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SAY YES TO PLASTICS Volume No. 90

PRN: - MCN/200/2015-2017

Issue No. 06

Pages 64

June 2015

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Plastics News • June 2015 • 2


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3 • June 2015 • Plastics News


Plastics News • June 2015 • 4


Contents

Plastics News MCN/200/2015-2017 Volume 90

June 2015 No. 6

IS H T N

I

Chairman - Editorial Board Mr. Rituraj Gupta

. . . E SSU

I

Hon. Editor Mr. Ajay Desai

13...... AIPMA At Work

Members Mr. A. E. Ladhaboy Dr. Y. B. Vasudeo Ms. Poorvi Desai

Report on the meeting to discuss issues of concern in ASEAN-India Trade in Goods agreement

Visit to Plast 2015

Meeting with Rajasthan's Industries Minister

Editorial Co-ordination: Padmesh Prabhune, Dhruv Communications, Mumbai, Tel No: 022 2868 5198 / 5049 Fax No : 022-28685495 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 Printed by her at : Dhote Offset Technokrafts Pvt. Ltd., Goregaon (E), Mumbai-400 063. Annual Subscription Single issue

Rs. 1,000/Rs. 75/-

Views/Reports/Extracts etc. published in Plastics News are those of the authors and not necessarily of the Editor. Furthermore except for copies of formal AIPMA communications no other matter in this journal should be interpreted as views of The All India Plastics Mfgrs. Association. Office Bearers Mr. Rituraj Gupta Mr. R. K. Aggarwal Mr. Meela Jayadev Mr. Sanju Desai Mr. Ashok Agarwal Mr. Haren Sanghavi Mr. Manoj R. Shah Mr. Jagat Killawala

President Vice President (North Zone) Vice President (South Zone) Vice President (West Zone) Vice President (East Zone) Hon. Secretary Hon. Jt. Secretary Hon. Treasurer

Meeting with Government officials of Madhya Pradesh Chinaplas 2015

23...... Company News 27...... Features CHINAPLAS 2015 ends successfully Hi-value cultivation through Plasticulture Choosing the Right Injection Mold Tooling Material, Part 2: Hardened Steels Injection Molding Economics Plastics now capable to resists Chemical attack Coca-Cola debuts PET Plant Bottle Malaysia on its way to ‘Go green’ Asia takes a spin on waste plastics Angelica Buan Show Review: Full order booked for POLYSTAR at NPE 2015 ZAMBELLO counter-rotating twin-screw extruders

44...... International News 48...... Business News 52...... Product News 56...... Technology 60...... In the News 5 • June 2015 • Plastics News


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Plastics News •• April June2015 2015•• 12 6 Plastics News


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Plastics News • April 2015 • 4

7 • June 2015 • Plastics News


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Plastics News • June April 2015 • 40 8


THE PRESIDENT SAYS

Growing with 'Plastics' for better future

W

ith the Lok Sabha and Rajya Sabha ending the

‘Some of the important items

Budget Session, the Parliament passed 24 important

showing high positive growth

Bills. Even though the government in power failed to get

during the current month

the Land Acquisition Bill & GST bill passed, the budget

over the same month in

proposals were approved. The eagerly awaited and crucial

previous year include ‘Plastic

GST Bill has been sent to a Select Committee for legislative

machinery including moulding

scrutiny. We, at AIPMA, are eagerly awaiting the smooth

machinery’ (266.4%), ‘H R

implementation of GST Bill w.e.f. 1 April 2016.

Sheets’ (157.5%), ‘Paraxylene’

st

India’s GDP (Gross Domestic Product) grew by 7.3 per cent in 2014-15 according to the latest official estimates of annual national income. The GDP growth for 2014-15 marks an improvement over the 6.9 per cent registered in 2013-14. Services have been the key drivers of GDP growth in 201415. They were equally instrumental in 2013-14 as well. ‘Financial, real estate and professional services’ recorded 11.5 per cent growth in 2014-15, much higher than 7.9 per cent in 2013-14. This is an expected outcome, given the buoyancy witnessed by financial markets in India

(95.0%),

‘ C o n d u c t o r,

Aluminium’ (92.0%), ‘Cashew Karnels’ (52.4%), ‘Vitamins’ (48.3%), ‘Boilers’ (40.3%), ‘Air Conditioner (Room)’ (34.4%), ‘Copper and Copper Products’ (33.4%), ‘Tea’ (33.2%), ‘Carbon Steel’ (32.5%), ‘Block Board’ (26.3%), ‘Three-Wheelers (Including passenger and goods carrier)’ (24.0%) and ‘Sugar’ (22.9%)’. Back home AIPMA was able to make its presence felt as one of the most active associations at the recently held ChinaPlas and as such ChinaPlas was a successful show for AIPMA as well.

during 2014-15 and the high capital inflows from Foreign

I am also glad to inform our members on the appointment

Institutional Investors (FIIs) for the greater part of the year.

of Shri Arvind Mehta - Chairman Governing Council AIPMA

The Quick Estimates of Index of Industrial Production (IIP) for the month of April 2015 have been released by the Central Statistics Office of the Ministry of Statistics and Programme Implementation. The General Index for the month of April 2015 stands at 179.7, which is 4.1% higher as compared to the level in

as Chairman of Plast India University being setup in GIDC, Vapi. This is a huge project (150 crore +) and we will need the assistance from members and industry to be partners in this gigantic responsibility bestowed upon him. AIPMA as promised has been working on skill generation and this is the first step. We are working for better future.

the month of April 2014. The cumulative growth for the period April-March 2014-15 over the corresponding period of the previous year stands at 2.8%. I am also glad to reproduce one paragraph of statistics from

Rituraj Gupta president@aipma.net

the report published by Ministry of Finance, Government of India. The figure shown are very positive indication of growth in plastic industry.

9 • June 2015 • Plastics News


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FROM THE EDITOR's PEN

In Roads for Plastics (waste)

D

isposal of waste plastic is no longer a problem in the city of Jamshedpur. Thanks to the Jamshedpur Utility and Services Company (JUSCO) that’s using bitumen technology on waste plastic, ranging from polybags to biscuit packets, for constructing roads. JUSCO, a 100 per cent subsidiary company of Tata Steel which maintains and provides municipal services in Tata command area of the city, has constructed 12-15 kms road in the steel city as well as Tata Steel Works besides widening 22 roads using the environment-friendly technology of utilising waste plastic. Also what we understand, Jamshedpur is the only city in eastern India where bitumen technology (Dry Process) patented by Thiagarajar College of Engineering (TCE), Tirupparankuram, Madurai, has been implemented on accumulated waste plastic for the first time. The best point is there is no maintenance cost involved for the first five years and for every stretch of such one km long and four metre wide road, one tonne of bitumen costing Rs 50,000 is saved. The use of bitumen has been reduced by 7 per cent ever since JUSCO began using waste plastic in road construction work, he said, adding that the quality and longevity of roads made of waste plastic-aggregate-bitumen was two times better than bitumen road. Besides being water resistant, it has better binding property, higher softening point, can withstand high temperature and higher load, has lower penetration value, costs less as compared to bitumen road and has no toxic gas emission.

Using plastic aggregated bitumen technology has helped. Also as we know the role of waterproof membranes has expanded from the traditional roof applications for dwellings and buildings to also serving a wide range of geomembrane applications in water containment, land reclamation, building and infrastructure protection. The developing world, and its increasing population, is driving up demand for waterproofing across all sectors. It is also challenging the waterproof membranes industry to contribute to the environmental consequences of global development. World over the industry is responding by adding or improving membrane functionality to improve durability, energy and water preservation, performance in broader climatic conditions and innovations in building design. The expansion of waterproof membrane applications has principally arisen through the continuous development of materials and construction of both bituminous and polymeric membranes. Measuring the expected and actual performance of membranes is crucial to driving further development. What I feel that it’s high time we have been blaming Plastics for all wrong doings. Let us look at the utility value and recycled value as well rather than condemning plastics.

Hon.Editor Ajay Desai

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Plastics News • June 2015 • 12

43 • April 2015 • Plastics News


Aipma at work

Visit to Plast 2015 T

he Plast 2015 exhibition was held at Milano Italy from 5thto 9th May 2015. Assocomaplast had organised excellent reception; hospitality and our visit to stalls were planned with the co-ordination of Italian Trade Agency. More than 38 countries’ leaders, delegates from the world were invited, escorted and taken care. FromAIPMA 7 members were invited.

Plast 2015 at MILAN, organised by Assocomaplast was a five day exhibition, spread in six halls. It was a showcase of European Plastics and Rubber machinery. The exhibition was visited by over fifty thousand serious business visitors. New technology and developments were shown. The business generation was good for exhibitors. AIPMA had a good location booth in Hall 11, from where promotion of Plastivision India 2017 and Plastivision Arabia2016 was done alongwith AIPMA by the Plastivision Team and AIPMA members present.

Arvind M. Mehta Chairman Governing Council AIPMA Past President – AIPMA &Plastindia 28th May 2015

BIO-PLASTICS - A REALITY NOW Italy banned shopping thin walled bags below 50 Microns which are non-biodegradable (i.e. our HMHDPE and PE bags). Italian Government issued a notification that bags must be BIO-DEGRADABLE i.e. made from NATURAL resources, they call agricultural raw materials. This legislation was passed by Italian Government before 3-4 years. Necessity is mother of invention, which is a reality now that shopping bags are made out of Bio-degradable plastics only and commercially accepted.

I came across a different growth area of interest to us in India i.e. BioPlastics

AIPMA team with Mr. Mario Maggiani – Secretary General of Assocomaplast

Bio-plastics Polymer ManufacturingPlant :The Plant in Italy have installed capacity of making Bio-plastics polymer of 200,000 tons per year and sell today 40 000 tons per year. They export bio-polymers to Europe / USA / Canada / Australia etc. PolyOne, Clariant are their customers.

13• June 2015 • Plastics News


Aipma at work Hygiene: Cotton buds, films for nappies and sanitary towels, and a range of medical products, such as gloves and other PPE (personal protective equipment) Motor Industry: Tyre additives Pets: PET accessories and toys Stationery and personal accessories: Pens, holders, combs Wrapping: For household goods, personal hygiene products and magazine mailing film

This bio-degradable plastic is created using patented technologies developed in the fields of starches, cellulose, vegetable oils and of their combinations. They make the products from raw materials that come from earth and return to the earth, thereby activating the whole sector of chemistry from renewable sources. Now Bio-polymer plants have been installed and are in operation, commercially selling bio-polymers at 2 to 3 times of normal polymers. Bio-degradable bags are 2-3 times costlier than nonbiodegradable bags but people are buying and paying the higher price for shopping bags. The Manufacturing Company name is Novamont Italy. Minimum 8 Micron Shopping bag can be produced from their bio-degradable polymers. It is creditable.

Sectors of use as below: Agriculture: Clip, mulch film, nursery pots, ropes and ties, devices for controlled release of active ingredients in integrated pest management Bags: For separate waste collection, shopping or food use Catering: tableware, beakers, cups, straws, lids, containers Education: Children’s toys, rulers and pens Expanded packaging: Expanded sheets and blocks for protecting and containing a variety of objects, packaging filter Food Packaging: High value films for food packing, extruded and woven netting

Plastics News • June 2015 • 14

Certified Quality: Mater-Bi® is a biodegradable and compostable product certified in accordance with international and Italian regulations (EN13432, UNI EN14995, ASTM D6400,) by officially recognised organisations, such as Vincotte (OK Compost), DIN-CERTCO (Kompostierbar), IIP – IstitutoItalianoPlastici –(the Italian Institute of Plastics, UNI certificates), Certiquality (Compostabile CIC), BPI – Biodegradable Products Institute USA and JBPA – Japan Bioplastics Association. The “OK Compost Home” certificate issued by Vincotte also guarantees that certain Mater-Bi® films biodegrade completely in lo-tech home composting bins while the “OK Biodegradable SOIL” certificate guarantees that the grades of Mater-Bi® for mulching biodegrade into thesoil. ICEA (Ethical and Environmental Certification Institute) has issued Mater-Bi® mulching film with the first certificate for


Aipma at work the ecological quality of the technical resources for organic and sustainable agriculture, Bio-degradability into the soil of Mater-Bi® mulching films at environmental temperature is certified by IIP in accordance with UNI standard 11183. The compostable bags made of Mater-Bi® bring about a progressive reduction in the weight of waste thanks to the loss of water vapour through transpiration, which is in accordance with the UNI standard 11185.

Conclusion: Bio Plastics is now commercialised in advanced country like Italy, is growing and exported. It can be moulded, blow moulded, extruded in regular machines by little modifications. So friends, it looks winds of change is there Bio-plastics has arrived.

Report on the meeting to discuss issues of concern in ASEANIndia Trade in Goods agreement

A

meeting was held to discuss issues of concern in ASEANIndia Trade in Goods Agreement at Udyog Bhawan, New Delhi on June 02,2015. The meeting was Chaired by Dr. Nagesh Singh, Principal Adviser, Office of the Economic Advisor, DIPP, Ministry of Commerce & Industry, Government of Indi. Mr R.K Agarwal, Vice President-North, AIPMA and Mr Deepak Ballani, Special Advisor, AIPMA represented our association AIPMA at the meeting.

Participants at the meeting included bodies like CII, FICCI, ASSOCHAM and associations like The Indian Paper Manufacturers Association (IPMA) , The Indian Newsprint Manufacturers Association (INMA), Consumer Electronics and Appliances Manufacturers Association (CEAMA), Indian Electrical & Electronics Manufacturers' Association (IEEMA), Automotive Tyre Manufacturers' Association (ATMA) , PHD House (4th Floor), All India Rubber Industries Association (AIRIA), Automotive Component Manufacturers' Association of India (ACMA) Society of Indian Automobile Manufacturers (SIAM) , All India Plastics Manufacturers Association (AIPMA), All India Flat Glass Manufacturers Association, Indian Footwear Components Manufacturers Association (IFCOMA), Indian Leather Products Association (ILPA), The Institute of Indian Foundrymen, Ball & Roller Bearing Manufacturers Association of India, Indian Machine Tool Manufacturers Association, EEPC, Vandhana, 4th Floor, Indian Non Ferrous Metals Manufacturers Association .

Introduction India’s engagement with the Association of South East Asian Nations (ASEAN) started with its “Look East Policy” in the year 1991. ASEAN's political and strategic importance in the larger Asia-Pacific region and its potential to become a major partner of India in the area of trade and investment has encouraged India to seek closer linkages with these countries. ASEAN comprises of Brunei, Cambodia, Indonesia, Laos, Malaysia, Myanmar, Philippines, Singapore, Thailand and Vietnam. The ASEAN-India Trade in Goods Agreement (AITiGA) has been operational since January 2010 with Malaysia, Singapore and Thailand. In respect of other ASEAN countries the Agreement came into force on subsequent dates. India’s trade volume with ASEAN has increased from US $ 43.91 billion in 2009-10 to US $ 76.58 billion in 2014-15. The FTA in goods focuses on tariff liberalisation on mutually agreed tariff lines from both sides and the tariffs have been eliminated on 80% of the tariff lines accounting for 75% of the trade in a gradual manner starting from 1 st January 2010. The agreement also provides for excluding the domestically sensitive items from the tariff reduction or elimination. India has excluded 489 items (at 6-digit HS) from the list of tariff concessions. There are some 590 additional items (at 6-digit HS) on which India will not eliminate the tariffs but would only give some tariff concessions.

15• June 2015 • Plastics News


Aipma at work Deliberations:-Government of India held consultations with representatives of industry associations to discuss the issues of concern relating with ASEAN-India Trade in Goods Agreement. Each association was asked to present their case (product line wise). With regard to both tariff and non-tariff issues, various associations presented issues of concern relating to this agreement. They presented the problems the industry is facing due to imports of various products due to this agreement. They also presented the issues concerning lack of benefits to their product line for the export under the same agreement. Several instances were presented that showed the tariff centricity especially in the context of FTAs often imparts a bias in the analysis of trade flows. Issues and concerns related to the PVC industry was raised by the ASSOCHAM. As per IndiaKorea FTA, Poly Vinyl Chloride, under Chapter 3904 (390410, 390421 and 390422) is under Exempt category. Similarly, as per IndiaSingapore FTA, Poly Vinyl Chloride under 3904 (39041010, 39041090, 39042110, 39042190, 39042210 & 39042290) is under Exempt category. However, as per India-Malaysia FTA and India-ASEAN FTA, while items under 390410 & 390422

are under “ST” category, items under 390421 are under “NT-2” category. For items under “ST”, duty is capped at 5% while for items under”NT-2”, duty gets progressively reduced to zero. Thus, there appears to be an inadvertent error in the FTAs with ASEAN & Malaysia. While FTAs with Singapore & Korea deals with items under 390410, 390421 and 390422 alike, which is logical and correct as these are like items, the FTAs with Malaysia & ASEAN treats items under 390410 & 390422 alike and items under 390421 on a different footing. CPMA also presented a similar case concerning PVC. Conclusion:-Industry associations including AIPMA has been asked to submit a detailed document on the issues concerning Plastic industry (product line wise) on ASEANIndia Trade in Goods Agreement (AITiGA). Suggestions:- AIPMA may undertake (self or outsourced) a detailed study of impact of ASEAN-India Trade in Goods Agreement on the Plastic industry. AIPMA may then submit issues of concern relating to AITiGA in respect of specific product lines/matters. These suggestions must be backed by cogent analysis and data.

