POLYMERS Communiqué Aug - Sep 2016

A CUSTAGE I N I T I A T I V E Aug-Sep 2016 l Issue 2.6 l ` 150

ANNIVERSARY EDITION

some

Super Women of the industry

RAW FEED

In conversation with L to R Geeta Goradia

Managing Director Jewel Consumer Care

A. N. Jha

Petra Cullmann

Global Portfolio Director Plastics & Rubber, Messe Düsseldorf

Sonali Kulkarni

President and CEO FANUC India

Khushboo Doshi Executive Director Rajoo Engineers

Executive Director (Petrochemicals) Indian Oil Corporation Ltd.

POLYMERS Communiqué l August - September 2016

1

CONTENTS

August - September 2016 l Issue 2.6

30

73

58

50

67

76

66 70

44

30

AUTOMATI NG PRODUCE

44

B R ISTLIN G SU C C ESS

“Our users still need to experience real automation and untie their almost umbilical cord like connection with rigid, limited, 2 axes solutions that pass for automation.

The silver lining is the segment serving automotive components, which is on the brink of a robot revolution”, says Sonali Kulkarni in dialogue with POLYMERS Communiqué.

“All electric moulding machines, use of variable drives and robots to enable pick and place of plastic products on the machines would certainly be of interest as this would conserve energy and reduce human intervention during operations; it is imperative to use appropriate technology as also highly automated technology”, states Geeta Goradia in dialogue with POLYMERS Communiqué.

38

Spirit of User-Vendor Co-operation Critical to Automation Success

Sonali Kulkarni, President and CEO FANUC India Pvt. Ltd., Bengaluru

GLOBAL CONNECT

“Some trends promising genuine customer benefits have already been announced in the run-up to the fair. To mention just a few buzz-words: resource efficiency; zero waste production; additive manufacturing; modification, functionalisation of polymer raw materials; higher material availability and reduced mould changeover times”, says Petra Cullmann in dialogue with POLYMERS Communiqué.

2

38

Plastics Shape the Future at K 2016

Petra Cullmann, Global Portfolio Director

Plastics & Rubber, Messe Düsseldorf, Germany

Passion Fuels Success and Success Fuels Dreams: Technology is the Flavour of the Day

Geeta Goradia, Managing Director

50

C O LLA B O R ATIV E TEC H N O LO GY

“Affordable world-class technology, along with comprehensive training and skill development help us contribute positively to our customers’ business; an approach that will continue to be a part of our strategy for growth”, says Khushboo Doshi in dialogue with POLYMERS Communiqué.

Khushboo Doshi, Executive Director Rajoo Engineers Ltd., Rajkot

Jewel Consumer Care Pvt. Ltd., Vadodara

Abilities Driving Capabilities

POLYMERS Communiqué l August - September 2016

Printed and Published by Manish Chawla manish@polymerscommunique.com

54

SIVA R AM S PEAKS

Dr. S. Sivaram, Former Director, CSIR-NCL

Honorary Professor and INSA Senior Scientist Indian Institute of Science Education and Research (IISER), Pune

Custage Marketing Solutions LLP 401, Vikas Classic Building No 4 4th Floor, Near Basant Cinema Chembur, Mumbai 400 074, INDIA

58

F OR GIN G AHEAD

Editorial Advisory Board

A. N. Jha, Executive Director (Petrochemicals)

63

R E C Y C L ING PAGES

Advertising Sales - National

Oliver Jahnke, Plant Manager

Michael Heinzlreiter , Head of Marketing Next Generation Recyclingmaschinen GmbH, Austria

Mumbai Sanjana Chugh +91-99872 62726 sanjana@polymerscommunique.com

Energising Energy: Fascinating World of Invisible Polymers

Make in India: Resins, Catalysts and Products

Recycling Agricultural Films: Economically Feasible

AFA Nord GmbH, Germany

67

Dow Packaging and Specialty Plastics

73

70

Mono-Material PE Flexible Packaging Solutions: Addressing Recycling Issues

Think Thin Borouge Pte. Ltd.

P A C KAG I NG W HI TE

Reto Bamert, Head of Business Unit PET Systems

76

KIC K- START

80

WAY F ORWARD

Milk in PET: Proven, Light and Inexpensive

Netstal-Maschinen AG, Switzerland

PLASTINDIA 2018 Launched: Furthering Progress

Information, Infrastructure and Implementation: Critical for Sustainability with Plastics

Vijay Merchant, Senior Advisor Environment

84

KN OWL EDGE FORUM

86

@ K 2016

Arvind Mehta Chairman and Managing Director Welset Plast Extrusions Pvt. Ltd.

Indian Oil Corporation Ltd., New Delhi

ADVE R TORI AL

Designed by

Plastindia Foundation; Past President, AIPMA; IPI Member Governing Council of ICPE, Mumbai

PAM 2016: SPE India Conference

Brückner @ K 2016: Increases Efficiency of Its Film Stretching Lines

NEWS

20

EVENTS

88

POLYMERS Communiqué l August - September 2016

Hyderabad Vani Sulakhe +91-93924 28927 vani@polymerscommunique.com New Delhi Vijay Babbar +91-98100 15111 vijay@polymerscommunique.com Vadodara Devindra Bhumra +91-81289 90887 devindra@polymerscommunique.com

Advertising Sales - International Dubai Pritam Bangera +971-5548-32330 pritam@polymerscommunique.com USA Manisha Janjikhel +1-908-720-3510 manisha@polymerscommunique.com

Prof. (Dr.) N. C. Saha Director, Indian Institute of Packaging N. K. Balgi formerly President & Director at Ferromatik Milacron India Pvt. Ltd. Pushp Raj Singhvi formerly Vice Chairman and Managing Director at Borouge (India) Pvt. Ltd. Rajesh Nath Managing Director VDMA German Engineering Federation India Liaison Office Rakesh Shah formerly Managing Director at Windmöller and Hölscher India Pvt. Ltd. S. K. Ray formerly Sr. Executive Vice President (Polymers) at Reliance Industries Ltd.

Printed at

Silverpoint Press Pvt. Ltd. A-403, TTC Industrial Area Near Anthony Motors Mahape, Navi Mumbai - 400709 District - Thane

Content Alliance Partners

Subscriptions Maharashtra Bhavesh Brahamaniya +91-22-2520 4436 bhavesh@polymerscommunique.com Rest of India Rajesh Mahapralkar +91-22-2520 4436 rajesh@polymerscommunique.com Printed and Published by Manish Chawla, and printed at Silverpoint Press Pvt. Ltd., A-403, TTC Industrial Area, Near Anthony Motors, Mahape, Navi Mumbai - 400709, District - Thane and published from 401, Vikas Classic Building No 4, 4th Floor, Near Basant Cinema, Chembur, Mumbai 400 074, INDIA. Editor: Manish Chawla.

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Views and opinions expressed in this magazine are not necessarily those of POLYMERS Communiqué. Readers are advised to seek specialist advice before acting on information contained in this publication, which is provided for general use and may not be appropriate for the readers’ particular circumstances and so POLYMERS Communiqué does not take any responsibility for any loss or damage incurred or suffered by any of its subscribers / readers / advertisers of this magazine. The publisher makes every effort to ensure that the magazine’s contents are correct but do not take any responsibility for the absolute accuracy of the information. Subject to Mumbai Jurisdiction. Some of the images used in this issue are from Shutterstock.

No part of this publication or any part of the contents thereof may be reproduced, stored in a retrieval system or transmitted in any form without the permission of the publisher in writing.

POLYMERS Communiqué reserves the right to use the information published herein in any manner whatsoever. The ownership of trademarks is acknowledged.

3

Mind Speak Rajesh Nath

rector Managing Di g an Engineerin rm Ge MA VD ion rat de Fe Office India Liaison

The

interaction of virtual and real production world is a crucial aspect process. manufacturing the in ‘Industry 4.0’ is paving the way for a complex technological revolution that will drastically change the entire value chain. Industry 4.0 provides the capital goods industry with the possibility to develop new and innovative business fields from engineering suppliers to long-term partners and solution providers.

Industry 4.0 will lead to a lasting change in work and its processes.

3D printing - also known as additive manufacturing - turns digital 3D models into solid objects by building them up in layers. In the last few years, 3D printing has additionally started to evolve into a nextgeneration manufacturing technology that has the potential to allow ondemand production of final products or parts thereof. Already it is possible to 3D print in a wide range of materials that include thermoplastics and thermoplastic composites. Right now, 3D printing as an end-use manufacturing technology is still in its infancy. But in the coming decades, and in combination with synthetic biology and nanotechnology, it has the potential to radically transform many design, production and logistics processes.

Prof. (Dr.) N

Director

Indian Insti

. C. Saha

tute of Pack

aging

The current trend of packaging is to have innovative sustainable polymer based flexible materials which will not only provide high functional properties and high yield, but at the same time, the materials should be amenable to printing.

The upcoming trend that the industry will witness is that of a ‘Virtual Factory’.

Factories with hundred s of moulding or extrusion machines will run with minimal manpower. Computers and automation will take over, shopfloors will run 24 x 7 (without breakdown), producing quality products, efficiently. This trend is very significant in Europe and is soon going to make its presence felt all over!

Arvind Mehta

tor Chairman and Managing Direc Welset Plast Extrusions Pvt. Ltd.

N. K. Balgi

Consumer beha viour is continuously being shaped by of awareness resource co ns er vation environment and protection w hile pursuing life of incr eased com forts. Plastic make it po s ssible. How ever, polym consumption er growth will moderated stand as productio n systems will produce more parts pe ‘virgin polym r unit of er’ converte d. Increased use of recycla tes, and thin ning of parts without losin g functionalit y will be the trend. Proces sors being un der pressure for improvin g cost com petitiveness by increasin g productiv ity will fast adopt autom ation and m ove towards IT enabled ‘Smart Prod uction, Smar Machine, Sm t art Service’ offered by Industry 4.0.

Industry will ha ve to retrain people for ne wer skills an d enhanced technical com petence.

formerly Presid ent & Directo r at Ferromatik Mi lacron India Pv t. Ltd.

Feedback

Our article is very well placed, presentation as well as the production is excellent. Infact, I have started receiving industry feedback appreciating the article. I much appreciate the work done. POLYMERS Communiqué provides very useful information to the plastics industry.

formative ué is an in ommuniq C S tents are n ER M co e POLY ustry. Th d in e th r ngratulate source fo e. We co impressiv d for their an é le u iq valuab Commun S ER M LY Team PO efforts.

gh rdhan Sin d. hines Lt

Harshwa

Windsor

Mac

D. L. Pandya

Medical Plastics Data Service

Thank you for incorporatin g varied information on all aspe cts of the industry. En joyed readin g the inputs thoroughly.

Trend Plastp

POLYMERS Co mmuniqué has been distin ctly inform ative since its inceptio n. Every iss ue carries very rich co ntent which gives an opportunity to understa nd new happenings in the indu stry.

Amit Kumar

Alok Maste

Bipin M. Shah

ouchpack Pv

t. Ltd.

ortunity this opp t, I take e ts iven to u g o At the veryyou for the supportPOLYMERS k ugh to than , thro really IPLEX16 It has t Kochi azine. g a m a ss bou niqué warene Commu ity, ng an a ti rn a te re a c fr us in plastics helped st the among . ia d IPLEX In rth P. J. lly in No especia Mathew EX16 L IP r, o Conven

Singh

rbatches Pv

t. Ltd.

ive to sh perspect given a fre s d ha ué iq en mun cont t an POLYMERS Com today’s digital/online age. Its s an indepth in m dards. It give print mediu s global stan in the plastic at par with g the latest in quality are rd ga s re ht sig in k! w or ne e good w coverage of d keep up th hoti l the best an Shailesh La Ltd. industry. Al urs Pvt. lo Co d en Bl

Communiqué stands research driven apart for its excellent benchmark for a tes crea It ts. conten whole team the h others to follow. I wis re. futu the for s ces more suc

POLYMERS

alia

Gurdeep Singh Ahluw

Jain Irrigation Systems

Ltd.

