SAY YES TO PLASTICS Volume No. 74
MH/MR/N/200/MBI/12- 14
Issue No. 1
Pages 74
Special Issue January 2014
Rs. 75.00
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CONTENT
IN THIS ISSUE... 15...... AIPMA At Work ...A Glance at the pavilions in Plastivision India 2013 Exhibition PLASTIWORLD PAVILION
The Official Organ of The All India Plastics Manufacturers Association Estd. 1945
MH/MR/N/200/MBI/12-14 Volume 74
January 2014 No. 1
Chairman - Editorial Board
Mr. Anandilal Oza
Hon. Editor
Mr. Ajay Desai
Members
Mr. A. E. Ladhaboy Dr. Y. B. Vasudeo Ms. Poorvi Desai
...Automisation in Plastic..... ...Consultants' clinic.....
Editorial Co-ordination: Padmesh Prabhune, Dhruv Communications, Mumbai, Tel No: 00-22-2868 5198 / 5049 Fax No : 00-22-28685495 • email: dhruvpr@vsnl.net Published by Ms. Umaa Gupta on behalf of the owners, The All India Plastics Manufacturers’ Association Plot No. A-52, Road No. 1, M.I.D.C., Andheri (E), Mumbai-400 093. Tel: 67778899 • Fax : 00-22-2821 6390 E-mail : office@aipma.net Website : http://www.aipma.net and printed by her at Dhote Offset Technokrafts Pvt. Ltd., Goregaon (E), Mumbai-400 063.
...The Medical Pavilion ...Plastivision India ’2013 – Green Pavilion ...Plastivision Job & Career Fair ...Congratulations!!! “Award Winning Exhibitors”.
Annual Subscription Rs. 1,000/-
24...... PVI 2013 Photo Gallery
Single issue Rs. 75/-
29...... Company News
Views/Reports/Extracts etc. published in Plastics News are those of the
33 .... Features
authors and not necessarily of the Editor. Furthermore except for copies of formal AIPMA communications no other matter in this journal should
...Plasticulture -- The untapped opportunity
be interpreted as views of The All India Plastics Mfgrs. Association.
...Waste at its Best…! ...Gas-Assist Injection Molding: An Innovative Technology
OFFICE BEARERS Mr. Anandilal Oza President
Mr. Sanju Desai Vice President (West Zone)
Mr. R. K. Aggarwal Vice President (North Zone)
Mr. Rituraj Gupta Hon. Secretary
Mr. Anil Bansal Vice President (South Zone)
Mr. Manoj R. Shah Hon. Jt. Secretary
Mr. Ashok Agarwal Vice President (East Zone)
Mr. Haren Sanghavi Hon. Treasurer
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43...... International News 47...... Business News 62...... Product News 67...... Technology 69...... In the News 71...... Events
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THE PRESIDENT SAYS
One more city bans plastic bag os Angeles has banned plastic bags in the city of Los Angeles. Effective January 1 2014 city’s plastic bag ban applies to stores of more than 10,000 square feet or with annual sales of more than $2 million. To add to it beginning on July 1, the ban will extend to smaller stores such as mini-marts. Los Angeles is joining a growing trend of cities across the country — in California alone, about 90 cities or counties have passed plastic bag ordinances within recent years, according to the group Californians Against Waste.
variety of studies questioning the science behind the bans and whether they reduce litter and municipal costs for cleanup.
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The city’s Bureau of Sanitation has tried to prepare the public for the coming change, handing out more than 400,000 multi-colored reusable bags. Sanitation head Enrique Zaldivar said the agency has been working for several years to impose the ban, and looking at what other jurisdictions have done to accomplish the changeover.
Los Angeles shoppers will no longer be presented with that checkout choice of Paper or plastic Instead, they will be required to bring in their own reusable bags or pay 10 cents for each paper bag they need.
World over Plastics Industry have been trying hard to create awareness among people at large that Plastics is the best alternate matter. It is the littering or shall we say the habit of littering that is the culprit and the poor plastic (processor) gets the punishment.
Los Angeles City Councilman Paul Krekorian, has said it on record, “We use them for about 15 minutes and then it takes hundreds of years for them to break down. We (in the United States) use about 200,000 plastic bags every hour.
AIPMA has recently made this a point during a conclave at PVI 2013 wherein the authorities have been made aware on the habit of littering. And there are hardly any processor making the bag lesser than 50 microns for everyone understands their social responsibility.. Also earlier this month we have protested against the said ban against plastics in Himachal Pradesh.
“And the city has to spend millions to clean up the damage caused by the bags through litter or clogging up storm drains or in the water. We shouldn’t be squandering that money, which can be spent on other things.” Krekorian said the city has done about all it can to make the public aware of the coming regulation and that he would like to see more from the stores.
It’s now for the aam admi to stop littering. Happy New Year !!
The plastics industry has tried to fight the growing trend of banning plastic bags with a
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FROM THE EDITOR'S PEN
Let’s welcome fuel tank and fire extinguisher ou might be thinking what I am saying at the
are eliminated good for the
New year but I mean it.. And no.. you can’t
environment and emissions
Y
standards. the process can
get me wrong.
be done on existing blow-
We all know that Plastics is the gem of a material.
molding machines. Well this is
I know all of our fellow industry men would agree.
fantastic for it would definitely
But what I would like to mention when I am saying
hold good as far as emission
fuel tanks and extinguisher (together, phew!) for we
standards are concerned.
have them made of plastics.
Japanese blow molding equipment supplier
Auburn Hills-based TI Automotive Inc. recently
Frontier Inc has launched the world's first
launched its newest innovation, the Tank Advanced
thermoplastic blow molded fire extinguisher. It took
Process Technology (TAPT), at its plant in Rastatt,
three years of research on behalf of a client to find
Germany, to supply the Daimler AG S class,
a way to mold a container capable of handling the
including the Mercedes-Benz S-500 plug-in hybrid.
intense pressure needed for an extinguisher, five
The technology was developed for the European
times what's required for a water bottle.
market in Germany, but engineers from Auburn Hills are developing tanks for the North American market
It also offers a glimpse into how industrial design
standards. The supplier has development contracts
can be used to freshen up an age-old product.
on the technology with a U.S. and a Japanese
One thing that is clear polyethylene naphthalate
automaker.
resin offers a lighter look and feel that might help it expand market share and appeal to design-oriented
The use of a plastic fuel tank in a hybrid is a
customers.
differentiator for TI, since most hybrids use steel tanks because of the intense heat from lithium-ion
Frontier built the molds and spent several years
battery packs. TAPT opens the mold during the
developing a specially designed blow molding
cycle to robotically insert fuel system components
machine that can process PEN resin and meet
inside the tank, then closes it again to complete the
technical requirements set by fire safety regulators.
molding and seal the tank. Other fuel tank makers
The extinguisher is also designed for recyclability,
use similar in-mold placement of components
using common grades of other materials like
during blow molding. The process provides TI a
polypropylene and ABS for the base and handle.
threefold benefit The stiff, pressurized tanks are
Well that’s the beginning of 2014.
heat-resistant, allowing the tanks to be used on hybrids and electric vehicles for the first time. Also,
Hon. Editor
because the tanks are sealed while still hot and
Ajay Desai
use no external sealing hardware, vapor points
editor@aipma.net
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AIPMA AT WORK
A Glance at the pavilions in Plastivision India 2013 Exhibition 'PLASTIWORLD PAVILION' n entire pavilion dedicated just for the promotion of finished products of plastic
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Segments of Exhibitors & Visitors for the show
Packaging Target Audience: Foods Industry, Pharmaceutical Industry, Oil Industry, FMCG, Cosmetics, Industrial Packaging. Products : Adhesive Tapes and Foils, Biaxial Oriented Films and Sheets, Blisters, Binder Cord (Sutli), Barrels, Bottles, Blown Film, Crates, Calendered Films and Sheets, Cast Films and Sheets, Carrier Bags, Cross Laminated Films, Caps and Closures, Cases, Corrugated Boxes, Cups and Containers, Drums, Different kinds of Plastic Bags, FIBC, Flexible Films, Flexible Containers, Flexible Pouches, Heavy duty bags, Insulating tapes, Jars and carboys, Laminating Tubes, Laminates, Metalized Films and Sheeting, Mono and Multi Filaments, Multilayer Films and Sheets, Poly Bags, Pallets, PET Performs, PP/HDPE Bags, Pipes and Pipe Fitting of Plastic, Perforated Films, Ropes and Twines, Shrink Films, Straps, Shrink Sleeve Labels, Shrink Tubing and Films, Special Decorative/ Lamination Films, Sheets/Paper/Fabric, Strapping, Seals for Aluminum, Plastic Caps & Closure, Thermoformed Trays, Woven Sack, Hot Stamping Foil.
Infrastructure / Construction: Target Audience: Builders. Products: Products for Building and construction, Corrugated Sheets, Pipes and Tubes, Doors, Electrical Goods, Electrical Components and Appliances, Extrude Nettings, Extrude Profile and Sections, Extrude /Compressed Sheets, Foam Pipes (P.E), Hoses (General and Reinforced), Light Fittings and Accessories, PVC Flooring Tiles, Sanitary Articles, Tarpaulins, Water Tanks, Window Profiles, Wires and Cables.
Agriculture:
Automobile and Engineering Products:
Target Audience: Supermarkets, FMCG Companies, Food Manufacturers, and Chain Restaurants are having huge requirements of Agriculture produce & are actively taking interest to raise technology for farms.
Target Audience: Railways Sector, Defense Sector, MSME Products : Auto Components, AC, Aerospace Industry Parts, Cast Rods and Tubes, Chemical and Petrochemical Engineering Components, Defense Products and Components, Electronic Components, Engineering Components, Extrude Rods and Tubes, Foamed Plastic Sheets/ Rolls, Mobile, Machined Parts of Engineering and High Performance Plastics, Rods, Sections, Stocks of Engineering Plastic Components, Textile Machinery Parts/ Bobbins, Valves and Fittings, Appliance Parts & Body, FRP, Composite Plastic, Wind Mill Parts. P L A S T I C S N E W S
Products Drip Irrigation Systems, Green House Films, Insect Nets, Mulch Films.
Healthcare: Target Audience: Pharmaceutical Industry, Hospitals Products: Disposable Syringes, Medical and Health Care Goods, Parma Packaging, Non Woven, Blood Bags, Infusion Sets, Implants, Dental, Spectacles, Fitness.
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AIPMA AT WORK Consumer Products:
and Games, Sporting Goods, Toothbrush, Brushes, Cleaning Products, Covers, Acrylicware.
Target Audience: Chain Shop Buyers, Importers
Show Report:
Products: Advertisement and Promotional Products, Display Articles, Bangles, Belts, Castor Wheels, Watch Cases, Bottles, Cups and Containers, Decorative Articles, Educational Products, Footwear, Furniture, House Ware / Kitchenware, Thermo Ware, Hangers, Hair Combs, Helmets, Licensed Products, Stationary, Writing Instruments, Toys
Area: 1208 Square Meters No. of Exhibitors: 91 Best Stall Award Winners:
Total Packaging Services Sarvottam Polymers Raman Polymers
Automisation in Plastic..... Harshad Desai, Chairman – Automisation Committee irst of all I would like to thank AIPMA, PVI Chairman and Committee to give me an opportunity to be a Chairman of AIPMA PVI Automaton committee.
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The concept of Automation and atomisation is talked about in plastic industry, but it is not being used widely and implemented. This is the first time in any international Standard Exhibition, where this is more specific and clearly defined and explained in practical ways. AIPMA and PVI should be congratulated for their attempt to keep in mind the interest of the industry people and demonstrate the industry, the benefit Of atomisation and developments being Done in the advance countries .The easy And practical ways of reducing the labour and Increasing the production and Quality of the Product at no Extra cost....How to make Use of new technology, Machineries and Processes to the mutual benefit of manufacturers And users.
systematic And in better ways. All the machine / mould Manufacturers were following 5 'S' and 6 Sigma Processes for their planning. 'UNIDO ' has done Wonders in guiding and advising the industries For their planning and proc There were few OEM from the industry in Overseas Pavilion section. more for the Processing of PET and other R.M. The New printing and production processes were In line with the modern trends. This is the Future for plastic and this Exhibition has Thrown light on many minor details of using Simple technic to reduce the labour improve Production without compromising on Quality.
This was being clearly demonstrated in Raw Material Recycling and processing. Mainly in PET scrap and granulation Machinery section. There was also a clear Indication, that quality checking, product counting And packing products can be done without extra labour and in line for the processing industry. And all these ideas and Machineries were Manufactured and demonstrated by all our Indian Manufacturers at a very reasonable Cost.
To summarise, the effect of implementation Of Atomisation and educating the processors of the industry has helped and appreciated By one and all. And after all this credit goes to the members of AIPMA and PVI team. We Should try to pay more attention to such Subjects in our future Exhibitions and Seminars.
There was very clear message from INDIAN Machine Manufacturers that, Storage and Handling of plastic goods/ moulds /equipments Can be handled without heavy Machineries and Extra labour, at the same time more P L A S T I C S N E W S
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AIPMA AT WORK
Consultants' clinic..... Harshad Desai, Chairman – Consultant Clinic his was very first of its kind initiative by AIPMA a step forward towards providing guidance and share ideas and an experience with all the entrepreneurs and the public.
The new concept of Consultant's Clinic has a very long way to go and has opened up a new chapter in the plastic field. This is a boon to plastic industry and all credit goes to AIPMA and Chairman of PVI for their vision.
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We got a very positive response from Visitors and new entrepreneurs. We were happy to provide them the guidance and Assistance in all fields. We had top experts and knowledgeable / experience stalwarts from every aspect connected with the Industry from production, planning to Legal and financial fields. We had many visitors, thinking that we have ready projects and fully guidance including financial assistance. Well they were provided with all necessary guidelines and all were very satisfied and were looking for more advise from the experts in their future planning.
We are trying to take this to higher Level and provide all our AIPMA members and people interested in the plastic field to benefit from such Exhibitions and Our AIPMA membership.
The Medical Pavilion Dr. Asutosh Gor, Chairman - Medical Pavilion of choice for manufacturing various medical products, a flow chart showing different Raw materials of plastic and specific products made out of them was on display. A few photographs of medical disposable manufacturing stages were shown.
he 9th Plastivision 2013 showcased use of plastics in medical field theme pavilion for the very first time in the history of Plastivision.
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A stall was set up with the help of inputs from Mr. D. L. Pandya from Medical Plastics Data Service. It showcased through graphic representation, Anatomy of human body parts, various plastic products that are used as prosthesis in human body, why plastic is the material
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Samples of various products manufactured out of plastic and used in medical field like catheters, I.V Canulae, syringes, dialysis pumps, insulin pumps to name a few were
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knowledge about use of medical plastics. All said the step taken by AIPMA under the able leadership of PVI chairman Raju Desai to introduce the above theme pavilion was a huge success wherein awareness and enhancement of knowledge about use of plastics in medical field was the motto.
on display. Surgical disposables made. Out of nonwoven P.P like disposable masks, gowns, caps were on display. Among the visitors, we had processors who are already into manufacturing of medical disposables looking for new products, Processors who were into moulding of other plastic products and were looking to venture into medical plastic moulding, First time entrepreneurs looking to enter plastic industry by taking up manufacture of medical plastics, students and other visitors curious to enhance their
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As a Chairman of the theme pavilion it was a very satisfying experience and I look forward to a bigger and better pavilion next time.