Meeting with Rajasthan's Industries Minister A meeting was held on June 03, 2015 with Shri Gajendra Singh Khimar, Industries Minister, Government of Rajasthan.AIPMA delegation led by Mr. Rituraj Gupta President AIPMA , along with Jaipur Shri R K Agarwal, Shri Kailash Murarka, Shri Deepak Ballani from AIPMA met Mr Gajendra Singh Khimsar, Industries Minister, Government of Rajasthan in Jaipur. Present in the meeting were Shri Abhay Kumar-Commisioner Industries Government of Rajasthan, Shri MadhuSudan Sharma- Jt Director Industries Government of Rajasthan, Shri Dinesh Pahadia Sr DGM RIICO, Mr Lalit- Sr Mgr Land Records & few other officers from Government of Rajasthan. The agenda for the meeting was in continuation of earlier meeting had with SMT Vasundra Raje Scindia - Chief Minister, GoR & Shri Gajendra Singh on 6th January 2015 during the CII Conference in Rajasthan & subsequent meeting arranged by Shri Bharat Vyas for PVI 2017. In that meeting Mr. Rituraj Gupta had discussions with SMT Vasundra Raje Scindia about Plastic Park in Rajasthan on the lines of Dahej. Also on the Agenda was participation of Rajasthan in PVI-2017 & PVA 2016 as State Partner.

Plastics News • June 2015 • 16

The outcome of meeting was very positive for one, the Minister asked his officers to inform AIPMA delegation whatever Land bank in possession with the Government. As industry friendly location was our objective, we opted for a land block app 100 acres on NH8 in village Udvariya, District Sirohi. This parcel of land is touching the Ahd - Jodhpur Highway, 49 Kms from Abu Road Railway Station, about 200 Kms from Ahmedabad Airport & it is a Plain Land. Ample availability of Labour, electricity & water was assured to us. We requested for inspection of Land before moving forward. The minister asked his officer to take us the next day itself. We requested for some time as the matter needed threadbare discussion in AIPMA. We requested for financial assistance on the lines of policy of Govt of Gujarat for Plastic units. The minister said first you shortlist the land & then only we can talk in detail. And second, on the request of Shri Kailash Murarka As regards to participation in PVI & PVA the minister forwarded the file to GM publicity & PR for his comments. Shri Deepak Ballani will follow up vigorously on the subject matter.


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Aipma at work

Meeting with Government officials of Madhya Pradesh

A

meeting with Government officials of Madhya Pradesh was held in Bhopal to discuss the issue of Plastic Park & Proposal for Madhya Pradesh to be State Partner in PVI 2017 on June 11,2015.

Mr. Rituraj Gupta, President AIPMA and Mr. Deepak Ballani, Special Advisor had one-on-one meetings with Mr. Anthony Desa, IAS, Chief Secretary, Government of Madhya Pradesh,Mr Mohd. Suleman, IAS, Principal SecretaryIndustries, Government of Madhya Pradesh, Mr. V.L Kantha Rao, IAS, Industries Commissioner, Government of Madhya Pradesh and Mr D.P Ahuja, IAS, Managing Director, M.P Trade & Investment Facilitation Corporation Ltd. Discussions on the Plastic Park:• Government of M.P has developed an Integrated Plastic Park in Tamot in Raisen district. This is within the constituency of the Hon’ble Chief Minister of M.P. • Government of India has approved its support under the ‘Scheme for setting up of Plastic Parks’. It has already released its first instalment of Rs. 8 crore. • AIPMA was one of the signatory to the agreement for setting up this Integrated Plastic Park.These officers from Government of M.P were bit puzzled due to absence of initiative from AIPMA after signing of initial agreement 3 years back. • Plastic Park is situated only 40 km from Bhopal (about 45 minutes’ drive from the Bhopal airport). It is well connected by Road and Rail network. Dry port is around 20 km from the Plastic Park. • Common facility Centre is being developed including a CIPET Centre within the Park. • 121.90 Acre of development area has been earmarked for the Park. It has 84 plots for the units. • Government of M.P has requested AIPMA to promote this Park for investment and projects from good Plastic units in India and other countries as well. • They are eager to extend major benefits to units who want to setup their plant in the Park.

Plastics News • June 2015 • 18

• Extensive and detailed discussions were held regarding current status and future potential of Plastic Industry in India and more specifically w.r.t Madhya Pradesh. • Government of M.P has requested AIPMA to organize a half day event (3-4 hours) in Mumbai in July 2015. Around 150-200 AIPMA members could be invited to this event. Senior officers from Government of M.P (also Industry Minister likely) would participate and present the benefits of the Plastic Park to the industry. They are also interested in having one to one meeting with interested companies who want to put up their projects in Plastic Park. Date finalized for this is 10th July 2015. Expenses for the same would be borne by Government of M.P. A proposal along with budget estimate has to be sent by AIPMA to M.P Govt as soon as possible. • Post the event in Mumbai on 10th July 2015, AIPMA would organize a delegation of interested units to Bhopal for interaction with government and stakeholders. A visit to the Park would also be organized by Government. For large projects, one to one meeting could also be organized with Hon’ble Chief Minister. State Partner Proposal Plastivision India 2017:• The proposal for M.P as a state partner in PVI 2017 was discussed in detail. Likely benefits to the M.P as State Partner was explained and extensively discussed at length. Government of M.P has shown its keen interest in becoming a State Partner for PVI 2017 due to its potential to become a platform for attracting investment projects in Plastic Park and also in other areas of Madhya Pradesh. They have assured that proposal of AIPMA will be considered positively by Government of M.P.


Repeat - may

19• June 2015 • Plastics News


Aipma at work

Chinaplas 2015 China Plast 2015 held 20th - 23rd May 2015 at Guangzhou, China PR. Since Mr. Mayhur D Shah lead the Chinaplas 2015 delegation in absence of Mr. Chandrakant Turakhia, the entire delegation of 105 people were very happy with the arrangement and the hospitality provided by Orbitz was excellent. Indian breakfast, dinner, all transfers were flawlessly handled. This amounts to giving service to the Industry. President informed that the B2B meetings held during Chinaplas 2015was excellent with approximately 200 Chinese companies doing business with over 200 Indian delegates under one roof. Our Agents CMEC were very satisfied and are keen to continue being our Agents for PVI 2019 as well. It was also noted by Hon. Secretary that the AIPMA’s show of Indian contingent strength was very well acknowledged by CMEC and other dignitaries. Mr. Mayhur D Shah thanked all the members who assisted him to manage the delegation and also thanked Mr.Raju Desai for getting M/s. L.K.Machinery to sponsor Cocktail and dinner on the first day. He thanked President, Bhurabhai and Ajaybhai to imposing faith and confidence in him.

Plastics News • June 2015 • 20


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Plastics News • June 2015 • 22


COMPANY NEWS

Henkel to build Adhesives Plant near Pune

H

enkel Adhesive Technologies India Pvt Ltd (a fully owned subsidiary of Henkel), a leading solution provider for adhesives, sealants and functional coatings, has announced an investment of about 30 million Euro to set up India’s largest adhesives plant in Kurkumbh, Pune. The new plant is expected to start production by early 2017. The foundation stone of the plant was laid down by Devendra Fadnavis, Chief Minister of Maharashtra along with Mr. Jeremy Hunter, President Henkel Group India, during a ground breaking ceremony at Kurkumbh.The plant will cater to the various end user segments such as automotive, metal and industrial sectors. Commenting on the plans, Jeremy Hunter said: “The Kurkumbh plant is a very important milestone of Henkel’s journey in India. This plant will enable us to

localise our product portfolio and reduce imports while bringing the best global technology to India. Considering the proximity of the plant to our customers, it will also help us to work closely with them in developing solutions. We are aiming to win a greater market share in India, which is one of the biggest emerging markets for us.” The Kurkumbh plant is being built in a phased manner. In the first phase, the state-of-the-art, multitechnology manufacturing facility, will have an operational area of about 20,000 square meters and the annual capacity is expected to be about 80,000 metric tonnes of adhesives and surface treatments. The plant will be LEED certified by the Indian Green Building Council (IGBC) and will follow the highest SHE (Safety, Health & Environment) standards.

Petronas to delay start-up of its RAPID refining and petrochem complex

M

alaysia’s state-owned oil and gas company Petronas is delaying the start-up of its US$16 bln RAPID refining and petrochemical complex in the southern state of Johor until mid-2019, from the earlier planned start up of early 2019, as per Reuters. For the refinery, the start up will be middle of 2019. That is the current schedule. The slide in oil prices over the past year forced Petronas to review and re-bid some of its engineering, procurement

and construction contracts (EPC)”, President and Group Chief Executive Officer Wan Zulkiflee Wan Ariffin said on the sidelines of the Asia Oil and Gas Conference in Kuala Lumpur. The weak oil prices also prompted Petronas to rephase some of its petrochemical projects. The project is slated to be Malaysia’s largest liquid-based green-field downstream development. It has been twice delayed due to issues with relocation of residents.

Solvay's profit sharing plan

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o l v a y, t h e B e l g i u m headquartered chemicals company, has signed an agreement with its global social dialogue body, the Solvay Global Forum, on a profit sharing plan which will benefit employees across the group. The profit-sharing scheme will be indexed to Solvay’s financial and sustainable development performance for 2015 and 2016. An annual budget of €10m has been allocated to the plan for 2015. The agreement comes following a year trial in 2014 which benefited more than 22,000 employees. “We wanted to introduce a simple value-sharing scheme benefiting everyone. This innovative approach allows us to raise the awareness of Solvay employees throughout the world, whether blue-collar or white-collar employees, to the group’s economic and societal performance and to strengthen their sense of belonging to the group,” said Cécile Tandeau de Marsac, Group General Manager Human Resources at Solvay. The plan benefits all group employees in all 51 countries, with the exception of senior executives and French employees who already benefit from an equivalent plan, says Solvay. Albert Kruft, coordinator of Solvay Global Forum, said: “This global agreement is a milestone because it rewards the engagement of the group’s employees worldwide in Solvay’s success.

23• June 2015 • Plastics News


COMPANY NEWS

Wacker starts up specialty monomer plant

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acker Chemie AG has started up a new specialty monomer plant with capacity of 3,800 metric tpa at its Burghausen facility in Germany at an estimated investment outlay of €8 million. The specialty monomers; vinyl neodecanoate and vinyl laurate are key raw materials in the manufacture of specialty dispersible polymer powders. The goal of the new plant is to ensure that Wacker has sufficient specialtybinder capacity available, both now and in the future, to provide its customers with a secure and longterm supply. WACKER invested some €8 million in the facility and has, as a result, strengthened its position as the world’s biggest producer of dispersible polymer powders. By expanding its capacities, WACKER

is meeting global demand for its dispersible polymer powders – which is rising amid such world trends as urbanization, renovation and energy efficiency. The specialty monomers vinyl neodecanoate and vinyl laurate give WACKER’s dispersible polymer powders special properties, such as hydrophobicity. Christoph Riemer, head of polymerpowder business at Wacker Polymers said, “with our new specialtymonomer plant, we now have the capacity we need to secure longterm a captive supply of these raw materials, which are important for polymer-powder production at Burghausen. In addition, the facility reinforces our leading market and cost positions sustainably.”

Modern-Expo to set up Plant in Poland

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utch-based manufacturer Modern-Expo has announced plans to establish a new production facility in Poland. The plant will be located in the Lublin subzone of the country’s Euro-Park Mielec special economic zone. The company makes a wide range of store fixtures, shelving, racks and counters with the use of plastics and other materials. “The investor plans to build a production facility … which will be fitted with modern production lines to extrude polymers, and it will make plastic components. Under the plan, the Dutch-based manufacturer will create about 84 new jobs in Lublin. The planned investment is estimated

Plastics News • June 2015 • 24

to be worth more than 18m zloty (€4.3m). Lublin is located in Poland’s south-eastern region of Lubelskie. The company has been given approval to carry out the project, the statement said. Modern-Expo says it was set up in 1993, and it supplies its output to more than 50 countries in Europe, Commonwealth of Independent States, Middle East, North Africa and South America. The producer is operated by a global workforce of more than 2,000. Its production facilities have a total floorspace of over 100,000 square metres and are located in Lutsk and Verhnedneprovsk, both in Ukraine, and Vitebsk, Belarus.

Dow reduces run rates at Argentina cracker

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ow has reduced run rates to 90% at its Argentinian cracker amid government-imposed natural gas curtailments, as per a company source in Platts. Every winter since 2006, the Argentinian government has curtailed ethane and LPG supplies to industrial users by up to 30%, and the start of this winter’s cuts kicked in over the weekend. Dow “began following processing restrictions [imposed] by the authorities that manage the country’s energy.” The reduced run rate was not due to any ethane shortages from Mega, Dow’s main feedstock supplier, or any issues at the joint venture’s plants. The restrictions began to diminish considerably thanks to imports of gas and new gas supplies, both conventional and unconventional. “We hope that similar to 2014, fewer restrictions will happen this year,” the source said. Dow Argentina has been looking to North America for ethylene prior to the reduction in run rates, market sources say. Dow Argentina operates two ethane-fed steam crackers and polyethylene production at its Bahia Blanca petrochemical complex. Ethane is a natural gas liquid used in the production of ethylene, which can then be transformed into polyethylene. Bahia Blanca site has an production capacity estimated at 765,000 mt/ per year.


COMPANY NEWS

China’s BOPP film firm Gettel to add factory

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roduction will start by the end of this year at biaxially oriented polypropylene (BOPP) film manufacturer Gettel Group China sixth plant, in Huishui, Guizhou province. Gettel claims to be the world’s biggest BOPP producer, turning out 316,200 tonnes last year. Sales for the year were CNY 3.2bn (€471m), said Jenny Yang, the company’s international trade department manager.

factory has more than 200 workers. Spreading factories throughout China provides better customer service. “The customer can save on freight costs,” Yang said. BOPP film is primarily used for packaging and labels. The company offers a wide variety of BOPP products, including film for adhesive tapes; laminationgrade film; heat-sealable film; matt film; metalising-grade film; pearlised film; and bag-grade film.

Gettel also has factories in C h o n g q i n g ; Pa n j i n , L i a o n i n g province; Suqian, Jiangsu province; Tongcheng, Anhui province; and at the company headquarters in Wenzhou, Zhejiang province. In all, Gettel has 13 BOPP production lines from Siegsdorf, Germany-based Brückner Maschinenbau. It plans to add another Brückner line next year at the Chongqing plant, Yang said.Each

Gettel began exporting in 2009. Last year it exported 8% of its production, mostly to Asian and Middle Eastern buyers, up 40% from the previous year, Yang said. The strong Chinese currency has had negligible effect on Gettel’s bottom line. “We import the raw materials [PP resin] and we export [finished product]. So for the BOPP [export] business, there’s not a big effect,” Yang said.

Lotte Chemical Titan plans upstream plant in Cilegon Lotte Chemical Titan, a subsidiary of the South Korean Lotte Group, is studying the possibility of building a US$4 billion upstream plant to reduce imports of raw materials, Lotte Chemical Titan president director Peter Yoon said the new plant would be built on 40 hectares near its existing plant in Cilegon, Banten. Lotte Chemical, which currently has a production capacity of 450,000 tpa of polyethylene, expects the upstream plant to boost production capacity to

1 million tons by creating ethylene. Around 40% of the total investment needed for the new plant would be taken from the company’s internal cash, while the rest would be from bank loans, Yoon said, adding that all investors would be from South Korea. The company is in the process of negotiating price with the land owner, date when construction is to begin remains undecided. Construction of the project is expected to take about three years.

BMW to use carbon fibre in new series BMW AG BMW's 2016 7 series sedan will use carbon fibre along with steel and aluminium in a mixedmaterial process in the passenger cell. Continuing its dedication to using carbon fibre in production vehicles, BMW AG this week unveiled its 2016 7 Series sedan with a passenger cell making significant use of carbon fibre-reinforced plastic. Lightweighting efforts have reduced the weight of the body shell by 88 pounds while the entire car comes in at 190 pounds lighter than the existing 7 series. BMW has a joint venture to produce its carbon fibre, including a plant in Moses Lake. Beyond carbon fibre, the Munich, Germany-based aut omaker’s redesigned flagship sedan will offer other technological goodies aimed at keeping buyers from defecting to cutting-edge competitors such as the Mercedes-Benz S class and Tesla’s Model S. New 7-series features include the largest head-up display in the industry, a transmission linked to the navigation system that optimises performance based on the road, a passenger compartment that uses carbon fibre to save weight, fully autonomous parking and the world’s first use of gesturerecognition controls in a production car.