Does your product need a makeover?

Introducing TransCol masterbatches !!!

R

Have your product stand out on the shelves amidst the rest with clarified and tinted solutions for polypropylene.

Rajiv’s TransCol master batches based on range of ClearTint Pigments help give you the edge.

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TM

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Suitable for PP sheet extrusion, blow moulding and injection moulding, discover h ow the Tra ns Col range can help your product look its best. Improve the aesthetics of your household products, bottles, caps, closures and even disposable cups. It just doesn’t stop at good looks, further advantages are lower density, good stiffness / impact balance, chemical and thermal resistance, good moisture vapour barrier and no warping.

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Global Support for the Lifetime of Your Investment Avoid Costly Downtime and Boost Productivity with Davis-Standard’s Parts and Service Global access to equipment upgrades, spare parts and nonstop service means optimal performance for the lifetime of your equipment. We listen to customers and observe market trends to provide the industry’s most complete offering of aftermarket services.

Whether you need new capabilities or an upgrade to existing equipment, our spare parts and modernization packages support cost-effective results with a fast turnaround. These include current drives and controls as well as a menu of options to keep production efficiency a priority. We recently added die upgrades at our facility in the United Kingdom to further support customers around the world.

Our service technicians are available 24 hours a day, seven days a week, to address extruder parts inquiries and solve emergency service issues. To find a service location near you, visit www.davis-standard.com/spare-parts or call toll-free, 800-480-8105.

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Speciality Colour Masterbatches l

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Visit us at: K | 19 – 26 October 2016 | Düsseldorf, Germany | Hall 4, stand A39

www.bobst.com

News ENGEL to Present Latest Technologies at K 2016

Digest Amcor announces agreement to acquire North American rigid plastics blow moulding operations of Sonoco products

BASF expands global production capacity of Ultrason®

A Strong Partner for Facing Future Challenges in Packaging Industry

At K 2016 in Dusseldorf between

19th and 26th October, ENGEL the injection moulding machine manufacturer, with headquarters in Austria and a subsidiary in Mumbai, will showcase its challenging applications

targeted

for

different

industries, including packaging as one

8-cavity cube mould built as a proof-ofprinciple prototype. The containers were

developed by Alpla for a customer in Asia

that until now packages its products in glass vessels. By substituting the material,

it reduces both production costs and packaging

weight

while

increasing

consumer safety at the same time.

to their innovative process technologies,

up in the opposite mould position parallel

intelligent control technology.

the ENGEL easix six-axis robot integrated

generate high customer benefits; thanks

previously produced preforms are blown

custom-built manufacturing concepts and

to injection moulding. At the same time,

Injection blow moulding makes it possible

to achieve economical production of ready-to-use small containers in a single step. However, the number of possible

cavities was hitherto limited. Together

with its system partners, Foboha (Haslach, Germany) and Alpla Werke Alwin Lehner

(Hard, Austria), ENGEL has succeeded

further for use with multi-cavity moulds,

A-B

WP injection moulding machine in an

In order to achieve short cycle times, the

in developing the integrated process Berry Plastics Group, Inc. announces agreement to acquire AEP Industries Inc.

an all-electric ENGEL e-motion 740/220 T

main focus. The packaging exhibits

Process Integration Reduces Unit Costs Belgian Monitoring Systems (BMS) will focus on globalisation, Industry 4.0 and Internet of Things with its new release of PlantMaster MES 8.30w at K 2016

producing polypropylene containers on

thus reducing cycle times significantly.

Based on cube technology, upscaling

to upto 96 cavities is possible without compromising cycle time and accuracy.

This significantly reduces unit costs

for high production output. ENGEL is showcasing the potential of the

new injection blow moulding process

in the production cell removes the finished containers from the fourth position and places these onto the conveyor belt with the opening facing upwards. The entire

handling thus occurs in phase with the

injection blowing and does not increase the cycle time. An insulating cover in

position 2 prevents the preforms from cooling off. The shot weight is 8 grams per container.

System partner for the blow moulding

technology is Bauer Compressors in Aix-Les-Bains, France. As an integrated part of the process, the gas pressure can

be controlled via the CC300 control unit

of the ENGEL injection moulding machine.

High Performance in a New Dimension With their innovative drive concept, the injection moulding machines of the ENGEL series

e-speed

guarantee

high efficiency at continuous speed

high-

operation,

Up to 96 containers per shot can be produced in the injection blow moulding even with high shot process on an all-electric ENGEL e-motion injection moulding machine.

20

POLYMERS Communiqué l August - September 2016

weights and high clamping forces. But ENGEL now takes this one step further at

Digest

K 2016. Thanks to IML integration, long thin-

walled packaging can be produced readyto-fill with injection moulding. ENGEL is presenting this increase in efficiency at

Braskem introduces new high-meltstrength PP

K 2016 in Dusseldorf in the production of cartridges for the construction and DIY

retail sector. For this, an ENGEL e-speed

500/90 injection moulding machine is being combined with IML automation

Cloeren to showcase extrusion die and feedblock systems at K 2016

Fkur resource conservation with Bio-Flex® FX allows for considerable reduction in thickness for compostable films

from Beck Automation (Oberengstringen, Switzerland).

The

16-cavity

mould

acknowledged

Vikram

Bhadauria,

Director, Alok Masterbatches Pvt. Ltd. In an upcoming award ceremony, the award

would be conferred by Hon’ble Prime Minister, Narendra Modi.

the labels is Verstraete in mould labels

diffusing agent and thermally conductive

it is possible to decorate cartridges using

both of which were created at Alok

enterprise category for its innovative light

(Maldegem, Belgium). For the first time

polymer products for the LED industry,

IML technology.

Technology Incubation Centre (ATIC),

The

cartridge

production

New Delhi.

makes

Light

optimal use of the advantages of the

Lumanex™

clamping unit and a servo-hydraulic injection unit. Moulding the long hollow

and injection performance. Very short cycle times are achieved despite the

relatively high total shot weight of 800 grams. A basic prerequisite for

high efficiency of the IML process are very precise movements of the mould

mounting platen, which the ENGEL

Its

exceptional

energy

efficiency

contributes significantly to the great

success of the ENGEL e-speed on the international packaging markets. To avoid

peak loads while operating at high speeds

even with high clamping forces, a system,

which functions according to the principle of a flywheel, stores the braking energy

of the platen movements and transfers it back to the motor as needed – for example, for reaccelerating the platen.

Thanks to this integrated energy storage,

the ENGEL e-speed is able to run with

a relatively low and above all constant connected load.

diffusing

masterbatch,

hybrid machine, which has an electric

clamping unit.

22

National Award for Innovation and

Switzerland), and the system partner for

e-speed ensures thanks to its all-electric

B-H

Micro Small & Medium Enterprises,

Government of India announced the

Alok stood third among the medium

1.2 mm requires very high dynamics

Hennecke will present some impressive sample parts from advanced areas of application for polyurethane at K 2016

O

n 12th July, 2016, the Ministry of

comes from Otto Hofstetter (Uznach,

bodies with a wall thickness of only Frigel to introduce portable chillers with advanced control technology including wi-fi for improved productivity and profitability at K 2016

A Proud Moment for Alok: Receives the MSME National Award for Innovation

works

on the concept of

Vikram Bhadauria diffusing harsh light Director into a softer form, Alok Masterbatches without sacrificing Pvt. Ltd. the lumen intensity of the LED. The thermally conductive polymer, ThermoFlux, evenly distributes heat generated from a device and transfers heat from sensitive electronic

and electrical components to improve performance and service life.

On the occasion Vikram Bhadauria mentioned, “These innovations stand testimony to Alok’s guiding principle

of making plastics safer, affordable and sustainable. I am honoured that our

effort has been acknowledged by the Government of India for being beneficial to public health, saving forex and giving impetus to the ‘Make in India’ campaign.

This is indeed a proud moment for the entire Alok Family.”

Rajiv Plastics Ties Up With Batchwerk GmbH, Germany

R

ajiv Plastics Pvt. Ltd. has entered into

a technical tie-up with Batchwerk

GmbH, Germany for their universal

POLYMERS Communiqué l August - September 2016

masterbatches. Batchwerk GmbH offers

‘For plastic processors, the compact

multiple polymers and is especially

are a major selling point, as they enable

a range of products that work with

Digest

useful for applications where many parts

are assembled in the same colour. This is especially useful for applications where

Innovia Films is expanding its portfolio of peelable Biaxially Oriented Polypropylene (BOPP) films; Propafilm™ RCP is now available in 52 and 60 microns

volumes are small and having resinspecific masterbatches may not be the most viable option in terms of inventory management and control.

In addition, Batchwerk will be the distribution partner of Rajiv Plastics

LPKF Laser & Electronics AG with high-precision laser welding of transparent plastics is targeting the challenging medical applications sector

space savings of 10 - 20% compared to the

competition’, states Sanjay Shrivastava, National Head, Neelgiri Machinery. The

compact concept continues with a six-axis robot. A newly developed servomotor-

controlled spruce picker with telescoping stroke ideal

is

also for

buildings with low ceilings.

in parts of Europe (e.g.

The new valve

Netherlands)

Xtreme series machines

Germany,

KRAIBURG TPE to present new products and applications for the automotive, consumer and medical sectors at K 2016

dimensions of the new Xtreme series

At

K

Austria,

2016,

Rajiv

Plastics will be showcasing some of their

latest innovations and developments.

technology ensures

of

speed

the

during

production.

This interacts optimally with hydraulic switching concepts.

Batchwerk team will also be present.

The Xtreme series machines include

Neelgiri to Launch the New Xtreme Injection Moulding Machine Series in January, 2017

The machines are also equipped with

N

eelgiri

Machinery

announced

the launch of its next-generation

Xtreme series machines having clamping

force range of 58 kN to 1788 kN for multicomponent injection moulding

at IPLEX 2016, Kochi exhibition. These

machines will be available in the market from January 2017. ‘Customers will

benefit from low expenses for energy, space, time and materials, while gaining LyondellBasell to build high density polyethylene plant at La Porte, Texas

important competitive advantages in the

I-L

outstanding value for money and is ideal

process’, highlights Mukesh Goel, MD, Neelgiri Machinery.

The new Neelgiri Xtreme series offers

for high-precision applications with large volumes for automotive, medical and electronics industries. It offers robust and reliable 5-point twin-toggle and rugged

several new capabilities and features. intelligent features that make it easier

to use with simplified controls for faster process set-up and improved repeatability.

Towards India’s Sustainable Future: Dow India Launches All-PE Packaging Solution

“Currently, what is it that deters effective

recycling and reuse of the flexible

packaging that packs products such as

salt, flour, detergent and many other food products? It is a fact that this packaging uses

multiple materials that are incompatible while recycling, thus impacting quality of recycled material. What would make the

whole plastics waste management and

recycling effort much more meaningful

and economical is adoption of packaging using

monomaterial

to

design

a

sustainable solution – an all-Polyethylene

(PE) laminate. This enables us to make film that does not impact packaging quality or

clamp mechanism. In the lower clamping force range, it is the extension to their range

of

multicomponent

injection

moulding machines, enabling them to

offer customers with high-quality, tailormade production solutions.

24

POLYMERS Communiqué l August - September 2016

performance, but generates completely

versatile

elaborated

clear, pigmented,

reusable

Digest M&H Plastics produces 50 ml bottle using lighter plastic, opening up new markets

material Vipul

upon

Babu,

recycling,”

Commercial

Director for Indian Subcontinent, Dow

Packaging & Specialty Plastics, while summing up the monomaterial laminate solution for a gathering.

