PRA November-December 2012 Issue

A S l A ’ S L E A D l N G m aga z l ne f o r t h e p las t l c s and r u b b e r l nd u s t r y

業界新聞 新興中的印尼市場

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210(W) x 276(H) (PRA)- Eng.pdf 1 2012/11/2 13:45:06

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In this issue

Volume 27, No 194

publlshed slnce 1985

A S l A’ S L E A D l N G m aga z l ne f o r the plastlcs and rubber lndustry

Publisher Arthur Schavemaker Tel: +31 547 275005 Email: arthur@kenter.nl

Features 焦 點 內 容 14 國家焦點: 新興中的印尼市場 16 Country Focus

Indonesia’s resilient growth is bolstered by a stimulated local industry that needs the technologies to cater to the rising demands

18 Cover Feature

Executive Editor Tej Fernandez Tel: +60 3 4260 4575 Email: tej@plasticsandrubberasia.com Editorial/Production Coordinator Angelica Buan Email: gel@plasticsandrubberasia.com

Taiwanese technology receives global accolade especially from the emerging markets in Asia, the Middle East and Africa

Chinese Editor Koh Bee Ling

22 Processor Report

Circulation Abril Castro Email: abril@taramedia.com.my

Since food wastage is a serious global problem, Indian processor Santoshi is innovating film packaging to become part of the solution

24 Automotive

Plastics and rubber polymers are taking a primary role in the automotive sector to reduce weight of vehicles

27 Country Focus

Admin & Finance Manager Tean Arul Email: tean@taramedia.com.my Singapore Office Contact: Anthony Chan Tel: +65 63457368 Email: acesap@gmail.com

The Philippines has jumped on the ban-the-bag wagon, but at what cost to the economy?

Permits

Regulars 概 要

Printer KHL Printing Co Pte Ltd

ISSN 1360-1245

MICA (P) 021/08/2012

4 Industry News PRA is published 8 times a year in Mandarin and English by Kenter & Co Publishers’ Representatives BV.

8 Materials News 10 業界新聞

Supplements 副 刊 Machinery makers at the recent Fakuma in Germany, beat the Eurozone strife, with an exemplary showcase of technology The Malaysian rubber industry expects to harness technology on its climb up to the world’s top spot

On the Cover In a climate of economic uncertainty, Southeast Asia is expected to weather the crisis and emerge as a model for growth-driven economies

Connect @ PRA facebook.com/PRA.Malaysia

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Whilst every effort is made to ensure that the information contained in this publication is correct, the publisher makes no warranty, expressed or implied, as to the nature or accuracy of such material to the extent permitted by applicable law. © 2012 Kenter & Co Publishers’ Representatives BV No part of this publication may be reproduced, stored or used in any form, or by any means, without specific prior permission from the publisher.

PRA is circulated free to trade readers in the plastics and rubber industry. Airmail subscriptions are available at US$160 within Asia and US$250 to all other countries outside Asia.

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www.plasticsandrubberasia.com www.rubberjournalasia.com

Industry News

Capacity additions in Europe/US

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ermany-based Ticona, part of US firm Celanese, says it has had a record breaking third quarter for its long fibre-reinforced thermoplastics business and expects to increase its output in view of this and to “meet increasing demand for this metal replacement material in automotive, industrial, electrical and electronic and consumer applications.” The firm produces the material at its facilities in Germany, US and China. A new LFRT pilot production line will also open in Germany end of the year and last year, Ticona opened the

world’s largest acetal production plant in Frankfurt.

Another German firm Evonik is increasing production capacity for 1-butene to 75,000 tonnes in the country, to bring it to a total capacity of 310,000 tonnes, making it the world's top producer of 1-butene. Worldwide demand for 1-butene is increasing by about 5% a year. In the production of PE, 1-butene is used mainly as a co-monomer giving it improved tear strength for packaging films.

Evonik is also constructing the first 120,000 tonnes/year MMA

M&As across the globe • US compounder PolyOne is paying US$343 million to acquire US film/sheet manufacturer Spartech Corp.

• US private equity firm SK Capital Partners is acquiring the antioxidant and UV stabiliser solutions business of Chemtura for US$200 million.

• Chemical solutions provider Borealis is acquiring the shares of DSM Plastomers and Exxon Chemical Holland Ventures, each holding a 50% interest in Dutch firm DEXPlastomers.

• US extrusion machinery maker Davis-Standard has acquired drive and control systems provider Circonix

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Technologies and turnkey machine relocator CX Systems.

• US extrusion machine maker Gloucester Engineering is acquiring Pearl, which offers low-friction surface technology for extrusion equipment.

• Germany-based Hillenbrand is acquiring compound machine maker Coperion, which will be integrated into the Process Equipment Group (PEG) unit, comprising auxiliary equipment makers K-Tron, Rotex and TerraSource Global.

• Canadian private equity firm Onex is buying German machinery maker KraussMaffei Group for EUR569 million from its owner

NOVEMBER / DECEMBER 2012

plant using the Aveneer process in the US. The process is distinguished by an improved carbon footprint with emissions lower than 1,000 kg CO2 per tonne of MMA, or a little over half of the current value. To date Evonik has produced MMA at the German sites of Worms and Wesseling as well as in Fortier (US) and Shanghai (China).

Both plants are scheduled to come on stream in 2015.

Meanwhile, UK-based Victrex Polymer Solutions is increasing capacity of its polyaryletherketones (PAEK) by 70% to bring it up to 7,000 tonnes/year

Madison Capital. Onex has owned Husky Injection Molding and also owns DavisStandard.

• US-based technology solutions provider Nordson Corporation has bought certain aspects of the extrusion die assets of Kodama Chemical Industry, a long-time distributor of Nordson’s EDI (Extrusion Die Industries) business in Japan. Early this year, Nordson acquired EDI Holdings, a provider of slot coating and flat polymer extrusion dies for processors and web converters.

• US-based Graham Group has acquired American Kuhne, a manufacturer of extruders, screws, and integrated extrusion systems, from the Kuhne Group in Germany.

by 2015, from its current capacity of 4,250 tonnes/ year.

Elsewhere, India-based polyester maker JBF Industries is setting up a 432,000-tonne/year PET plant in Geel, Belgium; to start up by 2014. Said to be Europe’s largest PET facility, JBF will make PET using purified terephthalic acid (PTA) supplied by BP Chembel, located adjacent to the site. The plant will be built by Uhde InventaFischer and will use its patented Melt-To-Resin (MTR) technology. The integration of a 54,000tonne/year Flakes-To-Resin (FTR) recycling line will also allow 25% of the PTA required to be replaced with recycled material.

• Malaysian stretch film major Scientex is buying its rival packaging firm GW Plastics Holdings’s (GWP) Great Wall Plastics and GW Packaging for RM283 million, thereby increasing its cast film ouput by a third to 154,000 tonnes from 120,000 tonnes currently, making it one of the world's largest industrial plastic packaging manufacturers and exporters with sales reaching RM1 billion.

• Indian flexible packaging films producer Jindal Poly Films is buying US-based Exxon Mobil Chemicals’s global BOPP film business, comprising manufacturing sites in the US, Netherlands and Europe.

Industry News

Baerlocher opens plant in China

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erman additves maker Baerlocher has opened a 40,000-tonne/year capacity plant in Changzhou. It will produce Ca-based and Pb-based-stabiliser systems.

News In Brief BASF’s R&D in China and TPU in Germany German chemical firm BASF has set up the Innovation Campus Asia Pacific to strengthen R&D activities within the region; and its new integrated Greater China headquarters.

The EUR55 million expansion in Pudong, Shanghai, will ultimately employ more than 2,500 employees. Meanwhile, BASF Polyurethanes in Lemförde will build a new production complex for its Elastollan thermoplastic polyurethane (TPU), its biggest investment in the site to date, with start-up planned by 2014. The firm is also acquiring Poland-based Ciech’s global TDI (toluene diisocyanate) business and also recently opened its first Russian applications technology centre for PU systems.

Petronas opts out of PVC Citing unsatisfactory business, Malaysia’s Petronas Chemicals is discontinuing its vinyl business, comprising two plants in Malaysia and one in Vietnam, by 2013. The discontinuation of the

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In his opening address, Dr Michael Rosenthal, Chairman of the Advisory Board of the Baerlocher Group, said that the Chinese market had been the biggest growth market for PVC for many years,

business will result in a charge of RM560 million in the fourth quarter of 2013. The three plants produce vinyl chloride monomer (VCM) and PVC. Toray goes to Indonesia Japanese firm Toray Industries is investing 600 million yen in a new resin compounding base in the country to produce 6,000 tonnes/year of PBT and nylon. The facility will start operation in November 2013 and will meet demand for engineering plastics in the country, which is expected to grow at an annualised pace of 9% from 21,000 tonnes/year in 2011 to 45,000 tonnes by 2020.

Versalis pushes Asian strategy Italian elastomer supplier Versalis, a subsidiary of Eni, and South Korean Honam Petrochemical are setting up a elastomer plant in Yeosu. The new site will use Versalis’ proprietary technologies and will have a production capacity of 200,000 tonnes /year of elastomers, mainly for the Asian markets. The start-up is planned by the end 2015. Versalis also recently set up an office in Shanghai and has entered into a joint venture with Malaysian firm Petronas for the development and joint

NOVEMBER / DECEMBER 2012

and thus warranted an investment of this nature for the company.

Baerlocher, through its local sales company Baerlocher (Shanghai) Trading, which has been operating since 2007, has been an importer of solid PVC stabilisers

use of a production plant in the country.

Dow adds R&D for PV films in China According to Applied Market Information, the photovoltaic (PV) industry grew at 70% a year from 2006-2011 and further growth is expected. In 2011, polymer usage in the manufacture of PV modules was worth US$2billion. With China housing a majority of PV suppliers, it is no surprise that Dow Chemical has set up a PV films application laboratory in Shanghai.

The firm produces Enlight polyolefin encapsulant films and back encapsulant composite materials. Dow also recently opened a facility in Map Ta Phut, Thailand, to make Enlight products.

Clariant/Wilmar to produce amines Swiss speciality chemicals supplier Clariant and Singapore-headquartered agribusiness group Wilmar International are setting up a 50-50 joint venture to produce and sell amines and selected amines derivatives.

Wilmar will contribute a new plant in China as well as its oleochemical expertise, including access to renewable raw materials. Wilmar is among the world's largest processors and merchandisers of palm

in the region.

The project further complements Baerlocher’s regional strategy following the earlier establishment of the production joint venture, Jiangsu U&B, which manufactures liquid mixed metal stabilisers.

and lauric oils.

Mitsui to expand metallocenes in Singapore Japanese firm Mitsui Chemicals is expanding its global metallocene business operations under its wholly owned subsidiary, Prime Polymer, by establishing a sales company and expanding its Singapore facility for its Evolue metallocene LLDPE. Last year, the firm expanded its capacity in Japan from 240,000 to 300,000 tonnes/year. The new plant with a capacity of 300,000 tonnes/ year will be situated in Singapore.

Huhtamäki buys Indian label firm Norwegian flexible packaging firm Huhtamäki Oyj’s subsidiary in India has acquired 51% equity of privately held Webtech Labels for EUR7 million. Webtech Labels specialises in manufacturing highend pressure sensitive labels, especially for pharmaceutical customers. The annual net sales of the company are EUR10 million. The firm says the acquisition complements its flexible packaging product portfolio.

INDUSTRY NEWS

Klöckner Pentaplast on global expansion drive

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ermanyheadquartered rigid films producer Klöckner Pentaplast is investing US$51.8 million to expand its capacity at its facilities in Suzhou, China; Cotia, Brazil; and Santo Tirso, Portugal.

The firm will open its first Chinese production site in Suzhou to produce packaging films for the growing domestic market. The first phase of operations will focus on transverse direction oriented shrink-label films and a R&D centre.

The US$29.5 million investment will increase Klöckner Pentaplast’s global shrink-films capacity by 6,000 tonnes.

In Brazil, the company will invest in 1,200 tonnes of additional coating and laminating capacity suitable for the production of PVdC-coated and laminated packaging films to service the Latin

American pharmaceutical industry. In addition, PVC calendaring capacity will be increased by 12,000 tonnes to service the pharmaceutical, food, print, card, and generalpurpose thermoforming markets. The US$15.1 million investment will add 36 employees and start-up will be undertaken progressively from 2013 to 2014.

The new capacity further complements the group’s existing film production capacity at two facilities in Latin America, Villa del Totoral, Argentina, and Cotia, Brazil.

Meanwhile, in Portugal, it will add to its European production capacity for polyester films.

Primarily used for food and consumer packaging applications, the new 8,000 tonne-capacity addition is expected to start up by late next year.