25• June 2015 • Plastics News


COMPANY NEWS

Piva to open its first US plant in Missouri

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talian window maker Piva Group is opening its first US manufacturing facility in Ste. Genevieve, Missouri, where it expects to be producing 300 windows a day in August and eventually triple its capacity. The family-owned company is investing $6.47m (€5.9m) into an existing 90,000-square foot site that will house distribution, customer service, accounting, and information technology personnel in addition to factory workers.The operation will create 122 new jobs in the community, which was founded in

1735 by French Canadian settlers. Piva’s other production facilities are in Italy and Spain and have a combined workforce of 400.Piva makes vinyl and aluminum windows and doors as well as vinyl wall panels for the residential and commercial markets in the US, Canada, Mexico, Africa, Australia and Latin America. The Genevieve plant will make vinyl products. Randy LaMotte, president of Piva Group North America, said that the overseas outreach made a difference in selecting a location. The company plans to install machinery

Taiyo Oil Co. Ltd. start s producing petrochemicals with UOP’s process

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OP LLC, a Honeywell company, announced that Japan’s Taiyo Oil Co. Ltd. has begun producing petrochemicals with UOP’s Tatoray™ process technology, which provides greater flexibility to produce either gasoline or valuable petrochemicals as demand changes. Taiyo Oil licensed the process technology from UOP in 2013 for its Shikoku Operations in Japan. The new unit started production late last year and met all of its performance guarantees two weeks after start-up. The Tatoray process substantially increases production of benzene and xylenes, which are used to produce polymers and plastics. “With domestic gasoline demand declining, Japan has become the world leader in reallocating feedstocks, such as

Plastics News • June 2015 • 26

naphtha, from making motor fuels to producing in-demand petrochemicals, making Japan one of the largest exporters of components used to make paraxylene,” said Pete Piotrowski, senior vice president and general manager of UOP’s Process Technology and Equipment business unit. “The Tatoray process can more than double the production of mixed xylenes, while significantly reducing the cost of production, making it one of the most economical ways to increase yields of xylenes and benzene.” Before Taiyo began using the Tatoray process, the plant used UOP Thermal Hydro-Dealkylation (THDA) technology to convert less valuable, heavy aromatics to benzene, which is used to make plastics and detergents

and equipment in the coming weeks. “It’s rewarding to bring jobs to Missouri where the workforce has demonstrated an outstanding work ethic and strong values,” LaMotte added. “This facility will provide the highest levels of quality and consistency in our products and allow us to deliver the best level of service and value available to our customers.” If Piva meets its hiring and investment goals, it will receive an economic incentive package from the Missouri Department of Economic Development.

DuPont to expand nylon capacity

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uPont is to expand production of its Zytel PA66 and PA6 portfolio at its factory in Hamm, Germany, by 20%. Accordig to the reports increased demand, primarily from the global automotive industry, was behind the move, as many customers looked to replace heavy, metallic parts with lighter, nylonmade products. However the group declined to give details of current production at the plant. Richard Mayo, global business director for the nylon businesses in DuPont Performance Polymers, said: “Nylon continues to be the starting point for many product designers because it’s versatile, easy to mould and offers exceptional longterm performance in the most challenging environments.


FEATURES

CHINAPLAS 2015 ends successfully

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HINAPLAS 2015 closed successfully on 23 May 2015 successfully, with the no of visitors surpassing the last exhibition held in Guangzhou in 2013, despite the bad weather that caused flight and train disruptions during the show period.

The heavy downpours could not cool down the determination of visitors to come to the show. The Asia's largest and the world's second largest plastics and rubber trade fair held on 20-23 May attracted a total of 128,264 visitors. According to reports the visitors peaked on the second day, having 49,732 visitors attended. As CHINAPLAS has been well-recognized by the plastics and rubber industries as well as their downstream sectors globally, the show this year welcomed 35,090 overseas visitors, representing 27.36% of the total. Visitors at ChinaPlas were reported from 137 countries and regions with India, Hong Kong, South Korea, Taiwan, Indonesia, Vietnam, Thailand, Iran, Malaysia and Japan as the top ten origins. As compared with the show

held in Guangzhou in 2013, the show registered a 12.41% growth in visitors, while overseas visitors rose by 14.04%. CHINAPLAS 2015 also marked new records in the show scale in terms of exhibition area and no of exhibitors over the past editions. This year, 3,275 exhibitors from 39 countries and regions participated in the show, of which over 700 exhibitors joined CHINAPLAS for the first time, representing over 20% of total exhibitors. The show also marked unprecedented exhibition area, with floor space over 240,000 sqm, up 9% compared to last CHINAPLAS held in Guangzhou in 2013, with the exhibitor number up more than 10%. Ada Leung, General Manager of Adsale Exhibition Services Ltd., the organizer of CHINAPLAS, said, "The majority of our exhibitors are very happy with the visitor quality and their participation results. Despite the heavy rain during the show, the fairground was busy with business networking and technological

exchange activities. At the same time, we have received many positive feedbacks from the visitors that the technology levels of exhibits and the quality of the show have kept on rising". She added, "As the show organizer, we are very glad to see that the global plastics and rubber industries have fully recognized CHINAPLAS as an effective platform for technology and trade promotion, and for the setting of market trends." During the CHINAPLAS 2015 a two-day conference on “New Era Manufacturing: Innovations in Medical Device Manufacture and Market Trends” on 21-22 May, in which 9 medical plastics experts presented the latest developments in the area of medical plastics. Mr. Mike Maczuzak, the President of Smartshape Design, delivered his speech on Medical Device Design for Human Variability focussing on innovative uses of plastics technologies on medical device designs, and inspired medical device designers to create such new ways to better accommodate

27• June 2015 • Plastics News


FEATURES human variability in user populations, including patients and caregivers.

patients in pre-operative anatomy planning.

Ms. Stefania Marconi, the Biomedical Engineer, PhD Student in Experimental Surgery and Microsurgery from University of Pavia, introduced the audience to the world of new technology of 3D models applied to laparoscopic and robotic abdominal surgery. This new technology gives high degree of personalization to

Also due to great market demand, the 'Industrial Automation Zone' was set up to highlight the latest high-tech products from leading automation equipment suppliers including Mitsubishi Electric, Rockwell, Honeywell, Siemens, ABB, SHINI, Engel, Wittmann and so on. Exhibits covered robots, robotic

Further Design and Innovation Open Forum Program was also conducted by industry experts and renowned product designers. CHINAPLAS 2016 will celebrate its 30th edition next year and will be held on 25-28 April, 2016 at Shanghai New International Expo Centre, Shanghai, PR China.

Hi-value cultivation through Plasticulture

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Plasticulture Applications in Horticulture (NCPAH)

ndia is endowed with a wide variety of agro climatic conditions and enjoys an enviable position in the horticultural map of the world. Almost all types of horticultural crops can be grown in one region or the other. Horticulture today, is not merely a means of diversification - AN nutritional OVERVIEW security, but forms an integral part of food and as also an essential ingredient of economic security.

wide variety of agro oys an enviable

region or the

not merely a t forms an

nutritional essential urity.

both by small and ught prosperity in y. Over the years, s an indispensable

part

of

range of choices to the farmers for provides ample opportunities for sustaining large number of agro-

Adoption opportunities. of horticulture, both by small and marginal ubstantial employment farmers, has brought prosperity in many regions of the

ourages private investment, to go for hi-tech horticulture with microcountry. Over the years, horticulture has emerged as an tivation, drip irrigation, fertigation, and integrated nutrient and pest indispensable part of agriculture, offering a wide range ing use of latest post-harvest measures particularly in the case of of choices the farmers for crop It also a result, horticulture croptoproduction has moved fromdiversification. rural confines provides ample opportunities for sustaining large number d has attracted youth since it has proved to be intellectually satisfying

of agro-industries which generate substantial employment opportunities.

horticulture has made steady and fast progress in the country during The area coverage under drip irrigation, green houses and plastic

bly increased with newer innovations in the available products.

Plastics News • June 2015 • 28

The changing scenario encourages private investment, to go for hi-tech horticulture with micro-propagation, protected cultivation, drip irrigation, fertigation, and integrated nutrient and pest management, besides making use of latest post-harvest measures particularly in the case of perishable commodities. As a result, horticulture crop production has moved from rural confines to commercial ventures and has attracted youth since it has proved to be intellectually satisfying and economically rewarding. The use of plasticulture in horticulture has made steady and fast progress in the country during VIII, IX, X, XI & XIIth Plan. The area coverage under drip irrigation, green houses and plastic mulching etc. has considerably increased with newer innovations in the available products.

al map of the of horticultural

g.

arms, sensors, drive and control system, vision control technique and refrigeration dryer system

n Plasticulture Applications in Horticulture (NCPAH) under Ministry of

The National Committee on Plasticulture Applications in Horticulture (NCPAH) under Ministry of Agriculture has played an extremely important role, in the field of horticulture, by promoting the use of plasticulture applications in improving the productivity and quality, water saving and protection from vagaries of weather to support Hi-Tech Horticulture through its 22 state-of-theart Precision field protocols for the growers and related stakeholders. Government of India, Ministry of Agriculture has initiated steps to address two critical factors to agricultural production, namely Water & Soil, in the Budget. Special emphasis is given through Pradhan Mantri Krishi Sinchai Yojana (PMKSY) &. Paramparagat Krishi Vikas Yojana in the current budget. In the past also Govt. has initiated


FEATURES National Committee on Plasticulture Applications in Horticulture (NCPAH)

Advantages of plasticulture applications

many such interventions from time to time to give a boost to horticulture sector through various centrally sponsored schemes & implement through State governments. The schemes are specifically targeted to promote proven technologies by providing financial assistance besides different kinds of institutional & technical support systems taking the Industry along. These include National Horticulture Mission (NHM), Mission for NE & Himalayan states (HMNEH), National Mission of Micro Irrigation (NMMI) and National Mission for Sustainable Agriculture (NMSA) etc. In the coming years, plasticulture is going to play a dominant role in horticulture development of the country. We would require much higher production of food grains, fruits and vegetables to meet the prescribed nutritional requirement of increasing population. This is of special significance in view of the decision of Government of India to double horticulture production in the country.

Water saving (%)

Water Use Efficiency (%)

Drip Irrigation

40 - 70

30 - 70

 Can be used in unlevelled lands  Saves water, fertilizers, electricity besides labour costs  Controls weed growth  Eliminates soil erosion

Sprinkler Irrigation

30 - 50

35 - 60

 Reduces soil compaction  Provides frost protection  Saves land as no bunds are required

Plastic Mulching

40 - 60

15 - 20

 Helps conserve soil moisture - reduces need for irrigation  Maintains soil temperature, control weed growth  Crop matures faster, increases yield, keeps crop clean, early fruiting  Prevents soil erosion & compaction

Greenhouse

60 - 85

20 - 25

 Manifold production - Off-season cultivation.  Early maturity of crop - Better quality of produce.  Controls pests & diseases

Shade nets

30 - 40

30 - 50

 Protects plant saplings by cutting intensity of sunlight – which reduces evaporation losses  Enhances yield during summer season.

Plastic tunnel

40 - 50

20 - 30

 Miniature Greenhouse - cultivation during extreme winters.  Control environment - enhances nutrient uptake and photosynthetic activity  Used for raising early & healthy nursery.

100

40 - 60

 Rainwater can be harvested in farm ponds/water tanks for irrigation of short duration crops.  Reduction in seepage loss.

Application

Farm Pond line with plastic film

Major Advantages

National Committee on Plasticulture Applications in Horticulture (NCPAH)

Despite the same is proven in many part of the globe still continue to offer lots of opportunity for wider adoption. Plasticulture applications have taken the agrarian economy to much greater level, offering solutions such as enhancement of production & productivity with quality produce. These modern methods not only helps savings of various most precious natural resources including water & by conserving the same make it available to other sectors. During Conveyance in the traditional surface method of irrigation, bulk of the water released from the source is lost by way of seepage, evaporation etc., Rainfed areas are low in productivity and sustainability. By proper management of the available water resource thru harvesting, the same is made available to enhance irrigated area of the country.

NCPAH, MOA, NEW DELHI

What Plasticulture offers? • Provides micro climate for crop development

Impact of climate change, rainfall pattern, reduction in

• Savings in inputs such as water, fertilizer, labour

Impact of climate change, rainfall pattern, reduction in operational holdings and grueling demand operational holdings and grueling demand to produce to produce more per unit of area will hold future for plasticulture applications to feed the ever

• Round the year cultivation of crops

increasing population of the country.

• Better quality and enhanced quantity of produce

more per unit of area will hold future for plasticulture applications to feed the ever increasing population of Cultivation of hi-value horticulture crops coupled with plasticulture applications would provide the country.

• Production of hi-value crops in hostile climates.

involved in such industry. Cultivation of

Advantages of plasticulture applications

substantial benefit not only to the farming community but also to the component manufacturers

hi-value horticulture crops coupled with plasticulture applications would provide substantial benefit not only to the farming community but also to the component manufacturers involved in such industry.

29• June 2015 • Plastics News


FEATURES

Choosing the Right Injection Mold Tooling Material, Part 2: Hardened Steels

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s we mentioned in our last article choosing the proper material for your next injection mold can often be as critical as choosing the right plastic resin for your part. In this post, we’ll answer those important questions to uncover when and why you may choose hardened steels for your next injection mold project.

1. How many parts are expected to be molded? Common grades of hardened steel include H13, S7 and 420SS. Similar to pre-hard steel, hardened steel offers a wide range of versatility in the injection mold making industry. Typically found with a Rockwell rating of RC 46-62 (S7 tends to be a little harder than H13), it can be a great material for creating core and cavity detail. With hardened steel molds, one can easily achieve 1,000,000 cycles for unfilled materials and 250,000-500,000 cycles with filled materials. Once again, this range is

dependent on the amount of filler present in the plastic material.

2. What surface finish requirements are expected of the molded part? Much like pre-hard steel, hardened steel has the ability to accept a multitude of different surface treatments. This may include light to aggressive textures, EDM finishes or polish. An A-1 or better polish can be achieved but this is grade specific. While materials like H13 is capable of achieving an A-1 finish it is generally preferred to use 420 SS. It is important that the grain structure of the material be at 90° to the mold surface to achieve best results.

3. What steel conditions exist as a result of the part design and are they conducive of excess wear? With hardened steels you can decrease the amount of draft of wiping shut-offs to about 3 degrees. When dissimilar

cavity and core steels are used in conjunction with pre-alignment features (straight side locks), less draft can be used for shut-off angles. While hardened steels perform better under these circumstances, don’t be alarmed if you mold maker and molder take exception to certain details with less than 3 degrees of draft from a “guarantee” perspective. Because of their increased hardness, it is typically not necessary to have different hardness/alloys materials where you have moving components (like when using pre-hard steel). With the pressures and heats seen during the injection molding process, small, intricate and tall details are inherently a potential weakness for any steel and should always be taken into consideration. Because S7 and H13 will not lose hardness over time, this material becomes an ideal candidate for such detail. It is generally recommended not to exceed a 5:1 aspect ratio for standing core details. However, if this aspect ratio is exceeded, it is best to insert the detail in the mold. As always, circumstances like this can often be a balancing act, so it is important that you consult your mold maker to understand any risks associated. As we touched on in the previous post, it is important to understand the compression strength. Compression strength is critical in mold construction as it dictates not only the strength of the steel but also the dimensional

General standards for the three most common injection mold materials

Plastics News • June 2015 • 30


FEATURES stability. Of the 3 materials being reviewed in this 3-part series, hardened steel has very good to excellent compression strength. Because of this, hardened steel is a great candidate for higher volume production tooling, including insert molding and overmolding. Lastly, hardened steel is considered to have excellent dimensional stability after heat treat and is not susceptible to warpage during the machining process.

4. What type of plastic resin will be used on the molded part? When molding high heat resins like PEI, PPS, PPSU, PPA and PEEK at higher volumes, hardened steels should be your go-to steel. Because of the way S7 and H13 are alloyed, they do not lose their hardness over constant heating and cooling cycles. Because of

its inherent resistance to heat cycling, many companies use S7 and H13 for components within hot manifolds. Hardened steels will also hold up better to highly abrasive materials. However, even with hardened steels, the abrasive nature of some materials can still wear on finer details. For highly abrasive materials, with volume expectations that exceed 250,000-500,000 cycles, a great “insurance policy” is to have the core and cavity surfaces of the mold coated/plated. When this very thin layer of material is applied to the core and cavity surfaces (typically .0003”.0005”), it can greatly increase the Rockwell hardness of hard steel. According to Bales Metal Surface Solutions, Rockwell coating of 45RC85RC can be achieved with various coatings. If molding highly corrosive molded resins, like PVC, common metals can quickly corrode, so 420SS

is highly recommended. There are many options that offer different levels of hardness, as well as corrosion resistance, so it is recommended that you consult with your mold maker or coating professional. A wide variety of mold materials are readily available for the construction of injection molds. By considering these 4 basic questions, you can make a more educated choice as to what the correct material is for you. While choosing the best option for your mold is not complicated once you understand the pros and cons of each material, it is a critical part of the process that can affect the success of your project. Re s e a r c h d o n e p r i o r t o m o l d construction, and more importantly vendor selection, can help ensure you receive the performance you expect from your next mold.

Injection Molding Economics

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he difference between the most efficient injection molders and the least efficient molders is simply the number of good parts they produce and the amount of plastic they use. Not getting into production quickly, interruptions to production and wasted plastic all cost money. Productivity is the name of the game. Unless your company can produce injection molded plastic parts at a profit, it can’t buy machines, auxiliary equipment or even plastic.