In the outreach event hosted at BOSCH

facility at Goa, P&SP team led by Mark Saurin, Commercial Vice President for Asia

Pacific and Vipul Babu, presented the all-PE Milliken SiVance® C2010 resin for epoxysilicone formulations, ups durability of protective coatings in harsh conditions

packaging solution, including new product

offerings in India: INNATE™ and RETAIN™.

Speaking about this initiative, Mark Saurin

said, “The umbrella initiative of Dow P&SP - our sustainable packaging solutions line

has been successful globally. In India, this is an opportune time to talk about some of

these technologies because of the recent Owens Corning to invest USD 110 million in India composites operations

plastics waste management policy of the

Government of India that looks to address

this issue in a more sustainable way. All-PE laminate solution is an effective way to

create a circular economy around plastics waste management.”

RPC-Group pack used for vegetable mix for egg dishes, Scramble™ is proving a clear success in the United States

Solegear awarded U.S. patent for high performance bioplastics titled ‘Compositions Comprising Polylactic Acid, Bentonite and Gum Arabic’

M-S

voided / pearlised products,

plus

tints in total or as

stripes. It measures the true thickness and

weight

of

voided, microporous or breathable films

and derived density. It can measure barrier materials such as nylon, EVOH or PVDC

simultaneously with other polymers such as PE, PP or ionomer. For embossed films,

FilmPro can handle most colours except dark / opaque films, while cast stretch film measurements include clear, tints and black tinted products.

Rajoo’s Pentafoil All-PE 5-Layer Co-Extruded Blown Film Line: Crowning Glory @ K 2016

R

ajoo solutions are always wellaccepted on global platforms. At K

2016, the difference will be evident when Rajoo will be the only Asian company to

Through this event, Dow India and

demonstrate live, a 5-layer all-PE blown

collaboration

chain

see how Rajoo takes India to the world!

the recyclability challenge faced by the

line, now operating successful with a

NDC Technologies Introduces its Versatile FilmPro Infrared Measurement Sensor

Indigenously designed and built, this line

BOSCH demonstrated the power of

film line @ Hall 15, Stand B04; come and

partners to offer practical solutions to

Last K, witnessed the 5-layer barrier film

flexible packaging industry.

reputed customer in South Africa.

N

among

value

incorporates the latest advancements

in technology such as Cylindrical Spiral

Die (CSD), internal bubble cooling,

DC Technologies, a global provider of

precision

measurement

and

control solutions, announces FilmPro™, its

new,

modular

high-performance

infrared thickness sensor. FilmPro is a universal sensor providing film, sheet

and coating measurements from thin film to thick sheet products with multilayer discrimination for upto six individual co-extruded components.

FilmPro’s new optical engine has been

enhanced to improve signal-to-noise, accuracy, web flutter and the effect of

optical interference. FilmPro is NDC’s most

26

infrared

gauge, measuring

circumferential

profile

control

with

elevated air ring and triple lip, full

automatic winder and touchscreen based supervisory control panel. Even with this, the Rajoo ‘Excellence in Extrusion’

continues to remain affordable - an

approach that has earned Rajoo global acclaim from users, industry experts and media alike.

Operating

at

600.4 kg/hour, TUV

during

certified

an

onsite visit, that the

specific

POLYMERS Communiqué l August - September 2016

electricity consumption under standard

conditions for the 5-layer co-extruded blown film line PENTAFOILAPE- RECF-

260-90/2400 IBC-A is certified to be 0.3001 KWh/kg of blown film (40 micron thickness, 2000 mm width).

“I would like to highlight here that the allPE PENTAFOIL 5-layer co-extruded blown film line is truly eco-friendly in a dual way –

one from the environment perspective (by

getting more out of less by down gauging and lower energy consumption) and the

other from the economics perspective (better performance with cheaper raw

materials)”, opines – Khushboo Doshi, Executive Director, Rajoo Engineers Ltd.

Centre at its headquarters in Lengerich for a four-day in-house EXPO.

W&H at K 2016 is at Hall 17 | Booth A57

while W&H EXPO during K 2016 is at, Lengerich on 20th / 21st October and

24th / 25th October, 2016.

Meusburger at K 2016

B

etween 19th and 26th October, at the

leading trade fair for the plastics and

rubber industry, Meusburger presents

both tried and trusted products as well

as numerous innovations. The highlights try out hands-on and the Meusburger technical tip video clips.

As of October, many innovations for mould

helps raise the performance bar of films

new products – mainly from the areas

with an unprecedented efficiency ratio; benefits of down gauging, lower cost of final film, adaptability across applications enhances the ROI still further.

New Machines and Technologies from W&H at K 2016

Toyobo and Avantium have jointly developed thin films made from PEF, a 100% bio-based plastic, based on Avantium’s proprietary YXY technology for the production of FDCA

at the Meusburger stand are products to

Tailored to meet specific needs, PENTAFOIL

all-PE 5-layer coextruded blown film line

Digest

making are available at Meusburger. The

of slide technology, locks, hydraulics, and

Toyota sports car first to feature plasmacoated polycarbonate rear quarter window

sprues – will be presented at K 2016 at the Meusburger stand 1D45. Take the

opportunity to have a closer look at the

innovations and try them out on the spot!

Victrex contributes integrated polymer solution to Commercial Aircraft Corporation of China (COMAC) to achieve higher aircraft efficiency goals

Besides

WEKO will present plastic film functionalisation using highly precise minimal application systems at K 2016

W

indmöller & Hölscher Group will introduce several new innovations

and present its comprehensive product portfolio for the production of flexible

packaging at K 2016 in Düsseldorf. Details about the new technologies will be

announced at the beginning of the show.

“It has become a tradition for W&H to celebrate the premieres of machinery and technologies for extrusion and converting

at K,” says Dr. Jürgen Vutz, CEO. W&H will continue to focus on the concept of Packaging 4.0. “We will show how

intelligent machines, integrated processes and

intuitive

handling

are

already

increasing efficiency and flexibility of the production,” explains Peter Steinbeck, Managing Director.

Coinciding with K, the family-owned company

will

open the doors to the 3,000 m2

Technology

POLYMERS Communiqué l August - September 2016

a

variety

of

innovations,

Meusburger also exhibits their tried

and trusted products at K 2016. The

multifunctional H 1000 Clamping system

has revolutionised the manufacturing processes in mould making and stands for high efficiency. The system enables

precise clamping of the plates with repeatable accuracy in the µ-range.

The innovative H 4062 assembly table

facilitates repair and assembly work on moulds. Air cushions on the underside of

the moveable plates enable a light and

easy movement of the mould halves. Both mould halves are freely accessible without

having to reposition or turn them around,

T-W

enabling efficient operating.

27

AUTOMATING PRODUCE

Sonali Kulkarni President and CEO FANUC India Pvt. Ltd. Bengaluru

30

POLYMERS Communiqué l August - September 2016

Spirit of User-Vendor Co-operation

Critical to Automation Success Q. The right ‘positioning of automation’ is key to its success. Your comments.

I would not necessarily term it as ‘positioning’. But it is true that every automation project at the outset needs to be carefully

envisaged in totality. Today, FANUC has almost 4000 robots

manufacturing our line up of products. The holistic planning that must precede and the approach to refining that a user must adopt,

is a must. At FANUC India, we emphasise this to any customer keen on robot automation. The work flow, volumes, the viability and even proper introduction to shopfloor team - all need due attention if the project is to succeed in the long term.

Another critical aspect is the spirit of cooperation between the

user and automation vendor. FANUC has a totally customer-centric approach. Even so, and having seen innumerable robotisation projects, I find the most successful and the ones which yield the

best RoI, are the ones where customer side too is lead by a senior

minded, solution-oriented person. Some years ago, we automated a press line at one of India’s top manufacturers. The presses

were over 50 years old, and were obviously not arranged with robotisation in mind. Yet, we succeeded - and the customer was

delighted. In fact, right now we are working on a repeat project.

The single most important factor was the extremely solution-

oriented attitude of the gentleman in charge of the project at customer end. We really worked as true partners.

“Our users still need to experience real automation and untie

their almost umbilical cord like connection with rigid, limited, 2 axes solutions that pass for automation. The silver lining is

the segment serving automotive components, which is on the brink of a robot revolution”, says Sonali Kulkarni in dialogue with POLYMERS Communiqué.

POLYMERS Communiqué l August - September 2016

31

China has aggressively embraced robotisation and even today consumes ~ 2000 units per year in plastic moulding alone, while we barely integrate ~ 200 robots. China is still the ‘Factory of the World’ and has clearly understood the value of automation for efficiently achieving volumes.

Q. Where do you see the Indian plastics processing industry and adoption of automation?

32

users take their cue from the OEM or Tier 1 that they supply to. They remain dependent on these

OEMs who design the specifications in entirety

As a whole, we have some way to go. Our users

and just have the plastic processors execute. So,

untie their almost umbilical cord like connection

better judgement of the automotive OEM / Tier 1

automation. The silver lining is the segment serving

the plastic processors against each other, purely in

robot revolution.

phase, differentiate itself, reach into newer markets

Our industry remains fragmented and most of our

said, but investing in good machines and sound

still need to experience real automation and

even the question of automation, is left to the

with rigid, limited, 2 axes solutions that pass for

suppliers. The players up the value chain tend to pit

automotive components, which is on the brink of a

a price game. Our industry has to grow out of this and acquire a more commanding presence. Easily

POLYMERS Communiqué l August - September 2016

automation will contribute, along of course with strong intent.

Knowing the criticality of cost angle, FANUC’s

solutions ensure lowest Total Cost of Ownership (TCO), with robots having MTBF of 8 years in India.

Thus, creative solutions like:

A single 6 axis robot handles a cell of 2 Roboshot

A

l l

robot

addressing

multiple

process

requirements like insert placement on to

mould cavity, (insert moulding), part extraction, inspection using 3D vision)

l

Turnkey automation solution for critical medical

to compare the two. China has aggressively embraced robotisation and even today consumes

~ 2000 units per year in plastic moulding alone, while we barely integrate ~ 200 robots. China

is still the ‘Factory of the World’ and has clearly understood the value of automation for efficiently achieving volumes.

Q. You have worked closely with the plastics industry. Would you highlight some specific automation solutions the FANUC offers for this industry?

parts (Petri dishes), right from extraction,

As partners in factory automation, we support a range

touch-free process

from injection moulding machines:

inspection, to assembly - making it a total human l

are like two orders of magnitude. It is unrealistic

Absolute part inspection, part stacking to the right product bins in the case of multi-cavity precise

of requirements within loading / unloading (L/UL)

l

Knowing the 12 - 15 sec cycle time required

by the automotive sector, we offer our single

connectors (tolerance ± 5µ) and so on.

10 kg payload robot (weighing just 130 kg) with

Q. How does this compare with the similar Chinese industry?

with a J3 axis that can flip over allowing the robot

Even though China has been slowing down for some years, we should recognise Indian

manufacturing is just not in the same league. They

POLYMERS Communiqué l August - September 2016

slimmest footprint, 2D vision and 1632 mm reach,

To know more, please subscribe to

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33

B2B Marketing Communication Specialists RELATIONSHIPS All India Plastics Manufacturers Association

Asian Packaging Federation

AVI Global Plast Pvt. Ltd.

Bennett, Coleman and Company Ltd.

Blend Colours

Brückner Maschinenbau GmbH & Co. KG

Central Institute of Plastics Engineering and Technology

Chemicals & Petrochemicals Manufacturers’ Association of India

Ferromatik Milacron India Ltd.

Indian Centre for Plastics in the Environment

Indian Institute of Packaging

Indplas Exhibition

IPLEX Exhibition

India Trade Promotion Organisation

J P Plaschem Ltd.

Kandui Industries Pvt. Ltd.

Mitsu Chem Pvt. Ltd.

