus preventing the product from

rancidity, which is caused by exposure to

UV light. This grade of film is usually

used in packing of biscuits, wafers, cough

lozenges, etc.

Pear lised BOPP: Bes ide

opacity, this film provides a shiny,

eye-catching, pearly appeal. Its low

density enables the convertor to

pack more products per quantity of

film. Thus, the pearlised film is mainly

used to pack confectionery items.

Metalised, heat-sealable film:

Metallisation is the process of depositing

a thin layer of aluminium over the

film under vacuum. The deposition of

aluminium drastically improves the light,

moisture vapour and oxygen barrier of

metalised films. It eliminates the problem

of pin holes and poor flex resistance,

which often occur in bare aluminium

foil. An optical density of about 2.0 is

maintained so as to achieve better barrier

properties. This film is available either

alone or as a laminate with other films

and is commonly used for packaging

of cream biscuits, stuffed biscuits, pan

masala, supari, etc.

Features and applicationsBOPP film combines several good

qualities, which make it a versatile and

cost-effective packaging material.

Yield: BOPP has the lowest specific

gravity, and, for the same weight and

thickness, it yields more area than any

other packaging film.

Tensile strength: This is a crucial

parameter for certain applications, such

as pressure-sensitive tapes. BOPP film

has higher tensile strength than other

films, making it a unique combination of

strength and economy.

Moisture-absorbing capacity: BOPP

has the lowest absorption rate. This

makes it a superior packaging material in

providing protection to packed contents.

This property is also useful in applications

such as print laminations and tea chest

linings to pack water-sensitive products.

Moisture Vapour Transmission

Rate (MVTR): BOPP has low MVTR,

which enhances its ability to protect

packaged food products from moisture

accumulation, which increases the

shelf-life of the packed products. This

property of the BOPP film makes

it suitable for packaging biscuits,

snacks and confectionery.

Tear strength: BOPP by far has the

best tear strength as compared to all other

films. This property signifies the stress it

can handle before snapping. BOPP has

high tear initiation strength. Low tear

propagation of BOPP can also be used

as an advantage by providing notches to a

sealed pack to enable the customer to tear

open a pack with ease.

Strength in uniqueness Owing to its numerous unique features,

BOPP film is widely used in the

packaging industry and suitable for

both general packaging purposes and

operations such as printing, coating and

lamination.

Ashish Kothavade is

Senior Manager-Business

Development at Plastiblends

India Ltd. Email: ashish.

[email protected]

BOPP packaging

Marketshare of different types of BOPP

Transparent 75%

Metalised12%

White/opaque/matte13%

INSIGHT & OUTLOOK: Case Study


From its humble beginnings in

1994, Primera Plastics has grown

to become a top manufacturer

of precision-moulded plastic

products. Today, it operates 30 injection

moulding presses at its award-winning

facilities in Zeeland, Michigan, USA. The

company produces custom plastic parts

for a range of international customers,

including premier furniture manufacturers

and automotive Original Equipment

Manufacturers (OEMs).

For delivering competitively priced,

high-quality plastic parts quickly,

Primera Plastics relies on Autodesk®

Moldflow® software. The company uses

this software to produce more accurate

quotes for prospective customers and

optimises injection mould designs prior to

manufacturing. With Autodesk Moldflow,

Primera Plastics has been able to:

Estimate and optimise production

cycle times

Improve part quality and aesthetics

Deliver more customer quotes with

greater accuracy

Struggling with the challengeIn order to win business in Michigan’s

struggling economy, Primera Plastics

had to bid competitively and deliver

high-quality, aesthetically attractive

plastic parts in the shortest possible

time. The company bases its bids, largely

on projected production costs and

cycle times, which are difficult

to estimate accurately.

“Before Autodesk Moldflow, we

approximated cycle time on the

basis of part volume and our previous

experience. After bidding, we

were locked into a quote, so we

always estimated conservatively to

reduce our risk,” explains Scott

Leatherman, Project Engineer, Primera

Plastics Inc.

Also, since many of the parts

manufactured at Primera Plastics are

used in automotive interiors and office

furniture, high quality and aesthetics

are critical features. Leatherman says,

“A majority of plastic parts that we

produce must be pleasing in appearance.

If a part is manufactured to specifications

and is dimensionally correct, but

has an unintended visual defect,

we are in trouble.”

The winning solutionThe Autodesk Moldflow software has

helped Primera Plastics to perform

simulations for developing more accurate

quotes after receiving requests for

plastic parts. Engineers run a range of

simulations to study the flow of melted

plastics, evaluate various runner systems

and gate configurations, determine the

most efficient cooling systems and predict

volumetric shrinkage. With Autodesk

Moldflow, one can virtually explore a

range of issues before delivering a quote

and starting manufacture.

A big problem that can arise with

quoting is under- or overestimating

cycle times. “Underestimating cycle

times cuts profits, but overestimation

might not help get the business,”

opines Leatherman. With Autodesk

Moldflow, Primera Plastics can now

more accurately predict the time taken

for a plastic part to reach ejection

temperature and identify the time

taken for the part to warp. He adds,

“This software informs about the time

required to keep the part in the injection

mould. With more accurate predictions

of cycle times, we are more confident

in our quotes.”

Virtual designing for enhanced productivityIn this day and time, delivering high quality plastic parts in the shortest possible time, thereby optimising production costs, in a prerequisite to win business. Considering these aspects, Primera Plastics utilised the Autodesk Moldflow injection moulding simulation software to hone its competitive edge.

Design simulation for quality and cost competitiveness

Source: Primera Plastics Inc

Case Study


Precision in mouldsThe cost of creating injection moulds

often plays a major role in the total

cost of manufacturing a plastic part – in

some cases, up to 75 per cent. “If the

mould is not designed correctly, it can

create problems for the entire production

process. And if the estimated cost for

the mould is wrong, our profit margins

can be affected.” Thus, Primera Plastics

must effectively communicate the exact

tooling specifications necessary to

mould a particular part to the third-

party vendors that it uses to create its

moulds. “Considerable time and money

is wasted if we have to go back to our

tooling vendors after the mould is

produced. But with Autodesk Moldflow

simulations, our vendors can accurately

design the moulds as per specifications.

Before a mould is built, we are confident

that it will be optimised for our injection

moulding requirements.”

Predictability in resultsAutodesk Moldflow simulations help

Primera Plastics find and fix potential

defects such as short shots, air traps and

weld lines well before manufacturing

begins, thus helping the company speed

up production times & lower costs.

“With Autodesk Moldflow software, we

can pinpoint exact areas of concern,

eg, incorrect draft wall or variations

in part thickness. It helps us address

possible defects inexpensively during the

design phase, rather than later during

production,” explains Leatherman.

Effective customer communicationUsing the insight gained from Autodesk

Moldflow simulations, the company

can now communicate more effectively

with customers about optimising plastic

part designs and the injection moulding

process. Leatherman says, “Autodesk

Moldflow software helps us rise above

our competitors who do not conduct

similar validation before production.

We can inform our customers if we

find a specific area of concern and help

them optimise their products & reduce

their costs.”

Tool for triumph With Autodesk Moldflow software, Primera

Plastics can create more accurate and

competitive quotes, thus protecting and

expanding the company’s profit margins.

“Thanks to Autodesk Moldflow, we can

easily save production time and cost. We

can now study every aspect of the injection

modeling process before manufacturing.

Autodesk Moldflow is a valuable tool that

has helped us maximise our profits,”

concludes Leatherman.

Courtesy: Autodesk Inc

Design validation before production

Source: Primera Plastics Inc

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AUTOMATION TRENDS: Thermoforming robot ic stackers

In the food industry, the approach

towards material handling is a

key consideration since hygiene

and safety are essential facets

of the manufacturing process. This

becomes particularly difficult since

market trends depict an increasing

need for high volume production, with

a tendency towards a more automated

manufacturing setup. The degree of

planning for an automated process to

work effectively for a long time along

with high initial setup costs requires a

concerted effort.

However, when properly executed, it

can help in the creation of an exemplary

manufacturing process that is in tune

with demanding market conditions.

This calls for smart manufacturing

decisions where a keen cost-utility

analysis is necessary, thus requiring

that technology is not necessarily top

of the line or highly expensive, but

fulfills manufacturing criteria. Another

requirement for automation is the need

for highly skilled and dependable labour

that can understand a complicated

automated setup.

Labour and manufacturing cost reductionThermoforming machine automatic

robotic stackers can significantly lower

thermoforming labour and material

costs, thereby shortening changeover

times. A robotic stacker, designed for

use with thermoforming machines, is

mounted above the stacking station

with its main beam either in line with

the direction of the web, designated

L-type, or transverse to the web

direction, designated X-type. While

the L-type stacker transfers part stacks

to the end of the machine, the X-type

stacker places stacks of parts on a

conveyor belt running on the side and

parallel to the web. The robotic stacker

consists of a robotic arm and the kit

gripper using up to six-axis servos and

is placed in front of the thermoforming

machine. The robotic stackers, with

dual-gripper heads capable of handling

two part stacks simultaneously, are used

for fast-cycle thermoforming machines.

The robot gripper head of an automated

robotic stacker withdraws the part from

the mould and rotates from the vertical

to the horizontal plane to stack the

parts on a conveyor.

Using a robotic stacker, manpower

requirements are reduced and, in an ideal

situation, only one operator is needed to

remove the stacks of parts from the end

Increasing competition and a rising retail sector emphasise the use of automation in improving the economics of a process, particularly thermoforming. Lionel Alva outlines how thermoforming robotic stackers help augment the dynamics of a highly competitive industry, especially food processing where safety and precision are a prerequisite.