Let’s talk about how injection molding cycle time can impact a molding job’s profitability…

Injection molding cycle time is made up of three elements • fill, pack and hold time • cooling time • mold open time The most important of these three factors is plastic part cooling time. Cooling of the plastic in the mold is typically 80% to 90% of the total cycle time. How quickly you can open the mold depends on the mold temperature, the plastic melt temperature, the maximum plastic part wall thickness, the part shape and the type of plastic material being used. The injection mold can be

opened and the plastic parts ejected when the parts are cool enough to hold their shape (i.e. no deformation occurs as the part cools). The two other phases of the injection molding cycle that can reduce cycle time are fill time and mold open time. Most injection molds should be filled as quickly as possible. There are some exceptions. But in general, fast filling reduces molded-in part stress, though it does increase molecular orientation in the direction of plastic flow. The injection molder should try to reduce fill time to the shortest time that will make acceptable parts.

31• June 2015 • Plastics News


FEATURES Minimizing the mold open time is another way to reduce cycle time. If the molding machine is running in semi-automatic mode, the mold open time should be consistent and minimized. But you must allow enough time for the operator to remove the parts and inspect the cavities and the mold surface. If a robot or a part picker is used, the mold open time must be long enough for the functions of that equipment to finish. So how does longer cycle time affect profits on a particular molding job? Let’s look at a very plausible scenario. The mold setup person got the machine and mold running and producing in-spec parts at a cycle time of 32 seconds. But, it could have been run at 30 seconds for one or more of the reasons cited above. In, fact maybe it can run at 29 or 28 seconds. Setting the molding job up to minimize cycle time would have taken more start-up time. But the few molding experts in the plant who could have further optimized the molding cycle didn’t have time to refine the cycle. What’s the cost of this extra 2 seconds? The molding job should have been completed in 15,000 hours of production, but the 2 extra seconds on a 30 second cycle requires an additional 1,000 hours of production. This extra 1,000 hours of production took $40,000 out of the expected profit (assumes $40/hr machine hour rate) Conversely, if the cycle time were reduced to 28 seconds the profit increases by $40,000. If the molding personnel on the production floor were aware of the effects of this longer cycle time on the profitability

Plastics News • June 2015 • 32

of the job, they probably would have taken the time to further optimize the cycle. So you have 2 potential areas that you can fix pretty easily. First, if you do not have injection molding experts in your plant who fully understand the 3 components of cycle time and how to reduce them, you’ll never get optimum cycles. That’s where training comes in. Second, if you do have molding experts on the floor fully capable of minimizing cycle time but they don’t understand the economics of cycle time, they won’t bother trying to reach the optimal 30 second (or below) cycle time. So your molding personnel need both the technical training on how to reduce cycle time and theawareness of cycle time economics. "Molding cycle" is an index for evaluating the production capacity of injection molding. A molding cycle is the unit of time from starting one injection molding operation until it is ended. In more concrete terms, a molding cycle consists of the following. Molding cycle (seconds / shot) = Mold closing time + Filling time + Holding (packing) time + Cooling time (including the charging time) + Mold opening time + Product taking out time As the molding cycle becomes shorter, it becomes possible to increase the quantity of production of the molded product per unit time. Example: Consider that there is a mold whose molding cycle at present is 10 seconds.

By modifying the cooling circuit of the mold, the cooling efficiency was increased, the cooling time was reduced, and as a result, it was possible to make the molding cycle 9 seconds. What kinds of factors are involved in this case? Example Answer: Since the molding cycle was reduced from 10 seconds to 9 seconds, it became shorter by 1 second. Although it is merely 1 second, if we think of it as a rate of change, it becomes Rate of change=(10−9)/seconds / 10 seconds ×100 =10% And hence the productivity is improved by 10%. If a large number of pieces are obtained from a mold such as 12 or 24 pieces per shot, and if there are many similar molds, the productivity of the entire factory will be improved by 10%, and when converted into money in terms of the production cost, it can become a very large amount. In other words, evaluating the molding cycle directly results in strengthening the profitability of the factory, and not merely reducing by 1 second but leading to an extremely large good effect. Therefore, in the design of a mold, it is very important to consider at all times by how much the molding cycle can be shortened. In addition, it is also very important that the mold designer estimates the target molding cycle. An excellent mold designer always estimates the target molding cycle.


FEATURES

Plastics now capable to resists Chemical attack

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hile you may wonder what are we talking about but that’s it. Yes now we have a technology that could resist the chemical attacks on plastics equipments done at hospital by the clinical disinfectants.

US firm RTP Company has developed a proprietary alloy technology designed to maintain strength, functionality, and integrity, under repeated exposure to hospital cleaners used to disinfect medical devices. Known as the RTP 2000 HC series, these thermoplastic compounds can help solve cracking issues in existing devices and open a new realm of possibilities for the design of hospital equipment and plastic housings that require frequent disinfection, such as mobile ultrasound and x-ray machines, enteral feeding devices, drug infusion pumps, blood filtration equipment, and more. The RTP 2000 HC series provides a unique solution to a widespread problem: the damage and premature,

catastrophic failure of plastic devices, equipment, and housings caused by harsh cleaners and disinfectants used in medical settings.

The best performer was optimised for physical properties, chemical damage resistance, colourability and flammability.

Medical facilities are acutely aware of the risks associated with hospital acquired infections, with as many as 2 million new cases and US$11 billion in additional costs per year in the US alone. To reduce these risks, medical facilities have increased the amount of harsh chemicals for sanitization purposes and the frequency of their use, only to discover that these cleaners cause cracks and degradation in plastic equipment and housings – and replacing them is costly.

The RTP 2000 HC series is available globally in flame retardant or nonflame retardant versions, and the compounds are colourable. It is also available in sheet format in thicknesses ranging from 0.5080.635 mm through Engineered Sheet Products (ESP), a division of RTP.

In developing the RTP 2000 HC series, engineers from RTP tested numerous polymers for damage resistance to six popular chemical classes of hospital cleaners and disinfectants. Moulded compounds were subjected to stressors in order to replicate field failures and relative resistance.

OEMs and injection moulding companies that create parts, housings, and equipment for medical facilities can use the RTP 2000 HC series thermoplastic compounds as a direct replacement for other amorphous resins such as PC/ABS and PC/PBT. The series is said to have proven performance for chemical resistance under moulded in stress conditions, allowing OEMs and injection moulders to improve the quality and service life of their medical devices. So no more attacks on plastics..

Coca-Cola debuts PET Plant Bottle

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oft Drinks major Coca-Cola has been following the eco friendly approach for quite long and in its endeavor to promote Bio degradable it has innovated a PET Bottle made from Plants. Coca Cola launched the world’s first PET plastic bottle made entirely from plant materials at the 2015 World Expo in Milan, Italy. PlantBottle packaging uses patented technology that converts natural

sugars found in plants into the ingredients for making fully recyclable PET plastic bottles. The packaging looks, functions and recycles like traditional PET but has a lighter footprint on the planet and its resources. Innovation comes from inspiration, and at The Coca-Cola Company we are greatly inspired by the very people who drink our beverages. Our

consumers expect us to deliver the beverages they know and love in a package that meets their needs such as convenience and safety, but also in a package that is environmentally considerate says Mackenzie Anderson. PlantBottle™ packaging has been meeting consumer expectations since 2009. The first-ever fully recyclable PET plastic beverage bottle made partially from plants looks and

33• June 2015 • Plastics News


FEATURES functions just like traditional PET plastic, but has a lighter footprint on the planet and its scarce resources. Since its introduction in 2009, PlantBottle packaging has been distributed in a variety of packaging sizes across water, sparkling, juice and tea beverage brands—from CocaCola to DASANI to Gold Peak. Today, PlantBottle packaging accounts for 30 percent of the Company’s packaging volume in North America and 7 percent globally, some 6 billion bottles annually, making The CocaCola Company a large bioplastics end user. PlantBottle packaging is reducing our dependence on fossil fuels and increasing our use of renewable materials. To date, more than 35 billion PlantBottle packages have been distributed in nearly 40 countries. The technology has enabled us to eliminate the potential for more than 315,000 metric tons of carbon dioxide emissions—equivalent to the amount of carbon dioxide emitted from burning more than 743,000 barrels of oil—and save more than 36 million gallons of gas. The innovative PlantBottle Technology™ has resonated with consumers, helped boost sales, generated headlines, and earned sustainable and innovation awards. From inception, we envisioned licensing PlantBottle Technology to non-competitive companies, based on the belief that we have a responsibility to work with others on solutions to our collective environmental challenges. In 2011,

Plastics News • June 2015 • 34

The Coca-Cola Company licensed PlantBottle Technology to H.J. Heinz for use in its ketchup bottles. In 2013, Ford Motor Company announced plans to use the same renewable material found in PlantBottle packaging in the fabric interior in certain test models of the Fusion Energi hybrid sedan. And in 2014, the first reusable, fully recyclable plastic cup made with PlantBottle Technology rolled out in SeaWorld® and Busch Gardens® theme parks across the United States. Committed to collaboration, in June 2012 and in partnership with Ford Motor Company, H.J. Heinz Company,

NIKE, Inc. and Procter & Gamble, we announced the formation of the Plant PET Technology Collaborative (PTC), a strategic working group focused on accelerating the development and use of 100 percent plant-based PET materials and fiber in their products. Together we are supporting and championing research and expanding knowledge toward technology that will enable commercially viable, sustainably sourced, 100 percent

plant-based PET plastic while reducing the use of fossil fuels. While pleased with our progress so far, we’re not fully satisfied. True innovators keep innovating and so our work continues. We have a goal to convert all new PET plastic bottles, to PlantBottle packaging (up to 30% plant-based) by 2020. In addition, partnering with select biotechnology firms we are working to move from lab to commercial scale in producing a 100% plant-based PET plastic bottle These companies are helping us make a significant step toward our vision of commercializing PlantBottle packaging made entirely from plantbased materials. After all, our ultimate goal is a 100 percent renewable, responsibly sourced bottle that is fully recyclable. Since 2009, Coca-Cola has distributed more than 35 billion bottles in nearly 40 countries using its current version of PlantBottle packaging, which is made from up to 30% plant-based materials. According to the beverage company, the use of PlantBottle packaging has helped save the equivalent annual emissions of more than 315,000 metric tonnes of carbon dioxide. PlantBottle packaging can be used for a variety of packaging sizes and across water, sparkling, juice and tea brands. Coca-Cola currently uses sugarcane and waste from the sugarcane manufacturing process to create PlantBottle packaging. Both materials meet Coke’s sustainability criteria to identify plant-based ingredients for PlantBottle material.


FEATURES

Malaysia on its way to ‘Go green’

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he Malacca state government, which aims to become a green state by 2020, is implementing plastics-free packaging effective September 1 this year. The State Education, Higher Education, Science and Technology, Green Technology and Innovation Committee Chairman Md Yunos Husin said that use of biodegradable bags is allowed. Other packaging alternatives will also be explored.

Prior to the full implementation of the ban, the Malaysian state enforces Non-Plastic Bag Days on Fridays, Saturdays and Sundays. The Malacca government will implement a plastic-free packaging policy in the state effective September 01, 2015.

State Education, Higher Education, Science and Technology, Green Te c h n o l o g y a n d I n n o v a t i o n Committee chairman Datuk Md Yunos Husin said under the policy, traders would only be allowed to use biodegradable bags. “The policy is being implemented with the future of the coming generation at heart as plastic pollutes the environment due

to it being non-biodegradable. “With this, all approval to provide plastic bags to customers at RM0.20 per bag will be nullified,” he said after a Workshop On The Setting Up Of Sustainable Schools. Malacca has implemented No-Plastic Bag Days on Fridays, Saturdays and Sundays as a preliminary step towards the complete implementation of the effort that was earlier planned for next year. Md Yunos said the Malacca Green Technology Corporation would also meet with traders state wide on providing alternative packaging to consumers. “The move is one among many measures by the state government to turn Malacca into a green state by 2020.” Accoording to reports the ban will first come into effect for all cafes, government buildings, food premises of local authorities and schools canteens. From September, it will come into full force for all food premises, including those located in private buildings throughout the state. M a l a c c a G r e e n Te c h n o l o g y Corporation chief executive officer Datuk Kamarudin Md Shah was quoted in local pressas saying that the programme ‘Malacca Without

Polystyrene’ intends to reduce the use of polystyrene. To replace polystyrene containers, food sellers and the public are encouraged to use biodegradable food packaging such as those made from sugar cane bagasse, corn or tapioca. Kamarudin also warned that stern action would be taken. Those defying the ban may find that they will not be able to renew their trading licenses. With this announcement, Melaka will be the third location in Malaysia to take a stance against polystyrene food containers. Penang was the first to ban the use of these containers, effective December 01, 2012, and on January 0 1 last year, Sibu became the first town in Sarawak to ban polystyrene takeaway containers. Both Penang and Sibu have enforced that biodegradable paper boxes be used to package takeaway food. While polystyrene is still widely used in other packaging, especially for electrical items, the highest use and throw frequency for polystyrene is for food, which we ‘tapau’ every day. Polystyrene is a type of plastic and the soft foamy form, also widely known by its trademark name Styrofoam is what we are familiar with. Many of us eat out of polystyrene containers at work, at schools and at events where food is sold or distributed to the masses. What makes these containers so bad that towns, states and even countries are starting to impose a ban on their use?

35• June 2015 • Plastics News


FEATURES

Asia takes a spin on waste plastics Angelica Buan

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n Asia, the increasing heaps of waste plastics outshine the usefulness of plastics. As a solution, recycling is regarded as the most effective form of making use of waste plastics, yet, growth in this mode is still moderate, says Angelica Buan in this report.

Plastics litter piling up from Asia The false image painted of plastics being a nuisance and responsible for clogged water ways, marine litter and climate change, may take a toll on the industry’s growth, according to speakers at the Asia Plastics Forum held during the Plastindia show in February at Gandhinagar, Gujarat. Industry delegates during the conference observed that, especially in packaging, the increasing volume of plastic wastes is the negative payback for using too much of plastics. The issues ranging from marine litter to mismanaged landfills have spurred measures like plastic bag bans, which, consequently, affect the industry. As demand surges for plastic packaging, more waste management issues are created. A highly-publicised issue, marine litter, has been trending lately in the plastics sector. A new study published in the Science journal, finds that the massive bulk of plastic garbage that litter the oceans comes from Asian countries and China. The latter’s heavy coastal population has been estimated to contribute 1.3 million to 3.5 million tonnes of plastics waste/year.

Plastics News • June 2015 • 36

Eight countries in Asia are also found to be top contributors to the 8 million tonnes of waste plastics produced. These include Indonesia, Philippines, Vietnam, Sri Lanka, Thailand, Malaysia and Bangladesh. The amount is projected to increase ten times by 2025, without inadequate waste management systems. The study suggests that insufficient infrastructure for waste management and disposal could not cut back the stream of wastes being generated. Even the US, which has a welldeveloped infrastructure for handling solid waste, still contributes 40,000 to 110,000 tonnes/year of waste. The study drew its findings from waste plastics generated from coastal population areas using indirect methods to measure how much of the waste was not properly disposed of, and estimated the quantity of the waste that would end up in oceans.

Recycling vs waste disposal According to the United Nations Environment Programme (UNEP), in Southeast Asia, solid waste management is expensive and mainly involves collection and transportation, which are also labour-intensive areas. In many cases, the cost is passed on to the public sector. Already, privatisation (of waste management services) is practiced in Singapore, Malaysia, Thailand, Philippines and Indonesia. Waste plastics also constitute waste

from the raw materials that are used to produce end-products. About 4% of the global oil production is used as feedstock to produce plastics and a further 3-4% is utilised to provide energy for their manufacture. Sustainable consumption and production of plastics to minimise the use of virgin materials and green gasses emissions, while delivering clean material cycles, are current practices, according to a report from Austria-based International Solid Waste Association (ISWA). In a paper published by UK’s national academy of science, The Royal Society, in 2009, it said that the current applications for plastics in disposable products or in durable polymer-based items that end up in landfills after end-of-life use, are not sustainable. Recycling can reduce the impact of these unsustainable practices to the environment. It, thus, provides opportunities to reduce oil usage, carbon dioxide emissions and the quantities of waste requiring disposal.

Varying recycling rates for Asian countries Several Asian countries are continuously improving their recycling rates. China has had a steady increase of domestic collection and utilisation of plastic scrap, pegged to have reached 30% in 2013, according to the Plastics Recycling Committee (PRC) of the China Plastics Processing


FEATURES Industry Association. The association also cited that within the Chinese plastics recycling industry, more than 40% of the total volume is managed by medium-sized or large companies that are mostly located in the coastal regions. The country has also paved the way for other novel means of repurposing plastics. For example, in the capital city of Beijing, recyclable plastic bottles can be exchanged for subway credit, usually between US$0.05 and US$0.15 cents. The city government and recycling firm Incom have recently installed more PET bottle-to-subway credit reverse vending machines in rapid transit stations across Beijing, after the scheme gained a large following since its launch in 2012.