Automatik expands rotor and pump service to Malaysia

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elletising rotor grinding machine provider Automatik Plastics Machinery has decentralised its service with the addition of a new grinding machine and pump repair service in its Malaysian service centre. When regrinding rotors, Automatik tailors the tooth profile so that the geometry of the cutting edge is adapted to the application, allowing for optimised cutting performance. In addition, Automatik offers rotors in a wide range of sizes and blade construction materials, including tool steel, stellite, powder steel, carbide and ceramic. The company regrinds more than 3,600 cutting rotors/ year and anticipates growth of about 10% in 2013. The Malaysian grinding centre was established in 2009 and Automatik also has other service units in Brazil, China, Germany, Taiwan

PRA

and the US. Meanwhile, with the addition of pump repair services, the firm is marking a further step in the integration of the facilities of Maag and Automatik. The strategic location within the region will offer benefits to both Maag and its Asian customers in terms of speed, cost and streamlined order handling. The firm also offers this service in China, Europe and the US and says that the first repair orders in Malaysia have already been completed.

Given the growing market for service requests, plans are already underway to further broaden the service organisation’s activities in Asia. With this newest additions to the portfolios, Maag and Automatik continue to operate the largest service network in the respective geographical markets.

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GREEN Materials News 8

Market developments across all fronts Bioplastics are expected to grow fivefold by 2016, with Asia in the lead, said speakers at the recent European Bioplastics Conference in Berlin, Germany. Meanwhile, the industry is being edged ahead with new launches.

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n above-average positive development in bioplastics production capacity has made past projections obsolete, says the European Bioplastics industry association in its latest report it publishes annually in cooperation with the Institute for Bioplastics and Biocomposites from the University of Hannover.

The market of around 1.2 million tonnes in 2011 will see a fivefold increase in production volumes to around 5.8 million tonnes by 2016. By far the strongest growth will be in the biobased, non-biodegradable bioplastics group. Especially the so-called ‘drop-in’ solutions, i.e. biobased versions of bulk plastics like PE and PET, which merely differ from their conventional counterparts in terms of their renewable raw material base, are building up large capacities.

Leading the field is partially biobased PET, which is already accounting for approximately 40% of the global bioplastics production capacity. Partially biobased PET will continue to extend this lead to more than 4.6 million tonnes by 2016. That would correspond to 80% of the total bioplastics production capacity. Following PET is biobased PE with 250,000 tonnes, constituting more than 4% of the total production capacity.

Meanwhile, production capacity of mainly PLA and PHA will increase by two-thirds by 2016, to 298,000 tonnes (+60%) and 142,000 tonnes (+700%) respectively.

But the report also says while Europe and North America remain interesting as locations for R&D and also important as sales markets, new production capacities are favoured in South America and Asia.

The automotive industry is expected to be a main user of bioplastics as was affirmed with the two winners, Bioplastics and Biocomposites (Hannover, Germany) and Takata Corp (Japan), who were awarded for developments at the conference. Takata received the award for its ongoing project to present the possibilities and limits of using biobased plastics in sensitive automotive applications such as airbags and steering wheels.

The company has tested components in accordance to automotive i n d u s t r y specifications, thus supporting its customers' efforts The Bioconcept car has a tailgate to define the made with an epoxy resin technical limits of reinforced with flax fibres biopolymers.

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Meanwhile, the Institute for Bioplastics and Biocomposites (IfBB) developed a racing car tailgate made with an epoxy resin reinforced with flax fibres as part of the biodiesel-powered Bioconcept Car project, a project aimed at building as many parts of the car - interior, underthe-hood and body parts - from biobased plastics and biocomposites. The project demonstrates how the various biobased materials can be precisely tailored to provide the properties required for the relevant applications.

New product launches, collaborations and capacities • US compounder PolyOne has introduced reFlex 300 bioplasticiser, which is derived from rapidly renewable feedstocks and is certified to contain 99% bio-based content, in accordance to the USDA BioPreferred programme.

The non-phthalate alternative provides a one-for-one replacement for general-purpose plasticisers used in flexible PVC formulations for the healthcare, electrical, building and construction and consumer goods sectors.

• US firm Metabolix has developed a series of PHA copolymers and demonstrated that they were miscible with PVC resins, significantly improving the mechanical and environmental performance. Metabolix worked with AlphaGary, a Massachusetts-based custom compounder of PVC and TPE/TPO materials, to validate the modifiers.

Metabolix plans to manufacture these new PHA products in the 10 kilotonne/year facility that it is establishing in Leon, Spain.

• Perstorp has introduced Capa thermoplastics for formulating biodegradable plastics. The firm says it has recently invested in making these competitive products available in large volumes.

• German firm Evonik Industries has started offering a rayon-fibre-reinforced variant of its biobased Vestamid Terra. By foregoing mineral reinforcement through glass fibres, this combination results in a merger between high bio-content and excellent reinforcing potential.

Evonik also plans to increase its capacity and expects to implement it in 2013. According to the firm, the castor bean oil-derived plastic has also established itself in the past few months as an alternative to its Vestamid PA12.

• US-based DuPont Packaging & Industrial Polymers will use sugar cane-based PE from Braskem to produce materials that are drop-in alternatives to the company’s conventional petroleum-based tie-resins and polymer

PLS MINB-VALU 1H:Layout 1 11/01/10 10:00 AM Page 1

Value in Flexible Packaging modifiers, as an extension of its Bynel and Fusabond resin families. Bynel coextrudable tie layer adhesive resins help packaging manufacturers optimise barrier, heat seal and other functions in multi-layer structures such as films, bottles, tubes and thermoformable sheet.

Fusabond polymers that have been functionalised (typically by maleic anhydride grafting) to help bond together dissimilar polymers used in toughened, filled and blended compounds.

• Dow Chemical is partnering with OPX Biotechnologies (OPXBIO) to commercialise a biobased precursor to acrylic acid, 3HP, using a range of sugar feedstocks.

OPXBIO's uses Efficiency Directed Genome Engineering (EDGE) technology to engineer microbes with an effective genome for producing a desired intermediate, rather than relying on the random aggregation of desired genetic mutations in the traditional approach.

This year, the firm scaled up the fermentation process for its BioAcrylic to 3,000 l.

• German chemicals supplier BASF and Dutch firm Purac, a subsidiary of CSM, are entering a joint venture to make biobased succinic acid, with an initial capacity of 10,000 tonnes in 2013, and an expansion to a second facility of 50,000 tonnes/year. The firms are modifying an existing fermentation facility at Purac’s Montmélo site near Barcelona, Spain.

• BioAmber from the US will supply biobased succinic acid to a Faurecia-Mitsubishi Chemical partnership for the production of automotive plastics. Faurecia from France has been conducting research into bioplastics derived from 100% natural materials since 2006 (BioMat project) and has signed an exclusive industrial partnership agreement with Mitsubishi Chemical to co-develop bioplastics designed for mass-production for use in automotive interiors. The partners will start by modifying Mitsubishi Chemical’s patented biomassderived polybutylene succinate (PBS) and ultimately target to be produced from 100% bio sources. Faurecia will hold exclusive rights to automotive applications of the specific polymers jointly developed under this project.

• Limagrain Céréales Ingrédients (LCI) of France is building a 8,000 tonne/year-facility for biolice bioplastic granules in Brazil. Biolice is a material that uses maize cereal flour as feedstock and is biodegradable and compostable. LCI, a division of grains company Groupe Limagrain, will start up the facility in the third quarter of 2013 and aims to grow its bioplastics business around the world, with India and China also named as target markets.

• Malaysian-headquartered natural-based chemicals producer Emery Oleochemicals is investing US$50 million to expand its facility in Ohio, US, to produce biobased polyols products for the automotive, furniture, major appliances (white goods) and various other industries. The company’s new manufacturing site is scheduled for commercialisation in 2014 and will be in addition to its existing Cincinnati operations.

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Country Focus

Emerging Indonesian market For four days, from 10-13 October, more than 665 companies participated in the 25th Plastic & Rubber Indonesia and ProPak 2012 exhibition. The question on everyone’s mind was how Indonesia’s industry is faring, says Oriana Titisari in this report.

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espite the global economic challenges that the world is facing, Indonesia is a force to be reckoned with. Recent reports say that the country’s economy grew 6.2% in the third quarter from a year earlier, in line with forecasts, as the global downturn finally began to drag on a country whose resilience has attracted an influx of foreign investments.

In the first quarter of 2012, investments totalled Rp53.6 trillion, of which Rp39.5 trillion came from overseas. Compared with last year, this is a 27.3% increase, according to Gita Wirjawan, Chief of Capital Coordinating Board (BKPM).

However, the growth is still strong by global standards and this enthusiasm has caught up in the country’s plastics and rubber industry. With a wealthy middle class of over 30 million and an overall population of 240 million, Indonesia is a captive market for the industry.

Early this year, Ariana Susanti, Business Development Director of IPF (Indonesian Packaging Federation), said that Indonesia’s packaging market is valued at US$4.9 billion and that it will grow 7% next year. Furthermore, Budi Susanto, Vice Chairman for Business Development, INAPLAS (Indonesian Olefin, Aromatic and Plastic Industry Association), said that this year Indonesia will consume more than 3 million tonnes of plastics.

Attraction to exhibition The exhibition featured group pavilions from Austria, China, Germany, Italy, Korea, Singapore, Taiwan and the Netherlands and showcased key European technology leaders like Engel, Erema, Gruber and GMT from Austria as well as Germany-based Kiefel, Vacuflex, and Kreyenborg; and Italian companies Amut, Torinova, and Plasmec.

One of the reasons for this is that the Indonesian government has imposed a regulation that 70% of all plastic products have to be produced locally. As such, local processors require the latest production technologies.

The event also attracted more than 12,000 visitors from 38 countries, according to show organiser PT Pamerindo.

“We think that this exhibition is quite small for a vast growing industry in the country. But we see lots of enthusiasm and are very excited to promote the Babyplast injection moulding machine,” stated Lee Hwa Chai from Singaporebased LNE Holdings.

The same excitement was shared by Samanyar Tongnat from Gala Industrial Asia. “This exhibition is a good place to build Aneka Lestari's Enviplast additive was relationships in the plastics industry. Since day one, our machine one of the attractions at the show demonstration has seen large crowds, just like when Apple launches its new gadgets and people queue up to see them!”

Rise of local players The huge opportunities and potential are being harvested by various local players, too. ISO 9001:200-certified Indonesian company PT Plasticolors Eka Perkasa was set up in 1998 and expanded to Vietnam in 2010. “The plastic industry in Indonesia is developing rapidly and we believe our company will expand along with it,” said Budi Kusuma Kwee, Executive Director. He added, “This year alone we are targeting a turnover of Rp70 billion. Our market has also expanded from Indonesia to other countries in Southeast Asia.”

Another local player’s booth that attracted many visitors is PT Inter Aneka Lestari Kimia, which offers Enviplast cassava fibrebased additive. When used for processing plastic bags, the bags

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NOVEMBER / DECEMBER 2012

Country Focus

Sachio Packaging was displaying a printing machine

naturally decompose in six months, with the help of microorganisms.

“We are very proud to be the first company in Indonesia to encourage the production of environmentally friendly plant-based plastic bags.

I personally think this is important since Indonesians use a lot of plastic in their daily lives and the awareness of going green is also expanding. We are optimistic that the industry will be attracted to our product,” said Marketing Manager Lanny Tjahjono.

Last August, many of the local manufacturers were disappointed with the Indonesian Finance Ministry’s new regulation that widened the coverage of plastic products that are exempted from import duty under the ASEANChina Free Trade Agreement, from 8,738 to 10,012 items. Included are plastic sheeting, toys and household equipment that represent 30% of overall plastic imports.

However with innovative products from Plasticolors and Inter Aneka, Indonesian plastic manufacturers will find a way to expand their markets.

Indonesian market opening up In his opening speech at the launch of the exhibition, Panggah Susanto, Director General of

that the firm had an average turnover Manufacturing Industry, Ministry of US$10 million and expects to of Industry of Indonesia stated that keep on growing. “Our plan is to there are 892 companies producing strengthen brand awareness in rigid and flexible packaging using Indonesia,” he added. thermoforming and extrusion

Another company that has processes. The 2.35 million-tonne opened a representative office capacity/year industry has a total in Jakarta is blown film machine production of 1.65 million tonnes. manufacturer Kiefel, a member of He believes that this will increase, the Brückner Group in Germany. considering that Indonesia’s plastic Said Sales Manager Willem Julienne, consumption is growing. Not to “We have offices in more than mention the 60% growth of the food 60 countries and we didn’t forget and fast moving consumer goods Indonesia because the country has all sectors. the qualifications that we needed to

However, he said that there are expand our Asian market.” problems that need to be dealt with.

Other foreign companies have “Our main obstacle to further growth appointed distributors to promote is the availability of raw materials,” their products in the country. Said he said.

Ifon Wijaya Martin from PT Bilplast

To meet local demand, Susanto Grapindo, “We are the official said that Indonesia imports 484,000 distributor of Linghein compressor, tonnes of PP. “We are also still a subsidiary of Atlas Copco Sweden, lacking enough oil refineries that are the world’s biggest producer of needed to produce naphthalene and compressors. Even Atlas Copco condensate. Thus, we need to import has confidence in the Indonesian 1.6 million tonnes of naphthalene and market.”

