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Volume 14 Issue 7 April - May 2014

CHIEF EXECUTIVE OFFICER Tarun Rai CHIEF FINANCIAL OFFICER Subramaniam S PUBLISHER, PRINT & PRODUCTION CONTROLLER Joji Varghese

EDITOR | Niranjan Mudholkar niranjan.mudholkar@wwm.co.in +91 9819531819 ASSISTANT ART DIRECTOR | Sanjay Dalvi sanjay.dalvi@wwm.co.in

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ADVERTISING SOUTH | Mahadev B mahadev.b@wwm.co.in +91 9448483475 WEST | Ranjan Haldar ranjan.haldar@wwm.co.in +91 9167267474

SUBSCRIPTIONS

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Printed and published by Joji Varghese for and on behalf of owners Worldwide Media Pvt Ltd (CIN:U22120MH2003PTC142239), The Times of India Building, Dr DN Road, Mumbai 400001. Printed at JRD Printpack Private Limited, 78, Resham Bhavan, 7th Floor, Veer Nariman Road, Churchgate, Mumbai - 400 020. Editor: Niranjan Mudholkar. Published for April May 2014 Disclaimer: All rights reserved worldwide. Reproducing or transmitting in any manner without prior written permission prohibited. All photographs, unless otherwise specified, are used for illustrative purposes only. The publisher makes every effort to ensure that the magazine’s contents are correct. However, we accept no responsibility for any errors or omissions and accept no responsibility for any loss or damage caused as an effect thereof. The information provided in this publication is for general use and may not be appropriate for the specific requirements and / or conditions of the reader/s. The opinions expressed by experts are their own and in no way reflect those of the publisher.

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Looking ahead and beyond

recently read a twit by Kaushik Basu, Senior Vice President and Chief Economist, World Bank as well as the C Marks Professor at Cornell University. Basu writes: “If suddenly asked for policy advice the safe option is to recommend ‘more economic reform’. No one knows what that means and it sounds right.” The twit is quite pertinent in these times when the economic horizon gleams with the hope of revival. While everyone is hoping for a stable government at the centre, it would be impractical to expect that the new government can change things overnight. Yes, we want ‘more economic reforms’ but beyond a few general (and essential) improvements like infrastructure development and certain changes in the tax regime, all other so called economic reforms are actually in grey areas. Of course, even infrastructure development needs to tide over issues like land acquisition and environmental approvals. So, what could work for one section of the society and economy may not necessarily work for another. And certain sectors could suffer more if the administration decides to favour others without considering the overall implications. For example, incentives and subsidies given to the IT sector in the past have indirectly wreaked havoc for the manufacturing industry. Already facing huge scarcity of skilled workers, manufacturing lost out on hundreds of good engineering graduates to the IT industry.

While there are many issues faced by the industry today, the wrong perception that the industry is detrimental to the environment is a major concern. Promoting, sustaining and enhancing a strong waste recycling infrastructure will go a long way in helping the industry’s cause.

It is in this context that trade bodies, industry associations and media can play important roles. The plastics industry has already (and long) suffered due to the negative perception amongst policy makers and the environmentalists. While there are many issues faced by the industry today, the wrong perception that the industry is detrimental to the environment is a major concern. Promoting, sustaining and enhancing a strong waste recycling infrastructure will go a long way in helping the industry’s cause. More research needs to be done in this field and the industry must whole-heartedly support the same. Plastics can add huge vale to the agriculture industry; in fact it is already happening. Highlighting this role and building further on the same could also go a long way in generating a positive image as well as growth for the industry.

Editor Niranjan Mudholkar

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CONTENTS 10

NEWS

39

16

Market: India beckons

17

Event: Packed for success

18

Recycling: Powered by waste

23

Recycling: Enhancing the value chain

34

Event: Innovating with sustainability

38

Innovation: Driving with collaboration

41

IT: Green and efficient

44

Calendar: Mark your diary

46

Market: Synergetic growth

47

Agriculture: Nurturing through plastics

49

Products

PACKAGING Bottled for growth

26

AGRICULTURE Tool for Transformation

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AGRICULTURE Low hanging fruit

14

FEATURE - GREEN SERIES Smart Paper

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FOREWORD

SK Ray

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Senior Executive Vice President - Corporate Affairs Reliance Industries Ltd, Mumbai

griculture contributes 13% to Indian GDP and accounts for 47% of employment. India is one of top two largest producers of fruits and vegetables, spices, staples like wheat and rice and several other agricultural commodities. Thus the role of agriculture in Indian economy can’t be undermined. Geo-climatic diversity in India offers major opportunities to expand the base and further enhance agricultural productivity with adoption of advanced agricultural practices. Investments in technology, irrigation infrastructure, modern practices and availability of fund have contributed to growth in Indian agriculture. This has helped India to become an exporter of several agricultural produces. However, full potential in the production of various commodities are yet to be realised Agricultural today due to small and fragmented land holding, prevalence of traditional methods of cultivation and lack of modern accounts for 11% of technology. Post harvesting handling, storage and plastic usage in India, distribution are others areas where technology can make major difference. next only to Packaging In all these areas plastic products can play significant role. and Infrastructure. Micro irrigation using plastic products for drip or sprinkler systems and mulching help conserve water and nutrients. Similarly plastic films and sheets are widely used for greenhouses, low tunnels and for crop protection in horticulture applications. Plastic nets for protection against hailstorm, birds and insects are also applications that contribute significantly to this sector. Agricultural today accounts for 11% of plastic usage in India, next only to Packaging and Infrastructure. Plastics like Polyethylene (PE), Polyvinyl Chloride (PVC) and Polypropylene (PP) are commonly used in these applications because of their functional properties, affordability and ease of production. This issue of ET Polymers focuses on the use of Polymers in Agriculture. It also highlights Recycling which is a cornerstone of sustainability. Recycling not only reduces pressure on material resources, but also conserves energy. Plastic products can be recycled very efficiently with least amount of energy and water as compared to traditional materials like paper, glass or metal. This attribute further underscores the preference for plastics in major applications. India has probably one of the highest rates of plastic recycling. However, the recycling industry is still an informal and fragmented one. Major challenges being faced are waste collection and segregation. Once we overcome these challenges, we would definitely be able to recycle more and therefore have a greener and more sustainable environment. This would require societal changes in consumer behaviour; robust waste collection infrastructure as well as regulatory frame work to support and encourage segregation at source. Many Indian urban centres are moving in this direction. This issue of ET Polymers is also offering a feature on CHINAPLAS 2014, one of the major expositions of global plastic industry. Hope ET Polymer readers would enjoy reading this issue.

Editorial Advisor

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NEWS - National

BASF opens global R&D centre in Mumbai, considering more investments

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ASF SE recently inaugurated a new global Research and Development (R&D) Centre in Navi Mumbai. The centre focuses on organic synthesis, advanced process and formulation research, discovery chemistry for modern agricultural solutions, and molecular modelling. With an initial investment of €2 million, this new facility has been set up under BASF Chemicals India Pvt Ltd. The new R&D facilities will accommodate more than 60 scientists in the first phase. “With this R&D Centre we have taken a significant step closer to BASF’s globalisation goal in R&D. By 2020, we plan to conduct 50 percent of our

Dr Harald Lauke, President, Biological & Effect Systems Research at BASF and Dr Raman Ramachandran, Head South Asia, Chairman, BASF Companies in India inaugurated the new Centre

research activities outside of Europe – one quarter in Asia Pacific,” said Dr Harald Lauke, President, Biological & Effect Systems Research at BASF. “By

Plastivision India gets UFI accreditation

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FI has granted full membership to Plastivision India in the category of ‘Exhibition Organisers’. Plastivision India is now the first trade fair exhibition focused on plastics industry from India to be accredited by UFI and the All India Plastics Manufacturers’ Association is the first Plastics Association to be granted full membership in the category by the UFI. Plastivision India was held last in December 2013 in Mumbai. “This not only recognises our stringent processes and the overall quality of the event, but it will also make more overseas participants confident and eager to participate in our future events,” said Raju Desai, Chairman of the National Executive Committee of Plastivision India 2013 at an awards ceremony held recently.

Lanxess makes managerial changes

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long with Matthias Zachert assuming his role as Chairman of the Board of Management at specialty chemicals company Lanxess, leadership changes at two business units and country entities, as well as one group function, are coming into effect. Joerg Strassburger, Country Representative of Lanxess in India since 2005, will leave the company as of April

The Jhagadia site in Gujarat will become Lanxess’ largest production site in India.

30, 2014. Jacques Perez will take over as Country Representative on May 1, while continuing his current role as Chief Financial Officer in India. Jorge Nogueira, currently head of the business unit Functional Chemicals (FCC), will take over responsibility for the business unit Performance Butadiene Rubbers (PBR) based in Fribourg, Switzerland, from Joachim Grub as of May 1, 2014. Grub will take a one-year sabbatical. Anno Borkowsky, in addition to being head of the business unit Rhein Chemie in Mannheim, Germany, will temporarily be responsible for Functional Chemicals. Par Singh, currently Country Representative of Lanxess in Singapore, will take over from Paul Wagner, effective May 1.

establishing a global research presence in Mumbai, we will be able to work directly with a wide range of scientific talents in India and take steps towards our strategic goal to innovate from Asia Pacific, for Asia Pacific and the world. We are also currently evaluating further investment options into R&D in Asia Pacific, including India.” BASF also recently established an Agronomical R&D Field Station in Pune. “By enhancing our local R&D presence, together we can realise advances which go beyond the scope of today’s solutions,” said Dr Raman Ramachandran, Head South Asia, Chairman, BASF Companies in India.

DuPont Announces Senior Leader Changes

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uPont has announced several senior leadership changes at the corporate, business and regional levels. Timothy P. McCann, president of DuPont Building Innovations, was named vice president of DuPont Integrated Business Management (DIBM), effective immediately. In his new DIBM role, McCann will lead DuPont’s demand creation, productline management and supply-chain strategy, in addition to direct end-toend business planning and customer management. McCann will report to Senior VP James C. Collins, Jr. Rajeev A Vaidya, President – DuPont South Asia & ASEAN and Chairman of the board of E. I. DuPont India Pvt. Ltd, was named president of DuPont Building Innovations, effective immediately. Vaidya will report to Senior VP Matthew L Trerotola. Balvinder Singh Kalsi, business director, Corporate Plans, is assigned president, South Asia & ASEAN and chairman of the board of E. I. DuPont India. Kalsi will oversee DuPont operations across India, Indonesia, Malaysia, Myanmar, the Philippines, Singapore, Thailand and Vietnam.

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NEWS - International

NEWS - International

Borealis and Borouge introduce innovation for caps and closures

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orealis and Borouge have launched an advanced grade of their BorPure high density polyethylene (HDPE) family to support the global beverage industry’s lightweighting trend for caps and closures.

BorPure MB5568 for beverage caps and closures. Image: © Borealis BorPure MB5568 for beverage caps and closures. Image: © Borealis

BorPure MB5568 brings a lightweight innovation to caps and closures for carbonated soft drinks, juices, teas and bottled water. The grade was launched in Europe by Borealis in early 2014 and is officially launched in Asia by Borouge at Chinaplas in April. Based on Borealis’ proprietary Borstar polyethylene (PE) technology, BorPure MB5568 is designed particularly to complement the industry’s widening adoption of lightweight, standard short-neck closures (PCO 1881) that bring savings for the total packaging. The unique Borstar platform allows the tailoring of PE mechanical and processing properties to match specific application needs without performance compromises, using less material. This advantage is further enhanced by the improved stiffness and Environmental Stress Crack Resistance (ESCR) exhibited by BorPure MB5568, which potentially enables additional cap and closure downgauging with consequent material and production cost savings, as well as contributing to carbon footprint reduction and, therefore, sustainability.

Waters unveils new data analysis software

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aters Corporation has unveiled two new data analysis software packages for proteomics and metabolomics/lipidomics analyses: Progenesis QI and Progenesis QI for Proteomics. These new releases of the highly acclaimed software packages are an early result of Waters’ acquisition of Nonlinear Dynamics Ltd., the world leader in ‘omics data analysis software. Progenesis QI software enables researchers to accurately quantify and identify compounds and proteins with unique methods to analyse and visualise LC-MS data. Supporting all common LC-MS data formats and with intuitive guided workflows, Progenesis QI software allows customers to rapidly, objectively and reliably discover compounds and proteins of interest in their valuable samples. “The development of Progenesis QI is a great example of the innovation outcome for ‘omics-focused scientists and laboratories that we at Waters envisioned when we combined Nonlinear Dynamics informatics

expertise with Waters worldwide leadership in chromatography and mass spectrometry,” said Dr Rohit Khanna, Vice President of Informatics and WW Marketing for the Waters Division. “With these latest releases, we have combined the functionality of legacy ‘omics-based data analysis software packages into a pair of stronger, broader reaching offerings. Progenesis QI maintains the heritage of previous releases and focuses our resources in delivering a suite of focused, worldleading informatics packages for ‘omics data analysis.” In response to customer feedback, new features of Progenesis QI include fragment ion support for compound identification, automation of data processing workflows, and improvements in data import routines for enhanced signal differentiation over background noise. Furthermore, new abilities to utilise Waters’ ion mobility data as well as MSE and HDMSE data independent analysis is a direct outcome of merging of Waters and Nonlinear Dynamics innovations.

Mauser joins hands with Sabmann in Thailand

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auser’s machinery division, Mauser Maschinentechnik GmbH, has signed a cooperation agreement with Sabmann Blasformtechnik (Sabmann), located in Thailand. This cooperation is for the joint manufacture and sale of highperformance blow molding machines for the production of industrial jerrycans from 20-30 litre. This cooperation allows Mauser Machinery and Sabmann to extend their existing product portfolio and to better serve their customers’ demand

for high-quality jerrycan blow molding machines. The new jerrycan blow molding machine range will comprise both conventional hydraulic as well as full electric machines.

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NEWS - International

Lanxess expands material testing centre

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anxess has expanded its material testing centre for high-tech thermoplastics in Dormagen with two sophisticated Kappa Multistation creep testing machines, engineered by Messphysik Materials Testing GmbH, the Zwick Roell Group’s competence center for creep testing. These machines can be used to test how Durethan polyamides, Pocan polyesters and TEPEX continuous fiber-reinforced high-performance composites deform over time when exposed to constant mechanical load. The characteristic material data obtained from these tests is used in simulation tools to reliably

predict the long-term behaviour of corresponding components under continuous mechanical and thermal load. The machines can perform not only creep tests according to ISO 8991, but also relaxation tests and tests with user-defined load profiles comprising several load sequences, and they can do so at temperatures of up to 200 °C. “These tests are part of our HiAnt customer services, and we conduct them in accordance with the needs of our development partners, but also for our own projects,” explains Dr Marcel Brandt, Technical Head of the Material Testing Centre.

Plastic additives market to reach US$57.8 billion

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ccording to a report by Allied Market Research the global plastic additives market is expected to reach US$57.8 billion. The global plastic additives market in terms of volume was estimated at 12.6 million tons in 2013 and is expected to reach 17.1 million tons by 2020 growing at a CAGR of 4.4 percent during 2013-2020, the report says. Decreasing mineral ore sources have increased the cost of metal equipment, which has triggered the application of plastics to replace the metal equipment. The low cost of plastic equipment and properties that match metal equipment is also pushing the higher adoption of plastics in a number of applications. Thus the demand for additive which enhances the properties of plastics is also on rise. The companies involved in manufacturing of additives are majorly concentrating on specialty chemicals that are used in construction and automobile equipment. The market growth is dampened by strict government regulations as some plastics additives such as Chlorinated flame retardant are banned in countries, namely Canada, US and the EU. The pending legal suits are also hindering the growth of plastic additive market.

The creep testing machines can be used to test how Durethan polyamides, Pocan polyesters and TEPEX continuous fibre-reinforced highperformance composites deform over time when exposed to constant mechanical load. Photo: Lanxess AG

The machines cover a load range of up to 10 kN per sample. Each one is equipped with five test axes installed in a temperature-controlled chamber. The test axes can be controlled individually.

Bayer sells patents for CNT and graphenes

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The plastic additives manufactures have high focus on developing economies due to economical advantages. Asia-Pacific is the largest revenue generating region among other geographies due to the availability of low cost raw material and economical work force. However, the availability of economical work force in under developed economies such as in Africa is also attracting the global players. The Asia-Pacific and Rest of the world region shared 42.1 percent revenue in 2013 which is expected to soar to 60 percent by 2020. The increase in consumption of plastic products and raising awareness for the preservation of depleting resources is facilitating the growth in these regions. The plastic additive market by types is ruled by plasticisers in terms of volume as well as values.

fter concluding its research work on carbon nanotubes (CNT) and graphenes, Bayer MaterialScience is divesting itself of fundamental intellectual property in this field. The company FutureCarbon GmbH, based in Bayreuth, Germany, will acquire, as leading provider of carbonbased composites, the bulk of the corresponding patents from the past ten years. The two parties have now signed an agreement and the financial details of the transfer will not be disclosed. “We are pleased that FutureCarbon, one of the partners from the Inno.CNT development network, will be carrying on our company’s work,” said Patrick Thomas, CEO of Bayer Material Science. “We remain confident that the technology harbors tremendous potential, particularly for a renowned specialist company like FutureCarbon.” FutureCarbon is a leading innovator and provider of novel, carbon-based composites. As a specialist in the manufacture of various carbon materials, it enables a wide range of industries, to easily utilise the extraordinary properties of carbon materials in their products.