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Plastivision India ’2013 – Green Pavilion Haren Sanghavi Partner - Satellite Plastic Industries Treasurer - AIPMA lastivision India 2013 show held from 12th to 16th December 2013, in NSE grounds, Goregaon, Mumbai was a large Exhibition in terms of Area, Participation and Visitors. Hall – 1 and Hall – 6 were having lot of participation from Recycling and Environment Related Product and Equipment Manufacturers.
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In Recycling greater emphasis was laid on Higher Production, Automation and Advanced Segregation Systems, Energy Efficiency, etc. The AIPMA Green Pavilion was a feather in the cap for Environment related solutions. There were live demonstrations for Waste Recycling, Waste Washing, Drying, Segregation, Waste to Fuel, etc.
Overview on Recycling Plastics Recycling is an industry which has a great demand in development and up-gradation especially in the sector of road waste. The demand is more on machines with higher production vis-a-vis lower power consumption (Energy Efficient Systems), Automation, Simpler Systems for sorting and segregation of Road Waste Plastics, etc. Though demand of bio-degradable plastics is picking up yet the same is not widely accepted as the consumer fears the toxic nature of the chemical additives to achieve the bio-degradable nature may be harmful. Moreover the high cost of these polymers means lower demand.
3.
Mr. Praful Jadhav – Assistant Engineer
4.
Mr. Vijay Patil – Assistant Engineer
5.
Mr. R. Surve – Assistant Engineer
6.
Mr. Haribhau Jadhav – Officer on Special Duty
7.
Mr. Bhoite – Assistant Engineer
8.
Mr. Khopkar – Sub Engineer
9.
Mr. Nagpure – Sub Engineer
11. Mr. Nikhil More – Sub Engineer 12. Mr. Vinod Shelar – Municipal Councillor These officers / corporators from the local ward office were surprised to note that plastics can be efficiently recycled and the different ways they can be recycled was news to them. The Plastics to fuel project was a complete attraction for mixed plastic wastes and Multi-layer films which till the time they visited the Plastivision show was thought to be non-recyclable.
Overview on Environment Concern AIPMA had invited almost all the decision makers from the Pollution Control Board as well as local Municipal Authorities. Few leading names from various Municipal wards were as follows:
The poster displayed by AIPMA should how plastics can be sorted, segregated, washed, cleaned, dried, reduced, recycle, reused and recovered.
Mr. Ashok Yamgar – Deputy Chief Engineering Solid Waste Management Operations MCGM
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Mr. Kishor Desai – Executive Engineer – Solid Waste Management, MCGM
10. Mr. Lalit Wankhede – Sub Engineer
There were visitors at the show who were ready to place orders for big projects for recycling worldwide. Indian visitors looked more positive. Major requests were for fully automatic high output recycling lines and for Waste to Fuel.
1.
2.
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AIPMA AT WORK ICPE was also part of the AIPMA Green Pavilion where they also displayed
power consumption as compared to the earlier days. In recycling GMS Plastic Machinery Pvt. Ltd., Erema, etc., were some companies offering energy efficient Machines.
1. How littering can be restricted,
Highly Contaminated Waste Recycling: Gamma Meccanica, Erema were some of the leaders in this sector. Highly contaminated road waste is hard to recycle. During the Plastivision Show there were some machines which were processing highly contaminated waste.
2. How environment can be protected, 3. How to convert mixed waste plastics to Fuel, 4. How to convert mixed waste plastics to products like lumber, etc. They had a running video for all these plus other environment related solutions. They had also displayed lot of plastic products made from 20% to 100% Plastic waste.
Summary Growth of Mechanical Plastic Waste Recycling is anticipated to grow in similar or bigger figures. Lot of research and developments are going on in this industry from “At Source” segregation equipment’s to better quality mechanical recycling lines, then direct products from waste lines like Wood Plastic Composites, Mixed Plastic Sheets, Waste to Energy, Waste to Fuel, etc.
What was new in recycling... Well the most important developments in Plastic Waste Recycling sector were: Plastics to Fuel: This was the most interesting project set up by M/s. Step who had a live machine to display how mixed plastic waste with dirt stuck on them can be converted with easy to various types of fuel and the residue i.e. carbon also fetches a premium for using as pigment.
Automation is the need of the hour and AIPMA Green Pavilion was well prepared to show Automation if all sectors of Waste recycling from Plastics to Fuel to Mechanical Recycling.
Energy Efficiency: This was a very popular in all fields of plastic Production Equipment. Everyone was showing equipment which had higher production rates and lower
Aipma Green Pavilion at Plastivision India 2013 displayed that: “PLASTICS ARE 100% RECYCLABLE”.
PLASTIVISION Job & Career Fair lastivision Job & Career Fair was first of its kind initiative done by AIPMA during Plastivision India 2013 tradefair with an objective to five common platform to industry, plastic professionals and academia world to meet and explore opportunities of growth prospects and take advantage of each others strength.
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JOB FAIR ARENA: it was created with an agenda wherein visiting employers had launched multiple jobopenings and conducted interviews at the private meeting rooms that were provided to them, they got the advantage to meet several candidates of various departments at all levels under one roof on a dedicated day Depending on industry segment. There were 12 reputed visiting employers in this season namely Prince Pipes & Fittings, Mutual Industries, Samruddhi Industries, Raj Industries, Prayag Polytech Pvt. Ltd., AVI Global Plast Pvt. Ltd., Essen Speciality Flims Pvt. P L A S T I C S N E W S
Ltd., Neo Essel Dispoware, Polysmart Technologies (Jyoti Plastics Works Pvt. Ltd. Group Co.), Vasantha Tools Pvt. Ltd., Efficient Engineering all had multiple job openings 20
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AIPMA AT WORK (90% experienced and 10% freshers) there were more than 200 interviews conducted at the venue and around 20 candidates were successful either with spot offers or selection in round of interview. As per our policy to safeguard our exhibitors. NOT A SINGLE EMPLOYEE OF THE EXHIBITORS OF PLASTIVISION INDIA 2013 WERE ALLOWED TO GIVE INTERVIEW OR EXPLORE THE JOBS OFFERED. CAREER FAIR ARENA: It was a unique task done where educational institutes engaged in imparting training in plastic / polymer technology and packaging from diploma level to PHD were present in our pavilion displaying their activities of academia, testing, certification, consultancy and interacting with the industry to promote their students as trainees etc… 8 institutes participated namely Shri Bhagubhai Mafatlal Polytechnic, MIT College of Engineering (Pune), MIT (Aurangabad), L.D. College of Engineering (Ahmedabad), Calcutta Institute of Technology (CIT), SIES School of Packaging, Laxminarayan Institute of Technology (Nagpur), Indian Institute of Packaging. They all got excellent response and have gained atleast 5 companies each who were interested in their campus recruitments.
Inaugurated by Shri Indrajit Pal, I.A.S - Hon’bleSecretary, Ministry of Chemicals & Fertilizers, Department of Chemicals & Petrochemicals, In presence of Mr. Saif Mohammed Al Midfa–CEO Expo Centre Sharjah. prospects of increment/progress is capped, thus we all in the industry will find it difficult to get good candidates by asking candidates to enter long term contracts.
We thank all the participants, staff of AIPMA and service providers for their contribution to make the event a great success…………………..
Observation of the Chairman on Current Job Markets Scenario •
On interaction with the candidates, I read, there was a stiff resistance / lack of interest from them on exploring /entering into 3 yr or 5 yr contracts as they feel their
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There is a good demand for mold designers and tool room related professionals with adequate supply on opposite side.
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There is severe shortage of candidates for sales related jobs in machinery and compounds/ additives / masterbatch segment.
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At this moment there are more MTech qualified candidates in job market seeking jobs in R&D and quality department.
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Industry is finding difficult to get machine operators specifically in injection molding and sheet extrusion as there is huge demand while CIPET qualified candidates are not happy with pay pack industry is offering thus they are diverted /lost.
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Please note: the above is Personal opinion of the Chairman while executing the event and Not of the association. The objective to write these lines are for all stakeholders to understand the current job scenario in plastic industry. Kishore Sampat Chairman – Job & Career Fair, PVI 2013
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CONGRATULATIONS!!! “AWARD WINNING EXHIBITORS” s like earlier practice, this year also there were awards presented to the exhibitors for showcasing their stalls/booths during the exhibition
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Maher-Investment Partner.
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Machines Boucherie India Pvt. Ltd.
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Spencer & Spencer.
The Criteria of Awards for Considerations:
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Kuraray India Pvt. Ltd.
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Fine Organics.
For Considerations of Awards to Exhibitors, “Award Committee” as well 12 Jury Members was decided for;
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Mittal Enterprises.
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Reliance Industries Ltd.
1]
Category of Exhibitors,
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Techno Print.
2]
Basis for Considerations/ for Awards- Number of Awards,
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Waaree Energies Ltd.
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Ashna Enterprise.
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Shanghai JWELL Machinery Co., Ltd. China
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Zhejiang Borerech Co., Ltd. China
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Daesung Ext. Korea
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Eco Plastics U.K.
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Teknomast S.r.l. Italy
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Da Fon Environmental technology Co., Ltd. Taiwan
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3]
International Pavilions shall be considered individually.
4]
Special Category Exhibitors Award to Exhibitors having Excellent Achievements like Energy Saving Systems, Increase in productivity with better Design, Environment friendly process, and use of Solar Energy.
We had received a letter from “Technopet Machineries” Registering its achievements covering above Category.
Hall Wise, a group of Jury visited 956 Exhibitors giving Credit Rating, a great task to cover in 02 days, area of 50,000 Sq. Mtrs.
Accordingly Jury had visited “Technopet Machineries” and considered it for the Award.
Computation completed overnight by 12th and 13th December 2013.
The winners at glance:
"Creative Exhibitor" Award Winning Exhibitors" Sr. No
Names
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ARBURG GMBH.
2
Anupam Heaters & Controls Pvt. Ltd.
3
Bry Air (Asia) Pvt. Ltd.
4
Steer Engineering Pvt. Ltd.
5
Yudo-Suns Pvt. Ltd.
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GMS Plastic Machinery Pvt. Ltd.
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Technopet Machineries.
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Acme Die Systems Pvt. Ltd.
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Sarvottam Polymers Pvt. Ltd.
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Raman Polymers.
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Total Packaging Services.
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Mr. Anand Oza – President, AIPMA, Mr. Raja Shah – Chairman Awards Committee PVI 2013 presenting award to Mr. Vineet Bannore – Director, and Mr. Sunil Bharkheda – Director, Technopet Machineries.
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Award being presented to Mr. D. N. Sheth of Anupam Heaters & Controls Pvt. Ltd.
Mr. Anand Oza – President, AIPMA, Mr. Raja Shah presenting award to Mr. Sanjay K. Shah – Chief Business Officer, Mr. Sudheendra P. – Marketing Manager and Mr. Sunil Dutt – National Sales Manager of Steer Engineering Pvt. Ltd.
Award being presented to Mr. Francis Yu – Chairman, Yudo and Mr. Vishal Agarwal of Yudo Hot Runner India Pvt. Ltd.
Details of Awards Considerations:1] No. of Exhibitors [Evaluated] 956 2] Number of Jury
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3] Number of Awards
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4] Memento Presentation at 15th December 2013 Winners Stalls: Reference: List of “Awards Winning Exhibitors” enclosed. A Beautiful Crystal Memento having base of LED Light, engraved with Winner Exhibitor’s name was presented to winners on 15th December 2013. The International Award winning Exhibitors Mementos were presented on16th December 2013. Wishing “Good Luck” to Exhibitors of PVI- 2017
Mr. Anand Oza – President, AIPMA, Mr. Kailash Murarka – Co – Chairman, PVI 2013, Mr. Raja Shah – Chairman Awards Committee, PVI 2013 presenting award to Mr. Nawal Kishor Modi - Director, Mr. Dipesh Goyal of Mittal Enterprises.
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RAJA M. SHAH, M.E. Chairman - Awards Committee - PVI- 2013 Cell: 983331 16051. Email: awards@plastivision.org 23
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PVI 2013 PHOTO GALLERY The happennings moments of PVI 2013 The Gala Nite ceremony with Sonu Nigam and his orchestra
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PVI 2013 PHOTO GALLERY The happennings moments of PVI 2013 The Business as usual continues...
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PVI 2013 PHOTO GALLERY The happennings moments of PVI 2013 Closing ceremony with the Organisers taking the last lap
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PVI 2013 PHOTO GALLERY The happennings moments of PVI 2013 The last lap
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COMPANY NEWS
Sasol inaugurates new ethylene purification unit asol Ltd’s Chief Executive Officer, David Constable, and the South African Minister of Trade and Industry, Dr Rob Davies, inaugurated Sasol's new ethylene purification unit, known as the Ethylene Purification Unit 5 (EPU5), in Sasolburg. Located at the Sasol Polymers Plant in Sasolburg, the R1.9 billion ethylene purification unit aims to address the growing demand for polyethylene material.
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The plant will also ensure better utilisation of Sasol's existing downstream polyethylene facilities. David Constable said, "Through the installation of the new ethylene splitter, considerable production capacity has been freed up to produce more ethylene. In so doing, our investment in EPU5, together with a new compressor unit in Secunda, will provide the
South African plastics manufacturing industry with an additional 47 000 tons of polyethylene annually." EPU5 is already in operation phase. Half of the additional 47 000 tons of polyethylene will be reached within the next six months, while the plant is expected to reach full capacity by 2017."The South African plastics industry is a significant contributor to the national economy. Local demand for polyethylene polymers continues to grow at a rate of 4 to 5% annually. With a rise in new plant capacities and the need to be globally competitive, we recognised the necessity to expand both polymer and ethylene production," said Marinus Sieberhagen, Managing Director, Sasol Polymers. The plant was also designed to reduce hydrocarbon flaring, which reduces the carbon
Sonner looks for expanding its base in Indian market hina based Sonner freeding and designs is to expand its presence in major cities like Mumbai ,Delhi and Gujarat. Speaking about expansion plans Sun Lu Sonner said, “We are looking to expand our base in India especially in Plastics. We have been catering to the textile industry earlier and now are focusing Plastics. Already we have launched our Indian subsidiary Sonner Freeding Systems India Pvt. Ltd., in Mumbai.”