33 million barrels of condensate,” he

Another distributor, PT added.

Mitra Guna Mulia Engineering,

Is the market potential able to is marketing US-based Conair’s open enough doors for Indonesia’s auxiliary equipment. Said company plastic industry, despite everything? representative Daniel Tirtadjaja, Many companies interviewed at the “For the Indonesian market, we are exhibition are quite optimistic. promoting a portable dryer system Wanco Industrial of Singapore, the from Conair. Though this is not a Asian representative for South Koreanew product, we are offering the based Yudo’s hot runner systems most suitable system for the plastics and parts, recently set up a branch industry in Indonesia.” office in Indonesia. “Though we don’t

Thus, it can be seen that have any plans to open a factory, we Indonesia’s plastics and rubber believe that Indonesia is a growing industry still has opportunity for market,” said Johnson Lim Chin further growth, especially since Kiat, General Manager of PT Yudo the country is in a ready stance Indonesia. to become one of Asia’s most

With the largest booth at the prominent players. show, South Korean LS Mtron introduced two machines. According to Corporate Sales Manager Ho Shim, the LS toggle injection moulding machine series is energy-saving.

“A few Indonesian companies are already using our machines, such as PT Yasunli, PT Artha and PT Victory.

That is why we have LS Mtron's latest energy-saving series introduced to set up a sales office in the market Jakarta.” He also said NOVEMBER / DECEMBER

17

Cover Feature

Emerging markets a focus for Taiwanese technology Whereas previously buyers from developed countries dominated the Taipeiplas show, this year 78% of the international buyers came from emerging markets.

An estimated US$67.26 million worth of business was concluded at the show held from 21-25 September in Taiwan. A large proportion of the business was generated

by Asian, Middle Eastern and African buyers, said the show organisers, the Taiwan External Trade Development Council (TAITRA) and the Taiwan Association of Machinery Industry (TAMI).

An eye on the Asian markets Manufacturer of converting equipment for flexible packaging Worldly Industrial’s focus is South Asia, including India and Bangladesh. The firm, which has 250 clients in 27 countries, suffered declining sales amidst the European crisis, although it did export 60 machines, said Sales Manager Michael Chen. However, things are beginning to look up. “The first half of the year, we exported 35 machines and with sales improving in Pakistan and the African countries, we are optimistic of a turnover of US$10 million this year,” he said, adding that the firm expects to double its turnover next year.

It demonstrated a combo rotogravure printing and coating machine with a working speed of 250 m/minute, with Chen adding that the machine has been developed to cater to market needs for narrower webs and better resolution. He also said, “Four years ago, Worldly only sold solventless machines but since the stickiness is insufficient for heavy packaging, we are now also offering solvent-based models.” The firm recently sold two solventless machines to Turkey, including a new combo rotogravure/ lamination machine.

Another company that has an Asian market strategy is film/sheet/hollow sheet and foam sheet extrusion machinery maker Leader Extrusion Machinery. “We expect to expand our sales to Indonesia, Thailand and Malaysia over the next three years,” said George Chuang, Sales Manager. The firm was promoting a hollow sheet line, with Chuang stating that it cost 50% lower compared to Western lines, adding that “the return on investment period is less than six months.”

IS09001-certified Fong Kee International Leader’s George Chuang Machinery that specialises in blow moulding says “due to pricing the (54%) as well as blown/cast film and sheet Southeast Asian market is extrusion machinery (17%) saw a drastic 40% competitive” drop in turnover in 2009 but rebounded with a 23% increase in 2010 and this year expects a 10% gain. Susan Wei, Sales Director, said, “Last year, we exported 90% of our output to 120 countries – 12% to Europe and Africa and 12% to the Middle East. Next year, we are focusing on the Asian, US and Middle Eastern markets, especially for blow moulding machinery,” she said.

Celebrating its 60th anniversary next year, Fong Kee has two factories in Taiwan (one which was set up in 2008 with an investment of US$6 million) and another in China, as well as three branch offices in Malaysia, China and India.

Improvements to machinery During the show, Fong Kee demonstrated a three-layer, 1,000 kg/houroutput blown film line for agriculture film, recently exported to Turkey; a double-station/single head continuous extrusion blow moulder (HBA series) for making 20-30 l jerry cans and a compact machine featuring 40% lower footprint, with the capability of fast colour change of 1 hour instead of 3 hours.

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Cover Feature Another highlight was the ABI (accumulator head-type) machine for 20-1,000 l IBCs, recently exported to Germany for producing road barriers. Due to the shortage of EVA polymer in the market, the firm improved a three-layer sheet extrusion line for PC/PMMA optical sheet to allow the use of regrind in the internal layer, said Wei. Other improvements include a 600 kg/ hour co-extrusion cast film line that is able to process TPU instead of PVC. The 3.4 m width line has been sold to Indonesian firm Inova.

Jon Wai’s Robin Pan says that the firm is trialling the rapid heat and cold method to render glossy surfaces on electrical parts

Injection moulding machinery maker Jon Wai Machinery Works claims it’s the first in Taiwan to produce a three-platen machine and also a pioneer of AC synchronous motors. Adding another feather to its cap, the 31-year old firm, which makes around 1,400 machines/year and has a turnover of US$3 million, showcased an 850-tonne twoplaten machine. Though it was innovated in 2005, the JW model has been improved to feature a shorter length (21% savings) and 50% savings on hydraulic oil, compared to a three-platen model.

It was shown producing a television LED back cover (previously made of metal) in a 56-second cycle, using the compression moulding process.

“By using the process, we’ve been able to reduce the wall thickness from 2.3 mm to 1.8 mm,” said the firm’s President Robin Pan, adding that the machine was using a prototype mould.

“We changed the platen design to prevent deformity. The machine

has a stronger structure and higher precision,” he added. “It has a hydraulic injection and electrical charging motor or torque,” went on Pan, adding that the injection speed has been improved to 800 mm/ second as a result of the Austrian Keba controller. “The machine allows for a greener production as it uses less material and power due to the servomotor,” claimed Pan, adding that inverters are supplied

by Danfoss in Denmark and ABB in Finland.

It also showcased the IML process on its JW280 SLIM model that was producing an ice cream container. “Not only have we reduced the cycle time to 4.5 seconds but we believe that we are the first company to showcase the IML with a family mould,” said Pan, adding that the latter allows for multiple parts to be produced with one shot. Another new highlight was the JW180 SLIM shown with a 2+2 stack mould. It was producing a food tray in a cycle time of 2.4 seconds.

With more than 40 years in the business, extrusion machine maker Queen’s Machinery has used its Queen’s Leonardo Lee says the firm sells its experience products in 100 countries to develop worldwide, concentrating a threeon Southeast Asia, layer Central America, Russia blown and the Middle East film line for laminated films with a claimed output of up to 800 kg/hour.

“The screw is based on a force feeding design and the air ring is an up/down concept, allowing for enhanced cooling,” said spokesperson Leonardo Lee, adding that up to 30% regrind material can be used in the line. This was rounded up with automatic profiling measurement from Swiss firm Kundig and IBC from Plas Control (Germany). With an estimated

turnover of US$25 million a year, Lee said the firm was expecting a growth of 10% is this year, with a targeted reach to Southeast Asian markets.

Pros/cons of producing in China Favouring production in China, machine tool and injection moulding machinery manufacturer Victor Taichung has three factories in the country. Overseas Marketing Manager Martin Li said that the reduced production costs enables the firm to offer a better service.

“Almost 30% of the components are produced in China and key parts are from Taiwan,” he said, adding that in the future the firm intends to produce Japanesestandard machines but at lower prices.

It also has four factories in Taiwan employing 850 workers and is able to produce up to 1,300tonne machines and an output of 1,500 machines/year, mainly for the electronics market, and 1,800 machine tools/year. It displayed four machines at the show: a four-cavity IML machine with a 6.5-second cycle; a four-cavity machine integrated with robots with a 4-second cycle; a 50-tonne all-electric machine with Rexroth Bosch servomotors for up to 65% energy savings and a 64-cavity machine making medical syringe parts in a 15-second cycle. The latter machine was sold to a mould maker during the show.

Li also said China was the largest export market (40%) followed by Europe (25%) and Southeast Asia (15%). “Next year, we expect a growth of 10% and are targeting the Indonesian and markets such as Egypt and Algeria.”

Meanwhile, auxiliary equipment maker Shini faced labour shortages in China early this year. But according to Alan Chen, Overseas Business and Marketing Director, these were resolved by working with technical colleges near the firm’s facilities to offer students apprenticeships. “We also offer housing and a good working environment,” he added.

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Cover Feature

While the Chinese market is the firm’s biggest (30%), Chen anticipates a 15% drop in sales this year. “The sales decline in China is due to the global economy slowdown but we are banking on the 3C sector to pull us through,” he said, adding that last year the firm raked in a turnover of US$100 million. But the firm is also targeting new markets like India.

Capturing the 3C markets The global 3C (computers/ communications/consumer markets) is another growth avenue with revenue estimated to reach US$1.4 trillion by 2015, according to a report by Global Industry Analysts.

With 40% of its sales accounted by the 3C market, injection moulding machinery maker Multiplas is doubling its machine Integrated solutions are capacity a trend, says David Wu to 7,200/ from Multiplas year by setting up a new factory in Taoyuan.

General Manager David Wu said, “Our sales increased by 50% because of the growth of Apple, HTC and Samsung mobile electronics.”

To cope with the demand, the firm is investing US$20 million in the new plant that will be ready in 2014. Meanwhile, Southeast Asia accounts for 40% of the business, Wu said, adding that the firm is keen on developing further business in Indonesia and Vietnam.

Allocating 20% of its manpower in R&D, Multiplas is also catering to the industry trend for turnkey solutions complete with mould, packaging and take-out robots. At the show, it featured an integrated multi-material process for a screwdriver, which came complete with six-axis robot/CCD camera inspection. It was sold to Japanese customer Asumo.

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Injection moulding machine maker OMC (Outstanding Machinery Manufacturing), with a turnover of NT600 million/year, is also cashing on the 3C market, said company President Jerry Cheng, giving an example of a Nokia mobile phone case that is produced using an OMC machine.

“OMC is not the biggest machine maker but the best in terms of quality and price:performance ratio,” he said, adding that the firm’s target markets are Indonesia and Malaysia.

Jerry Cheng of OMC says though the company is “small” it prides itself on its quality products

During the show, OMC showed its OS320 48-cavity IML total solution in a 6.8-second cycle producing spoons, which is dubbed as a “consistent and stable machine”. Another 24-cavity OS250 model, integrated with a Yushin robot with inline packaging, was shown producing forks in a 6-second cycle.

Prize winners in the Tapeiplas awards A first prize winner in the extrusion machinery category was Jenn Chong‘s JC-3CX three-layer blown film line, shown processing Dow Chemical’s XUS LLDPE/ LDPE material. “The target is to achieve high clarity shrink film without using PVC,” said General Manager, Tony Wang, adding the Jenn Chong’s Tony 65/75/65 mm Wang said that the extruder line new line targets high clarity shrink film has an output

capability of up to 450 kg/hour.

"Also, the height of the bubble is only two decks instead of the previous three decks, allowing for 25% savings on material costs." Other highlights were the Sypro air ring from Italy and servomotor drives. The firm’s JC-EcoTrim prototype inline edge trim recycling machine also won second place.

And though the firm’s forte is not in blown film technology (“due to too much competition”) but monofilament and strapping lines, it spent six years developing its JC-3CX line. In terms of sales, Wang said that Asia was a focus, “since the European crisis”, adding that 95% of the output is directed at export markets. “We didn’t have much growth this year but our order books are full,” he said, adding that the firm rakes a turnover of US$7 million/year.

Meanwhile, blow moulding machinery maker Kai Mei Plastic Machinery’s latest MIB-85-PC injection stretch blow moulder (ISBM) boasts 30% savings in power use (it won second place in the awards).

Ten years in the making, Kai Mei's Jack Chen the eightspoke about the new cavity, multiblow moulder layer (up to six layers) model features interchangeable moulds (from 12-20 l) and an up/down extrusion system. “Compared to an extrusion blow moulder (EBM), the ISBM is able to save 30% on materials plus the finish is smoother. Also, an inverter can be installed to support two pumps,” said General Manager Jack Chen.

Whilst previously the container handle was produced separately it is now made in an integrated single process. “The handle has only 2-5% flash and around 20% regrind can be used for further savings on material costs,” said Chen.

Cover Feature Instead of using PC, which does not have good optics, Kai Mei is also recommending the use of Tritan co-polyester from Eastman Chemical.

It has also started trialling a PET and South Korean company SK Chemicals’s Ecozen bioplastic material. The 35-year old firm has sold six units locally as well as in Europe, Middle East and South America.

Fu Chun Shin (FCS) won second prize winner in the injection moulding machine section for its LM850SV two-platen machine. “The 850-tonne twoplaten hybrid machine is a new milestone.