Key to efficient material handling

Illustration: Chaitanya Dinesh Surpur


Thermoforming robot ic stackers

of the machine compared. Furthermore,

operator health/safety is improved since

the usual operator twisting and turning

motion is eliminated, significantly

lowering the incidence of back injury

to the operator. Robotic stacking can

also improve material usage by up to

20 per cent. As each part is lifted

individually by the robot, using grippers

or vacuum pads, there is no need to

provide clear uninterrupted lines of space

between part rows. This allows individual

parts to be staggered and more closely

spaced than with mechanical stacking,

which makes for more efficient use of

the thermoform sheet. With mechanical

stacking, operators sometimes cannot

keep up with the machine output, which

can cause significant scrap rates to incur.

Robotic stacking can easily provide

anti-nesting to avoid stacking parts too

tightly together by rotating successive

parts through 90° or 180°, thus eliminating

expensive mould undercuts otherwise

required to provide for anti-nesting.

After thermoforming is complete,

the products are picked by the robotic

stacker and placed on the conveyor belt

or magazine as per the product shapes.

“The number of product on a stack can

be programmed as per requirement and

as soon as the preset count is reached,

the conveyor belt moves forward to

deliver the stack to the following

packaging unit or further processing

unit such as hole punching press, rim

rolling and bag making,” avers Hari

Gangi, Project Manager, Godrej Efacec

Automation & Robotics Ltd.

Stackers offer reliabilityThe stacker is built to withstand the

rigours of the modern, high-speed

thermoforming environment. The

product is stacked onto a primary

conveyor in a combination of A-B-C

rows, with the servo-controlled arm

decrementing the nest height with

each stack (eg, minus 5 mm at a

time.) Once the stack height count

is reached, product is fed onto an

accumulating conveyor. Depending on

stack height and machine speed/setup,

the accumulating conveyor will hold

typically 20-30 minutes of production.

As products are stripped, the stacker

tooling automatically matches the

machine transport speed and distance.

This helps when the formed product is

not 100 per cent cut and strips poorly.

Individually operated vacuum generators

allow for A, AB or ABC stacking (if

three are fitted.) One option is to add

a 90° rotation (cylinder) to this mount

head. Therefore, products that need

to be stacked across the sheet can be

accommodated. Tooling consists of an

inexpensive 6-mm laser cut aluminium

plate fitted with vacuum cups, air line

and fittings where the cups/fittings can

be continually reused on any number of

stack plates.

“Robotic stackers are important,

especially in the food industry where

hygiene is a prime consideration. The

machines are usually programmable,

lending them a great degree of

flexibility and high energy savings, and

are extremely efficient. Considering

the benefits they offer, robotic stackers

provide immense help in a cost-

competitive volume-driven environment

where there is little margin for error,”

avers Vijay Chauhan, Vice President,

Artek Enterprises Pvt Ltd.

Manufacturing automation Considering the demanding nature of

the market today, where cost, efficiency

and speed of production can make or

break an organisation. It is imperative

for medium- to large-scale industries

to incorporate automation within the

manufacturing process. Moreover, this

is ideal when an organisation is looking

to achieve economies-of-scale with a

high-volume and high-quality output.

This will allow organisations in India

to set a precedent and bring forth a new

level of efficiency and profit. It would

also reduce dependence on highly skilled

labour, reducing the slightly convoluted

nature of the manufacturing process

while making it far more approachable

and accessible.


Vijay ChauhanVice President, Artek Enterprises Pvt Ltd

Hari GangiProject Manager, Godrej Efacec Automation & Robotics Ltd

The machines are usually programmable, offering a � �� and high energy savings, �� offer, robotic stackers provide immense help in a cost competitive, volume-driven environment where there is little margin for error.

The number of products on a stack can be programmed as per requirement. As soon as the preset count is reached, the conveyor belt moves forward to deliver the stack to the following packaging unit or further processing unit such as hole punching press, rim rolling and bag making.

Today, keeping energy concerns

in mind, the demand for hot

runner systems is growing

by the day. It is one of

the important enhancements that

manufacturers can incorporate into their

mould to improve part quality, reduce

production times & energy usage and

remain price competitive.

Rajendran Kasi, Regional Manager-

SAARC Nations, Husky Injection

Molding Systems Pvt Ltd, says,

“Demand for direct gating of plastic

parts is increasing. Hot runners continue

to replace cold runner technology,

thus allowing customers to run faster

cycles and achieve more efficient

production. In fact, the hot runner

industry is growing faster than the

overall plastics industry.”

Functioning of hot runners A hot runner system is an assembly

of heated components used in plastic

injection moulds that inject molten

plastics into the mould cavities. A hot

runner system usually includes a heated

manifold and several heated nozzles. The

main task of the manifold is to distribute

the molten plastic material entering the

mould to various nozzles, which then

meter the melt precisely to the injection

points in the cavities. Hot runners are one

of the most sophisticated components of

an injection mould – key to achieving

profitability and part quality.

Kasi notes, “Decreased energy

consumption can be achieved in two

ways. First, better insulation, which

enhances energy efficiency by using

appropriate materials with low thermal

conductivity in places where hot steel

touches the cold plate. Secondly, more

efficient heaters and the use of electrical

actuated valve stems versus pneumatic

or hydraulic actuation systems. This

can be achieved through the use of hot

runner systems.”

In a nutshell, hot runners are fairly

complicated systems that have to ensure

the plastic material inside are heated

uniformly, while the remaining part of

the injection mould is cooled in order to

solidify the product quickly.

Types of hot runner systemsHot runner systems are of two main types

– insulated and heated. Insulated runner

moulds have oversized passages formed

in the mould plate. The passages are

of sufficient size through which, under

conditions of operation, the insulated

effect of the plastic material (frozen

on the runner wall) combined with the

heat applied with each shot maintains

an open, molten flow path. For heated

runner systems, there are two designs –

internally heated and externally heated.

In the internally heated system, the

plastic melt flows directly over slender

heaters inside oversized runners. This

system takes advantage of the insulating

effect of the plastic melt to reduce heat

transfer (loss) to the rest of the mould.

On the other hand, the externally heated

system consists of a cartridge-heated

manifold with interior flow passages.

The manifold is designed with various

With intensifying global competition for moulding plastic parts, the pressure is rising on reducing per piece moulding cost and energy consumption in the injection moulding process. This has increased the demand for hot runner systems. Avani Jain analyses the benefits of hot runner systems in reducing energy consumption during the plastic injection moulding process.

Investing in innovation, harvesting efficiency

ENERGY MANAGEMENT: Hot runner systems


Cou

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In

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Hot runner systems

insulating features to separate it from

the rest of the mould, thus reducing heat

transfer (loss).

Shorter cycle time, reduced energy usageThe cycle time of any mould is largely

influenced by the cooling cycle –

how fast the resin can be sufficiently

cooled so that the part can be ejected

without permanent deformation. The

usage of hot runners systems help in

reducing the overall moulding cycle by

individual time reductions of the various

processes involved, thereby contributing

to increased output per unit time. The

shorter cycle time also results in less

energy consumption. Although hot

runner systems are more expensive

capital investments upfront, they are a

significantly more cost-efficient means

to keep production costs to a minimum

over the long run and reduce energy

consumption to a large extent.

Husky has made many changes

in their hot runner systems to help

moulders achieve maximum energy

efficiency. Kasi notes, “Two of our recent

developments help reduce overall energy

consumption to a large extent in the

injection moulding process. The electric

actuated valve gates consume 70 per

cent less energy compared to a similar

pneumatic or hydraulic actuation system.

Further, our new side-gating technology

allows customers to direct gate plastic

parts that previously would have to be

gated with a cold runner.”

Additional advantages Since there is no cold runner to discard

or recycle, resin consumption is reduced.

They also help reduce the labour cost as

secondary operations such as manual part

de-gating and trimming are eliminated

with a hot runner system. Further,

they help in mould cost savings, as a

smaller cavitation hot runner-equipped

mould may be able to satisfy production

quotas using a smaller number of

cavities since it runs at a faster cycle.

Hot runners allow reduced injection

pressures during packing, as the system

does not have to deal with injecting resin

through a cooled runner.

Thus, the use of hot runner systems

not only improves energy efficiency to

a large extent but offers other benefits

as well. Amit Mahant, Director, PK

Plastic International Pvt Ltd, says,

“Hot runner systems offer high rates of

efficiency and productivity. Most notably,

these cut production costs dramatically.

The elimination of cold runners

makes hot runners the preferred solution

for clean room production and for

achieving energy efficiency.”

Hot versus cold runner systems Hot runner systems help in better energy

savings than cold runners. Kasi avers,

“With cold runner tools, a significant

amount of resin needs to be melted just for

the purpose of filling the cold runner to

reach the cavity. Even if re-used, this resin

serves no other purpose than to transport

the resin to the cavity. In contrast, with

a hot runner mould, the amount of resin

required for filling the cavity is prepared

in the injection unit, which leads to

reduced shot volume. Further, cold

runners often have a higher pressure drop

than hot runner moulds. The extra energy

(higher machine pressure) required to fill

the cavity with a cold runner is wasted as

the pressure drops. This is not the case

with the hot runner system.”

Future outlookDespite the higher initial cost, the

long-term benefits of equipping a mould

with a hot runner system can be easily

justified. In future, every plastics moulder

will focus on maximising productivity

and efficiency by using hot runner

systems. “When compared to cold runner

technology, hot runner technology helps

customers achieve this goal by allowing

parts to be produced at faster cycle times

and with less resin. In addition, increasing

labour costs are driving the need for more

automation and precision. Therefore, hot

runner systems are a key technology to

achieve a higher degree of automation,

productivity and precision,” claims Kasi.


Rajendran KasiRegional Manager-SAARC Nations, Husky Injection Molding Systems Pvt Ltd

Cold runners often have a higher pressure drop than hot runner moulds. The extra energy (higher machine pressure) required to fill the cavity with a cold runner is wasted as the pressure drops. This is not the case with the hot runner system.

