Etpolymers apr may 2017

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Volume 18 Issue 1 April - May 2017

CHIEF EXECUTIVE OFFICER Deepak Lamba CHIEF FINANCIAL OFFICER Subramaniam S PUBLISHER, PRINT & PRODUCTION CONTROLLER Joji Varghese EDITOR & CHIEF COMMUNITY OFFICER | Niranjan Mudholkar niranjan.mudholkar@wwm.co.in +91 9819531819

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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 2017 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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Positive impacts! n this issue we have two good stories about innovative uses of plastics – one of them is in fact our Cover Story. These stories explain how the functionality and versatility of plastics have benefitted various industries and ultimately the common people.

Particularly noteworthy is the example of an innovation that has made life easy for the rural women in India. It briefly also explains how this new innovation positively impacts not just the lifestyle but also the health and overall well being of the hardworking women of our villages.

Imagine the long-term advantages of this innovative product! With better health and more time, these women will be able to lead enhanced lives not only for themselves but also for their children and families. Ultimately, this will benefit the society at large and also the country!

With better health and more time, these women will be able to lead enhanced lives not only for themselves but also for their children and families. Ultimately, this will benefit the society at large and also the country!

Just goes on to show how plastic – the often criticised and abused material – can make positive impacts if used correctly. While blaming plastics for the different environmental hazards caused as a result of littering and irresponsible behaviour of people, environmentalists and politicians need to also focus on educating and informing the people about the same. It is easy to suggest that plastics bags can be replaced by paper bags. But we seldom give a thought to the carbon footprint of a paper bag (or a cotton bag for that matter). And we absolutely never think of the use these bags are put to use!

Susan Freinkel, in her brilliant book ‘Plastic: A Toxic Love Story’, says that “For all the environmental troubles single-use shopping bags cause, the much greater impacts are in what they contain. Reducing the human footprint means addressing fundamentally unsustainable habits of food consumption, such as expecting strawberries in the depths of winter or buying of seafood that are being fished to the brink of extinction.”

I leave you with that thought!

Editor & Chief Community Officer

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CONTENTS 8

30

20

News

Event Calendar

Blow Moulding:

28

Thinking globally, working locally

Automotive:

35 36

COVER STORY Breaking the mould

Prototype carbon fiber composite subframe New clearcoat with biobased hardener

Innovation:

38

44

Materials transformation is integral to long term growth

50

Development of key components for water pressure booster

Case Study - Recycling:

48

52

Milking it completely!

Products

CONSTRUCTION Piping it right

24

AUTOMOTIVE Space frame with a unique mix of materials

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46

PACKAGING Factory of the future

51

SUSTAINABILITY Bottled up for a cause

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NEWS NATIONAL

Panasonic lays the foundation stone for its first refrigerator plant

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anasonic India recently laid the foundation stone of its First Refrigerator Plant in Jhajjar, Haryana.

Manohar Lal Khattar, Chief Minister of Haryana, Om Prakash Dhankar Agriculture Minister, Haryana and Devender Singh, Principal Secretary Industries, Haryana, Sudhir Rajpal, MDHSIIDC, were present at the occasion along with Manish Sharma, President & CEO, Panasonic India and South Asia, Hisao Yamane- Managing Director Appliances Company (APIN) and Saurabh Rawat- Divisional Head APIN, with other senior Panasonic rep-

resentatives. The refrigerator plant will manufacture Top and Bottom-mounted refrigerators comprising of unique features such as energy-saving, long-lasting

Trade Infrastructure for Export Scheme launched

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ommerce and Industry Minister Nirmala Sitharaman launched the Trade Infrastructure for Export Scheme (TIES). Speaking at the event she said the Scheme is focussed on addressing the needs of the exporters.

Sitharaman said the focus is not just to create infrastructure but to make sure it is professionally run and sustained.

The Minister added that there will be an Empowered Committee to periodically review the progress of the approved projects in the Scheme and will take neces-

sary steps to ensure achievement of the objectives of the Scheme.

She said the proposals of the implementing agencies for funding will be considered by an inter-ministerial Empowered Committee specially constituted for this Scheme to be chaired by the Commerce Secretary. While appraising the project the justification, including the intended benefit in terms of addressing the specific export bottlenecks, would be evaluated.

Commerce Secretary Rita Teaotia said the scheme would provide assistance for setting up and up-gradation of infrastructure projects with overwhelming export linkages like the Border Haats, Land customs stations, quality testing and certification labs, cold chains, trade promotion centres, dry ports, export warehousing and packaging, SEZs and ports/airports cargo terminuses.

She said last and first mile connectivity projects related to export logistics will also be considered.

freshness and design, to address the local demands.

With an annual production capacity of approximately 500,000 units the new plant will be spread across 10,000 sq. meters and will manufacture refrigerators comprising of unique features such as energy-saving, long-lasting freshness and design. The company plans to invest Rs 115 crores and shall create a comprehensive eco system for manufacturing appliances in the Indian market. The operations will begin from January 2017 and sales for the will commence from April 2018 in India.

India, Russia sign Joint Declaration on Innovation

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he Department of Science and Technology, Government of India and the Ministry of Economic Development of the Russian Federation signed a joint declaration recently to stimulate cooperation in the field of promoting innovation ecosystem between the two countries. The declaration was signed on the sidelines of the Global R&D Summit 2017 organised by The Department of Science and Technology, Govt of India and FICCI in Bengaluru.

Stating that India and Russia are natural partners on innovation, Ashutosh Sharma, Secretary, Department of Science and Technology said “With increased people to people contact, we will take the relations to new heights through this Joint Declaration.�

Signing the declaration, Fomichev Oleg Vladislavovich, State SecretaryDeputy Minister of Economic Development of the Russian Federation spoke of the long running India-Russia partnerships and particularly stressed on the need to extend the collaborations in developing innovation capabilities for various sectors.

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NEWS NATIONAL

BASF makes South Asia’s biggest R&D investment of €50 million in India

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ASF Group has inaugurated its new Innovation Campus Asia Pacific, located in Mumbai, India.

The project will involve a total expected investment of up to €50 million from BASF Group, and marks the Group’s largest research and development (R&D) investment in South Asia.

All global research operations at BASF Innovation Campus Asia Pacific (Mumbai) will be housed under BASF Chemicals India Private Limited, a 100% subsidiary of BASF SE. The

new innovation campus will expand the company’s existing R&D activities in India to include global and regional

CII Business Confidence Index at all-time high

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midst expectations that economic activity would gather pace in the current year, there is optimism among companies that green shoots of recovery, which have started becoming evident, would be sustained.

This finds a reflection in the CII Business Confidence (BCI) which has gone up to an all-time high of 64.1 during the fourth quarter of 2016-17 as against 56.5 recorded in the previous quarter. There has been a sharp rise in the CII-BCI after it remained subdued in the last few quarters.

Commenting on the recent rebound in Business Confidence, Chandrajit Banerjee, Director General, CII stated that the turnaround in business expectations, as indicated in the survey, gives credence to the belief that a new growth narrative is being scripted for the country based on improved business sentiment and investor confidence.

A sharp uptick in business outlook, at the onset of 2017, underpins the hope that the reform initiatives of the government would unravel a host of investment opportunities for firms, going forward.

These findings are a part of CII’s 98th edition of quarterly Business Outlook Survey, which was based on around 200 responses from large, medium, small and micro firms, covering all regions of the country.

The significant rise in the index this quarter could be attributed to the distinct improvement in the Expectations Index even as there is a marginal uptick in the Current Situation Index, indicating that business sentiment is strong and firms are particularly upbeat about activity in their sectors in the future.

research on a wide range of specialty chemicals. Topics will cover personal and home care, process development, organic synthesis, crop protection and many more.

“A growing need for energy, food and clean water, limited resources, and a rising world population pose huge challenges. Innovations based on chemistry will enable new solutions,” said Dr. Martin Brudermueller, Vice Chairman of the Board of Executive Directors, BASF SE and Chief Technology Officer.

India’s fast growth will resume with GDP expanding to 7.4 percent by FY 2017

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ndia’s fast growth will resume with gross domestic product (GDP) expanding by 7.4 percent in fiscal year (FY) 2017 and 7.6 percent in FY2018 supported by reform measures, says a new Asian Development Bank (ADB) report.

In its new Asia Development Outlook (ADO) 2017 report, ADB notes that the deceleration to 7.1% registered last year was due in part to slower investment growth. Also contributing to the moderation was the impact of the government’s demonetization of high-value currency notes, though this effect is seen as largely temporary. ADO is ADB’s flagship annual economic publication.

“An array of important reforms has propelled India’s economic success in recent years,” said Yasuyuki Sawada, ADB’s Chief Economist. “A continued commitment to reform — especially in the banking sector — will help India maintain its status as the world’s fastest growing major economy.”

India’s growth in FY2016 was fuelled by agriculture and government services. Industrial growth, however, slowed to 5.8% over the last 12 months from 8.2% in FY2015. Growth in services moderated to 7.9% due to slowdowns in finance and real estate.