It is paired with Kuka robots and a German FCS’s “boat”-shaped HT machine servomotor,” said Executive Director David Chen, adding that it renders 50% energy savings, which is “quite close to all-electric energy savings.” FCS sold one such model to TATA Group in India in 2010. At the show it was producing a 1.2 kg chair.

But the firm’s HT150-SV servopower-saving machine was a highlight as it took the Excellent Design award. “This machine has been selected as part of a government plan to value-add aesthetics in a machine design. First impressions do count and we are working to enhance the looks of our machines,” said Chen. The multi-component rotary table was shown producing a 135 g iPhone holder in PMMA, in a 120 secondcycle. Chen said that the display model had been sold to a Thailandbased houseware processor.

Another firm focusing on aesthetics is blow moulding machine maker Chumpower. It took the top prize for its CPSB-LS8 PET stretch moulding machine, which was designed in conjunction with the Yu-Lin University. Said Managing Director Bush Hsieh, “Not only does the machine use less air, power and has a lower footprint, it also comes in an enhanced design.” The displayed eight-cavity model, with a capability of up to 1,500 bottles/hour, a Yaskawa servomotor and Bekhof controller, had been sold to a Taiwanese beverage maker in Nantong.

Hsieh also shared the firm’s plans, ”We are expanding the China plant to increase capacity by another 100 units. Our target is to produce 400 machines/year, at both the Taichung and Fujian plants.” With 90% of its output exported, the firm’s main markets are still the Southeast Asian countries, South Korea, Japan, Africa and the Middle East, said Hsieh, adding that 8% of the US$40 million turnover/year is allocated for R&D. “We have enjoyed 15% growth over the past three years, simply because Chumpower Chumpower's Bush Hsieh caters to the food packaging market, which says R&D is vital for improvement is growing,” he added.

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Processor Report

Innovating barrier films for a cause India’s packaging industry is expected to grow 11% a year, with a turnover reaching US$21.59 billion by 2015, driven by the rising demands from the retail sector.

One company that will benefit from this is Santoshi Barrier Film India, a multilayer co-extruded plastic film manufacturer established in 2003, which last year installed a sevenlayer line from Indian machine supplier Mamata Extrusion Systems (MES), with a SCD die from Canadabased Brampton Engineering, to meet the demand.

After accumulating experience working as an operator in another factory, Madan Atkare started up Santoshi, together with his brother Dinesh, with a three-layer line before proceeding to the seven-layer barrier film line

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Why packaging?

Packaging is essential in reducing the amount of food wastage at different stages in the supply chain.

Conversely, inappropriate and sub-standard quality packaging promotes food wastage. At retail level, packaging innovation should extend shelf life.

Food wastage is becoming a serious problem worldwide, based on various studies including that of the Food and Agriculture Organisation (FAO) estimating some 280 to 300 kg of food/person is wasted each year in Europe and the US.

In Europe alone, food wastage is running at 90 million tonnes/year, and is expected to grow 40% by 2020.

Amidst this threat, the European Union is enforcing counter measures to this, urging all sectors, including the packaging sector to strategise. Otherwise, it says that food wastage will go up to 126 million tonnes or up by 40% in 2020, if unabated.

The figure, it says is twice the amount for developing countries including those in Southeast Asia. While convenience to dispose rather than re-use seems to be the practice in industrialised countries, the lack of technology within the producing-processing-distributing chain is causing wastage before food reaches the consumer. The organisation recommends that various technologies are now available including bag sealing to prevent wastage.

This is where packaging comes into the picture.

Curbing wastage in film packaging Currently ranked 11th in the global packaging industry, India’s fast paced growth will see it climb up to the fourth rung of the ladder in no time.

With competition gearing up, innovation is what delineates one company from the other. Santoshi Barrier Film India says it has been combining innovation and sustainability in its film lines to produce three-layer films made of PE and PP. It also manufactures barrier packaging material for packaging of oxygen-sensitive products and incorporates a nylon/polyamide barrier for products requiring 6 to 24 months shelf life.

Now, it has progressed to seven-layer EVOH film made from PA/PE, which preserves the freshness of the food and is used in applications such as the Modified Atmosphere Packaging (MAP) for oxygen-sensitive products as well as those requiring storage in controlled atmospheric conditions.

Dinesh Atkare, Managing Director, who is known in India’s flexible packaging industry for his processing knowledge and forward thinking, agrees that improving

Processor Report the films used in packaging can help reduce food wastage.

“By improving the barrier properties of films (to be at par) to world class standards, it is possible to protect perishable products and reduce spoilage due to better protection and longer shelf life.

Spoilage of perishable items like milk, edible oil and other dairy products is a national wastage,” he emphasised.

Driving this point, he said, “One of the most important ways of processing milk in absence of a cold supply chain is to pack milk in seven-layer films using the Ultra Heat Treated (UHT) process. In this way milk can be preserved for up to three months without refrigeration.”

Using blown film technology To realise this, the company bought the seven-layer co-extrusion blown film line from Mamata Extrusion Systems (MES) last year. The entire line was supplied by MES while Canada-based Brampton Engineering supplied the seven-layer streamlined co-extrusion die (SCD) component of the line. MES was formerly known as Mamata Brampton Engineering and was a joint venture of Brampton Engineering and the Mamata Group.

MES supplied this 4+1 pancake-type IBC Line with computerised controls. The line is capable of producing seven-layer films from 40-200 microns at maximum layflat width of 1,500 mm. The line, which consists of four 65 mm extruders three 50 mm extruders, has an output of 375 kg/hour.

“With the advanced SCD die technology, we are able to produce films that are superior (in quality) and more cost effective,” Atkare said of the MES machine.

“Another big advantage is the capability of MES to

Madan’s brother Dinesh also shares his passion.

“Our clear understanding of customer's requirements and hands on experience coupled with hard work has helped us expand our business threefold,” he says

upgrade this seven-layer line, in the future, to a nine-layer line with the addition of just two more modules in the die and two more extruders,” he said, adding that MES has already shown this capability when it upgraded a five-layer line to seven layers for one of its customers located near Ahmedabad.

“With the installation of this new seven-layer line, we will be able to bring to the market world class film with correct barrier properties and contribute positively in reducing wastage of perishable products,” Atkare said.

MES has seven barrier lines installed in India, translating to nearly 1,500 tonnes/month processing capacity – a point that favoured with Atkare’s plan for revving up his company’s productivity.

“MES’s machines render excellent film thickness variation control, achieving outputs of up to 400 kg/hour and bring about an extremely competitive cost to output ratio, all of which have accorded us the competitive edge in the market,” he said.

Furthermore, Atkare says the SCD die technology from Brampton Engineering has provided flexibility in terms of expensive polymers usage due to thermal isolation and individual layer thickness control. Due to the flexibility of the modules it is also possible to switch PA (nylon) usage from the middle layer to the outside.

“With such asymmetric structures it is possible to replace expensive laminates for packaging of dairy products like cheese and paneer,” he explained.

“The addition of this new seven-layer line to the existing facility has increased the application range covering films for packaging of UHT milk, skimmed milk powder, cheese packaging, meat and poultry; thermoformed barrier webs, lidding films, barrier films for toothpaste and many more,” he said.

Atkare further believes that the potential of barrier films with specialised applications in India is huge and the company is tapping on these opportunities.

The sevenlayer line was added on to meet the potential of the country’s growing packaging needs

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Automotive

Leading change with green mobility Plastics and rubber have long played a secondary role to metal in the world of car manufacturing but this trend is reversing.

Today, the plastic content in any car can amount to 20% and this is showing an upward trend. Similarly, synthetic rubbers will play a key part in tyres’ properties, boosting performance and ultimately reducing carbon emissions. Materials supplier Lanxess is leading the change with its wide offering of both plastics and rubber polymers.

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A

ccording to the American Chemistry Council (ACC), the average vehicle uses about 150 kg of plastics and plastic composites and 65 to 72 kg of rubber(1) as compared to 1,163 kg of iron and steel. However, the automotive industry is increasingly seeing the usage of these two raw materials – for instance, the application of rubber components in automotives is on the rise with modern vehicles using between 200 and 250 rubber parts made wholly or in considerable part out of rubber.

Considering the fast-rising number of vehicles on the roads worldwide and the importance of minimising the impact of mobility on climate change, high priority must be placed on protecting the environment.

The National Climate Change Secretariat in Singapore recently said that the transport sector is the third largest consumer of energy after the industry and building sectors in the country – accounting for about 13% of national energy consumption. It is also responsible for approximately 15% of total carbon dioxide emissions in Singapore, placing it as the second largest contributor behind the industrial sector.

Therefore the chief design consideration for automotive manufacturers going forward, under the scrutiny of regulators, will be to make vehicles as fuel-efficient as possible – all other environmental factors will also be affected by this consideration.

Innovative materials that help weigh it down Plastics already account for up to 20% of the automotive materials mix; after all, a 100-kg weight reduction results in fuel savings can reach as much as 0.5 l per 100 km.

Speciality chemicals firm Lanxess says its weight-saving materials and technology innovations can play a key role in achieving “Green Mobility” to conserve the environment, climate and resources. The firm supplies polyamides (PA) and polybutylene terephthalates The hybrid technology (PBT), marketed under the names features parts that are made Durethan and Pocan respectively. of plastics/metal or nylon These materials allow lighter composite sheets weight plastic parts to replace metal parts, rendering fuel saving and carbon emission solutions to the automotive industry.

Another element that will facilitate efficiency in comparison to metal parts are plastic composite sheets. These are easier to process, have excellent mechanical properties and weigh up to 40% less.

Over the last decade, automotive manufacturers have gradually shifted their focus from just using

Automotive

metals to using metals combined with plastics. Lanxess’s Durethan plastic compounds can already be found in car parts in combination with steel or aluminium.

For example, with the use of the super-tough PA6 for natural gas car tanks, an in-liner made of PA6 remains tough, even in extremely cold conditions. The material can be used to produce lighter highpressure tanks weighing four times less than a tank made entirely of steel.

Lightweight construction materials are in demand under the hood, too. Lanxess's new PA66 oil pan for cars with gasoline turbo engines will weigh around 1 kg less than the corresponding steel component and 50% less than an equivalent aluminium design.

Lanxess actualises the opportunities that can be harnessed by making oil pans using the highly reinforced PA6 Durethan DP BKV 60 H2.0 EF with 60% glass fibres by weight.

The next stage in the development process of hybrid technology is based on nylon composite sheets reinforced with continuous fibres.

The firm says it is confident

about the potential of composite hybrid technology in lightweight construction applications such as the world's first polyamide car brake pedal, reinforced with continuous glass fibres and designed for series production.

It is only about half the weight of comparable conventional sheet steel designs. Another ‘lightweight’ product is the housing for a passenger airbag module, which is over 30% lighter than an injection-moulded PA6 series design.

Lanxess has produced a new material model for composite sheets based on polyamide and can simulate the forming process with integrative simulation.

This has enabled the firm to factor in the appropriate loads when designing fibre-reinforced composite hybrid components made of polyamide on the computer for series applications.

Rubber contributes to green mobility, too Today’s high-tech tyres are quiet, and they gently cushion bumps in the road. They have a good road grip even when it’s raining or snowing. They provide secure

braking and do not burst even at super-high speeds of 300 km/hour.

Some of these tyres continue to roll even if they get punctured, while others help to improve fuel efficiency. These qualities would have been considered unthinkable just a few decades ago.

Developing the ideal tyre involves conflicting goals. When developers improve one of a tyre’s properties, others often worsen.

By their very nature, the tyres’ physical and chemical properties and performance characteristics are invertedly proportionate to one another. For example, the rubber compound has to be as soft as possible if a tyre is to drive, accelerate and brake very well on wet roads. But the softer the mixture, the greater the rolling resistance and abrasion, which, in turn, increases fuel consumption and causes the tyre to be more susceptible to wear and tear.

Although such conflicts cannot be eliminated, engineers, chemists and designers can make clever improvements that help to ‘cheat’ the laws of physics, so to speak. New types of materials, tread patterns, manufacturing processes, and, above all, altered

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Automotive rubber compounds improve the tyres’ properties and boost their performance. An especially important consideration in all of this is the fact that the chemical properties must be exactly right.

Lanxess manufactures neodymium-based performance butadiene rubber (Nd-PBR) and solution styrene butadiene rubber (SSBR), which is used in the sidewall and tread of a tyre. Nd-PBR enhances tyre performance in terms of lower rolling resistance and higher abrasion resistance and SSBR improves a tyre’s grip on wet roads.

On average, 20-30% of a vehicle’s fuel consumption and 24% of its CO2 emissions are related to tyres – Nd-PBR and SSBR are therefore key ingredients in “Green Tyres”, which render vehicles to become more fuel-efficient, are longer-lasting and, above all, more environmentally-friendly.

As one of the market leaders for Nd-PBR used in “Green Tyres”, Lanxess acknowledges that it is the fastest growing sector in the tyre industry, with an annual global growth rate of about 10%. Growth is even more pronounced in Asia at 13% per year(2).

The demand for “Green Tyres” is being driven by the mobility megatrend, above all in the regions of Asia and Latin America, as the middle classes in these regions becomes more affluent.