Amit MahantDirector, PK Plastic International Pvt Ltd

Hot runner systems offer high rates of efficiency and productivity. Most notably, these cut production costs dramatically. The elimination of cold runners makes hot runners the preferred solution for clean room production and for achieving energy efficiency.


POLICIES & REGULATIONS: Impor t duty on t i tanium diox ide

Raw materials’ supply in the plastics and polymers industry face severe limitations owing to the growing menace of

unrestricted dumping. The rising cost of power, energy, financial services and equipment are adding to the woes, making raw material production an incredible challenge that is threatening to dampen the prospects of a promising masterbatch industry in the country.

Titanium dioxide in masterbatchesTitanium dioxide is widely used by the paint industry and in the dyes & pigments sector, besides production of white masterbatches in the plastics & polymers industry. These sectors are

promising and growing fast. Various chemicals such as titanium dioxide, antimony oxide, zinc oxide and zinc sulphide are used to provide plastics properties. Some of the major reasons for the use of titanium dioxide are for its special properties, eg, average particle size (0.19-0.22 μm), high refractive index, etc. Titanium dioxide is perhaps the most critical of these components. At present, the Custom Duty on rutile grade titanium dioxide is 10 per cent.

Various forms of titanium dioxide can be used in masterbatches or similar polymer compositions. One form of titanium dioxide – pigmentary titanium dioxide – is used for producing a white composition and/or improving opacity.

Titanium dioxide is also used in the formulation of masterbatches, which is often called ‘transparent’ titanium dioxide since, due to its particle size, the attenuation of visible light is low. This form of titanium dioxide has a high attenuation for Ultraviolet (UV) light; therefore, it is added to plastic compositions to provide protection from UV light. Titanium dioxide can be prepared by various processes such as the ‘sulphate’ or ‘chloride’ process, and may be in the anatase or rutile crystal form, although rutile titanium dioxide is the preferred form.

Considering that a principal use of treated inorganic pigments is the formulation of masterbatch

The import duty structure for sourcing of titanium dioxide has adversely affected the core competency of the domestic masterbatch market, resulting in fluctuation of raw material prices in India. Lionel Alva assesses the influence of this duty structure on titanium dioxide and its impact on the masterbatch industry as well as the plastics industry as a whole.

Opening trade avenues for Indian industry


Impor t duty on t i tanium diox ide

compositions for pigmented plastics, the particle size of inorganic solids will be such that the material is suitable for this purpose.

Among several pigmented films, almost all are found to consist of higher concentrations of hydroperoxide species before and after thermal oxidative ageing as compared with the control unpigmented polymer film. Thus, titanium dioxide pigments play an important role in the photothermal oxidation of polyethylene through their ability to catalyse thermal oxidation of the polymer.

The primary purpose of titanium dioxide has been to impart white colour to plastics films. Each year, the demand for masterbatches has increased at a sporadic rate and their overall demand level has also increased. Functionalities such as weather resistance and optical reflectance are in high demand from masterbatches. Evidently, titanium dioxide is an integral aspect in the formulation of high-performance masterbatches.

“Anomalies in the import duty structure rate for sourcing of titanium dioxide have put a strain on the core competency of the domestic masterbatch market, leading to a fluctuation in the prices of raw materials and, conversely, making import of masterbatches a cheaper and sustainable alternative. They are integral to not only the plastics industry, but also chemicals industry at large, which forms the backbone of the Indian industries,” avers Aditya Tandon, Director, Classic Polymers & Resins.

Need to rethink the import duty structureThe cost of titanium dioxide as a commodity has been spiraling upwards, with an appreciation of 5-6 per cent in the last one month. This has had a great impact on plastic masterbatch manufacturers who have seen little respite from the already sporadically high duty structure. Moreover, with masterbatch imports coming in easily from countries in close proximity such as China and Thailand have further exacerbated the current scenario. It would make little

sense for masterbatch manufacturers to ramp up their production capacity since they would find few takers, thus making large-volume business a difficult and expensive proposition in terms of risk.

This is also critical for the plastics industry since the actual content and particle size of titanium dioxide in masterbatch formulation have significant impact on non-homogeneity of mixing of masterbatch formulation and cause to reduce optimised pigment colouration.

Manoj Dugar, Chairman, Dugar Group of Industries, asserts, “Globally, there is extreme shortage of titanium dioxide, which makes production a difficult endeavour. It is important to rethink the duty structure since titanium dioxide is among the most crucial components of plastic masterbatches and makes producers look towards reformulation of masterbatch production when batch production does not meet the right appeal or specification, and this affects the cost of manufacturing, production schedule and customer satisfaction. This also complicates the production process since the use of other additives need processing and refinement, but titanium dioxide does not need much work. This is the primary reason why Indian masterbatches are not on par with international standards.” Therefore, a positive change in outlook requires a better cognisance of the plastics industry by the bureaucracy.

Strengthening policy structureIn the present context, where the country is not doing well fiscally, the impact of a weak policy on the industry is all the more severe. It is imperative that the burden on the industry be lessened by re-thinking the policy framework on several chemicals that are integral to maintaining the competency of the Indian industry. A reformulation towards a lesser duty levied on imports would ease the burden on producers and establish homogeneity in bringing the efforts of the raw material industry towards fruition, leading to strong economic machinery that can overcome minor price fluctuations.


Aditya TandonDirector, Classic Polymers & Resins

Anomalies in the import duty structure rate for sourcing of titanium dioxide have put a strain on the core competency of the domestic masterbatch market, leading ��prices of raw materials and, conversely, making import of masterbatches a cheaper and sustainable alternative.

Manoj DugarChairman, Dugar Group of Industries

It is important to rethink the duty structure since titanium dioxide is among the most crucial components of plastic masterbatches and makes producers look towards reformulation of masterbatch production when batch production does not meet the right appeal or ��

STRATEGY: Masterbatch processing units


Additives and masterbatches constitute a highly successful and essential segment of the global plastics industry. The

last 15 years have witnessed a constantly increasing impact of masterbatches in applications such as antistatics, foaming and flame retardancy. The masterbatches market in India has been growing at a rate of 15 per cent in the last few years, driven by demand from end-user segments. At present, the Indian masterbatches industry has a total capacity of 350,000 Tonne Per Annum (TPA), comprising organised (25 per cent) and unorganised (75 per cent) players.

This increase in demand is a good sign for the industry, encouraging quality focus. Companies can achieve this goal by preventing contamination in masterbatch processing units. Dr Premal Vashi, Director-Engineering Plastics, Som Shiva (Impex) Ltd, avers, “Technically, masterbatch manufacturing is not easy, but Indian manufacturers have taken it in a different way. Masterbatch is a concentrated pigment and has to be diluted as per requirement. Also, colour contamination is a normal

occurrence in masterbatch processing, which affects product quality. Masterbatches contain a high percentage of pigments, and handling pigments is a difficult task. Thus, it is important to process masterbatches in a clean and dust-free manufacturing environment.”

Cleanliness in processing environment The concept of masterbatches was developed to avoid direct use of pigments by end-users, ie, injection moulding, blow moulding, extrusion and other applications. Dr Vashi explains, “Masterbatches are made with various base polymers using organic/inorganic pigments along with other additive packages. These pigments have particle sizes in microns and generally float in the air during the blending and feeding stage. To avoid floating and dusting, many methods have been incorporated such as the use of waxes and anti-flocculants. It must also be noted that some of the pigments are hazardous in nature and must be carefully monitored during the mixing and feeding stage.

Some additives and pigments can also affect the performance of the surrounding lines; shade variation can also occur if not controlled properly. Hence, a clean

environment with proper practices are mandatory for processing safety

at all stages, ie, storage of pigments/fillers, opening

of bags, transfer to primary silos or

feeders, etc.”

Preventing contaminationCompanies can adopt various steps to prevent contamination in masterbatch processing units. They must have scrubbers at feeding points, ie, from silos to feeders. All mixing activities should be planned away from processing area and split feed systems should be used to the maximum extent possible. The processing area should be kept clean and floors washed regularly to avoid colour contamination.

Dusty atmosphere impacts masterbatch processing. Parag Parikh, Partner, Universal Colorant Company, comments, “The area of mixer and extruder should be separated with a wall. There should be exhaust fans to remove dust particles; the extruder and its surroundings should be kept clean after

With increasing demand for quality masterbatches, manufacturers are constantly adopting new technologies to achieve a better product and prevent contamination during masterbatch processing. Avani Jain highlights methods that companies can adopt to prevent contamination in masterbatch processing units.


Masterbatch processing units

every colour change; and steps should be taken to keep the shop floor clean from dust/spillages. Dust collectors can also be used.” Cross-contamination of pigment can also impact masterbatch quality. “Steps should be taken to clean the mixers after every colour change and, if possible, separate mixers should be used for all basic colours. Different pigments (colourants) should be kept separately in closed containers. Also, base polymers need to be stored and covered in separate areas,” notes Parikh.

Many companies in the segment have adopted the above-mentioned steps. Dr Vashi claims, “We maintain environment-f riendly manufacturing through a closed-loop plant with gravimetric feeding systems, silos and positive air with proper dust collection system. We have seven different sophisticated lines with all necessary accessories. We have a facility to take up different colour production at a time in different lines without any contamination. Human safety is equally important for us and we regularly educate the workers and train our manufacturing teams.”

Safety and quality Quality today is a key word in the industry. No company can survive without ensuring product quality and consistency. “The market is competitive and if we fail to deliver product quality, we will be out of the market. The general points a manufacturer should consider during masterbatch processing include

the use of proper masks during blending operations, protective eye-glasses during extrusion process, fire extinguishers at all points near the processing areas and in the mixing room. These points are mandatory as some of the pigments may create problems in mixing and yield volatile products. The finished goods should be tested for their quality and properties, eg, shade, strength, etc,” asserts Dr Vashi.