Organization of Plastics Processors of India

Pennwell Publishing

Plastasia

Plastindia Foundation

Rajoo Engineers Ltd.

Sintex Industries Ltd.

Technical Training and Research Institute

The Economic Times Polymers

Welset Plast Extrusions Pvt. Ltd.

Windsor Machines Limited

World Packaging Organisation

Adeka India Pvt. Ltd.

THE TIMES OF INDIA

Key Services l

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Developing Customer Case Studies

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HO: 401, Vikas Classic, Building No.4, Near Basant Cinema, Dr. C. G. Road, Chembur, Mumbai 400 074 +91-22-2520 4436 l info@custage.com l www.custage.com Branches: Hyderabad l New Delhi l Vadodara

Reliance Industries Ltd.

Vasantha Tool Crafts Pvt. Ltd.

and more...

GLOBAL CONNECT

Plastics Shape the Future

at K 2016

“Some trends promising genuine customer benefits have already been announced in the runup to the fair. To mention just a few buzz-words: resource efficiency; zero waste production; additive manufacturing; modification, functionalisation of polymer raw materials; higher

material availability and reduced mould changeover times”, says Petra Cullmann in dialogue with POLYMERS Communiqué.

Q. What is the theme of K? How does it resonate with the industry?

provides real added value for visitors. One of

As the most important flagship fair of the global plastics

this year’s highlights will be the special show,

pools central trends and future developments in one

polymer materials have shaped the appearance

business platform not only for raw material producers,

also in terms of aesthetics and sustainability. This

processors, but also for stakeholders from the main

performance as well as addressing problems such

plastics and rubber come to meet, demonstrate the

Another novelty is the Science Campus, a forum

and rubber industries and all related applications, K

‘Plastics Shape the Future’. It will spotlight how

venue. It has become established as the innovation and

of our modern world – not just functionally, but

manufacturers of plastics and rubber machinery and

event deals with economic and environmental

user industries.This is where experts from the world of

as marine litter.

industry’s leading edge and inform visiting experts

from the automotive industry, packaging, E+E and

communication, construction, medical engineering

and the aerospace industry about new and visionary areas of application for plastics and rubber materials.

Q. What new has been incorporated by Messe Düsseldorf to enhance exhibiting and visiting experience?

K has always had its finger on the pulse of

technological development. This is borne out not only by the presentations at exhibitor stands,

38

but also by the supporting programmes, which

where businesses and universities can exchange

information. It provides K 2016 exhibitors and visitors

with a comprehensive overview of scientific activities and findings in plastics and rubber research. Four central issues that are expected to dramatically affect

the development of the industry’s markets for the next few years will be focused. These are:

Resource efficiency

Digitalisation of the value chain / Industry 4.0

New materials

Lightweight construction

l l l l

POLYMERS Communiqué l August - September 2016

Petra Cullmann Global Portfolio Director Plastics & Rubber Messe Düsseldorf Germany

POLYMERS Communiqué l August - September 2016

39

I would like to take the opportunity to express my gratitude to the Indian plastics and rubber industry associations, especially the Plastindia Foundation, which has supported us considerably in our efforts to make sure that every Indian exhibitor and visitor can make the most of his participation in K 2016.

Beyond the Science Campus, these topics will also be reflected elsewhere at the trade fair.

Q. What numbers would be the reflection of this K? Some 3,200 exhibitors from 60 nations will be taking

part and showing their products and services on over 1,70,000 square metres of net exhibition space. The

strongest contingent of exhibitors come from Europe, especially from Germany, Italy, Austria, Switzerland, France and Turkey, but there is also an impressive

number of participants from the USA. At the same

time, K is a clear indicator of changes in the global market: over the past years, the number of Asian

companies and the exhibition space booked by them has been rising steadily, and this year, particularly China, India, Japan, South Korea and Taiwan will be impressing visitors with their strong presence.

Q. India at K, a growing movement.

Your thoughts.

As mentioned before, India will be demonstrating the strength of its plastics and rubber sector

with the attendance of far over 100 exhibiting companies presenting their products and services

40

on a net exhibition space of some 4,700 square metres. They all take advantage of the fact that

exhibitors at K 2016 will meet industry experts

from over 100 countries and come together with potential customers that they would not otherwise meet.

On the other hand, experts from India are the largest

visitor group coming from outside Europe, some 9,000 Indian visitors travelled to K 2013. They

appreciate the fact that K is the premiere platform for innovations. Another reason for their trip to Düsseldorf

is the high internationality of the exhibitors. It makes

sure that the spotlight is not only on the industry’s major talking points such as energy, resource and materials efficiency, but also on niche segments.

Q. With the growing importance of India as a processing hub for plastics, what special initiatives have been undertaken to attract increased exhibitors and visitors from here?

Major efforts have been made to inform the experts of To know more, please subscribe to

POLYMERS Communiqué at subscriptions@ polymerscommunique.com

POLYMERS Communiqué l August - September 2016

S.M.A.R.T.*

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15.07.16 08:55

BRISTLING SUCCESS

Geeta Goradia Managing Director Jewel Consumer Care Pvt. Ltd. Vadodara

44

POLYMERS Communiqué l August - September 2016

Passion Fuels Success and Success Fuels Dreams

Technology is the Flavour of the Day “All electric moulding machines,

use of variable drives and robots to enable pick and place of

plastic products on the machines would certainly be of interest as

this would conserve energy and

reduce human intervention during operations; it is imperative to use appropriate technology as also

highly automated technology”,

states Geeta Goradia in dialogue with POLYMERS Communiqué.

Q. How did you conceptualise Jewel Consumer Care Pvt. Ltd. (JCCPL) and Why? I joined M. S. University as a lecturer in Business Economics in 1984. Although I enjoyed the teaching profession, I always

wanted to be an entrepreneur. A multinational company with a major market share in oral care products in India

was on the lookout for someone who could manufacture premium quality toothbrushes for them. Having grabbed this wonderful opportunity that came at my doorstep, I set

up a small scale toothbrush manufacturing unit in 1986 with state-of-the-art equipment. Consistently manufacturing high

quality products and on-time delivery brought my company and me immense recognition in the oral care industry.

Being Managing Director as well as a minor shareholder in the company, I was in total control of all operations at

the factory from 1986 to 1993. It was during this period that I worked long hours with missionary zeal in order

to acquire technical know-how. Brush manufacturing became a passion for me. This success propelled me to

dream bigger, take on greater challenges and resolved to

become one of the largest world-class manufacturer of oral care products.

This recognition came as a big boon. HUL (then HLL) at that point of time decided to take the plunge into toothbrush

manufacturing in India. This earmarked the beginning of a new era for me in the oral care industry. HUL approached us

to set up a unit for manufacture of toothbrushes exclusively for them and this encouraged me and my husband Amit

Goradia to start Jewel consumer Care Pvt. Ltd. in 1993, (family owned company).

Q. What technologies have you currently deployed for your production?

We

use

appropriate

automated technology.

POLYMERS Communiqué l August - September 2016

technology

as

also

highly

45

The following process-wise technologies have been deployed at our manufacturing facility.

Injection Moulding Horizontal and vertical injection moulding machines hydraulically operated with capability to mould single,

double and triple component handles. We also have all electric moulding machines which are energy efficient and oil free machines.

have a battery of these automatic blister packing machines.

Q. To further your business, what more do you look to from supply chain of the plastics industry?

We are compelled to import raw materials like

nylon, wire, PET sheets and stamping foil to ensure international quality standards. This is because we do

not have quality manufacturers of these products in

Bristling Machines ‘State-of-the-art’ pneumatically operated bristling machines imported from Germany, Belgium and

a few from Taiwan. These are fully automatic and

high speed, precision machines. We also have

newer version which are CNC machines that ensure speedy changeovers.

We have also invested in rare and innovative fusion technology.

India. We need to have quality manufacturers of these

products in India who can make on-time delivery at a reasonable price.

Q. Do you wish to highlight areas of upcoming plastic processing technologies that would interest you? What has been the role of automation in your business?

We are a company committed to continuous

innovation and upgradation of technologies relevant

Blister Sealing Machines

‘State-of-the-art’ pneumatically operated blister packing machines which does blister forming, sealing and punching, automatically. We

To know more, please subscribe to

POLYMERS Communiqué at subscriptions@ polymerscommunique.com

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46

INDIA: Tel: +91 9650752420 ndcindia@ndc.com

An ISO9001 Company

POLYMERS Communiqué l August - September 2016

A new generation takes shape. s V i s i t u 16 0 a t K 2 l d o r f, e s s i n D Ăź m a ny Ger

5 Hall 1 5 8 C Stand

Take the proven and tested, make it even better and explore something new – that is what makes ENGEL and their customers so successful.

Following our claim be the first, we will present a new generation of injection moulding machines setting new standards at K 2016. For now, we will entice you with this: We do not compromise on energy efficiency, ergonomics or precision. Do you want to know more?

Meet us at stand C58 in hall 15, starting October 19. www.engelglobal.com

Media for Packaging Professionals Your Partner in Packaging Sector Editor: Prof. (Dr.) N. C. Saha (Director - IIP) - 9819996630 For Advertisement and Articles Contact: Asst. Editor: Bhushan Surpur (Assistant Director) - 9821022112 Email: director-iip@iip-in.com/infoiip@iip-in.com Website: www.iip-in.com

Published By

COLLABORATIVE TECHNOLOGY

Q. Within the sectors you operate in, which sectors are showing a strong and sustainable growth?

Flexible packaging growth is better in this period as compared to semi-rigid packaging. The ban in several states has affected the disposable container segment. However, it does show signs

of improving as some states have realised that

it is not the disposable plastic containers which

are the culprits, which should improve business in this sector.

Khushboo Doshi Executive Director Rajoo Engineers Ltd., Rajkot

Abilities Driving

Capabilities

“Affordable world-class technology, along with comprehensive training and skill development

help us contribute positively to our customers’ business; an approach that will continue to be a

part of our strategy for growth”, says Khushboo Doshi in dialogue with POLYMERS Communiqué.

50

POLYMERS Communiqué l August - September 2016

Q. Your take on Industry 4.0 From the perspective of Rajoo Engineers,

Q. How easy would it be for Rajoo to embark on the next level of expansion?

automation and data exchange technologies

focus, leadership and clarity of thoughts, which

there are two focus domains - employing

Growth is never easy. It does require immense

in manufacturing machines on one hand, and

I am confident we do have. Skilled and trained

our machines being automated and using cyber technology controls on the other hand.

We have taken steps in both the directions.

Cloud based ERP for creating a virtual factory

is already under implementation. Further, our customers using high output blown film lines

already get internet based remote support.

Similar technologies are also being introduced in our complete range of machines. However,

bandwidth and speed for internet access

manpower, globally, will continue to be a challenge as we compete with other emerging

employment opportunities. But, at Rajoo, we have comprehensive training and skill development programmes for existing employees and new entrants to combat this challenge.

Q. How competing or complementing are your relationships with your business partners?

continues to be a challenge.

Our relationships with our partners are

Q. Do you see any regulations / compliances in the near future that would make plastic processing machines more green.

The whole objective is to synergise and be

always complementary and not competitive. partners in progress. With Commodore, we have successfully implemented a project in

Africa. We continue to supply critical parts

We do not foresee any such regulations, but we

to Hosokawa Alpine in addition to offering

our machines more energy efficient which is our

blown film extrusion – fully German plant

Both in blown film extrusion and sheet extrusion,

critical parts from Alpine. WPC (Wood Plastics

continue to constantly make more efforts in

been well accepted in the markets where we

continuously upgrade our technology to make

a range of technologies to our markets in

contribution towards the ‘Go Green’ movement.

and a cost effective hybrid configuration with

our machines are most energy efficient and we

Composite) in partnership with Bausano has

this direction.

use complete extruders from Bausano. It is really

There will be an increased demand on the ability of the plastic processing machines to be

able to process more and more bio or oxy biodegradable polymers, a step towards being more environment-friendly.