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Prashant Tatkare Advisor Director Sonner Freeding Systems India Pvt. P L A S T I C S N E W S
Ltd., in Mumbai, maintains that the Indian Plastics industry is growing and Sonners freeding systems are best suited for the plastics industry be it the Injection or the Extrusion process. The company provides customized tailor product and are already leading in polymer compounding. According to Sun Lu with the growth in the sector polymers compound would be leading. Sonner might initially look for joint venture or may be a workshop. The company has 3500sq. mt. plant in Shanghai. 29
footprint of Sasol's total ethylene production capacity in South Africa. Local engineering and construction service providers were sub-contracted to execute significant portions of the work.
Sacmi to double press capacity in India taly-based Sacmi Group is moving ahead with plans to assemble Negri Bossi injection presses in India. The company bought 12 acres of land in Sanand, in the western Indian state of Gujarat, to set-up its own new facility.
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Sanand is a major hub for India's auto industry. Currently, we are operating from rented premises in Ahmedabad and land has been taken to build a new factory in Sanand,” said V. Ramesh, CEO of Sacmi Engineering India Pvt. Ltd., Once the new plant is ready by the middle of 2014, the Ahmedabad operation will move to the new location. Sacmi makes around 55 Negri Bossi and is expected to double the production as it moves to the new plant . It is assembling presses ranging from 100-900 metric tons, but with expansion it will hike the tonnage level to 2,000 metric tons.
J A N U A R Y 2014
COMPANY NEWS
Clariant to acquire Plastichemix Industries lariant, a world leader in specialty chemicals is to acquire Plastichemix Industries, a masterbatch business in India, located in Vadodara with production facilities in Rania, Kalol and Nandesari in Gujarat. With this acquisition, Clariant Chemicals (India) Limited (CCIL) gains a leading position in the masterbatches business in India.
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The deal enables the company to offer a strong and extensive product portfolio with customized products and solutions and to expand
its customer base significantly. Plastichemix Industries is a leading manufacturer of black, white, filler and colour masterbatches, additive masterbatches, flushed pigments and mono-concentrates as well as engineering plastics compounds. As part of the future business approach an upgraded Technical Service Laboratory will be introduced to offer the market highly innovative and customized products. “This acquisition is part of our global strategy to explore business opportunities in
our Masterbatches business and to focus on emerging markets like India. The strong growth perspective of the plastics industry results in a bright future for the masterbatches business in India", says Hariolf Kottmann, CEO of Clariant. Hans Bohnen, Head of Clariant's Business Unit (BU) Masterbatches, explains: "Clariant and Plastichemix Industries have a complementary product portfolio that will enable us to cater to a larger customer base. This synergy will help us to develop our business. .
Weener takes full ownership of Indian packaging company igid packaging company Weener Plastic Packaging Group has taken full ownership of Weener Empire Plastics (WEPL), its operation in India which has seven factories in the country. In a statement, Weener, Germany-based Weener said it had been a minority shareholder in WEPL for eight years, but it now owns 100 percent of the Indian company's shares after completing a transaction in December.
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WEPL molds plastic closures and containers for the personal care, food and pharmaceutical industry. "This acquisition is aligned to our strategy of enhancing our footprint in the emerging markets. WEPL has performed well in the past years and we target to add to this growth
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further in the coming years," said Roel Zeevat, CEO of Weener Plastic Packaging. WEPL's managing director A. B. Gupta and director Abhinav
Gupta will keep their current positions and stay on the board of the Indian operations.
Manali Petrochemicals to partner BPCL for polyurethane project in Kerala anali Petrochemicals is to partner BPCL to set up a 3,50,000 tpa polyurethane project in Kerala at an investment outlay of Rs. 3,000 crore.
(PU) manufacturing plant. The JV partners are also considering to dilute around 5% stake each to the technology provider and to a trading company.
The capacity of the project has been increased from 250,0003,00,000 tons. The project will be India’s single-largest polyurethane
The project will be spread over 150 acres of land next to the BPCL's existing facility at Kochi, Kerala.
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J A N U A R Y 2014
COMPANY NEWS
Total Packaging Services bags the Deignan named “CREATIVE EXHIBITOR” awards at PVI 2013 Americhem's new otal Packaging Services has bagged the “CREATIVE EXHIBITOR” awards at the recently held Plastivision India 2013. Urvi Shah Manager at Total Packaging says: ‘The credit of our continuous growth goes to our TOTAL TEAM, which is our family and thus we say it as “TOTAL PARIVAR”. and are working to take it to 250 crores till next year. Total packaging is also
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looking to focus It is their hardwork , efforts and sincere dedication which is taking the company to a next level.” Total Packaging Services is one of the largest Polybag manufacturer having the turnover of 200 crores on rural Maharashtra as there is a huge demand of plastic bags in the market. Also there is a lot of potential in rural Maharashtra that remains untapped adds, Urvi Shah.
IOC evinces interest to partner HPCL in 15 mln tpa refinery at Vizag PCPIR ndian Oil Corporation Ltd is the latest public sector undertaking to have evinced interest in the 15 mln tpa integrated refinery-cumpetrochemical complex proposed to be set up in the Vizag-Kakinada Petroleum, Chemical, Petrochemical
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Investment Region (PCPIR). HPCL is scouting for a foreign partner to set up the 15 mln tpa integrated refinerycum-petrochemical complex along with partner Gas Authority of India Limited (GAIL) in the PCPIR.
president ohn Deignan has been named as the President of the Americhem Inc firm. Deignan, 46, was hired in November by Americhem, a color and additive concentrate maker in Cuyahoga Falls, Ohio. He had spent the previous 21 years in a variety of leadership roles at Diebold Inc., a maker of banking and security systems in nearby North Canton, Ohio. As president, Deignan will lead the day-to-day operations of the company and foster Americhem's strategic relationships with customers. In his new role, Deignan replaces Dorian Alexandrescu, who left Americhem in the second half of 2012. Americhem ranks as one of North America's 30 largest compounders and concentrate makers.
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Sinopec Engineering to build coal-to-petrochemicals plant, worth $3.1 bln, in China inopec Engineering Group has entered into a deal to build a US$3.1 bln plant in northern China to turn coal into petrochemicals, as China seeks to reduce its reliance on petrochemical imports.
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According to reports form Reuters, Sinopec Engineering will be responsible for engineering, procurement and P L A S T I C S N E W S
construction of the 18.67 billion-yuan project in Inner Mongolia, which it said would be the largest of its kind in the world. The plant will produce 3.6 mln tpa of olefins - mostly ethylene. China, the world's biggest net importer of oil, is a leading buyer of petrochemicals, and imports about 45% of its ethylene. 31
Sinopec Engineering, a newly listed unit of state-run Sinopec Group, would deploy a self-developed technology to make olefins from methanol, which can be extracted from coal. The coal-based process is cost competitive versus China's conventional way of making petrochemicals from more costly naphtha, a refinery product processed from crude oil. J A N U A R Y 2014
COMPANY NEWS
Haldia Pertochemicals board decides to opt for rights issue he Board of Haldia Petrochemicals Ltd has decided to opt for rights issue to save the ailing petrochem unit. According to report in The Hindu, around 52 crore shares will be issued at a discovered price of Rs 25.10 per share or around Rs 1,305 crore. HPL shares have a face value of Rs 10. Shares will be issued as per
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the existing shareholding pattern. Also as per a company statement, "After detailed study and looking at various options available, the HPL board arrived at a conclusion that the only option available before the company to avoid making reference to BIFR and its revival through fresh infusion of funds, is to go forward for a rights issue
SK Incheon Petrochem mulls legal action against Seo-gu paraxylene plant being built by SK Incheon Petrochem faces possible closure, resulting in damages upto US$1.5 bln. About 90% of PX plant construction has been completed. SK Incheon Petrochem, which was spun off from SK Energy last May, is considering taking legal action against the Seo-gu Office of Incheon City to rescue its investment project, SK Innovation.
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The Seo-gu Office plans to officially send a notice to halt the construction by mid-January. The office said the
decision was based on findings that SK Incheon Petrochem had not properly attained the license for the project. SK Innovation, however, refuted the claim, saying that the company attained the license in a legitimate manner in 2006. Also, the project has faced strong objections from citizens living in Seogu, where the expanded PX plant will be located as reported by heraldcorp. com. As per another source, it was found that SK Incheon Petrochem had built the plant in excess of the area previously permitted with the city.
Formosa Chemicals & Fibre Corp likely to sell shares of Formosa Petrochem. ccording to reports Formosa Chemicals & Fibre Corp plans to sell about 2% of its stake in Formosa Petrochemical- a maximum of 51.6 million shares of affiliate Formosa Petrochemical Corp by the end of Q2-2014. Formosa Plastics, Formosa Chemicals and Nan Ya Plastics are
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the three largest shareholders in Formosa Petrochemical. Experts say, if completed, the share disposals would contribute earnings per share for Formosa Chemicals, Formosa Plastics and Nan Ya Plastics of about NT$0.5, NT$0.47 and NT$0.38 respectively. 32
of equity shares inviting its existing shareholders to subscribe in 51.2 crore equity shares at a price of Rs 25.10 per share being the discovered price which emerged from the disinvestment process by WBIDC."
Constar files for bankruptcy for the third time onstar International Holdings, a maker of plastic bottles primarily for food and beverage markets, has filed for Chapter 11 bankruptcy protection. This is the third bankruptcy filing since 2008 for the Trevose, PAbased company, which listed assets of as much as $100 million and debt as high as $500 million according to U.S. Bankruptcy Court papers.
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The largest unsecured creditors listed in the bankruptcy filing include DAK Americas and DAK Resinas de Mexico, owed more than $15 million, and Britvic Soft Drinks Ltd. of London, which is owed $5.43 million. Constar is a major producer of PET bottles and containers including barrier and hot-fill technology. In 2013, Constar obtained six new patents related to its Diamond Clear Oxygen Scavenging technology for PET packaging. A proposed buyout offer from Amcor Rigid Plastics USA has been made for $68.5 million. Constar operates seven plants in the U.S. with 470 employees, and two in Europe.
J A N U A R Y 2014
FEATURES
Plasticulture -- The untapped opportunity griculture, which is the mainstay of the Indian economy, contributes about 18 percent of the national income and provides employment to more than 50 percent of the population. Diverse agro-climatic conditions conducive for a variety of crops almost round the year; highest arable land-to-land size ratio and the largest irrigated land network are the hallmarks of agriculture in India.
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Given the inherent strengths and highest policy resolve to strengthen agriculture, India is emerging as one of the most favorable destinations for making agri-business investments and presents widespread opportunities across the value chain. Thus calls for paradigm shift in agriculture mechanization in various domains of cultivation like tillage, sowing, irrigation, plant protection, threshing etc. Plasticulture represents use of applications of plastics in Agriculture, Horticulture, Water management & related areas. Speaking about Plasticulture Krish Iyenger, Joint secretary, NCPAH said that the
National Committee on Plasticulture Applications in Horticulture (NCPAH) is constituted in the Ministry of Agriculture (MOA), Govt. of India to focus in a coordinated manner to popularize adoption of various plasticulture applications in horticulture and the over all development of plasticulture applications in the country. Plasticulture applications offer a multitude of benefits and are considered most important indirect agricultural inputs which results moisture conservation, water saving, reduction in fertilizer consumption, helps in precise application of water & nutrients, controlled environment agriculture is economically viable, plant protection through the use of nets and use of innovative packaging solutions help in increasing shelf-life and during collection, storage & transportation of fruits and vegetables. M o r e o v e r to propagate Plasticulture NCPAH has the mandate to promote and develop the use of plastics in agriculture, horticulture, water management and other allied areas.
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The Committee during its tenure has submitted several reports and documents to the Government of India which have paved the way for plasticulture development in the country. Plasticulture applications includes Drip & Sprinkler irrigation system, Greenhouse, Shade net house, Pond lining, Plastics Mulching, Low tunnel etc. The plasticulture applications can be broadly categorized into: I
Water management: •
Lining of canals, ponds & reservoirs with plastics film
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Drip & Sprinkler Irrigation
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PVC & HDPE pipes used for water conveyance
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Sub-surface Drainage
II Nursery Management: •
Nursery bags, Pro-trays, Plastic plugs, Coco-pits, Hanging baskets, Trays etc
III Surface cover cultivation: •
Soil Solarisation
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FEATURES fertility of the soil is also retained. This is just one example.. there are many more.”
IV C o n t r o l l e d e n v i r o n m e n t agriculture: •
Greenhouses
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Shade net houses
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Low tunnels
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Plant Protection nets
On the recommendation of NCPAH, the Government has also established 22 Precision Farming Development Centres (PFDCs) all over the country to promote research and extension activities in promotion of these applications. The NCPAH also provide subsidy for opting plasticulture.
V Innovative Packaging: •
Plastics crates, bins, boxes, leno bags, unit packaging products etc
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CAP Covers, Controlled Atmospheric Packaging(CAP) & Modified Atmospheric
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Packaging (MAP)
Advantages of plastic in Agriculture The unique advantages of plastic over conventional materials are: •
Higher strength/weight ratio
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Superior thermal insulation properties
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Excellent corrosion resistance
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Superior flexibility
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Resistance to most of the chemicals
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Excellent moisture barrier properties
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Favourable gas permeability.
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Smooth surface – resulting in reduction in friction losses
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Excellent light transmissibility
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Helps to enhance shelf-life of the produces
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Better visibility of the produce
boon the industry. To support his argument Iyengar says, “Let’s say what happens when one opts for Mulching. First it saves water, which further helps in retaining the moisture of the soil as there is no evaporation. Second as the surface is covered there is no weeding; this in turn increases the yield. Third, the
Iyengar maintains that the need of hour is looking for effective irrigation system to increase per hectare productivity in different crops by saving water for the water level is shrinking by 1 meter every year. Plasticulture applications are one of the most useful indirect agricultural inputs which hold the promise to transform Indian agriculture and bring in the "Second Green Revolution".