Strategies for a bright futureMasterbatch processing in India is slightly different as compared to international standards. Dr Vashi emphasises, “Indian manufacturers are not techno-savvy and do not prefer to use sophisticated technologies, but things are changing gradually. Today, manufacturers are upgrading technologies to compete against multinational companies. New technologies, sophisticated extruders, feeders and downstream equipment are important in masterbatch industries.”

New technologies keep surfacing every now and then for ensuring good quality. Dr Vashi concludes, “Companies today are adopting highly sophisticated technologies to produce environment-f riendly products. As the world is now targeting the Indian market and big players are establishing their plants in India, the time is now right to invest in proper technology and infrastructure, thereby providing quality products to customers and the industry at large.”


Dr Premal VashiDirector-Engineering Plastics, Som Shiva (Impex) Ltd

Indian manufacturer are not techno-savvy and do not prefer to use sophisticated technologies, but things are changing gradually. Today, manufacturers are upgrading technologies to compete against multinational companies.

Parag ParikhPartner, Universal Colorant Company

Steps should be taken to clean mixers after every colour change and, if possible, separate mixers should be used for all basic colours. Different pigments (colourants) should be kept separately in closed containers.

Clean room practices for compounding lines

Location Courtesy: Loxim Industries LtdPhoto: Vijaykumar Soneji

TIPS & TRICKS: P last ic packaging


Plastic packaging often requires barrier properties that are specific to the contents inside. Hence, it is important for packaging companies to choose the right additives and masterbatches for the right applications. Anwesh Koley enlists some of the key requirements of raw materials for packaging.

barrier performance

Among plastics’ attributes for applications in packaging are flexibility, clarity, low cost, shelf appeal, ease

of transport and storage. The most important feature for food and beverage packaging is delivering fresh & safe

products to the consumer. This often involves maintaining performance over long intervals between actual production and eventual consumption. This time interval, commonly known as ‘shelf life’, is increasing as food and beverage producers seek to distribute

their products on a global basis and as plastics makes inroads into areas that were previously the domains of metal and glass packaging.

Email: [email protected] inputs from Sumit Dhingra,

Director, Dhingra Polymers

Following are some of the key requirements for better barrier properties:

M e d i u m b a r r i e r properties: This is a cost-driven approach that requires small micelles of high-barrier polymer to be created and evenly distributed. High-barrier plastics usually has refractive index different from its medium-barrier hosts. But blend levels are only in high single digits before clarity suffers, limiting this approach to shorter shelf-life applications.

Oxygen scavengers: Nano-clay is usually used as a barrier layer of a multilayer structure. Commercial oxygen scavengers are incorporated in to po l ye thy lene terephthalate or polyamides, while commercial nano-clays are incorporated primarily into polyamides. As these additives become part of the polymer matrix, concerns about adherence, scratching and delamination are minimised.

Spray or dip technology: Packaging external surface is coated with high barrier epoxies, using spray or dip technology. Coated articles are limited by the adherence between the coating and plastic substrate. The rigours of filling and transportation can compromise the coating, and hence packaging shelf-life. Exterior coatings can scratch off while interior ones can crack or delaminate.

Barrier enhancing additives: Although this concept is not new, it has only recently become feasible with the advent of advanced material technology. Two commercial approaches are in use – oxygen scavengers and nano-clays. As the additive term implies, the approach consists of incorporating functional materials directly into a plastic matrix, and then using the upgraded plastics as a component of an article.

Oxidative polyolefins: Conventional polyolefins are not biodegradable due to their high molecular weight. Besides, biodegradation occurs in an aqueous medium, whereas polyolefins are hydrophobic. Oxidatively degraded polyolefins are polar molecules of lower molecular weight that are conducive to biodegradation. Traditional polymers undergo slow oxidative degradation.

Right coating: Both flexible films and rigid containers are coated with ultra thin layers of materials that provide high intrinsic barrier. A variety of vapour deposition technologies are used for coating of aluminium and silicon oxides. A new variant uses microwave plasma deposition to deliver amorphous carbon coatings onto the interior surfaces of beverage containers.

STEPS TO BOOST

PROJECTS


Coextruded plastic sheetsXpro IndiaProject typeNew facilityProject newsAs part of its long-term consolidation strategy, Xpro India is implementing a co-extruded plastic sheets manufacturing unit in Maharashtra. This facility will feature state-of-the-art equipment in light of the much anticipated demand in the near future. Xpro India believes that the plastics industry is in for a paradigm shift by 2015, and there already exist enormous prospects in the market.Project locationPune, MaharashtraProject cost Not knownImplementation stage Planning

Contact details:Xpro India Ltd1, Industrial Area, NITFaridabad - 121001, IndiaTel: 0129-2233915/17Fax: 0129-4028300 Email: [email protected]

Coles mixed plastic recyclingColes SupermarketsProject typeServicesProject newsColes Supermarkets will conduct a six-month trial that provides Victorian customers with a convenient and responsible way to recycle a range of plastics that are currently not included in the kerbside recycling programme.Project location AustraliaProject cost$ 254,220Implementation stageOngoing

Contact details:Coles SupermarketsPO Box 2000, Glen Iris VIC 3146Tel: +1800-061 562 Fax: +1800-0829-3818Email: [email protected]

In-line polymer inspection systemIbanez ExtrusorasProject typeExpansionProject news This project proposes to develop a compact, non-invasive, real- time sensor based on an ultrasonic piezoelectric transducer for in-line measurements during polymer processes.Project locationSpainProject cost€ 12 millionImplementation stage Planning

Contact details:Ibanez ExtrusorasSL calle Doctor Fleming Quart de Poblet, Valencia, SpainTel: +34-961549411 Fax: +34-961533197Email: [email protected]

Packaging and hot runner systemsHusky Injection Molding SystemsProject typeNew facilityProject newsThe Canada-based company will make large plates for its packaging and hot runner systems produced at its Shanghai regional headquarters and manufacturing plant, where it is running out of space. Since it started operations in China in 2004, the new facility will be located in Suzhou, Jiangsu Province. The company has doubled its footprint and more than tripled its regional workforce.Project locationSuzhou, Jiangsu, China

Project cost€ 39.8 millionImplementation stagePlanning

Contact details:Husky Injection Molding Systems500 Queen Street South Bolton ON L7E 5S5, CanadaTel: +905-951-5000Email: [email protected]

Petrochemical complex Rosneft Petroleum CompanyProject typeNew facilityProject newsThe construction of a petrochemical production plant in the Primorsky (maritime) Territory (PT) will be conducted with a strict observance of all environmental norms. It is planned that Rosneft’s new plant near Nakhodka will produce monoethylene glycol, polyethylene, polypropylene, aromatic hydrocarbons and ethyl benzene. Petroleum, supplied via the Eastern Siberia-Pacific Ocean oil trunkline, and will be used as feedstock. Construction of this petrochemical complex will stimulate processing sectors in the Far Eastern Federal District, giving a boost to PT’s foreign economic activities to increase the port’s cargo handling capacity and create new jobs in the area.Project locationPrimorye krai, RussiaProject cost$ 10 billionImplementation stagePlanning

Contact details:26/1, Sofiyskaya Embankment117997, Moscow, RussiaTel: +07-4957774422Fax: +07-4957774444Email: [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.

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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TENDERS

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


Collection bagsOrg : Ministério da EducaçăoTRN : 11775067Desc : Purchase of bags for material collectionBOD : 10 August, 2012Loc : BrazilBT : International competitive bidding

Plastic bottlesOrg : Uttarakhand Jal SansthanTRN : 11734348Desc : Supply, installation, testing and commissioning of plastic bottlesBOD : 13 August, 2012Loc : IndiaBT : Domestic competitive bidding

Plastic crates for perishable agricultural commoditiesOrg : Empresa Municipal de Mercados (EMMSA)TRN : 11810494Desc : Plastic crates (350,000) for perishable agricultural commoditiesBOD : 13 August, 2012Loc : PeruBT : International competitive bidding

Processing of polypropylene granules Org : Al Furat CompanyTRN : 11795615Desc : Processing of Polypropylene (PP) granules for factory plastic bags with PP amount at 1,000 tonneBOD : 13 August, 2012Loc : IraqBT : International competitive bidding

Paper and/or plastic bagsOrg : Southern District Health BoardTRN : 11749593Desc : Supply of paper and/or plastic bagsBOD : 14 August, 2012Loc : New ZealandBT : International competitive bidding

Plastic water tanks Org : Lake Victoria North Water Services BoardTRN : 11808451Desc : Supply and delivery of plastic water tanks (in three lots)BOD : 14 August, 2012Loc : Kenya

BT : International competitive bidding

Recanning wooden chairs with cane plastic Org : Military Engineer ServicesTRN : 11821620Desc : Recanning of different type of wooden chairs with cane and plastic. Repair of wooden and steel furniture items in PathankotBOD : 14 August, 2012Loc : India

BT : Domestic competitive bidding

Paper and plastic articles Org : Troms Fylkeskommune

TRN : 11487408

Desc : Paper and plastic articles

BOD : 15 August, 2012

Loc : Norway


Automatic toggle machineOrg : Ordnance Factory Board

TRN : 11620653

Desc : Supply of automatic toggle machine


Loc : India

BT : Domestic competitive Bidding

Injection moulded axle box front coverOrg : South East Central Railway

TRN : 11632591

Desc : Supply of injection moulded

thermoplastic polyster elastomer [Hytrel]

axle box front cover for BG main line

and EMU coaches


Loc : India


One unit bioreactor Org : Municipality Of Linamon, Lanao Del Norte

TRN : 11829195

Desc : Supply & delivery of one unit bioreactor

(0.5 tonne capacity), one unit plastic

densifier with 50 kg capacity

and one unit shredder


Loc : Philippines



TENDERS



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

Plastic waste processor Org : Public Works and Government Services Canada

TRN : 11774079

Desc : Plastic waste processor


Loc : Canada


Plastic water tanksOrg : Lake Victoria North Water Services Board

TRN : 11741453

Desc : Supply and delivery of plastic water tanks


Loc : Kenya


Plastic packagingOrg : Poczta Polska SA

TRN : 11811619

Desc : Supply of plastic packaging


Loc : Poland


Injection moulding plastics for high school godart roger Org : Conseil Régional Champagne Ardenne