In addition, demand will be accelerated by tyre labelling being introduced around the world.

In 2011, Lanxess commissioned a study with research firm Frost & Sullivan to examine how motorists in Singapore would benefit from “Green Tyres”. According to the study, the use of “Green Tyres” on all vehicles in Singapore would result in a saving of 357,468 tonnes of carbon dioxide, as well as 146 million l of fuel annually(3).

The mandatory tyre labelling in the European Union (EU) was recently launched. Tyres will be graded from A to G according to their fuel efficiency and wet grip.

Rolling noise is also measured.

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Therefore, the new legislation provides more transparency for consumers by highlighting the added value of “Green Tyres”.

According to the Technical University of Munich, the market share of class A and B tyres in the EU is expected to reach 20-30% in 2017 and then rise further to 70-80% in 2022. Here in Asia, South Korea will lead the initiative with a similar labelling law that will officially commence on 1 December 2012.

Aiding customers to prepare their products to meet these legislations globally, Lanxess recently introduced the AA concept tyre, which is among the first to be presented that would earn a double-A rating under the new EU labelling regulations. “A” rated tyres provide the most wet grip since cars equipped with such tyres need 18 to 21 m less to come to a standstill from a speed of 80 km/hour compared to “F”-rated tyres.

key differentiating criterion among top-ranked tyres. Traditionally, tyre makers have operated within the “magic triangle” design principle, where improvements in durability have always come at the expense of either poorer performance in terms of rolling resistance or wet grip.

But now, Lanxess says that with its synthetic rubber, that is no longer the case.

The German firm also produces high-quality halobutyl rubbers (Bromobutyl and Chlorobutyl) for the tyre industry. Having high impermeability to gases and liquids, halobutyl rubber is particularly useful in helping tyre inner liners stay air-tight and safe. A properly inflated tyre with sustained tyre pressure translates to reduced rolling resistance and therefore lower fuel consumption and lower carbon dioxide emissions, and also a longer service period for the tyre.

Regular butyl has similar properties and is used in the inner tubes of tyres.

Looking into the future is always a difficult business — not least for car manufacturers. For them, it would be ideal to have some idea about tomorrow's forms of transportation, if only so they could start talking about the kind of technology and investment this might require. Yet one thing is certain: innovative materials are set to play a crucial role, not only in building future vehicles, but doing so with less negative impact on the environment.

Notes:

Lanxess says its AA concept tyre enables it to offer materials that have already been subject to rigorous testing, allowing customers to bring new tyres to market faster and strengthen their competitive position

With this concept tyre, Lanxess intends to demonstrate the importance of its Nd-PBR to increase durability. Even though the latter will not be rated on the new EU tyre labels, it will be a

(1) According to Automotive Products Finder, May 2010 (2) According to study by Technical University of Munich on Tire Labeling and Green Tires, study inquired by LANXESS (3) Based on the recorded vehicle population of 932,046 in 2010 by the Land Transport Authority.

Country Focus

Plastic bag ban in the Philippines: debating for real solutions The ban on plastic bags and other plastic single-use products has reached fever pitch across the globe, in view of the collective response to environment protection. The antithesis is the shrinking demand and dwindling market, leading to loss of jobs.

One country that has recently jumped on the ban-the-bag wagon is the Philippines, where it has become a political issue rather an environmental solution, and poses risks to the economy, says Angelica Buan in this report.

(L-R) Crispian Lao and Peter Quintana of PPIA are pushing for regulations and effective waste management

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arly this year, 14 Philippine plastics industry groups, including the Philippine Plastics Industry Association (PPIA), the Association of Petrochemical Manufacturers of the Philippines, the Packaging Institute of the Philippines, the Polystyrene Packaging Council of the Philippines (PPCP) and the Metro Plastics Recycling Industries, placed advertisements in major newspapers to vilify what they said were unfair attacks against plastics.

Plastics were deemed to be the root cause of solid waste problems in the country, which therefore transpired an intensifying campaign to ban plastic bags, instituted by local government units (LGUs).

To date, over 60 cities and municipalities nationwide have imposed plastic bag bans or other regulations, from imposing recovery fees per use of bags to stiffer fines for businesses caught violating ordinance provisions.

While the ordinances have commonalties, there are variations in the proposed plastic bag alternatives and penalties. Short of an ultimatum, the plastics industry, which according to the Philippine Chemicals 2012-2030 Master Plan will be contributing significantly to the Php300 billion revenue projected in the chemicals, plastics and rubber sectors, is calling for a more informed campaign. Some suggestions include the implementation of systematic recovery, segregation and recycling schemes, based on the framework of the Philippine Republic Act (RA) 9003 (The Ecological Solid Waste Management Act of 2000).

Why plastics?

Plastic bags and Styrofoam (PS foam) packaging were accused of being the main culprits for clogging up waterways and drains, thereby leading to extensive flooding in the country, during the Ondoy typhoon in 2009 and Habagat this year.

Peter Quintana, President of the Philippine Plastics Industry Association (PPIA), expresses his dismay over the growing anti-plastic sentiments. “Plastic products float and are thus visible, unlike other materials that submerge and tend to cause silting in flood waters,” he said during an interview at the recent Plastics Philippines show held 10-13 October at the SMX Convention Centre in Pasay City.

Echoing his statement was Daisy Concepcion Coroza, Secretary-General of the Polystyrene Packaging Council of the Philippines (PPCP), “Unfortunately, unlike other materials, plastic waste is easily seen and thus it is deemed an eyesore.”

Both agreed that misinformation about plastics and PS has led to this drastic campaign. It all started with the lead toxicity issue in plastic toys and plastic curtains.

While agreeing that lead-based paint used in toys and the PVC component of shower curtains does pose risks, they say that “plastic, per se, is safe.”

“There are many types of plastics just like there are many types of paper,” Coroza said, adding, “The ban is based on non-scientific facts, like the fact that PS is not biodegradable.

That is so passé since PS wastage can be recovered and recycled.”

Both plastics and paper are especially used in food packaging. “PS foam is increasingly being replaced with wax or plastic-lined paper. To recycle this type of paper, the wax or plastic lining has to be separated from the paper, which is a longer and more expensive process,” she explained.

She said that the association is encouraging its members to switch from PS foam to degradable food packaging, adding that bioplastics are also being eyed but compliance to food usage is still a stumbling block.

PPIA also debunks the notion that paper is an environment-friendly alternative in view of the fact that it takes 17 trees to make a tonne of paper and a gallon of water to make a single paper bag, using up to 300% more energy, whereas the same volume of water can produce 116 pieces of plastic bags.

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Country Focus This view is shared by Henry Gaw, President of PPCP, “Compared to plastic bags, paper bags are bulky and heavy (600% more) and more expensive (US$1.80 compared to US$0.60 cents for a plastic bag.” He also said that a PS foam cup only weighs 1 g whilst a paper cup weighs about 4 g.

Cardboard boxes, being alternative packaging in supermarkets and retail shops, are also posing problems to manufacturers of corrugated boxes.

Gaw said that since these boxes are used for packaging, the stores no longer sell the boxes back to manufacturers, and thus the supply cycle is affected. Moreover when disposed improperly, just like paper, the heavier cardboard boxes sink to the bottom of waterways and cause silting; and since they are “unseen” also make waste collection a problem.

Over and above that consumers prefer plastic bags, Coroza added.

“Since it is not a blanket ban, when plastic bags are used, supermarkets report higher sales, compared to when paper bags are used.” She also said that more staff is required to do the packing in paper bags.

Alternative to plastic bags Meanwhile, Pasig City, one of the local government units in Manila (dubbed as the recycling capital of the Philippines) that has implemented the plastic bag ban under the City Ordinance, is offering an alternative.

Led by the City Environment and Natural Resources Office (CENRO), a project team is recycling waste from aluminium doy packaging (used for juices and drinks) by sewing it into bags with fabric straps.

Speaking to PRA at Pasig City Hall, Raquel Naciongayo, Head of CENRO, said that the Eco-bag is a durable alternative. “It is indestructible for 50 years!,” she said, adding that the Eco-bag is also targeted at export markets, retailing at Php2,000 (US$40) a piece.

Eco-bag made of recycled packaging is an alternative

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Domestically, it is retailed at Php200 (about US$4) outside the city and 50% less in the city since the cost is partly subsidised by the local government.

Other alternatives include bags made of tarpaulin scraps and nonwoven fabric. The bags are produced by local community groups, as part of the city’s livelihood programme, involving 6,000 families in the city, thus creating jobs and improving living standards.

The CENRO chief also explained that whilst the authorities are open to reviewing the ordinance, the probability of changing the provision depends on whether the National Government with the Department of Natural Environment and Resources (DENR) will issue an official statement in favour of plastics and PS foam. At the moment, Naciongayo said that the ordinance’s provisions will remain.

Not helping the economy However, not all groups are in favour of the shift to paper and non-woven bags.

“It is not helping the local economy,” said Quintana, explaining that the materials are imported. “We are giving jobs and opportunities to China and other countries,” he said, adding that in 2011 alone, the country imported 14,000 tonnes of paper, an increase of 45% over the previous year.

The plastics industry employs 175,000 direct and indirect workers.

With the plastic bag ban, 30% of the workforce has lost jobs and work days have been reduced to four days, whilst some jobs have become seasonal.

In fact, Quintana says the outlook for the industry is bleak, adding that the ban is counter-productive and will ultimately affect the overall economy.

Drawing the worst scenario for the country if the outright ban continues, he said that the manufacturing industry will suffer; discouraging further investments and reducing the country to a trading hub.

Based on a recent International Monetary Fund (IMF) country report, manufacturing comprised 33.3% of the country’s GDP, with chemical products, including plastics, as strong industry drivers.

Crispian Lao, former President of the PPIA, says a factor in favour of the plastics industry is that it is an equal opportunity industry that employs

workers regardless of their academic status and working age. “The second generation manufacturers have workers that are above 60 years as well as youths just out of school,” he explained, adding that this is an incentive to keep the workforce employed.

A needed respite Amidst all of this, a ray of hope shines bright as locals hinge on potential foreign investments to bail out the industry. For instance, recent talks were held with Japanese investors under the auspices of the Philippine-Japan Economic Partnership Agreement (Pjepa).

Likewise, several industry groups are also embarking on recovery schemes to recycle waste plastics into consumer products.

But above all, the best solution is to go back to the basics. Lao says that about 45% of plastic waste is not disposed or segregated properly and calls for a concerted effort in this area.

“The plastic ban has become politically popular but is it the right way to go?” he asks, adding that the authorities need to look at countries like Japan that has an extensive recycling programme in place.

The industry is also pushing for the full implementation of the Comprehensive Solid Waste Management System of the RA 9003, which already has the necessary effective measures to reduce waste problem, including mandating the LGUs to establish respective waste management and segregation systems.

Quintana adds, “We were not well represented when cities started implementing the plastic ban drive.

We are now taking every opportunity to intensify our campaign and inform people about plastics.”

But above that Quintana said that consumers need to be educated on waste disposal habits while Gaw stressed that discipline needs to be instituted. “If we continue to litter indiscriminately, whether it is paper or plastics, the waste will end up clogging drains and waterways.”

In conclusion, both agreed that disciplined segregation of waste and recycling is what is required. “That is the real solution,” opined both industry leaders.

Injection Moulding Asia Industry News

Kuka’s new facility in China

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anufacturer of robots and automation Kuka is setting up a new facility in Shanghai. To start operating later next year with about 350 employees, the facility’s first robot series will be the KR Quantec, followed by the KR C4 universal controllers. The assembly capacity of 3,000 robots and controls in the first year is expected to grow to 5,000 units by 2015.

The Augsburg-based company says it has more than doubled its year-on-year robot sales in 2011.

It will now manufacture for the automotive industry and increasingly also for the general industry from its 20,000 sq m plant. The company set up its Chinese subsidiary in 2000 and has another four Kuka distribution and service subsidiaries, apart from the head office in Shanghai.

Alliance to produce TPCs for automotives

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enCate Advanced Composites and German firm BASF have formed a strategic alliance to develop thermoplastic composite materials for high-volume vehicle production. Currently, TenCate produces continuous fibre-reinforced thermoplastic composites that are mainly used for aircraft structures and interiors, such as the Airbus A380, A350 and Boeing 787.

BASF will contribute its know-how in the production and formulation of thermoplastic resins in order to develop special variants of its Ultramid PA, Ultradur PBT and

Ultrason PESU product lines.

Compared to metal parts, fibre-reinforced plastic composites can be 30 to 50% lighter, there by economising on fuel consumption.

Furthermore, much experience has been built up over the last decades in connection with welding technologies to connect composites materials to complex structures and to integrate these components and structural parts with multi-material end-products. Target applications are semi-structural parts as well as primary structures in car bodies and chassis.

Technology for fusing moulds

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S hot runner supplier Polyshot has introduced a vacuum brazing technology for fusing of multi-component mould cores and cavity assemblies for conformal cooling systems, which reduce cooling time and achieve overall cycle time reductions of up to 60%.