Net foreign direct investment (FDI) in the country remained strong at $36.7 billion in FY2016 following the government’s efforts to simplify guidelines and allow FDI in key economic sectors.

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NEWS INTERNATIONAL

Songwon opens new Technology Innovation Center in South Korea

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eading specialty chemicals manufacturer, Songwon Industrial Co., Ltd. has officially opened a new Technology Innovation Center in Korea recently.

In line with the company’s aim to strengthen its position on the global specialty chemicals playing field, Songwon says that the new center is a major milestone for the organisation.

Not only will it support innovation, it will enable Songwon to take another key step forward in entering new business areas with high value and sophisticated technology.

Located on the company’s Maeam site in South Korea, the center encompasses 32,000 m² and is currently three stories high. However, keeping an eye

Ricardo Hernandez appointed as TE’s Industrial Business new industry sales manager

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E Connectivity (TE) has announced the appointment of Ricardo Hernandez to the post of Industry Sales Manager, Americas, for Motor Connectivity in TE’s Automation & Control business.

Hernandez, who has already taken up his post, is based in Houston, Texas,

USA and reports to Jason Moore, sales director, Automation & Control.

Prior to joining TE, Hernandez was a sales engineer at Bosch Rexroth. He holds a technical degree in Mechatronics, Robotics, and Automation Engineering from Instituto Tecnológico y de Estudios Superiores de Monterrey in Mexico and did an intensive program in France at École Spéciale des Travaux Publics in electro-mechanical engineering.

In announcing the appointment, Moore said: “Ricardo has an outstanding track record as an industrial automation professional. With his 10+ years of mechatronic systems design experience, we look forward to him being a knowledgeable partner for motor connectivity with our customers.”

WACKER and STC Silicones enter into agreement

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ACKER and the Brazilian silicone compounder STC Silicones have concluded an agreement on the co-branding of ready-to-use silicone compounds. Under its terms, STC is allowed to promote silicone compounds made from WACKER raw materials with the quality seal

“Based on ELASTOSIL”. ELASTOSIL has been synonymous with high-quality silicone rubber products over more than 60 years, and is now one of WACKER’s most successful brands. STC Silicones is based in Ribeirão Pires in the Brazilian state of São Paulo.

on the future, the facility has been especially designed with future expansion in mind and is constructed to allow the company to add two more floors later as required.

The new facility will host both R&D, Global Application Community and Technical Service. It will enable the organization to leverage the synergies between the groups, consolidate Songwon’s technologies and support the complete development of new products from the design phase to final customer applications.

First scalable 3D printing platform launched

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elivering on its strategy to transform 3D manufacturing workflows, 3D Systems (NYSE:DDD) has announced the industry’s first modular, scalable and fully-integrated additive manufacturing platform.

3D Systems’ disruptive Figure 4 production platform produces plastic parts more than 50 times faster than current systems, delivering dramatically lower total cost of operations while offering competitive and compelling comparisons to conventional methods.

3D Systems’ Figure 4 fully automated, high-volume 16-print engine production solution.

Based on its revolutionary Figure 4 technology, 3D Systems’ new platform allows customers to tailor configurations and select materials to address specific applications. Configurations range from single-print engine machines to fully automated, high-volume production systems with 16 or more print engines, automated material delivery and integrated post-processing.

The company recently shipped the first system to a Fortune 50 industrial customer, and plans to ramp customerspecific shipments throughout the second half of 2017.

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NEWS INTERNATIONAL

Bosch to showcase leak detection of rigid containers at Interpack 2017

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t Interpack 2017, Bosch Packaging Technology presents the new KLV series for Container Closure Integrity Testing (CCIT).

“In the pharmaceutical industry, non-destructive CCI technologies are becoming increasingly important,” explains Dr Jérôme Freissmuth, product group head at Bosch Packaging Technology. “Even the smallest leaks can be highly hazardous for patients. The active ingredient could alter, administering the medication

could lead to serious side effects as a result of non-sterility, or the medication could become ineffective. Furthermore,

SABIC offers lightweight PP and plastic-metal hybrid solutions for the automotive industry

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ith the automotive industry’s continued focus on reducing emissions and increasing fuel efficiency, materials-maker SABIC is presenting a range of solutions at this year’s VDI Plastics in Automotive Engineering Congress in Mannheim, Germany.

The solutions cross a range of application segments – from a vehicle’s exterior and glazing to components like instrument panel carriers and structural reinforcements for the body-in-white (BIW). Combined, these solutions can potentially reduce the overall weight of a vehicle by 13-15 kg.

A good example of this is plasticmetal hybrid (PMH) structural reinforcements for the vehicle’s BIW. A PMH floor rocker reinforcement, for

instance, can help reduce weight by up to 45 percent vs. an all-steel alternative.

In this component, NORYL GTX resin (MPPE/PA) from SABIC combines with steel to form a very efficient energy-absorption crash box structure. This saves 1 kilogram (kg) in weight and maintains the required level of crashworthiness.

The component is an industry-first use of plastic in a BIW reinforcement without the use of structural adhesives or foams.

Use of the NORYL GTX resin allows the part to go through the automaker’s e-coat process with the rest of the BIW. Additional opportunities across the BIW means that a manufacturer could save up to 8 kg of weight with these hybrid solutions vs. all-metal reinforcements.

SABIC is also featuring an injection-molded, foamed instrument panel carrier. The part uses the company’s STAMAX resin (LGFPP; 60YK270E grade) with SABIC PP resin (612MK10EE grade) in a structural foaming process.

non-destructive integrity testing protects pharmaceutical manufacturers against the loss of valuable medication, since the container remains intact during testing.”

High voltage leak detection and laser-based headspace analysis are now complemented by the new KLV series for vacuum leak detection. At Interpack, Bosch unveils the first in the series – the KLV 1360, which has been specially developed for vials. Generally, the platform is suited for all rigid glass containers.

Henkel submits binding offer to acquire Darex

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enkel has entered into exclusive negotiations with GCP Applied Technologies to acquire their global Darex Packaging Technologies business for 1,050 million US dollars (around 995 million euros) on a cash and debt free basis.

Henkel has submitted a binding offer for the Darex Packaging Technologies business. Darex is based in Cambridge, MA, USA and supplies high-performance sealants and coatings for the metal packaging industry around the world.

It serves various global customers producing beverage, food or aerosol cans, ensuring with its solutions the highest quality standards for many bestknown brands. In fiscal 2016, Darex Packaging Technologies generated sales of around 300 million US dollars (around 285 million euros). Darex has about 700 employees and 20 sites in 19 countries.

“The intended transaction is in line with our strategy to strengthen our portfolio through targeted acquisitions and would reinforce the position of our Adhesive Technologies business as a global market and technology leader,” said Henkel CEO Hans Van Bylen.

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NEWS INTERNATIONAL

DSM introduces Somos Taurusfor elevated temperature 3D printed part applications

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oyal DSM has introduced Somos Taurus at the Additive Manufacturing Users Group (AMUG), an annual technology conference dedicated to the advancement of additive manufacturing.

Somos Taurus is the latest addition to the Somos SLA material portfolio which expands its product offering for elevated temperature performance.

It is the first SLA material to be both durable and have the abil-

ity to withstand elevated temperatures.

With a heat deflection temperature

Milliken highlights clear packaging solutions

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illiken plans to showcase innovative solutions Interpack 2017 trade fair for clear packaging applications in polypropylene and PET. The company will demonstrate why NX UltraClear PP, the optimal, cost-effective option to help brand owners address the growing packaging trends for both resource efficiency and attentiongrabbing appeal.

“NX UltraClear PP, which is polypropylene clarified with Milliken’s Millad® NX™ 8000, is the ideal material to bring exceptional clarity, aesthetics, lightweighting and increased sustainability to a variety of commercial packaging applications,” according to Sami T.K. Palanisami, Milliken Commercial Manager – EMEA. “It offers the clarity of materials such as PET, while delivering specific benefits for different processes” Injection molders use NX UltraClear PP because it can help them to boost productivity and enhance sustainability. The material allows molders to reduce processing temperatures from 235°C to 190°C, resulting in lower energy use, reduced CO2 emissions and up to 10 percent faster cycle times.

(HDT) of 95°C (203°F), fully functional parts can be created for applications that have more stringent high heat requirements for prototyping or low volume end-use parts.

The material is charcoal grey in appearance giving it the look and feel of traditional thermoplastics. In addition, Somos Taurus builds quickly and is easy to process, clean and creates parts with smooth surfaces, fine features and details.

adidas brings footwear with new technology

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didas has unveiled Futurecraft 4D, the high performance footwear featuring midsoles crafted with light and oxygen using Digital Light Synthesis, a technology pioneered by Carbon.