Mr. Iyengar stresses the need to create the awareness not only among the framers but also across the processors. There is a huge opportunity that remains to be tapped. Plasticulture or the use of Plastics in agriculture would definitely be a
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J A N U A R Y 2014
FEATURES
Waste at its Best…! Waste Plastics and polymers to Fuel The world is facing the problem of disposal of waste plastics. The ease of manufacture and the abundant availability of plastics in all wakes of life have created a situation where the useless and waste plastics from the abandoned electronics, carry bags, automobile accessories etc. are piling up day by day and there are no economical disposal methods are available. Unless, economic disposal methods are found out, world will see the menace of soil degradation, loss of water table and many other problems associated with the non-biodegradable plastics. Based on this reasoning, the novel POLYCRACK*process has been developed and successfully tested by STEPS (Sustainable Technologies & Environmental Projects Limited). Speaking about the process Raghvendra Rao T. Chairman & CEO, STEP Pvt. Ltd says, “Many
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technologies have been developed to address this problem since past, but they have posed one limitation or the other.” Sustainable Technologies & Environmental Projects Limited has developed a new technology to process Hydrocarbon sludge and convert the same into Synthetic oil, which is very similar in properties to diesel. We know that for the refineries, heavier hydrocarbon chains such as paraffin’s and asphaltenes are a problem. When processing this heavier hydrocarbon in the form of sludge, sludge minus the sediments and water are put back into the crude oil storage tanks. In sludge processing, crude oil heavies are recovered and water and sediments are disposed off. This method is not exactly an ideal solution as the hydrocarbons are of paraffinic or asphaltinic nature and the heavy hydrocarbons are mixed with good crude and creates an inferior mixture. Further, the heavy hydrocarbons are diluted with diluents such as diesel, kerosene etc. Thus good products are used to dilute a bad product and finally a bad product is delivered to the crude oil tanks. The cost of the diluents along with that of processing charges are high and thus refineries tend to lose good margins because 35
of such a process. Added to the cost is the cost of disposal of oily solids which will have to be bio-remediated or incinerated. The effluent water from the process is normally taken to the refinery ETPs, loading the existing systems. The new method has been developed after years of experience in handling, processing and converting the sludge to crude oil. The experience gained from the field experience had given a direction for STEPS to develop a method which will deliver true value to the refineries and sludge is no longer a problem but a perennial source of revenue for the refineries. The value of recovered oil adds to the bottom line of the refineries. In the STEPS method the heavier hydrocarbon chains are broken and converted into lower hydrocarbon chains. The lower molecular weight hydrocarbons in the range of gasoline to Diesel and LDO can be used as a direct feed stock to the refinery, or can be co-mingled with the individual streams of gasoline to diesel fuels directly, increasing the overall yield of the saleable hydrocarbon fuels. The higher market value achieved due to direct conversion of sludge to useful fuel grade materials, adds to the refinery profits. The main specialty of this process is that all kinds of plastics, both recyclable and non-recyclable plastics are converted into petroleum fuels, which can be used as alternate sources of fuels for industrial, residential and other needs.
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FEATURES Waste Plastics to Fuel How does it work? All plastics are polymers manufactured from the petroleum lighter ends like propylene, mostly containing carbon and hydrogen and few other elements like chlorine, nitrogen etc. Polymers are made up of small molecules called as monomers which combine and form single large molecule called polymer. When this long chain of monomers breaks at certain points or when lower molecular weight fractions are formed this is termed as degradation of polymer. This is the reverse of polymerization. In the process of conversion of waste plastic into fuels random De- Polymerization is carried out in a specially designed Reactor in the absence of oxygen and in the presence of a proprietary catalyst. The maximum reaction temperature is 3500C. The plastics are converted completely into value added fuel products.
The System The system will consist of three separate skids. One skid will contain the forced circulation evaporator and catalytic conversion reactor, Catalytic converters etc; the second skid will include the condensers and collection systems exhaust gas scrubbers, and the third will consist of Gas Engine. Generators. Additional small skids may be provided, based on the detailed engineering of the system and space requirements for the equipment. The system will function as follows:
The Process The waste plastics are shredded and conveyed into a hopper. The plastics are then heated inside an extruder where the plastics melt into a liquid mass. The molten plastic mass is pumped into the reactors where the molten plastic is converted into a vapour phase. The vapours exit into a catalytic converter. The catalytic converter converts the heavy hydrocarbon
chains into lighter hydrocarbon chains. The lighter hydrocarbon chains of vapour will then pass into a condenser where the lighter ends are condensed and collected into the storage tank as petrol or gas oil. The uncondensed LPG gas is pumped to a receiver and from the receiver; the same is pumped to the burners in the TF boilers to act as fuel. The coal resides and solids will flow by gravity to the residual conveyor and the powdery residue is pumped into a collection bin for further disposal and re-packing. Heat to the entire system will be supplied by a proprietary heating system which uses electricity as a source of energy. Process leaves no catalyst in the residues. The residue is free carbon that can be compressed into pellets and used as fuel in furnaces. A plant with capacity of 25 tons a day using our technology would typically produce residue of about 1 ton of free flowing carbon powder which has commercial value. In other words it is a zero discharge process. Our process can handle moist, dirty plastic, mixed plastics and industrial plastics including automobile fluff. The process can handle mixed feedstock like plastic along with biomass, waste oil, refinery sludge etc. We can practically run all kinds of plastics including the metalized ones; plastics backed with aluminum foils, packagings, tetra packs etc. The yields however will vary depending upon the polymer content in the input material. Presence of metals, glass, fiber, wire, cable, organic, inorganic, TiO2 fillers etc., does not impact the process in anyway.
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FEATURES
Gas-Assist Injection Molding: An Innovative Technology as Assisted Injection Moulding has improved the quality and cost effectiveness of injection moulded components. By using Gas Assisted Moulding parts can be manufactured with enhanced surface finishes, reduced weight, reducing production costs and material usage.
to create thin-walled parts. Such parts can be molded with low clamp tonnage, which reduces both tooling cost and required injection molding machine size. The gas-assist technique is ideal for adding thick, hollowed-out sections to otherwise thin-walled parts.
The principle of this process is that nitrogen gas is injected, during the moulding cycle, either through the sprue or directly into the mould tool. At a controlled high pressure this has the benefit of overcoming sink marks or introducing a cavity without the requirement of a core. During the cooling phase, of normal Injection Moulding, the moulding will shrink away from the mould cavity and a pack of material has to be introduced to counteract the sink. When using Gas Assisted Moulding this pack is replaced by nitrogen, introduced at high pressure while the moulding cools, which helps eliminate sink and improves overall surface finish.
The process improves upon polymer fill and packing techniques and boosts melt-flow length. A designer can create larger, more-complex parts with fewer injection gates than conventional molding, while minimizing costs incurred with complicated hot-runner systems. In addition, the sections that are cored out cool rapidly, reducing overall cycle time.
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How Does It Work? Gas-assist equipment suppliers offer a variety of hardware and controls, but the basic process is similar in all variants. Generally, improvements in gas pressure and flow control enable more-detailed control of process variables. The stand-alone gas unit is wired into the injection molding machine. It uses process signals to time and control the gas-assist process sequence.
Gas-assist injection molding was developed several years ago to overcome the limitations of conventional injection molding. A molding technique that requires special knowledge, like gas-assist, usually takes some time to move into new industries. Accordingly, the gas-assist process has been adopted by several industries during the last few years, and this innovative technology is now making inroads in the medical industry, offering new technical and creative possibilities to device OEMs.
The gas unit is also linked to a nitrogen source (e.g., bottles, a liquid nitrogen tank, or a nitrogen generator). The nitrogen source can be located close to the gas unit or can be part of a central plant system. The gas can be injected into the polymer melt either through a molding machine nozzle or through a gas nozzle.
The process features a unit that introduces nitrogen gas into a mold cavity after it has been filled with plastic. The compressed nitrogen displaces a portion of the molten plastic when injected into the cavity. The result is hollow parts that are light and Figure 1. Pressurized nitrogen gas is injected into a melt to penetrate relatively inexpensive the part via a network of thicker to make. Designers can cross-sectioned gas channels. use gas-assist molding P L A S T I C S N E W S
With a machine nozzle, the nitrogen gas flows through sprue, runners, and gates before entering the part. With a gas nozzle, the gas flows directly into the part.
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Figure 2. During melt and gas injection, some of the polymer melt solidifies at the outer wall and forms a solid layer of resin.
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FEATURES The Process Sequence
the part. The advancing gas pushes the displaced molten plastic toward the melt front to fill and later pack those areas in the cavity. After a complete volumetric filling of t h e c a v i t y, t h e g a s pressure replaces the holding pressure, which compensates for the shrinkage. The internal gas pressure keeps the Figure 3. Machine cycle of the part in good contact with the mold walls. The gas-assist injection process. hotter melt core of the part has the most shrinkage potential, and because of the applied gas pressure, the cooling melt shrinks the most in the hot core section. The shrinkage becomes less toward the mold wall. At the tip of the gas bubble, a so-called shrinkage lance forms because of the differential shrinkage
Figure 1 shows the principal gas-assist process sequence. Pressurized nitrogen gas injected into the melt penetrates the part via a network of thicker, crosssectioned gas channels. The process can accomplish partial or volumetric fillings of a cavity with polymer melt, as in injection molding. Next is the injection of compressed gas. Nitrogen is usually used because of its availability, cost, and inertness. Some processes will, in addition, use overspill cavities for structural or cosmetic reasons. Some resins require a complete filling of the tool prior to applying the gas to produce cosmetically acceptable parts.1,2 After the gassing phase, the pressure is released either by gas recycling or by releasing the gas into the atmosphere. As soon as ambient pressure is reached, the molded part can be ejected. Figure 2 illustrates the process of forming a part using gas assist molding. During melt and gas injection, some of the polymer melt solidifies at the outer walls and forms a solid layer of resin. This layer grows during the delay between the polymer and gas injection. During gas injection, the compressed nitrogen flows through the plastic core and displaces a portion of the molten plastic. Normally, after plastic is injected and fills the cavities, the molding machine goes into a packing stage to prevent void formation. With gas-assist molding, the gas performs the packing, and the voids are intentionally created to reduce part weight and minimize cycle time.
(a) Rod-Shaped Parts
Nitrogen gas has a lower viscosity than the polymer melt. For this reason, the pressure drop over the flow length of the gas bubble is much lower than over the flow length of a molded part. The pressure drop in the holding and packing phase influences the shrinkage across the part and the ability to pack a part. Shrinkage differences promote buildup of internal molded-in stresses and subsequently influence the warpage of a part significantly. The gas-assist process reduces internal stresses and warping and thus improves part quality. It provides a higher and more evenly distributed packing pressure across the part, resulting in better overall part flatness.
(b) Large Cover-Shaped Parts
(c) Complex Parts with Localized Heavy Sections
Gas always takes the path of least flow resistance; it flows into the direction of the melt front. The gas channel’s course goes through the cores of thicker or hotter portions of P L A S T I C S N E W S
Figure 4. Three main categories of molded parts are especially appropriate for gas-assist injection molding. 38
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FEATURES in different layers over the cross section of the part. The lance prevents the molded part from sinking in.
For some resins, the short-shot method cannot be used because of cosmetic surface requirements. Full-shot processes that have additional cavities into which the resin in the core is evacuated generally provide more control over the process.
Figure 3 illustrates the machine cycle of the gas-assist process. It’s important to note the efficiencies that can be gained using this process
Geometric Categories
First, gas-recycling technology is fully developed and can be used in production, thereby reducing costs. Also, when gassing through the machine nozzle (rather than directly into the part), the runner system can be sealed after pressure release. During the remaining cooling time, the injection unit meters the shot size for the next cycle, which reduces cycle time.
Three main categories of molded parts are especially appropriate for gas-assist technology. The first group—tube or rodshaped parts—typically includes handles and foot pedals (see Figure 4a). The second category consists of large, cover-shaped structural parts. Such parts are made with a network of gas channels that is often combined with the rib structure of the parts. Examples include side panels and covers for medical devices (see Figure 4b).
Many part designers still see the gas-assist process as a solution only for simple, hollow, tube-shaped parts. In practice, however, it is much more versatile and can often solve many of the problems inherent in conventional injection molding. Some of the benefits include thin-walled parts and fast cooling for reduced cycle times. Less required clamp tonnage means smaller molding machine size. In addition, gas-assist molding minimizes tooling costs and can make large, complex parts using fewer gates and lesscomplicated hot-runner systems than traditional machines.
The third group involves complex parts with both thin and thick sections. The gas-assist process is used for part integration by consolidating several assembled parts into a single design (Figure 4c). Typical examples would be handles with mounting sections or tray-like parts with thick perimeter sections.
There are different gas-assist injection molding techniques, including the following: •
Short-shot molding (prefill of cavity with melt, followed by gas injection).
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Full-shot molding (complete fill of cavity with melt, followed by gas injection).
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Full-shot molding with overspill (complete fill of cavity with melt, followed by gas injection and opening of overspill cavities).
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Full-shot molding that pushes resin back into barrel (similar to the overspill technique using the machine barrel as the overspill cavity).
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External gas molding (adding a layer of nitrogen gas to the part surface adjacent to the cosmetic surface after complete fill of the cavity).
Because the flow path for tube- or rod-shaped parts is one-dimensional, a good distribution of the gas channel can be ensured. With these parts, uniform wall thickness throughout the cross section is the goal. The resulting wall thickness is a function of the viscosity and temperature
In addition, there are variants of these techniques. One includes a process that uses low-temperature nitrogen gas to create a gas flow through the part for an additional cooling effect.
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Figure 6. Using gas-assist molding ensured consistent wall thicknesses over the length of Alcon’s Infiniti main handle 39
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FEATURES Gassing Unit • Gas Profile• Process Variant 5 Process Analysis • Mathematical Modeling • Experiments • Finite Element Methods It is critical to adapt part design to the gas-assist injection molding process. It is essential to take the specific processing requirements and conditions into account in the early stages of part concept and design. Doing so can reduce the necessary adaptation work to a minimum. It is also very important to understand and appropriately design the filling pattern before injecting the gas. The design should be adapted according to the planned or existing gas channel network. The gas channel layout depends on the size, shape, course, and length of the gas channels. It also depends on the location of the injection points and geometry and the needle position for gassing. Manufacturers can obtain this information through iterative testing or by using mold-filling simulation programs. Here, the processing parameters, as well as rheological and thermal behavior of the polymer, are very important.
Figure 7. The gas evenly hollowed out the Infiniti’s side handle. It is a closed-loop part, so overspill technology was required. distribution within the melt when the nitrogen gas is injected. For extended thin-walled parts, the desired distribution of nitrogen gas can only be achieved through a geometrical adaptation. These parts require some ribbing to create a network of gas channels. Injecting nitrogen during the gassing and holding phases of the process forms the hollow spaces.
Benefits of Gas Assisted Injection Moulding Creating a more efficient mould process During the 'normal' injection moulding process of packing a mould cavity with plastic material, stresses are introduced into the component. Often these are along the line of flow of the packing material. In service these will result in the moulding warping and changing its dimensions. By using the gas medium, transmission of pressure throughout the moulding is more efficient and therefore less pressure is required.
Ultimately, the process produces parts with reduced internal stresses and, consequently, less war page. Gas penetration into the adjacent thin-wall sections should be avoided. It is possible to determine the probability of gas penetration into adjacent wall sections by examining part design, gas channel geometry, the relation of wall thickness to gas channel dimensions, and the gas pressure itself.
Optimizing Parts and Tool Design
By injecting a gas into the material the cavity pressures are lower and being derived from within the component will considerably minimise the risk of warping
Five significant factors influence the production of gasassist- injection-molded parts . These factors and their interdependencies are the most important checkpoints for part and tool design.
In addition, with the material being pressed against the mould surface by the gas until it solidifies, the moulding will have better surface definition and will be more likely to be dimensionally correct.
1 Material Data • Rheological Behavior • Thermal Behavior 2 Part • Geometry Categories • Injection Point Location • Part Design
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Reduced material requirements – By not having to pack a component the result is a part with a hollow core. In larger components this can save up to 30% in material requirements providing much reduced costs.