The rPET also represents a significantly improved technology for production from recycled PET, which can also enable producing larger volumes of the bottles. The technology used allows an extensive process of selection, crushing, washing and drying to produce pure, rPET, say the suppliers. India, which is forecast by the Asian Development Bank (ADB) to likely outpace China’s economic growth this year to 2016, may also face environmental mayhem as a result of its industrial growth. Data from the World Bank indicate that while highincome countries generally produce more waste per capita than low-income ones, India and parts of China are found to generate high volumes of rubbish.

The machine, with its built-in scanners, detects the type and weight of the plastic to determine its value. The bottles are also crushed and sorted by colour and type by the machine.

In Mumbai, more than 450 g of material a day goes to the bin, accounting for more than 6% of the entire country’s waste. The nearby Deonar dumpsite is also amongst the largest of its kind in the world.

Meanwhile, in Hong Kong, a newly launched recycled PET bottle has received recommendation from USbased Ocean Recovery Alliance (ORA), a non-profit organisation. Watsons Water, a leading manufacturer of pure distilled water in Asia, has turned to rPET bottles for its product.

According to the study, on top marine polluting countries, India was cited as responsible for dumping an estimated 0.24 million tonnes of plastic every year; whereas the amount of mismanaged plastic waste per year amounts to approximately 0.6 million tonnes.

Claimed as the first in Asia to be made of 100% rPET, the new bottle will create a positive impact on sustainability in packaging and promotion of the circular economy whereby materials and products are designed for recycling, according to Douglas Woodring, founder of ORA.

Honing into Southeast Asian countries In Singapore, recycling waste is reported to have declined by 1% in 2014 from 61% rate a year ago, according to data from the National Environment Agency.

The country’s target of reaching a recycling rate of 70% by 2030 may fall short of expectation with the reported drop, quoted to be the first time in 15 years. On the other hand, Thailand shows an uptrend in its recycling rates, according to analysis from Bangkokheadquartered Kasikorn Research Centre. In 2013, Thailand recycled over 0.8 million tonnes of plastic scrap, increasing 48.8% over 2012 when only 0.5 million tonnes was recycled. The value of resin from recycled plastic in Thailand may reach THB23.56 billion in 2014, up 14.7% year-on-year. Moreover, the presence of large local and international recycling operators, who are highly-experienced in the field, particularly in sorting waste, is pushing up recycling rates. Hence, the research projects that the proportion of plastic waste going into the recycling process will jump to 40% this year from 37.9% in 2014. Also this year, the market for resin from recycled plastic is expected to grow to nearly 23% year-on-year to almost THB30 billion.

Recyclable waste trade opportunity – China biggest The scale of recycling may vary from country to country, sometimes, regardless of the adequacy of recycling systems. Since recycling, a mode of waste management is still capital and labour-intensive, this affects how the waste is handled. In this context, globalised trade in waste plastics is becoming a favoured option.

37• June 2015 • Plastics News


FEATURES According to ISWA, recycling operations for traded recyclable wastes are being shifted to Asia, accounting for 40% by weight of total world production, with China being the largest single country accounting for 24%. ISWA suggests that the drivers were “increasing local demand and lower costs on labour as well as environmental and health and safety costs, due to the initial absence of regulations and/ or their implementation in both manufacturing and reprocessing.” Most of plastic waste exports (by weight) from Europe go to China and Hong Kong, it said.

the University of Bologna, School of Economics, Management and Statistics.

Recycled plastic trade is a lucrative business. The market for waste is now worth an estimated US$443 billion, according to an article published by

According to a paper by the Institute of Developing Economies Japan External Trade Organisation (JETRO), China began importing recyclable

Leading the league for used plastics import is China, which ISWA said needs affordable secondary plastics to meet the increased demand for plastic products, which are partly coming from local recycling, and partly from the international market. However, the locally recycled plastics are found to be mostly inferior and not suitable for use in larger, more advanced manufacturing facilities for export goods.

waste in the 1990s because of scarcity of locally sourced raw materials. The country then imported various recyclable waste to sustain its high economic growth, nevertheless it also has had issues of environmental pollution being generated by improper recycling. Meanwhile, global economic integration is also driving the international trade of recyclable waste, including hazardous wastes. Transboundary movement of these wastes have yet to be looked into seriously and appropriate trade regulations should be adopted and enforced, according to JETRO. (Courtesy:PRA)

Show Review: Full order booked for POLYSTAR at NPE 2015 In March 2015, POLYSTAR showcased its latest film recycling technology in Orlando USA. The re-engineered cutter-compactor recycling line was first introduced in K show 2013 and has been demonstrated throughout important exhibitions worldwide. Both long-term and new customers took the opportunity to discuss current and future machinery requirements with POLYSTAR as well as the right solutions for different recycling needs. Important sales projects were finalized during the exhibition for US as well as Central and South American customers. Many have already ordered their second and third recycling lines during NPE after having experienced their first re-engineered line for 1 ~ 1.5 years since K show 2013. From Canada

Plastics News • June 2015 • 38

to the US, from Mexico to Chile, customers from North, Central and South America are providing positive feedback on their experience with POLYSTAR’s recycling machines. “The visitor quality during this year’s NPE was surprisingly high”, says POLYSTAR regional sales director Aria Chen. “Most customers who visited our booth were experts from the corresponding industries, mainly in flexible and woven packaging production as well as plastics recycling – and knew precisely what they wanted. Visitors will see live in action of a Polystar recycling machine again in Full Plast (Chile), Plast Eurasia (Turkey), Taipei Plas 2016, Plastimagen (Mexico) 2016, and K Show (Germany) 2016

POLYSTAR at NPE 2015

Polystar in Arabplast 2015


FEATURES Supported by:

Organised by

Supported by:

INDIAN PLASTICS FEDERATION

Still haven’t booked your stall? What are you waiting for? Top Plastic Industries have already signed up and are occupying premium positions. Book your stall immediately online at www.indplas.in and reserve your seat in the most promising developing market in India.

: www.facebook.com/indianplasticsfederation : @ipf_india : www.youtube.com/IPFINDIA

Platinum Sponsors:

Gold Sponsors: PRATAP GROUP OF COMPANIES

Silver Sponsors:

Support Associations:

39• June 2015 • Plastics News


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FEATURES

Plastics News • June 2015 • 42

Repeat - May


FEATURES

ZAMBELLO counter-rotating twin-screw extruders Parallel type

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lthough the range of gearboxes for counter-rotating twin-screw extruders used for medium, high and very high torques is already very wide, Zambello updates it constantly both with new sizes of standard products and tailored gearboxes for the exacting needs of customers.

NRB series - With a transmissible torque density up to 17 Nm/cm3 per shaft The gearboxes of the NRB range have a horizontal shape (mounting position B3), which requires a connection to the electric motor by belts and pulleys. As a matter of fact, the reduction ratios available cover a ratio up to a maximum of i=25. ZT3 series - With a transmissible torque density up to 17 Nm/cm3 per shaft The gearboxes of the ZT3 series have approximately the same features as the NRB series, but have a vertical

shape (mounting position B7). In this case the connection between gearbox and electric motor is carried out by an elastic coupling. Due to the possibility to mount the electric motor in the U arrangement, the final result is a very compact extruder. Reduction ratios available go from i=14 to max. i=80. TST range The TST range (Twin Super Torque) is available in two versions: TST-H and TST- 2H. Both series offer very high performance rates. TST- H series - With a transmissible torque density up to 20 Nm/cm3 per shaft.

torque density up to 22.5 Nm/cm3 per shaft.

The gearboxes of this series are designed for exacting applications, where a high torque is required, which is transmitted by means of a single reversing unit. The connection to the electric motor is obtained by means of an elastic joint. The reduction ratios available go from i=14 to max. i=80.

The gearboxes of the TST-2H series present the highest technical level for which these are the best worldwide for heavy-duty jobs. The transmission of the torque is obtained by means of a double reversing unit. The reduction ratios available go from i=14 to max. i=80.

TST- 2H series - With a transmissible

Conical type As a completion of the range of gearboxes for counter rotating extruders, Zambello proposes the new ZC3 gearboxes for conical twinscrew extruders. At the moment the new gearboxes are available in three sizes, which are suitable for extruders having screw diameters of 55 mm, 65 mm and 80 mm. The essential feature of these gearboxes consists of ground conical gears according to AGMA 11 - DIN 3. Like the entire range of Zambello, also the gearboxes ZC3 enable an extremely high transmissible torque

43• June 2015 • Plastics News


INTERNATIONAL NEWS

Sunoco Logistics acquiring rights to build two 350 mile pipelines to Marcus

WPC supports G7 leaders marine plan

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unoco Logistics confirmed that it is acquiring the rights to build two 350 mile pipelines through Ohio and West Virginia to the Marcus Hook Industrial Complex as part of its Mariner East 2 project, which would bring natural gas liquids such as propane, butane and ethane for storage and distribution to domestic and international markets.

According to Bloomberg, Sunoco Logistics has been moving about 70,000 bpd of propane from the Marcellus Shale in western Pennsylvania to Marcus Hook. Most of the 350 mile line travels along an 8 inch line, although a new 12-inch line was constructed to connect a 50-mile stretch between Houston, Pa. and Delmont, Pa. Current plans for Mariner East 2 anticipate

that a single line running from Ohio through West Virginia to Delaware County would carry 275,000 bpd. Sunoco Logistics has estimated that the construction of a 300 mile line for this 350 mile project would cost about US$2.5 bln. The cost of constructing a twin line are not yet available. However, Shields explained that if two lines are constructed, one would be 16 inches in diameter and the other would be 20 inches, allowing for an additional capacity between 225,000 barrels to 400,000 barrels per day. The total capacity of both the Mariner East 1 and 2 projects would be 745,000 bpd, according to Shields. Construction on Mariner East 2 is planned for 2016 with operations beginning later that year.

Packaging firm Liqui-Box expands its business reach to America

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ustainable packaging firm LiquiBox has extended its offering into America following investments announced last year in its Wythenshawe -based manufacturing plant. According to the company the new high capacity multi-lane bag machine, vision inspection systems, and an additional beverage bag-line are now fully commercial. Liqui-Box can now also offer an expanded portfolio of multi substrate and EVOH film structures combined with the company’s proprietary

Plastics News • June 2015 • 44

fitment solutions. Ken Swanson, chief executive of Liqui-Box, said: “Our recent wins and growth in Europe continue to support our long term commitment in the region.  He also added that the new equipment investments producing Liqui-Box’s uniquely designed products make for a winning combination, giving our customers many great options to shift to a better performing package and dispensing system that is more economical and sustainable than the alternatives.”

he World Plastics Council has welcomed news that leaders of the G7 group of countries laid out a “bold action plan” to cut marine litter while at the recent summit in Germany.

Abdulrahman Al-Fageeh, newly elected WPC chairman, said: “The plastics industry is contributing a number of concrete solutions to this global challenge. “One of these solutions is the Operation Clean Sweep program which is currently being rolled out, globally and along the value chain. “The plastics industry is successfully contributing to reducing the loss of plastic WPC also welcomed that the G7 leaders underlined the importance of improving countries’ systems for waste management, reducing waste generation, and encouraging reuse and recycling. The council was created during the K show in 2013 and set marine debris and post-consumer recycling and energy recover as its initial top priorities. The group was initiated by Brussels-based PlasticsEurope and the Washington-based American Chemistry Council’s Plastics Division. Current members include companies from China, the Americas, Europe and the Gulf. pellets. We are pleased that the G-7 leaders have recognized this as an important measure.”


INTERNATIONAL NEWS

EPS ban in New York

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ingle-serve foam containers will be banned in the city of New York starting July 1.The single-serve foam containers that come with New Yorkers’ coffee, lo mein and other food to go are about to hit the road themselves.

resolved. Also, businesses with annual revenue of $500,000 or less can apply for an exemption. According to reports business owners have started to think about alternatives and how they will be affected as the city moves toward materials considered greener.

Next month, New York will become the largest city in the country to prohibit restaurants and other food establishments from putting their victuals in expanded polystyrene. Enforcement of the ban won’t begin for six months, though, and the moratorium could be extended until a legal challenge by the foam industry is

Most say foam containers cost less than half as much as the cardboard or plastic ones that will remain legal, although when former Mayor Michael Bloomberg administration pushed the foam ban through the City Council in 2013, city officials said the price difference was marginal and getting smaller.

PET imports into USA declines

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mports of polyethylene terephthalate into the US have declined and have also been coming from a changing mix of sources in the wake of an anti-dumping investigation. According to reports, the US Department of Commerce has commenced investigations into alleged dumped and subsidized PET resin. The Department of Commerce will have determinations on preliminary countervailing duties this month and determinations on preliminary antidumping duties in August, the Department of Commerce said. US producers DAK Americas, M&G Chemicals and Nan Ya filed a petition with the US International Trade Commission on March 10 claiming damage due to dumping by producers in Canada, China, India and Oman and

by government subsidies to producers in China, India and Oman. Increasing amount of West Coast imports have come from Taiwan instead of China, and a producer said the East Coast has seen an increase in imported Brazilian product. US PET producers have also claimed a larger market share since the anti-dumping investigation, sources have said. it is expected to see prices of imported Chinese PET to drop due to the risks of duties that may be applied to the product. From 2012 to 2014, Canada, China, India and Oman provided 55.83% of US imports of the PET specified in the petition, according to ITC data. The four countries supplied a combined 820,000 mt over that period, with imports from China and Oman increasing 70.9% and 53.3%.

New Yorkers on the whole appear more enthusiastic about the ban than merchants are.In a 2013 Quinnipiac University poll, 69 percent of city voters supported the ban, which they said was justified because plastic foam blows around and becomes litter, takes hundreds of years to degrade and cannot be recycled economically. The city has also said foam cannot be recycled, although the American Chemistry Council has been pushing back against that claim, saying there is commercial demand for recycled EPS.

Iran plans to commission three new petrochem plants by 2016

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ran is reportedly planning to commission three new petrochemical plants by March 2016. According to reports Iran is reportedly planning to commission three new petrochemical plants at Mahabad, Kordestan and Lorest. These facilities are located along the West Ethylene Pipeline in West Azerbaijan, Kordestan and Lorestan provinces. The projects are expected to increase Iran’s low and high density polyethylene production by around 900,000 tons. The necessary feedstock for these petrochemical plants will be supplied by various phases of South Pars gas field.

45• June 2015 • Plastics News


INTERNATIONAL NEWS

US Trade groups call for a vote on chemical regulations bill

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fter decades of attempts, it seems this could be the year the muchmaligned U.S. chemical regulation laws get an update. The House Energy and Commerce Committee on June 3 voted unanimously to send to the full U.S. House of Representatives floor a bill (HR 2576) to reform the 1970s-era Toxic Substances Control Act (TSCA). Meanwhile, across the Capitol, the Senate version of the bill (S 697) was approved for the floor by the Senate Committee on Environment and Public Works with a 15-5 vote on April 28. The full Senate has not yet taken up the bill, though pressure is mounting on Senate Majority Leader Mitch McConnell (R-Ky.) to put it on the calendar. In a June 2 letter, more than 145 trade associations, under the banner of American Alliance for Innovation called on McConnell to take up the bill before Congress leaves for its annual month-long summer vacation in August. The more than 40 cosponsors from both sides of the aisle have also begun calling for action on the measure soon. Experts who have long followed the ups and downs ; mostly downs of TSCA reform over the years remain optimistic. During the House committee markup, Rep. Anna Eshoo (D-Calif.), who ultimately abstained from the 47-01 vote to move the bill, offered and withdrew an amendment that would have attempted to address preemption concerns. Attorneys General of 12 states, including California, New York,

Plastics News • June 2015 • 46

Oregon, Massachusetts and Washington, have repeatedly voiced concerns to the committee that changes to the federal chemical regulations should not preempt state laws that have been passed over the years while Congress failed to update TSCA. California’s Proposition 65 is perhaps the most famous of these statutes, requiring businesses to notify citizens when significant amounts of certain chemicals are present in products, workplaces, public spaces or released into the environment. Bisphenol A and PVC have both come under Prop 65 attack in recent years. “In a national economy, a state regulation quickly becomes a national standard, often without the due process and back and forth discussion that comes with rule making at the federal level as well as the expert scientific study at the federal level,” Duvall said. “BPA is a good example,” where the federal government has repeatedly declared it safe yet California, using a different standard, has added it to the Prop 65 list. The question of pre-emption has also hindered TSCA reform progress in the Senate, where Sen. Barbara Boxer (D-Calif.) wants several changes before she will support the bill, including all possibilities of preemption removed from the bill and the naming of specific chemicals as toxic in the legislation, including asbestos. But with 41 bipartisan supporters and numerous Republicans who have not yet taken a position on the bill, Boxer is unlikely to be able to mount a filibuster and hold up the bill

when it reaches the Senate floor. The bigger question, Duvall said, is how the two bills could be reconciled by a conference committee. The House bill is 43 pages long; the Senate’s is 179 pages. The pre-emption provisions in both bills are very different, as are the methods for how the EPA should prioritizing chemicals for review. Once both bills are passed by their respective chambers, members still have to come together to reconcile them, which could be contentious. “The Senate is shooting for a more comprehensive overhaul of TSCA whereas the House is looking for a very targeted approach.