TRN : 11676425

Desc : Injection moulding plastics for high school

hydraulic godart roger


Loc : France


Plastic traysOrg : Department of Posts

TRN : 11764980

Desc : Supply, install/commissioning of 20,000 LSM and

60,000 MMS plastic trays to be installed at

AMPC Delhi and Kolkata


Loc : India


Cardboard, paper and plasticOrg : Renovasjonsselskapet Glřr Iks

TRN : 11606263

Desc : Provide cardboard, paper and plastic


Loc : Norway


Laboratory twin-screw extruderOrg : Universität des Saarlandes

TRN : 11796039

Desc : Laboratory twin screw extruder


Loc : Germany

BT : International Competitive Bidding

Plastic pipes and fittings for water pipes Org : Dunea NV

TRN : 11741829

Desc : Supplying plastic pipes and fittings for

water pipes made of PVC and PE to

500 mm diameter


Loc : Netherlands


Co-kneader Org : Université Jean Monnet

TRN : 11796041

Desc : Acquisition and installation of a co-kneader for

laboratory research and development of

formulations based on thermoplastic

polymers and thermosets

BOD : 6 September, 2012

Loc : France



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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EVENT LIST


Specialty Films and Flexible Packaging Global Conference 2012This one-day conference is dedicated

to the surging flexible packaging sector

in India and the opportunities &

challenges faced by the industry. With

representative speakers from the Indian

as well as global industry, this event will

offer key insights into the developments

in flexible packaging materials and

processing machinery; September 11,

2012; at Hotel Grand Hyatt, Mumbai

For details contact:

Nidhi Verma

Elite Plus Business Services Pvt Ltd

61, Radheya, 14th Road, Plot 359

Khar (W) Mumbai - 400052

Tel: 022-2600 0555/56

Fax: 022-26000556


Website: www.eliteplus.co.in

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


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

Plexpo India 2013In its 6th edition, Plexpo India 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 equipment, testing equipment,

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

Mob: 9925017136

Fax: 079-26579204


Website: www.plexpoindia.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:Network18 Media & Investments 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 & future 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


Fire is a worldwide problem. It claims thousands of lives and causes significant loss of property every year. Polymers are materials of choice due to their versatility and use in various application sectors. Therefore, the relationship between fire and polymers is an important social issue. American Chemical Society (ACS) had organised a symposium in 2004. Thirty-eight papers were presented at the symposium and 28 papers are compiled in the book Fire & Polymers IV, which include synthetic thermoplastics and thermoset class of plastics. This book covers the latest research at the intersection of fire and polymers. Polymers or plastics are combustible materials and additives are used to make them flame retardant. This is a billion-dollar business worldwide. This book gives a good account of traditional halogen-based additives and has papers on non-halogen fire retardants as well as nano-scale additives.

These 28 papers have been grouped under various topics – nanocomposites, specific flame retardants, specific polymers, modeling & toxicity and new high temperature polymers. This is because there is lot of interest among researchers in nanocomposites due to their ability to impart best of flame retardant properties to polymers. The book focusses on research that improves fire retardance of polymers through a detailed understanding of polymer degradation chemistry, new and refined analytical techniques & analysis, mathematical fire models as well as a new approach by creative chemists to achieve more thermally stable polymer structures.

Fire & Polymers IVEditors : Charle A Wilkie and Gordon L NelsonPrice : ` 9,550

The textile fibre industry has always relied on synthetic fibres with larger diameters. Synthetic polymeric fibres with nanometre-scale diameters could never become an important part of the textile fibre industry. As the broad field of nanotechnology gained widespread recognition in 1990s, it became apparent that electro-spinning provides a route to the creation of long fibres with nanoscale diameters. Earlier, there have been successful efforts with polymeric nanofibres. However, the technology was maintained as trade secret by the US Defense and Soviet Union. However, the 1990s witnessed a rapid growth in nanomaterials, nanotechnology and nanofibre applications & technology. All the contributors have tried to unveil this aspect. Therefore, a pioneering spirit pervades this book. Each chapter describes the earlier successes of polymeric nanofibres, produced mostly by electro-spinning and reveals a promise of future efforts.

The earlier applications of polymeric nanofibres were in the field of filtration and gas masks for protection of soldiers, while today they are considered as scaffolds for the growth of artificial biological organs, membranes with engineered porosity and tissue engineering. This book is based on the American Chemical Society (ACS) Symposium on Polymeric nanofibres held in September 2003. This book includes only original research and review papers.

Polymeric Nanofibers

Avaliable at: Wisdom Book Distributors, Hornby Building, 1st floor, 174, D N Road, Mumbai 400 001 ;�<=�>//+//>Q�JJJ�OO?�Z��V�;�<�^�Y=�>//+//>?�J>��V�[��<=��`� ��]��<5_��

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

Editors : Darrell H Renekar and Hao FongPrice : ` 10,900

PRODUCTS


Injection moulding machine Model DCM-250T-

2C two-component

horizontal injection

moulding machine

that features

hydraulic clamp is

particularly suitable

for either two-colour

or two-component

injection mouldings.

It features super-wide rotary table and super-large mould thickness

available. Dual hydraulic clamping cylinders minimise possible

distortion of the rotary table. Electric servomotor-driven rotary table

ensures accurate and fast positioning. It also offers lubrication-free

and easy maintenance operations.

Multiplas Enginery Co Ltd

Taoyuan - Taiwan

Tel: +886-3-318-0090


Website: www.multiplas.com.tw

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

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

Masterbatch feederYa n n B a n g ’s

masterbatch feeder

mixes with resin

automatically without

changing f requently

and keeps product in

good quality. With the

patented throat adapter

(TAIWAN PAT.

M336147, CHINA PAT. 96215963.8), the masterbatch and resin

will not be stocked between the inlet and screw unit, the masterbatch,

additives, smooth powder, regrinded resin and virgin resin are able to

mix consistently and accurately with less rejects. Its unique design

to change screw easily can help save time and cost in clean working

place. Feeder for powder series is also available.

Yann Bang Electrical Machinery Co Ltd

Taichung City - Taiwan

Tel: +886-4-22710000


Website: www.yannbang.com

Pneumatic-driven large beam robot Cobra series is

applicable to all

types of horizontal

injection machines

of 450t to 4,000t for

take-out of products

and sprues. It can be

added with a runner

arm for three-plate mould to clamp product and sprue at the same

time. Light, high-rigidity alloy aluminium extrusion beam applied

in kick and vertical axles, realises high speed, high efficiency, low

vibration and long life expectancy of the machine. Installation of

robots will increase productivity, reduce defect rate, ensure safety

of operators, reduce manpower and accurately control the output to

reduce waste.

Dongguan Alfa Automation Machinery Ltd

Guangdong - China

Tel: +86-769-83180326

Email: [email protected]; [email protected]

Website: www.alfarobot.com

Energy saving system Jon wai AC synchronous

servo power saving system

integrates all the excellent

features such as energy

efficiency water saving,

hydraulic oil saving, easy

operation and precision

moulding. The system

closes the gap between

hydraulic and all-electric

machines, which can offer a new green solution at low cost. Jon

wai servo system is available for all series machines. Its advantages

are electricity saving, water saving, hydraulic oil saving, quick

response, moulding stability, quiet operation, reliability, reliable

holding pressure and unique motor control design.

Jon Wai Machinery Works Co Ltd

Taipei - Taiwan

Tel: +886-2-25954867


Website: www.jonwai.com

PRODUCTS


Laboratory chiller Polystat Laboratory Chiller

has quick ramp-up and cool-

down with all operational

and preventive maintenance

accessed through the front

panel. Designed to provide

temperature control with

the flexibility needed for

demanding applications,

they fit comfortably on

a laboratory bench top.

These chillers feature a

temperature range of -10°C

to 80°C. The chillers allows

the user to choose between

five temperature set points.

The air-cooled refrigeration

system eliminates the need

for external water source and

the small internal reservoir limits evaporation. With built-in energy-

saving mode, this series provides an environment-friendly option

for any laboratory. This mode activates a responsive control that will

allow the chillers to operate with minimal energy consumption.

Cole-Parmer India Pvt Ltd

Mumbai - Maharastra

Tel: 022-67162224/2222


Website: www.coleparmer.in

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 PP polypropylene straps. Extruder available

from dia 65 mm to dia 120 mm for 2, 4, 6, up to 8 strap extrusion.

The JC-ST/PET series extruder is available from dia 85 mm to dia

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


Website: www.jennchong.com.tw

Cleanroom mouldAdapplicator, Alu

cap, Snap cap, PE

bottle pack cap, PE

twin-port cap are

some of the many

cleanroom moulds

from Braunform.

Highly sensitive

packaging and

m e a s u r i n g

c o m p o n e n t s ,

caps for use in

dental and insulin

fields, dialysis components, hygiene products & the Adapplicator

system developed by Braun, are spray alternatives to needle injection.

Application areas are medical and cleanroom moulds, IML & IMD

moulds, multi-cavity, multi-component & stack moulds and rotary

table programmes.