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Reduced cycle times – Due to the nitrogen there is no
3 Process Parameters • Delay Time • Gassing Time • Gas Profile • Degree of Prefill • Melt/Mold Wall Temperature 4 Machine Data • Gassing Position/Location • Concept of P L A S T I C S N E W S
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FEATURES molten core on the part to solidify which causes a major reduction in cycle times.
Enhanced Surface Definition External gas injection provides an enhanced surface definition of the component.
Weight and Cost Reduction The combined benefits of not packing a moulding are less material is used. By not having to pack the material, and in thicker components the resultant hollow core, can save as much as up to 30% on the material used. Another major benefit is the reduction in machine cycle times that can be achieved. With no molten core to solidify, the material in the mould cavity solidifies quicker thus enabling the component to be ejected sooner.
Figure 8. To make a Datascope main handle, a number of gas nozzles were timed to control the introduction of the gas in different locations.
Quality
Figure 6 shows the Infiniti main handle by Alcon Laboratories (Irvine, CA). The handle is sectioned to show the hollowed out center in its tube-shaped portion. It is important to note that the wall thickness is consistent over the length of the handle and around its perimeter. This optimizes the mechanical properties of the molded part. Thin-walled, ribbed mounting sections located at both ends of the handle mean that the handle could be attached to the main unit.
structural integrity.
Better dimensional control, and increased surface quality are major benefits of using gas injection. Sink marks caused by local thick/thin deviations in wall section can be eliminated. •
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Reduced wear on moulds – Gas Assisted Moulding can reduce in-mould pressures by up to 70% meaning a lower press lock force is required. This means larger mouldings can be formed in smaller presses and there is less overall wear on the cavity of the tool. These factors help to reduce overall running costs.
Figure 9. This keyboard for Philips Medical Systems combines a thick-walled injection-molded part with attached handles.
Improved component quality – The use of gas creates a uniform pressure within the mould cavity. This helps to eliminate sink marks and greatly improves the overall surface finish of the component.
The Alcon handle needed high structural strength combined with impact resistance requirements and good cosmetic surface finishes. These specifications required overspill technology. The part is completely filled and packed
Application Examples In the following examples, parts fall within one of the three categories shown in Figure 4.
Gas-Assist Handles with Attached Thinner Sections. Because of the thick cross section of the molded handles, a gas-assist process is used to mold a hollow, tube-shaped part with a highly cosmetic surface and a consistent internal gas channel. The molding process ensures mechanical and
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FEATURES nozzles in the appropriate locations, based on the filling pattern, to create hollow sections. The cross sections in some areas are close to 2 in., making straight injection molding economically impossible.
prior to using nitrogen gas to push the hot melt into an additional cavity. The Alcon Infiniti side handle in Figure 7 is cut open through the entire length of the part, illustrating the extent to which the gas evenly hollowed out the cavity. The part needed to meet the same design requirements as the main handle. Because the side handle is designed as a closed-loop part, the same overspill technology was required.
Gas-Assist Overmolded Parts with Localized Gas Channels. The image in Figure 10 illustrates the top and bottom assembled parts for the clamshell of an overmolded automated external defibrillator made by Zoll Medical Corp. (Chelmsford, MA). The design required high mechanical structural integrity, impact resistance, and good functionality. The image shows the upper and lower housing parts of the device, which are attached to each other with a screw/boss design. A screw/boss design is a method for assembling two parts by ultrasonically welding or heat staking a metal insert into a hollow plastic part. A screw threads into the metal insert and mechanically interlocks both parts. Gas channels in each part, top and bottom, were located on both corners of the cut. The bosses on the lower part created thick sections, which were hollowed out prior to overmolding to avoid sink marks on the substrate part. The gas channels were strategically placed in localized areas close to the mass accumulations of material. The gas channels ensured that nitrogen gas hollowed out and packed the bottom of the bosses. The resulting surface was free of sink marks for the subsequent processing step.
The main handle by Datascope (Montvale, NJ) shown in Figure 8 is an example of a gas-assist molded part consisting of a closed-loop handle with thinner attached portions. Some of the cross sections’ walls are more than 1.5 in. thick. Again, the nature of the design required the use of overspill technology. The challenge with this part was hollowing out a thick closed-loop section, which was split up into different channels. This required placing a number of gas nozzles within the tool. The nozzles were carefully timed to control the introduction of the nitrogen gas in different locations. The result is a highly structural, tubular part.
Gas-Assist Structural Parts Featuring Thicker Sections and a Handle. The keyboard part for a medical application made by Philips Medical Systems (Andover, MA), shown in Figure 9, combines a thick-walled injection-molded part with attached handles. It also features built-in thickwall part details and a tubular cross section perimeter detail. The thick tubular sections are primarily located on the perimeter of the part, making it a complex application from a processing perspective. Again, the challenge was placing the gas
On the upper half of the clamshell design, the gas next to the coring helped to minimize part warpage. That was especially important in the opening for the battery door. Placement of the gas nozzles and the processing conditions for the gas were important considerations. The part was completely filled prior to gas injection. Nitrogen gas replaced packing pressure and ensured that certain areas with mass accumulations were hollowed out and packed. Using gas-assist technology also enabled molding with minimum warpage, which was important for the subsequent processing steps.
Conclusion Gas-assist injection molding technology has evolved to include many different techniques. The process offers numerous possibilities for designing parts with thick sections, such as handles, as well as parts with localized thick areas or other part features.
Figure 10. The gas channels ensured that the gas hollowed out and packed the base of the bosses on a clamshell for Zoll. P L A S T I C S N E W S
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INTERNATIONAL NEWS
British officials critical of slow bag tax introduction embers of a committee within the United Kingdom's Parliament have slammed their government for delays on a bag tax.
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The members of Parliament on the Department of Environment, Food and Rural Affairs claim the tax will bring immediate environmental benefits. "We are pleased that the department has finally agreed to impose a charge for single-use plastic bags in supermarkets and larger food retailers, but disappointed that the charge will not come into effect in England until 2015, despite evidence of its success in reducing plastic carrier bag usage in other parts of the (U.K.) We recommend it be implemented sooner," the members said in the DEFRA annual report, published in early January.
The government estimated that in 2012, supermarkets gave out more than eight billion bags across the U.K., adding up to an average of 120 bags per person. While the use of these bags in England has increased since 2010, usage was cut dramatically by the Republic of Ireland after charges were introduced there in 2002, the MPs noted. A similar tax in Northern Ireland has reduced carrier bag usage since April 2013. Supermarkets in Wales reported a drop in use of up to 76 percent after a charging scheme was brought in two years ago. "Reducing the number of single-use carrier bags which are given away is a quick win: reducing both waste and environmental pollution with little effort," the committee members said in the DEFRA report. "Given the evidence elsewhere, we recommend
VDMA and its members show their green credentials ore than 50 members of the German plastics and rubber machinery producers association VDMA - have signed on to an effort to reduce energy consumption and greenhouse gas emissions.
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The "Blue Competence" campaign builds on previous successful efforts which saw the plastics industry cut energy consumption by 50 percent between 1974 and 2010 while also tripling productivity. VDMA officials said during the 2013 K trade fair in Düsseldorf that they expect the industry to reduce energy consumption P L A S T I C S N E W S
by a further 20 percent by 2020. The Blue Competence marketing group formed in 2012 is made up of representatives from injection molding machinery producers Arburg GmbH & Co. KG, Engel Austria GmbH and KraussMaffei Technologies GmbH. AZO GmbH & Co. KG represents ancillary equipment producers in the group and the area of extruders and extrusion lines is represented by Brückner Maschinenbau GmbH & Co. KG, Reifenhäuser GmbH & Co. and Windmöller & Hölscher KG.
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the early introduction of the charge." The politicians added that when fully degradable plastic bags are available they should be exempt from any charge.
EU to hike import duties on petrochemicals ith effect from January 1, 2014, the European Union has changed the rules on its so-called General System of Preferences (GSP), which provides countries classed as developing with preferential access to the EU market, largely in the form of reduced import taxes.
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Amendments in the list will remove nations that are classified as high-income or uppermiddle income, meaning many companies in the Middle East that are big suppliers of petrochemical products will have to pay 3.5% more in tax to sell goods in the EU. Steep hike Union in import duties on many petrochemical products will do little to protect Europe's battered petrochemical industry, but it could well be a boon to downstream producers of plastics and chemicals by injecting momentum into free-trade talks with individual producing nations, lobbyists and consultants say. Experts say it will in turn motivate countries to sign freetrade agreements and hammer down the cost of making plastics across the continent.
J A N U A R Y 2014
INTERNATIONAL NEWS
Los Angeles bans plastic bag os Angeles has banned plastic bags in the city of Los Angeles. Effective January 1 2014 city’s plastic bag ban will start with stores of more than 10,000 square feet or with annual sales of more than $2 million. Then, beginning on July 1, the ban will extend to smaller stores such as mini-marts. Los Angeles is joining a growing trend of cities across the country — in California alone, about 90 cities or counties have passed plastic bag ordinances within recent years, according to the group Californians Against Waste.
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Los Angeles shoppers will no longer be presented with that checkout choice: Paper or plastic? Instead, they will be required to bring in their own reusable bags or pay 10 cents for each paper bag they need. “I think we have all seen a push throughout the world to get rid of disposable items like these plastic bags,” said Los Angeles City Councilman Paul Krekorian, one of
the backers of the ban. “We use them for about 15 minutes and then it takes hundreds of years for them to break down. We (in the United States) use about 200,000 plastic bags every hour. “And the city has to spend millions to clean up the damage caused by the bags through litter or clogging up storm drains or in the water. We shouldn’t be squandering that money, which can be spent on other things.” Krekorian said the city has done about all it can to make the public aware of the coming regulation and that he would like to see more from the stores. The plastics industry has tried to fight the growing trend of banning plastic bags with a variety of studies questioning the science behind the bans and whether they reduce litter and municipal costs for cleanup. The city’s Bureau of Sanitation has tried to prepare the public for the coming change, handing out more than
400,000 multi-colored reusable bags and holding a series of events leading up to the Jan. 1 switch. Sanitation head Enrique Zaldivar said the agency has been working for several years to impose the ban, and looking at what other jurisdictions have done to accomplish the changeover. “The one thing we learned is there is a need for education and we know there are going to be people who come into the stores who will be caught by surprise,” Zaldivar said. “There are always going to be people who have not heard about it or thought it was coming later.” The city will have given out nearly 500,000 reusable bags to let people know the new law is coming, Zaldivar said. It has set up a special web page, LACITYBAG.com, to provide information on the ban. It also plans to hand out another 50,000 reusable bags leading up to the start of the program.
Polisan Holding to restart the PET polymer plant of Spanish group La Seda de Barcelona in the greece Tu r k i s h p e t r o c h e m i c a l s group, Polisan Holding plans to restart the former PET polymer plant of Spanish group La Seda de Barcelona in Volos, Greece by the end of this year.
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According to reports the 80,000 tpa Artenius Hellas facility, which was mothballed by the insolvent Barcelona-based group early this year, was bought in September by P L A S T I C S N E W S
Polisan of Ankara for €8.6 mln. After the buy out the Greek plant, which employed almost 100, has been renamed Polisan Hellas as a matterr of policy. Polisan has been negotiating with potential PET customers for the PET and bottle preforms unit. The local news reports that the group’s CEO, Necmettin Bitlis, is confident that the market will accept more than 44
90% of the Volos output. The group is targeting sales in Greece, the Balkans and Turkey. The former La Seda plant suffered from a cutback in production capacity and dwindling local demand. The Spanish group has been seeking buyers for its PET operations and originally looked at possibly closing down the Greek unit altogether if it was unable to sell it. J A N U A R Y 2014
INTERNATIONAL NEWS
Malaysian plastics group concerned over Electricity tariff he Malaysian Plastics Manufacturers Association (MPMA) has expressed its concern over the 16.85 percent increase in the electricity tariff for the industrial category, effective January 01,2014.
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In a official statement, Lim Kok Boon, MPMA President said, "Given that electricity is the second largest cost component in the manufacture of a plastic product, the drastic increase in electricity cost will cause the plastic products made in Malaysia to be less competitive in the international market and, consequently, exports would be adversely affected," said MPMA President Lim Kok Boon. "Other export-oriented and energyintensive manufacturing industries in the country would also be expected to be similarly affected." In addition, Lim pointed out that
the proposed increase in valuation of property and assessment rates by the Kuala Lumpur City Hall and Ipoh City Council is too excessive and unreasonable.
He urged the government to look at a gradual increase in the electricity tariff over a reasonable period, and that any rate should not exceed 10 percent.
"Some of our members are hit by a 600 percent increase, which is far too drastic," added Lim.
Lim also recalled MPMA's past call on the government and the electricity board to extend the off-peak rates to all the plastics manufacturing companies as this would assist in mitigating the impact.
Lim said the plastics manufacturers were already facing a drastic cost increase following the increase in minimum wages, which also went into effect Jan. 1. "While we understand the government's need to rationalize subsidies and increase the assessment rate, however, a sudden and huge increase would have serious adverse effects on the manufacturers. The recent announcement on the proposed toll increase will be further a burden to our members," Lim said.
Axiall declares force majeure on VCM from Lake Charles xiall has declared force majeure on vinyl chloride monomer (VCM) from its PHH Monomers VCM plant at its Lake Charles, Louisiana complex.
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According to the reports the force majeure stemmed from a fire at the PHH site, which started around 1:40 pm earlier this month."The fire affected the PHH's vinyl chloride monomers unit, but the investigation into the incident is just starting, so the full extent of the damage is not yet known,"
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the company stated. The VCM unit is shut indefinitely, and the company is assessing the cause of the fire and related damage, according to the letter. "At this time, Axiall cannot predict with any precision when repairs will be completed or when the unit will be operational, nor what its impact, if any, will be on upstream or downstream production of products other than VCM by various Axiall affiliated companies," the company added.
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Plastics Color expanding in Illinois lastics Color Corp. will add 40,000 square feet to its facility in Calumet City, Illinois to boost production at the site by 40 percent.
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PCC will request quotes for the new extrusion equipment at Calumet City and select have seen an increased customer demand. PCC has already boosted capacity there by 18 percent by moving to a seven-day-aweek schedule suppliers by late February. The company expects to hire seven to 10 new employees as part of the project, including an operations manager. The company had earlier announced of adding two extruders at its Ashboro plant.
J A N U A R Y 2014
INTERNATIONAL NEWS
China's engineering plastics sector needs controlled growth hina's engineering plastics industry needs to grow mindfully, said Zheng Kai, secretary general of the China Synthetic Resin Association, while addressing the media on the sidelines of the Society of Plastics Engineers' first conference in China. "This is a big problem in China especially the biggest challenge is that the production capacity is greater than the need," he said He gave as an example polybutylene terephthalate resin, which he said has an annual production capability of 900,000 tons in China, but only has an actual need of 300,000 tons.
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"So it has created a lot of waste of resources," he said. "We need to allocate this production capability in a reasonable manner, and avoid vicious competition."
tons, up 5.5 percent from the year before. Net imports were 14.39 million tons, and apparent consumption was 79.743 million tons, representing an increase of 4.9 percent.