The firm says that the expansion of its fusion technology to conformal cooling has resulted in strong growth with more than half the business coming from overseas customers.

Polyshot’s fusion technology fuses together two or more steel plates to create internal flow paths, allowing the creation of internal full round flow paths that allow generous sweeping curves and no hold-up areas. These internal flow paths withstand very high injection pressures and external forces while still maintaining the integrity of the

brazed joint.

For conformal cooling systems, Polyshot’s vacuum brazing technology is a proprietary process that makes use of a high-temperature vacuum furnace. Rough cores and cavities with machined conformal cooling paths are fused together by Polyshot in a stack which is typically one to six layers. Typical materials that are fused include H-13, 420 stainless steel and S-7. Cores are shipped back to the customer in a soft state, approximately 30 RC, and require additional post brazing hardening at a local heat treat facility.

The typical turnaround time for the process is up to two weeks.

The vacuum brazing process is targeted for high-cavity moulds (32-128 cavities) for high-volume packaging applications such as caps and closures.

Injection Moulding Asia German machinery and technology

Exhibition proves its mettle with new technology The recently concluded Fakuma show, held in Friedrichshafen, Germany, attracted an estimated 44,176 visitors, compared with 44,823 last year, which was a slight decrease of 1.5%. Nevertheless, with about 1,700 exhibitors from 35 countries no momentum was lost with the exhibits on show and technology proved to be the draw factor.

US firm Huntsman has developed a new polyetherbased PU (Irogran A85P5050DP) with low melt properties that is easy to process and is suitable for coating textiles by calendaring – a technique used to give fabric a smooth, glossy, hard-wearing finish.

Meanwhile, barely two years after its introduction, the high-temperature resistant Ultramid PA Endure from Germany-based BASF has been used by automotive parts supplier Montaplast for a heat shield in the charge-air manifold used on the four-cylinder diesel-powered engine from Daimler.

New developments from materials suppliers S firm Invista Engineering Polymers showcased its Torzen Marathon PA66 resin for the automotive sector. The resin boasts property retention when subjected to high temperatures for an extended amount of time, at least 100% tensile strength retention at 210°C after 1,000 hours. Invista is also developing technical tools for customers and other market players, including mould flow and FEA analysis.

Another US firm DuPont Performance Polymers collaborated with injection blow moulding equipment specialist Ossberger to produce the jounce bumper component, which is part of a vehicle’s shock absorber system, from its Hytrel thermoplastic elastomer. Other new grades from the Zytel long-chain polyamides deliver salt stress cracking resistance similar to PA11 and PA12, for use in fuel and air brake lines, typically the domain of PA12. The firm also extended its halogen-free materials, with a new flameDuPont applied FEA on retardant (FR) PA66 with the blow moulding of an enhanced thermal ageing. automotive jounce bumper To cater to the growing made from Hytrel TPE global demand for PC for LED lighting, Germany-based Bayer MaterialScience is expanding its grades for injection moulding and extrusion, including high thermal conductivity grades for cooling elements used for the thermal management of LEDs and a film that joins the points of light from individual LEDs to form a homogenous band of light.

Machinery highlights njection moulding machine maker Arburg had more than 20 exhibits and a variety of applications such as multi-component technology, LSR and HTV processing, powder injection moulding, packaging, medical technology and optical applications, as well as the overmoulding of inserts, also using the hot melt process.

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Arburg showed 20 machines at its stand

It also showcased the new long-fibre direct injection moulding process, developed together with Süddeutsches Kunststoff-Zentrum SKZ in Würzburg, that allows inline feeding of fibres and melt, enabling longer fibres (30-50 mm) to be processed, with lower occurrences of fibre damage. This was shown on a Allrounder 820S that was moulding glass-filled PP automotive housings, with the glass rovings fed into the melt using a Coperion dual-shaft side feeder.

Meanwhile, a 40-tonne Allrounder Golden Edition demonstrated another new process: particle-foam composite injection moulding, a joint project with 2

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German machinery and technology Krallmann and Ruch Novaplast. Here, a foamed component is moulded with a polymer. The two components are bonded together, so that there is no need f o r a subsequent assembly step. This technology opens u p new options in the fields of electric mobility, lightweight construction and insulation. A Multilift robot was loading a small wheel made of expanded foam into the injection press, with rigid PP in the middle.

Austrian firm Engel showcased its all-electric e-mac in two applications: a 50-tonne machine producing two-pin PBT plug housings in a fourcavity mould in a shot weight of 3.6 g and an e-mac 310/100 with an integrated Engel Viper 6 linear robot producing PP/LSR wine bottle stoppers, in a single step, using a mould from Elmet. The firm says it has succeeded in combining barrier technology with thinwall moulding thanks to the co-injection of PP and a 0.05 mm EVOH barrier layer.

Another Austrian firm Wittmann exhibited five injection moulding machines, 11 robots, and more than 60 auxiliary devices, with complete production cells, including auxiliaries, automation, and machinery, combining the machinery of the former Battenfeld with the automation and auxiliaries prowess of Wittmann.

Germany-based Boy, meanwhile premiered the 25 E VV insert moulding machine with increased clamping force and an energy-efficient servo-motor pump drive, with an 11% reduction in the footprint.

Also, the firm showed its Procan ALPHA control for the first time, with a user interface that can be operated like a smart phone. The control system, which will become standard at the beginning of 2013, has been changed to the PCT technology (Projective Capacitive Touch) replacing the outdated resistive touch technology.

German machine maker KraussMaffei also showcased its GX for the first time at a trade fair.

The GX 450-3000 produced an automotive component using physical foaming from MuCell technology. It also had on display a three-component process with metal injection moulding on a CX 160-750 machine.

Sister company Netstal, meanwhile, showcased the new Elion 3200, demonstrating the manufacture of thinwall PP lids in a 3.4 seconds cycle time. The machine features a hybrid drive concept and the Eco-Powerunit for efficiency. The Swiss firm also introduced Preblow, an injection blow moulding process that the company claims reduces bottle weight and cycle time. During the patent-pending Preblow process, the preform is blown out in the base area directly after injection moulding, thus creating a thinner wall in the base area. The resulting larger surface area, and thinner wall, means less heat energy is needed in the blowing machine.

Sumitomo Demag displayed an IMD-IML production cell using its 210-tonne Systec with a one-cavity mould from HBW-Gubesch KunststoffEngineering, to produce 2 mm PMMA display frames in a single step. A laminar-flow module from Max Petek cleans the sucked-in external air and uses a filter fan unit (FFU) to prevent particles entering. The IMD decor foil for the front of the display is placed by means of a feed unit from Leonhard Kurz.

Ancillaries and robots och-Technik presented two new types of its patented gravimetric Graviko dosing system: GK65 and GK200, able to dose tiny quantities, with an accuracy of 0.001 seconds, says the firm.

These are paired with the MCm-G control unit for gravimetric dosing systems.

Engel, meanwhile, expanded its Viper linear robot series, which it launched at Fakuma 2009, to a 120 kg model.

French robot maker Sepro Robotique launched the 5X and 6X linear robots with additional axes in the wrists, utilising Staübli technology, and a partnership with Machines Pagès, a specialist in IML systems One of the latest equipment from for 25 years, to create high-speed IML system for the packaging sector. The 5X Koch-Technik Visual multi-axis robots are based on Sepro three-axis Cartesian beam robots but feature a two-axis Stäubli wrist that has been added to provide additional compact servo rotations. The 6X Visual robots, combine a Stäubli six-axis articulated-arm robot with the Sepro Visual 3 control for a generalpurpose automation system in five models for machines from 20-4,000 tonnes.

The IML cell demonstrated the moulding of 1.2-l pails with wrap-around labels in a two-cavity mould in a 4.5-seconds cycle. A 250-tonne Demag El Exis used an SE 350 side-entry model controlled by the new Visual 3 dual-core controller, which also controlled the label-handling module supplied by Machines Pagès.

Sepro is offering the IML systems for machines from 100-500 tonnes, applying flat or shaped labels to parts such as lids, pots and trays.

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Rubber Journal Asia Industry News

Europe to have abundant butadiene

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utadiene output in Europe is expected to overtake demand for the first time since 2000 due to lower demand from the automotive industry, according to GBI Research’s latest report. Last year, demand for butadiene was 2.5 million tonnes while production was 2.23 million tonnes. However, this is expected to reverse in 2015 when production will outpace demand by 162,953 tonnes.

While the demand for new cars has had an effect on butadiene demand in Europe, suppliers are not reducing production but increasing it to cater to the export market. Major butadiene production capacity additions include LyondellBasell’s expansion of its extraction unit in Wesseling, Germany, and Versalis’s plans to build a new 70,000 tonne/year unit at its Dunkirk site in France.

Last year, global demand for butadiene was 10 million tonnes and GBI Research expects this to grow to 14 million tonnes by the end of 2020, representing a CAGR of 3.9%. Asia Pacific is expected to continue as the world’s highest butadiene growth sector with demand to reach 8 million tonnes before the end of decade.

Sinopec invests in Sibur rubber plant

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inopec International, a subsidiary of Chinese petrochemical firm Sinopec, is acquiring a 25% stake in Russian firm Sibur’s rubber plant, in the Siberian city of

Krasnoyarsk.

The deal is said to be worth US$100 million, though financial details were not disclosed. Under Russian law, a stake of 25% plus one extra share allows Sinopec to have management control.

Early this year in April, the two firms also set up a joint venture to produce nitrile rubber.

Sibur’s rubber plant has an annual production capacity of 42,500 tonnes but the two companies plan to increase capacity to 56,000 tonnes. Furthermore, the two companies are also discussing setting up a 100,000-tonnes/year facility to produce rubber in Shanghai using Sibur’s techniques and patents.

provide funding to expand the Rubber Out-Growers Expansion Programme to boost the capacity of Nigeria’s rubber plantations.

Clariant to fast forward latex pigments in Asia

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ecognising that its business related to colourants for dipped latex applications is still in an infancy stage, Clariant Malaysia’s Pigments Business Unit has been actively promoting it over the past year, said Philip Martin Adams, Marketing & Sales Director, Plastics & Special Applications Business, Asia/Pacific. ”For various reasons, we have not been focusing on the latex sector in Malaysia, but we are now putting together a business model to support this,” said Adams, speaking to RJA at the recently concluded 6th International Rubber Glove Conference & Exhibition in Malaysia.

The Swiss firm has comprehensive setups in the region for its pigments/pigment dispersions business. In China, where it operates through a joint venture, it has doubled its output to 7,000 tonnes/year, said Adams, adding that the facility was relocated from Tianjin to Shanghai to support growing domestic and export demands.

In Indonesia, where the business is smaller, it is looking at doubling its capacity. “This is one of our expansion plans over the next two years,” he added.

In Malaysia, the firm set up a technical laboratory

France to boost Nigeria’s rubber sector

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igeria is said to have the capacity for 18 million ha rubber plantations. Of this, only a small 13,500 ha is currently being utilised, making the country accountable for only 11% African output while Ivory Coast is responsible for more than 50%.

Hence, pursuant to a November 2000 bilateral agreement signed between Nigeria and France on sustainable management of resources and development of the non-oil sector of the Nigerian economy, the Agence Francaise Development (AFD) is set to inject a multi-billion dollar investment to promote the growth of rubber output in Nigeria.

Under the initiative, the AFD, which is the French government’s development finance institution, will

for plastic pigments in Shah Alam several years ago. In fact, Adams said the company is in the process of expanding the laboratory and relocating it into the main building.

The focus of the firm is now on building and expanding its services to the latex sector, with an eye on the healthcare/ medical sector. Products from Clariant’s Colanyl, Flexonyl, Cosmenyl and Hostafine pigment preparation ranges cater to applications in natural and synthetic rubber systems for colouring gloves, balloons and other rubber items, including testing for bleedfastness.

“Clariant’s pigment preparations are based on both organic and inorganic pigments, which are dispersed using Clariant’s own technology,” explained Adams, adding that the products meet all the relevant US and EU regulatory approvals.

While the regulatory approvals are not all that stringent in the Asian rubber market, Adams expects similar enforcements to follow.

“Emerging economies are moving towards better healthcare and the regulatory procedures will follow soon. We are ready for this as we offer this service to our customers to meet these requirements.”

When asked of the future outlook for the segment, Adams said, “We’re relatively new in the market so we are looking for significant growth.”

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Rubber Journal Asia Dow plans EPDM plant in the US

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S-based chemical firm Dow Chemical plans to build a new world-scale plant for the production of metallocene ethylene propylene diene monomer (EPDM), sold under the brand of Nordel IP Hydrocarbon Rubber, to be operational by 2016.

The manufacturing site will be located on the US Gulf Coast and Dow is currently assessing location options. This production facility will leverage Dow’s investment plan to increase ethylene and propylene production in the Gulf coast and will connect the company’s US operations into feedstock opportunities available from increasing supplies of shale gas in the country.