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NEWS - International

NEWS - International

Engel Austria supplies to BMW i3 car

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ngel Austria has won another contract to supply system solutions to BMW’s Leipzig factory, where Engel duo injection moulding machines are used to manufacture car body shell components for the i3 electric vehicle. The latest order includes two largescale Engel duo machines with 40,000 kN clamping force integrated as a double system. In master/slave mode, both machines can be synchronised to injection mould and complete two components at the same time. This manufacturing principle makes sure

that both components undergo exactly the same material aging process and that the high quality demands are met. As the general contractor for the manufacturing cells, Engel has taken responsibility for incorporating automation into the entire system. Both machines have a multi-axis robot. Engel Austria is a leading supplier of lightweight solutions for the international automotive industry. At its technology centre for lightweight

Nampak bags top sustainability award in UK

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ampak Plastics, the UK’s leading producer of plastic milk bottles excelled at The Sustainable City Awards recently, winning the overall Sir Peter Parker Award for sustainable business leadership. Nampak’s multiaward winning Infini bottle was also highly commended in the Responsible Waste Management category. In the last 12 months alone, Nampak has achieved two world records with their Infini bottle. The company trialled, tested and supplied the first four-pint milk bottle containing up to 30 percent rHDPE,

double that of any other milk bottle on the market. This breakthrough came shortly after Nampak created a fourpint Infini bottle weighing only 32g, representing a 20 percent material saving on the standard version found in supermarkets today. This has saved 34,000 tonnes of carbon each year, achieved ‘zero waste to landfill’ status and reduced the overall amount of carbon it uses by 16 percent. Judges from the Environment judging panel commented “The Infini bottle is a product designed with circular economy thinking at its heart.”

Simona to acquire Boltaron in North America

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imona has entered into an agreement to acquire the business operations of Boltaron Performance Products, LLC, Newcomerstown, OH, US. Boltaron is a leading North American producer of thermoplastic sheet products for components used in aircrafts, masstransit vehicle interiors and for applications within the construction, chemical process and semiconductor industries. Boltaron’s manufacturing facility brings together extrusion, calendering and press laminating under one roof. In acquiring the company,

Simona AG has reaffirmed its strategy of expansion through targeted acquisitions in the important US plastics market as well as its commitment to unlocking new fields of application. In January 2014, Simona America acquired the plastics manufacturer Laminations Inc., based in Archbald, PA, US. “We have pursued this strategy vigorously over several years due to the strategic fit of Boltaron with both Simona America and Laminations”, says Wolfgang Moyses, Chief Executive Officer of Simona America.

composites, which opened in 2012 in St Valentin, Austria, Engel develops new technologies and processes for the manufacture of fibre-reinforced composite material in conjunction with partner companies and universities.

RKW prepares to enter the Chinese market

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y establishing the new company Ai Ke Chi Sheng Plastics Ltd, the RKW-Group is signalling its entry into the Chinese market. The plastics specialist plans to open its first Business Unit in China at the end of 2014. The RKW-Group is currently preparing to enter the Chinese market. Construction of the first Business Unit in the People’s Republic is under way and is set to be completed by the end of 2014. The Head Office of RKW China will be located on the premises of its affiliate Renolit in the southern Chinese business metropolis of Guangzhou. Renolit has maintained a presence in Guangzhou since 2006. “This move into the world’s largest economy is entirely consistent with our global growth strategy,” says Roland Roth, CEO of the Executive Management Board of the RKWGroup. From its base in Frankenthal, Germany, the RKW Group already operates 20 business units in nine countries and will supply personal care films for the local Chinese market. RKW has otherwise been present in Asia since 2004 and is reporting steady growth. Its production facility in HoChi-Minh-City, Vietnam, specialises in the production of high-quality consumer packaging.

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FEATURE GREEN SERIES

Smart

paper YUPO’S SMART PAPER WITH ITS INTRINSIC ELECTRONIC SECURITY LAYER PRESENTS AN EXTREMELY POWERFUL AND INNOVATIVE YET A VERY COST EFFECTIVE APPROACH TO VARIOUS INDUSTRY APPLICATIONS

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mart document solutions, pioneered by YUPO through its speciality synthetic paper have the potential to completely transform a paper saturated economy to a smart paper ecosystem, involving efficient electronic document security, making counterfeiting impossible. For years various government agencies and the private sector has been grappling with innovations in printing to protect the integrity of the documents issued. Be it universities, municipal corporations, land record offices and consumer product companies, all industry sectors are faced with an acute challenge of innovating on the best of the methods and technologies to prevent blatant counterfeiting.

YUPO Structure The base layer of YUPO is biaxially stretched, which mainly provides strength and stiffness, while the paperlike surface layers that make up the top and bottom of YUPO are stretched horizontally only. Specifically, the stretching process creates many microvoids that scatter light, providing a high level of whiteness and opacity. The manufacturing process also gives YUPO a paperlike quality that is good for both printing and writing. In addition, the numerous microvoids reduce YUPO’s relative density, which contributes to its light weight. Although the base layer is biaxially aligned, because the paper-like layers on the top and bottom are aligned horizontally only, YUPO has directionality.

YUPO, a world leader in synthetic paper products, recognised that the ideal solution offering has to be an optimum mix of both a smart paper substrate combined with a very simple, cost effective electronic security that enables every consumer to self check the product authenticity. A few innovative and path breaking applications of such technology worthy of mention are as below:

Smart documents in universities and municipal corporations

Smart degree certificates and marksheets that use YUPO speciality paper for printing, which are nontearable and water proof along with a uniquely designed QR codification of them are beginning to change the look and usability of these lifetime assets to students.”

Smart degree certificates and marksheets that use YUPO speciality paper for printing, which are non-tearable and water proof along with a uniquely designed QR codification of them are beginning to change the look and usability of these lifetime assets to students. Gone are the days when the students had to send the physical certificate to the registrar’s office for attestation. Thanks to innovative online verification methods, today the embassy, the corporate hiring the student or the higher university needing to verify the document authenticity can do it online in just a few seconds. Encrypted QR code printed on the documents that can be decrypted only by the university server gives immense security

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GREEN SERIES FEATURE

advantages

Bharathiar University is going green and high-tech by adopting smart degree certificates printed on YUPO speciality paper. It’s proving beneficial for the students too.

leverage to the university. Importantly, it reduces the cost and the time involved Riding on the in carrying out mundane backdrop of rampant verification otherwise. While duplication of optional auto identification packaging which is technologies like RFID are a perennial problem available, the uniqueness brand managers face, of the encrypted QR code YUPO has engineered technology lies in its cost. innovative solutions At no additional front-end in this field using cost to codify the certificates smart in mould and with verification process labels.” involving no speciality hardware, it’s the best value that can be packed in offering secure, duplication-resistant documents to the community at large. Every progressive municipal corporation is working feverishly today to bring its entire document generation and verification process online. Efficient municipal corporations not only allow residents to make online requisitions for birth certificates, death certificates, but also are implementing verification and attestation of these documents online. Now it is possible to have one single electronic database of all residents of a city

 Withstands repeated water exposure: Even if YUPO gets wet, there is virtually no reduction in its strength or deformation, making it outstanding against water exposure.  Resistant to tearing: Because the primary raw material is polypropylene, YUPO is resistant to stretching, folding and other stress.  Smooth surface: YUPO is good for finishing with a laminated coating.  Resistant to oils and chemicals: Since there is virtually no deterioration in quality even when YUPO is exposed to chemicals, including acid, alkalis, organic solvents and oils, it can even be used for labels on oil drums.  Environmentally friendly: Because the primary raw materials of YUPO are carbon and hydrogen, it does not give off toxic chlorine gas when ignited. In addition, YUPO is reusable.

with their documents issued by a centralised system, wherein a resident can pay a nominal fee online and get the document attested/verified on the website. It’s not a utopian thought!

Smart labels in the consumer products industry

Riding on the backdrop of rampant duplication of packaging which is a perennial problem brand managers face, YUPO has engineered innovative solutions in this segment using smart in mould labels. These labels allow an end consumer to scan the product using an android mobile phone and get instant benefits on rebates, discounts and most importantly, know for sure that the product he/she is buying is 100 percent genuine. While prevention of counterfeiting with 100 percent consistency has been a distant thought, these smart paper applications with intrinsic electronic security layer do present a very powerful and yet a very cost effective approach to protect product integrity for all users and brand managers. In the years to come, India will certainly see a fast proliferation of such applications, empowering consumers and all users immensely.

Going GREEN

is now cost effective

For more information, contact: Prashant Mandewal, GM Business Development, Mitsubishi Chemical India Pvt Ltd. Ph: +919987183330; Email: IDA3048@cc.m-kagaku.co.jp & prashant_mandewal@yahoo.com

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MARKET

India

beckons AS PART OF ITS WORLDWIDE MANUFACTURING CAPACITY EXPANSION, GLOBAL CPVC MAJOR LUBRIZOL CORPORATION HAS BROKEN GROUND FOR A NEW COMPOUNDING PLANT IN DAHEJ.

Members of Lubrizol’s executive staff, guests and dignitaries ceremoniously break ground on the site

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he Lubrizol Corporation has broken ground for a new TempRite chlorinated polyvinyl chloride (CPVC) compounding plant in Dahej, India. Construction of this plant is an integral component of the company’s previously announced US$400 million global expansion of its resin and compounding manufacturing capacity. Further solidifying Lubrizol’s commitment to the Indian market, investment in this new plant marks Lubrizol as the first major global producer of CPVC to establish operations in India. The estimated investment in the new plant is more than US$50 million US, and it will have the capacity to produce approximately 55,000 metric tonnes of compounds annually. The plant will be strategically located in the Gujarat Industrial Development Corporation (GIDC), which is one of the largest chemical parks in the country. Many of the raw materials required for Lubrizol’s specialty chemical product portfolio are produced in GIDC. The plant is located near excellent infrastructure and is well-positioned geographically to serve the growing Indian market as well as support the emerging growth of the TempRite CPVC business in South Asia, the Middle East and East Africa.

Highlights  First major CPVC global producer to construct operations in India.  Estimated investment of more than US$50 million.  Plant expected to be operational during Q1 2015.

Our investment in India is a major step forward for our customers based in the region. With the projected growth of our FlowGuard hot and cold plumbing system products, this plant will be instrumental in enabling us to better meet the growing demands in the market. Manoj Dhar, Head of TempRite Engineered Polymers in South Asia.

“Our investment in India is a major step forward for our customers based in the region,” explains Manoj Dhar, Head of TempRite Engineered Polymers in South Asia. “With the projected growth of our FlowGuard hot and cold plumbing system products, this plant will be instrumental in enabling us to better meet the growing demands in the market.” “Lubrizol remains committed to supplying our customers and manufacturing partners with quality piping solution products for their continued global growth,” states John Nunnari, Global General Manager of TempRite Engineered Polymers. “Utilising the most advanced compounding technology developed in the US, the India compounding plant is expected to provide us with a strong, reliable manufacturing base for India and other nearby markets.” A groundbreaking ceremony at the Dahej site was attended by Eric Schnur, President of Lubrizol Advanced Materials; John Nunnari, Global General Manager of TempRite Engineered Polymers; Timothy Madden, Managing Director of Lubrizol Advanced Materials, South Asia; and various other members of the Lubrizol India management team.

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EVENT

Packed for

success

WITH INDIA EXPECTED TO BE AMONGST THE TOP TEN PACKAGING CONSUMERS BY 2016, PLASTINDIA 2015 PROMISES TO BOOST THE FOOD PACKAGING INDUSTRY

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ndia is envisaged to be one among the top ten packaging consumers by 2016 with the demand set to reach US$24 billion. Food packaging is expected to be a major growth driver in the near future for polymer consumption as the retail sector flourishes. Packaging accounts for 48 percent of all commodity polymer consumption and is growing at 15 percent annually, gargantuan by all standards. Key application areas include multilayer films, BOPP films, shrink & stretch wraps, thin wall moulding, thermoforming and blow moulded containers. Within packaging, food packaging comes a distinct first. To achieve this growth, Plastindia Foundation is organising the ninth edition of Plastindia 2015 from February 5-10, 2015 at Pragati Maidan, New Delhi. This international exhibition is supported by the Ministry of Chemicals and Fertilizers and will be one of the three largest shows in the plastics industry globally. With strong international participation Plastindia 2015, spread over 125,000 sq m of area, will have over 2,000 exhibitors from over 40 countries and over 150,000 business visitors.

With rising demand for innovative solution in food packaging in India, the multibillion plastic packaging industry is scaling new heights. However, in order to become more competitive in global markets, Indian food packaging industry heavily relies on plastic applications in food industry. JR Shah Chairman National Executive Council, Plastindia Foundation Focusing on the increased use of plastics in the healthy and safe packaging of food, Prabuddha Dasgupta one of the most respectable packaging professional said: “In the current business environment, the key areas of growth are agriculture, retail, food processing, medicines and plastic packaging plays a vital role in ensuring quality products reach the consumer. Plastics are perhaps the most versatile group of materials used in packaging. However, in international markets or at duty free shops overseas and in India as well, Indian packaged food is very difficult to find

Dignitaries unveiling the event brochure in Bangalore

on shelves; the primary reason being, lack of high quality of packaging solutions. With the increased use of technology which has provided high quality and safe plastic for various applications in the Indian food industry, the industry will become more competitive and will gain cost effectiveness. Plastindia 2015 will make this happen and be the gateway to skyrocket such opportunities.” M Maheshwar Rao, IAS, Commissioner for Industrial Development & Director of Industries & Commerce - Department of Industries & Commerce - Government of Karnataka, said: “Backed by a huge workforce of economical yet skilled manpower; a high emphasis on quality as well as value for money; and a favourable regulatory environment, India’s plastic processing sector is surging. The industry has surplus processing capability to cater to more business and is constantly upgrading itself on technology and automisation front to keep pace with the developed nations. Plastindia 2015 will be the gateway to the profusion of unlimited possibilities as India is poised to become the next global hub for plastics. All in all, Plastindia 2015 promises opportunities for growth and success to anyone associated with or willing to associate with the wonderful world of plastics.” Rao further added: “Government of Karnataka is establishing two Plastic parks - one in Bangalore and one in Dharwad.” JR Shah, Chairman National Executive Council, Plastindia Foundation, said, “With rising demand for innovative solution in food packaging in India, the multibillion plastic packaging industry is scaling new heights. However, in order to become more competitive in global markets, Indian food packaging industry heavily relies on plastic applications in food industry.” April-May 2014 | The Economic Times POLYMERS | 17

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Powered by waste THE PRODUCTION OF FUEL FROM WASTE PLASTICS THROUGH PYROLYSIS IS AN EMERGING SOLUTION TO THE VAST AMOUNT OF PLASTICS THAT CANNOT BE ECONOMICALLY RECOVERED BY CONVENTIONAL RECYCLING. By Dr Achyut Kumar Panda

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than for the plastic industry elsewhere in the world. India had lastics have now become indispensable matea plastic consumption of 3.2 MT during 2000 and has reached rials and the demand is continually increasing nearly 12.5 MT by 2010. due to the diversified and attractive As the life of plastic products is relatively small, applications in household and there is a vast plastics waste stream added to the industries. The total global 4,000-5,000 solid waste creating a serious environmental production of plastics has tonnes problem due to its high visibility, non-biogrown from around 1.3 million tonnes (MT) Approximate amount post degradability and other secondary problems in 1950 to 245 MT in 2006 and is expected to consumer plastics waste generated per day in India. such as clogging of drains and animal health touch 297 MT by 2015 (GIA, 2012). However, pre-consumer problems. Plastics wastes constitute a signifiThe growth of the Indian plastic industry waste or scrap is directly cant portion of the total municipal solid waste has been phenomenal; at 17 percent, it is higher utilised in the industry itself.

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(MSW). It is estimated that approximately 10 thousand tonnes per day (TPD) of plastics waste is generated i.e. nine percent of 1.20 lakh TPD of MSW in India. As per data available on MSW, approximately, 4,000-5,000 tonnes per day post consumer plastics waste is generated, however, pre-consumer waste or scrap is directly utilised in the industry itself. Worldwide, plastic waste constitutes 20 percent of the MSW. As against this, percentage of plastic in MSW found in bigger cities of India such as Ahmadabad, Bangalore, Lucknow, Nagpur, Vadodara, Bhubaneswar and Visakhapatnam was reported to be 5.29, 9.72, 7.45, 7.45, 7.58 8.0 and 9.24 percentages respectively. Of the total plastic waste, over 78 percent of this total corresponds to thermoplastics and the remaining to thermoset. Thermoplastics are composed of polyolefins such as polyethylene, polypropylene, polystyrene and polyvinyl chloride and can be recycled. On the other hand thermosets mainly include epoxy resins and polyurethanes and cannot be recycled. Use of biodegradable/ green polymers as a substitute would have been a promising solution for reducing the amount of plastic waste in the waste stream, but it is too limited at this point of time to substitute the nonbiodegradable plastics in different applications. Recycling of such a huge amount of plastics has become a major response to the environmental challenges facing the plastic industry. Again, disposing of the waste plastics to landfill is becoming undesirable due to shortage of land, rising cost of land, increased legislation due to generation of green house gases.