Zheng presented an update on China's plastics industry to conference attendees. According to the statistics he presented, the growth rate for China's plastics processing industry is slowing. Production as a whole continues to grow, but at a slower pace in 2012 than in the previous year. Zheng reported that last year China's plastic resin output was 52.1 million
In the first half of 2013, 28.3 million tons of plastic resin was produced, an increase of 7.8 percent over the same period a year ago. By 2015, he told the conference, China's synthetic resin output will reach about 64 million tons. Zheng told attendees that while in the past the growth rate was always 8-9 percent, this year it was 7-8 percent.
New Jersey town threatens to sue Solvay Specialty Polymers he borough of Paulsboro, N.J., has threatened plastics and chemicals maker Solvay Specialty Polymers USA LLC with a lawsuit over alleged water pollution coming from the firm's fluoropolymers plant in West Deptford, N.J.
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Paulsboro Mayor W. Jeffery Hamilton also has asked New Jersey Gov. Chris Christie — a potential Republican presidential candidate — to intervene on the borough's behalf. According to reports, Hamilton has said that Solvay "must provide long-term protection for Paulsboro's drinking water…or face the borough in Federal court." He also criticized the state's Department of Environmental Protection. He also said "Despite more than 20 years of oversight by the New Jersey Department of Environmental
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Protection, toxic chemicals from Solvay's West Deptford facility continue to taint Paulsboro's drinking water supply. Every Paulsboro resident…has a fundamental right to safe drinking water.Solvay is the source of the problem and Solvay must provide and pay for a solution." Groundwater and sediments in and around Paulsboro contain a range of perfluorochemicals — feedstocks used to make fluoropolymers — that originated at the Solvay plant. Paulsboro's drinking water currently meets federal and state safety standards, but, according to the release, PFC contamination in West Virginia recently has been linked to "a number of potential adverse health effects." The report also refers to Solvay's "laggard cleanup" and "apparent
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indifference to Paulsboro's concerns," as well as the NJDEP's "failure to intervene properly and effectively." It adds that Solvay canceled a Jan. 6 meeting to discuss recent water sampling results and to discuss possible solutions. In a letter to Christie who's currently embroiled in a traffic scandal — Hamilton asks the governor to bring together state officials to respond to "a public health issue that has been ignored for too long." Officials with Solvay in West Deptford has said that the firm was investigating information about alleged pollution from the plant and said that the firm had stopped using a certain perfluorochemical known as PFNA - at the site in 2010, ahead of a voluntary program to eliminate the use of the chemical.
J A N U A R Y 2014
BUSINESS NEWS
Schulman buys Prime Colorants hio-based Schulman had paid $15.1 million to acquire Prime Colorants Inc., a maker of custom color and additive concentrates in Franklin. The deal is Schulman’s ninth acquisition in less than five years Chairman, President and CEO Joseph Gingo said, “This latest acquisition is part of our ongoing strategy to grow our custom color capabilities in the United States, as well as further transform our U.S. operations from commodity products to a business focused on niche products and services.”
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Color products “remain an area of opportunity for [Schulman] in the U.S.,” he added. “The acquisition of Prime will enable us to serve customers better by offering color expertise in an area of the country where we were not previously located.” Prime employs about 50 at a 60,000-square-foot plant
in Franklin. The firm had annual sales of about $12 million in 2013, primarily into the automotive and building and construction markets. In addition to pelletized and powder color materials, Prime will provide Schulman with an entry into the liquid color market, officials said. Schulman most recently bought British compounder and resin distributor Perrite Group for $52 million in September. Earlier in 2013, Schulman had purchased Network Polymers Inc. - a compounder/distributor in Akron, Ohio - for about $50 million. Schulman posted sales of more than $585 million in the first quarter of its 2014 fiscal year, ended Nov. 30. That’s a jump of 10 percent vs. its first quarter in fiscal 2013. The firm’s firstquarter profit also increased almost 26 percent to $15.3 million.
Indian Oil Corporation to withdraw from sales process of Haldia Petrochem ndian Oil Corporation (IOC), the sole bidder for picking up a stake in Haldia Petrochemicals Ltd. (HPL), has sought the release of its earnest bid money, indicating withdrawal from the sale process. “We have written a letter asking for the earnest money of around Rs. 20 crore submitted for the bid,” an IOC official told PTI.
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IOC is of the view that the recent developments on the legal front between the State Government and promoter The Chatterjee Group (TCG) will delay a final order on the 155 million shares in questions.
Solvay deal to sell stake in Solvay Indupa deal by Solvay to sell its majority stake in South American PVC producer Solvay Indupa will move forward and remains unaffected by an objection from the Argentinian share regulator.
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.Speaking to the media Solvay clarified that “Contrary to what we have been reading in some media reports this week, Solvay confirms that the planned divestment of its 70.59% stake in Solvay Indupa to Brazil's leading chemical producer
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Braskem is well underway.” The Solvay Indupa shares not owned by Solvay are publically traded on the Argentinian stock exchange. Braskem is required by Argentinean law to launch a tender offer to buy these outstanding shares. According to reports, On 3 January, Comision Nacional de Valores (CNV) announced Braskem’s tender offer price of 1.35 Argentinian pesos was too low, based on the market traded share price. The market regulator
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told Braskem to set an equitable price in order to comply with market standards. Solvay said in its statement that Braskem has subsequently been in discussions with CNV to understand its decision and to set a new price. Solvay said that its divestment of the 70.59% stake is not conditional on the success of the tender offer. In the meantime, anti-trust filings are being made as planned in Brazil and Argentina.
J A N U A R Y 2014
BUSINESS NEWS
Chandra Asri to invest US$965 mln over next two years ndonesia’s largest petrochemicals companyChandra Asri Petrochemical, has allocated US$965 mln over the next two years for three projects to expand facilities and boost production.
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The Indonesian petrochem major has been granted a tax waiver facility as the government aims to strengthen the structure of the petrochemical industry from upstream to downstream in a bid to reduce the country’s dependence on imports, which reached $8.5 billion in 2012. Under the government tax holiday facility, which waives corporate income
tax for up to 10 years, Chandra Asri can pioneer petrochemical projects with a total value of over Rs. 1 trillion (US$82 mln). Chandra Asri’s investment plan’s first project, which costs US$150 mln, to construct a butadiene plant in Cilegon, Banten, is expected to be completed by the end of this year. The second project, estimated at US$380 mln, will expand its a new naphtha cracker plant’s production capacity by adding furnaces, as well as modifying the main equipment. The naphtha cracker plant expansion will increase propylene production
Indorama refinances 640 mln term loan for US business n d o r a m a Ve n t u r e s P u b l i c Company Limited (IVL), the world's leading vertically integrated Polyester Value Chain producer, has successfully completed the refinancing of a US$640 million term loan for its business in the USA.
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The Company was able to increase the average tenor of this loan from 3.31 to 5.40 years from a consortium of banks led by Siam Commercial Bank Public Company Limited, Krung Thai Bank Public Company Limited and Bangkok Bank Public Company Limited. Moreover, the Company has refinanced a working capital facility led by Regions Bank and Bank of America Merrill Lynch totalling US$360 million. The term loan and P L A S T I C S N E W S
working capital facilities are expected to improve the liquidity and cash management of the Company's North American businesses by combining their treasury needs. The longer term loan tenor will also benefit the internal cash flows required for the Company's committed growth capital expenditures. Indorama Ventures has approximately a third share in North American PET market with approximately 1.5 mln tons of capacity and produces a range of products within the Polyester Value Chain sphere, such as Polyethylene Terephthalate (PET), Polyester and Polyolefin Fibers and Yarns, Mono Ethylene Glycol (MEG) and Purified Ethylene Oxide (PEO). 48
to 470,000 metric tons in 2015 from 320,000 metric tons currently, and ethylene to 860,000 metric tons from 600,000 metric tons. The construction of the new plant was initiated in Q4-2013 and will be completed in late 2015. The major will spend US$435 mln to build a new synthetic rubber plant, also in Cilegon, through a joint venture with Francebased tire maker Michelin, named Synthetic Rubber Indonesia.
Hanwha signs LOI to build a petrochemical plant in Iraq outh Korea's leading polyethylene and polyvinyl chloride producer Hanwha Chemical Corp. has signed a letter of intent (LOI) to build a petrochemical plant in Iraq. According to the reports under the joint investment deal, the South Korean company will build an ethylene cracking center and a plant to produce petrochemical products.
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Upon completion in 2020-21, the complex will have capacity to produce 1 mln tpa of key petrochemical products per year. These facilities will be part of a larger ethylene and natural gas processing complex planned to be built in southern part of Iraq.
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BUSINESS NEWS
Braskem inks joint development agreement with Genomatica raskem and Genomatica have announced an agreement for the joint development of commercial process technology to make biobased butadiene from renewable feedstocks. Braskem is the world's leading producer of biopolymers and the world's third largest producer of butadiene.
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Under the agreement, Braskem anticipates providing significant funding of Genomatica's development work over several years; will allocate significant Braskem R&D resources; and fund the construction and operation of pilot and demonstrationscale butadiene production plants using the process. In return, Braskem will receive certain exclusive license rights to use the resulting process technology in the Americas. Genomatica will also receive fees and royalties for each licensed
commercial plant. Braskem has a clear strategy for investing in the research and development of renewable based chemical technologies as alternatives to complement our current product portfolio based on petrochemicals. In 2012, we became the world leader in Biopolymers when we announced the production of plastic made from sugarcane, and we are now further reinforcing this vision," said Alexandre Elias, director of renewable chemicals at Braskem. "Braskem's leadership in biopolymers and understanding of the potential of biotechnology make them a natural partner for Genomatica," said Christophe Schilling, Ph.D., CEO of Genomatica. "Our partnership brings the industry closer to commercializing a more sustainable and cost-predictable butadiene." The new agreement adds significantly to
Venezuela, India agree to build a naphtha unit in SA n a bid to widen energy ties, Venezuela and India have agreed to build a naphtha production unit in Venezuela However, no details have been revealed about the deal or the size of the proposed unit. Venezuela's foreign minister said that Venezuela and India have agreed to build a naphtha production unit in the South American OPEC nation in the latest sign of widening energy ties between the two countries. Details have not
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been disclosed about the deal, the size of the proposed unit. Several big Indian energy firms, including Reliance Industries, already work with Venezuela's state oil company PDVSA. In brief comments carried by Venezuelan state TV, Jaua said the unit would be built in the Orinoco extra heavy oil belt. The naphtha, a liquid mixture of hydrocarbons, would then be mixed with the area's tar-like crude to produce lighter oil for export.
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Genomatica's butadiene program, which now includes investments of over $100 million anticipated under current agreements. Program milestones already include the successful production of pounds of butadiene in 2011, and funding from Versalis for Genomatica's development efforts announced in April 2013. The combined strength of current and future program partners will facilitate aggressive pursuit and delivery of commercial-grade process technologies for licensing to and use by the global chemical industry, using a range of feedstocks. The agreements with Braskem and Versalis provide a commercialization path in all major butadiene-producing and consuming regions of the world.
Qatar Petroleum plans to raise US$ 880 mln through an IPO atar Petroleum (QP) plans to raise 3.2 billion Qatari riyals (approx. US$ 880 million) through an initial public offering (IPO), of the shares of Mesaieed Petrochemical Holding Co. (MPHC)., in the local market.
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QP expects to start selling a 26% stake in Mesaieed Petrochemical Holding Co in a sale only open to Qatari citizens. the IPO of MPHC will be offered at Qatari riyals 10.2 per share (US$2.75) till January 21, 2014.
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BUSINESS NEWS
Braskem and Siluria to coopertae for commercial deployment of methane to ethylene technology iluria Technologies, a pioneer in the commercial production of fuels and chemicals made from clean, abundant natural gas, and Braskem, a leading producer of thermoplastic resins in the Americas, have formed a broad-ranging collaboration around the deployment of Siluria's proprietary oxidative coupling of methane (OCM) technology for the direct conversion of methane in natural gas to ethylene. Under the collaboration, Siluria and Braskem will jointly explore commercial deployment of Siluria's technology for supplying ethylene to Braskem. In particular, the two companies will conduct a joint feasibility study to identify commercial deployment opportunities of Siluria's technology at Braskem's ethylene consuming plants. The collaboration also provides for certain non-exclusive technology license options for the
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world-scale deployment of Siluria's technology by Braskem, as well as opportunities for Braskem to be a purchaser of ethylene produced from future Siluria plants, and rights for Siluria ownership participation in Braskem commercial projects using OCM technology. The collaboration is in conjunction with the previously announced hosting of Siluria's OCM demonstration plant by Braskem. "We are very pleased to be working with a world leader in olefins and derivatives manufacturing in Braskem," said Siluria CEO Ed Dineen. "Their industry expertise, substantial footprint and aspirations for growth make them an ideal first partner in Siluria's multiple-partner strategy to deploy our technology across the chemicals, fuels and natural gas processing industries." "Braskem is pursuing the growth of
Amcor acquires Constar US assets mcor has agreed to acquire the United States assets of Constar International Holdings for a sum still to be finalised. Constar, which makes plastic food and drink containers in the US and Europe, has filed for bankruptcy in the US. Amcor said in a statement on Friday that the US business of Constar operates six plants, with annual sales of about $US190 million.Amcor said the assets were an attractive fit with Amcor's rigid plastics business. The transaction will
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be made through a court-supervised process under the US Bankruptcy Code which is expected to conclude in the first quarter of 2014. Amcor said that further details of the acquisition, including the final acquisition price, would be released to the market after the conclusion of the bankruptcy process. Shares in Amcor were 10 cents higher at $10.55 at 1018 AEDT.
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our business in the Americas and globally," said Braskem America CEO Fernando Musa. "We believe the Siluria technology can play an important part in our growth strategy as well as potentially strengthening our current asset base." Siluria's OCM technology provides a novel process for the conversion of methane from natural gas to ethylene and liquid fuels. The flexibility of the technology provides multiple highvalue opportunities for the deployment across multiple industry segments.
ONGC plans stake in OPaL il and Natural Gas Corporation Ltd (ONGC) is poised to sign a memorandum of understanding (MoU) with Kuwait Petroleum Corporation, furthering Kuwait’s plans to acquire a stake in ONGC Petro Additions (OPaL) and ONGC Mangalore Petrochemicals (OMPL).
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According to reports for OPaL project at Dahej Special Economic Zone, ONGC is looking for foreign participation of about 25%, in which it holds 26%. The other partners are GAIL and GSPC. ONGC is scouting for a overseas partner for 26% in OMPL, in which it holds 46% stake.