UK inflation returns The UK’s flirtation with deflation lasted but a month, with the Consumer Prices Index (CPI) rising 0.1% in the year to May, after April’s 0.1% fall. Transport costs were the prime driver behind the increase, according to the Office for National Statistics (ONS), “with the timing of Easter in April a likely factor in the movement”. The ONS said the largest downward contribution came principally from games, toys and hobbies, notably computer games, and data processing equipment, principally computer peripherals such as printers and routers. There was a smaller downward contribution from price movements for alcoholic beverages and tobacco, particularly wine, it added.


INTERNATIONAL NEWS

Dallas does away with its bag fee, rejects plastic bag ban

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allas is the latest U.S. city to push back against plastic bag taxes and bans with a 10-4 vote on Wednesday to repeal the city’s 5-cent bag fee. The City Council also rejected an attempt to ban plastic bags outright, voting against Councilman Dwaine Caraway’s proposal to ban plastic bags 9-6.

Since June 8, 2015, all bags are available and paper bags will be free at Dallas retailers.The ordinance taxing plastic and paper bags became a hotter-than-usual issue May 1, when a group of bag manufacturers and recyclers filed suit against the city.

The lawsuit, brought by Hilex Poly Co. LLC, Superbag Corp., Inteplast Group and Advanced Polybag Inc., alleges that the 5-cent-per-bag tax passed by the City Council in March 2014 violates the Texas Solid Waste Disposal Act. When the Dallas ban was passed, then-State Attorney General Greg Abbott was already looking into whether bag bans or taxes were legal in the state. He eventually concluded that such ordinances were a violation of state law. No other action has been taken on the nine other existing bans or fees in the state. Abbott has since been elected governor of Texas.

While bag bans and fees have not been as popular in Texas as in some other states, the backlash against them is growing everywhere. In April, the Huntington Beach, Calif., city council voted 6-1 to repeal its 2-year-old ban on plastic and 10-cent fee on paper bags. And while California voters will decide on a bag ban for the entire state next November, other states are doing exactly the opposite. In April, Arizona Gov. Douglas Ducey (R) signed a law prohibiting local bans, taxes or fees on plastic bags and other containers

Action ‘needed on redundancy consultations in insolvencies’

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he collective redundancy process in insolvencies needs government action to help reform, according to insolvency trade body R3. In response to the ‘call for evidence’ the organisation is calling for a number of measures including clear guidance from government and reform of the ‘protective award’ compensation regime, which currently sees the taxpayer foot the bill for incomplete redundancy consultations. Current rules require 45 days of redundancy consultation, and alternatives to redundancy to be discussed. Insolvent businesses however, do not have the funds to comply and there are rarely any realistic alternatives, said R3. The government ‘call for evidence’ is very welcome. This is a perfect chance to embrace the calls for reform and sort out the very real problems

that exist with trying to consult on redundancy when companies fail. Existing consultation requirements are near impossible to fulfil in many company insolvency situations. This is a hopeless state of affairs which needs to be addressed urgently. “Clear guidance is needed from government. Insolvency practitioners will try and save jobs and businesses, but the rules on what they should do when they can’t are problematic and unworkable. R3 has called for clarity now for some time. The government needs to work with a range of stakeholders, from the unions to the insolvency profession, to achieve meaningful reform. If a full consultation cannot be completed, the insolvent company may be required to pay employees a ‘protective award’ by an Employment Tribunal. Since the company is insolvent,

this award is usually paid by the taxpayer via the National Insurance Fund – the fund then seeks to recoup this payment from the insolvent company’s remaining assets later on. Tate added: “The existing protective award scheme does not work. The current legislation intends that the awards be a penalty for nonconsultation, but the company’s management has no incentive to avoid the penalty: they are no longer involved or liable by the time the penalty is awarded. The award punishes the taxpayer in this situation and there is little deterrent. A protective award in insolvency becomes a penalty borne by the taxpayer and the other creditors of the failed business.

47• June 2015 • Plastics News


Business NEWS

DSM, NHU come together to form DSM NHU Engineering Plastics

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oyal DSM, the global Life Sciences and Material Sciences company and NHU have formed a new joint venture company for the market development and manufacturing of high performance plastics compounds based on polyphenylene sulphide (PPS).

According to the company the new venture will be of immense help. The compounds will further enhance DSM’s offering in the high performance engineering plastics space, adding to its leadership positions with Stanyl® polyamide 46 and Stanyl® ForTii™ polyamide 4T. All sales at the joint venture, including those in China, will be handled by DSM’s Marketing and Sales organization with the brand name of Xytron™ PPS. The joint venture, DSM NHU Engineering Plastics (Zhejiang) Co Ltd, in which DSM will hold a 60% share and NHU 40%, will be located at Zhejiang, Peoples Republic of China. It will produce a range of high performance engineering plastic compounds based on PPS polymer produced by NHU. The partners do not disclose financial details of the agreement or information on the capacity of the new operation. Products will be targeted principally at Automotive, as well as in Electrical and Electronics, and Industrial markets. Subject to anti-trust and other approvals from the relevant authorities the transaction is expected

Plastics News • June 2015 • 48

to close within a few months. The partnership will benefit from a commitment by NHU to long-term supply of PPS polymer from its existing plant in Zhejiang. This plant uses proven technology to provide high quality base polymer for compounds. NHU will also contribute its existing compounding capacity to the JV. DSM for its part brings its longstanding expertise in application development and materials science, as well as access to its global customer network. “The new joint venture will help DSM deliver on its growth strategy, and will reinforce its High Performance Plastics portfolio as a key growth driver”, says Roelof Westerbeek, President DSM Engineering Plastics. “PPS fits very well alongside our current range of materials, and will be particularly useful for us in presenting complete solutions for customers operating in key markets, especially automotive, electrical and electronics. PPS has a long and successful track record and a promising future, and we are very excited about presenting it to existing and new customers. We already know that the addition of PPS products into our product portfolio will be highly appreciated by our existing global key customers. It will strengthen DSM’s position as a preferred solutions provider and strengthen our current product portfolio.

Tosoh and Chemtura signs LoI

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hemtura and Tosoh have signed a letter of intent, under which Tosoh will promote and sell Chemtura’s Emerald Innovation 1000 flame retardant product to customers in Japan. Under the terms of the agreement, Tosoh will also obtain a license to manufacture the new polymer-based bromine flame retardant using its proprietary production technologies for sale to the customers. In a bid to further expand sales in the domestic market, the company also plans to work on new applications for the product. Completion of the arrangements is subject to satisfaction of both the parties’ corporate requirements. Tosoh plans to launch sales for the product sometime during 2015. Developed and manufactured by Chemtura, the products have been designed to replace decabromodiphenylether and decabromodiphenylethane in various end-use marketsThe companies jointly announced that they propose innovating new technologies and provide better products that increase fire safety in various markets such as electronics, construction and transportation. Chemtura and Tosoh have selected Japan as the ideal region to promote these products as it uses the new technologies. Tosoh associate director and senior general manager Katsumi Mineshige said: “This relationship will be positive for Tosoh, since it gives us access to Chemtura’s innovative technologies for brominated flame retardants.


Business NEWS

Total Petrochemicals chooses PA as site for new ethane cracker

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o t a l Pe t r o c h e m i c a l s h a s selected Port Arthur as the site for an estimated US$1.6 bln an ethane cracker, likely to start-up as early as 2019. Total, which had filed for state environmental permits and negotiated for a property tax abatement with county officials, previously said Port Arthur was one proposed location for the project. Total had been mulling two different expansion locations, one is Port Arthur and the other in Louisiana, to construct the estimated $1.6 billion project. Melyssa Rodgers, spokeswoman with Total, said the project will require thousands of workers during the engineering and construction phase and once the plant is operational, permanent positions will be created and that number has not been decided. Port Arthur Mayor Deloris “Bobbie” Prince was pleased to hear the Total had selected The Energy City for its expansion. “We are so blessed. We’ve been waiting to hear which side Total was going to choose,” Prince said, referring to Total’s process to select a site for the project. “We are thankful to Total for considering Port Arthur and having actually chosen the city of Port Arthur. Any additional expansion is a boost to our economy and we’re looking forward to that.” Jeff Branick, Jefferson County judge, was likewise pleased with the decision. “Obviously we’re overjoyed by the decision,” Branick said.

“This has the economic impact to create not only full time operational jobs but hundreds if not thousands of construction jobs and that money will turn over in our community and ultimately, for the economy to make us a healthier community.” Rodgers said Total decided on Port Arthur because the city is the best fit for what the company already has. “We intend to launch the FEED (Front End Engineering Design) and to select an engineering company in the coming months,” Rodgers said. “Our anticipated start-up is expected in end 2019.” Representatives of Total sought tax breaks in Jefferson County earlier in the year as well as with officials in Louisiana before choosing the site. Earlier in May the city of Port Arthur approved an expansion of

existing facility agreement with Total for a 10-year term. During the fiveyear construction period the company will receive a 75 percent discount on what the taxes would have been if the facility were located within Port Arthur city limits. During year six, the first year of operations, Total will receive a 90 percent discount;followed by 80% gradually making a 50 percent discount at the 10 th year. Total is eligible for additional discounts above those already granted if the company employs Port Arthur residents and utilizes Port Arthur vendors. Port Neches-Groves Independent School District approved an agreement in late April with Total that amounts to a $108 million tax benefit.

Gekoplast eyes higher sales and acquisitions

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olish plastic panel maker Gekoplast is planning to acquire a local plastics industry player, according to Piotr Górowski, the company’s chief executive. In addition to this, the company aims to spend PLN 7.8m (€1.9m) this year with the aim of expanding its output capacity.

"Over the next year, year and a half we want to move to the main floor of the Warsaw Stock Exchange. We are open to acquisitions, we are carefully observing the market, but currently, we are not holding any

concrete talks,” Górowski. Gekoplast is planning to spend "several dozen millions of zloty” to purchase a local plastics industry player. In 2014, the producer reported revenues of PLN 76.3m (€18.4m).This year, Gekoplast aims to reach an output capacity of 15,800 tonnes. This would represent an incrase of about 16% compared with its current output capacity. "We forecast that, over the next four to five years, we will incrase our share in the European [plastic panel] market to 15%. Export sales represent 50% of our total sales,” Górowski said.

49• June 2015 • Plastics News


Business NEWS

Evonik acquires Monarch Catalyst

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vonik Industries AG, Essen (Germany) has successfully completed acquisition of Mumbai based Monarch Catalyst Pvt. Ltd. According to reports an agreement to acquire Monarch Catalyst was announced in March 2015, subject to certain closing conditions. The company employs approximately 300 employees and will be renamed to Evonik Catalysts India Pvt. Ltd. All of Evonik’s future catalyst activities in India will be operated through the newly acquired company. The parties have agreed to keep the purchase price confidential. Evonik with its Business Line Catalysts is a

global leader in producing specialty catalysts, custom catalysts and catalysts components for the Life Sciences & Fine Chemicals, Industrial & Petrochemical and Polyolefines market segments. Monarch’s global activities in oils & fats hydrogenation catalysts range is a broadening of the Evonik catalysts portfolio. The activated base metal catalysts and precious metal catalysts portfolio strengthens Evonik’s positions in India and the Asia region. Monarch’s existing customer base will continued to be served through the established sales channels.

MRPL starts commercial production of polypropylene from new unit

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angalore Refinery and Petrochemicals Ltd (MRPL), a subsidiary of Oil and Natural Gas Corporation Ltd (ONGC), has begun commercial production of polypropylene from its new unit as a part of its phase III expansion plan.

MRPL has successfully commenced commercial production of polypropylene from its polypropylene (PP) plant as part of its phase III refinery expansion and upgradation project on June 18, 2015. The plant has capacity to produce 440,000 tpa of polypropylene. The polypropylene unit has been set up at an estimated Rs 1,803 crore as part of the refinery’s third phase of expansion. MRPL has completed its phase III expansion project which included capacity addition of 3 MMTPA, polypropylene

Plastics News • June 2015 • 50

unit and single point mooring (SPM) facilitywith the commissioning of petrochemical fluidised catalytic cracking unit (PFCCU).The feed stock for the polypropylene plant, polymer grade propylene, is being produced from upstream petrochemical fluidised catalytic cracking unit (PFCCU). The technology for the polypropylene plant, which has been engineered and constructed by Engineers India Limited, has been provided by Novolen of Germany. With the commercial production of PP unit, MRPL will be able to meet the polypropylene demand from industries such as textile, automobile, plastic product processors, etc in the south India. MRPL PP unit is the only plant in South India, which is estimated to have 5,00,000 tpa demand for polypropylene.

Dow’s Sadara plant expected this year

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ow’s joint venture project in Sadara, Saudi Arabia, will start churning out plastic resins by the end of the third quarter, “plus or minus,” said Diego Donoso Global Business President . The $20bn (€18.3bn) Sadara project between Dow (35%) and Saudi Arabian Oil (65%) has been in the works since 2011 and is expected to bring substantial output to Asia Pacific. The plastic packaging market in China is going through rapid technological expansion and developments, fueling demand for higher performance solutions. That’s exactly what our strategy is focusing on. It’s exactly why we are supporting major investment in Saudi Arabia to bring new capacity,” he added. Sadara is a huge complex with 26 manufacturing units, plastics and chemicals, and the plastics operations are the things that’ll be first ready. Sadara is a small piece of volume comparing to an 85-millionto-90-million tonne industry we have today, it’s a drop in the ocean in terms of the impact.” Donoso added that Sadara will ramp up with very staged penetration.Two thirds of Sadara’s production is expected to supply Asia Pacific. “China is probably going to take a lot of that, because China has the appetite and the rate of growth that not many places have.


Business NEWS

Oman to invest US$7 bln in refining, petrochemicals complex in Indonesia man has committed to invest US$7 bln to build oil storage facilities, a petrochemical plant and a refinery in Indonesia’s Riau province, with the oil products being purchased by stateowned Pertamina. The project is now in the process of issuing of permits, and groundbreaking is expected to begin in 2016.

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the process of obtaining a permit. Ground-breaking of the refinery project is expected to be as early as next year. To date, the country has six oil refineries operated by state owned firm Pertamina. However, the refineries are old and can no longer operate at full capacity, leading to rising imports of petroleum products.

An agreement was also signed for the supply of crude oil, but details on the amount and price were not disclosed. Indonesia’s fuel output has suffered from a lack of investment in its refining sector since the construction of its last refinery was completed in 1994. Oman would supply the required crude oil for the refinery, develop storage facilities, and could later expand into petrochemicals, Energy and Mineral Resources Minister Sudirman Said “It has prepared US$7 billion in total and is now in

Pertamina is currently working to upgrade four of the six refineries so that they will be able to produce more and better products.The Energy and Mineral Resources Ministry’s director general for oil and gas, IGN Wiratmaja Puja, said earlier that the government was working on new public-privatepartnerships for the development of four new refineries in the country. The refinery development is also expected to improve Indonesia’s energy security.

GS Engineering & Construction signs US$4.5 bln petrochem deal in Uzbekistan

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outh Korea’s GS Engineering & Construction Co. has signed a deal on a petrochemical production project in Uzbekistan estimated at US$4.5 bln, Under the memorandum of understanding (MOU) with Uzbekistan’s state-run oil and gas firm Uzbekneftegaz, the South Korean builder will help set up a production unit to make olefin, used in making plastic materials.GS E&C will form a consortium with other South Korean

investors to cover 50 percent of the project cost, while the remaining share will be held by the Uzbek gas company. The two firms are currently negotiating the final cost and production capacity of the olefin facility, GS E&C said.The latest MOU came amid Uzbek President Islam Karimov’s meeting with South Korean President Park Geun-hye on Thursday to discuss ways to boost bilateral economic cooperation.

Indorama acquires PTA business of CEPSA

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ndorama Ventures (IVL), a worldleading producer of intermediate petrochemicals, has completed the 100% acquisition of the PTA business of CEPSA Chimie Montreal, as per The Nation. The 600,000 ton PTA plant will provide Indorama Ventures with feedstock security to better serve its customers and anenhanced leadership position in North America. “With the integration of the Canadian PTA facility, we now have all our global businesses present in North America and I believe this unique position is a win-win since we can now serve our customers more reliably and simultaneously to create accretive returns for our shareholders. Vertical integration into feedstocks has always been an important part of our global business strategy and we are now very excited to have finally completed the loop in our North American value chain,” said Aloke Lohia, Group CEO. “The PTA business in North America is robust and the timing of this acquisition comes with firmer margins and potentially firmer operating rates pending the results of the anti-dumping investigations on imported PET into USA", Lohia added.