Neejtech India

Ahmedabad - Gujarat

Tel: 079-26561312

Mob: 09825040231


Website: www.neejtech.com

Plastic injection moulding machine

This injection moulding machine provides complete plastics processing

solutions. The machine is used to mould plastics into the desired

shape. This is designed as per the current technical developments and

is quality tested. The plastic injection moulding machine comes with

an auto-centralised lubrication system and a motorised mould height

adjustment.

Sarada Machinery Company

Hyderabad – Andhra Pradesh

Tel: 040-23076557, Mob: 09849546022


Website: www.saradamachinery.com

PRODUCTS


Rotomoulding machine

Swing-arm robotThe SS series swing arm robot

is useful for those using injection

moulding machine. This robot

is designed for rapid and precise

removal of sprue & runner from

the injection moulding machine

and place them into granulator for

recycling. The robot is suitable for

injection moulding machines under

250-T clamp force. Swing arm robot

is equipped with various useful

mechanisms in arm, swing, kick stroke

and base.

Shini Plastics Technologies (India) Pvt Ltd

Thane - Maharashtra

Tel: 0250-3021132


Website: www.shini.com

Dehumidifying dryerThese are carousel plus

dehumidifying dryers. With

these dryers, users can have

greater control over drying

dewpoint and temperature than

ever before, in a package that is

simpler, smaller, lighter, more

energy efficient and easy-to-

use & maintain. Some of their

features include reduced energy

costs, maximum uptime &

maximum reliability as well as

precise, adjustable dew point control.

Nu-Vu Conair Pvt Ltd

Ahmedabad - Gujarat

Tel: 079-32985993


Website: www.conairgroup.com

Extrusion coating lamination plantT h e e x t r u s i o n

coating lamination

plant offers various

substrates required for

PP/HDPE woven fabric,

non-woven fabric, paper

poly coating requirements,

etc. These machines

consist of unwinder turret or mechanical type, corona treater, anchor

coating, extruder 75 mm with 28:1 screw ratio, coat hanger-type

die, laminator unit with line speed of 120 mpm, sandwich unwinder,

winder turret or surface type, AC control panel cabinet and heating

panel cabinet.

Ocean Extrusions

Ahmedabad - Gujarat

Tel: 079-22902200

Mob: 09724325401


Website: www.oceanextrusions.com

Engineering plastic materialsAarkaymid range of engineering

plastic materials saves lubricants

as well as cuts down on

maintenance and downtime.

The product is non-corrosive

and wear resistant. Besides being

light-weight, it facilitates easy

handling, transport and storage,

especially during monsoon

when metal parts call for great

attention. The product is available in different sizes and shapes to suit

all sorts of engineering requirements.

Classic Polymers & Resins

Mumbai - Maharashtra

Tel: 022-24465251


Website: www.classicpolymers.com

The Speed-90 rotomoulding machine is equipped with

the latest features keeping in mind all inconvenience that users face

with their exisiting machines. Newly designed heating system, better

powerful arms, sensors and speed controllers, etc, are some of the

features. The machine is built to manufacture with high efficiency,

eg, water tank.

N A Corporation

Ahmedabad - Gujarat

Tel: 079-25840374


Website: www.naroto.com

PRODUCTS


GranulatorThe efficient range of

granulators is available for

different types of materials

and products. Its capacity

starts from 20 kg/hr to 400

kg/hr with low and high speed

of crushing. The granulators

are also available with various

options such as titanium-

coated blade, strong 2-axis

crushing blades. These are

easy to move with a handle, easy to check blade through transparent

window with CE certified controller.

Yudo Hot Runner India Pvt Ltd

Thane - Maharashtra

Tel: 0250-2451155


Website: www.yudo.com

Plastic milk cansA wide range of plastic

milk cans in various

sizes and designs are

offered. These cans

are apt for the Indian

dairy farms and are a

perfect substitute for

aluminium cans. Cost-

effectiveness, light

weight and durability

are some of the core traits of the plastic milk cans.

Samruddhi Industries Ltd

Sangli - Maharashtra

Tel: 0233-264573

Mob: 09423677084


Website: www.samruddhi.com

Plastic raw materialsThese are BioAdd

range of biodegradable

additives. Heat,

oxygen and sunlight

are used to cause

degradation benefits.

F l a m e - r e t a r d a n t

masterbatches are used

for engineering and

commodity plastics.

Also offered are colour

and special effect masterbatches, filler masterbatches for raffia,

blown film & moulding and performance additives leading to

biodegradation.

AVI Additives Pvt Ltd

Hyderabad - Andhra Pradesh

Tel: 040-23550551


Website: aviadditives.com

Polymer application packThe polymer FT-IR

application pack is

a quality control

tool for the polymer

industry. This offers

fast, reliable, simple

and cost-effective

analysis. The selection

of right technology

helps in obtaining good quality data and not extracting

desired sample information. Additional efforts and time are required

Thin film dryerThe wiped and

agitated thin film

dryer comes in

a spectrum of

sizes, tailored to

suit customers’

application needs.

The design varies

according to the

applications. These

dryers come in

horizontal (predominantly) and vertical configurations, with a variety

of proprietary wiping and scraping arrangements, accompanied by

solvent-recovery systems where required.

Alpha Process Engineers

Chennai - Tamil Nadu

Tel: 044-28111351


Website: www.alphaprocessengineers.com

to extract information and convert into knowledge from the

data generated.

PerkinElmer

Thane - Maharashtra

Tel: 022-33261700

Mob: 09930137484


Website: www.perkinelmer.com

PRODUCTS


Temperature controller and waterflow regulatorThis temperature controller

controls the temperature

of manifold block and

the nozzle with correct

circuit connection and

parameters on the panel. It

also maintains a constant

temperature within the

system. The water flow

regulator is designed to work with mould heaters, water chillers and

cooling towers, which can be connected to more than one mould

connector. It has functions like temperature and flowrate display,

flowrate control in order to meet the requirement of different

working conditions. Modularised combination ensures installation

and maintenance. It is a necessary equipment for modern plastics

industry to improve its moulding efficiency.


Thane - Maharashtra

Tel: 0250-3021132



Plastic injection moulding machineThe range of plastic injection

moulding machine is suitable for

manufacturers and engineering

industries. Designed using

latest technology, the range

is known to perform better

even in harsh conditions. This

plastic injection moulding

machine is available in various

specifications to suit different requirements of engineering and

manufacturing industries.

Mechatronics Machinery & Tools (India)

Delhi

Tel: 011-27830809, Mob: 09810129642


Website: www.mechatronicsmachinery.com

Plastic brighteners/shiners and whitenersThese p l a s t i c

brighteners, shiners

and whiteners are used

for natural transparent,

colours and milky white

end products. These are

also used for adding

clarity and gloss finish

to natural transparent

polymers. The products

give shining and bright

finish colours to end products. These remove yellowness and

dullness from the end products and make them super milky white.

The products are used in virgin, second, dull natural or milky white

sutli, ropes, twine, reprocess granules, HDPE-LDPE-PVC pipes &

profiles, etc.

Plast Fine Polymers

Ahmedabad - Gujarat

Tel: 079-65242332, Mob: 09825587152

Email: plastf [email protected]

Blown film extrusion lineThe monolayer blown film extrusion

line is used for HM-HDPE/

LLDPE/LDPE/PP. It comes in

widths of 90 mm to 1,300 mm

and has an output of 20-70 kg/hr.

The plant is available with stationery

and rotating die. Applications are in

plastic bags, vest bags, liners, garbage

bags, packaging films, stretch films,

shrink films, detergent bags, etc.

Dura Exports Pvt Ltd


Tel: 022-26744053, Mob: 09930476588


Website: www.duraexport.com

Mould-temperature controller and chillerThe mould temperature controller

and special custom-made chiller

are new products that include

cold-hot all-in-one mould

temperature controller, die-casting

mould temperature controller,

quick-cooling & heating mould

temperature controller, two

machines in one water circulation

temperature controller, and rubber/

high temperature/roller mould

temperature controller. These machines are intended for processes

such as plastic injection moulding, extrusion moulding, blow

moulding, chemical industry, dye-casting, reaction axe rubber tyre,

rubber vulcanisation, electric wire, calendar, printing, ban-burying

and other related industries.

Weichi Enterprise Co Ltd

Guangzhou - China

Tel: +86-020-36850626


Website: www.weichigz.com

PRODUCTS


Quick mould change systemThe complete single-source

system solutions available

include Quick Mould Change

(QMC) and Quick Die Change

(QDC) systems for plastic

injection moulding industry and

for metal stamping applications.

Magnetic Clamping Systems

(MCS) are used for injection

moulds and dies. Mono-coupler, manual and automatic multi-

coupler systems are for general industry use. Mould and die rotation

units, die splitters and other tool handling & storage equipment are

also offered.

EAS Mould & Die Change Systems Co Ltd

Wujiang City - China

Tel: +86-512-63093091


Website: www.easchangesystems.com

Robotic automationThe Sepro Robotique S5

line of high-performance

robots features fast, precise

servo-driven robots,

including three different

models to serve injection

moulding machines in the

range of 30-800 tonne. The S5 line of robots is developed with longer

strokes and larger payload capacities than units of comparable size in

Sepro’s earlier Generation 4 (G4) range. There are three models in

this series. All S5 robots are equipped with the top-of-the-line Sepro

Visual 2 controller as standard equipment. At its core is a high-speed

PLC, featuring scan rates as fast at 100 millisecond.

Demag Plastics Machinery (Ningbo) Co Ltd

Zhejiang - China

Tel: +86-574-86181500


Website: www.sumitomo-shi-demag.eu

In-mould labelling equipmentSupreme in-mould labelling

(IML) equipment is reliable

and sustainable. The IML

equipment is offered on

turnkey basis to customers.

This label supply machine,

integrated with technology

knowledge, has features like

both electrostatic and vacuum, easy understanding, durable quality,

low abnormal, cost-down and simple maintenance, simultaneously

available machine for containers with varied shapes, suitable for

different label options, etc.