The firm plans to use its next generation technology to produce a broader offering including high mooney viscosity products with enhanced quality, to meet demand from the automotive and building and construction as well as wire and cable markets

Glove firm rooted in Malaysia

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nlike other Malaysian glove makers that are in search of greener pastures in countries abroad, medical glove maker YTY Industry is intent on staying at its home base. Not only is it building a new factory on 22 acres in Sitiawan, Perak, it is also adding on surgical gloves to its portfolio, with the intention of doubling its capacity to 18 billion pieces/year.

Speaking to RJA recently, Roger Moh, Group Executive Director, said, “Some companies are moving their production overseas to capitalise on the availability of cheaper labour or raw materials.

But the respective governments may change their policies and this may prove to be unfavourable to foreign companies operating in the countries.

We don’t want to get into this kind of dilemma.”

Set up in 1988 with six production lines, today the firm operates two manufacturing plants with over 50 production lines, generating a turnover of US$270 million, and is still growing, said Moh. “We are constructing a plant adjacent to where we are currently located. This will be ready by next year.” The new facility will be built in three phases, with the first phase to be completed in the first quarter of next year.

Furthermore, the firm has just refurbished one of its existing lines and is putting in new production lines, to double its current output from 9 to 18 billion pieces/year by 2013.

“Next year we are planning to introduce surgical gloves. We have been developing this line of product for nine years,” said Moh, adding that the expansion is based on customer demand.

Amongst its product lines are accelerator-free and powder-free nitrile examination gloves as well as gloves that are 2.5 mil thick. “We have undertaken a lot of research to develop the thin type of gloves. Not only are they thin but also strong,” said Moh,

adding that all the gloves produced meet the US FDA and European EN standards.

The firm caters to the export markets and mainly exports to the US, UK, Germany, Italy, Norway, Japan, Singapore and South Korea.

“The demand in Malaysia is not sufficient, and it is because of this most companies export 100% of their output,” explained, Moh, adding that Malaysia utilises about 25 million pieces/month.

He also went on to say that the demand in the country is mainly for B grade type of medical gloves, which are below par, “cosmetic wise”, adding that private hospitals are willing to fork out more for premium gloves.

Rubber seedling demand growth

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alaysia’s Rubber Industry Smallholders Development Authority (Risda) is calling on smallholders and idle land owners in the East Malaysian state of Sabah to rent or jointly develop their land with the agency to cater to the growing demand for rubber seedlings.

Risda says that currently Sabah needs no less than 2 million seedlings/year and it is able to push production at the existing nurseries to 60,000 seedlings/month.

Though Sabah currently has 20 fully operational nurseries, including those jointly developed by land owners and Risda through contract farming agreement, rubber tree seedlings needing at least

Industry News eight months to mature before they can be transferred to farms, and demand is expected to continue to grow as more smallholders start to plant rubber. Risda has this year allocated RM300,000 for renting nurseries.

Freudenberg keen on Chinese market

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ermany-based Freudenberg Group says its sales in China rose by 10% in the third quarter of 2012 to 2.98 billion yuan, compared with the same period of 2011.

Furthermore, the group is investing intensively in China and further expanding its activities in the long term. From 2004 to the end of the third quarter of 2012, the group had invested about 2 billion yuan.

Meanwhile, the company’s focus in the country is on medical technology as seen with its recent acquisition of Anura Plastics Engineering in Shenzhen, where the group has invested US$500,000.

Elsewhere in the world, Freudenberg has acquired US-based MedVenture Technology, a manufacturer of medical technology solutions for minimally invasive surgery (MIS). Acquisition activities already started in 2004 when Freudenberg acquired Jenline Industries.

In September, Freudenberg inaugurated a new plant in Costa Rica, to add on to its medica technology facilities in China, the US, Germany and Ireland.

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Rubber Journal Asia Industry News

Sinopec starts up Nd-Br plant

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fter nearly 20 months of construction, Chinese petrochemical firm Sinopec’s subsidiary, Sinopec Yanshan has opened its the 30,000 tonnes/year butadiene rubber plant.

The company says it produced its first batch of commercialised products for the market in October.

Yule Catto to change name to Synthomer

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K-based speciality chemicals supplier Yule Catto will hold an extraordinary general meeting on 4 December 2012 to seek shareholder approval to change the group’s name to Synthomer.

Over the last five years, the group has been transformed from a small, diversified chemical business, of which Yule Catto was the holding company, to a much larger, focused speciality polymer business. The group trades under the name Synthomer across the majority of its business, hence the proposed name change.

In 2011, the group acquired Polymer Latex and united all of its polymer activities under the existing brand name Synthomer.

The acquisition of Polymer Latex created an emulsion polymers group with a combined turnover in excess of EUR .4 billion and almost doubled the size of the former Synthomer operations. Today more than 1,900 people work for Synthomer across 33 production units in

11 countries and at its commercial centres in the UK, Germany, Italy, Finland, USA, Dubai, South Africa, Malaysia and China.

In terms of its performance, despite the challenging macroeconomic conditions, particularly in Europe, the group’s profit to date remains well ahead of prior year. “This has been achieved notwithstanding year to date volumes down 10%, and an adverse translation impact of £4.5 million in the first nine months of the year due to the weaker Euro,” the firm.

In Asia and ROW, the non-nitrile businesses continued the positive momentum achieved in the first half. “We continue to make strong progress with synergy delivery from the PolymerLatex acquisition, and remain firmly on track to realise £19 million of synergies in the current year, a yearon-year improvement of £16 million. The group continues to expect to deliver the total £25 million of targeted annual synergies

by March 2013,” it said in a press release.

The group’s financial position remains robust with net debt at the end of September at £160 million, down from £174 million at the half year.

always keep a step ahead of its competitors. At the recently concluded Taipeiplas show in Taiwan, it showcased the THP-V-100-2RT compression moulding machine for rubber seal vulcanisation that has been enhanced so that there are no pipes or hoses visible on the outside.

“We have adopted a brand new image for the machine. In fact, the controller has fingerprint identification instead of passwords to lock the press or the touchscreen,” said a company spokesperson. “We need to distinguish the machine from our competition,” he added.

Other features include easy operation and a fixed daylight and stroke for easy mould change. It also features a vacuum cover design, shortening curing time and increasing productivity, and a high speed vacuum system to eliminate air bubbles inside the cured rubber products, said the spokesperson.

The displayed machine had been sold to Taiwanese firm Maxmold Polymer that makes rubber oil seals.

Bridgestone’s goal for sustainable tyres

Technology News

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apanese firm Bridgestone recently exhibited a 100% sustainable materialproduced concept tyre at the 2012 Paris Motor Show, in line with its goal for rolling out these tyres by 2050.

Reaching the goal of 100% raw material

Enhanced compression moulder from Tung Yu

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aiwanese rubber machine maker Tung Yu Hydraulic Machinery knows that it has to

Tung Yu’s latest machine on show at Taipeiplas

utilisation means the world’s largest tyre maker will have to adopt a new approach to raw materials and Bridgestone says it needs to diversify the regions where it produces natural rubber in order to meet the target.

It is also expanding the range of reinforced plant fibres it uses. For the concept tyre, it used synthesised biomasssourced substitutes for synthetic rubber, carbon black and rubber compounding agents – ingredients traditionally produced from fossil resources. Bridgestone has set 2020 as a target for the commercial sale of “certain sustainable materials used in the manufacturing process.”

Bridgestone intends to supplement the para rubber tree-sourced natural rubber it uses with rubber from the guayule plant, while cellulosic fibre will supplement or replace rayon as a reinforcing fibre.

Meanwhile, petroleumbased synthetic rubber, curing agents, anti-ageing chemicals and reinforcing fillers will be substituted by equivalent materials made from biomass, vegetable fats and oils.

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Rubber Journal Asia Rubber regrind for optimising plastics and roads

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he German research institute Fraunhofer Umsicht has developed a process that uses 60-80% content of recycled scrap rubber to modify plastics.

Elsewhere, in the US, the National Centre for Asphalt Technology (NCAT) says using ground tyre rubber (GRT) powder in asphalt mixture improves the performance for road construction.

The objective of Fraunhofer’s research was to analyse elastomers in powder and granulate form to optimise the recycling of rubber residues since the elastomers in this form can be used as functional additives, to provide plastics compounds with the desired properties such as haptics, hardness or elasticity. Thus, Fraunhofer says it has now developed high quality plastics compounds known as elastomeric powder modified thermoplastics (EPMT) and is conducting trial runs on products such as lawn mower wheels and splashguards. The recyclable EPMTs are processed into granulates in the compounder system, together with thermoplastics and additives, and can be processed in injection moulding or extrusion machines.

Meanwhile, NCAT’s study debunks a common industry belief that the asphalt manufacturing process, whether cryogenic or ambient, does not impact the performance of the rubber material or, ultimately, the asphalt.

NCAT says that by increasing the use of GTR, asphalt producers will

benefit from price stability, compared to traditional, oilbased polymers.

According to the US Environmental Protection Agency, benefits of using GTR include longer lasting road surfaces, reduced road maintenance, cost effectiveness, lower road noise and shorter braking distances.

its production to the US, Middle East and Australia.

Evonik and Solvay expand silica outputs

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riven by the need for energy-efficient tyres and the new European Tyre labelling legislation that came into effect in November, Solvay recently inaugurated its silica capacity expansion in France, while German firm Evonik Industries says it will expand its output by 30%, by 2014.

Solvay’s worldwide capacity now exceeds 400,000 tonnes at its site in Collonges-au-Mont-d’Or site, France. This investment follows a similar expansion last year in the US and the start-up in 2010 of a new plant in China, together totalling EUR74 million.

Meanwhile, Evonik says it is mobilising total funds for the expansion in the upper double-digit million euro range, to keep pace with the growth in the car tyre market.

The market development for precipitated silicas is carried primarily by the trend toward advanced low rolling resistance tyres. Europe’s labelling of tyres provides consumers clear information on such concerns as fuel efficiency, CO2 savings, braking on wet road tops and rolling sound. Japan has already introduced optional labelling, and other countries such as South Korea and Brazil are following suit with their own labels. The growing automotive markets in threshold countries, in China in particular, also offer massive growth

Tyre News

Hankook to export tyres to Middle East

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he seventh largest tyre manufacturer in the world Hankook Tyre said recently that two of its popular tyre products in Saudi Arabia, Optimo ME02 and Optimo ME04, will now be made at its newly constructed manufacturing plant in Cikarang, Indonesia, starting from 2013.

Following completion of the plant in Indonesia, the South Korean firm will produce a large volume of Optimo ME02 and Optimo ME04, two of the best-selling tyres in Saudi Arabia, which were previously manufactured at the Daejeon and the Geumsan plants in South Korea.

Hankook Tyre’s newly constructed manufacturing facility in Cikarang is its seventh plant worldwide, joining the existing two in South Korea, one in Hungary and three in China. With a total investment of US$1.1 billion by 2018, the plant has recently started its initial production. It will export as much as 80% of

potential for this tyre technology.

Combined with silanes, silicas are used as reinforcing fillers for the rubber in tyres and significantly improve the properties of the tyres. The silica-silane system can substantially lower rolling resistance and therefore achieve as much as 8% fuel savings (compared to conventional car tyres). At the same time, the silicasilane system ensures outstanding road traction, even in wet or wintry conditions. Evonik is the only manufacturer of these additives that has both products in its portfolio.

The firm has already expanded the facilities for its Ultrasil and Sipernat precipitated silicas in Asia and Europe, which are produced at ten sites in nine countries.

India gets tough on Chinese and Thai tyre makers

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ndia’s Ministry of Finance has implemented antidumping duties on bias-ply tyres imported from China and Thailand.

The duty will be applicable for five years with tyres imported from Thailand to be subjected to a duty of US$0.86/kg, while most bias-ply tyres from China will be liable to duties of US$1.31/kg.

Tyres produced in China

by Hangzhou Zhongce Rubber will have a lower US$1.12/kg duty. The anti-dumping duty also will be applicable on certain tubes and flaps.

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Rubber Journal Asia Country Focus

Malaysian rubber industry in a competitive mode When the country shifted its focus to oil palm

“Malaysia must grow 6% a year to reach this GNI target,” he said, adding that the rubber industry is one of the key players in this growth.

For the industry, a high rubber production can sustain growth through upstream development and revitalisation of existing downstream products, Sumormo said. “Increased rubber productivity translates to more job opportunities,” he explained, referring to the smallholders who will be benefiting from a higher income. The income of smallholders, which occupy 2.3 ha of plantations in the country, is currently RM4,000 a month.

Meanwhile, Ramesh Veloo, General Manager for Advisory Services of Tradewinds Plantation, said rubber output needs to be increased because global demand for rubber is expected to reach 31.5 million tonnes by 2020. “The healthcare sector and the rising health scares have increased the demand for high quality latex-based products such as gloves. Also, the booming transportation industry is stimulating the demand for NR, especially since 70% of consumption is coming from this sector,” he said.

Factors that affect NR output include declining plantation areas, matured untapped trees and labour shortages.

Addressing the dwindling numbers of rubber planting areas, Veloo pointed out that the marginal areas were economically viable options but could prove to be more challenging.