51• June 2015 • Plastics News


Product NEWS

Kuhne’s Modular Quick-Change for medical extrusion

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new modular extrusion system enables processors of tubing and other small-diameter medical products to be up and running with a new job just three minutes after the previous run, leaving the tasks involved in die and barrel cleanout to take place outside the clean room environment. American Kuhne’s Modular Quick-Change™ system has four components: an extruder drive module for the clean room; a purge module for the tool room or other maintenance area; and two barrel modules, one used on-line while the alternate is purged and cleaned. At the end of a job, the “dirty” barrel module, including die head, is rolled away to the tool room for cleanout—a procedure that typically takes two hours. The alternate barrel module, preheated and with the new job recipe pre-loaded, can be installed on-line in about three minutes. Based on Single-Minute Exchange of Die (SMED) concepts, the new system is especially suited for medical and other contaminationsensitive applications, according to Bill Kramer, chief technology officer for extrusion systems. “The medical industry demands best practices in machine design that provide stability, efficiency, and control,” said Mr. Kramer. “Beyond these, this SMED solution enables a novel hot-swap process that reduces to minutes what would otherwise take hours and, perhaps more importantly, preserves the clean room environment.” The Modular Quick-Change system is

Plastics News • June 2015 • 52

available for extruders up to 2 inches (51 mm), though custom-engineered systems are available for larger units. How Production Downtime for Job Changeovers Is Reduced: a) Switching jobs. This roughly three-minute process takes place as follows: After dumping unused material from the hopper and vacuuming material from the feed throat, the operator unbolts the dirty barrel module from the drive module, unplugs its electrical connections, rolls it to the tool room for cleaning, and rolls a clean, preheated barrel module to the clean room, where it is positioned for mounting to the drive module. After inserting a feed section liner into the drive module, the operator bolts the barrel module to the drive module, plugs in the electricals, adds material, and starts the new run. b) Purging and cleanout. After inserting a feed section liner into the purge module, the operator puts the purge module into “engage” mode to align the screw keyways, mounts the dirty barrel module to the purge module, turns off engage mode, bolts the barrel module to the purge module, and plugs in the electricals. The operator then unbolts the die head clamp for cleanout, runs out the material remaining in the barrel, and uses a pneumatic screw pusher to remove and clean the screw. After replacing the cleaned screw, breaker plate, and die head, the operator preloads the recipe for the next run and preheats the barrel module to have it ready for use.

Songwon launches SONGXTEND 1301 New stabilizer solution

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stabilizer, specially designed to protect new polymeric flame retardants (pFR) in XPS applications, has been launched by Songwon. Songwon will be launching its new SONGXTEND® 1301 stabilizer for XPS containing new polymeric flame retardants.

This stabilizer is specially designed to protect new polymeric flame retardants (pFR) in XPS applications. As the 2nd generation stabilizer for this market, it maintains better molecular weight and color of XPS containing pFR. In addition, the SONGXTEND 1301 stabilizer offers a broader processing window compared to the current state-ofthe-art stabilizers on the market. “With SONGXTEND 1301, we are very pleased to provide the XPS market with an alternative and upgraded stabilizer,” says Thomas Schmutz, Director Global Technical Service at Songwon. The product demonstrates Songwon’s drive to support masterbatch suppliers and XPS producers meet the challenges of the upcoming change from HBCD to pFR. We consider SONGXTEND 1301 to be the best stabilizer for XPS containing pFR


Product NEWS

Teknors Monprene® CP family of TPEs

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new family of thermoplastic elastomers (TPEs) for consumer products provides vivid color, tactile appeal, and soft-grip ergonomics while spanning a broad range of physical properties and exhibiting excellent moldability. Teknor Apex Company’s Monprene® CP Series compounds are standard products available in identical formulations to customers in North America, Europe, and Asia. Two series are available: Monprene CP-10100 low-density compounds, with specific gravity of 0.89; and Monprene CP-11100 high-density compounds, with specific gravity of 1.15. Initially each series is comprised of six grades with Shore A hardness ranging from 40 to 90. With a light hue in natural form, Monprene CP Series compounds exhibit excellent colorability. All grades are suitable for skin contact and are resistant to cosmetics and household chemicals. When over-molded onto a rigid substrate, they provide a soft grip with ergonomic benefits. The highflow properties of Monprene CP Series TPEs make them suitable for a wide range of part shapes and sizes in

injection, insert, and two-component molding. They exhibit excellent adhesion to polyolefins. Teknor Apex recommends Monprene CP Series compounds for grip, handle, cushion, anti-skid, anti-vibration, knob, and button applications in such products as writing instruments, sporting goods, appliances, tools, personal care items such as toothbrushes and razors, and flexible or soft items like toys. “The versatility of the Monprene CP Series family provides OEMs and molders with great design flexibility,” said Brian Mulvany, senior market manager for the TPE Division of Teknor Apex. “These new materials are safe enough for skin contact yet still tough enough to resist the chemicals commonly found in household cleaners.” Teknor Apex maintains inventories of all standard Monprene CP Series grades to ensure fast and easy sample turnaround for customers everywhere, Mr. Mulvany noted. “We produce these new compounds at all of our TPE manufacturing locations worldwide, ensuring dependable and steady supply in any region around the globe.

HyRobotics debuts EPIK line

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t . L o u i s b a s e d H y Ro b o t i c s Corporation launched a new servo robot, with a Keba controller and motor, aimed at the North American market. HyRobotics calls it the EPIK line (for “excellent programmable injection robot with Keba controller”). At the recently held trade show HyRobotics demonstrated its Muge:in

and Temp:in systems. Muge:in screens out defective products measured by weight, through a specially designed load cell on the robot arm. Temp:in uses the robot arm to detect the surface temperature of the mold or molded parts. Both systems save data, which can be checked on a smart phone.

Battenfeld introduces antiwear solution

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attenfeld-Cincinnati introduced a modular, anti-wear solution for extruders the STC coating (superior tungsten carbide) for extruder screws and barrels. The hard-metal coating is available for Cincinnati-Battenfeld equipment, and for all other extrusion applications, regardless of the equipment’s brand or manufacturer, according to the company. Thus far, hard metal coatings have mainly been used for high-tech applications such as aerospace, motor sports, the petroleum sector and for drilling and machining equipment. If desired, the STC coating can be applied to certain parts of the screw, or the entire screw can be coated.

LEHVOSS Introduces LUVOCOM® LEHVOSS (Shanghai) Chemical Trading Co., has announced the introduction of LUVOCOM® XTF, a new generation of polymers lubricated with an advanced proprietary PTFE formulation. These new high-performance compounds exhibit significantly increased wear resistance, especially at high loads, when compared to standard PTFE formulations. The new compounds are an innovation driven to meet increased requirements combining high pressure and elevated temperature. This new material technology is opening up opportunities in auto & industrials.

53• June 2015 • Plastics News


Product NEWS

Nordson Asymtek automates manufacture of smart assistive-hearing devices

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ordson Asymtek, (Carlsbad, CA), a Nordson company that supplies fluid dispensing and conformal coating equipment, has announced the sale of two Spectrum II S2-922 in-line dispensing systems to GN ReSound (Ballerup, Denmark), one of the world’s largest manufacturers of hearing products. A developer and manufacturer of Bluetooth-enabled, smart hearing aids, GN ReSound presently has an installed base of offline Nordson Asymtek coating systems and Axiom X-1000 dispensers. The Spectrum II systems were purchased to automate production lines for the application of underfill in the manufacture of hearing aids.

“We chose the Nordson Asymtek systems because we are familiar with the brand and have found that the equipment gives us the required performance and flexibility for many different processes needed in conjunction with manufacturing hearing aid electronics,” said Elvin Solberg (pictured), Manufacturing Engineering Manager for GN ReSound. “Before, underfill was done manually off-line. Dispensing underfill inline with the Spectrum II reduces manual handling and gives a more uniform result, a more efficient SMD manufacturing process and better yield,” said Solberg in a prepared statement.

The Spectrum II dispensing platform is a high-speed precision dispensing system for microelectronics, semiconductor, MEMS and manufacturing/assembly applications. It has a small footprint, but accommodates dual valves, up to six heaters and dual-lane conveyance. Parent company Nordson Corp. (Westlake, OH) provides precision dispensing technology, plastics extrusion and injection molding, electronics testing and inspection and surface preparation to a global customer base

Roemheld introduces EN 289–compliant magnetic clamping technology

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ilma-Roemheld GmbH (Hilchenbach, Germany), a global provider of systems for the industrial manufacturing, assembly, clamping and drive industries, has introduced magnetic clamping technology for molds and dies that complies with the EN 289 standard for plastic and rubber molding machines. It Roemheld points out in its release that the Hilma magnetic clamping plates in the M-TECS series are currently the only ones that meet the new version of the European standard, which went into effect in January 2014. They comply with safety requirements related to mold monitoring, power supply, magnetization and emergency

Plastics News • June 2015 • 54

stopping at performance levels D and E. The new controller is available for all magnetic clamping plates in the M_TECS series. They belong to the quick clamping system, which allows dies and molds of any size, geometry and weight to be rapidly positioned and clamped. Roemheld offers a variety of quick clamping systems that are designed for use at varying operating temperatures up to 240°C. All magnetic clamping plates are available with an optional integrated heating unit and are delivered in custom sizes and geometries. Roemheld notes that the magnetic clamping systems can be

easily retrofitted to existing vertical or horizontal injection molding machines, mold carriers and transfer molding. The combined use of long and square poles takes full advantage of both technologies—the high force concentration of the long poles and the inexpensive design of the square poles. Setup times are reduced to just a few minutes, making it convenient for job shops and companies that do a lot of small-series manufacturing. Using magnetic force to clamp the mold reduces the risk of an accident because the machine operator does not come into direct contact with the hot working surfaces.


Product NEWS

Bayer developes scratch-resistant PC film Plasmatreat developes coating ayer MaterialScience LLC has an optional finish. Bayer says it aims developed a scratch-resistant the new Makrofol at OEMs and Tier 1 for stains

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polycarbonate film that is thermoformable, weather-resistant and durable. Makrofol SR 906 is a clear, transparent film with a glossy surface finish. Bayer caps the film with a functional acrylic layer that includes a UV-protective additive. The company claims the film offers a 50 percent scratch resistance improvement over glossy PC films.

suppliers, especially those that use a film insert process exposing the film to high forming pressures. The acrylic cap layer allows back-molding or over-molding with acrylic resins as well as standard PC resins often used on the PC film side. High filmto-resin adhesion helps the film pass typical climate test conditions for auto interiors.

The new product is suited to use in information technology and electrical/ electronic components as well as auto interior parts such as bezels, knobs and switches. Its versatile aesthetics can create appearances ranging from high-gloss, piano black effects to velvet and graphics-friendly, very fine matte surfaces obtainable with

“Makrofol SR 906 film enables the manufacturer to use a scratchand weathering-resistant film to manufacture formed 3-D parts and eliminate secondary coating operations,” notes Chris Cooper, specialty films business development manager for the company based in Pittsburgh.

Conair's Dehumidifying Wheel Dryer In Conair make, Dehumidifying wheel dryer, the molecular sieves film is crystallized on glass fiber substrate forming a rotating wheel. The structure is like Honeycomb. Thousands of small air channels allows process and regeneration air to flow past the desiccant.While most of the wheel is being used to dry the process air and the rest is undergoing high temperature regeneration and cooling.As this is a continuously rotating wheel, these dryers are able to achieve consistent low dew point without any spike. Also these dryers required lower regeneration temperature as there are no binders use and only molecular sieves needs to be regenerated. These dryer also have

fewer rotating/moving parts. These dryers offers following advantages: • Consistent dew point – No Spikes • 33% less energy compare to twin tower dryer • Quick start- as dew point is achieved in 5 minutes • Selectable dew point control and monitor • Lower regeneration temperature • Drying hopper are designed for mass flow and uniform heat/air distribution • F e w e r r o t a t i n g p a r t s , l e s s maintenance, maximum uptime • Less flower space • Fast acting tubular wire heaters

I

llinois based Plasmatreat North America, working with an industry coating specialist, has co-developed a durable plasma coating for plastic food storage containers made with low density polyethylene, polypropylene and PET. The coating prevents the orange stain that results from hot tomato-based products, either heated in the container or put away while still warm.“In addition to being unsightly, this staining is also disconcerting from a health perspective: If pigments from the food are seeping permanently into the plastic, it stands to reason that some of the plastic is making its way into the food, too,” said Andy F. Stecher, Plasmatreat North America’s president and CEO.

Floreon’s PLA patent approved

B

ioplastic technology company Floreon Transforming Packaging Ltd, Hull, U.K., has been granted a patent for Floreon, a biodegradable, polyester-based polymer blend of a standard bioplastic, polylactic acid (PLA). The patented technology yields a resin that is much tougher and easier to process than current materials and has the potential to expand the uses of bioplastics. Produced from sustainable (plant) feedstock, conventional PLA has been characterized for lack of toughness and a tendency to lose strength during storage in warm conditions.

55• June 2015 • Plastics News


Technology

Researchers succeed in recording a binary code on a synthetic polymer Researchers have, for the first time, succeeded in recording a binary code on a synthetic polymer. Inspired by the capacity of DNA to retain an enormous amount of genetic information, a team from the Institut Charles Sadron de Strasbourg (CNRS) and the Institut de chimie radicalaire (CNRS/Aix Marseille Université) synthesized and read a multi-bit message on an artificial polymer. The results were published in Nature Communications. With its 3.4 billion base pairs, human DNA can compile a tremendous amount of information in a tiny space. All of the information stored is expressed using four nitrogenous bases: A, T, G and C. Researchers had previously been able to use the sequencing of these veritable molecular building blocks to reproduce a binary code. However, the technical limits of DNA made it necessary to develop the first synthetic polymer -- cheaper,

more malleable and able to store binary information. This has now been achieved for the first time by a team of French scientists from the CNRS and Aix-Marseille Université. Instead of using the four nitrogenous bases of DNA, in this study the researchers used three monomers . Two of these monomers represent the binary code numbers 0 and 1, and can be used interchangeably during synthesis. A third nitroxide monomer was inserted between the bits in order to facilitate the writing and reading of the coded sequence. A short binary message is synthesized by hand, monomer by monomer on a growing chain. The operation takes approximately a day, but should be quicker once automated. Decoding is done by sequencing, in the same way that DNA has been decoded for decades. A mass spectrometer thus takes less than five minutes to decipher the information -- a

duration also destined to be reduced in the short term. While sequencing systematically destroys the polymer, it is also possible to erase the code at any time and without reading it, by exposure to temperatures above 60ºC or to a laser. Researchers showed that at room temperature, the polymer can be conserved for a number of months, and could even last several years given the molecule’s stability. The team hopes to store messages of a few kilobytes or even megabytes within 3 to 5 years. This technique, patented by the CNRS, also makes it possible to develop molecular barcodes in the short term. Sequences could provide labeling that would be extremely difficult to falsify, ideal for high value-added products such as luxury goods and medicine. The use of monomers and secret codes, known only to the laboratory and the industrial partner, would make it very difficult to produce counterfeits.

Aimplas aids research into insecticide plastic

A

i m p l a s , t h e Te c h n o l o g i c a l Institute of Plastics located in Valencia, Spain, has announced that along with Inesfly Corporation from Valencia and the University of Zaragoza it is working on developing a plastic for the manufacture of sandals and mats which repels insects that transmit endemic diseases. The new generation of foamed plastics will have insecticide properties in order to avoid the transmission of diseases such as malaria, dengue fever,

Plastics News • June 2015 • 56

Chagas’ disease and leishmaniasis. The project called Inmaplesp will last 24 months and is funded by the Ministry of Economics and Competitiveness. The project has a budget of €372,321. So far insecticide substances in plastics have consisted of powder incorporation and were limited to mosquito nets, animal collars, cattle ear tags and anti-mosquitoes bracelets. The Inmaplesp project will see the incorporation of insecticide to material through microcapsules which

will protect the insecticide substance from its possible degradation during processing. Inesfly’s microencapsulation technology has already seen success in the field of insecticide paints. The insecticide containing plastic products, such as sandals and mats, will be useful in Africa, Central America and South America says Aimplas. But the organisation highlights that they will also be useful in Europe, in countries such as Spain, where the effects of climate change is causing plagues of subtropical species like the tiger mosquito.


Technology

KraussMaffei New Small CX Series

K

raussMaffei Technologies GmbH launched its new CX series features many optimizations with regard to energy efficiency, productivity, and space requirements. KraussMaffei has reworked its CX small machine series in the clamping force range of 350 to 1600 kN and consistently taken advantage of every opportunity to increase efficiency. Customers

New CX series features many optimizations with regard to energy efficiency, productivity, and space requirements.

benefit from low expenses for energy, space, time and materials, gaining important competitive advantages in the process. At CHINAPLAS 2015 (May 20 – 23), KraussMaffei showed a new CXV 160 at its booth 5.1J41. From hydraulics to control software to automation, almost every component in the tried-and-true CX machines in the small clamping force range was subjected to testing and numerous improvements were defined. "The CX series is already a successful product line. Our goal was to align this series more consistently with customer needs. Plastics processors should have the option of producing plastic with outstanding cost efficiency and flexibility," explains Dr. Hans Ulrich Golz, President of the Injection

Molding Machinery segment of the KraussMaffei Group. The new CX in the series of small machines up to 1600 kN has now become top of the class thanks to a large number of individual innovations. "We were in fact able to technically implement all of our customer requirements: 10 percent less energy, 15 percent faster, 30 percent quieter, oil volume reduced by 20 percent, and 25 percent greater efficiency; thanks to automation and faster set-up times means 100 percent added value for the customer," says Dr. Golz. Additional highlights specifically for small machines include the new sprue picker, the ejector coupling and the BluePower Vario Drive concept The new CX from KraussMaffei features high productivity and innovative detailed solutions with respect to energy efficiency, automation, space-saving design and zero-defect production.