Supreme Technic Package Co Ltd

Kalol - Taiwan

Tel: +886-7-6141505


Website: www.emdpack.com.tw

Plastic flap loaded foot valveThe new range of plastic flap-

loaded foot valve is most popular

due to its friction-free low cost

design. It gives better linear flow of

water in the suction lines than CI

foot valves. These products exhibit

some of the distinguished features,

such as durability, friction-free

design, corrosion resistance, leakage-proof and dimensional accuracy.

Technical specifications include standards as per IS:10805:1986 of

BIS, thread as per IS:554:1985 of BIS, body test pressure at 0.5 MPa,

seat test pressure at 0.02 MPa, normal bore size 21/2" and 3" (65 mm

and 80 mm), and materials of construction: PP body, PP strainer &

PVC washer.

Arti ProductsRajkot - Gujarat

Tel: 0281-2388908, Mob: 09428155144


Website: www.artiproducts.in

Dehumidifying dryer The SDD series dehumidifying dryer

uses honeycomb dehumidifier with

elegant and semi-integral appearance.

This model contains dehumidifying and

drying into same unit. The drying hopper

comes with downwards dry air blowing

system, which improves drying efficiency.

It also reduces energy consumption and

is most economical for customers using

it. The dehumidifier of SDD contains

two coolers inside it, which ensures low return air temperature and

low dew point. This equipment is microprocessor controlled and

compact. It has applications in plastic processing industries and is

unique for processors who use PA, PC, PBT, PET, etc. All models

come with process heaters and insulated drying hopper.


Dist Thane - Maharashtra

Tel: 0250-3021132



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

��

Plastic plantersThese coloured plastic planters are made

from optimum quality and hard plastics.

Durable in nature and sturdy by frame,

the plastic planters are offered in various

colours and design patterns. The plastic

planters are ideal for indoor as well as outdoor applications. These are

used to hold plants and enhance the decor of surroundings. The products

comply to all national and international standards set by the industry.

Samruddhi Industries Ltd

Sangli - Maharashtra

Tel: 0233-264573, Mob: 09423677084


Website: www.samruddhi.com

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

Thermic fluid heaterThe thermic fluid heater and hot water

generator have capacities ranging from 30,000

kCal/hr to 20,00,000 kCal/hr. Maximum

operating temperature is 300°C for thermic

fluid and 130°C for hot water. Concentric coil

is made from MS seamless tube of Asthma

106 GR-B. The unit is equipped with high

efficiency oil/gas burner with air pre-heater

arrangement giving high thermal efficiency of

87 ±2 per cent on NCV. The unit is outside

the purview of IBR.

Aero Therm Systems Pvt Ltd

Ahmedabad - Gujarat

Tel: 079-25890158, Mob: 09825008720


Website: www.aerothermsystem.com

Injection moulding machine The two-platen injection

moulding machine is

available in 850-3,500

tonne. This machine takes

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 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 there is no risk of damaging seals while

changing tie bars.

Jon Wai Machinery Works Co Ltd

Taipei - Taiwan

Tel: +886-2-25954867


Website: www.jonwai.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 can be used

outside for 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 metre. 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

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LIST OF PRODUCTS


Accumulator high-speed injection moulding machine 111

Acoustic enclosure ............................................................ 31

Additive masterbatches .................................................... 51

Adhesives .......................................................................... 25

Air audit blowers .............................................................. 50

Air chiller ......................................................................... 21

Air-cooled compressor ................................................... 116

Analog timers ................................................................. 121

Ancillary equipment ......................................................... 61

Automation system .................................................... 69, 91

Baking & drying ........................................................63

Barrel screws..................................................................... 97

Barrels............................................................................. 126

Bed knives ........................................................................ 71

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

Biodegradable masterbatches ........................................... 51

Black masterbatches ................................................... 51, 99

Blenders .................................................................. 4, 17, 75

Blow film extrusion line ................................................. 114

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

Blower series .................................................................... 91

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

Bottle testing equipment .................................................. 81

Box series wormgear units ............................................... 27

CASI (coating) ..........................................................25

Center seal.......................................................................... 3

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

Cleanroom applications .................................................... 35

Cleaning ovens ............................................................... 126

Cleanroom moulds ......................................................... 109

Co-extruded sheets and telecom cables ........................... 49

Co-kneader ....................................................................... 61

Co-rotating extruder ...................................................... 107

Colour masterbatches ..................................... 13, 51, 61, 99

Compact chiller ........................................................ 21, 125

Compressed air dryer ....................................................... 83

Compressors ..................................................................... 50

Conductive compounds .................................................... 51

Conical twin-screw extruder ........................................ 6, 14

Continuous screen changers ........................................... 126

Conventional phase failure relays ................................... 121

Conveying ........................................................................ 69

Counters ......................................................................... 121

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

Crystalliser........................................................................ 83

Curing .............................................................................. 63

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

Cyclic olefin copolymer (COC) ....................................BIC

Dehumidifying air dryer ..................21, 85, 110, 115, 125

Delphi ATDC brake motor ............................................. 27

Delphi three-phase motor ................................................ 27

Die face cutters ................................................................ 71

Die plates ......................................................................... 71

Digital panel meter .......................................................... 10

Digital temperature controller .......................................... 77

Dosing & blending .......................................................... 69

Dosing & mixing ............................................................. 91

Drives ............................................................................... 77

Dry van pump .................................................................. 31

Dry-break couplings ......................................................... 50

Drying .............................................................................. 69

Drying & dehumidifying ................................................. 91

Dual channel with modbus .............................................. 77

Dynamic controller .......................................................... 77

Ejectors .....................................................................50

Elastomer refinery/petrochemicals ................................... 25

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

Energy saving system ..................................................... 108

Engineering plastic materials ......................................... 110

Engineering plastic compounds ....................................... 99

Extruder machine ....................................................... 37, 87

Extruder screws ................................................................ 71

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

Extrusion coating lamination plant ................................ 110

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

Extrusion pumps .............................................................. 32

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

Feed rolls ...................................................................71

Feeding & conveying ................................................. 83, 91

Fibre grade masterbatch ................................................... 99

Film cutters ...................................................................... 71

Fueling systems ................................................................ 50

Gearbox .....................................................................40

Gear motor ....................................................................... 40

Gear pump ............................................................... 32, 126

Granulating & recycling .................................................. 91

Granulator .................................................. 21, 83, 112, 125

Granulator blades ............................................................. 71

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

Gravimetric dozer .............................................................. 4

Grinder ............................................................................. 21

HDPE pipes & blown films ........................................ 4

HDPE tarpaulin heat-sealing machines ........................ 101

Heart valve frame........................................................... 107

Heat transfer rolls .......................................................... 126

Heating & cooling ..................................................... 69, 91

Helical inline geared motors/reducers .............................. 40

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

High-performance screws .............................................. 126

High-speed mixer ...................................................... 37, 87

High-speed precise injection moulding machine........... 111

Hopper dryer .................................................................... 21

Hopper loader .......................................................... 21, 125

Hot air dryer ............................................................ 85, 125

Hot runner system ........................................................... 91

Hydraulic injection moulding machine .......................... 111

IML technique ..........................................................35

Infrared (IR) .................................................................... 63

Injection moulding machine 15, 56, 68, 108, 111, 116, BGF

Injection moulding ....................................................... 4, 99

Inks ................................................................................... 25

Inline drip tubing ......................................................... 8, 19

Inline shaft mounted helical geared motors/reducers ...... 40

In-mould labeling & injection moulding machine ........ 111

In-mould labelling equipment ....................................... 115

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

Laboratory chillers ...................................................109

Large flow water heaters .................................................. 91

Liquid crystalline lymer (LCP).....................................BIC

Loading arms ................................................................... 50

Manual & hydraulic screen changers ........................126

Manufacturing plastic auxiliary equipment ...................... 28

Masterbatch/plastic compounds ....................................... 25

Masterbatch feeder ......................................................... 108

Masterbatches................................................................... 49

Material dryers ........................................................... 17, 75

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

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

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

LIST OF PRODUCTS


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

Material testing instruments ............................................ 81

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

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

Mould temperature controllers ........................................ 85

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

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

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

Monolayer blown film line ....................................BC, 8, 19

Motor ............................................................................... 27

Mould temperature controller .................................. 21, 125

Moulding compound injection moulding machine ....... 111

Moulds ....................................................................... 37, 87

Mould-temperature controller and chiller ..................... 114

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

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

Multilayer blown film line ..............................8, 12, 19, BC

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

Napkin dies ...............................................................71

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

Optical brightners ............................................................ 51

Panel meters ............................................................121

Paperless recorder ............................................................. 10

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

Pelletiser parts .................................................................. 71

Pelletisers .................................................................. 71, 126

Perform injection moulding machine ............................ 111

PET bottle testing equipment ......................................... 81

PET perform dedicated machine..................................... 65

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

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

Pharmaceuticals/cosmetics ............................................... 25

Phase failure relays ......................................................... 121

Plastic board production system ...................................... 73

Plastic brighteners/shiners and whiteners ...................... 114

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

Plastic flap-loaded foot valve ......................................... 115

Plastic injection moulding machineries ........... 23, 109, 114

Plastic masterbatches ....................................................... 67

Plastic milk cans............................................................. 112

Plastic moulding ............................................................... 25

Plastic planters ............................................................... 116

Plastic processing machinery ancillaries and spare .......... 97

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

Plastic raw materials....................................................... 112

Plastic textile and machinery ........................................... 47

Plastics washing line ........................................................ 61

PLC .................................................................................. 77

Pneumatic-driven large beam robot ............................... 108

Polyacetal copolymer .....................................................BIC

Polybutylene terepthalate ..............................................BIC

Polyester staple fibre ......................................................... 61