Recycling of plastic wastes Plastic waste treatment and recycling processes has been historically classified into four major categories, re-extrusion (primary), mechanical (secondary), chemical (tertiary) and energy recovery (quaternary). Each method provides a unique set of advantages that make it particularly beneficial for specific locations, applications or requirements. Primary recycling, which involves the re-introduction of clean scrap of single polymer to the extrusion cycle in order to produce products of the similar material, is commonly applied in the processing line itself but rarely applied among recyclers, as recycling materials rarely possess the required quality. Secondary recycling involves processing of waste/scrap plastics into materials that have characteristics different from

The cost of feedstock recycling even in the best case of large-scale plants may be similar (as high as) to the cost for incineration and energy recovery and it does not produce harmful emission if designed properly. Dr Achyut Kumar Panda

Benefits of tertiary recycling over other processes  Solid waste management: This process would also take care of hazardous high volume plastic wastes simultaneously produce useful fuel/ monomer.  Ecological aspect: This is important today from the Global Warming point of view as it doesn’t produce greenhouse gases and it is beneficial to the operator and a developing country like India.  Easy feed stock: Whereas mechanical recycling requires homogeneous, clean and dry waste before processing stage (mostly extrusion), complicated mixtures of plastics waste can be recovered by Feedstock Recycling without problem as long as the waste can be mechanically fed to the system and the waste is free from some contamination / hazardous substances, to avoid complications in specific systems.  Cost: The cost of Feedstock Recycling even in the best case of large-scale plants may be similar (as high as) to the cost for incineration and energy recovery.  Substitute of fossil fuel: A suitable process which can convert waste plastic to hydrocarbon fuel if designed and implemented then that would be a cheaper partial substitute of the petroleum without emitting any pollutants. The consumption of petroleum product would decrease. It reduces the import of crude oil.

those of original plastics product. Tertiary recycling is also known as feed stock recycling, involves the production of basic chemicals and fuels from plastics waste/scrap as part of the municipal waste stream or as a segregated waste. Quaternary recycling involves complete or partial oxidation of the material, producing heat, power and/or gaseous fuels, oils and chars besides by-products that must be disposed of by burning / incineration. The suitable treatment of plastic wastes is one of the key questions of the waste management and is important from energetic, environmental, economical and political aspects. Feedstock recycling would be a better alternative from cost and ecological aspects. The cost of feedstock recycling even in the best case of large-scale plants may be similar (as high as) to the cost for incineration and energy recovery and it does not produce harmful emission if designed properly. Again this process is complementary to mechanical recycling since it is less sensitive to unsorted or uncontaminated plastic waste and enlarges the overall recycling capacities for large waste quantities to be supplies in future. This is also important today from the global warming point of view and April-May 2014 | The Economic Times POLYMERS | 19

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the operator in a developing country is able to cash on the carbon credit as there is reduction in dependence on fossil fuels.

Chemical (tertiary) recycling Chemical (tertiary) recycling of waste plastics should be considered more than as a solution for waste plastics disposal. It should be looked at as an alternative for generating environmentally acceptable transportation fuel and chemical feed stock for the production of virgin plastics. The basic idea of tertiary recycling is to break up polymer molecules at 300-500째C in the absence of oxygen, into smaller organic molecules or monomers, usually liquids or gases, which are suitable for use as a feedstock for the production of new petrochemicals and plastics. The degradation of plastics waste may be three types such as thermal cracking/pyrolysis, catalytic cracking/pyrolysis (in presence of a catalyst) and hydro-cracking (in presence of hydrogen). Catalytic pyrolysis is preferred as the catalyst lowers the reaction temperature, enhances the rate of reaction and the yield of the products, narrows and provides better control over the hydrocarbon products distribution. The process is affected by feed composition, catalyst loading, catalyst contact mode, The basic idea of particle/crystallite size of cattertiary recycling alyst, reactor type and other is to break up process parameters such as polymer molecules temperature, residence time, at 300-500째C in pressure, presence of other the absence of gases such as O2, H2, Ar, N2 oxygen, into smaller etc. organic molecules Various waste materials or monomers, that are suitable as the raw usually liquids or materials in this process are gases, which are electronic waste, mixed plassuitable for use as tics (HDPE, LDPE, PE, PP, a feedstock for the PTFE, PS, ABS, FRP, PA, production of new PMMA etc.), mixed waste petrochemicals and from the waste paper recyplastics. cling, multi layered plastic, waste tires, rubber, plastic or

rubber parts of the vehicles, waste engine oils, industrial oils, food industry and other oils etc. By their nature, a number of polymers such as polymethyl methacralate (PMMA), polyamides (nylon 6 and nylon 66), polystyrene (PS), polyethylene teraphthalate (PET), can be efficiently depolymerised to their monomer, and are advantageous for such treatment since monomer is a high value product. Polyolefins, mainly PE and PP, the main commodity plastics, decompose into a range of paraffins and olefins. The most commonly researched solid acid catalysts in plastic waste pyrolysis include molecular sieves, silica alumina, zeolites, and MCM-41. Amongst the numerous kinds of zeolites investigated in polyolefin pyrolysis, Beta, USY, ZSM-11, REY, Mordenite, ZSM- 5.

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Environment related observations during the Catalytic Pyrolysis Process in the lab  There are no liquid industrial effluents and no floor washings as it is a dry process.  There are no organised stack and process emissions.  Odour of volatile organics may be experienced in the processing area due to some leakages or lack of proper sealing.  Absolute conversion of liquid-vapour was not possible into liquid; the gas can be used in dual fuel diesel-generator set for generation of electricity.  The charcoal (charcoal is formed due to tapping of tarry waste) generated during the process has been analysed and contain heavy metals, polyaromatic hydrocarbon (PAH) which appears to be hazardous in nature. The source of metals in charcoal could be due to the presence of additives in plastics and due to multilayer and laminated plastics.  Monitoring of process fugitive emissions in the work area as well as emissions from the engines/ diesel generator sets is necessarily required (where this liquid fuel is used) for various parameters such as CO, HCl, Styrene, Benzene, VOCs.

Reports on the FCC process are also found in literature. The common features shared by the different zeolite catalysts are proper acid strength, pore size and pore structure. Other catalytic materials such as clays (montmorillonite, saponite), reforming catalysts, acFuji process, BASF process, Hunan university process, Hamburg tivated carbon, metal oxides (ZnO, MgO, TiO2, BaO and K2O), university process, United carbon process and Likun process. This metal complexes of the type MCln–AlCl3 or M(AlCl4)n (M = Li, is also reflected by a number of pilot, demonstration, and comNa, K,Mg, Ca, Ba; n = 1–2), and alkali metal carbonates or alkaline mercial plants processing various types of plastic wastes in Germametal carbonates have also been tested for polymer degradation. ny, China, Japan, US, UK, India, and elsewhere. Catalysts such as metal oxides, metal complexes, Few researchers at IIT Kanpur, IIT Guwaand alkali metal carbonates or alkaline metal hati, NIT Rourkela etc., are working on this carbonates have appeared to be used mainly for Catalytic pyrolysis project in India. Significant work on this area enhancement of monomer recovery. Degradation is preferred as the has been done by Professor Alka Zadgaonkar, of polymers on solid bases (ZnO, MgO, TiO2) catalyst lowers GH Raisoni College of Engineering, Nagpur yield more oils than on solid acids, though the the reaction and she has developed a patented catalyst as well time required to complete the degradation on temperature, as a process to convert waste plastics to fuel and a solid bases is much longer than on solid acids. enhances the rate zero-pollution industrial process to convert nonof reaction and biodegradable and mostly non-recyclable plastic Research and commercialisation the yield of the waste into liquid hydrocarbons has been set up Substantial research work has been carried out products, narrows at Butibori industrial estate, Nagpur in 2005 and by researchers in different countries on the cataand provides converts it 100 percent into liquid hydrocarbon lytic and thermal pyrolysis of waste plastics usbetter control over fuels (85 percent) and gases (15 percent). This ing different catalyst and by adopting different the hydrocarbon is the world’s first continuous process for plastic process. Some of the successful process includes products recycling to liquid fuel. However, now the plant Sapporo plastic recycle process, Niigata waste distribution. is not in operating condition. Some pilot plants plastic liquefaction process, Mikasa waste plastic have been set up at some cities like Mumbai, liquefaction process, Veba process, BP process, April-May 2014 | The Economic Times POLYMERS | 21

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The suitable treatment of plastic wastes is one of the key questions of the waste management and is important from energetic, environmental, economical and political aspects. Feedstock recycling would be a better alternative from cost and ecological aspects.

Mangalore, Bangalore etc., using other established technology. The research group at Department of Chemical Engineering NIT Rourkela, Odisha, India (Achyut Kumar Panda, Sachin Kumar, Debalakshmi Pradhan, lead by Professor RK Singh) has carried out research on the optimisation of process to convert waste plastics (PP, PE, PS, Rubber) to liquid fuels and chemicals using kaolin based patented catalyst and obtained significant amount of liquid fuel under optimum condition. They have successfully converted waste polypropylene to 92 percent liquid fuel using the patented catalyst.

Uses of the plastic fuels There is tremendous scope for these fuels. Consumers range from boilers, generators (electric generators mixed with 50 percent diesel, diesel generators; cogeneration units), diesel pumps (mixed with 50 percent diesel), hot-water and steam generators, hot-air generators, thermic fluid heaters ovens, road construction etc. It can be easily used as a substitute for Furnace oil or LDO and sometimes as a substitute of gasoline, diesel, and kerosene after refining.

Conclusion The production of gasoline, kerosene and diesel from waste plastics through pyrolysis is an emerging technological solution to the vast amount of plastics that cannot be economically recovered by conventional mechanical recycling. The major advantage of this technology is its ability to handle unsorted, unwashed, and hard to recycle plastics such as laminates of incompatible polymers, multilayer films or polymer mixtures plastic. The development of bench-scale experiments carried out in laboratories to full-scale pyrolysis processes have now resulted in a number of technically mature processes. However, there are challenges associated with this process need to be sorted out through research. The author works with the Department of Chemistry, School of Engineering and Technology, Centurion University of Technology and Management, Parlakhemundi, Odisha, India

References [1] Achyut K Panda, RK Singh, DK Mishra, “Thermolysis of waste plastics to liquid fuel A suitable method for plastic waste management and production of value added products- A World prospective” Renewable and sustainable energy The following table summarises the properties of the oil obtained in the laboratory batch reactor Reviews, 14 (1) 2010, 233-248 at optimum condition. [2] Sachin Kumar, Achyut K Panda and Physical properties PP oil LDPE oil Gasoline Kerosene Diesel RK Singh, “A review on Tertiary recycling of Refractive Index 1.452 1.45 1.434 1.44 1.484 high density polyethylene to fuel”, Resources, Density (g/cc) 0.7771 0.778 0.72-0.736 0.78-0.82 0.83-0.85 Conservation & Recycling, 55 (2011) 893– Specific gravity 0.7777 0.7794 0.72-0.73 0.78-0.82 0.83-0.85 910, Elsevier publications. API gravity 50.447 50.050 65.03-62.34 49.91-41.06 38.98-34.97 [3] Scheirs J, Kaminsky W. Feedstock Kinematic viscosity (Cst) 2.27 1.92 1.076-1.140 1.54-2.20 2.4-5.3 recycling of waste plastics, John Willy & Sons, @ 30OC Ltd. (2006). Flash point (0C) < - 12oC -18oC 38 50-55 55-60 [4] S.M. Al-Salem, P. Lettieri, J. Baeyens, Pour point (0C) < - 45oC - 30C “Recycling and recovery routes of plastic solid Boiling point range (0C) 39-346 66-374 40-205 175-325 150-350 waste (PSW): A review”, Waste Management Calorific value (MJ/kg) 47.27 42.55 46.9 45.5 43.7 29 (2009) 2625–2643

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Enhancing the

value chain

FOR THE WHOLE VALUE CHAIN TO WORK AND SUSTAIN ITSELF, THE FINAL RECYCLED PRODUCT NEEDS TO FIND USE IN A VARIETY OF APPLICATION. By Samit Jain

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n April 4, 2013 the Supreme Court of India said â&#x20AC;&#x153;We are sitting on a plastics time bombâ&#x20AC;?. According to Central Pollution Control Board, India generates about 56 lakh tonnes of plastics waste and only 60 percent of that is recycled. This waste is expected to increase considerably over the next few years as the per capita consumption of plastic increases with the growth in economy. The per capita consumption of plastic in India is approximately 7.4 kg which is still far below the world average of 26 kg. We can imagine the amount of plastic waste that will be generated when India reaches the world average of plastic consumption. India needs to prepare itself for the challenges ahead.

Hazards of waste The developed countries are recycling more than 90 percent of the plastics waste with Germany leading the pack, recycling

98 percent of the plastic waste generated. As 40 percent waste is not recycled in India, it lies uncollected and scattered all over our towns and cities, polluting the surrounding land and water resources This also leads to proliferation of rodents and vectors

If the recycled product gets a higher value, it can be passed on to the recycler and the waste collector. The whole value chain then starts working. So the need of the hour is to increase the value of recycled product. Samit Jain, Director, Pluss Polymers

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carry bags) and nylon (automobile parts under the hood). Another major source of plastics waste is mixed plastics film waste. Packaged food industry has seen unprecedented growth over the past decade. Almost all the food packaging is polymer based and this waste has become one of the largest contributors to polymer waste in India. Such plastics waste can be seen around us in the form of chips packs, snacks packs, drink packs – such as tetra packs, betel nut and areca nut packs.

Incentivising the process There are a number of challenges faced by recycling industry ranging from changing life style patterns to increase in population along with lack of awareness and acceptance for the recycled products*. Compatibilisers such as OPTIM and OPTIPET can help bring the properties of the mixed polymer waste to virgin levels. The government needs to come up with policies that incentivise polymer recycling. Moreover, the spreading diseases; not to mention the air pollution from dust waste collection needs to be incentivised as well. For the whole and smoke when burnt in the open. Plastics account for nearly value chain to work, the final recycled product needs to find use 16 percent of chlorine in the environment and have over 54 carin a variety of application. cinogens. If the recycled product gets a higher value, it can be passed Polythene bags for disposal if burnt irresponsibly release on to the recycler and the waste collector. The whole value chain highly toxic gases like phosgene, carbon monoxide, chlorine, sulthen starts working. The need of the hour is to increase the value phur dioxide, nitrogen oxide, besides deadly dioxin. For achieving of recycled product through better mechanical properties, more substantial diversion of waste from landfills, there is an urgent applications/end products. need for efficient and practical method for collection of waste. Collection of waste is labour intensive. However, segregated collection leading to greater resource recovery can render this activCompatibilisers ity not only cost-effective but also environmentally and economiRecycling of plastics has several technological challenges. The cally sustainable. So the solution is a proper collection method presence of other materials like aluminium and metals in the plasfollowed by recycling. tic waste makes it difficult to recycle; compatibilisation is difficult

Major sources of plastics waste More than 60 percent of the plastics waste generated which is capable of undergoing recycling is from packaging, automobile and white goods industry. The most common plastics are polyesters (the common plastic for mineral water and cold drinks), polypropylene (mostly used in automobiles), polyethylene (the infamous

*Major challenges hampering the comprehensive utilisation of polymer scrap/waste include:  Improper waste collection process  Low competitiveness of individual enterprises.  Lack of industry concentration.  Lack of leading players  Lack of social acceptance and recognition for the recycler.

Since economics of the polymer scrap is an important concern, speciality additives give an edge in the competitive manufacturing world to recyclers of engineering polymer scrap. because of the presence of these and a combination of different polymers in the waste. The properties of plastics deteriorate after recycling and therefore cannot be used to replace virgin polymers. The focus has to be on innovation to create additives that can help rework polymer waste to be re-used in the production of quality products. For example, compatibilisers such as OPTIM and OPTIPET help bring the properties of the mixed polymer waste to virgin levels. OPTIM has been designed to improve the impact properties of scrap nylons (tyres, fishing nets, under the hood automobile components), PET/PBT (CFL holders, pet bottles, straps) and

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Taking the initiative - combating electronic waste

Nearly 100 kilos of e-waste was collected and sent for recycling/ safe disposal

Pluss Polymers – a materials research and manufacturing company – recently initiated a campaign towards e-waste awareness in the city of Gurgaon. The campaign – a brainchild of Pluss employees – aims to spread awareness on the impact of electronic waste on our health and environment while emphasising the need for their safe disposal. The use of electronic products has grown substantially over the past two decades. Rapid changes in technology, falling prices and planned obsolescence of electronic products are resulting in a fast-growing surplus of electronic waste around the globe. Solid waste management, which is already a mammoth task in India, is becoming even more complicated by the invasion of e-waste. “Electronics contain various toxic substances such as mercury, lead, and cadmium that are harmful to both humans and the environment. Therefore proper collection and disposal of e-waste is needed, instead of accumulating it in houses or just throwing away in trash or selling to the unorganised sector,” says Jain. As part of this campaign by Pluss Polymers, awareness sessions and e-waste collection drives are being organised by the company. The program is being conducted with knowledge support from Advit Foundation, a not-for-profit organisation. During the first leg of this campaign, nearly 100 kilos of e-waste was collected and sent for recycling/ safe disposal to Earth Sense Recycle Pvt. Ltd, an authorised company providing e-waste management services. “This campaign is a first-step towards the arduous task of streamlining e-waste management at community level and aims to set in motion the wheels of change,” says Ajith Kumar, an employee of Pluss Polymers who is volunteering for the campaign.