Process to make a thermoset that can be reshaped and reused A process to make a thermoset that can be reshaped and reused has been developed by researchers at Oak Ridge National Laboratory. The new plastic is a shape-memory polymer, so named because the material can “remember” its original shape and return to it after being deformed with heat or other forces. Orlando Rios from the Department of Energy's Oak Ridge National Laboratory and a team of researchers from Washington State University and the

University of Idaho have developed a process to make a thermoset that can be reshaped and reused. The team's study is published in the journal Macromolecules. The new plastic is a shape-memory polymer, so named because the material can "remember" its original shape and return to it after being deformed with heat or other forces. The materials exhibit tripleshape memory behavior, meaning that the polymers can transform from one temporary shape to another

temporary shape at one temperature, and then back to a permanent shape at another temperature. Rios explains that although researchers have been interested in making use of shape-memory polymers' intriguing characteristics, managing the shape-shifting behavior has been a struggle. "One big issue that has limited their use is controlling the transformation temperatures and their properties," he said. "We give a recipe where you can adjust the

57• June 2015 • Plastics News


Technology transformation temperature and shift the performance of the material." Changing the ratio of ingredients allows the researchers to control the overall properties of the material. The team's method also uses off-the-shelf chemicals that can be easily scaled up to manufacture the material in bulk. "We've taken it from somewhat of a scientific curiosity or fundamental research material to something that can be produced in larger volumes," Rios said. Mixing the shape-memory polymers with other materials could produce

stronger and stiffer composite parts that can later be recycled or reprocessed. Recyclable carbon fiber and glass fiber composites, for instance, are in high demand in the automotive industry. "The ability to control the shapememory behavior of the material provides great design flexibility," said Yuzhan Li of Washington State University. The material could also be used as binding glue for new types of rare earth-free magnets made from powders. The team is already experimenting with 3-D printing

powder-based magnets with shapememory polymers. "The applications for these materials are very broad, since the shape-shifting temperatures for these materials can be finely tuned by controlling the ratio of the chemicals used in their synthesis," said Michael Kessler of Washington State University. The team has filed for a patent on its method.

Graphene 3D Lab introduces water-soluble 3D-printing filament

G

raphene 3D Lab Inc. (Calverton, NY) recently announced its newly developed water-soluble 3D filament, the latest in a line of specialty functional filaments. Elena Polyakova, COO at Graphene 3D, introduced the new 3D filament at the Canadian Manufacturers & Exporters’ Canada Makes: Graphene is a single atomic layer of carbon atoms tightly bonded in a hexagonal lattice, and is a million times thinner than paper, stronger than diamond and more conductive than copper. Polyakova noted that graphene and other nanomaterials can be used to produce many types of advanced 3D-printer filaments, the feedstock for 3D printers.

Filament types include electrically conductive (PC boards and connectors); thermally conductive (heat sinks to reduce overheating of electronic devices); mechanically reinforced; magnetic; transparent (3D-printed lenses, windows and

Plastics News • June 2015 • 58

light guides); and electromechanical devices such as batteries for powering 3D-printed devices. Water-soluable filaments are primarily used to occupy negative space during a 3D print. These filaments are essentially used to fill gaps designed in objects and allow the print to be suspended over air. Following completion of the printing process, the object can be placed in water, and the watersoluble material will completely dissolve, leaving empty space. The new water-soluble filament will work in most commercially available 3D printers and Graphene 3D expects to have them to market within three months. It has no toxic fumes and it is a popular material to work with. we can control the properties of PLA after the graphene is added and can layer the PLA. The company is working on graphene as an additive for a number of different materials for commercial applications. Graphene can be added

to materials used in injection molding applications as well as for electrical and electronic products. One of the reasons that Graphene 3D Lab developed the filament for 3D printing is that they “command very high profit margins,” said Polyakova, “but we also have materials for injection molding applications. Graphene has superior shielding properties—0.3 ohms per centimeter— but electrical conductivity is just one aspect of the material.” Currently the price of graphene is very high, approximately $350/kg. “We expect the price to go down to $100/Kg,” Polyakova said. “If the price goes down, we expect wider applications. Currently we are looking for end markets for our materials. Graphene is an umbrella additive, and we can make changes to materials [resulting] in different properties for different applications. We’re planning on adding more products in the future.


Technology

Researchers succeed in recording a binary code on a synthetic polymer Researchers have, for the first time, succeeded in recording a binary code on a synthetic polymer. Inspired by the capacity of DNA to retain an enormous amount of genetic information, a team from the Institut Charles Sadron de Strasbourg (CNRS) and the Institut de chimie radicalaire (CNRS/Aix Marseille Université) synthesized and read a multi-bit message on an artificial polymer. The results were published in Nature Communications. With its 3.4 billion base pairs, human DNA can compile a tremendous amount of information in a tiny space. All of the information stored is expressed using four nitrogenous bases: A, T, G and C. Researchers had previously been able to use the sequencing of these veritable molecular building blocks to reproduce a binary code. However, the technical limits of DNA made it necessary to develop the first synthetic polymer -cheaper, more malleable and able to store binary information. This has now been achieved for the first time by a team of French scientists from the CNRS and AixMarseille Université. Instead of using the four nitrogenous bases of DNA, in this study the researchers used three monomers . Two of these monomers represent the binary code numbers 0 and 1, and can be used interchangeably during synthesis. A third nitroxide monomer was inserted between the bits in order to facilitate the

writing and reading of the coded sequence. A short binary message is synthesized by hand, monomer by monomer on a growing chain. The operation takes approximately a day, but should be quicker once automated. Decoding is done by sequencing, in the same way that DNA has been decoded for decades. A mass spectrometer thus takes less than five minutes to decipher the information -a duration also destined to be reduced in the short term. While sequencing systematically destroys the polymer, it is also possible to erase the code at any time and without reading it, by exposure to temperatures above 60ºC or to a laser. Researchers showed that at room temperature, the polymer can be conserved for a number of months, and could even last several years given the molecule's stability. The team hopes to store messages of a few kilobytes or even megabytes within 3 to 5 years. This technique, patented by the CNRS, also makes it possible to develop molecular barcodes in the short term. Sequences could provide labeling that would be extremely difficult to falsify, ideal for high value-added products such as luxury goods and medicine. The use of monomers and secret codes, known only to the laboratory and the industrial partner, would make it very difficult to produce counterfeits.

Aimplas aids research into insecticide plastic Aimplas, the Technological Institute of Plastics located in Valencia, Spain, has announced that along with Inesfly Corporation from Valencia and the University of Zaragoza it is working on developing a plastic for the manufacture of sandals and mats which repels insects that transmit endemic diseases. The new generation of foamed plastics will have insecticide properties in order to avoid the transmission of diseases such as malaria, dengue fever, Chagas’ disease and leishmaniasis. The project called Inmaplesp will last 24 months and is funded by the Ministry of Economics and Competitiveness.The project has a budget of €372,321. So far insecticide substances in plastics have consisted of powder incorporation and were limited to mosquito nets, animal collars, cattle ear tags and anti-mosquitoes bracelets. The Inmaplesp project will see the incorporation of insecticide to material through microcapsules which will protect the insecticide substance from its possible degradation during processing. Inesfly’s micro-encapsulation technology has already seen success in the field of insecticide paints. The insecticide containing plastic products, such as sandals and mats, will be useful in Africa, Central America and South America says Aimplas. But the organisation highlights that they will also be useful in Europe, in countries such as Spain, where the effects of climate change is causing plagues of subtropical species like the tiger mosquito.

59• June 2015 • Plastics News


in the NEWS

Global polyethylene industry witnessed low growth due to slowdown in China

T

he global polyethylene industry has witnessed a period of low growth in the last two years due to a slowdown in China and India, which showed strong demand in the past decade and proved themselves to be the growth engine of the global polyethylene industry. Russia has emerged as another growing market for polyethylene with a twofold increase in demand volume in the last decade, as per a report by GlobalData. It is also expected to show a strong demand growth rate

over the next five years. The Middle East and Africa has seen the fastest pace of production in the last decade. In terms of absolute change in production, Asia-Pacific continues to lead the market with an increase in production from 16.77 mln tpa in 2003 to 27.703 mln tpa in 2013, at Compound Annual Growth Rate (CAGR) of 5.1% in the last decade. New plants in China and India will continue to drive production in the region to 35.72 mln tpa in 2018.

Weholite pipes used for Irish natural gas project

N

ewport-based plastic pipe manufacturer Asset International has been employed to work on the ongoing Corrib gas project in Mayo, Ireland. The landmark project, anticipated to be operational this summer, is estimated to harvest 168.2 billion cubic metres of natural gas.When it was discovered in 1996, the Shellowned Corrib gas field was the largest of its kind discovered in Ireland for more than a quarter of a century. At peak it is predicted that it will supply up to 60% of Ireland’s natural gas requirements for 20 years.Shell began work on the offshore section of the pipeline in the summer of 2009. More than 7,000 lengths of pipe have been welded together on board the Solitaire

Plastics News • June 2015 • 60

pipe laying vessel. Asset International provided 4.9km of 750mm 4k Weholite pipe, which was used to create an air duct for part of the marine section of the project. Weholite exploits an advanced technology polyethylene material and is used primarily in water infrastructure projects across the UK. Simon Thomas, managing director of Asset International, said: “The Shell Corrib Mayo natural gas project is another one of the largest schemes Asset has been involved with. “It is truly epic in scale and we are extremely proud of our connection with this landmark project that will deliver much of Ireland’s gas requirements for the foreseeable future.”

WPA meeting to look at bag bans, new technology

T

he Western Plastics Association will focus on extrusion technologies and the shifting bag-ban environment at its annual conference June 23-25. A referendum on California’s November. 8, 2016, general election ballot will ask voters whether the state should ban supermarkets and other businesses from handing out single-use plastic bags. Gov. Jerry Brown signed the act into law in September 2014. A plastic-bag-industry-backed petition succeeded Feb. 24 in delaying implementation until voters have their say on the issue next year. “WPA is on front lines in what is going in with the referendum and bag bans,” said John Picciuto, WPA president and Western market manager in Tustin, Calif., for compounder H. Muehlstein & Co. Inc.WPA Executive Director Laurie Hansen assembled the program with strong support from Steve DeSpain, vice president of event co-sponsor Reifenhäuser Inc. The WPA event includes a June 23 reception, the June 2 4 Re i f e n h ä u s e r - o r g a n i z e d technology day and the June 25 business and policy forum at the Hyatt Regency in Newport Beach, California.


in the NEWS

48-50 kms of roads in Jamshedpur made using plastic waste

A

n initiative which started out as a pilot project is now being replicated across the city of Jamshedpur, and so far 48 to 50 kilometers of roads in the city have been constructed using plastic waste. According to reports Plastic bottles, wrappers, etc, are collected from across the city and brought to 10 collection centres. The waste is then broken down by shredding it to 2mm to 4mm before processing it further. This initiative was a result of a research started two years back by Jamshedpur Utilities and Services Company (JUSCO), a subsidiary of Indian corporate giant TATA. Plastic helps bind the road construction mix better resulting in longer lives for roads and also helps in cutting down the overall maintenance cost of a road. Disposal of waste plastic is no longer a problem in the steel city with Jamshedpur Utility and Services Company (JUSCO) using bitumen technology on waste plastic, ranging from polybags to biscuit packets, for constructing roads. JUSCO, a 100 per cent subsidiary company of Tata Steel which maintains and provides municipal services in Tata command area of the city, has constructed 12-15 kms road in the steel city as well as Tata Steel Works besides widening 22 roads using the environment-friendly technology of utilising waste plastic. As far as we know, Jamshedpur is

the only city in eastern India where bitumen technology (Dry Process) patented by Thiagarajar College of Engineering (TCE), Tirupparankuram, Madurai, has been implemented on accumulated waste plastic for the first time", said Gaurav Anand, Senior Manager (Quality Assurance) of JUSCO. Claiming that there is no maintenance cost involved for the first five years, Anand, who is an environment engineer, said that for every stretch of such one km long and four metre wide road, one tonne of bitumen costing Rs 50,000 is saved. The use of bitumen has been reduced by 7 per cent ever since JUSCO began using waste plastic in road construction work, he said, adding that the quality and longevity of roads made of waste plastic-aggregatebitumen was two times better than bitumen road. Describing plastic tar road as a "new pathway", Pratyush Dandpat, Deputy Manager (Quality Assurance) of JUSCO, said that the technology turned out to be successful. Besides being water resistant, it has better binding property, higher softening point, can withstand high temperature and higher load, has lower penetration value, costs less as compared to bitumen road and has no toxic gas emission, Dandpat said. Though there is great demand for the

technology, including from Chattisgarh, Himachal Pradesh, Uttarakhand and Jharkhand governments, but "we do not have any plan to commercialise it but to serve society. We have even received a request from Nigeria, which wants to replicate it in their country", Anand said. Due to the JUSCO initiative, the city will now have strong, durable, ecofriendly roads which will also relieve the residents from the sight of heaps of plastic waste.

India plans to generate 100,000 jobs in its North East

I

ndia’s Central Government is looking to generate one lakh jobs in the northeast through development of the plastic industry, Surjit K Chaudhary, s e c r e t a r y, c h e m i c a l s a n d petrochemicals, ministry of chemicals and fertilizers, said. Chaudhary was speaking with local entrepreneurs during an interactive session on prospects of the plastic industry in the northeast, organized by Federation of Indian Chambers of Commerce and Industry (FICCI) and Brahmaputra Cracker and Polymer Limited (BPCL) in Tinsukia

61• June 2015 • Plastics News


in the NEWS

India plans to generate 100,000 jobs in its North East India's Central Government is looking to generate one lakh jobs in the northeast through development of the plastic industry, Surjit K Chaudhary, secretary, chemicals and petrochemicals, ministry of chemicals and fertilizers, said. Chaudhary was speaking with local entrepreneurs during an interactive session on prospects of the plastic industry in the northeast, organized by Federation of Indian Chambers of Commerce and Industry (FICCI) and Brahmaputra Cracker and Polymer Limited (BPCL) in Tinsukia

Global polyethylene industry witnessed low growth due to slowdown in China The global polyethylene industry has witnessed a period of low growth in the last two years due to a slowdown in China and India, which showed strong demand in the past decade and proved themselves to be the growth engine of the global polyethylene industry. Russia has emerged as another growing market for polyethylene with a twofold increase in demand volume in the last decade, as per a report by GlobalData. It is also expected to show a strong demand growth rate over the next five years. The Middle East and Africa has seen the fastest pace of production in the last decade. In terms of absolute change in production, Asia-Pacific continues to lead the market with an increase in production from 16.77 mln tpa in 2003 to 27.703 mln tpa in 2013,

Plastics News • June 2015 • 62

at Compound Annual Growth Rate (CAGR) of 5.1% in the last decade. New plants in China and India will continue to drive production in the region to 35.72 mln tpa in 2018.

Weholite pipes used for Irish natural gas project Newport-based plastic pipe manufacturer Asset International has been employed to work on the ongoing Corrib gas project in Mayo, Ireland. The landmark project, anticipated to be operational this summer, is estimated to harvest 168.2 billion cubic metres of natural gas.When it was discovered in 1996, the Shellowned Corrib gas field was the largest of its kind discovered in Ireland for more than a quarter of a century. At peak it is predicted that it will supply up to 60% of Ireland’s natural gas requirements for 20 years.Shell began work on the offshore section of the pipeline in the summer of 2009. More than 7,000 lengths of pipe have been welded together on board the Solitaire pipe laying vessel. Asset International provided 4.9km of 750mm 4k Weholite pipe, which was used to create an air duct for part of the marine section of the project. Weholite exploits an advanced technology polyethylene material and is used primarily in water infrastructure projects across the UK. Simon Thomas, managing director of Asset International, said: “The Shell Corrib Mayo natural gas project is another one of the largest schemes Asset has been involved with.

“It is truly epic in scale and we are extremely proud of our connection with this landmark project that will deliver much of Ireland’s gas requirements for the foreseeable future.”

WPA meeting to look at bag bans, new technology The Western Plastics Association will focus on extrusion technologies and the shifting bag-ban environment at its annual conference June 23-25. A r e f e r e n d u m o n C a l i f o r n i a ’s November. 8, 2016, general election ballot will ask voters whether the state should ban supermarkets and other businesses from handing out singleuse plastic bags. Gov. Jerry Brown signed the act into law in September 2014. A plastic-bag-industry-backed petition succeeded Feb. 24 in delaying implementation until voters have their say on the issue next year. “WPA is on front lines in what is going in with the referendum and bag bans,” said John Picciuto, WPA president and Western market manager in Tustin, Calif., for compounder H. Muehlstein & Co. Inc.WPA Executive Director Laurie Hansen assembled the program with strong support from Steve DeSpain, vice president of event co-sponsor Reifenhäuser Inc. The WPA event includes a June 23 reception, the June 24 Reifenhäuser-organized technology day and the June 25 business and policy forum at the Hyatt Regency in Newport Beach, California.


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63• June 2015 • Plastics News


Plastics News • June 2015 • 64


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