Polymer application pack ............................................... 112

Polymer conveyer belt ...................................................... 21

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

Polyphenylene sulphide .................................................BIC

Pouch maker ....................................................................... 3

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

Presses .............................................................................. 73

Priming valves .................................................................. 50

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

Printing presses ................................................................ 73

Process controllers ............................................................ 10

Profile controller ............................................................... 77

Pulverise ..................................................................... 37, 87

Pulverise discs .................................................................. 71

Pump .......................................................................... 31, 50

PVC .................................................................................. 25

PVC compounds .............................................................. 49

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

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

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

PVC perforated cable tray ............................................ 116

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

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

Quick mould change system .....................................115

Recycling ...................................................................69

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

Reducer ............................................................................ 27

Relays ............................................................................. 121

Resin dehumidifier ........................................................... 83

Right-angled helical bevel geared motors/reducers ......... 40

Right-angled helical worm geared motors/reducers ........ 40

Rigid injection moulding machine ................................. 111

Robot system .................................................................... 21

Robotic automation ...................................................... 115

Rock-n-roll machine .................................................. 37, 87

Roots blower .................................................................... 31

Rotary automatic hot colour marking machines .............. 93

Rotary cutters ................................................................... 71

Rotary dies ....................................................................... 71

Rotomoulding machine .................................................. 110

Round table carrousels ..................................................... 37

Safety access equipment .............................................50

Screws ............................................................................... 97

Sealants............................................................................. 25

Servo-driven pouch maker ................................................. 3

Servo energy-saving machine ........................................... 65

Sheet calendaring line ...................................................... 73

Shut-off nozzles ............................................................. 126

Side-weld bag maker .......................................................... 3

Single mill pulveriser .................................................. 37, 87

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

Single-screw extruder plant .......................................... 6, 14

Software for central monitoring....................................... 83

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

Storage tank equipment ................................................... 50

Strapping band extruding line ....................................... 109

Strech blow moulding ...................................................... 18

SV power-cooled motor ................................................... 27

Swing-arm robot ............................................................ 110

System solution ................................................................ 91

Tank truck equipment ................................................50

Tape stretching line with inverter-driven cheese winders 12

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

Temperature controller ....................................... 10, 77, 121

Temperature controller and waterflow regulator ............ 114

Temperature indicator .................................................... 121

Testing instruments .......................................................... 81

Thermic fluid heater ...................................................... 116

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

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

Thermoplastic polyurethane ............................................. 89

Thermoset ........................................................................ 25

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

Thin flim dryer .............................................................. 112

Three arm biaxial rotomoulding machine.................. 37, 87

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

Transmissions & ptos ....................................................... 50

Twin-mill pulveriser ................................................... 37, 87

Twin-screw ..................................................................... 107

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

Twin-screw element ....................................................... 107

Twin-screw extruder ................................................. 61, 107

Twin-screw extrusion line ............................................ 6, 14

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

Two-platen injection moulding machine ....................... 111

Ultrasonic flow meter .................................................10

Universal bag maker ........................................................... 3

Universal controller .......................................................... 77

UV stabilisers ................................................................... 51

Vacuum booster pump ................................................31

Vacuum dryer ................................................................... 85

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

Vacuum pumps & systems ............................................... 50

Vacuum system ................................................................. 31

Variable displacement pump energy-saving machine ...... 65

Vario speed variators ........................................................ 27

Vertical machining centre .............................................. 111

Vertical sachet packing machine ........................................ 3

Vibro screens .............................................................. 37, 87

Volumetric dosing unit ..................................................... 83

Warehouses ...............................................................73

Water chiller ..................................................................... 83

Water jetting .................................................................... 50

White masterbatches ........................................................ 51

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

ACS Auxiliaries India Pvt Ltd ...................... 28

T: +91-02135 - 329112

E: [email protected]

W: www.aecinternet.com

Aerodry Plastics Automation Pvt Ltd ............ 69

T: +91-120 4766777


W: www.aerodry.com

Aeromec Marketing Co Pvt Ltd .................... 93

T: +91-250-2454915


W: www.aeromec.in

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

T: +91-011-41612244


W: www.alokmasterbatches.com

Ask Me .......................................................119

T: +91-3555 5555

E: twitter.com/AskMe_35555555

W: www.facebook.com/AskMe.infomedia18

Boge Compressed Air System ....................... 33

T: +91-44-43009610


W: www.boge.in

Eng Expo Hyderabad ...................................113

T: +91-09819552270


W: www.engg-expo.com

Everest Transmission .................................... 31

T: +91-11-45457777


W: www.everestblowers.com

Ferromatik Milacron India Pvt Ltd ............... 21

T: +91-79-25890081


W: www.milacronindia.com

Gardner Denver Engineered Product

India Pvt Ltd ................................................ 50

T: +91-79-40089312


W: www.gardnerdenver.com

Gelco Electronics Pvt Ltd ............................121

T: +91-79-22200902


W: www.gelco-world.com

Glaves Corporation ...................................... 71

T: +91-141-2460324,+91-9983330808

E: [email protected], [email protected]

W: www.glaves.biz

Hinds Machineries ....................................... 23

T: +91-0124-4368305


W: www.hindsmachine.com

Hindustan Plastic And Machine

Corporation ..............................................6, 14

T: +91-011-25473361


W: www.hindustanplastics.com

Huarong Plastic Machinery Co Ltd .............111

T: +91-9825739634


W: www.huarong.com.tw

Husky Injection Molding Systems Pvt Ltd ..BGF

T: +91-22-25706316


W: www.husky.ca

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

T: +91-2646-222163


W: www.jpextrusiontech.com

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

T: +91-22-2673 4822


W: www.kolsite.com

Landmark Extrusion & Engineering ............. 61

T: +91-9873252699


W: www.landmarkextrusion.com

Larsen & Toubro Ltd ................................... 53

T: +91-22-6752 5656


W: www.larsentoubro.com

Litel Infrared Systems Pvt Ltd ...................... 63

T: +91-020 - 66300633/636/637


W: www.litelir.com

Lohia Starlinger Ltd. .................................... 47

T: 011-30641770


W: www.lohiagroup.com

Lubrizol Advanced Materials India Pvt Ltd .. 89

T: +91-22-66027800


Mamata Machinery Pvt Ltd ............................ 3

T: +91-79-66309800


W: www.mamata.com

Matsui Technologies India Ltd. .................... 85

T: +91-0120-4243862


Mifa Systems ................................................ 77

T: +91-79-26870825


W: www.mifasystems.com

Mold - Masters Technologies Pvt Ltd ........... 95

T: +91-422-4502171


W: www.moldmasters.com

Mona Chem Additives Pvt Ltd ..................... 25

T: +91-261-2894847


W: www.monachem.com

N.A. Corporation ......................................... 87

T: +91-79-25840374


W: www.naroto.com

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

T: +91-79-26561312


W: www.neejtech.com

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

T: +91-9909974224


W: www.niigataindia.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 .................................... 83

T: +91-22-27782367


W: www.piovan.com

Plastiblends India Ltd .................................. 51

T: +91-022-67205200


W: www.plastiblendsindia.com

Poly Mechplast Machines Ltd ....................... 18

T: +91-265-2631211


W: www..polymachplast.com

Polyplastics Marketing (India) Pvt ............. BIC

T: +91-22-67587668


W: www.polyplastics.com

Power Build Ltd ........................................... 40

T: +91-2692-231070


W: www.pbl.co.in

Prasad Koch Technik Pvt. Ltd. ...................... 37

T: +91-79-25830112


W: www.prasadgroup.com

Prayag Polytech Pvt Ltd ............................... 67

T: +91-011-47262000


W: www.prayagmb.com

Presto Stantest Pvt Ltd ................................. 81

T: +91-129-4085000


W: www.prestogroup.com

Procon Technologies Pvt Ltd ........................ 10

T: +91-79-27492566


W: www.procon.co.in

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

T: +91-22-42461500


W: www.rrplast.com

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

T: +91-2827-252701


W: www.rajoo.com

Rotomotive Powerdrives India Ltd. ............... 27

T: +91-2692-230430


W: www.rotomotive.com

Sacmi Engineering India Pvt Ltd .................. 56

T: +91-7600003968


W: www.negribossi.com

Sanity International ..................................... 97

T: +91-79-65227458


W: www.sanityindia.com

SCJ Plastics Ltd ........................................... 49

T: +91-011-25439950


W: www.scjindia.com

Shanghai Forward Machinery Co., Ltd ......... 73

T: 86-21-5990-8899


W: www.forwardsh.com

Shini Plastics Technologies I Pvt Ltd ............ 91

T: +91-250-3021166


W: www.shini.com

Shri Gurukrupa Engineering Works ............101

T: ‘+91-265-3042371


W: www.gurukrupaengg.com

Som Shiva Impex Ltd ................................... 99

T: +91-79-26763503


W: www.simpexin.com

Sri Sai Plasto Tech ....................................... 65

T: +91-44-42994365


W: www.srisaiplastotech.com

Steer Engineering Pvt Ltd ...........................107

T: +91-80-23723309

E [email protected]

W: www.steerworld.com

Toshiba Machine (India) Pvt. Ltd. ................ 68

T: +91-011-43291111


W: www.toshiba-machine.co.jp

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

T: +91-22-25506712


W: www.unimark.in

Unimark (Stahuli)......................................... 75

T: +91-22-25506712


W: www.unimark.in

Vista Intergraded Pvt Ltd ............................... 4

T: +91-020-46781106


W: www.liad.co.il

Witte Pumps & Technologie ........................ 32

T: +91-11-41613643


W: www.witte-pumps.de

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

T: +91-44-42077009


W: [email protected]

Xaloy Asia (Thailand) Ltd. ..........................126

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

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 August 2012

Modern Plastics & Polymers August 2012

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Modern Plastics & Polymers - August 2012