Q. What do you consider as the major landmarks in the Rajoo history?

Rajoo now celebrates three decades of

its existence. We have introduced several new technologies in the country – both, in

a win-win for all.

Q. From the customers’ perspective, the two tangible and two intangible benefits that he can enjoy with a relationship with Rajoo.

Cost effective and affordable world-class

technology in addition to efficient after-

sales-support is visible tangible benefits directly contributing to the bottom-line for our customers.

blown film and sheet extrusion segment.

Ethical, spiritual and a professional approach

was indeed a major landmark. Further, I

customers’ trust and confidence in us which

technology partners to the country are

In addition, our upcoming foray into research

Merger with Wonderpack for thermoformers

to our customers has always enhanced

would say that bringing several world-class

has helped us forge family-like relationships.

major landmarks; to name, Commodore of

and development – Rajoo Innovation Centre

USA in foamed PS disposable containers,

Hosokawa Alpine of Germany in blown film segment and Bausano of Italy in PVC pipe / profile extrusion.

POLYMERS Communiqué l August - September 2016

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51

SIVARAM SPEAKS

Energising Energy

Fascinating World of Invisible Polymers

While emerging polymer-based technologies in energy harvesting, conversion and storage must be viewed as platform technologies with diverse end-applications, polymers are increasingly becoming invisible as they become embedded components of many advanced devices and systems, opines Dr. S. Sivaram.

P

olymers were the product of post-war renaissance in the chemical

industry driven by the promise of inexpensive petroleum derived feedstocks. The fifties and sixties saw the introduction of many

polymers that changed the face of human civilisation. From early curiosities, polymers became an indispensable part of our daily living and

so ubiquitous that we no longer realise how dependant we are on polymer materials! The industry grew from zero to present capacities of close to

three hundred million tonnes in about sixty years, the fastest ever growth of any industry in the post-industrialised world.

Dr. S. Sivaram Former Director, CSIR-NCL Honorary Professor and INSA Senior Scientist Indian Institute of Science Education and Research (IISER), Pune

54

Polymers - The Embedded Components in Advanced Systems In the early years, advances in polymer science led to materials and objects

that you could see, touch and feel; however, in the twenty first century,

polymers are increasingly becoming invisible as they become embedded components of many advanced devices and systems. These include

energy harvesting, conversion and storage devices, micro-electronics,

POLYMERS Communiqué l August - September 2016

ingots that are sliced to form wafers. This process is

energy intensive, has poor atom economy, generates

Aluminium

by-products that are not easy to dispose off, uses

chemicals and reagents that are either toxic or have ozone depleting properties and emits humongous PEDOT-PSS

ITO

Glass substrate

amount of carbon dioxide. In fact, it takes an average of six years of operation for a solar photovoltaic facility

to just recover the energy that was spent in creating

the silicon panels in the first place! It is, therefore, Light Donor Acceptor Figure 1: Hierarchical structure of an OPV.

medicine / therapeutics / diagnostics, air and water

purification devices, formulated products such as adhesives, coatings, lubricants, cosmetics, personal care products, construction chemicals, oil and fuel

additives, among others. Polymers were valued for their structural properties in the first wave of its

growth; as they enter the second wave of applications, polymers will be valued for both, structural and

functional properties. Therefore, endowing polymers with a diversity of specific functional properties will

be one of the overarching themes of polymer science and technology in the years to come.

ironic that we consider silicon photovoltaics as a

clean and sustainable form of energy! Additionally, the current ‘top-down’ technology of fabrication of

silicon wafers from ingots is incapable of achieving

the scale of operation that is needed to replace even

30% of the current energy needs of the world. Clearly, there is a technology gap.

The Big Question, Answered It is believed that organic solar cells can bridge this gap2,3. The process is a ‘bottoms-up’ approach, namely,

to create energy harvesting systems from molecules to polymers and finally to a device, using a continuous

processing technique. The technology is likely to be

clean, uses earth abundant materials, light in weight, has low energy intensity for manufacturing, can harvest

electrical energy out of diffuse lights and is scalable.

They are easy to fabricate using technologies already in

One of the key areas of functional polymer

commercial use (roll-to-roll printing, inkjet printing)4,

storage and conversion. Emerging science and

readily placed on roofs, windows, walls and fabrics.

applications is in the area of energy harvesting,

provide unlimited design freedom and can be

technology of polymer applications in this area will

OPV devices are complex hierarchical structures

disrupt conventional technologies and will provide humankind with new and more sustainable options

of energy sources for everyday life. These include flexible organic photovoltaics (OPV) for converting

solar energy to electricity, more efficient lighting devices, polymer-based anodes, cathodes, separators

consisting of a stack of fourteen layers of which

atleast four are polymers that are the active functional

materials. The basic science behind such polymers was described by Alan Heeger (Nobel Prize in Chemistry, 2000) in 19925,6.

and solid electrolytes for safer and more efficient

OPVs have a certified efficiency of conversion of

membranes for efficient fuel cells that convert

devices. The most advanced technologies to date

energy storage devices and selective proton transport

sunlight to electricity of about 11.5% in small area

hydrogen to electricity.

have an energy conversion efficiency of 2 - 3% in

The Big Question

Printing rates are around 1 metre per minute7. The

large area devices with a lifetime of about 2000 hours.

The question that is becoming increasingly important

current maximum achievable capacity for roll-to-roll

of the sun apart from using silicon. In spite of rapid

is a need to scale up the printing technologies to

is whether there is another way to harvest the energy

printing is about 10,000 to 20,000 m2 per year8. There

growth of silicon-based photovoltaics in the last

1 million m2 per year. More material innovations are

twenty years, it should be noted that there are many

problems with this technology1. Solar photovoltaics

manufacturing processes involve converting quartz

to metallurgical grade silicon and then to polysilicon

POLYMERS Communiqué l August - September 2016

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55

FORGING AHEAD

Make in India

Resins, Catalysts and Products “Defence, aerospace and electronics are going to be thrust areas for manufacturing under the ‘Make in India’ programme and will throw new challenges to engineering plastics;

with the ‘Make in India’ campaign of our Government, many technology providers are now harping on JV route to start their plants in India”, enunciates A. N. Jha in dialogue with POLYMERS Communiqué.

Q. What has been the petrochemical import in 2015-16? In which sectors do you see India becoming self-reliant or surplus?

Volume of major petrochemical imports in India in 2015-16

was approximately 11 MMT in comparison to approx. 10 MMT in 2014-15 with 9% spurt.

By volume, PVC remains at the top with imports of almost 1.5 MMT in 2015-16 followed by MEG at around 1.1 MMT. However, PTA (Purified Terephthalic Acid) imports was

drastically subdued to 700 KT from over one million MT in 2014-15 due to domestic capacity addition.

Styrene butadiene rubber import numbers have shrunk from 220 KTA in 2014-15 to 170 KTA in 2015-16.

In polyolefin, impact copolymer polypropylene witnessed reduction of imports by 23% YoY in 2015-16 owing to better availability of grades from domestic sources.

In view of several domestic capacity build-ups, India is becoming self-sufficient in products such as PTA, SBR,

benzene etc. After commissioning of OPaL and full operation

A. N. Jha Executive Director (Petrochemicals) Indian Oil Corporation Ltd. New Delhi

of

GAIL

Univation

line

and

BCPL,

polyethylene availability will also improve significantly.

Post RIL Refinery Off-Gas Cracker (ROGC),

LDPE will also be attaining self-sufficiency.

Several niche grades in PP and PE will continue to remain dependent on imports.

Q. Which new end-use segments are emerging for the plastics industry?

Geo-textiles for infrastructure projects

like roads, airports, retention of sloppy hilly terrain, double wall corrugated pipes for telecom, HDPE gas pipe for city

gas distribution, melt blown PP filters for water purifier, in-mould levelling in thin wall moulding & extrusion blow moulding and blow moulded water

tanks are some of the emerging polymer applications in India.

In addition to the niche applications,

POLYMERS Communiqué l August - September 2016

Flexible packaging is expected to grow at almost 24 - 26%, while rigid packaging is expected to grow by 14 - 16% with organised retail and e-commerce providing necessary thrust.

emerging growth areas are being

changer

such as Make in India, Smart Cities,

open up new avenues for the Indian

created with new Government initiatives Digital India, AMRUT etc. These are the additional growth drivers for end-use

applications in India where polymers can play a pivotal role.

Defence and aerospace are two sectors which are surely going to be a game-

in

Indian

manufacturing

industry. Both of these industries will polymer industry.

Similarly, infrastructure will be the prime

focus as it is the heart of any development.

With rising emphasis on increasing axle load of freight trains, dedicated freight corridors, high speed trains and

59

improved life of roads, geotextiles will

Digital India for connecting 2,50,000

Plinth (CAP) where huge wastage was

objectives. Other major thrust will come

RailTel, defence and several private mobile

technology has not been adopted by

play an important role in achieving these

from electronics and automotive vehicles wherein plastics may be an elixir for both these sectors.

Q. Currently, which are the fastest growing end-use segments?

gram panchayats project by BBNL, PGCIL,

operators are consuming about 0.15 MMT HDPE for teleduct application.

Agriculture is one sector which despite

having huge potential has not been able to register high growth, but with

encountered; but unfortunately, this some other states where every year, heavy wastage is encountered in storage

of foodgrains and it is also cost-effective

in comparison to steel warehouse of godown storage.

Automotive, packaging, HDPE pipes in

the slogan of ‘More Crop Per Drop’ of

Besides the above, I foresee the following

appliances are some of the fastest growing

that micro-irrigation is all set to get a big

in India:

water supply as well as teleduct, and

our Hon’ble Prime Minister, it is expected

end-use segments at present.

thrust in coming years and is forecasted

However, plasticulture, food processing

2.5 times of GDP.

and post-harvest management are also

expected to grow at a faster rate due to

to register a growth rate of minimum 2 to

around 18 - 20%. Two wheelers is going

understand the reality of today. The

to grow at 8 - 10%.

Similarly, flexible packaging is expected to grow at almost 24 - 26%, while rigid

Before

discussing

strategy,

let

l

is approx. 7.6 kg as against the world average of close to 30 kg.

Change of Perception is the Need-of-

providing necessary thrust.

Several myths around plastics in terms

It is expected

microirrigation is that

hazardous

approach

like

and

environmental

unfriendly issues are to be tackled first by way of proper awareness campaigns,

demonstrations etc. Polymer is inert and

fund

on

development

for

research

and

technology

the

Indian

Oil

INDMAX

has

developed

technology

propylene maximisation.

l

for

Skilled manpower availability needs to be increased through academia partnership

models:

Domain

specific training centres and foreign collaboration.

Q. The impact of the current band of oil prices for the petchem business?

much better sustainable resource for the

Availability of cheap feedstock is of

to several conventional materials.

petchem business. At present, due to

all set to get a big

Effective plastics waste management

the economics favour naphtha cracking

thrust in coming years

to be in place by way of enforcement

and is forecasted to register a

growth rate of minimum

2 to 2.5 times of GDP. 60

the-hour

More

viz.

per capita consumption of polyolefin

of

cluster

PCPIR for leveraging advantages with

innovation and commercialisation

us

packaging is expected to grow by 14 - 16%

with organised retail and e-commerce

Dedicated

attracting investors.

‘Make in India’ initiative, especially in auto components for passenger vehicles will be

l

Government incentive schemes for

Q. What strategy do you suggest to increase the per capita consumption of plastics in India?

very favourable monsoon this year.

as strategy for increasing the per capita

industry and less polluting when compared

with respect to mechanical recycling is of segregation of plastics at source and avoidance of littering.