Futurecraft 4D is a fruition of adidas Futurecraft. Digital Light Synthesis is a breakthrough process pioneered by Carbon that uses digital light projection, oxygen-permeable optics, and programmable liquid resins to generate high-performance, durable polymeric products. Through Futurecraft, adidas started exploring additive manufacturing as a tool to change the way products, and launched Futurecraft 3D Runner, the brand’s first 3D printed performance footwear a year later. With this, it has revolutionised additive manufacturing with Carbon, and is committed to scaling and mass-producing Digital Light Synthesised footwear.

Plastic Omnium invests $300 million in the US for two new plants

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fter the new plants in Chattanooga (Tennessee for Volkswagen) and Fairfax (Kansas for General Motors), Plastic Omnium launches the construction of two additional plants in the United States.

The Greer (South Carolina) plant under construction is intended to deliver all large exterior painted body parts for the BMW X3, X4, X5, X6 and future models at the BMW plant adjacent to Plastic Omnium; it will also supply Volvo in South

Carolina and Daimler in Alabama.

Moreover, Plastic Omnium will produce, in its new Tennessee plant, fuel systems for a Japanese car maker.

These two state-of-the-art plants will come on stream mid2018.

In total over 3 years, Plastic Omnium will have invested $300 million in the construction of 4 new plants in the United States, which will employ nearly 1,000 people.

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NEWS INTERNATIONAL

SSI SCHAEFER opens new reusable packaging fabrication facility in Mexico

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he Packaging Systems Division of SSI Schaefer Systems International, a leader in reusable packaging systems, has expanded production capabilities with a new manufacturing facility in San Luis Potosi, SLP, Mexico. SSI Schaefer Packaging, SA de CV, is centrally located in Mexico, and is the newest addition for SSI Schaefer Group headquartered in Neunkirchen, Germany. The San Luis Potosi plant will service existing and new clients located within Mexico. The new 8,500 square meter facility opened March 1, 2017.

We’re committed to being a longterm partner for our clients located

within the region,” said Dave McCulloch, CEO of Schaefer Systems International’s packaging systems division.

“Schaefer innovates products for green logistics. It’s only fitting that we also practice sustainability too. The new facility drastically shortens delivery time while reducing logistical delivery

Total-Hanwha JV invests $450 million to expand its refining & petrochemicals platform

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anwha Total Petrochemical, a 50/50 joint venture between Hanwha and Total, will invest to expand its Daesan refining & petrochemicals integrated platform. The planned $450 million investment will increase the site’s ethylene capacity by 30 percent to 1.4 million tons per year.

Daesan is one of Total’s six worldclass integrated platforms and a strategic asset for Hanwha. This site which is comprised of a highly flexible condensate splitter, a competitive steam cracker and polymers, styrene and aromatics

units, generated a net result of nearly $1 billion in 2016.

The extension will significantly increase the site’s flexibility, enabling it to process competitively priced propane feedstock which is abundantly available, notably due to the shale gas revolution in the United States. The expansion project is set to be completed by mid-2019.

The additional ethylene production will meet local demand and also supply the nearby fast-growing Chinese market which imports a significant part of its ethylene requirements.

“This project is part of our strategy to invest in world-class integrated platforms to develop petrochemicals based on competitive feedstock and targeting high-growth markets,” said Bernard Pinatel, President Refining & Chemicals of Total. “The investment reflects the strong partnership with Hanwha and will contribute to the growth of our Refining & Petrochemicals cash flows.”

costs for our clients located in and around Mexico. We chose San Luis Potosi for its excellent logistical location for both highway, rail transportation and its proximity to sea container port access,” continued McCulloch.

The new packaging fabrication plant will provide turn-key packaging solutions servicing the automotive, aerospace, home appliance, electronic, heavyequipment, and recreation vehicle industries. The significant investment made by SSI SCHAEFER into the state San Luis Potosi will generate approximately 50 jobs over the next several years.

Global Polyethylene Terephtalate market to reach $47.9 Bn by 2022

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he global production of Polyethylene terephthalate (PET) was 46.25 MMT in 2016 and is estimated to reach 74.71 MMT by 2022, at a CAGR of 8.32 percent for the forecasted period. While, on the other hand, in terms of demand the market was $31.44 billion in 2016 and would reach $ 47.98 billion by 2022 growing at a rate of 7.3 percent compounded annually.

APAC leads the market in terms of production of PET resin and is expected to dominate for the forecasted period as well. In particular, China has more than half of the market share in 2016 and exports to various countries across the globe.

Factors like increasing demand for packaging for Carbonated Soft drinks, growing consumption of packaging, no better substitute are driving the market of PET resin. On the other hand, oversupply market, low profit margins, price fluctuations are restraints to the market.

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CALENDAR

Mark your DIARY

September 20-23, 2017

July 8-14, 2017

June 8–10, 2017

May 16-19, 2017

A LIST OF KEY TRADE SHOWS HAPPENING BETWEEN MAY 2017 TO DECEMBER 2018.

Chinaplas 2017

Location: Guangzhou, China Organised by: Adsale Exhibition Services Ltd Website: www.chinaplasonline.com Background Following the very successful staging of the 30th edition this year, CHINAPLAS 2017 will return to China Import and Export Fair Complex in Guangzhou from 16 -19 May next year, occupying 26 exhibition halls with total exhibition area reaching 250,000sqm! The show spotlights “Intelligent Manufacturing High-tech Materials Green Solutions”, featuring “Automation Technology Zone”, “Composite & High Performance Materials Zone” and “Recycling Technology Zone” which gather international suppliers of advanced plastics & rubber machinery and materials.

Kenya Plast

Location: Nairobi, Kenya Organised by: Enterprising Fairs Website: www.kenyaplast.in Background 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. The event will be leveraging the support of leading chambers in Kenya, Tanzania and Uganda who have already committed their support to promote Kenya Plast.

Plastasia

Location: New Delhi Organised by: Triune Exhibitors Pvt. Ltd. Background 6th PLASTASIA-2017 in its sixth edition will showcase the latest technology and machineries used in manufacturing of plastics and petrochemicals with participation from different parts of the world. This event will be an excellent platform for exhibitors to publicise and display their products, innovation and services, build brand image and develop leadership in market position in the global areas. It will be an ideal stage for those who are interested to explore and acknowledge the most recent technologies and trends of the relevant market as well as exhibit a vast range of products and services related to the PLASTIC INDUSTRY.

T-Plas

Location: Bangkok, Thailand Organised by: MDNA Website: www.tplas.com Background A unified business platform for the plastics and rubber industries, T-PLAS - International Trade Fair for the Plastics and Rubber Industries will present a comprehensive range of solutions from the latest machinery and equipment, semi-finished products, raw materials, technical parts and reinforced plastics, to a full suite of services for the two industries.

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October 17-21, 2017 December 6–9, 2017

Plast Eurasia

Plastivision Arabia 2017

February 07 –12, 2018

Fakuma

December 11–14, 2017

CALENDAR

Location: Friedrichshafen, Germany Organised by: P. E. Schall GmbH & Co. KG Website: http://www.fakuma-messe.de/en/fakuma/ Background Fakuma offers a comprehensive overview of all plastics technologies; whether injection moulding – Fakuma holds a top international position here – extrusion technology or thermoforming: the user can find out specifically about all processes machines and tools that are relevant for the working and processing of plastics. The focus here is on practice, as around 1,700 exhibitors present the entire process chain for the economic production of plastic components.

Location: Istanbul, Turkey Organised by: Tüyap Fairs and Exhibitions Organization Inc. Website: www.plasteurasia.com Background The exhibition areas of the Plast Eurasia include plastic, machinery and equipment, mould making, plastic products, raw materials, packaging technology, hydraulics, pneumatics, etc. International exhibitors can present their latest trends, products and developments to an interested audience here. The trade fair is an ideal platform to establish new business contacts in the plastics industry.

Location: Sharjah, UAE Organised by: AIPMA and Expo Centre Sharjah Website: www.plastivision.ae Background The event has become the leading platform to showcase the latest machineries and global manufacturing trends. It gives the regional plastic processors an opportunity to source the complete range of plastic converting requirements – from raw materials, additives, moulds & machinery. Moreover, since the show will be held along with 4th Arabia Mold, it will be an exclusive multiindustry trade event for the regional plastics, mold-making, printing and packaging industries.

PlastIndia 2018

Location: Gandhinagar, Gujarat Organised by: PlastIndia Foundation Website: http://www.plastindia.org/plastindia-2018/ Background One of the major exhibitions for the plastics industry in India is being held at Gandhinagar. Around 2000 exhibitors are expected to showcase technological prowess at the trade fair. Also, the around 600 international exhibitors are expected to participate from 40 countries. Some of the industry focus pavilion to be seen at the trade fair would be Composite, Automotive, Medical & Health Care, 3D Printing, Sports, etc.

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AUTOMOTIVE

Space Frame with a unique mix of materials IN TERMS OF ITS OVERALL DIMENSIONS, AN ULTRA-HIGH-STRENGTH, TORSIONALLY RIGID REAR PANEL MADE OF CFRP IS THE LARGEST COMPONENT IN THE OCCUPANT CELL OF NEW AUDI A8.