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THE ALL INDIA PLASTICS MANUFACTURERS' ASSOCIATION SERVICES AVAILABLE IN AIPMA HOUSE • Elegant Auditorium • Board Room • Business Centre & Ground Floor Hall at very nominal tariff for your business purpose • Library - Free use of books and reports available AIPMA House, A-52, Road No. 1, M.I.D.C., Marol, Andheri (E), Mumbai - 400 093. Tel.: +91 22 6777 8899 (100 Lines) / 2821 7324/25/2835 2511 Fax : +91 22 2821 6390
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PRODUCT NEWS
Underwater Pelletising Technology – Nordson Bkg,Germany ordson BKG as the name stands for Nordson Bruckmann & Kreyenborg Granuliertechnik Gmbh, for more than 50 years, symbolizing quality components and machines for the extrusion and polymerization industries.
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In polymer processing, the underwater pelletising system proves to be the up to date solution. It is a complex process and has to be observed in its entirety. Therefore, after having intensively checked the respective procedural specifications, BKG offers complete and perfectly supplemented systems.
advantages in improved product quality.
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Water system with Automatic filling.
The underwater pelletiser mainly comprises of:
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Dryers has two big doors for easy cleaning - ultimately it saves the time during product changeover.
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Faster start time- less wastage during production.
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Less moisture contain at the end product.
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Tungsten carbide die-plate with high wear resistance.
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Flexible pelletising system for all kinds of virgin & filled products like Polyolefin's, polyamides, Thermoplastics Elastomers, Polycabonates, PET, Hotmelt additives, PVC & more...
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BKG can offer complete package for Screen Changer, Gear Pump, Polymer diver valve & Silos all from one source.
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Under water Pelletizer & water box
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along with 2 cutterhubs and 1 dieplate
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Watersystem
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Centrifugal dryer
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Control System
Packed with ‘Best in the market’ features: •
Compared with traditional dryer and strand pelletizing systems, this technology has a number of •
Manual Knife adjustment instead of spring loaded - Uniform product quality & uniform shape of the pellets throughout the production, less wear of blades. Mechanical seal instead of gland sealing- completely leak proof system.
For customers,this means: •
Reliable and precise manufacturing
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Complete, in-house, quality control
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A high level of innovation demonstrated by many patents
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Quality certified, “made in Germany”.
For Further information, please contact: Reifenhauser (India) Marketing Ltd. (T) +91 22 26862711 (F) +91 22 26862722 (E) info@reifenhauserindia.com (W) www.reifenhauserindia.com
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PRODUCT NEWS
PEEK compounds continue progress in wear-resistant applications aint-Gobain Seals Group has introduced ehe latest polyetheretherketone (PEEK)-based semi-finished product specifically created for tribological applications -in particular for moving components in applications where friction and wear rate at contact points are significant parameters for consideration.
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Meldin 5530 is available in the form of compression or injection molded and machined components, as well as basic shapes for the "ultimate in customization and design flexibility. Rotors and gears (pictured here in a gerotor; a type of positive displacement pump) are target applications, as are thrust washers and piston rings. The new grade reportedly complements the Seals Group's extensive offering of highperformance materials developed for similar applications for bearings, rotors, gears, thrust washers and piston rings, including those based on performance thermoset polyimide (PI) materials. PEEK is one of the few thermoplastic materials able to operate above 230째C (445째F), and Saint-Gobain Performance Plastics has adopted this base resin as its backbone for the Meldin 5000 product family. Tribology plays an important role in manufacturing, adds the
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Seals Group. Controlled wear on components limits their replacement, which translates into savings deriving both by fewer number of parts needed during the lifetime of the equipment as well as number of production stops for maintenance operations. Friction is also a key parameter; when high, it increases the power that is needed to operate a piece. The potential savings offered by materials with improved tribological properties are therefore significant. Material development of the Meldin 5530 grade included rigorous wear and friction testing, conducted internally at well-equipped laboratories at different Saint-Gobain Seals Group site locations. There are many factors that influence the behavior of tribological applications such as pressure and speed, type of motion, environment (dry or lubricated), temperature and mating surface (type of material, finish and hardness). Thorough testing provides a good indication of wear and friction ranges as well as PV (pressure x velocity) limits that characterize the different materials analyzed and therefore, can be used when designing parts out of these materials. The behavior of the new Meldin 5530 grade is said to be exceptional in terms of both reduced friction and wear and in line with polyimide or
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polyimide-amide compounds, even under dry conditions, which translates into extended service life and lower risk of failure for the systems in which the parts are installed. Due to these high-performance properties, In other recent developments at Saint-Gobain, a Meldin 5000 PEEK-based offering has been selected for packing kit backup rings for a down hole drilling application in the oil and gas market. The backup ring parts are used in a hydraulic drilling jar that helps free and move the drill pipe components in the event that they become stuck in the formation. The drilling jar is versatile and operated on land, offshore or ultra-hot boreholes. For this high-pressure, high-temperature (HPHT) drilling application where temperature can rise up to 500째F and the system pressure in thousands of PSI, the back up ring parts provide excellent durability through superior thermal resistance combined with strong mechanical properties and chemical resistance. Meldin 5530 material represents an excellent choice for parts like rotors and gears, but also thrust washers and piston rings when conditions are too demanding for the Seals Group's other well-known and established grades, Meldin 5330, 5350 and 5055.
J A N U A R Y 2014
PRODUCT NEWS
CABKA offers new light weight Plastic pallets ABKA, a manufacturer of plastic pallets, containers and bins, is now offering a lightweight, nestable half pallet, the CPP 200. With dimensions of 32 x 24 x 5.1 inches and a weight of only 8.5 lbs., the pallet is very easy to handle at the point of sale and safer as well, according to information supplied by the company.
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The new size of the CPP 200 "perfectly cubes out" many commonsized displays and RPCs used in various applications, including the retail level. Its rounded corners, smooth surfaces and low weight offer decisive advantages when empty
pallets much be moved and stacked, according to St. Louis, MO-based CABKA. The new CPP 200's special design allows it to carry dynamic loads of up to 2200 lbs., with a nesting height of only 2.2 inches. This permits dense stacking of empty pallets, which considerably reduces freight costs, reduces storage costs and protects the environment. The CPP 200 is made of ACM recycled material, offering a cost effective alternative wooden pallets, the company said. It is also available in special recycled PE material for closed loop shipments were a much lower cost per trip is applicable.
Maharashtra Maha Polyplast launches self watering mobile plant for domestic use aharashtra Maha Polyplast Pvt. Ltd. has developed a "self-watering mobile plant unit" displaying at the Plastivision 2013 . Speaking about new product RK Sethi, MD Maharashtra Maha Polyplast Pvt. Ltd, , said with concrete jungles in the city , there is hardly space left for plants and greenery. We are thus helping city dwellers through a rotationally molded "self-watering mobile plant unit," which can be placed on a balcony in a multi-story housing complex.
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interconnected by a tube that supplies water to tanks below the plant. The chambers need to be filled with water only once every 25 days, and supply water to the plant through capillary action as needed. Maharashta Polyplast is building the unit based on a design developed by a U.S. company with a designer in Pune. The product, which was launched at Plastivision, will cost about 30,000 rupees ($485). The company already has orders for 150 units. The company has manufacturing in Mumbai and Vasai. Maharashta Polyplast also showcased a garbage chute, which would provide a central 64
New fully disposable eco-friendly ethylene filter BioXTEND速 new fully disposable/ recyclable eco-friendly ethylene fi lter to better protect produce freshness all along the supply chain has been introduced. The brand new BioXTEND速 Ethylene Filter is absolutely dust-free and offers outrageous absorption capacity that could have been because of a special permanganate mix developed in cooperation with FGC University.
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The whole product line is made in Florida (USA) with high quality standards exceeding the produce industry requirements. Besides, the products are suitable for organic farming according to RCE n属 834/2007 (approved by ECOCERT) and the BioXTEND速 Ethylene Sachets are OMRI Listed in the USA (organic compliant). space to throw refuse from multi-story buildings. It is a common system in Europe, but is only beginning to expand to India. Sethi said the plastic chute could be extended for use through a 100-floor building, and is already installed in a few 20-floor housing complexes in Mumbai. The system costs about 25,000 rupees. The company also showed a PVC underground manhole chamber, in development for almost three years. The chamber can range from 300 millimeters to 1,200 millimeters and replace a traditional concrete system. J A N U A R Y 2014
PRODUCT NEWS
Japanese firm designs plastic fire extinguisher apanese blow molding equipment supplier Frontier Inc. has launched found a potentially redhot new market for replacing metal with plastics hand-held fire extinguishers made of plastic replacing metal that is likely the world's first thermoplastic blow molded fi re extinguisher. For Frontier, it required three years of research on behalf of a client to find a way to mold a container capable of handling the intense pressure needed for an extinguisher, five times what's required for a water bottle.
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It also offers a glimpse into how industrial design can be used to freshen up an age-old product. Onething that is clear polyethylene naphthalate resin offers a lighter look and feel that might help it expand
market share and appeal to designoriented customers. Frontier built the molds and spent several years developing a specially designed blow molding machine that can process PEN resin and meet technical requirements set by fire safety regulators. The bottle preform, for example, has to be 20 millimeters thick, which is 10 times the 2mm preforms for a typical water bottle, said Frontier President Yoshinori Nakamura. That preform thickness makes it much more difficult to keep the final bottle clear, a key requirement for the final product, said Nakamura. Improvements in the plastic extinguisher: •
traditional version. •
It's see-through, allowing firefighters and others with training to visually inspect the powder inside and see if it's still OK.
• Redesigning from the ground up allowed Hatsuta to add some functional improvements, such as a soft grip at the end of the hose and a larger ring on top to carry it. The extinguisher is also designed for recyclability, using common grades of other materials like polypropylene and ABS for the base and handle. Named the Calmie, the extinguisher cannot be sold in the market yet, as it has yet to get approval from Japanese fire safety authorities.
It's 60 percent of the weight of a
Staubli’s Quick mould clamping Solutions for higher productivity utomation of the injection molding process could be efficient solutions to increase productivity. The Stäubli tool changers for robots and the comprehensive range of Stäubli SCARA and 6 axis robots improve the flexibility of your production.
presented by Staubli. With the help of Staublies solutions companies can ensure reliability and high level of productivity. Staubli offers Plastic entrepreneurs and processors big savings with its products which helps to processes to get smoother and without having any problem.
These quick mould clamping systems can be integrated into existing and new machines for both horizontal and vertical loading and clamp your moulds in seconds. The audience showed interest in the coupling technology and the quick-mould-change solutions as well as in the plastics robot range
While commenting on what is the objective of Staubli at PVI 2013, Thierry Parent, Plastics Marketing Manager, Stäubli, said, “Safety requirements in manufacturing units are the need of hour and being a global mechatronics solutions provider it’s the responsibility of staubli to give an attention to need
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of the hour and Stäubli’s solutions are applied for loading, clamping, connection of energies and parts handling. It might happens that a customized solution that has worked well for one customer can also work well with others who have similar requirements but still we are focusing on what our customers actually wants to achieve. We at staubli are trying to help industry by reducing their downtime and ensuring safety.” Stäubli is a solution provider with three dedicated divisions: textile machinery, connectors and robotics. Today, with a workforce of over 4000 employees Stäubli runs 12 production sites. J A N U A R Y 2014
PRODUCT NEWS
Fractional Geometry-An Optimum Kneading Prodigy By - Chetan C.J, & Raja Ganeshan, STEER Engineering neading blocks are always been the focus for engineers and researchers as it does multiple tasks like material deformation, melting, melt-mixing, mixing etc. in any screw extruder. Most commonly used is the kneading block with bilobe geometry (figure 1). As a result of its geometry there exists nonuniformity in the force field hence the work done on the processing material. This problem was scientifically addressed and was overcome with the “Fractional Geometry” (patented), the invention of Dr. Babu Padmanabhan (CKO, STEER), an Applied Analytical Kinematician. Kneading blocks with this fractional geometry (figure2) imparts uniform force field (figure
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Time Graph 1: Temperature rise while Kneading
Figure 3: Force Field of Fractional and Bi-lobe Geometries Table 1: Work done by Individual Kneading Block Type Kneading Block Type
RKB
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Work Done
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3) without sacrificing the required melting and mixing efficiencies.
Figure 1: Kneading Block with Bi-lobe Geometry
Figure 2: Kneading Block with Fractional Geometry P L A S T I C S N E W S
Kneading blocks with fractional geometry (FKB) eliminates the shear peaks forming the optimum kneading members when compared to regular bi-lobe kneading block types like forward conveying (RKB), reverse conveying (LKB) and neutral (zero) conveying (NKB). Results of Numerical (CFD) and Physical experiments (under identical physical conditions) carried-out using Ø20 CoRotating Twin Screw Extruder with an inter-meshing ratio of 1.8 at STEER’S Archimedes Lab are presented below. It is clear from the results that fractional geometry imparts an uniform 66
force field thus eliminating the shear peaks and temperature peaks forming the competitive powerful kneading blocks for the next generation processing equipments. Suggested Reading: 1) Babu Padmanabhan, Chetan Chincholi Jayanth, “Shear Uniformity in Co- Rotating Twin Screw Extruder- A Geometrical Study of Shear Rates in a Fully Filled Zone”, SPE Conference, Antec 2009 2) “Fractional and Higher Lobed Co-rotating Twin-Screw Elements” US 6783270 B1, Aug 31, 2004 Kneading Block Type RKB NKB LKB FKB Work Done Less Medium Heavy Optimum
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TECHNOLOGY
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Automotive launches TAP technology for plastic tanks
uburn Hills-based TI Automotive Inc. recently launched its newest innovation, the Tank Advanced Process Technology, at its plant in Rastatt, Germany, to supply the Daimler AG S class, including the Mercedes-Benz S-500 plug-in hybrid.
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The technology was developed for the European market in Germany, but engineers from Auburn Hills are developing tanks for the North American market standards. The supplier has development contracts on the technology with a U.S. and a Japanese automaker, Deane said. In the 1990s, the Golden State's regulations on greenhouse gas emissions spurred a flurry of engineering advancements in North America and Europe to prevent vehicle
emissions. The use of a plastic fuel tank in a hybrid is a differentiator for TI, since most hybrids use steel tanks because of the intense heat from lithium-ion battery packs, said Al Deane, chief technology officer for TI Automotive. TI Automotive's TAPT opens the mold during the cycle to robotically insert fuel system components inside the tank, then closes it again to complete the molding and seal the tank. Other fuel tank makers use similar inmold placement of components during blow molding. The process provides TI a threefold benefit The stiff, pressurized tanks are heat-resistant, allowing the tanks to be used on hybrids and electric vehicles for the first time. Also, because the tanks are sealed while still hot and use
Biocompatible plastic with Antibacterial plastic properties arx Plastics of the Netherlands, has developed a way of making biocompatible plastics with effective antibacterial properties. The company says the technology offers a safe and non-toxic alternative to currently available products such as nano-silver or triclosan.