With change in perception, people will

have better acceptability and will not think twice before using any plastic finished product. Swift adoption of

technology is also necessary and the

Government can play a pro-active role in that. For e.g., Madhya Pradesh has shown

the way ahead and resolved one of their

major problems with plastics - storage of wheat in scientific PE based silo bags in place of open storage with Cover and

paramount importance for sustainable lower crude price and hence naphtha, compared to gas or condensate.

Due to this price band of crude, several

gas cracker projects including shale gas of North America are slow on addition.

Several coal to olefin through MTP or MTO route are also on hold in China. Similarly, PDH through propane / butane are also uneconomical at present.

While naphtha cracker makes money at

this band, Middle East is suffering due To know more, please subscribe to POLYMERS Communiqué at

subscriptions@polymerscommunique.com

POLYMERS Communiqué l August - September 2016

It’s produced on Lohia Machines Our machines not only extrude tapes and weave fabrics but also coat, print and convert to produce world class flexible packaging for a wide range of solid materials like food grains, fertilizers, cement, animal feed and minerals, including special applications like tarpaulins, geo-textile and big-bags.

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Winding .

RECYCLING PAGES

Sponsored by

Recycling Agricultural Films

Economically Feasible

Enterprises within the business area of post-consumer recycling report will be able in generating sufficient profit-levels to support their business on the long-term. Recycled PE can be used for processing towards applications as agricultural films or pipes or garbage-bags, indicate Oliver Jahnke and Michael Heinzlreiter.

Shaping a Feasible Business Model AFA Nord GmbH, located in Northern Germany, started

with the recycling of agricultural film in March 2012 and is in the front-line of companies changing our economies from ‘linear’ to ‘circular’. “Other than most commercial enterprises, the organisational set-up needs

to be equally strong in purchasing power, as well as in sales - this, because the sources of input materials have to be secured for constant input into the washing-line and subsequently to the further downstream equipment

of extrusion and pelletising”, reports Oliver Jahnke,

Oliver Jahnke Plant Manager AFA Nord GmbH, Germany

Plant Manager, AFA Nord GmbH. The company has

contracts with farmers all around Northern Germany

and neighbouring countries, where the used agricultural films are being purchased. “Some farmers bring the

materials and others prefer pick-ups from our end. All are being refunded on a price per kg basis”, conveys Oliver Jahnke.

POLYMERS Communiqué l August - September 2016

Michael Heinzlreiter Head of Marketing Next Generation Recyclingmaschinen GmbH Austria

63

Sponsored by

Material Flow Material Collection

Material Sorting

Grinding, Washing, Drying

Material flow as organised by AFA Nord.

Extruding, Filtration, Pelletising

(Source: AFA Nord)

Economy of Recycling PE Agricultural Films

The basic formula: Higher quality equals higher

price is the key-point for running an operation

The key-points in making the recycling of

agricultural films economically feasible are,

like AFA Nord.

besides securing a constant flow of incoming

Efficient Separation of Impurities, Increasing Value of r-LDPE

washing plant and the extrusion equipment,

Although the PE-flakes exit the washing-line

programme including the control of r-LDPE

lower than 1%, yet impurities need to be

materials, the correct dimensioning of the as well as establishing a quality assurance quality. The output-level is 1450 kg/h, operating

in three shifts. All equipment and qualityassurance-measures

are

focused

towards

producing r-LDPE to a quality-level to again being able to produce r-resin, which can be sold to plastic converters, for applications as agricultural film or pipes or garbage-bags.

in very good condition and at moisture levels removed at a flow of 1450 kg/h at minimal material-spill. AFA Nord uses an automatic

band melt filter. Once the filter-area is full of contamination, a valve closes the material

flow from the extruder. The material is then bypassed into a storage-cylinder, leaving the extruder running on full capacity.

The feeder-extruder-combination with sophisticated filtration.

64

POLYMERS Communiqué l August - September 2016

Sponsored by

1600 1500 1400 1300 1200 1100 1000 900 800 700

3 3 3 3 3 3 3 3 3 4 4 4 4 r. 1 y 1 n. 1 l. 1 g. 1 p. 1 t. 1 v. 1 c. 1 n. 1 b. 1 r. 1 r. 1 Ap Ma Ju Ju Au Se Oc No De Ja Fe Ma Ap

r-LDPE dark

virgin LDPE nat

Figure 1: Pricing-comparison between film grade virgin-LDPE and film grade r-LDPE in EUR/tonne for 12 months. As rule of thumb, the r-LDPE is marketpriced half than that of virgin-LDPE. (Data Source: www.kiweb.de as of 6th May, 2014).

Automatic band melt filter with a capacity of 1450 kg/h.

Now, the brackets holding the screen can be opened to enable the screen-band to move

forward. By this movement, the impurities caught by the screen are removed with the screen itself and the next ‘fresh’ screen area

is introduced and again clamped by the screen-brackets. Now the valve opens and gives way for the material-stream coming from the extruder and the material collected

in the storage cylinder is slowly added to the melt flow.

With this system, the fineness of filtration can be tuned down to 2.75 mil (thou). The cycle of

Screen-band in contaminated condition.

‘screen-change’ can be done within 18 seconds.

Depending on the size and structure of the

impurities themselves, the typical material-spill

is lower than 0.2%. Typically, one role of screen-

band allows an operation of one shift (8 hours).

The screen-band can then be ‘elongated’ by adding the next screen-roll-end by means of spot-welding.

Conclusion

New directions

in changing our

economies from

‘linear’ to ‘circular’

can be supported

by using plastic

materials, like PE for films.

New directions in changing our economies from

‘linear’ to ‘circular’ can be supported by using plastic materials, like PE for films. The business

models of companies providing such services have to put equal focus on the purchasing routes as on selling routes to ensure constant

material-flow. Enterprises within the business

area of post-consumer recycling report will

be able in generating sufficient profit-levels to support their business on the long-term.

Recycled PE can be used for processing towards

applications as agricultural films or pipes or Screen-band in virgin condition.

POLYMERS Communiqué l August - September 2016

garbage-bags.

65

INNOVATIONS TO PRESERVE RESOURCES AND REDUCE WASTE...

STARTING NOW. Non-rigid containers that offer numerous sustainability benefits. Protective wraps that can double the shelf life of fresh-cut produce.* And that’s just a sample of real-world answers in place today from Dow. Learn more about how Dow can help address today’s challenges and inspire packaging solutions of tomorrow.

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*Per independent tests.

Additional information is available upon request. ®™ The DOW Diamond Logo is a trademark of The Dow Chemical Company © 2016

ADVERTORIAL

T

he recent guideline from the Government of

India on, ‘Plastic Waste Management Rules 2016’

spotlights plastics waste minimisation by phasing out

manufacturing and use of non-recyclable, multi-layered, multi-polymer packaging in the next two years. This calls for

a collective response from the industry to address current waste management issues.

Flexible Packaging: A Preferred Choice Changing lifestyles and the increasing dependence of consumers on packaged food, home and personal care

products are increasing the use of flexible plastics packaging.

Rigid packaging such as bottles, cans, tins, glass and plastic containers are gradually being replaced by flexible

packaging because of its convenience. Its lightweight and superior barrier properties coupled with prudent use of

material resources and high-quality printability make it a good alternative.

Flexible pouch, as a mono-layer or multi-layer, when made

from one polymer family is fully and easily recyclable.

However, Brand Owners (BOs) currently face the challenge

to create an all-encompassing flexible package that provides

Mono-Material PE Flexible Packaging Solutions

Addressing Recycling Issues Adopting all PE packaging laminates will be the first step towards recyclability postconsumption. Greater collaboration among value chain partners, including retailers and consumers, will enable the industry to create and sustain an environmentallyfriendly circular economy while keeping flexible plastics packaging as the preferred packaging option for years to come.

POLYMERS Communiqué l August - September 2016

67

from

beverage cans and tins (aluminium

adopt a more sustainable solution using

any other ingress to protect

plastic bags (PE or PET) are all easily

solution - all polyethylene (PE) laminate.

enough

protection

oxygen, light, moisture and the product ab initio, in

addition to the shelf-

life that consumers, retailers

and

The

existing

suppliers require. makeup

of

a

flexible

is

hence

package

multi-material

laminated

meet

desired

together

majority

packaging

to

functionality

and economics.

The

layers

of

materials

flexible today

require at least two different polymer substrates, polyester (PET) as the print layer and polyethylene (PE) for sealing.

For

products

further

which

enhancement

may in

require barrier

properties, additional layers could

include aluminium foil, metallised

or steel), paperboard boxes and some recyclable

to recover the various components of the multi-layers and convert them

individually into new recycled resins.

the

materials

used to make the package are either

mono-material or easily separated.

This allows the creation of a highvalue material that can be re-used in the same application from where it is originated.

In flexible packaging, the high value and

performance

complex

film

created

structures

using

to

meet

all requirements has unfortunately resulted in the un-recyclability of the

package.

Adhesives,

mixed

materials and coatings each create

complications that make it extremely difficult

to

and recycle.

classify,

separate

To make the whole plastics waste

management and recycling efforts more meaningful and economical, BOs can

This

enables

OPET Adhesive LLDPE / LDPE LLDPE / LDPE mLLDPE / LDPE

All PE Laminate

quality

in combination with virgin resins in

similar plastic converting processes.

However, due to the sheer number of

compositions in multi-layered packaging laminates, this recycling process is

often too difficult and complicated to implement.

The Need for Recyclable Flexible Packaging A

look

into

the

way

packaging

recycling has evolved will reveal that professional recyclers are only working with packaging types that are fairly

make

and

performance

while

generating completely reusable material for recycling at the end of its lifecycle.

All mono-material PE flexible packaging laminate can be considered ‘recyclable’ and ‘environmentally-friendly’.

India Case Study: All PE Mono-material Flexible Packaging for Salt Packaging Leveraging its innovation platforms and broad range of PE resins, Dow

Packaging and Specialty Plastics has developed a unique combination of

PE resins to create the all PE monomaterial flexible laminate for various

powder packaging including salt. The laminate was developed using existing DOWLEX™ ELITE™ DOWLEX™ Adhesive / PE Film

Blown Sealant Film

The process which is called ‘cradleto-cradle’ recycling can then be used

to

resin, i.e. PE, which meets packaging

Blown PE or Cast PE Film

PET / PE Laminate

companies

packaging films using only one polymer

12 µ PET// 38 µ Blown PE Film

films, paper or barrier resins.

To recycle flexible packaging, it is crucial

because

‘mono-material’ such as Dow’s latest

ELITE™ + LDPE ELITE™ + LDPE ELITE™ + LDPE

Figure 1: 2 - ply laminate structure.

Table 1: Comparison of Various Attributes of Films Attribute

PET FILM

Conventional

PE Solution

Barrier, WVTR

Poor

Good

Excellent

Printing Flexibility

on Rotogravure

+ + +

+

+++

Stiffness

+ + +

+

++

Optical Properties

+ + +

+

++

Low

High

Low

+ + +

+

+++

Gauge Variation Balance of Orientation

PE Film

from Dow

standardised. Bottles (PET and glass), ®TM Trademark of The Dow Chemical Company (“Dow”) or an affiliated company of Dow

68

POLYMERS Communiqué l August - September 2016

1.5

Table 2: Dow’s Solution for PE Print Substrate: Benefit to Stakeholders in Packaging Value Chain

Puncture

1.0

Elmendorf Tear (TD)

COF (F/M)

0.5

Value Chain

Dow’s Solution

All PE Laminate

l

l

l

Printing

l

Stakeholder

0.0

Print PE film can be made upto 20 micron thickness on

Sealant PE film can be made on existing blown film

Lamination can be done either by adhesive lamination

Dow

Manufacturing

WVTR

Elmendorf Tear (MD)

PET / PE Cast PE / Blown PE Blown PE / Blown PE

Figure 2: Comparison of 50 micron laminate properties made with commercial film extrusion equipment.

manufacturing infrastructure and has

replacing multi-polymer, multi-layered

l

flexible packs.