A

udi is writing a new chapter in its lightweight design success story. For the next generation of the Audi A8, an intelligent mix of four materials is being used for the first time in the weight-bearing body structure – more materials than in any of the brand’s previous production models. The luxury sedan is thus once again rightfully claiming its role as an innovation driver in automotive lightweight design: Its low weight and impressive rigidity offer greater performance, efficiency and safety.

The lightweight design experts at Audi long ago abandoned the fixation on using a single material in lightweight design.

With a mix of aluminium, steel, magnesium and carbon fiberreinforced polymer (CFRP) they are establishing a new stage in multi-material construction in the Audi Space Frame (ASF) for the next generation of the Audi A8 – in keeping with the principle “the right material in the right place and in the right amount.”

Audi consistently applies new material technologies and designs that directly benefit the customer – and not only in terms of

The lightweight design experts at Audi long ago abandoned the fixation on using a single material in lightweight design. With a mix of aluminium, steel, magnesium and carbon fiber-reinforced polymer (CFRP) they are establishing a new stage in multi-material construction in the Audi Space Frame (ASF) for the next generation of the Audi A8 – in keeping with the principle ‘the right material in the right place and in the right amount.’

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AUTOMOTIVE

weight. The upcoming flagship’s torsional rigidity – the critical parameter for precise handling and pleasing acoustics – surpasses the excellent values of its predecessor by a factor of about one fourth.

Innovative production process In terms of its overall dimensions, an ultra-high-strength, torsionally rigid rear panel made of CFRP is the largest component in the occupant cell of the new Audi A8, and it contributes 33 percent to the torsional rigidity of the total vehicle.

To optimally absorb longitudinal and transverse loads as well as shearing force, between six and 19 fiber layers are placed one on top of the other, ensuring a load-optimized layout. These individual fiber layers consist of tapes 50 mm (2.0 in) wide and can be placed individually in a finished layered package, with any desired fiber angle and minimal trimming of the fibers. The innovative direct-fiber layering process specially developed for this purpose makes it possible to entirely dispense with the normally needed intermediary step of manufacturing entire sheets. Using another newly developed process, the layered package is wetted with epoxide resin and sets within minutes.

A comparison with the predecessor model shows that it contributes a 28-percent weight savings. Aluminium bolts secure the connection to the strut tower domes, making them a guarantor of the body’s high torsional rigidity. In the event of a frontal collision, the forces generated are distributed to three impact buffers in the front end.

A high-strength combination of hot-formed steel components make up the occupant cell, which comprises the lower section of the front bulkhead, the side sills, the B-pillars and the front section of the roof line. Some of these sheet metal blanks are produced in varying thicknesses using tailoring technologies – meaning they are customised – and others also undergo partial heat treatment.

That reduces weight and increases the strength, especially in areas of the vehicle that are particularly critical for safety.

The aluminium components make up 58 percent of the new Audi A8 body, the largest share in the mix of materials. Cast nodes, extruded profiles and sheets are the elements characteristic of the ASF design. And here too the competition of materials has been driving progress.

New heat-treated, ultra-high-strength cast alloys attain a tensile strength of over 230 MPa (megapascals). The corresponding yield strength in the tensile test is over 180 MPa, and for the profile alloys it is higher than 280, i.e. 320 MPa – significantly higher values than seen previously.

Rounding out the intelligent mix of materials is the magnesium strut brace. A comparison with the predecessor model shows

The new process makes it possible to precisely control the penetration depth of the laser by means of the heat input. that it contributes a 28-percent weight savings. Aluminium bolts secure the connection to the strut tower domes, making them a guarantor of the body’s high torsional rigidity. In the event of a frontal collision, the forces generated are distributed to three impact buffers in the front end.

Benefits for customers and the environment In addition to the complete redevelopment of the Audi Space Frame for the next generation A8, the production halls at the Neckarsulm location were specially built for the upcoming flagship. A total of 14,400 metric tons of steel were needed just for construction of the new, 41-meter-high body shop, twice as much steel as was used for the Eiffel Tower in Paris.

The highly complex yet energy-efficient production operation uses 14 different joining processes, including roller hemming at the front and rear door cutouts. This mechanical, “cold” technology is used to join the aluminium side wall frame to the hotformed, ultra-strong steel sheets at the B-pillar, roof line and sills.

The engineers thus realized improvements of up to 36 mm (1.4 in) at the door cutouts compared to the predecessor model. That in turn makes getting in and out of the car even more comfortable and widens the driver’s field of vision around the Apillar, an area that is key to safe driving. As for the “warm” joining processes, Audi stands alone among the premium automakers by virtue of its development of remote laser welding for use with aluminium. Exact positioning of the laser beam in relation to the welding edge considerably reduces the risk of hot cracking during the production process.

The new process makes it possible to precisely control the penetration depth of the laser by means of the heat input. In this way, process control can immediately determine the gap width between parts being joined, and this can effectively be closed using regulating controls. The laser beam’s high feed rate and low energy use reduce the CO2 emissions of this production step by about one fourth.

This new process also results in a 95 percent savings on recurring costs in series production because it eliminates the need for costly process controls required with conventional laser welding. The remote laser welding technology perfectly symbolizes the entire production of the new Audi A8. In 1994 it was the first generation of this luxury sedan, with its aluminium unitary body, that made the Audi Space Frame an established presence in the automotive world. Since then the company has built more than one million production cars in accordance with this design principle, and it has been continually building upon its know-how in the use of materials and joining techniques.

Source: Audi

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BLOW MOULDING

Thinking globally, working locally DUE TO INCREASE IN DEMAND FOR WATER TANKS, THE DEMAND FOR BLOW MOULDING MACHINES IS ALSO INCREASING SAYS ANAND PANCHAL, MARKETING DIRECTOR AND PARTNER, N. A. ROTO MACHINES & MOULDS INDIA.

By Swati Deshpande The company is in the business since last 35 years.

Please tell us about the company’s journey.

We started our journey in 1982 year at micro level for manufacturing roto molding moulds. Decade later, Backward Integrated to manufacture machines and presently have infrastructure spread over 16,000 Sq Mtrs. of area with Strength of more than 275 people delivering highly efficient- high production machines to 79+ countries with technology supports from reknown Rotomoulding consultants.

Recently, we have also forayed into blow moulding Machine Manufacturing to enhance our market spread. And even before we made our first machine, it was already sold to one of the reputed Indian clients and two more machines are underway.

Customers now-a-days are value oriented rather than price oriented.

Keeping this in mind, we have built a blow moulding machine, which helps customers reduce production wastage by sizeable amount, thus enhancing their top line.

Tell us about your manufacturing capabilities.

For Roto molding, we have installed capacity of machine manufacturing and dispatching at 25-28 plants per annum. As I mentioned we have recently entered into the space of blow moulding and capacity for this segment is 4–5 machines per annum. Our products are volumetric by nature and also it amounts to an industry in itself. Hence, many a times we have experienced that customer is not ready to lift it owing to one reason or the other. As they do not lift their order on time, hence our capacity is blocked and we cannot effectively utilise the same to its full potential. This ultimately leads to non-utilisation of installed capacity.

Demand for water tanks is increasing in the country day by day. In this case, how has been the demand for blow

In order to cater increasing demand for water tanks, there has been addition of capacities by manufacturers as well as addition of new manufacturers for water tank. With government’s thrust on infrastructural projects, building and constructions like affordable housing projects, etc., this demand is expected to grow exponentially in time to come.

moulding machinery currently? How do you foresee it growing in the future?

It is true that demand for water tanks is increasing in the country day by day. In order to cater to this demand, there has been addition of capacities by manufacturers as well as addition of new manufacturers for water tank, which has led to further surge in demand.

If we consider demand for blow moulding machines in last couple of years, there significant increase in imports from China.

With government’s thrust on infrastructural projects, building and constructions like affordable housing projects etc., this demand is expected to grow exponentially in time to come.

Tell us about technology breakthroughs that N A Roto has brought in the area of blow moulding.

N. A. Roto has a reputation as a reliable quality supplier and keeping up with same expectations. For blow moulding, we bought technology from most reliable source, which has helped us build machine which reduces production wastage by sizeable amount.

It is a breakthrough technology in its own sense. Due to increased competitive environment, manufacturers are not able to increase

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BLOW MOULDING

Earlier, Roto moulding process was in nascent stage and customers’ expectations from machinery were limited. As time passed by and market of roto moulded products evolved, competition increased and presently customers are expecting great value from machinery and hence, we have to almost continuously innovate some engineering aspects of machine to keep up with expectations. For blow moulding, same logic applies as customers now-a-days are value oriented rather than price oriented. Keeping this in mind, we have built a machine, which helps customers reduce production wastage by sizeable amount, thus enhancing their top line.