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Eastman’s Tritan EX401 copolyester is one of the first materials that Parx has integrated with an antibacterial property, with results of 98.7% for Gram- and 98% for Gram+ bacteria. What distinguishes this technology is that it only targets bacteria cells, causing them to lyse and die. Human cells are left untouched. The company says the technology is not cytotoxic and is fully safe for contact with humans and biomaterial. It adds that the plastics are also suitable for food contact. 67
no external sealing hardware, vapor points are eliminated good for the environment and emissions standards. the process can be done on existing blow-molding machines, cutting costs for TI Automotive. TI Automotive can create fuel tanks of multiple shapes, sizes and complexities all on one machine, it's prepared to offer the process on customers' global platforms. "TAPT lets us produce multiple types of fuel tanks for the different powertrains from one blow molder." TI Automotive holds 20 patents around the world for the technology, which has been in development since 2008. TI Automotive's Rastatt plant will produce 300,000 units in the first year, but more contracts are on the way.
Water cooler made from recycled PET ntario based Ice River Springs Water Co. Inc. is introducing a 100-percent recycled plastic bottle for water coolers.
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The new 15-liter PET bottle is green in color, allowing the bottled water company to reclaim plastic from other used green PET bottles that might otherwise be wasted, the company said. Ice River is introducing the bottles in retail outlets in Western Canada under the Arrowhead brand name.
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TECHNOLOGY
Polymer beads help reduces 70% water usage he Xeros washing machine from a company based in Rotherham, UK, is looking to revolutionize domestic and industrial laundry alike with “bead cleaning.” The technology is claimed to be superior to traditional soap and water as well as environment friendly.
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Xeros is a six-year-old spinoff from the University of Leeds, where textile chemist Stephen Burkinshaw had the original inspiration to reverse the dyeing process. Instead of adding pigment to textiles, the team experimented with removing pigment-stains. Nylon readily takes up dye, and forming the polymer into round beads yielded the most effective stain extractor. The beads' surface area, weight, and chemistry have since been
engineered with regard to four independent factors—temperature, chemistry, time, and mechanics-that affect the washing process. The proprietary Xeros washer looks like a standard front-loading machine. About 50 kilograms of beads, held in a wet sump below the machine, are pulsed in with water through the top of the drum. The beads fall out of the drum and then recirculate. The process to laundry is like taking a shower that also aids in water savings. Xeros claims a 70% reduction in water usage compared with standard washing. The bead cleaning works in cold water (20 °C), hence heating is not required, which cuts energy use in half by Xeros’s estimate. The one and a half million or so beads used per load
constitute the fundamental ingredient in the cleaning cocktail. Xeros now has two main bead compositionspolyester (specifically, polyethylene terephthalate) and nylon (nylon 6,6). The mechanical action of the beads passing over clothing removes soil, and the weight of the beads reduces creasing by pinning the fabric down. But it is the beads' polymeric structure that attracts and traps dirt. Thanks to the presence of polar groups, the beads adsorb solubilizable stains. Because the beads are particularly good at clinging to dirt and grease, they might require a periodic wash themselves-perhaps once a month when used in lightly soiled washes. The beads are reusable and have been tested to last through 500 washes.
Plastics assist designers with Chrysler 200 interiors nterior suppliers have been developing ways to use natural products — including a thin veneer of wood — as an aesthetic covering which is married to the plastic substrate. Chrysler Groups adoption of it in the 200 allows it to echo what Busse called the "American design language" of allowing materials to show their true face — like the curved plywood in an Eames chair or the aluminum skin of an Airstream trailer.
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new ideas in design. "Look at the way we used wood this time," Busse said Busse pointed to the curving shape of the wood trim surrounding the instrument cluster. "It used to be that we could only use wood in simple shapes. This is one complex, free flowing design." That design is capable, he said, because of improvements in production and engineering. " For the past few car development cycles, Chrysler has co-located both designers and engineers within the same team, so they can combine their ideas on new projects as quickly and simply as possible.
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"What that means is that when we having some complication come up, it's very easy for us to get management together and say: 'Let's compare notes here. Let's see what we can do." For the 200, this combination came to the fore not only for the trim, but within interior packaging.Chrysler has replaced the standard shift lever to a rotary dial for the 200. That freed up space With that space, the materials engineers, design team and suppliers combined ideas for a space that feels far more solid than the storage in the previous models. Structural plastics along with key soft-touch panels and trim created an expanded space. J A N U A R Y 2014
IN THE NEWS
Mexican company finds solution to waste problem n enterprising company in Mexico has come up with a unique solution to the country's growing problem of plastic waste. Kuadro Ecological Solutions SA de CV is turning soda bottles, car parts, water pipes and shopping bags into oneinch thick panels which can substitute for wood, steel and concrete in the construction of houses, schools, fences and dog kennels. "We want to give this plastic [waste] a destination," said Ramon Martin Espinosa, commercial director of the 25-year-old company. "It's great because we are using a plastic product that is a problem and converting it into a solution."
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Every month, 160 metric tons of plastic waste is trucked in from recycling collection centers all over the country to Kuadro's factory on the outskirts of Guadalajara, in the western state of Jalisco, located approximately 320 miles from Mexico City. A team of workers sorts the mountain of plastic into piles according to the type of material, such as PET, polyethylene and polypropylene, so they can be mixed together in specific quantities to create long-lasting boards. Inside the factory, which operates 24-hours a day, five days a week, the plastic waste is shredded, then packed into steel trays, which are then baked in gas-fired ovens. The result is a board measuring 1.2 meters by 2.44 meters made entirely out of recycled plastic. To keep up with growing demand for the boards, the company has increased production capacity by 200 percent in the past 12 months and it is now churning out
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2,000 boards a month, Espinosa said. The plastic products are competitively priced. A house made entirely from plastic boards, for example, is about 35 percent cheaper than one made from conventional material, Espinosa said. Kuadro believes its products are helping to resolve a growing problem of plastic waste in Mexico, where just 15 percent of plastics are recycled, according the National Plastic Industry Association. In that same vein, Kuadro is also keen to ensure its factory is as green as possible. The company is overhauling its energy-intensive production process to make it more environmentally friendly. In the past year, it has converted the nine ovens
to a gas fire, rather than electricity. It is currently testing a combination of hydrogen and gas in one of the ovens, which has proven to be 22 to 27 percent more energy efficient. "For each 10 liters of gas that we normally use, we are now using 7.5 liters," Espinosa explained. Eventually, the company wants all the ovens running on hydrogen gas at night and solar power during the day. Kuadro sells a range of products made from plastic, including dog kennels, flower pots, pallets and mail boxes, but its biggest selling items are plastic fences and posts, particularly in the south of Mexico where the hot, humid climate shortens the lifespan of wood, cement and steel.
Chatterjee exits Haldia Petrochem artha Chatterjee has exited from Haldia Petrochemicals Ltd (HPL) as chairman with uncertainty shrouding the recentlyapproved Rs. 1,300 crore rights issue, according to a report in Business Standard.
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According to the report West Bengal Chief Minister Mamata Banerjee is not keen to provide the required money of about Rs. 520 crore for the proposed rights issue. The rights issue was planned for the company, which is struggling for working capital, as a last resort to infuse funds into the firm and save it from reporting to the Board for Industrial and Financial
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Reconstruction (BIFR) as a sick entity. In proportion to its stake in HPL, WBIDC has to infuse about Rs. 520 crore for the rights issue or it has the option to renounce it in favour of the other existing stakeholder, possibly Indian Oil Corporation (IOC), which has about 9% stake in the company. However, this would lead to change in the company’s shareholding pattern, which is under dispute. Concerns abound that private promoter The Chatterjee Group could haul the matter to the courts if the shareholding pattern changes at this moment.
J A N U A R Y 2014
IN THE NEWS
Bank of England to opt for Plastic banknotes from 2016 he Bank of England has announce to opt for Plastic banknotes. According to a report in the Guardian the Bank of England will follow in the footsteps of Canada, Australia and Hong Kong as it announces the move to plastic banknotes starting in 2016.
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Bank officials have been on a shopping centre roadshow testing the prototype polymer notes among members of the public and looking for approval of money they say is cleaner, longer lasting and harder to counterfeit.
A final decision is widely expected to be in favour of polymer. The introduction of plastic notes will have widespread implications. Introducing polymer will make things much harder and more expensive for fakers. Polymer also allows banknote issuers to bring in new security features, such as transparent windows. The Bank of England is not the only institution issuing banknotes in the UK, seven commercial banks in Scotland and Northern Ireland (S&NI) are also authorised to do so. Sheridan is hoping
polymer will be adopted there too. "If everyone went across to polymer it would be happy days from the NCA's perspective," he says. Cash machines are largely unaffected by the polymer notes but the cassettes that hold five pound notes will have to be changed. Tha BoE has already said that polymer notes will be printed at its print works in Debden, Essex, but it is not yet decided which company will have the printing contract. At the moment De La Rue produces all Bank of England notes.
Public hearing on Vizag-Kakinada PCPIR likely by June ublic hearing on Petroleum, Chemical and Petrochemical Investment Region (PCPIR) is likely to be held by mid-2014 as the PCPIR Special Development Authority readies to complete the exercise on various environmental studies and master plan. According to a report the process would be completely in few months. Addressing the media , Jayesh Ranjan, APIIC Vice-Chairmancum-Managing Director and PCPIR Development Authority Chairman said, “We have got in-principle nod for six-lane expressway between Visakhapatnam and Kakinada, rail sidings, roads connecting highway and jetty near Atchutapuram.
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Once we furnish all required data on environmental impact and other issues, we will seek environmental clearance from Central Empowered Committee and Ministry of Environment and Forests.� The process, he hinted, would P L A S T I C S N E W S
be completed in a few months. He said there was a tremendous progress with regard to completing preliminary studies and draft master plan for the ambitious project in 2013. The PCPIR project, for which Central approval
was obtained in 2008, envisages an investment of Rs.3,43,000 crore by attracting investments in infrastructure and petrochemical units in an area of 610 sq. km. in Visakhapatnam and East Godavari districts.
5 killed, 12 injured in explosion at chemical plant in Japan here was an explosion and fire at a Mitsubishi Materials chemical plant in central Japan on Thursday January 9, 2014. According to reports from CNN the incident occurred on Thursday afternoon a Mitsubishi Materials chemical plant in Yokkaichi, located about 320 Kilometers (200 miles) west-southwest of Tokyo, killing five people with 12 others injured, Yokkaichi police said.
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Earlier, the Yokkaichi Fire Department had reported that 17 people had been injured, five critically but did not report any deaths. The incident happened during a maintenance and cleaning operation at the plant, the Mie Prefecture Police Department said. A fire from the blast lasted about 10 minutes, according to police.
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EVENTS
Events and Exhibitions every corner of the globe that are specially tailored to the Russian market.
Indpack New Delhi 16 - 18 January 2014
At INTERPLASTICA 2014, an impressive range of innovative products and services will be on show in the areas of machines and equipment, raw material production and processing.
Venue: Pragati Maidan,New Delhi, India. Indian Institute of Packaging is organizing INDPACK 2014, 16th National Packaging Exhibition and conference on 16th -18th January 2014 at Pragati Maidan. The main objective of INDPACK 2014 is to provide Indian packaging industry a unique platform where the industry could showcase "state of the art" packaging technology and machinery, products and services along with international companies providing effective packaging solutions in terms of costs, productivity suitability and quality.
Despite worldwide economic uncertainties that have existed over the past few years, the development potential in the Russian plastics industry continues to be enormous! Secure a competitive edge by obtaining on-time information about innovative technologies and by cultivating business contacts and by building new ones! Take advantage of it at INTERPLASTICA 2014!
After the successes of the previous editions of Indpack it has grown as a brand name within the Indian Packaging Industry as well as the world over. Recognizing that new trends and development are essential to a bright future of the industry the Indian Institute of Packaging with Indpack, seeks to provide a perfect platform to bring the full range of the packaging industry under one roof.
Oman Plast 2014 Oman’s largest plastics packaging show 11th – 13th February 2014 Venue: Oman International Exhibition Centre, Muscat, Oman 2nd OMAN PLAST 2014 is an exclusive Plastics, Petrochemicals, Rubber, Packaging and Allied Industry Exhibition is being held for the second time in Oman. The objective of this prestigious exhibition is to display and demonstrate the products and services of plastics, petrochemicals, rubber, packaging and allied industries to the fast developing market of Sultanate of Oman while further encouraging development of trade links between Oman and the rest of the world.
With the support from Ministry of Commerce and Industry, Ministry of Food Processing Industry Government of India and many trade associations from India and abroad including World Packaging Organization and Asian Packaging Federation, Indpack is all set to continue its success story in 2014 edition.
Interplastica 17th International Trade Fair for Plastics and Rubber
2nd OMAN PLAST 2014 offers a perfect gateway to reach this highly potential market and holds tremendous prospects of excellent business opportunities and new collaborations.
January 28- 31, 2014 Venue: Moscow, Russia Interplastica is an international specialized exhibition for plastics and rubber processing and the region’s leading industry platform. It provides a representative overview of machinery and equipment for the plastics and rubber industry, as well as processing and recycling machinery, tools and peripheral equipment, measuring, controlling, regulating and verification technology, raw and auxiliary materials, plastics and rubber products, logistics, warehouse technology and services. The enormous international presence offers trade professionals the unique opportunity to gain a comprehensive overview of innovations from P L A S T I C S N E W S
An event of its kind in Oman is planned purely on aggressive development on Plastics and Petrochemical Industry. It will showcase the latest technology and machineries used in manufacturing of plastics, petrochemicals, rubber, packaging and allied industries. It will be an ideal opportunity for Oman and neighboring countries. 2nd OMAN PLAST 2014 is poised to establish new records in terms of number of exhibitors, visitors, industrialists, traders and businessmen.
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YUDO. ...........................................................................................................................................................cover Madhu Machines & Systems ...............................................................................................................inside cover Anupam Heaters...................................................................................................................................................3 Polymechplast ......................................................................................................................................................4 Plastlink Technologies ..........................................................................................................................................6 Ferromatik Milacron. .............................................................................................................................................7 Nijtech India. .........................................................................................................................................................8 Satellite Plastic Industries...................................................................................................................................10 PASL Windtech... ................................................................................................................................................12 Reifenhauser India Ltd.. .....................................................................................................................................13 Koplas 2015........................................................................................................................................................14 Leister Technologies India Pvt. Ltd.. ...................................................................................................................28 Reliance Polymers..............................................................................................................................................51 KABRA Extrusion Technik Ltd.. ..........................................................................................................................52 Vora Packaging. .................................................................................................................................................53 Plastivision Arabia 2014 .....................................................................................................................................54 Merit Polyplast. ...................................................................................................................................................55 AIPMA Industrial Park.........................................................................................................................................56 TAGMA ..............................................................................................................................................................57 R R Plast Extrusion ...........................................................................................................................................58 Steer Engineering ..............................................................................................................................................59 Andritz Biax. .......................................................................................................................................................60 Yann Bang Electrical Machinery Co. Ltd. ...........................................................................................................61 Forwell Precision Machinery Co. .......................................................................................................................61 Zambello Riduttori Group ...........................................................................................................Inside back cover Rajoo Engineers ................................................................................................................................... Back cover
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