The all PE laminate is a sustainable

flexible packaging solution from Dow

that enables effective recycling and reuse of flexible packaging material post-

consumption. This fuels a sustainable circular economy, helping BOs comply

with evolving Government regulations regarding plastics packaging in India. revolve

around

functionality,

aesthetics and supply driven dynamics

of various substrates to the industry.

Polyester films are generally preferred

as the print layer while PE films display higher performance in sealing, abuse developments

in

print

film

can

run

on

existing

Printing stretching ability is three times lower than

conventional PE film on rotogravure machines giving

All PE packaging laminates can run on existing

l

Offers high temperature resistance

l

Packaging Lines

Offers twice the bending stiffness as compared to

l

Good optical properties (gloss and contact clarity)

l

conventional PE film

packaging lines for powder packaging with minor modification on sealing jaws

Opportunity to save on the film width as PE-PE laminate

l

Sharp and clean cut of laminates without threading as

l

Runs at same speed and efficiencies

l

seen in conventional PE films

can be lap sealed (i.e. seal with two layers of substrate

overlap, forming a bond with no material standing out

catalyst

from the package)

technology and manufacturing process

in the last few years, PE films have

PE

rotogravure machines without compromising on

resistance and ease of processing.

With

or extrusion lamination using PE

excellent print registration

Most of flexible packaging laminates today

extrusion line

printing speeds

the potential to extend to a range

of products, from solids to liquids,

existing blown or cast extrusion line

significantly expanded its breadth in

Dow has designed a unique PE film to

be the first step towards recyclability

These advances now allow surfaces of

conventional PE film while effectively

among value chain partners, including

density and toughness-stiffness balance.

PE films to be printed, much like PET

and BOPP, and when combined with existing sealant films, create an all PE

laminate that can meet performance requirements

of

packaged products.

vast

majority

of

POLYMERS Communiqué l August - September 2016

overcome most of the drawbacks of replacing the print surface of the PET

film. Table 1 provides the comparison of various attributes.

In Conclusion Adopting all PE packaging laminates will

post-consumption. Greater collaboration retailers and consumers, will enable the industry to create and sustain an

environmentally-friendly

circular

economy while keeping flexible plastics packaging as the preferred packaging option for years to come.

69

PACKAGING WHITE

Milk in PET

Proven, Light and Inexpensive “Assuming an annual output of 70 million, a

manufacturer will save € 960,000 on material costs with PET alone compared to an HDPE bottle

(calculated with an average PET raw material price of € 1,150 per tonne). Also compared to 24-gram single-layer packaging, the

financial advantage as a result of additive savings jumps to € 1,386,000”, highlights Reto Bamert.

‘What counts is on the field’. This old saying from the world of soccer, although slightly altered,

also applies to the packaging industry, for which it would be: ‘What counts is on the shelf’. This is

because whenever new low weights for PET bottles are announced, it is worth taking a closer look and

questioning the provided information. For example,

when it comes to containers for milk products.

Ultimately, the deciding factor is sustained success in the market.

A Look Into the Milk Pack What First?

Reto Bamert Head of Business Unit PET Systems Netstal-Maschinen AG Switzerland

70

Anybody who wants to fill milk into plastic bottles

has to make many decisions. HDPE or PET? If PET, then one, two or three layers? Which options are even

suitable for the desired expiration date? Also, what is

best from an economic perspective?

POLYMERS Communiqué l August - September 2016

In many parts of the world, HDPE packagings

remain widely popular even though they have some significant disadvantages. For example, their significant weight. In addition to the

approximately 30 grams needed for a one-litre

bottle, production requires 30 per cent more material and energy - and the raw material price is significantly higher than that of PET. HDPE also has 20 times lower oxygen and CO2 barrier effect.

Lastly, the design limitations of extrusion blow

moulding are quite severe, which is a significant problem in an era in which optical differentiation is in high demand in all consumption areas.

What’s Next?

of expiration

dates. It comes

with a shelf-life time of

upto six months and thereby surpasses

fresh and so-called, ‘extended shelf-life’ milk

Once a decision in favour of PET has been made,

(approximately 21 days) by far. Single-component

are some single-layer preforms that, at first glance,

manufactured with existing production lines and,

it was announced that the weight had been

new machine. However, there is also a downside

that low weight is achieved with a 32-millimetre

Single-layer preforms require a large amount

the question of the layers must be settled. There

preforms offer a supposed advantage: They can be

appear to be unbeatable lightweights. Recently,

therefore, without investing in a new mould or a

reduced to 20 grams per litre of milk. However,

that quickly negates the anticipated savings:

thread, which is not very popular in the market (38 millimetre is standard) and without information

on whether the bottle can be filled with ultrahigh temperature treated (UHT) milk - the queen

POLYMERS Communiqué l August - September 2016

To know more, please subscribe to

POLYMERS Communiqué at subscriptions@ polymerscommunique.com

71

ADVERTORIAL

Think Thin The industry must meet requirements in a sustainable manner that increases efficiency and reduces carbon footprint. Borstar range of bimodal polyolefin resins provides superior characteristics that allow converters to produce collation shrink film with less material, while maintaining excellent pack integrity.

G

lobal population is expected to increase to 9.7 billion by 2050. This, combined with increasing urbanisation and changing consumer lifestyles, is changing the food production and packaging industry.

Fresh products from rural areas have to travel further to reach customers in towns and cities, while the general consumers seek more convenient

products that better suit their lifestyles, in packaging that ensures content integrity of what they buy. At the same time, the industry must meet

these requirements in a sustainable manner that increases efficiency and reduces carbon footprint.

The Trends The trend in flexible packaging film is moving towards multi-layer,

POLYMERS Communiqué l August - September 2016

73

co-extrusion film structures with enhanced properties and performance features. Flexible

packaging converters are continuously sourcing for raw materials that give the best cost / performance balance in order to maintain their

market competitiveness. Use of collation shrink film in multipacks for bottles and cans has been

growing steadily. Today, consumers tend to buy larger quantities in multipacks, which are convenient to carry. Furthermore, adding a high

quality print to the film enhances the product’s consumer appeal even more at the point of sale (POS). As a result of increased requirements for

optical performance, packaging line speeds and cost reductions through downgauging, collation shrink

films

have

undergone

continuous

development. Collation shrink film occupies a big part of the PE film market. They provide

Collation shrink film occupies a big part of the PE film market. They provide

significant value in the supply chain by enabling

cost-efficient product protection and stability during transit.

significant value in the supply chain by enabling

is its Borstar range of bimodal polyolefin resins

during transit.

allow converters to produce collation shrink film

The Borouge Value-add

pack integrity.

cost-efficient product protection and stability

with less material, while maintaining excellent

Inferior shrink packaging can be damaging

not only to goods, but also to profit and brand reputation. Flimsy shrink film that tears apart and spills its contents does not just annoy and

inconvenience

consumers,

which provides superior characteristics that

it

wastes

precious resources that go into producing

the goods and affect a store’s bottom line.

Among Borouge’s solutions to this challenge

Borouge provides the food value chain with

a portfolio of plastics packaging solutions, meeting the international standards of quality

and durability for all food and beverage packaging

applications.

High

performance

Borstar polyolefin solutions are sustainable alternatives to glass, metal and paper for

the entire food value chain processing and

packaging industry. They enable packaging suppliers to better manage storage

logistics, facilitate transportation and

minimise

breakage,

spillage and spoilage of food the

causes

of

food

waste.

The innovative solutions for advanced food packaging are recognised for their durability,

high

impact

resistance

and

their capability to protect, thus

ensuring the integrity and shelf-

life of the packed food without

compromising its taste, odour or freshness.

(For more information from Borouge Pte. Ltd., visit www.borouge.com)

74

POLYMERS Communiqué l August - September 2016

EXTRUSION | PRINTING | CONVERTING

What do you get when teams of brilWhat do youscrutinize get when each teamscomponent of brilliant minds liant minds scrutinize each component of the proven VAREX range to make of the proven to superb make it even better?VAREX Higherrange output, it even better?

Higher output, superb ergonomics, improved safety and a ergonomics, safety and a new world ofimproved energy efficiency. new world of energy efficiency.

More than just a pretty face: VAREX II. More than just a pretty face: VAREX II.

VAREX II’s modular design provides flexibility for producing blown films from diverse resins.

With the new ENERGY MONITORING module, VAREX II’s modular design provides flexibility you get real-time data, making it easier than ever for producing blown films from diverse resins. to identify potential savings. And that’s just the With the new ENERGY MONITORING module, beginning ... you get real-time data, making it easier than ever to identify potential savings. And that’s just the beginning ...

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Windmöller & Hölscher India Pvt.Ltd.

KICK-START

P

LASTINDIA

2018,

Conference

and

the

10th

event not only brought together stalwarts

Convention

but also trade leaders and policy makers

International Plastics Exhibition,

promises to present the very best of the growth of the plastics industry.

from the world of plastics manufacturing, that share the common vision of propelling

the plastics industry towards exponential

The evening of 9th September, 2016

growth. The inauguration aptly claimed

PLASTINDIA 2018 to be held between

for any player in the plastics paradigm

witnessed

the

inauguration

of

the

7th and 12th February, 2018 in Gujarat. This

that PLASTINDIA 2018 is the destination anywhere in the world.

Power Packed Presence Graced by the presence of Avinash Joshi, Hon’ble Joint Secretary Petrochemicals, Department

of

Chemicals

and

Petrochemicals, Ministry of Chemicals

and Fertilizers, Government of India and Nikhil Meswani, Executive Director, Reliance

Industries

Limited;

the

Plastindia Foundation (PIF) represented

PLASTINDIA 2018 Launched

Furthering Progress NEXT is HERE!

Progress with Plastics - tough to miss this industry, tough to miss its impact, still tough to miss this event – PLASTINDIA 2018!

PLASTINDIA 2018: Expected Numbers by

K.

K.

Rajeev

Seksaria,

Chitalia,

President

Chairman

–

and

NEC,

PLASTINDIA 2018 announced the launch

of the much awaited PLASTINDIA 2018,

the 10th International Plastics Exhibition,

Conference and Convention. As expected,

the inaugural event revealed interesting perspectives on the future of the plastics

industry in India and the scope of growth.

Kick-started by the welcome address of

Area: 1,25,000 sq.mts.

and

Exhibitors: 2000+ Overseas Companies: 600 Participating Countries: 40 Visitors: 2,00,000+

PM Narendra Modi’s poem.

Building the excitement to the main event, the launch too was carried

out in great grandeur. The special guests on the dais and the PIF leaders

inaugurated this 10th International Plastics Exhibition, Conference and Convention by unveiling the Plastindia app to the fraternity. Displaying the various

facets and advantages of the app, the

PLASTINDIA 2018 was declared open by announcing calls for participation. A

video highlighting the past events and the new developments in the plastic industry enthralled the audience.

Plastics, the Sunrise Industry Plastics is one of the fastest growing

industries in India and the world. The per capita consumption of plastics in

India stands at 10 kgs against the global

average of 30 kgs. This itself is testimony

to estimate the growth potential of this industry in India.

Currently, India is the 4th largest plastics

manufacturer in the world while China ranks 1 . However, growth of the plastics st

industry in India has been higher than

the GDP of the country in the recent

With Make in India is in full swing, the great boost, thus making India a global hub for plastics manufacturing.

Various factors like rapid industrialisation, urbanisation, changing lifestyles and growing youth population are offering a great array of opportunities to the plastics

industry. Furthermore, India is one of the

few countries that is growing at a steady rate of 7% (GDP) in the present day. With

multiple development programmes like

Make in India, Digital India, Swachh Bharat Abhiyan, Smart Cities project etc., the

demand for plastics is only going to sky rocket thus giving the industry yet another

stream of opportunities and a golden

chance to contribute to the progress story of India, with PLASTINDIA exhibitions playing the pivotal role of being a catalyst.