In brief, we are truly ‘Thinking Globally but Working Locally’.

product prices. However, using our machines, due to low wastage/efficient production, their product cost would automatically come down avoiding need of price increase.

R&D is backbone of innovation. Please tell us about N A Roto’s strength in this area.

Please tell us about company’s exports.

As I mentioned earlier, presently we are exporting to 79+ countries spread across Africa, Middle East, Asia and South American region apart from some isolated exports to CIS, Australia, etc.

Speaking about the domestic market, we have presence all over the country. Our current export to domestic sales ratio is about: 60:40.

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COVER STORY

Breaking the

MOULD

HITEN V PAREKH, JOINT MD, NILKAMAL LTD EXPLAINS HOW THE COMPANY HAS REPLACED CONVENTIONAL MATERIALS WITH PLASTIC ACROSS APPLICATIONS.

By Swati Deshpande

W

hen one thinks about plastic furniture, the first and probably the only brand that comes to his/her mind is Nilkamal. This is the kind of brand image that the company has created in the country. When I asked about this to Hiten V Parekh, Joint Managing Director, Nilkamal Ltd., he says, “Moulded furniture is one of the pillar businesses of the company.” And he is very proud of it. Again, why shouldn’t he be, the company sells a million chairs per month. Yes, you read it right. This is apart from the other moulded furniture such as tables. The company introduced moulded chairs in 1990s. That was an era, when wooden furniture was prevailing. In this condition, how was it for the company to venture into the unknown? “Initially the business was slow.

The chairs weren’t easily accepted in homes. However, marriage decorators were the ones who made it popular. Those traditional wooden chairs were uncomfortable and its nails, which popped out frequently posed danger to the expensive clothes as well to

It’s a relatively new concept. What we can see today that new projects are coming at scattered locations. As they need our material handling products during construction, I can definitely say that slow and steady impact of Make in India can be seen.

the health. As a result, our aesthetically appealing, water resistant, comfortable and stackable chairs got absorbed by marriage decorators and other community halls easily,” he says. Further he adds that once people saw its benefits at such ceremonies, it also became popular in Indian houses. “Slowly we became pioneers in the market. However, we just did not only take the lead but maintained it by far margin against competitors till today.”

Expanding its portfolio, the company has recently launched range of office furniture and is in process of launching home furniture. “We understand ergonomics very well from our experience of making chairs for more than 20 years.

This has helped us to come up with office furniture and we have introduced chairs for all the levels of staff. Similarly, we are coming up with furniture that is exclusively designed for homes. And we expect to create an impact in the market with these two ranges,” he hopes.

Another art that Nilkamal has mastered Bubble Guard a rigid board made of is material handling equipment. Gone are polypropylene - a upcoming product of Nilkamal

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COVER STORY

Plastic is an eco-friendly material. First and foremost it requires much lesser energy for production in its lifecycle as compared to other conventional materials. the days when products such as milk or soft drinks were carried in a wooden container. All of these are replaced by lightweight plastic containers, most of it coming from Nilkamal. “Again we are pioneers in this arena and way ahead of competition in business,” Parekh mentions.

“Furniture and material handling are our core businesses,” he continues. But the family run business hasn’t stopped there.

Nowadays Nilkamal is also known for its construction equipment. The earlier used metal barricades are now getting replaced by plastic ones. “As plastic is lightweight, weather-proof and does not rust, it turns out to be a great material for these barricades,” asserts Parekh.

But why is this material is so close to him and to the company? “Plastic is an eco-friendly material. First and foremost it requires much lesser energy for production in its lifecycle as compared to other conventional materials. Moreover, it saves wood cutting to some extent by replacing wood used in the furniture.

And of course, it has its other advantages such as aesthetics, weather-proof, water resistance, etc. Also, it is recyclable and reusable. So I believe plastic is the clever solution.”

Moving on from core businesses Innovation has been a part of the company since its inception.

Continuing the trend Nilkamal has ventured to various new areas even lately. “We realised that we have to leverage on our brand name and also on distribution strength that we have across the country. That led to the thought that why don’t we tie up with appropriate companies to offer products which are need of the hour.

Also, as the government is focusing on Swachh Bharat Abhiyan, our new innovations are in line with the prime Minister’s objectives,” Parekh says.

Speaking on its products that are made for rural India, he explains “Water Wheel is especially made for women who carry the litres of water on their heads and walk for kilometres. The practice of head loading can cause chronic back, neck, and eye pain, curvature of the spine, and can lead to death during childbirth,” he raises his concern. To overcome this challenge, Nilkamal and Wello together have launched Water Wheel. As the name suggests it’s a water carrier which can be filled and carried with push or pull. It prevents women from carrying heavy loads on their heads,” he informs. Further he shares that, the product is well received by rural women.

Another masterpiece that the company has developed is Sato Pan. “In order to solve the problem of open defecation, we tied up with Lixil of Japan to develop these pans,” he mentions. The problem of open defecation comes from lack of toilets and even if there are toilets, availability of water is a major concern. “ConApril-May 2017 | The Economic Times POLYMERS | 31

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COVER STORY

Bubble Guard sheets come with various thicknesses

sidering these challenges, we have developed Sato Pans. Where the normal toilet flush consumes 8ltr of water each time, this pan does the job in approx. 1.5 ltr,” Parekh says.

Besides these innovations, Nilkamal also has waste bins that are in line with cleanliness mission. And the Swachh Bharat Abhiyan has given big boost to these businesses. Speaking on it he mentions, “Our business for waste bins has registered 100 percent year on year growth for past three years.”

Additionally, under its CSR initiatives, the company is also making products for Anganwadi projects. “We have developed

The Company has advanced machinery in injection moulding, rotational moulding, vacuum forming, polyurethane injection (of insulation) and capabilities for blow moulding.

benches and other furniture for school. And we are also in process of making a blackboard for these schools,” Parekh reveals.

Manufacturing capabilities Making such variety of products and ranges is a humongous job.

“For this we have facilities across the country. We have strengthened our manufacturing capabilities in every corner of the country,” he proudly says. These factories are located in Samba (Jammu & Kashmir), Greater Noida (Uttar Pradesh), Barjora (West Bengal), Sinnar, Nashik (Maharashtra) and Silvassa (Union Territory of Dadra & Nagar Haveli) (2 plants), Pondicherry (Union Territory) and Hosur (Tamilnadu). The company also has a plant in Sri Lanka. “This country is quite similar to India on the parameters of culture and weather. Therefore, understanding this market was comparatively easy for us,” Parekh asserts.

Elaborating further on the manufacturing capabilities, he says, “The Company has advanced machinery in injection moulding, rotational moulding, vacuum forming, polyurethane injection (of insulation) and capabilities for blow moulding. Each of these plants has dedicated tool rooms. Occupying a massive total constructed area of 1 million sqft; all of Nilkamal’s manufacturing plants are ISO 9001/2008 Certified and practice 6 Sigma manufacturing process. This extensive manufacturing infrastructure is ably supported by our wide and strong sales network.”

These manufacturing capabilities are strengthened by dedicated Research & Development team. “We have over 22 people in design and development team who think of new solutions day in and day out. We do some mock-up, talk to our customers, talk to people in the office. Take their views make the changes accordingly. Also we have testing labs that are BIFMA cerified,” he says.

Having a facility in Sri Lanka already highlights acceptance of products and solutions in the foreign market. Apart from Sri Lanka, Nilkamal has footprint in approximately 37 countries. “We

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COVER STORY

add couple of more to this every year. Also, we have operations in UAE. We export our products there and then they are distributed in the vicinity,” Parekh informs

Way forward

Parekh mentioned that although Nilkamal is a family run business it does not stop evolving We have vision and innovating. The next innovation is already statement for in the pipeline for the company. “We are setting 2020 for Nilkamal. up a new line for Bubble guard, which is s a new Understanding the market This is essential product for our country. Its rigid board made of Parekh is careful while speaking on the new buzz for employees as polypropylene. It can be made in different thickword -‘Make in India’. He says, “It’s a relatively well as the next nesses and has multifarious uses. In the automonew concept. It takes time to see its penetration. generation that is bile sector, it can be used as a sheet that covers It takes time to factories to be set-up and start now entering in the wheels in the boot of the vehicle. Currently it is manufacturing, so it will take 2-3 years for imbusiness. made of various materials sticking together and pact to be seen. What we can see today that new Automobile industry is already looking for a reprojects are coming up at scattered locations. As placement and this would be the right material they need our material handling products durfor this application. Also, it is recyclable. The other industries it ing construction, I can definitely say that slow and steady impact can find application is packaging, and printing. Construction is of Make in India can be seen.” also one of the sectors where it can be used for preventing flooring Ease of doing business is another initiative of the Governgetting damaged while doing the ceiling work. Bubble guard is ment that catches attention. “All the states are now clambering to customisable and can be offered in required thickness,” he shares. attract the industry to put up in their states. Now bureaucracy has The company has discussed and decided upon its goals and become serious to attract businesses. There is certainly a change vision. “We have vision statement for 2020 for Nilkamal. This in attitude. States like West Bengal and Odisha, which neglected is essential for employees as well as the next generation that is industries before have now jumped into the race. There is big now entering in the business. It does not only explain the goals change in the attitude. As a result, we can see of lot of developin terms of profitability but also highlights company’s approach ments. E.g. In Tamil Nadu lot of automobile companies are settowards business and what it stands for,” Parekh concludes. ting factories or increasing capacities. “

Water Wheel is especially made for women who carry litres of water on their heads

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AUTOMOTIVE

Prototype carbon fiber composite subframe

M

agna International Inc., in cooperation with Ford Motor Company, has developed a prototype carbon fiber composite subframe, which reduces mass of the vehicle by 34 percent compared to making a stamped steel equivalent.