PC (electric meter boxes, switches etc) and also help compatibilise the mixed waste. They not only compatibilise immiscible polymers well but also enhance filler dispersion into the polymer matrix thereby giving enhanced properties. Recycling of packaging waste is another area of major concern for the society as a whole. While recycling of mixed plastics films is not easily done as it contains mixture of polar and non-polar plastics materials. These contain metal coatings (like aluminium), incompatible laminates such as PET, PE, nylons, inks and adhesives. OPTIPET is another range of speciality polymers which can help in overcoming the above stated problems associated with plastic film recycling. In automotive industry, there is an increasing shift towards reuse and reprocessing of plastics for economic, as well as environmental reasons. There are many praiseworthy examples of companies developing technologies and strategies for recycling of plastics. Since economics of the polymer scrap is an important concern, these speciality additives give an edge in the competitive manufacturing world to recyclers of engineering polymer scrap. It enables the recycler to bring materials to virgin levels. The society needs to accept polymers as a given, given our way of life today. The focus has to shift from not using polymers to using them intelligently and responsibly. It also needs to shift

The focus has to be on innovation to create additives that can help rework polymer waste to be re-used in the production of quality products. Compatibilisers can help bring the properties of the mixed polymer waste to virgin levels. to developing proper methods for collection and disposal of waste and developing technological solutions to handle the waste. Only few companies in India have been actively engaged in finding solutions to environmental problems posed by polymers and the special additives required to get the desired properties.

Hierarchy of waste management Sustainable polymer waste management needs to be based on the waste management hierarchy of, firstly, avoiding generation of waste, followed by reducing, reusing, recycling, recovering, treating and responsibly disposing waste. Waste Management envisages an integrated approach, encompassing technological, policy, administrative and legal actions to address the challenge of waste management in India. Strategic planning based on local needs and long-term goals should inform any policy addressing community involvement and public health issues. A careful analysis of cost-effective segregation and collection methods needs to be done and viable alternatives implemented throughout the country. Hence, there is a need for action to effectively translate these approaches into a unified goal, incorporating local, regional and national priorities. The author is Director, Pluss Polymers

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AGRICULTURE

Tool for

Transformation

APPLICATIONS OF PLASTICS ARE ONE OF THE MOST USEFUL INDIRECT INPUTS, WHICH HOLD THE PROMISE TO TRANSFORM AGRICULTURE BY BRINGING ‘SECOND GREEN REVOLUTION’ IN INDIA By Dr SD Ramteke and Anil Birhade

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he use of polymers in agriculture and horticulture on a significant scale started from 1950s when low density polyethylene (LDPE) was used in trails to replace paper for mulching vegetables. The optical properties of plastic films were also investigated as a replacement for glass with the cladding of frames and greenhouses in mind. The plastic industry itself was then young and - being hungry for more outlets - was quick to co-operate with agricultural and horticultural organisation to support research and field trials and to generally promote plastics to the framer. The great success of use of plastic in horticulture applications reflects the trend in many industries where traditional materials have been increasingly replaced on cost, and perhaps more importantly, on performance grounds. Wood, natural fibres, glass, ceramic and metal have all been replaced in products as diverse as working clothes, parts of tool, machinery components, plant containers, packaging and mulches. However, it has not only been a matter of plastic replacing traditional materials; use of polymers has allowed the introduction of many new products such as drip irrigation and direct covering materials. Certainly, use of polymers has made an enormous contribution to increased yields, earlier production and efficiency. Agriculture is the backbone of developing countries as it pro-

Origin Plastic was first used in horticulture in 1948 by Professor EM Emmert. Emmert had no money to buy a glasshouse so he came up with the idea of covering a wooden structure with cellulose paper. He later replaced cellulose paper with polyethylene film when it became available. This inventive gentleman is also credited with inventing plastic mulch and row covers.

vides food, fibre and raw materials to other industries and The great success creates avenues for employof use of plastic ment. The sector has passed in horticulture through critical phases in applications India in the past few decades reflects the trend and has achieved self suffiin many industries ciency in food production. where traditional Plastics, as an agricultural materials have input would break the technological barrier to increasing been increasingly agricultural productivity and replaced on cost, provides impetus to postand perhaps more green revolution for a new importantly, on phase of rapid development. performance In order to promote and grounds. develop the use of plastics materials in agriculture and associated field, the Government of India decided to constitute a National Committee on the ‘Use of Plastic in Agriculture’ in March, 1981 under the Ministry of Petroleum, Chemicals and fertilisers. Plasticulture represents use of applications of plastics in agriculture, horticulture, water management and related areas. Plasticulture applications offer a multitude of benefits and are considered most important indirect agricultural inputs. It results in moisture conservation, water saving, reduction in fertiliser consumption, helps in precise application of water & nutrients,

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Crucial factors The introduction of plastics in agriculture, water management and related areas would depend on several crucial factors such as:  Government policy on irrigation water tariff and fiscal concession on new irrigation methods.  Government policy on new agriculture methods using modern materials.  Availability of plastic products and grass root level distribution network.  Know-how and technical information dissemination at grass root level through extension measures.  Price of plastic product.  Testing and standardisation facilities for plastics used in agriculture and irrigation applications.

controlled environment agriculture is economically viable, plant protection through the use of nets and use of innovative packaging solutions help in increasing shelf-life and during collection, storage & transportation of fruits and vegetables. Many parts of the world including India are facing severe stress in natural resources, particularly for land and water. Meeting the food and material demands in the face of increasing population and shrinking resource base is going to be a challenge in

Estimated Polymer (KT) in Horticulture under Government Scheme Applications

2011-12 (KT) Drip Irrigation System PE, PVC, PP 73.3 Sprinkler Irrigation System PE, PVC 41.9 Piped Conveyance PVC, HDPE 5.3 Sub Surface Drainage PVC 4.0 Greenhouse PE, EVA 6.4 Plastic Tunnel PE 0.9 Shade House HDPE 5.5 Plant Protection Nets HDPE 2.0 Plastic Mulching PE 0.7 Soil Solarisation PE 0.04 Canal / Pond lined with Plastic PE, PVC Membrane 35.1 Cap Covers PE 1.6 Total 176.8 Source: NCPAH

Polymers Used

the immediate future. Achieving food security is of high priority in many countries including India and agriculture must not only provide food for increasing population, but also save critical inputs for agriculture and their better management. Sustainability of food production increasingly depends on sound and efficient crop management and conversion practices consisting primarily of irrigation development and management with respect to agriculture and other allied areas. Application of plastics such as micro irrigation and controlled environment agriculture, help in better utilisation of land, water, sunlight and raising crops in extreme climatic conditions. The use of advanced irrigation techniques such as drip and sprinkler irrigation technologies have enabled the raising of crops on undulating terrains, saline soils, areas with blackish water besides attaining saving of water and other inputs as fertiliser, increase in productivity, improvement in quality of produce and thereby the environment.

Scope of plastic use The green revolution with its emphasis on irrigation, high yielding varieties, fertilisers, pesticides and scientific farming methods, swept across the country. This resulted in turning India from a food deficient nation to a food surplus nation. The increased agricultural productivity, better quality of produce as well as crop diversification are going to be the keys to the success of the country in both, meeting the increasing domestic demands as well as being competitive in the international market. The WTO regime calls for closer look at the horticulture sector in terms quality and quantity of the produce so that the Indian farming sector does not lose to international competition. Innovative agro practices need to be adopted towards transformation of Indian agriculture – to precision farming practices, which will April-May 2014 | The Economic Times POLYMERS | 27

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result in stretching our agro input resources Benefits of applications of plastics manifold to increase agriculture productivApplication Water savings Water use Fertiliser efficiency ity, both in quality and quantity. Applica(percent) efficiency (percent) (percent) tions of plastics are one of the most useful Drip irrigation 40-70 30-70 20-40 indirect agricultural inputs, which hold the Sprinkler irrigation 30-50 35-60 30-40 promise to transform agriculture by bringPlastic mulching 40-60 15-20 20-25 ing ‘Second Green Revolution’ in India. Greenhouse 60-85 20-25 30-35 Plastics can provide answers to the Shade Nets 30-40 30-50 Not available low productivity areas by way of adopting Poly/Low tunnel 40-50 20-30 Not available various applications in the areas of water Farm Pond lined with plastic 100 40-60 Not applicable management, in-situ moisture conservafilm tion, protected technologies, nursery management, innovative packaging for pre and Source: PFDCs Research findings post harvest loss. This would help the country to meet Horticulture Progree in India both, food and nutrition demands, at a time when popuCAGR Area - 3% / Production 5% lation growth is @+ one percent per annum with deplet12 250 ing natural resources such as land and water. Canopy 10.3 10.4 9.9 9.8 management is the manipulation of tree canopies to op10 8.8 8.9 200 8.1 8.0 timise the production of quality fruits. The canopy man8 150 agement, particularly its components like tree, training 6 and pruning, affects the quantity of sunlight intercepted 100 4 by trees, as tree shape determines the presentation of 50 leaf area to incoming radiation. Some of the basic prin2 ciples in canopy management are maximum utilisation 0 0 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 of light, avoidance of built-up microclimate congenial for diseases and pest infestation, convenience in carryArea Production Productivity (in Million HA) (in Million MT) (in MT/HA) ing out the cultural practices, maximising productivity with quality fruit production and economy in obtaining Source: NHB Horti Database 2009 required canopy architecture. net sown area, while 193.7 MHA is the gross cropped area. More It is equally important to understand the country’s agriculthan 61 MHA is under different forms of irrigation sources, of tural spread in its entirety to recognise and appreciate the sigwhich more than five MHA is under micro irrigation. India is the nificance of plastics in this context. The total geographical area largest producer of coconut, mango, banana, cashew nuts, pulses, of India is 329 million hectares (MHA), of which 140.3 MHA is ginger, turmeric and black pepper. It is also the second largest producer of rice, wheat, sugar, cotton, fruits and vegetables. Nearly 20 MHA is under the horticulture sector out of a total net sown area of 140.3 MHA and more than 10 lakh hectares have been added under horticulture sector between 2007-08 to 2009-10. The potential for use of plastics in agriculture is simply huge given the fact that plastics are still under utilised in the agricultural sec Higher strength/weight ratio tor in India standing just one percent vis-à-vis seven percent in  Superior thermal insulation properties the developed countries.

Advantages over conventional materials

 Excellent corrosion resistance  Superior flexibility

 Resistance to most of the chemicals  Excellent moisture barrier properties  Favourable gas permeability.  Smooth surface – resulting in reduction in friction losses  Excellent light transmissibility  Helps to enhance shelf-life of the produces  Better visibility of the produce. 28 | The Economic Times POLYMERS | April-May 2014

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Advantages over conventional materials  Higher strength/weight ratio  Superior thermal insulation properties  Excellent corrosion resistance  Superior flexibility  Resistance to most of the chemicals  Excellent moisture barrier properties  Favourable gas permeability.  Smooth surface – resulting in reduction in friction losses  Excellent light transmissibility  Helps to enhance shelf-life of the produces  Better visibility of the produce. Today, around 90 percent agricultural plastic business is subsidy driven. Enhancing agricultural productivity to meet growing demand for food and achieving food security for the entire populations is one of the key objectives through efforts under the central sector schemes impleoptimal use of agricultural land, water and agrimented by the Ministry of Agriculture i.e. Nainputs by adopting improved cultivation pracApplication of tional Mission on Micro Irrigation (NMMI), tices and plastic applications in agriculture secplastics such as National Horticulture Mission and Horticultor. Plastics are vital inputs in all these areas and micro irrigation ture Mission for North East and Himalayan only through increased plastic usage can achieve and controlled states (HMNEH) and other related Governthese targets. Plastic pipes for drip and sprinkler environment ment schemes such as the National Food Secusystems for irrigation, water conveyance, plasagriculture, help in rity Mission (NFSM), Rashtriya Krishi Vikas tics films for lining, greenhouse and low tunnel, Yojna (RKVY), Integrated Scheme on Oilseeds, mulching, food grain storage and used in inbetter utilisation of novative packaging solutions for reducing postland, water, sunlight Pulses, Oil palm and Maize (ISOPOM) and so on, for enhancing the use of various plastics in harvest losses, nets for shadenet house, plant and raising crops horticulture are mentioned in the table titled protection etc can improve agricultural producin extreme climatic ‘Estimated Polymer (KT) in horticulture under tivity significantly and contribute towards the conditions. Government Scheme’. food security in India. The National Committee on Plasticulture Pioneering work by agricultural scientists Applications in Horticulture (NCPAH) in the Ministry of Agand the efforts of farmers had helped to achieve a breakthrough riculture, Government of India is the national agency making in the agriculture sector in 1960s, popularly known as the ‘Green Revolution’. High agriculture production Major applications and productivity achieved in subsequent Field Applications years has been the main reason for attendWater management Linings of canals, ponds and reservoirs with plastic films; Drip ing food security to large extent. The counand sprinkler irrigation system; Water conveyance using PVC try has made remarkable progress ever since and HDPE pipes; and Sub-surface drainage. 1960 and ranks high in many commodities Nursery management Nursery bags, pots, pro-trays, root trainers, cocopeats, hanging in horticulture. So, plasticulture applicabaskets, plastic trays etc. tions are indeed one of the most useful inSurface cover cultivation Soil Solarisation and Plastic mulching direct horticulture inputs which hold the Controlled environment Greenhouses, Shadenet houses, Plastic tunnels and Plant promise to transform Indian agriculture and agriculture protection nets. bring in the ‘Second Green Revolution’.

Innovative packaging solutions

Plastic crates, bines, boxes, leno bag, unit packaging nets etc; and Modified Atmospheric Packaging (MAP) and Controlled Atmospheric Packaging (CAP) Covers.

The authors work with the National Research Centre For Grapes, (Indian Council Of Agricultural Research), Pune

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Low hanging fruit FOR ACHIEVING THE COUNTRY’S AGRICULTURAL PRODUCTIVITY POTENTIALS, INDIAN FARMERS MUST IMPLEMENT CERTAIN COST EFFECTIVE PRACTICES. ONE SUCH MEASURE IS THE USAGE OF AGRO TEXTILES – NON-WOVEN FABRIC MADE OF POLYPROPYLENE. By Shrichand Santani & Shrish Trivedi

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griculture in India accounts for over 16 percent of the country’s GDP and employs about 50 percent of the country’s entire workforce. After the United States, India has the largest amount of arable land – land that is suitable for cultivation of crops. Hence agriculture sector is an important part of Indian economy. While India has claimed its place in the world as the largest producer of many fruits and vegetables, the country lags behind a big way in terms of yield and earnings. Indian farmer on an average receives anywhere between 10-23 percent of the price that the end consumer pays while in countries like the United States, farmers receive anywhere between 64-81 percent of the price.

Targeting farm productivity In order to make farming a more rewarding profession, multiple issues along the entire chain, start-

Agro textiles that are used to offer protection from insect attacks make agriculture more productive. In some cases, the textile can be used to limit sunlight and retain moisture, especially in arid regions.

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Crop

Mangoes Bananas Potatoes Tomatoes Onions Fresh Vegetables

Average yield, India* (tonnes/ hectare) 6.3 37.8 19.9 19.3 16.6 13.4

Highest yield achieved in the world* (tonnes/ hectare) 40.6 59.3 44.3 524.9 67.3 76.8

*Source: FAOSTAT – Production Crops: 2010 data

ing from the farm and ending at the consumer, need to be addressed. One such issue that needs attention is farm productivity. India’s productivity for many crops lags behind the world’s standards. The table below provides a snapshot of the situation for a few fruits and vegetables: As it can be seen, the gaps in yield for all the crops shown above are staggering. While it may be debated that it is unfair to compare India’s productivity with the best in the World, it is undeniable that the country is nowhere in the vicinity of the sort of potential that can be achieved. To achieve that there are practices which are cost effective, and yet, our farmers are totally incognisant of such practices. One such measure is the usage of Agro textiles – Non-woven fabric made of polypropylene.

with reputed agricultural centres and the results have been hugely encouraging. Polypropylene nonwoven has the potential to increase the agricultural productivity in India. The main impediment to this is a lack of awareness. Reliance Industries Limited is putting major efforts to create awareness by participating in many awareness programs. Once stakeholders realise the immense benefits it provides, Polypropylene nonwoven would become an integral part of Indian agriculture.