Citing his comparative income data for oil palm versus rubber in marginal areas, the projected profit/ha of oil palm is RM5,719 against RM6,800 from rubber – an 18.9% difference in favour of rubber.

“There are limited potentials for reviving rubber in Malaysia for both greenfield and brownfield development,” he said, adding, “But it can be economically viable if all the marginal land being used for oil palm can be used for planting rubber.”

However, Veloo also explained that planting of rubber in marginal areas may have lower yields, requires more labour and therefore has higher production costs. Moreover, these areas have distinct dry climates, less-than-ideal soil and hilly terrain.

Some parts of the oil palm-planted greenfield land (or undeveloped tracts used for, but not limited to, agriculture), which some farmers reserve to enhance biodiversity, may be planted with rubber, he suggested.

and natural rubber (NR) had to take a back seat, Malaysia’s ranking as the top rubber producer in Asia slipped to three notches lower, pushing Thailand to the top spot, followed by Indonesia.

Although a volatile market commodity, demand for NR is gaining in the world market. But Malaysia cannot take the short route if it is to climb back to the top, except to embrace an innovative edge, says Angelica Buan in this report.

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he global rubber demand is surging and along with it Malaysia is revving up its advantage as one of the leading global rubber producers, said many speakers at the recent International Rubber Technology and Economic Congress (IRTEC), held 10-11 October in Kuala Lumpur.

Synthetic rubber, having reigned as a more viable substitute for natural rubber (NR), has grown rapidly, at the expense of the NR sector, inciting price volatility that is influenced partly by domestic and global demand, said Tan Sri Bernard Giluk Dompok, Chairman of the Malaysian Rubber Board (MRB) in his opening speech.

“One way to strengthen the rubber industry is through innovations in technology, which provides opportunities to enhance the use of natural rubber for the production of new products and applications,” he said, also emphasising the importance of the industry to Malaysia’s economy.

“The natural rubber industry is one of Malaysia’s socio-economic drivers that benefits 442,510 rubber smallholders, comprising more than 1 million family members,” he added.

Pulling up productivity he country’s National Key Economic Agenda (NKEA) is undoubtedly a yardstick for the industry to hit its target within a specific time frame, in this case by 2020. To achieve its High Income nation status Malaysia has to generate a projected GNI per capita of RM48,000, according to Dr Suami Sumormo, Deputy Director-General for Policy & Operations of MRB, in his presentation.

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Country Focus Currently, other Asian countries are showing potential as rubber planting territories, Veloo also said, pointing out Laos and Myanmar as potential rubber destinations for local companies.

“Africa is also being eyed in view of its proximity to Europe and the US,” he said, adding that the continent is expected to reap about US$2.6 trillion collective GDP by 2020. “Also, Africa will have a working age population of 1.1 billion by 2040,” he said, highlighting the continent’s edge in the labour-intensive global rubber industry.

However, Veloo explained that the shortage of labour is a hindrance to the expansion of rubber plantations. “Compared to the oil palm sector, the rubber industry requires more workers and those who have higher skills,” he said, explaining that recruiting local workers, let alone foreigners, to work in rubber plantations is becoming difficult.

Adopting new technologies o overcome the productivity stumbling blocks, MRB presented its newly hatched technologies to make life easier for rubber producers (and increase productivity, too).

Presenting the Automatic Rubber Tapping System (ARTS), Datuk Dr Salmiah Ahmad, Director-General of MRB, said this technology, which is in a pre-commercial trials now, was developed to primarily address labour shortages (and to reduce dependency on foreign workers) and increase output.

“Rubber tappers have to be at the plantations early in the morning when the turgor pressure is high and more latex can be tapped,” she said. A mechanised and automated device, ARTS is able to undertake the task without any human supervision.

The solar-powered device is attached to a rubber tree and at a programmed time can perform the tapping (without the presence of a field operator). The system has a rotating blade to skin the bark with precision to expose the latex vessels.

It can also cut at precise depth and thickness. The tapping time is also The ARTS (inset) is expected programmable and has a short tapping to revolutionise tapping in the length of 1 inch. A piping system is also attached at each tree to collect the country latex.

The development of the ARTS is congruent to Malaysia’s NKEA’s 4-point EPP, which is to increase the average national rubber productivity to 2,000 kg/ha/year by 2020.

Currently about 2,000 units of ARTS are being used in a pre-commercial trial until the end of 2012.

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Five other technologies were also highlighted at IRTEC: 1) An Android-powered smartphone application i-Klon, which is a clone-inspector application designed as an alternative as well as to augment the shortage of expert clone inspectors. The technology evaluates a clone and does an image analysis that is displayed on the phone screen.

Rubber Journal Asia Country Focus 5) Latex Collection Vehicle, consisting of a latex storage tank, an air compressor, a diaphragm pump, Teflon tubing and a carriage vehicle, to aid in increasing latex collection. As observed

by MRB, smallholders collect their yield by cuplumps as it is a simpler method but with this new vehicle, productivity of collecting latex can be improved. Harvesting in latex form is important to deter dependency on imported latex, which according to the MRB data is 50% of the country’s total NR imports. Domestic consumption of latex is also high and 80% of the total rubber products export is latex-based.

One of the technologies launched

Given the availability of these technologies, adoptability is an issue. In 1985, Motoray Mark II, a hand-held mechanical tapping tool was invented but adoptability was poor, said Datuk Salmiah in her presentation. “Even with the availability of new clones, smallholders are still using old clones,” she also observed.

Because the younger labour force does not seem interested in rubber tapping, older tappers do the work, exposing them to further health risks such as musculoskeletal problems, thus compounding the problem of low productivity.

But Dr Salmiah agreed that it is just a matter of time before the smallholders appreciate these innovations and uitilise them.

is the i-Klon, an Android-powered smartphone clone-inspector application

2) Rubber Information Traceability System (RITeS), a monitoring tool to ensure the quality of the planting materials obtained by tracing their source. All private nursery operators will be required to input their product details into a barcode generating software. These barcodes, printed on special labels, will be affixed to the planting materials. This allows enforcement personnel to easily retrieve pertinent details by scanning the labels and thus ensuring that only high-quality materials are passed on to the smallholders.

Future of rubber industry iven the scenario at the home front, is there a future for the local industry? Yes, said the country’s former Prime Minister Tun Dr Mahathir Mohamad who delivered the inaugural address at IRTEC, adding that it is important to engage in research to innovate more applications for rubber.

However, he said that funding for research is in itself a concern. Investors, when approached for research funds would demand that a feasibility of the return of investment (ROI) be provided, which usually does not apply to research endeavours.

Aside from funding, research requires persistence, Mahathir said, explaining that success would come at the expense of failures. Nonetheless, he emphasised that without research the industry would flounder.

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3 Automatic Rubber Nursery Machine, an automated polybag filling device that lifts the polybag using a vacuum system, and at a horizontal position is opened by gravity and an air blower. Slotted into a gripper, the polybag is rotated vertically and soil will be released into it. A rotating auger will transfer the bags from the lower chute to the upper chute and by means of an actuator will move the bags to a pallet for collection. Not only consistency of planting quality is ensured with this system, but it also increases productivity whilst lowering manpower use.

4) Automatic Planting Machine for Rubber Seedlings, which aids in planting and replanting schemes to increase productivity. Attached with an auger where a hole for planting can be created, the operator-controlled machine automates the preparation of the planting platform and dropping seedlings into them. The auger displaces soil, which produces a hole for planting. A conveyor system holds the seedlings whilst an actuator pushes the seedlings to drop into the holes.

In his inaugural address, Malaysia’s former Prime Minister Tun Dr Mahathir Mohamad said that R&D is the only way forward for the rubber sector to remain competitive

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Rubber Journal Asia Country Focus

Rubberisation of Infrastructure The 2011 earthquake in Japan resulted in

vulcanisation-bonding of compounded rubber to thin steel reinforcing plates.

These rubber bearings have been used for up to eight-storey high buildings whilst continuous research takes place to further improve their capability.

thousands of lives being lost and about ¥25 trillion worth of property damage. Now that mega earthquakes are resounding across the globe, how safe is our infrastructure? This topic

A more efficient technique ccording to Dr Kamarudin Ab Malek, CEO of the UK-based Tun Abdul Razak Research Centre (TARRC), In his presentation, conventional Dr Kamarudin Ab structures tend Malek, CEO of the to amplify forces UK-based TARRC, said and affect larger that rubber bearings inter-storey drift are not able to totally compared to a base-isolated eradicate seismic forces structure, which results in a nil amplification of forces and inter-storey drift.

The first rubber base-isolated building was the four-storey Foothill Communities Law and Justice Centre in Rancho Cucamonga San Bernardino County built in 1985. With a full basement and sub-basement isolation system, consisting of 98 rubber bearings reinforced with steel plates, the building was designed to withstand an 8.9 magnitude earthquake.

Dr Kamarudin also explained that rubber bearings may not totally eradicate the seismic forces, illustrating a comparison between the eight floors of the University of Southern California (USC) Teaching Hospital in Los Angeles, which used rubber bearings, and the Los Angeles County (LAC) General Hospital built on conventional structural systems in the aftermath of the 6.7 magnitude Northridge earthquake in 1994.

However, the bearings could mitigate seismic impact. At USC, accelerations were reduced by 70% at the base, thus requiring no repairs and remaining operational post-earthquake.

Meanwhile, the LAC General Hospital, at 225% amplified forced, suffered US$400 million damage.

Whilst in the past, rubber bearings with dampers have been used as isolators, improved options of High Damping Rubber Bearings (HDRBs) are offered now. In Japan, HDRBs are used in structures such as the six-storey West Japan Postal Computer Centre in Kobe that has 120 bearings installed and which withstood

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was covered extensively at the recent IRTEC in Malaysia by Prof James M. Kelly, who was awarded this year’s Mahathir Science Award for his work on rubber bearings, and others.

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ubber has been regarded as an invaluable engineering component to reinforce structures, considering that it has inherent damping capability.

As early as the 1950s, rubber laminated bearings were used in bridges to safeguard them from strains of expansion and contraction – a technique that was also applied to buildings to isolate them from seismic forces. Rubber bearings made from natural rubber (NR) have been used for base isolation.

Evolving A recent Mahathir further, joint Science awardee, R&D efforts James M. Kelly have been headed the EERCconducted on USC seismic bearings NR bearings research in 1976 since 1976.

This has involved the former Earthquake Engineering Research Centre or EERC (presently known as Pacific Engineering Research Centre) of the University of California at Berkeley, led by Prof James M. Kelly and the Malaysian Rubber Producers Research Association (MRPRA) in the UK. Based on their studies, rubber bearings are proven “resistant to environmental degradation and unaffected by time.” They are also easy to manufacture: the bearings are made by 8 n o v e m b e r / d e c e m BER 2 0 1 2

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Rubber Journal Asia Country Focus damages during the Asia, extending from 6.9 magnitude Kobe the Penang island to earthquake in 1995. the mainland. “This is These bearings are the first commercial also installed in other use of the rubber buildings such as the bearings in Malaysia,” Tohoku Electric Power said Dr Kamarudin.

Company in Sendai, The bridge, which Miyako; and the is longer than the Nagoya, Nishinomiya first Penang Bridge and Totsukawa bridges. that spans 13.5 In earthquakekm, commenced prone Iran, the HDRB construction in 2008 technology was used and will be completed for the first time after in 2013. It has more the 6.6 magnitude than 2,700 HDRBs Bam earthquake in installed and boasts a 1993 crippled the lifespan of 120 years; Residential project in Parand, Iran, that employs HDRPs at the base southeastern historical it can also withstand city. The project, a up to 180 tonnage load.

10,000-unit residential development in Parand, Dr Kamarudin said that the RM4.5 billion consisting of 150 eight to 12-storey high blocks, project has significant savings in construction was undertaken by Fame Square, a subsidiary cost since seismic bearings are used to brace it of the Malaysian developer Amona Group. The against the destruction of the strongest magnitude completed project has more than 8,000 rubber earthquake over a 2,500 year return period. bearings installed. The Malaysian Rubber Board (MRB) has been involved in the design, testing and bearings manufacture of the said project.

Some Southeast Asian countries, such as the Philippines, are mulling the use of the seismic rubber bearings for their infrastructure and retrofitting the existing ones.

The second Penang Bridge he anti-seismic performance of HDRBs is utilised in the construction of Malaysian state Penang’s second bridge, a 24-km long bridge, purported to be the longest in Southeast

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Doshin Rubber’s HDRP for base isolation

Manufacturing these bearings is the Malaysian engineering and construction specialist, Doshin Rubber. A subsidiary of Kossan Group, Doshin has manufactured High Damping Rubber Pads (HDRP) for use in the Parand, Iran, project. It also made the specialised 900 mm x 400 mm x 300 mm thick Laminated Rubber (Neoprene) bearing pads for the base of the Petronas Philharmonic Hall in the Kuala Lumpur Commercial Centre (KLCC) to cancel external noise and vibrations.

Impression of the 24-km second Penang Bridge that uses seismic rubber

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