By replacing 45 steel parts with two molded and four metallic parts, the prototype subframe achieves a dramatic 87 percent reduction in the number of parts.

The moldings are joined by adhesive bonding and structural rivets.The carbon fiber subframe is the result of a research and development project between Magna and Ford to investigate potential mass-reduction benefits and technical challenges of using carbon fiber-reinforced composites in chassis applications.

The subframe is a key part of a vehicle’s structure, typically pro-

viding a place to attach the engine and wheels while also contributing rigidity and crash management.

The design has passed all performance requirements based on computer-aided engineering (CAE) analyses.

The prototype subframes are now being produced by Magna for component and vehicle-level testing at Ford. “Collaboration is the key to success in designing lightweight components that can give our customers fuel economy improvements without compromising ride and handling, durability or safety. We must continue to work hard to achieve these lightweight solutions at the most affordable costs,� said Mike Whitens, Director of Vehicle Enterprise Systems within Ford Source: Magna International Inc

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AUTOMOTIVE

New clearcoat with biobased hardener A CLEARCOAT CONTAINING A BIOBASED HARDENER WAS APPLIED TO TEST BODIES OF THE AUDI Q2 UNDER NEAR-SERIES CONDITIONS AT THE AUDI PLANT IN INGOLSTADT, GERMANY. TEST BODIES SUCCESSFULLY COATED UNDER REALISTIC PRODUCTION CONDITIONS.

I

n the automotive industry, manufacturers and suppliers are working constantly to reduce energy consumption and CO2 emissions in production.

A project team consisting of employees of the car maker Audi, BASF´s Coatings division and materials company Covestro has now passed a new milestone: for the first time, a clearcoat containing a biobased hardener was applied to test bodies of the Audi Q2 under near-series conditions at the Audi plant in Ingolstadt, Germany.

BASF developed the clearcoat using the bio-based hardener Desmodur eco N 7300 from Covestro. A total of 70 percent of the hardener’s carbon content is sourced from renewable raw materials.

This innovation reduces the consumption of fossil resources.

The clearcoat forms the top layer of the coating system, lending it scratch resistance, a glossy appearance and protection against sunlight and other weather effects.

and topcoat development Europe at BASF. Dr. Markus Mechtel, Head of Marketing for automotive coatings at Covestro adds, “Using renewable raw materials in the production of bio-based hardeners helps to conserve fossil resources. At the same time, the biomass, as it grows, captures CO2 in the environment.”

In addition, process steps are eliminated during bio-based raw material production for this hardener, thus leading to an additional reduction of CO2 emissions.

Improved eco-balance, high quality

Promising test results

“Our new clearcoat helps our customers to reach their sustainability targets, without having to compromise in terms of quality and performance,” says Dr. Matthijs Groenewolt, Head of clearcoat

“The use of biobased raw materials in automotive coatings is still in its infancy,” says Thomas Heusser, head of Materials and Process Engineering at Audi. “But the application of the new clearcoat on our existing machines fulfilled all our specifications and delivered promising results. With this project Audi takes up a pioneering role in this field in the automotive industry.”

After successful coating of test bodies of the Audi Q2, Thomas Heusser is optimistic: “Even though not all tests required for approval of the coating for use in full-scale production have been concluded, the three companies have taken an important step toward an even more sustainable automotive coating process.”

This innovation reduces the consumption of fossil resources. The clearcoat forms the top layer of the coating system, lending it scratch resistance, a glossy appearance and protection against sunlight and other weather effects.

Using renewable raw materials in the production of bio-based hardeners helps to conserve fossil resources. At the same time, the biomass, as it grows, captures CO2 in the environment.

Dr. Markus Mechtel, Head of Marketing for automotive coatings at Covestro

Source: BASF

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CONSTRUCTION

Piping it right SPUTNIK, A BRAND OF KISAN PIPES PVT LTD, HAS INNOVATED QUITE A FEW PRODUCTS. SIPHON PIPE IS AMONGST ONE OF THEM. HERE IS MORE ON THE COMPANY’S INNOVATIONS AND FUTURE PLANS.

By Swati Deshpande

T

he corrugated pipes for wash basins and kitchen sinks are not new concepts. But while fitting these pipes, different sizes of filters made the scenario difficult for plumbers and ultimately pipe manufacturers. Elaborating on the challenge, Rajiv Sanghavi, Director, Kisan Pipes & Profiles Pipes Pvt. Ltd. said, “Normally each wash basin or sink has a filter through which water flows and goes to the waste pipe. This filter is made of brass with threaded portion on which we fix the waste pipe. In India, these filters come in three different sizes—one of them is as per ISI standards, smaller than ISI and larger than ISI. Often plumbers are the ones who buy waste pipe and when it does not fit to the filter, it had to be thrown away or replace it with the required diameter.”

This challenge led Sputnik, a brand of Kisan Pipes & Profiles Pvt. Ltd. to bring about Siphon pipe that fits all these measurements. “As a solution to this problem, we have made a tapered connection, which fits on any of these filters easily. As a result, it saves time and labour and also ensures a leak-proof joint,” he explained. This pipe has also won The Economic Times Polymers

A few years ago we developed a corrugated sleeve to cover and protect the rubber tube connected from the gas cylinder to the stove. This product got a fantastic response from the market.

Rajiv Sanghavi, Director, Kisan Pipes & Profiles Pipes Pvt. Ltd. Award for Excellence in Plastics in Construction in 2017.

Flexibility of measurement is one of the key features of the Siphon Pipe. Speaking on the additional advantages, Sanghavi said, “While making a product that is flexible, we also had to give it a good external finish to it as the pipe was going to be visible.

Hence, we made it aesthetically appealing for use in bathrooms.

We manufacture these pipes in standard tile colours so that it

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CONSTRUCTION

The company is in the process of developing hot & cold connection.

Currently pipes used for hot and cold water are made of metal. However, we are trying to replace them with plastic pipes. We have developed the pipes however, the product is at the testing stage and soon you can expect it to hit the market.

In the field of medical tubes we have developed a range of products with one of the leading manufacturer of surgical and medical disposables in India and we provide respiratory tubes, cathedral tubes, urinary tract tubes, and so on. All this is manufactured in Clean Room Environment to provide highest sanitation and hygiene in view of the application of the final product. matches the bathroom tiles.”

Adding about the company’s approach towards innovation, he noted, “Our company gives importance not only to designing but also to production planning and quality control. Technical innovation has been prime goal of our company. Each and every

Siphon Pipes in nutshell Challenge: Different sizes of filters demanded waste pipes in respective sizes Solution: Tapered connection for Siphon Waste Pipe Benefits: • This is pipe is flexible and fits to the filer of any size • Time saving • Leak-proof joint

product is conceived, analysed, designed and developed in-house at our facility in Rajkot.”

Giving an example of another innovation, that he is personally proud of, Sanghavi mentioned, “A few years ago we developed a corrugated sleeve to cover and protect the rubber tube connected from the gas cylinder to the stove. This product got a fantastic response from the market. It was only in 2012, the Government introduced reinforced gas tubes forcing people to use the same for safety and security. Until then, it was only our product that prevented leakage of gas. Looking at the safety matters, we still believe that this corrugated sleeve is one of our most important developments brought by us in all these years.”

Besides industries mentioned above, the company also operates in sectors such as medical, automotive, etc. “In the field of medical tubes, we have developed a range of products with one of the leading manufacturer of surgical and medical disposables in India. We offer respiratory tubes, cathedral tubes, urinary tract tubes, and so on. All this is manufactured in Clean Room Environment to provide highest sanitation and hygiene in view of the application of the final product,” elaborated Sanghavi.

Throwing light on the company’s business in the automotive segment, he asserted, “Automotive harness is a new field as far as corrugated pipe is concerned. We at Sputnik, decided to venture into this field to cater to the replacement market,” Sanghavi mentioned. While elaborating on the point, he said, “Every vehicle, which requires to be refurbished or repainted, the entire Electrical Kit is replaced with new Harness Kit. Here, we come into the picture. We cater to the replacement market and not to the OEMs.”