Fruit Cover and its applications

In India, Polypropylene nonwoven can be used as fruit cover or crop cover to save fruits from insect attacks while allowing air and sunlight to pass through, thereby improving the yield as well as the quality of the fruit.

Agro textiles – Offering Farm Productivity Solutions: Fruits and vegetable crops need a certain degree of environmental consistency to grow. However, in a country like India, weather patterns are not very predictable. Many fruits and vegetables grown across the country are sensitive to environmental parameters and often fall prey to unexpected fluctuations. This is where Agro textiles stand to play an important role. There have been numerous cases in India where crops have been destroyed by frost (Tinda in Jaipur). In many other areas in India, there have been cases of crops getting destroyed because of insect attacks – mango, bananas and pomegranates face this situation. Agro textiles that are used to offer protection from such attacks make agriculture more productive. In some cases, the textile can be used to limit sunlight and retain moisture, especially in arid regions. In India, Polypropylene nonwoven is used to cover the agricultural field but it is used very sparingly. It can be used as fruit cover or crop cover to save fruits from insect attacks while allowing air and sunlight to pass through, thereby improving the yield as well as the quality of the fruit. It is lightweight, cost effective and can last for 2-3 seasons if handled properly. To study its suitability in India, Reliance Industries Limited has sponsored many trials in different regions where fruits like mango, banana and grapes etc. have been covered by Polypropylene nonwoven cover. These trials have been done in coordination

One of the most simple and convenient ways of improving the fruit yield and fruit quality is using polypropylene nonwoven as fruit cover. It can be used either as bunch sleeve (where it covers the whole bunch of the fruit) or as an individual fruit cover where it can save the fruits from various deterrents (while allowing air and sunlight to pass through) such as1) Insect attacks, 2) Extreme hot and cold weather, and 3) Cross pollination. It also advances the fruit maturity, increases the bunch weight, improves the physic-chemical parameters and increases the shelf life of the fruit. It can be used to benefit many fruits such as:

Banana Research Project was carried out by National Research Centre for Banana in the villages of Trichy. Results- The yield and quality improved drastically. Fruit maturity was advanced (early harvest), bunch weight increased, physical-chemical parameters improved and blemish free, injury-free bananas were obtained. After the success of the above trial, States like Tamil Nadu, Maharashtra, Gujarat. Uttar Pradesh has started using PP NonWoven Banana covers to realise these benefits.

Cost benefit analysis assuming 1,200 banana plants per acre Details

Control Plot Plot with PP Nonwoven Average Production Cost Rs. 1.68 Lacs Rs. 1.78 Lacs Average Yield 25 kg/bunch 31 kg/bunch Then Market Value Rs. 8/kg Rs. 9/kg Net Profit Rs.84,800/acre

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Mango PP Non Woven has been used as a fruit cover for Alphonso Mango in Maharashtra. Results of trial done with Dapoli University-

• Avoids damage to fruit due to abrasion/friction amongst fruits • Prevention from dangerous disease from sucking pest called “Telya” • Enhanced /uniform coloration to the fruit • Juicy pomegranate arils / red colour leading to better price Grapes

Result of trial conducted at National Research Centre for Grapes1) Stark reduction in incidences of pink berry formation. 2) Improvement in shelf life 3) Advancement in fruit ripening

Crop covers – An Introduction

• Protects mango from insect attacks and reduces incidence of stem end rot • Improves fruit retention (fruits/bunches) • Increases fruit weight significantly • Delay in ripening/ extended shelf life • Reduced occurrence of spongy tissue • Provides good shine & skin gloss with lesser spots • Helps in uniform produce Pomegranate Trial conducted at National Research Centre for Pomegranate, Solapur. Results of the trial• Prevents sun burn

Worldwide, the application of using crop covers has been gaining significant mileage. A significant amount of research on the positive effects of crop cover, also popularly known as row cover, has been done. ReResearch has proved search has proved that crop that crop cover cover measures increase the measures increase yield of the crop apart from improving the quality of the the yield of the crop produce. The higher volume apart from improving of produce ensures greater the quality of the return on investment and produce. The higher better quality paves the way volume of produce for higher profit margins per ensures greater unit weight of produce. return on investment Apart from this, these and better quality covers have also helped repaves the way for duce the usage of pesticides higher profit margins and protected growing crops per unit weight of from insects and birds, thereproduce. by protecting it from potential damage. The method has proven to be economical with a vastly improved volume and quality of produce. With some research and trials in India for similar crops, there is scope to create a tremendous impact to our farmers by making this a standard practice. Crop cover examples: Tomato: Tomato crops can be protected from frost by the usage of crop

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Impact of Polypropylene Non Woven Crop Cover 10.68% Increase in fruit weight 8.71% Increase in number of fruits per plant

22.62% Increase in yield

3.68% Increase in number of branches per plant 6.81% Increase in number of bunches per plant

Crop affected by frost

Healthy crop upon row cover usage

Source: Research by C S Azad University of Agriculture and Technology, Kanpur

the picture. Trials have been conducted successfully at Pratapgarh, near Allahabad in Uttar Pradesh.

Light red colour of fruit (no Crop Covers)

Darker and Richer fruit (using Crop cover)

covers. A research study was done at CSA Agricultural University, Kanpur. The following positive effects on the crop were seenTinda: Tinda is another crop that is adversely affected by frost in North India. As can be seen, the crop cover virtually transforms the field entirely by protecting the crop against harsh frost conditions. The trial was successfully carried out in Jaipur.

Frost effect prevented because of cover Effect of frost on the cover

Profitability Analysis- (Value in Rs.) Per Acre of land

Without PP With PP Nonwoven Fabric Nonwoven Fabric Cost of Wind Breaking Grass 30,000 5,000 Cost of PPNW Fabric 0 10,000 Cost of Pesticide 40,000 20,000 Yield 1,30,000 1,68,000 Earning 60,000 1,33,000 Green Chilly: Green chilly is yet another crop that can be protected against the negative effects of frost by using row covers. A tunnel-like structure with nonwoven covers can have a positive effect as seen in

Musk Melon/ Water Melon There are numerous advantages of Fruit Cover on Musk Melon & Water Melon which have been observed in adjoining areas of Jaipur• Early Harvesting • Higher Yield • Reduction of Pesticide • No requirement of Wing Breaking Grass

Per Acre of land Cost of wind breaking grass Cost of PPNW Fabric Cost of Pesticide Monetary Value of Yield Earning

Without PP With PP Nonwoven Fabric Nonwoven Fabric 10,000 5,000 0 35,000 60,000 15,000

10,000 12,000 87,000 70,000

Way forward Fruit covers and Crop covers have been in existence for over a few decades outside India. The materials that have been used for the same have continuously evolved over the years and have impacted the agricultural yield globally. Considering the kind of impact that they have had, similar tests have been conducted in India for various fruits and crops over the last few years, and the results have been very encouraging. In a sector that badly needs innovative solutions that don’t go hard on the pocket, non-woven applications present that kind of opportunity to increase field outputs and reduce transit losses in a simple, yet cost-effective manner. Studies have been conducted continuously in Universities to establish the relevance of these materials in improving the yield of farm produce. Campaigns are being conducted by various stakeholders to increase the awareness across the entire farming community. By maintaining similar resolve and focus, the partnership between companies, Agricultural Universities and the Government has the potential to tackle an important impediment that has been bothering our farmers for far too long, and deservedly, help them earn more. The authors are AVP, Business Development-PP, Reliance Industries and Manager, Business Development-PP , Reliance Industries, respectively.

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All images courtesy: Chinaplas

EVENT

Innovating with

sustainability

BESIDES BEING THE LARGEST SHOW FOR THE PLASTICS INDUSTRY IN ASIA, CHINAPLAS 2014 WILL PROMOTE SUSTAINABILITY THROUGH GREENER MANUFACTURING METHODS, TECHNOLOGIES AND PRODUCTS

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hinaplas 2014, the 28th international exhibition on plastics and rubber industries, will promote sustainability. With ‘Greenovation – Solution to Sustainability’ as its defining theme, the show features two concurrent events, namely ‘The City of Tomorrow’ and ‘Green Conference’. Ada Leung, Assistant General Manager at Adsale Exhibition Services Ltd, the organiser of Chinaplas, notes, “The word ‘greenovation’ is a combination of the meaning of ‘green and innovation’. When companies evaluate their business five years from

now, sustainability shouldn’t be the things for them to neglect. The two events give the opportunities for visitors to learn the latest trends on green solutions from market leaders. They also create a perfect synergy complementing with the exhibition that brings together many new eco-friendly technologies and raw materials for the plastics, rubber, automotive, building & construction, E&E, IT & telecommunications and packaging industries at the fairground.”

The City of Tomorrow ‘The City of Tomorrow’ features an open semi-spherical structure

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EVENT

Borouge to showcase value creating solutions

SNAPSHOT CHINAPLAS 2014 The 28th International Exhibition on Plastics and Rubber Industries Date: April 23-26, 2014 Opening hours: 09:30 - 17:30 Venue: Shanghai New International Expo Centre, PR China (2345 Longyang Road, Pudong, Shanghai, PR China, Postal Code: 201204)

located at Central Square of the exhibition centre which will portray a sustainability model encompassing four aspects of manufacturing cycle, namely green & alternative raw materials, energyefficient machinery, green solutions for customers & products, and recycling. Visitors can wander inside the structure, personally interact with each of the exhibits displayed in various formats for visitors to see and touch while exploring the latest green technologies and trends in the plastics and rubber industries in a fun-filled atmosphere. Bayer MaterialScience, the leading producer of polymer and hi-tech plastics, is the exclusive sponsor for this event. Holly Lei, Vice President, China – Polycarbonates Business Unit at Bayer MaterialScience says, “Sustainability, as part of Bayer’s corporate strategy, is an integral part of our day-to-day work routines. By applying our scientific know-how, we deliver innovations that help meet the global challenges of our time.” She continues “We sponsor ‘The City of Tomorrow’ to raise the awareness of sustainability at where we can get all parties in the industry and society involved and this show is the place to be. The sustainability is something we need to do it together and create social benefits for all stakeholders.” The company will display various kinds of exhibits ranging from electrical vehicle charging station, solar panel, eco window frame to notebook housings and soccer ball to tell the stories about sustainability contributed by plastics technology in different aspects of people’s daily life. Furthermore, Bayer’s participation at ‘The City of Tomorrow’ demonstrates not only the green properties of plastics, but also its innovative solutions which contribute significantly in energy-efficiency and climate protection. Other companies such as Arburg, W&H, Matsui and Trexel will also showcase green manufacturing with energy efficient machinery of injection, extrusion, auxiliaries and moulding. With the growing problem of waste plastics, effective recycling and the use of bioplastics are highly sought after by the industry. Good practices in Europe and America and the applications of NatureWorks’ bioplastics will be shared at the event.

Borouge will bring its holistic polyolefin solutions for infrastructure, automotive and advanced packaging applications to Chinaplas 2014. Borouge is inviting the industry to visit them and learn more about how it can help its business partners increase their competitiveness and Hall contribute to the Company’s N2 vision of shaping the future Booth with plastics. “This show provides a F01 unique opportunity for the Asian market to learn about Borouge’s commitments to investing in production capacity, commercial operations and innovation capabilities,” said Wim Roels, CEO of Borouge. “Together with the most innovative plastic convertors and end-users, we are well prepared to meet Asia markets’ booming demands and the specific needs of the market.” At this year’s Chinaplas, Borouge will also be launching two new exciting innovative polyethylene solutions for the plastic’s caps and closures market. BorPureTM MB5568 and MB5569 will provide significant performance advantages and cost benefits that will allow brand owners and converters to use less materials without compromising the integrity and performance of the closures for beverage bottles. Borouge continues to innovate in the advanced packaging market with differentiated solutions that benefit the value chain. Reflecting this, an interactive “Value Calculator” iPhone and iPad App will also be launched at the exhibition, helping customers quantify the environmental and financial impact of choosing Borouge materials. Borouge will also highlight its expansion projects that will contribute to increasing its production capacity of polyethylene and polypropylene solutions from the current two million to 4.5 million tonnes per year in 2014. This development will provide new value adding plastics solutions for infrastructure, automotive and advanced packaging markets. Borouge will also organise three informative technical seminars during the show to share its unique plastics innovations: 1.Sustainable packaging solutions with cast polypropylene; 2. Innovative solutions to rigid packaging; and 3. Advanced engineering lightweight solutions for the automotive industry. Many of the solutions showcased at Chinaplas this year will show how those solutions help customers to achieve sustainable growth and prosperity. For more information, visit www.borouge.com

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EVENT

Green conference

Kistler systems to reduce the cost of poor quality Kistler will be presenting the COPQ tool for the first time at Chinaplas 2014, which will help to contrast the ‘costs of poor quality’ (COPQ) with the cost of investing in Kistler products. It can be tested at the Kistler stand during the show and will subsequently be available to Kistler customers on its Hall website, free of charge. Kistler will be presenting E5 its new cavity pressure Stand sensors at Chinaplas 2014. R43 Kistler has developed new sensors with a front diameter of 1 mm and 2.5 mm, which will be available in two variations – with an exchangeable cable and as a cable-less variety. This provides greater flexibility when using these sensors as well as easy repair of damaged cables. In addition, a miniature measurement pin for contact free measuring of cavity pressure is also provided, which can be used in the production of parts with high optical requirements and confined working environments. The new strain transmitter for electrical injection molding machines is used for simultaneous clamping force measurement and protection. The new mold technology showcases Kistler’s continued evolution of sensors into high-speed injection molding machines.

Green conference is the half-day event running on April 24-25 in conjunction with Chinaplas 2014, covering industry’s hottest topics across green moulding, 3D printing, plastics recycling as well as various solutions for end-of-life plastic wastes, etc. Eminent and influential speakers from Austria, China, Germany, Italy, Japan, US, and Taiwan will share their invaluable experiences and insights. Conference session on April 24 on ‘Innovative Solutions for Plastic Recycling’ will delve into the latest developments of green raw materials, waste treatment methods and recycling technologies for post-consumer plastic materials. Michael Heitzinger, Chief Technology Officer at EREMA will reveal a new technology to boost recycling efficiency of difficult treated waste plastics in a just single working step. Kim Holmes, Director of Recycling & Diversion at SPI: The Plastics Industry Trade Association will present about how the new treatment technologies changing the landscape of solid waste management and how it can be used in tandem with the existing mechanical recycling infrastructure. Additionally, executives from Plastics Recycling Committee of China Plastics Processing Industry Association, Plastics Recyclers Europe (PRE) and Bayer MaterialScience will also be speaking in the conference.

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‘Green moulding to halve the cost and double the wealth’ will be the theme of the second day of the conference which will discuss how green moulding and 3D printing technologies can achieve cost and resources savings. Paris Ba from Shanghai Matsui Machinery will talk about how moulding companies can harness the potentials of green moulding to enhance competitiveness and productivity with less resource used. Yan Chin, Vice General Manager, Risemold Laser will share cases of how metal 3D printing technology can help manufacture precision injection mould. Member companies from the Association of Green Moulding Solutions (AGMS), e.g. Frigel, Trexel and Moldex3D will also exchange their experiences in the conference. In the light of the growing number of enterprises in China looking for opportunities to venture out to other Asian countries, Chinaplas organisers will hold a seminar entitled ‘Key to Open Up ASEAN Market’ on April 26 morning to provide audience useful information on business environment, investment information, as well as challenges and opportunities in entering the markets in ASEAN countries. Representatives of the ASEAN Federation of Plastics Industries and overseas experts will be invited to share their experiences. With the total exhibition area spanning over 220,000 sq m, Chinaplas 2014 will house exhibits from 3,000 exhibitors coming from 39 countries. Machinery sets numbering 3,200 will be displayed with 14 pavilions organised from Austria, Canada, France, Germany, Hong Kong, Italy, Japan, Korea, Switzerland, Turkey, UK, US, PR China and Taiwan. Building on the past success of Chinaplas, the show offers a truly international sourcing platform as a prime destination converging professional buyers and decision makers in plastics and rubber industries from around the world. It is expected to attract 120,000 visitors for this year. Leading end-users such as L’Oreal, Nike, New Balance, Toyota, BMW, Dongfeng Nissan, Geely,

Manufacturing larger size of electrofusion fittings with MSA In the past it’s been very difficult to produce electrofusion fittings that are much larger than 710mm diameter. With MSA’s new development of the VWL 1200 machine, it’s now possible to manufacture larger electrofusion fittings up to 1200mm internal diameter SDR11 (1400mm SDR17) using especially extruded/fabricated billets. The VWL 1200 uses special fixtures which clamp onto an innovative feature that’s integral to the coupler design, so there is a separate fusion zone in each half of the coupler. The wire laying process starts at one terminal at the end of the fitting. Wire is inserted at double the required pitch to the end of the fusion zone, before the tooling system rotates and then moves in the opposite direction in between the first laid pitch, to its rest position at the second terminal. The process is completed in the second part of the coupler. The VWL 1200 is designed to accommodate loading and unloading of larger couplers (which can weigh up to approximately 350Kg even before wire is inserted). The machine features a completely open top which allows easy overhead loading using a gantry type system. Alternatively, parts can be loaded through the extra wide operator doors using appropriate gripping and manipulation equipment.