By 2020, the estimated use of plastics is set to rise to 20 million metric tonnes from

the current 12 million metric tonnes. In the coming decade, India will more than

double its plastics consumption. From advanced plastics in renewable energy to sturdy plastics for smartphones to

recycled plastics that caters to the rapidly changing lifestyle; the growth potential

is huge. Exports of plastics finished

goods alone is set to nearly double from USD 7.9 billion currently to USD 15 billion in the next 5 years.

years and this only shows the potential to rank higher in the world order. India

PLASTINDIA 2018 - Set to Raise the Bar Still Further

already exports to over 150 countries; the industry is poised to witness a 2x

Over the years, PLASTINDIA exhibitions

growth in the consumption of plastics

have provided a great platform to showcase

POLYMERS Communiqué l August - September 2016

India’s

2000 exhibitors, today.

Apart from integrating the plastics

and the 3rd largest in the world, triennially.

plastics industry in India is set to get a

the nation”, as he quoted a few lines from

grown from 500 exhibitors in 1990 to

the largest plastics convention in India

INR 3,000 crore

of the upcoming event. He said, “The vision of PM Narendra Modi in building

and

organises the PLASTINDIA exhibitions,

Business Turnover:

in the packaging industry in India alone.

plastics industry will jointly support the

capacity

industry and its various activities, PIF

the President of PIF, K. K. Seksaria, the

launch event highlighted unique features

manufacturing

capabilities; and the exhibition has

plastic

products

From the 1st edition in 1990 to the 10th in 2018, Plastindia has grown multifold.

“PLASTINDIA 2018 will span over 1,25,000 sq.mts. across 15 state-of-the-art halls

and brings together over 2000 exhibitors

(with 600 overseas companies from over 40 countries) to display products, innovation and technologies,” said Rajeev

Chitalia. “We truly believe that the Indian

plastics industry is on the threshold of a big revolution and with PLASTINDIA 2018,

we surely will make the world say, ‘Next is Here’,” added Rajeev Chitalia.

Next is Here Presence of the special guests, Avinash

Joshi and Nikhil Meswani, made the inauguration of this much awaited event

even more exciting. The audience had the chance to share and interact with visionaries of this industry.

In his address to the audience, Nikhil Meswani reminisced his early days as a

young boy in 1990, when the industry spoke about the 1st PLASTINDIA event,

during this time plastics consumption was less than one million tonne. He applauded its phenomenal growth ever since. He

said that plastics consumption in India has grown from less than one million tonne then, to over 15 million tonnes today (infact 20 million tonnes, including

recycled material); and he believed that

it will cross 25 million tonnes by 2018, especially looking at the new capacities

coming in. “In a world of uncertainties, To know more, please subscribe to POLYMERS Communiqué at

subscriptions@polymerscommunique.com

77

WAY FORWARD

Information, Infrastructure and Implementation Critical for Sustainability with Plastics

“The first issue for the industry whose turnover would cross Rs. 1,50,000 crore needs to put in place a well-planned social communication 5-year plan. Create awareness of the hundreds of uses of plastics that benefit Indians, the way it serves to be eco-friendly and show them the way the plastic waste needs to be disposed so that every kilogram gets recycled into useful products,” points out Vijay Merchant in dialogue with POLYMERS Communiqué.

Q. The ban calls on plastics are adversely disrupting industry working. What do you see as way forward?

Ad hoc bans disrupt any trade and industry. Every business needs clarity in policy and implementation by authorities that are fair

and reasonable. Uncertainty hurts not only business, but also

common citizens i.e. the consumers. India is a very large country with 29 states. If one city or state announces some bans, but the

neighbouring city or state does not, obviously it becomes unfair.

There will be cross-border movement of materials hurting those who respect laws and benefit the rule breakers.

In the case of plastics, by and large, the bans are not announced because the material is bad or hazardous, but because the solid waste management system is not being put in place as per

central guidelines. Without proper waste collection infrastructure in cities and towns and apparent laxity in implementation of

simple waste and anti-litter rules, the collection and disposal of post-consumer waste will always be an issue. The way forward is to manage short-life packaging items that create plastic waste. All

stakeholders need to join in and share responsibility facilitating Vijay Merchant Senior Advisor Environment Plastindia Foundation Past President, AIPMA IPI Member Governing Council of ICPE, Mumbai

80

collection and recycling the waste. It can be done and is being done in several countries not only in almost 30 countries of

Europe and in America, but also in Singapore, Australia, Japan To know more, please subscribe to POLYMERS Communiqué at subscriptions@polymerscommunique.com

POLYMERS Communiqué l August - September 2016

KNOWLEDGE FORUM

S

ociety of Plastic Engineers is a global

A masterbatch is also an additive. The

technical conferences. Society of

concentrated mixture of pigments and/

leader in arranging seminars and

Plastics Engineers India (SPE India) has been managing seminars and technical

conferences to create platforms for techno-commercial discussions within the plastics industry.

only difference is that a masterbatch is a

or additives encapsulated during a heat process into a carrier resin.

Steady

economic

industrialisation

growth,

and

rapid

increased

penetration of plastic products are the

One such conference is the PAM 2016

key driving forces in the market. Product

masterbatches and compounds.

the major strategies adopted by the

The Rational

competitive edge in the market. Further

which is focused on polymers, additives,

The simplest definition of an additive could be ‘a chemical that adds to the value of a product’. Additives come into play when the product to be manufactured needs to

be given special attributes. It could be just

a differentiating colour or special features

such as stabilisation against heat and light;

innovation and differentiation are among masterbatch manufacturers to gain a growth in the market is forecast to come

from emerging economies and growing demand from the end-use markets. India

especially stands out as a noteworthy

market given the production activities, increase in foreign investment and rise in number of manufacturing establishments.

additives play a significant role in taking

Technology advances that help impart

position. Except for the specific end-use

while simultaneously optimising cost, is

polymers to a commercial and respectable

applications of some medical or food

contact requirement - where the polymer

is almost additive free, all other application requirements are met with significant contribution of additives. Even at the ppm

level of dosing, they are as important as salt in food preparations!

desired colour and property to plastics,

also expected to turbocharge growth in coming years, particularly against the backdrop of evolving demand

for high performance and functional products from various end-use sectors.

Demand for improved performance

will continue to push manufacturers

PAM 2016

SPE India Conference

to invest in R&D efforts to improve product capabilities.

Global market for masterbatches is

projected to reach USD 11 billion by 2020 driven by rising demand from end-use markets such as packaging and consumer goods, among others. Europe represents

the largest market, worldwide. Asia-

Pacific is projected to register the highest CARG of ~ 6%. Colour masterbatch which find application in the production of plastics for appliances, food & beverage, automotive

and

pharmaceutical

packaging accounts for the largest share

of the global market in volume terms.

Additive masterbatches, on the other hand, are forecast to witness the fastest

growth driven by increased demand in personalised plastic products. With manufacturers of consumer products seeking

packaging

materials

that

facilitate low cost production and ensure

product protection during storage and

transportation, the demand is expected to rise for advanced masterbatches that offer functional performance as well as To know more, please subscribe to POLYMERS CommuniquĂŠ at

subscriptions@polymerscommunique.com

The SPE India PAM 2016 technical conference to be held on 8th and 9th December, 2016 at Hotel Leela in Mumbai.

@ K 2016

Brückner @ K 2016

Increases Efficiency of Its Film Stretching Lines Intelligent Line Management

8.7 m. For K 2016, Brückner Maschinenbau

combination with newly developed

output with ever shorter delivery times

time ever in the world. This will fulfill the

production costs. Furthermore, these

running a film stretching line a highly

production: The new lines convince with

their operating personnel stand before

the proven speeds of up to 515 m/min.

to guaranteeing a stable and efficient

Brückner

and

will present a 10.4 m concept for the first

and growing demand for quality make

demands for higher productivity in BOPET

complex business. Film producers and

around 20% more output capacity with

increasing challenges when it comes

Film producers can hereby profit from

A new winder system caters for higher

production with the highest quality film.

from many successful projects with over

lines can take 40% more winder length

Continually

This

is

increasing

where

speed

Brückner’s

Maschinenbau’s

experience

10 m working widths, from fewer specific

lubrication

basis

for

lower

also available for upgrades on the current high-performance lines.

line efficiency. In the future, Brückner

by increasing the winder diameter from

1.55 m to 1.8 m. More winder length means fewer roll changes

(ILM) comes in. This is an solution

the

newly developed lubrication materials are

‘Intelligent Line Management’ integrated

is

and

which

which

smooths the way for Brückner’s

therefore, effects

less

waste

productivity,

changeover time and energy

customers’ ‘Smart Production’

consumption for the entire line.

and ‘Industry 4.0’. The focus here

lies on a new way of operating lines, putting emphasis on the

BOPA: Higher Yield on Simultaneous Lines

process view as opposed to the usual machine view. This

Brückner

growing interest in the market

new operating concept is

supported by an increasing amount of assistant systems.

Film producers will find it easier to produce highest film quality all over the world, independent of surroundings, time, climate and weather conditions.

BOPET Lines with 10.4 m Working Widths Now-a-days the established working width

for lines that produce biaxially stretched polyester packaging film (BOPET) is

for

has

polyamide

noticed

a

packaging

production costs as well as reduced

films and offers a selection of line

overall profitability.

Simultaneous Stretching) simultaneous

energy consumption and therefore, better

BOPP Lines: Lower Operating Costs with Higher Efficiency Brückner’s newly designed sliding system for transversely stretched film means speed increases from over 600 m/min. At

the same time, newly developed materials led to a reduction of the lubrication use by more than 50%. The new design in

types. Brückner’s LISIM (Linear Motor

stretching process is enjoying an increased demand as BOPA film can

be produced in the highest quality and with optimised finishing characteristics.

For K, the company presents LISIM

BOPA lines with a working width of 6.6 m, instead of the usual 5.1 m. This

increases output by a good 30% and substantially increases productivity.

It’s our country, let’s keep it clean!

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POLYMERS Communiqué l August - September 2016

Events VietnamPlas 2016 28th September – 1st October, 2016 Saigon Exhibition & Convention Center - SECC, Ho Chi Minh City, Vietnam

10th Plastivision India 2017

Chinaplas 2017

25th Fakuma

19th – 23rd January, 2017 Bombay Exhibition Centre, Mumbai, India

16th – 19th May, 2017 China Import & Export Fair Complex, PR China

17th – 21st October, 2017 Friedrichshafen, Germany

Plastics Recycling 2017

PLASTEC East

19th – 26th October, 2016 Düsseldorf, Germany

6th – 8th March, 2017 Hyatt Regency, New Orleans, Mexico

13th – 15th June, 2017 Jacob K. Javits Convention Center, New York

11th – 14th December, 2017 Expo Centre Sharjah, UAE

Plast Show 2016

PU TECH 2017

6th Plastasia 2017

Plastindia 2018

26th – 29th November, 2016 The Gujarat University Convention & Exhibition Centre, Ahmedabad, India

8th- 10th March, 2017 India Expo Centre, Greater Noida, New Delhi, India

8th – 11th July, 2017 Pragati Maidan, New Delhi, India

7th – 12th February, 2018 Gandhinagar Ahmedabad, India

ARABPLAST 2017

P4 Expo 2017

Interplas 2017

NPE 2018

8th – 10th January, 2017 Dubai World Trade Centre, Dubai, UAE

3rd – 6th May, 2017 Pragati Maidan, New Delhi, India

26th – 28th September, 2017 NEC, Birmingham, UK

7th – 11th May, 2018 Orlando, Florida, USA

K 2016

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4th Plastivision Arabia 2017

POLYMERS Communiqué l August - September 2016