Manufacturing capabilities Electrical conduits is yet another area where the company has its presence. Such a massive product line automatically requires

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CONSTRUCTION

The corrugated pipe concept is fast picking up in India and although we play a very small role in this Industry as we produce Pipes only up to 50 mm diameter, there a greater scope in this Industry if we could produce larger diameter pipe, which are used in telecom ducting, sewerage and drainage, fibre optic cable protection, and so on.

sophisticated manufacturing facility. Speaking on its manufacturing capability, Sanghavi informed, “Our manufacturing facilities are located in Shapar, Dist. Rajkot, Gujarat and we have a plant that is spread over 15,000 sq. ft. consisting of five extrusion lines with Italian Technology from ITIB Italy. This is capable of making pipes in the diameter range of 7–50 mm.” Additionally, the company also has four injection moulding machines and one recycling machine at its manufacturing facility in Rajkot.

“This facility caters to the company’s range of products in the areas of electrical conduits, washing machine pipes, wash basin waste pipes, medical pipes, garden pipes and automotive harness pipes. We serve variety of industries and our close proximity with our customers and end products makes it possible to do the business in these many areas,” Sanghavi opined.

Continuing further, he revealed, “With this range of products, turnover of the Kisan Pipes is Rs. 6 crore. Out of which 50 percent comes from exports to Middle East countries where Sputnik is synonymous to quality and workmanship. Needless to say sanitary pipes is the most revenue making business for Kisan Pipes.”

In the time, where building & construction market is seeing unfavourable market conditions, how has it affected Sputnik? “Last financial year was subdued in comparison to previous year predominantly due to a glut in the construction activity. Most of our products are used in building and infrastructure and since the building construction industry has got a serious hit due to demonetisation, sales have been low since November and December 2016. On the bright side, from the new year, the situation seems to be improving and if this trend continued we hope to recover the lost turnover,” he stated.

Apart from India, Middle East countries are the major markets for Sputnik pipes. “We export our products to Middle East Countries and Africa viz. Kenya and also to Italy. In order to remain competitive in the market, your products have to be competitively priced. In this regard,

we have an advantage of proximity – India being close to Middle East, our products turn out to be economical in the peninsula.

And that could be one of the secret behing our success in that market compared to the producers from other countries,” Sanghavi shared.

…and the journey continues The journey of innovation does not stop here for Sputnik and Kisan Pipes. Speaking about taking the product next level, Sanghavi said, “The company is in the process of developing hot & cold connection. Currently, pipes used for hot and cold water are made of metal. However, we are trying to replace them with plastic pipes. We have already developed pipes however, the product is at the testing stage and soon you can expect it to hit the market.”

While concluding the conversation he noted, “The corrugated pipe concept is fast picking up in India and although we play a very small role in this industry as we produce pipes only up to 50 mm diameter, there a greater scope in this Industry if we could produce larger diameter pipe, which are used in telecom ducting, sewerage and drainage, fibre optic cable protection, and so on.”

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n

o o S ng

i m o C

Global Conference on Plastics in Automotive September 2017 • Pune

Some of our previous speakers

Rajan Wadhera M&M Ltd

Vishal Agarwal Yudo

Ajay Durrani Covestro India

Amit Kavrie Supreme Treon

Topics

• CEO Panel Discussion • Role of Plastics in Vehicle Interiors & Exteriors • Light-weighting of auto components • Additive manufacturing: Disrupting design with plastics (For automotive professionals only)

For Speaker Opportunities, contacts

Niranjan Mudholkar | +91 9819531819 For Partnership, contacts

Mahadev. B | +91 9448483475 Ranjan Haldar | +91 9167267474 For more details, visit: gcpa.themachinist.in Book-ETPolymers-Apr-May2017.indb 43

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INNOVATION

Materials transformation is integral to long term growth GLOBALLY INDUSTRIES ARE LOOKING FOR NEW MATERIALS HAVING BETTER FEATURES SAYS SHYAM SUNDAR S PANI, DIRECTOR, MARKETING AND COMMUNICATIONS, STEER ENGINEERING PVT. LTD. What is spurring material transformation in the plastics industry?

Materials are responsible for changing the way new products are being designed and developed to ensure that the enhanced features and functionality are appealing to the rapidly evolving consumer segment as well as from the industry demand perspective.

Irrespective of whether they are household, industrial or defence related products and components, newer materials displaying better physicochemical properties and performance are entering the market. These materials should not only display the potential to withstand acute deterioration because of physical, chemical and environmental stress, but also eco-friendly and sustainable in manufacturing.

Why is it important to master effective transformation of materials?

Let’s take a few examples to justify this. Global car manufacturers are exploring several types of materials to reduce the weight of vehicles for fuel efficiency. At the same time, they need materials that meet their business objectives and stringent requirements.

Global car manufacturers are exploring several types of materials to reduce the weight of vehicles for fuel efficiency.

At the same time, they need materials that meet their business objectives and stringent requirements. Similarly, aircraft manufacturers are experimenting with new generation materials to build bigger and better fuel-efficient aircraft aimed at revolutionising global transportation.

Similarly, aircraft manufacturers are experimenting with new generation materials to build bigger and better fuel-efficient aircraft aimed at revolutionising global transportation. Today, automobiles and aeronautical industries are growing at an exponential rate, particularly in the emerging economies. Both are at the forefront of innovation and the plastics industry has a bigger role in this transformation.

“Materials are responsible for changing the way new products are being designed and developed to ensure that the enhanced features and functionality are appealing to the rapidly evolving consumer segment as well as from the industry demand perspective.”

What are the challenges faced by the plastics industry in ensuring effective transformation of materials while compounding?

One of the familiar challenges is obtaining an optimum dispersion and distribution of pigments into the polymer matrix. For example, not all technology platforms can successfully achieve good dispersion of blue organic pigment (colour masterbatch for multiple end-user applications in the plastics industry). As the particle size is minute, it drastically loses chemical and physical properties during processing. If the dispersion in the polymer matrix is not optimum, it will affect the physical properties of the pellets. Eventually, the blue masterbatch will be unfit for use in any end applications. The formulation, processing parameters, screw design and processing techniques must be right. Suppose we get the desired dispersion, the next challenge is to mix it with other materials. Plastics can incorporate other ingredients and

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INNOVATION

such an effective modification leads to transformation.

So, you mean that the challenge to effectively transform materials remains a challenge?

Though technology platforms to transform materials effectively are today widely available, not all of them have mastered control over three factors - Control over Temperature; Pressure applied and Time consumed for Processing Materials. A correct combination of these three can usher in better control over transformation of materials. Extensive R&D work is in progress to evolve 21st century processing platforms. For instance, a platform technology aimed at continuously processing materials with self-cleaning ability resulting in a chemical reaction to increase the molecular weight or viscosity without gelling, is spurring the development of newer extrusion technology using co-rotating twin-screw extruder at STEER. We have been successful in transforming materials by mixing rubber, jute, natural fibers, edible ingredients, seaweed, soya seeds, and even chicken feathers!

Can you elaborate on a specific case study where STEER has been successful in materials transformation?

Yes. At our Application Development Centre in Bengaluru, we developed a process for a compound comprising Aluminium Trihydroxide (ATH) flame retardant, Polylactic Acid (PLA), chopped glass fiber, silicon oil, and plasticizer (oil). Achieving an optimal dispersion of these complex additives while protecting the PLA from degradation is a challenge as PLA and ATH are highly sensitive to heat and shear. PLA will have excessive loss of molecular weight and properties while ATH will degrade to lose

Though technology platforms to transform materials effectively are today widely available, not all of them have mastered control over three factors - Control over Temperature; Pressure applied and Time consumed for Processing Materials. A correct combination of these three can usher in better control over transformation of materials.

A platform technology aimed at continuously processing materials with self-cleaning ability resulting in a chemical reaction to increase the molecular weight or viscosity without gelling, is spurring the development of newer extrusion technology using corotating twin-screw extruder at STEER. We have been successful in transforming materials by mixing rubber, jute, natural fibers, edible ingredients, seaweed, soya seeds, and even chicken feathers! its flame retardant capability. There are other challenges - ATH loses its water molecules when heated or sheared while PLA is sensitive to hydrolysis in the presence of water. If ATH loses its water during processing, water will hydrolyze the PLA. Therefore, water must be removed immediately using vacuum venting after PLA is melted.

After multiple trials, we were successful in producing an output that retained the properties of the PLA, provided optimal dispersion of the ATH and oils while preserving the length of the reinforced glass fibers. The favourable performance resulted in sale of a STEER Omega class extruder to produce PLA product lines.

What is the way forward for materials transformation from the long-term perspective?

Material transformation is all about doing it right with least energy, inputs, and Specific Mechanical Energy Input (SMEI). For instance, a good compound is the result of a thorough understanding of what goes inside the ‘extruder processing zone (EPZ)’ for materials transformation. The key to success lies with the design of the ‘element & barrel’ configuration and the shaft design.

A reliable materials processing platform technology, which can deliver the desired results, is important for the plastics industry to sustain growth in the long-term. Materials transformation is all about bringing multiple ingredients together and mixing them effectively to evolve better and newer applications, especially for businesses in the core sectors of the economy.