Lenovo, Foxconn, Samsung, TCL, Midea, Hitachi, Coca-Cola, Danone, Wahaha, Mattel along with other buyers have already registered to the show. April-May 2014 | The Economic Times POLYMERS | 37

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INNOVATION

Driving with

collaboration A SPORTS GOODS MAJOR HAS JOINED HANDS WITH A SCIENCE AND TECHNOLOGY GIANT TO CREATE A NEW RESIN COMPOSITION FOR GOLF BALL CORES THAT PROVIDE COMPRESSION AS WELL AS SPEED FOR THE BALLS

D

uPont science is at the core of Nike Golf ’s next generation RZN golf ball, designed to deliver more energy at impact for faster ball speed, longer distance and a more stable ball flight. Three Nike athletes using the ball with Speedlock RZN core technology won tournaments in the United States, China, and South Africa in the first weekend the ball went on sale to the public. “The strong relationship we have with Nike Golf invites the type of collaboration that generates breakthrough ideas that help differentiate products through science-powered innovation,” said William J Harvey, President, DuPont Packaging & Industrial Polymers (P&IP). Until now, softer golf balls gave better control, and harder golf balls travelled faster and further - but not both. DuPont P&IP broke the paradigm with a new resin composition for golf ball cores that provides compression (softness) and speed for golf balls. Nike’s proprietary Speedlock RZN core technology uses this revolutionary science of highly engineered DuPont HPF advanced ionomer resin technology to achieve both distance and control.

Working in partnership with DuPont we were able to develop a softer and faster RZN material and created the interlocking core design to reduce energy loss at impact. Rock Ishii, Senior Director, Nike Golf product development

“We knew we hadn’t pulled 100 percent of the energy that we could out of the existing RZN core,” said Rock Ishii, Senior Director, Nike Golf product development. “Working in partnership with DuPont we were able to develop a softer and faster RZN material and created the interlocking core design to reduce energy loss at impact. That means more distance, especially with fair-

way woods, irons and wedges, and softer feel and sound around the greens.” Nike says the key to this design is core technology based on an interlocking design – with a surface area similar to that of a waffle iron – so the compression layer forms a tighter bond and helps promote better energy transfer at impact. “The holy grail in the industry is to merge both the best distance ball with the best performance ball,” said Jim de Garavilla, DuPont Packaging & Industrial Polymers Technology Associate and Project Team Technology Lead. “To get that in one golf ball is very difficult. With this technology, we no longer need to sacrifice or compromise ‘speed’ and ‘control around the green.’ It’s exciting what this technology achieves, not only for the pro golfer, but the average golfer as well.” In addition, the advanced performance resin technology also offers the potential for improved sustainability in golf, since up to 30 percent of the core material’s weight is from renewablysourced content. Most Nike Golf athletes, including Rory McIlroy and Paul Casey, have put the new ball into play in 2014. To date, five Nike athletes including McIlroy, have won with the new RZN technology on the professional tours around the globe. “I want something that sounds fast off the club head, and something that sounds soft around the green,” said Casey. “This new ball with Speedlock Technology does that.” “I’m finding that especially around the greens there is a big difference,” adds McIlroy. “The ball feels and sounds a lot softer. Even from inside 50 yards, it felt like the ball was getting a little more grip and a little more spin. My iron shots were great, and wedge shots were great, too.” Four new RZN golf balls were added to the franchise and started hitting retail shelves in March 2014. For more than 50 years, DuPont has been collaborating with innovators in the golf-ball industry. This latest innovative material – DuPont HPF high-performance resin – is based on a patented, advanced ionomer technology that enables unprecedented levels of ionic crosslinking to deliver a combination of high resilience and low compression previously reserved to thermoset polybutadiene rubbers.

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PACKAGING

Sidel General Beverage Thailand line

Bottled for growth A NEW BOTTLING PLAYER IN THAILAND HAS RECENTLY INSTALLED A TURNKEY ASEPTIC PET PACKAGING LINE TO SERVE THE ENTIRE SOUTH EAST ASIA REGION.

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idel has installed its first complete aseptic production line in Thailand. The installation was for a new company set up to serve the whole southeastern region of Asia. When Thai businessman, Pongsakorn Pongsak established the General Beverage Company Ltd in his home

country, he was entering the beverage industry for the first time. In doing so, he turned to Sidel for the first time too, for the supply of a turnkey aseptic PET packaging line.

From textiles to aseptic bottling Founder and owner, Kitti Pongsakdi (Pongsakorn’s father), originally established the textile company, ‘Suwan Spinning and Weaving’ - which is today one of the top producer of yarn and fabric in Thailand - along with other textile business interests. This latest manufacturing venture in the beverage industry by Pongsak in the General Beverage Company saw the business become a co-packer for the major ASEAN (Association of Southeast Asian Nations) beverage producers.

The plant is being built at a cost of nearly US$160 million in three distinct stages. The first stage already completed - now boasts the country’s fastest production line of PET aseptically filled bottles.”

Equipment at the plant

A supplier to provide the right turnkey solution Following a visit to the Sidel exhibition stand at Anuga in Germany in 2012, the world’s largest food and beverage trade show, senior managers from General Beverage were introduced to Sidel technology and witnessed aseptic filling for the first time ever.

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PACKAGING

They became keen on Sidel’s aseptic filler and the comThe line can handle pany’s overall technology cahigh volumes of high pabilities. Several project disquality beverages of cussions and meetings were conducted with Sidel’s expert low or high acidity, team to consider the solution including the most that best matched the cussensitive products. tomer’s needs. It was the very first Pongsak’s company, General Sidel aseptic line Beverage, wanted a supplier of any kind to be installed in Thailand able to supply a turnkey safe and flexible solution to produce broad ranges of highgrade beverages like coffee, tea, milk and fruit juices - the Thai producer choosing to partner with Sidel to import nearly all of its packaging equipment. As a result, Sidel designed, manufactured, supplied, installed and commissioned the entire bottling line.

drink with high dietary fibre (white grape juice with pieces of aloe vera), yoghurt and milk in a 280 ml format - with green tea and juice in the larger 350 ml format. Being new to the beverage industry, the company’s decision to bottle such sensitive products was a bold move as it necessitates having the specialist knowledge required for setting up and maintaining the most stringent standards of food safety to protect the integrity of the products being bottled. However, through working closely with Sidel and drawing on the company’s extensive expertise and experience in developing solutions for aseptic production, the challenges were readily overcome. Commenting on the project, Kongkiat Ramphaisri, South East Asia Pacific (SEAP) Zone Business Development for Sensitive Products at Sidel, said, “We have worked closely with General Beverage to evaluate their products’ characteristics, packaging materials, bottle designs and aseptic filling technologies. This has ensured we can provide the highest quality, hygiene and food

Three distinct stages for development The plant, which is in Bangkok only 60 km away from Sidel’s local office, is being built at a cost of nearly US$160 million in three distinct stages. The first stage - already completed - now boasts the country’s fastest production line of PET aseptically filled bottles. It includes: a Sidel SBO20 Universal2eco blow moulder equipped with the Ecoven which reduces energy consumption; the first-ever Sidel aseptic filler to handle production of particulates size 5 mm x 5 mm x 5 mm connected to an Aidlin Eco cap feeder. It has a production capacity of 40,000 bottles per hour and is the most-advanced, eco-friendly, manufacturing system in the region. The factory’s second stage will follow in mid-2014, while the third and final stage is scheduled to be finished over the following five years. The company performed roadshows across the country and other South East Asian nations to announce its presence as the supplier of various packaged products including coffee, tea, milk and fruit juices covering over 20 local and overseas brands.

Co-packer for the region The purpose-built plant of General Beverage was set up in the Sam Phran district of Nakhon Pathom to drive the market with its innovative packaging facilities for safe, high-grade food products. The company is offering its services for aseptic PET filling as a high technology copacker to major players in both domestic and nearby international markets. The line can handle high volumes of high quality beverages of low or high acidity, including the most sensitive products. It was the very first Sidel aseptic line of any kind to be installed in Thailand, where the tropical conditions make aseptic production even more challenging. The line is currently set up to produce a nutritional

Workers at the plant

It has a production capacity of 40,000 bottles per hour and is the most-advanced, eco-friendly, manufacturing system in the region. The factory’s second stage will follow in mid-2014, while the third and final stage is scheduled to be finished over the following five years.”

safety, together with optimum efficiency of the production line.”

Stimulate a growing market General Beverage is positioning itself as a company that will drive the SEAP beverage market by adopting innovative packaging strategies and offering high quality, high grade products. Within the region, the juice drinks, teas and sports drinks sector is forecast to grow by four percent per annum over the next four years, with the market share of PET bottles in this sector expected to grow by six percent as consumers increasingly recognise the material as more convenient and lighter than glass, and more hygienic than HDPE. Courtesy: Sidel

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IT

Green and

efficient

SUPREME INDUSTRIES MIGRATED TO AN IT INFRASTRUCTURE THAT CONSUMES LESSER AMOUNT OF ELECTRICITY, HAS BETTER MANAGEABILITY AND HAS ALSO ENHANCED EMPLOYEE PRODUCTIVITY

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and looking at the changing business dynamics of the plastics ounded in 1942, Supreme Industries Ltd is industry, the company was looking towards inculcating a user Indiaâ&#x20AC;&#x2122;s largest plastic processor headquarfriendly IT infrastructure that is both eco-friendly and encourages tered out of Mumbai in India, handling over better IT usage among its set of employees. In order to achieve 200,000 tonnes of polymers annually. The this, Supreme Industries implemented company employs the Virtual Desktop Infrastructure over 5,000 person(VDI) solution from Huawei Enterprise. nel and offers the widest and most comThe old distributed IT Driven by its traditional infrastructure prehensive range of plastic products in infrastructure was also adding that comprised of PCs and desktops, the India. It has 25 advanced manufacturing to Supreme Industries hardware company used to get a lot of issues and plants, which complement its extensive and bandwidth costs. Data complaints from its employees in remote facilities for research and new product security was also a big issue as locations of slow response times from IT development. in a distributed infrastructure teams. And also, there were several cases While the company was using PCs of PC downtime resulting from virus atand desktops, this scenario was not cenenvironment, company data tacks. tralised and data security was also a big was clearly at risk.â&#x20AC;? For the organisation, this kind of issue. Keeping this scenario in mind,

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IT

The VDI solution

scenario meant that IT staff had to travel to remote locations to solve OS (operating systems) related issues and also to address application access problems being faced by the employees quite regularly. The distributed IT infrastructure was also adding to Supreme Industries hardware and bandwidth costs. Data security was also a big issue as in a distributed infrastructure environment, company data was clearly at risk. And the most critical challenge was that operational access newly joined employees was being denied IT services as it used to take about a week time to incorporate new employee into the IT fold. Huawei Enterprise conducted a detailed study of the Supreme’s existing IT infrastructure requirement and business processes. Based on the findings, Huawei deployed its VDI solution, which is aptly injecting the next generation cloud capabilities to its existing IT infrastructure. The Huawei VDI solution has offered maximally shared computing resources and

Background Company: Supreme Industries Industry: Plastics manufacturing Solution: Keeping the changing business dynamics

of the plastics industry in mind, Supreme Industries was looking towards inculcating a user friendly IT infrastructure that is both ecofriendly and encourages better IT usage among its set of employees. Accordingly, it employed the VDI (Virtual Desktop Infrastructure) Solution catering to the following business needs:  Desktop mobility and desktop operations & maintenance  Employee productivity  Connecting distributed platforms & optimal resource utilisation  Data security  Reducing energy and cooling cost

on-demand resource management to Supreme Industries today. This solution has virtualised at the same time centralised the computing and storage resources (including CPU, hard drive, and memory) of PCs into a cloud environment so that the employees of Supreme Industries access their own ‘virtual PCs’ using monitors and thin clients (TCs). “Earlier we used to deploy desktops, laptops and do the installation of required software and then configure it with the system. It was a cumbersome and time consuming process. That’s why we were looking at an easy to operate solution that can lift our existing IT infrastructure to the next level. Huawei’s VDI is a thin client solution that is connected to the server and hence all the critical data can be centrally placed and monitored. This is surely giving our employees a new experience of having a synergised approach towards IT. As part of the VDI implementation, Huawei Enterprise has delivered a great tool to flexibly utilise the available IT infrastructure in the hands of Supreme Industries. VDI is also saving a lot of time and effort for the organisation’s IT team,” says Bhavesh Vekaria, CIO, Supreme Industries.

VDI is a thin client solution that is connected to the server and hence all the critical data can be centrally placed and monitored. This is surely giving our employees a new experience of having a synergised approach towards IT. Bhavesh Vekaria CIO, Supreme Industries As a result, now the IT systems consume lesser amount of electricity and are far more eco-friendly today. There is a clear increase in ease of manageability. Most importantly, the VDI solution has also managed to bring about a positive change in the employee acceptability to use IT systems with great confidence. There are clear business benefits for using VDI as it consumes lesser amount of electricity – it is eco-friendly, ensures a more optimal utilisation of resources and also reduces management costs. It is also bringing Supreme Industries the promise of flexibility, user convenience, and also allowing the company to extract the most out of existing computing resources in a better way. “As we are a manufacturing oriented organisation, it was very important for us to have a system, which can have a positive impact on the productivity of the employees. Huawei’s VDI has surely impacted us in a positive manner. Employees are able to access any application, any time, from any terminal. Additionally, earlier it was very difficult to introduce a new employee into the system. It used to take a week’s time for us to synchronise the IT system for the employee. Now our IT systems have the ability to bring new users on-board from provisioning to their profile configuration –

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IT

VDI is surely helping us achieve great flexibility and at the same time driving scalability. Also, being a green solution has not only added to its acceptability within our employees, but also reduced the TCO and created a quieter office environment for us.” Vekaria

Results VDI has enabled Supreme to flexibly utilise the available IT infrastructure. It is also saving a lot of time and effort for the organisation’s IT team by delivering the following:  Reliable, highly available and scalable cloud computing infrastructure, with end-to-end data and information security.  Dynamic Cloud Computing environment with a centralised management platform, and simplified deployment processes. Maintenance efficiency improved by five times.  Flexible and mobile environment for employees to access any application, any time, from any place and from any terminal or device, via the VDI solution.  Green and innovative solution with superior resource utilisation/sharing capabilities, resulting in a significantly reduced TCO. Efficiency of IT deployment improved by 10 times.

all this in only about 30 minutes of time. Hence, VDI is surely helping us achieve great flexibility and at the same time driving scalability for the organisation. Also, being a green solution has not only added to its acceptability within our employees, but also reduced the TCO and created a quieter office environment for us,” Vekaria explains. As a result of this VDI implementation, today the company’s IT infrastructure is now more flexible than ever and, more importantly, scalability of IT infrastructure is ensuring that the company’s IT is fairly supporting its expanding business line in every possible way. As the company data is now cen“There are clear business benefits for tralised, VDI implementation has elimiusing VDI as it consumes lesser amount nated PC information security problems of electricity – it is eco-friendly, ensures a from worms, Trojan horses, and maliThere is a clear increase in more optimal utilisation of resources and cious data interception, at the same time ease of manageability. Most also reduces management costs. It is also the solution is eco-friendly as it conimportantly, the VDI solution bringing Supreme Industries the promise sumes lesser amount of energy. This has has also managed to bring of flexibility, user convenience, and also revolutionised PC maintenance for Suabout a positive change in allowing them to extract the most out of preme Industries by liberating help desk the employee acceptability existing computing resources in a better from repeated, low-value work. VDI has to use IT systems with great way. As a result of VDI implementation, also simplified IT asset management confidence.” Supreme Industries IT is consuming less processes and taken the management efamount of energy, considerably increasficiency to the next level. As a result of ing the organisation’s green quotient to a new dimension,” says VDI implementation, Supreme Industries IT is consuming less Vekaria, Supreme’s CIO. amount of energy, considerably increasing the organisation’s green Breaking the myth that VDI implementation requires huge quotient to a new dimension. investment, Huawei came forward to enable Supreme Industries in order to stitch VDI into the organisations core requirements Efficient Deployment Anytime and Automatic O & M and at the same time create big value. anywhere access “We got great support from Huawei. We are extremely happy Elastic with the way Huawei has delivered this solution. This is quite Lower Desktop Architecture TCO cost-effective to us and at the same time increases our producCloud tivity as a whole. That is why we are looking forward to having VDI rolled out to at least 500 users. Eventually, we want to have this solution for all our 25 manufacturing units spread across the country. This will give us a great platform to seamlessly integrate User High our operations and provide the freedom of mobility to our emExperience Security ployees,” adds Vekaria. Access Networks Delivering the tool of mobility in the hands of its employees, Data Applications Platforms the company is also planning to use VDI to drive access to its Documents business applications from any device environment - over the Internet so that users can work from home as well. Desktop cloud April-May 2014 | The Economic Times POLYMERS | 43

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CALENDAR

Mark your DIARY May 8, 2014

A LIST OF RELEVANT SHOWS HAPPENING IN THIS CALENDAR YEAR Recycling Conference

Location: Interpack Fair - Room 814, Hall 8B (conference area), 1st floor, Stockumer Kirchstraße 61, Düsseldorf 40474, Germany Theme: Let’s work together on plastics packaging design! - Plastics Recyclers Europe Recycling Conference Organised by: Polymer Comply Europe Website: www.plasticsrecyclers.eu/events/recycling-conference

June 16-18, 2014

June 16-19, 2014

June 2-4, 2014

Background Today, products are very often designed without any real knowledge of their actual recyclability. However, design of a packaging has a detrimental impact on the recycling. Consequently, the first step in minimalising a negative impact of a product on the environment shall be its design. During the Recycling Conference in Düsseldorf Plastics Recyclers Europe will launch RecyClass, a platform for recyclability assessment, which is the key step in ensuring better recycling of plastic packaging. This tool will help packaging designers to find the correct way to approach and evaluate their new products.

Kenya Plast 2014

Location: Kenyatta International Conference Center (KICC), Nairobi Theme: Ride the next wave of growth in East Africa Organised by: Enterprising Fairs (India) Website: www.kenyaplast.in/ Background Welcome to the second edition of Kenya Plast. The major highlight of this edition will be the significant number of visitors not just from Kenya, but from all the neighbouring East African countries. Kenya Plast will be leveraging the support of leading chambers in Kenya, Tanzania and Uganda who have already committed their support to promote the event.

Argenplás 2014 - 15th Plastic International Exhibition

3rd Congress of the Plastic Industry in the Americas 1st Latin-American Congress on the plastic industry Location: Centro Costa Salguero, Buenos Aires, Argentina Organised by: CAIP: Cámara Argentina de la Industria Plástica Website: www.argenplas.com.ar/en/ Background Conducted every two years, this show is important for doing business in all Spanish speaking countries. The 2014 edition will discuss key issues 1. Current Status of the industry in the Americas; 2. Sustainability of the industry, environment and recycling; 3. Plastic industry and globalisation; 4. Raw materials 5. Machinery and equipment - Technology and competitiveness.

End of Life Plastics 2014 conference

Location: Hotel Nikko, Düsseldorf, Germany Theme: International conference on markets and technology options for end of life plastics Organised by: Applied Market Information Ltd (AMI) Website: www.amiplastics-na.com/events/Event.aspx?code=C589&sec=3962 Background Waste plastics are a commercially viable source of income and a valuable resource. What are the best options for End of Life Plastics? Is it recovery and mechanical recycling, energy from incineration, plastics to fuel technology, upcycling, or chemical recycling and return to the virgin plastics? What plastics are fully recyclable, how are they separated, what about contamination and can black plastics be identified? Are exports to Asia going to continue or are global markets becoming more self-sufficient? Each global region has concerns about waste and different regulations. Producer responsibility is a big issue and means that major brand owners and manufacturers are seeking solutions for waste recovery from packaging to automotive applications, as the targets for recovery are increasing each year. The EU market regulations on End of Waste (EOW)) state that: ‘The waste ceases to be waste when a useful and safe product is placed on the market”. What is the market demand and limits on applications for recycled polymers? Is cradle-to-cradle a viable option? What about compounding and colour options for re-used materials? And what about old plastics that contain additives which are no longer permitted?

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December 2-3, 2014

November18-21, 2014

September 3-6, 2014

July 20-22, 2014

June 18-19, 2014

CALENDAR Plastics Recycling Expo Telford

Location: Telford, United Kingdom Organised by: Plastic Recyclers Europe Website: www.plasticsrecyclers.eu/events/plastics-recycling-expo-telford Background The June meeting of the PRE Working Groups will be co-located together with the Plastics Recycling expo and will take place on June 18-19, 2014 at the Telford International Exhibition Centre, Telford, United Kingdom. Plastics Recycling Expo is a launch exhibition and conference specifically for plastics recycling professionals. It will bring together key players from the plastics and recycling sectors in order to learn, network and capitalise on the business opportunities plastic recycling offers. Network with a broad cross section of the industry and meet decision makers from the public and private sector. This two day exhibition and strategic conference will unite specialists from design/manufacturing, brand owners from the packaging, automotive, medical and consumer goods sectors and those already involved in plastics recycling.

Agricultural Plastics Recycling Conference & Trade Show (APRC 2014) Location: Marco Island, Florida, US Organised by: Southern Waste Information eXchange Inc. Website: aprc2014.com/

Background Plastic products and packaging have become an integral part to all aspects of farming. Plastic films are used to wrap forage, to cover greenhouses, and to mulch fields of vegetables and fruits like tomatoes and strawberries. Most nursery containers are made of plastic, as are the containers used for pesticides and dairy sanitizers. Irrigation and maple tubing are plastic. The list goes on. Much of it has been burned in the field, generating dioxins and other pollutants, or dumped in some out of the way place on the farm. In addition, plastics are buried in landfills. The options for farmers to recycle these used plastics have been neither robust nor sustainable.

Indoplas 2014

9th Indonesian International Plastics Exhibition Location: Jakarta International Expo, Kemayoran, Indonesia Organised by: Messe Duesseldorf Asia and local partner PT. Wahana Kemalaniaga Makmur Website: www.indoplas.com/ Background Modeled after the world’s largest trade shows in the plastics, packaging and printing sectors - K, interpack and drupa, this show along with Indopack and Indoprint will continue on the successful streak with an even more notable display of global innovative technologies, machinery and equipment, and best-in-class solutions for the industries in Indonesia and the region.

PlastImagen Mexico 2014

Location: Centro Banamex, Mexico City Organised by: E.J. Krause & Associates Website: www.plastimagen.com.mx/2014/home-plasti2014eng.html Background Considered as the plastics industry’s primary exhibition and conference in Latin America, Plastimagen Mexico 2014 will have more than 850 exhibitors displaying their offerings across 34,000 sq m of exhibition floor to more than 27,000 attendees. Additionally, this year will feature unprecedented support from EUROMAP (Europe’s Association for plastics and rubber machinery manufacturers) and include international pavilions from 12 countries as well as two new pavilions from Germany and Great Britain. This will complement the already strong participation from the United States, Canada and Asia. Mexico expects strong gains as business levels for manufacturers and suppliers of primary plastics machinery continue to rise.

9th European Bioplastics Conference

Theme: Driving a resource efficient Europe. Location: The Square in Brussels, Belgium. Organised by: European Bioplastics Website: en.european-bioplastics.org/conference/ Background From the use of renewable sources to diversified waste management options – bioplastics offer the unique potential to realise an efficient circular bioeconomy. The innovative force and dynamic growth of the European bioplastics industry enables it to be a key player in putting Europe on the road towards resource efficiency. Each year, about 400 experts from around the globe come together and impressively demonstrate the conference’s tremendous effectiveness in information exchange and networking. The Conference’s mix of presentations includes industry innovations, material and application developments, as well as policy trends. April-May 2014 | The Economic Times POLYMERS | 45

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MARKET

Bayer officials at the ground breaking ceremony

Synergetic growth BAYER MATERIALSCIENCE IS INCREASING ITS PRODUCTION CAPACITIES IN ASIA PACIFIC TO MEET THE CONTINUED GROWTH IN DEMAND IN THE REGION FOR RAW MATERIALS FOR COATINGS AND ADHESIVES.

50,000

metric tonnes Annual capacity of the new plant, scheduled for completion in 2016

B

ties (CAS) Business Unit at Bayer MaterialScience. “We are deayer MaterialScience is increasing its protermined to continue to grow here in harmony with the rising duction capacities in the Asia Pacific region demand in the region for innovative solutions for polyurethaneto meet the continued growth in demand based coatings and adhesives.” Thanks to raw materials such as there for raw materials for coatings and adHDI, many everyday products last longer, have better properties hesives. Ground was broken at the site in and a more attractive appearance. Shanghai, China, recently for a new plant The expansion of its production capacity at the integrated for the production of the precursor hexamethylene diisocyanate site in Shanghai ensures that Bayer MaterialScience will be able (HDI). With an annual capacity of 50,000 metric tonnes, it will to supply the regional and global market with HDI reliably and be the one of the largest facilities of its kind in the world, and flexibly. The project also reinforces and further expands the comproduction there will be efficient and ecological with a maximum pany’s outstanding production technolof safety. Completion is scheduled for ogy capabilities. The new plant will uti2016. Bayer already has one HDI plant lise gas-phase technology, which requires in Shanghai, which was expanded in There is considerable demand substantially less energy and solvent than 2013 from its original annual capacity conventional processes. of 30,000 metric tons. in the region and China, in There is considerable demand in particular, for coatings and the region and China, in particular, for Leveraging synergies adhesives, which are used in coatings and adhesives, which are used “The HDI plant represents a major adthe automotive industry, the in the automotive industry, the convancement in polyurethane production,” construction sector and the struction sector and the textile and shoe said Dr Tony Van Osselaer, Head of Intextile and shoe industries, industries, among others. This growth dustrial Operations at Bayer MaterialSamong others.” is being driven to a large extent by the cience. “Shanghai is one of our largest growing middle class, which has an inproduction sites, and we are represented creasing appetite for high-quality end products. there by all of our business units. Building the plant at this site allows us to make full use of the synergies offered by our global production network.” Van Osselaer said that this would enable Positive market development Bayer to introduce a new manufacturing process that has a low “The construction of our new HDI plant documents our conenvironmental impact while at the same time satisfies stringent fidence in the Asia Pacific market and China, in particular,” safety requirements. said Daniel Meyer, who heads the Coatings, Adhesives, Special46 | The Economic Times POLYMERS | April-May 2014

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AGRICULTURE

Nurturing through plastics THE NATIONAL COMMITTEE ON PLASTICULTURE APPLICATIONS IN HORTICULTURE WORKS IN A COORDINATED MANNER TO POPULARISE ADOPTION OF VARIOUS PLASTICULTURE APPLICATIONS IN HORTICULTURE AND OVER ALL DEVELOPMENT OF PLASTICULTURE APPLICATIONS IN THE COUNTRY. AN OVERVIEW

A

agement and conservation practices consisting primarily of irrigagriculture in India has passed through critition development and management with respect cal phases in the past few to agriculture and other allied areas. decades and has achieved The plastics which are most widely used in self sufficiency in food grain In order to agriculture, water management and related approduction. Despite the fact provide flexibility plications are – LDPE, HDPE, PP, PE and PVC. that the country supports to the States in The range of plastics raw materials are being nearly 16 percent world population with 2.4 implementation constantly upgraded to offer cost economy and percent land resources and four percent water based on regionally technical advantages – unheard of in earlier days resources, the achievement in the agriculture differentiated – which constantly upgrades the plasticulture sector is laudable. Many parts of the world including India is approach, to promote product scenario to work in favour of the farmer. crop diversification Plasticulture applications such as protected facing severe stress on natural resources, particuand to provide cover cultivation and controlled environment larly land and water. Meeting the food and raw focused approach agriculture, helps in better utilisation of land material demands in the face of increasing poputo the programmes, and raising crops in extreme climatic conditions. lation and shrinking resource base is going to be Centrally Sponsored The use of advanced irrigation techniques such a challenge in the immediate future. Achieving Integrated Scheme as micro and sprinkler irrigation technologies food security is a high priority in many countries of Oilseeds, Pulses, have enabled the raising of crops on undulatincluding India, and agriculture must not only Oil palm and Maize ing terrains, saline soils, areas with brackish waprovide food for rising population, but also save ter besides attaining saving of water and other critical inputs for agriculture and their better (ISOPOM) have been inputs as fertiliser, increase in productivity and management. implemented from improvement in quality of produce. Sustainability of food production increas2004.” The National Committee on Plasticulture ingly depends on sound and efficient crop manApril-May 2014 | The Economic Times POLYMERS | 47

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AGRICULTURE

Applications in Horticulture (NCPAH) is constituted in the Ministry of Agriculture (MOA), Government of India to focus in a coordinated manner to popularise adoption of various plasticulture applications in horticulture and over all development of plasticulture applications in the country.

What is PFDC? Precision Farming Development Centres (PFDCs) been established in India to promote “Precision Farming & Plasticulture Applications for hi-tech horticulture” and located in State Agricultural Universities (SAUs); ICAR Institutes such as IARI, New Nursery bags

Government Schemes NMMI: National Mission on Micro Irrigation (NMMI) is a centrally sponsored scheme implemented by the Ministry of Agriculture (MoA), GoI since 2005-06 to promote use of Drip / Sprinkler Irrigation Systems in the country. NHM: National Horticulture Mission (NHM) has been launched during the year 2005-06 as a Centrally Sponsored Scheme to promote holistic growth of the horticulture through area based regionally differentiated integrated approach of water management, protected cultivation, nutrition & pest management, post harvest, processing & marketing. HMNH: In order to improve the improve livelihood opportunities and bring prosperity to the North Eastern Region (NER) including Sikkim; Government of India has launched Technology Mission (TM), which is now known as Horticulture Mission for North East and Himalayan States (HMNH). The Mission is based on the ‘end to end approach’ taking into account the entire gamut of Horticulture development, with all the backward and forward linkages, in a holistic manner. RKVY: National Development Council (NDC), resolved that a special Additional Central Assistance Scheme know as Rashtriya Krishi Vikas Yojana (RKVY) be launched during 2007. The scheme would focus on agricultural development strategies reoriented to meet the needs of farmers and called upon the Central and State governments to evolve a strategy to rejuvenate agriculture. NFSM and ISOPOM: The National Development Council (NDC) during 2007 launched a Centrally Sponsored Scheme, ‘National Food Security Mission’ comprising rice, wheat & pluses to increase the production of rice by 10 million tons, wheat by 8 million tons & pulses by 2 million tons by the end of the eleventh five year plan (2011-12. The National Food Security Mission will have 3 components (i) Rice (ii) Wheat & (iii) Pulses.

Delhi; CIAE, Bhopal & CISH, Lucknow and IIT, Kharagpur. Presently 22 PFDC have been operating to promote various plasticulture applications in horticulture by undertaking Trials, Demonstrations in state focused crops, Workshops / Seminar, Transfer of Technology through training and awareness programmes, use of Radio / TV programmes, Publications etc in different agriculture climate zones of the country.

Precision Farming Precision farming or precision agriculture is about doing the right thing, in the right place, in the right way, at the right time. The intent of precision farming is to match agricultural inputs and practices as per crop and agro-climatic conditions to improve the accuracy of their applications.

Plasticulture Plasticulture applications are one of the most useful indirect agricultural inputs which hold the promise to transform Indian agriculture and bring in the ‘Second Green Revolution’. Plasticulture applications offer a multitude of benefits and are considered most important indirect agricultural inputs which results moisture conservation, water saving, reduction in fertiliser consumption, helps in precise application of water & nutrients, controlled environment agriculture is economically viable, plant protection through the use of nets and use of innovative packaging solutions help in increasing shelf-life and during collection, storage & transportation of fruits and vegetables.

Green Revolution and after The first Green Revolution swept like a wave into the Indian countryside. It turned us from being deficient in food grains to being self sufficient. But the increase in agricultural yield has to keep pace with the growing population. To remain self sufficient, we need another green revolution, or rather, a greener revolution. Innovative agro practices need be adopted towards transformation of Indian agriculture. We need to adopt precision farming practices which will result in stretching our agro input resources manifold to increase productivity both in quality and quantity. Courtesy: National Committee on Plasticulture Applications in Horticulture

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PRODUCTS

Flexibility for PVC compounding

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he quantec 46 G3 is the latest addition to the Buss quantec G3 family presented at the K 2013. According to the company, these high-performance Kneaders are predestined for compounding rigid and soft PVC. With throughputs up to 500 kg/h for compounding filled PVC, this smallest version offers optimal flexibility and supports short change-over times for handling frequent formulation changes. Its well-proven scalability of technical parameters also makes the quantec 46 G3 an ideal pilot line both for PVC producers and for prototype model testing in development and research applications. The BUSS quantec 46 G3 debuts this year at Chinaplas 2014 in Shanghai. The quantec G3 series covers PVC compounding throughputs up to 6,000 kg/h with further sizes ranging Courtesy: Buss AG through 60 up to 110 mm screw diameter. The machine is delivered as a turnkey compounding line, with all components fixed kneading pins in the Kneader barrel. Together, these from feed intake to control cabinet and pelletiser mounted two design features intensify mixing while enabling a broad directly on the baseframe. This minimises installation and process window and high compounding throughput. PVC commissioning time – only the power, water and compressed pellet quality can be optimised even further by adjusting the air supplies have to be connected. The quantec 46 G3 is so number and arrangement of freely configurable conveying, compact that its footprint is only about 30 sq ft. Operation mixing and kneading elements on the screw shaft. is greatly facilitated by an optimally ergonomic layout of “This is a growing need particularly in the fast growing all controls. The built-in screw shaft temperature control industries in Asia, where more and more small to medium significantly reduces energy consumption. enterprises are now challenged to Common to all quantec G3 sizes combine high quality with an excellent is the distinguishing combination of For more information: price/performance ratio,” says Wolfgang four-flight kneading elements on the Email: marco.senoner@busscorp.com; Walter, Head of Technology, Buss. axially oscillating screw shaft with website: www.busscorp.com

Newly developed laboratory extruder

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ne of the latest developments Stuttgart/Germany, to make its debut in Asia is the ZSK 26 Mc18 twin screw laboratory extruder with 25 mm screw diameter. This new

extruder, which will be shown on Coperion’s booth E1J01 in Hall E1, offers all the advantages of the ZSK Mc18 series; it has a simple design, it is operator-friendly and easy to clean. It is suitable for the development of formulations, for conducting sample compound trials and for the production of relatively small batches with up to approximately 180 kg/h. Compared to its predecessor, the ZSK 26 Mc, this newly developed laboratory extruder of the ZSK Mc18 series is capable of an increase in throughput of up to 100%, as the specific torque has been increased to 15 Nm/cm3, and is more energy efficient thanks to the reduced specific energy input. The increased filling degree and the lower melt temperatures Courtesy: Coperion GmbH ensure extremely gentle product handling. The new ZSK 26 Mc18 is a mobile unit and requires of Coperion GmbH, only a minimum of floor space, as the control cabinet is integrated into the For more information: base frame of the machine. Heating and Email: bettina.koenig@coperion.com; cooling are installed ready for use. website: www.coperion.com April-May 2014 | The Economic Times POLYMERS | 49

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New production concept for UV-curing liquid silicone rubber

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new production approach – first presented by Elmet at K 2013 – is directed at the processing of liquid silicone rubber (LSR) which cures under UVlight from a LED source. This method eliminates the high curing temperatures required for conventional heat-curing LSR grades. Hence, also thermoplastics with a low melting point, including polypropylene (PP), polyethylene (PE) or polymethyl methacrylate (PMMA), are suitable for twocomponent injection molding with LSR as the soft component, whereas otherwise materials providing higher temperature resistance at higher prices are required, such as polyamide (PA) or polybutylene terephthalate (PBT). Thus a broad diversity of new applications is opened up in the production of hard/soft composites using LSR as the soft component. Courtesy: Elmet An application example is a soap dish made of translucent part to a higher mold region, the LSR base is then injectionpolypropylene (PP) which has a directly molded-on silicone molded onto it. Finally, the silicone component is exposed to support base. For making this item, Elmet had developed UV light through the PP article for curing. The light sources a complete production system in cooperation with the used in this application are rugged LED lamps which are machine manufacturer Engel and the raw materials supplier noted for their long service life. The activation point and ON Momentive. This solution was then built on a turnkey basis. time duration of these LEDs can be accurately matched to the One key element of the system is an innovative injection curing reaction so as to minimise energy input and cycle time. mold operating in a standard injection molding machine. Another innovation is the new air-powered injection unit In this mould, which has steel sealing surfaces on both for the LSR component. It provides a mould halves, the molding is initially precise, repeatable injection pressure produced from UV-transparent PP. For more information: and velocity for process stability. After demolding and relocating this PP Email: w.leitner@ELMET.com

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High-speed cup production

new Illig IC control concept are particularly relevant to t this year’s Chinaplas, Illig will present an IC-RDM the process and effectively support high-speed production. 54K automatic roll-fed machine, state-of-the-art in Besides modules used for general process optimisation, such thermoforming. With a forming area of 520 mm x as the self-adaptive start up for material and mold change, 300 mm, 54,000 APET cups are manufactured per hour using the IC modules ensure high productivity and availability of an 18-cavity mold at a speed of 50 cycles per minute. RDM-K a production line and help to reduce costs at the same time. machines are designed specifically for serial production The complete thermoforming line with all integrated of cups in various shapes and sizes from thermoplastic machines is centrally managed, material. Equipped with the controlled and optimised using the new ‘IC’ operating concept (Illig ThermoLineControl module. This Intelligent Control Concept), makes the system more operatorthe user can utilise the high friendly and saves a considerable efficiency of this servo-driven amount of time during mold or thermoformer much easily and format changes. Error analyses reliably and also to the full extent. and troubleshooting in case Thermoformers of the of malfunction can be carried RDM-K series are frequently out easier and more effectively. employed in-line in combination The Illig NetService allows with upstream material Heilbronn engineers to look into extruders. Such configurations all line components directly and always involve high-volume Courtesy: Illig comprehensively via internet, to manufacturing, e.g. of drinking diagnose errors and promptly correct cups made in millions of units. For more information: setting-related malfunctions. Accordingly, the modules of the Email: wolfgang.konrad@illig.de 50 | The Economic Times POLYMERS | April-May 2014

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PRODUCTS

New space-saving tunnel gate inserts

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manufactured by i-mold, the TGHL -mold GmbH & Co KG has now and TGLL versions are machined from extended its range of tunnel gate HHS steel (M2/1.3343) and are readily inserts by two new, particularly and quickly exchangeable whenever the space-saving versions featuring need arises. tightly curved runners. The TGHL The new versions are yet a further design (Tunnel Gate High Level) also addition to i-mold’s already wide range permits the internal gating of parts in of tunnel gate inserts. The four sizes the region of the parting line in cases cover the maximum shotweight range where the parts have a rim all the way from 20g to 1,000g. Time-tested and round or are ribbed close to the edge. service-proved are i-mold’s tunnel gate Conversely, the TGLL design (Tunnel inserts for cashew gating applications. Gate Low Level) is used for the gating Available in round or square design and of parts featuring an internal contour Courtesy: i-mold in numerous sizes, they are suitable for below the parting line. The tunnel gate the injection moulding of parts weighing anything between inserts are suitable for the processing of almost all polymers. one gram and 1,000 g. i-mold will also be presenting the i-mold however recommends prior consultation in new Series A2 hot runner nozzles from cases where very brittle and/or glass For more information: Heatlock as a further addition to its fibre reinforced polymers are to be Email: info@i-mold.de; portfolio of melt flow related products. processed. Like all tunnel gate inserts website: www.i-mold.de

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Testing systems and digital image correlation

nstron brings advanced testing systems and accessories for determining the mechanical properties of composite materials and fibre composite parts. Providing high precision, measuring accuracy, and repeatability of test procedures, the systems are ideally suited to the challenges presented by these materials, with their unique strength to weight ratio, low strain at failure, high stiffness, and pronounced fibre directionality. Thanks to their versatile capabilities, these systems provide highly reliable data from tensile, compression, shear, fatigue, and impact tests. As an example of its wide portfolio of testing systems for the composites industry, Instron is presenting a Model 5980 floor-standing universal testing system specially equipped for performing measurements on composites. With nominal load Courtesy: Instron capacities up to 600 kN and a sturdy, high-stiffness frame, supplied by an Instron Advanced Video Extensometer (AVE). these systems are an excellent choice for testing carbon or The associated DIC software provides visualisation and also glass fibre reinforced plastic materials and aeronautical or saves the data at an adjustable rate of up to 50 Hz in the form automotive structures. They can be combined with Instron’s of individual images for subsequent analysis in post-processing newly developed manual wedge grips, providing repeatable, mode. high precision, reliable alignment of specimens in accordance For dynamic and fatigue testing of composites, Instron will with the stringent requirements of NADCAP guidelines be exhibiting an ElectroPuls E1000 all-electric test instrument AC7101 and AC7122-1. with a nominal force capacity up to ±1 kN, designed both Instron’s new Digital Image Correlation (DIC) Software for static testing at low speeds and high-frequency dynamic is a new combination of hardware and software. It is designed testing at several hundred Hertz. With its patented, oil-free to optically detect strain and displacement within a defined linear motor technology, the system specifically supports clean area on the surface of specimens or components exposed to working conditions. Coupled with the loads, and visualise these in real-time ElectroPuls system is Instron’s Specimen on a computer screen, so that they can For more information: Self-Heating Control – a powerful addbe traced over the entire duration of Email: Emma_Forrest@instron.com; on for WaveMatrix Software. the test. Image and calibration data is website: www.instron.com April-May 2014 | The Economic Times POLYMERS | 51

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Efficient plant engineering

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Courtesy: ProTec

t this year’s Chinaplas, ProTec Polymer Processing presents efficient plant engineering solutions. The OHL tumble reactor is a solid-state polycondensation (SSP) reactor that can be heated and evacuated. It is available in coordinated modular sizes, from 50-litre sizes for laboratory use all the way to large 44 cu m containers for manufacturing plants. Designed for improving the properties of free-flowing materials, the reactor on display at Chinaplas will feature optimised geometry The optimised OHL tumble reactors, used here during PET recycling to decontaminate and to perform controlled postas well as revised drive and condensation of rPET pellets, consume as much as 20 percent less energy. control technology. Heated ProTec Polymer Processing at Chinaplas is suitable for using heat transfer oil, it uses a significantly smaller volume of manufacturing a broad range of materials using a diverse oil to achieve the necessary heat transfer to control the process polymer matrix and different types of fibre reinforcement. than its predecessor, which also lowers energy consumption. These composite materials are created with fibres of granulate Together with the overall optimisation of the reactor length – lengths of 7 mm to 25 mm are the industry norm container’s weight and drive system, energy consumption for – using what is called the pultrusion this process step is reduced by around process. This is achieved using 20 percent. The OHL tumble reactor technology jointly developed by is used, for example, to purge polyester ProTec Polymer Processing and project and polyamides of volatile pollutants The OHL tumble reactor is a partner PolymersNet, which isolates (de-contaminating) and/or to postsolid-state polycondensation the fibre strands in the impregnation condense these materials, i. e. increase (SSP) reactor that can be tool to create filaments. The individual their molecular weight. In addition, heated and evacuated. fibres are then coated with the polymer the reactor is used in the chemical Designed for improving the melt. The LFT created in this way and pharmaceutical industries for properties of free-flowing produces components with excellent systematically and gently improving materials, it features optimised surface quality and high mechanical the properties of free-flowing solids. geometry as well as revised strength. The technology can be used The tumbling rotation of the drive and control technology.” to realise fibre content of up to 60 reactor, due to its inclined position percent by weight and plant sizes with relative to the horizontal rotational throughputs of up to 1.2 t/h. axis, results in permanent, homogeneous mixing while placing a low mechanical strain on the packaged goods. Precise control LFT is opening up fields of application that were over the parameters of temperature, vacuum and time ensures previously the preserve of thermosetting plastics. In that granulates – recyclates or new product – are individually addition to high strength, stability and impact strength, processed to the required quality, depending on the technical components made using it exhibit excellent heat resistance. specifications and requirements for their intended use. The Since LFT can be processed using injection-molding reactor operates in batch mode to guarantee exactly the same techniques, it can be used to make components much more retention time for the entire contents. This also results in cost-effectively than conventional thermosetting plastics reproducible, consistent product characteristics. (GRP) reinforced with long glass fibres. This is because the The plant technology for manual laminating process for GRP For more information: manufacturing long-fibre reinforced is extremely labour-intensive and Email: grit.feistkorn@sp-protec.com thermoplastics (LFT) presented by therefore expensive. 52 | The Economic Times POLYMERS | April-May 2014

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PRODUCTS

Functional fillers to boost performance

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term and flexible answers to new issues and products. At ased on naturally occurring and synthetic minerals the refining plant, units of various sizes are available for the such as quartz, wollastonite, kaolin or mica, HPF processing of mineral raw materials. Minerals ranging from a range of high-performance fillers can impart amazing functional or optical properties to plastics. Silatherm increases the thermal conductivity of thermoplastics and thermosetting plastics, while the after-glowing Silglow filler is for creative designs and security technology, and Microspar is a filler for films and dental applications. Silatherm improves the thermal conductivity of compounds without downgrading their electric insulating properties. Facing an ongoing miniaturization, typical applications include electronic devices, containing an ever increasing number of components with a high energy density. Silatherm helps to ensure their long-term reliability by efficiently dissipating the resulting heat. Featuring a special inorganic coating of very high mechanical and thermal stability, the Silglow filler absorbs daytime sunlight or light from any other source and emits it in the dark. Polymers as well as colors and lacquers thus receive a long-term luminescence. Typical applications of Silglow include creative designs and security technology. Microspar is a feldspar powder, which improves the anti-blocking properties of films, without significantly affecting their optical properties. Thanks to its high UV transmission, this filler is also suitable for agricultural film production. Finely ground grades of Microspar were especially developed for dental Shortly after areas 3 and 4 were touched simultaneously by fingertips (above), the applications. Silatherm containing area 4 shows a much lower residual heat due to its improved thermal conductivity (below right). In close cooperation with their customers, the interdisciplinary teams of HPF develop efficiency few millimeters down to a few hundred improving solutions for the entire area nanometers can there be crushed and of filled plastics. With its experienced For more information: surface modified. employees, HPF provides shortEmail: Liesenfeld@hpfminerals.com

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New antifog masterbatches

osaf has further expanded its existing line of AF4953LL is designated for multilayer high barrier antifog masterbatches to meet challenging needs packaging applications, including films with a high amount of the packaging industry, whilst, at the same time, of mPE-LLD. This grade provides very good immediate as maintaining uncompromised high level optical properties of well as prolonged antifog activity. AF5979PE is specifically films and sheets. Based on extensive R&D work, four new developed for high clarity barrier films, providing superior and advanced grades have become available, all of them food optical properties with ability to improve film clarity. contact approved. Being adjusted for optimal processing AF6851LL is a unique and efficient antifog solution for and activity, they are individually formulated to create fast sealing layers containing PB-1. AF2327PP is specially responsive and long lasting antifog activity in polyolefins tailored for PP barrier films. Beyond meeting the challenges including metallocene polyethylene of this demanding application, this (mPE), linear low-density polyethylene grade offers outstanding processability For more information: (PE-LLD), polybutene (PB-1), and and excellent activity even after Email: kerenl@tosaf.com; polypropylene (PP) resins. lamination. website: www.tosaf.com April-May 2014 | The Economic Times POLYMERS | 53

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PRODUCTS

The cable drag chain re-invented A cable carrier developed specifically for use in environments with heavy contamination from chips and dirt.

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subaki KabelSchlepp is one of the world’s leading suppliers of cable carriers, guideway protection and conveyor systems. Founded as a small start-up nearly 60 years ago, the company has since become a global player, with foreign representations and subsidiaries in over 50 countries. KabelSchlepp cable carrier systems are in use around the world, ranging from standard applications to such complex applications as industrial robots, offshore oil rigs and the space shuttle. Tsubaki KabelSchlepp therefore has developed an impressive solution for these types of environments with their cable carrier TKA55. The closed plastic cable carrier was also awarded the Eco-Link label of excellence, and fulfils the very strict

cover designs fit seamlessly into one another and reach over the sidebands to form a compact, closed unit. The covers can be opened and removed easily on the inside or outside • Cable drag chains are an integrated part of the to load the cable carriers. The interior of the TKA55 can be machine or a material handling equipment which modularly partitioned with various divider solutions for even gives un-interrupted supply of power, data and cable distribution. The TKA offer secure hold even under control signals to the machinery. severe mechanical stresses, e.g. when used with hydraulic • They also convey media like Air, Fluid & Water in large lines. The smooth, dirt-repellent contour of the sidebands diameter hoses. with their encapsulated stroke system prevents the entry of • Conventional Systems which can be replaced by any foreign objects. The TKA55 cable carriers are particularly cable carrier systems. tight and therefore reliably protect cables and hoses from dust, • Better compared with Festoon Systems. dirt, chips and spray water right up to the connection area in • Better compared with Cable Reeling Drum. accordance with protection class IP54. The tightness of the TKA55 was tested and attested in • Better compared with Bus Bar System. accordance with IP54 by the German Technical Inspection • Better of using cable carriers over conventional systems. Authority TÜV Nord. With this attest in accordance with IP54 the user receives comprehensive protection from allenvironmental compatibility standards of Tsubaki Group. The round spray water and dust entering in harmful quantities, all-round closed structure of the TKA cable carriers effectively along with complete contact protection. prevents the intrusion of contamination particles into the cable space, and allows for reliable protection right up to the In addition, the optimised geometry of the TKA connection area. For this special design the TKA received the chain links and a triple encapsulated stroke system allows IF product design award 2013. the TKA55 to span extensive unsupported sections. The TKA was developed specifically for use in environments integrated gliding surfaces make the cable carrier the ideal with heavy contamination from chips and dirt. Wood, metal solution for long travel lengths. Integrated noise damping or plastic chips entering into the cable space of cable and ensures that the cable carrier is running silently and with hose carriers can quickly result in costly problems. Carriers low vibration at all times. The closed cable carrier is available wear faster, the service life of the routed cables and hoses is in over 300 varieties with interior widths between 15 mm shortened, and the availability of the entire machine or system and 175 mm. Generally speaking cable carriers are a smart is failure. solution to ensure the safe guidance of The innovative design of the cables and hoses. Here is what it’s all For more information, contact, TKA contains an optimised sideband about, the use of TKA cable carriers Kabelschlepp India Pvt Ltd, and cover contours which effectively is advantageous e.g. in industries Ph: 080-41158997, prevent functional faults caused by like Machine tools, Metal-cutting Fax: 080-41158998; chips and dirt entering into or sticking manufacturing, Steel mills and Wood E-mail: india@kabelschlepp.in; www.kabelschlepp.de to the cable carrier. The compact new processing industry.

Features and advantages of cable carriers

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Polymers april may2014 final