Source: STEER Engineering Pvt. Ltd.

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PACKAGING

Factory of the future LEARN MORE ABOUT HOW PACKAGING IS BECOMING SMARTER WITH NEW TECHNOLOGIES

G

ebo Cermex, part of the Sidel Group is introducing its latest advanced performance systems and innovative packaging line solutions at Interpack 2017. At the show, the company is demonstrating its portfolio for the beverage and food, home and personal care (FHPC) customers based on its Agility 4.0 program.

Marc Aury, President & Managing Director of Gebo Cermex, explains: “As a key player in the Factory of the Future movement with our Agility 4.0 program, at Interpack this year we are excited to give visitors a preview of our vision of the ‘Smart Machine’, with a comprehensive robotic/cobotic case packing solution embedding advanced and connected systems.” A ‘Smart Machine’ is so much more than a piece of machinery. Featuring the latest motion technology, robotics and cobotics, auto adjustment and auto feeding, as well as being a connected machine, it establishes itself as a forward looking comprehensive solution. Aury continues: “It is no longer a case packer simply putting products in a case. It’s a 360° integrated approach using the latest technologies to deliver all functionalities.”

New shaped bottle infeed system to preserve product integrity As a global launch at Interpack 2017 will be CareSelect - Gebo Cermex’s patented universal and modular shaped-bottle infeed and collating system for robotic or traditional case packers. Utilising Rockwell Automation’s iTRAK technology and capable of

As a key player in the Factory of the Future movement with our Agility 4.0 program, at Interpack this year we are excited to give visitors a preview of our vision of the ‘Smart Machine’, with a comprehensive robotic/cobotic case packing solution embedding advanced and connected systems.

Marc Aury, President & Managing Director of Gebo Cermex achieving speeds of up to 400 products per minute depending on package size, shape and weight, the CareSelect system easily surpasses traditional ‘endless screw’ collation systems in terms of bottle integrity and protection. It delivers shaped bottles to the packing machine with precision and care in the correct orientation and pitch, turning each bottle 90°.

Even unstable shaped products are smoothly and individually handled via independent movers. To eliminate contact between products, flow is managed without accumulation at the infeed and ‘friction time’ between the bottle and the system - when the bottles come into contact with machine parts - is dramatically reduced (by at least 20 times) compared to an endless screw infeed system.

In response to the demand of customers for flexibility and reduced downtime when managing production of different batches,

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PACKAGING

CareSelect offers fully automatic changeovers in less than one minute, with no need for mechanical adjustments. Additionally, adaptation of movers and product guides is carried out automatically, without involving any manual intervention. Unlike the previous screw infeed which required the manipulation of heavy parts, CareSelect™ needs no tools or parts to implement the changes. As a result, storage space for cranes and other kinds of equipment is also saved.

Automatic magazine loading

A ‘Smart Machine’ is so much more than a piece of machinery. Featuring the latest motion technology, robotics and cobotics, auto adjustment and auto feeding, as well as being a connected machine, it establishes itself as a forward looking comprehensive solution.

Featured on booth C47 (Hall 13) too, will be FlexiLoad, the reliable robotic solution for magazine loading, suitable for any case packing system regardless of type and speed. This eliminates the need for time-consuming, manual corrugated board magazine feeding and, importantly, the potential for operators’ musculoskeletal disorders (MSDs). Exhibited for the very first time on this year’s booth will be the latest version, enabling a completely fenceless unit as it embeds the world’s strongest collaborative robot, the Fanuc CR35 with a 35 kg payload.

This represents a further testament to the leading role played

by Gebo Cermex with the implementation of cobots in packaging applications, helping make previous manual ancillary tasks fully automatic while enabling complete interactive human/machine relationships.

Comprising also a universal gripping tooling and PC based software, this latest version delivers a compact solution fitting in the same space as when the task is carried out manually. Yet, having no fence, the system ensures easy circulation around the magazine loading equipment and leaves operators free to carry out more skilled work.

WB46 Wrap-Around packing technology With a large installed base worldwide, the WB46 offers excellent performance in terms of flexibility, hygiene and ergonomics.

This is due mainly to a new automation platform, thermoplastic polyurethane timing belts and quick-release systems for format changeovers.

Now, and exclusively for Interpack, Gebo Cermex will be revealing a new on-the-fly robotic product loading station, which reduces the overall footprint of the machine by eliminating the need for a pre-collating system. This latest version of the WB46 will feature the company’s brand-new, user-friendly human machine interface (HMI), which is based on an intuitive, tablet-approach navigation and offers rich media tools for preventive maintenance procedures. On the booth, visitors will also have a hands-on experience of a format changeover on the WB46, via virtual reality, demonstrating a new approach to operators’ training.

Digital connectivity and simulation

Also available as part of the smart packing solution, is the company’s Equipment Smart Monitoring (ESM) system which connects to the machine in order to read, transmit and organize performance data into a coherent dashboard.

This system helps customers maximize the efficiency of component machines within their packaging lines (OEE): by operating at individual machine level and collecting a continuous stream of data via a connected measuring device, ESM gathers and analyses data to generate a number of key indicators. Based on these, engineers at Gebo Cermex are able to come up with recommendations tailored to clients’ exact requirements, to maintain and improve the efficiency of their installed base.

Marc Aury concludes: “With Agility 4.0 Gebo Cermex is proposing a unique integration business model, offering enhanced performance, cost-effectiveness, high productivity and greater agility for today and tomorrow. This programme brings Smart Factories to life in order to create a world of greater choice and unique consumer experience driven by packaging mass customization and product diversity. At Interpack, visitors to our booth will see an end-to-end approach on an intelligent, efficient, integrated packing solution, giving its full potential at all levels.”

Source: Gebo Cermex April-May 2017 | The Economic Times POLYMERS | 47

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CASE STUDY - RECYCLING

Milking it completely!

A US BASED LEADING MANUFACTURER OF OUTDOOR FURNITURE MADE FROM RECYCLED HDPE IS RECYCLING EMPTY BUT UNCLEANED NON-RETURNABLE MILK CONTAINERS INTO FLAKES AS AN IDEAL INPUT MATERIAL FOR THE RECYCLING PROCESS IN TERMS OF PURITY, RESIDUAL MOISTURE AND PARTICLE SIZE.

“In the Twister, a highly efficient friction washer from Lindner, we separate any paper labels adhering to the plastic as well as other remaining contaminants.”

P

oly-Wood, based in Syracuse, IN/USA, a leading manufacturer of outdoor furniture made from recycled HDPE, is now also a highly efficient plastics recycler. At its production centre, Poly-Wood operates one of the most modern recycling plants for HDPE with systems from Lindner washTech. At the heart of the plant is a combination of shredders and wash components specifically customized by Lindner for this particular application.

The starting material is post-consumer HDPE material, primarily in the form of empty but uncleaned non-returnable milk containers. The Lindner systems convert this waste into flakes as an ideal input material for the recycling process in terms of purity, residual moisture and particle size.

Focus on sustainability and efficiency Chad Rassi, Process Engineer at Poly-Wood, says: “We had the fortune of planning our recycling plant from scratch. The key aspect here was to ensure a high level of sustainability through the particularly efficient use of water, heating and energy power, as well as low-maintenance operation, maintenance-friendly design and a high nominal throughput in long-term operation. We wanted to achieve outstanding cost efficiency so as to make the recycling of plastics a success for us both technically and economically.”

Lindner reSource America LLC, the US branch of German company Lindner washTech, then offered Poly-Wood to tailor a

To achieve requested size of flakes, material is size-reduced on specially designed Wet Grinder. Here, a jet of water is directed onto the rotor so that the friction arising during the grinding process can be used to detach remaining dirt particles. complete washing line including all supply lines for the recycling of the non-returnable milk bottles.

Rassi continued: “We finally accepted this offer because Lindner had really got to grips with our project and familiarised itself so intensively with our work that it was able to come up with the best possible solution at every stage. The company’s regular presence on the site, the expertise of its representatives, and the personal trust we built up with them was just as convincing for us as the excellent reputation of this manufacturer’s products.”

Made-to-measure shredding, perfect cleaning and drying In the first step of a Lindner system, a Micromat Plus 2000 singleshaft shredder is filled by feeding chain conveyor. This powerful shredder is designed to consistently ensure low energy consumption plus high efficiency.

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CASE STUDY - RECYCLING

It is possible, for example, to freely combine different drive systems, rotors and blades with one another to maximise productivity for the respective shredder material. The point blade rotor (length 78”, diameter 22”) is equipped with hundred and four 2.6” x 2.6” blades, four times changeable, to ensure precise cutting and a high throughput even with very abrasive (not pre-cleaned) material. The large inspection and maintenance flap allows comfortable adjustment and replacement of the blades and counter-blades as well as cleaning of the hopper or replacement of impurities.

Due to special characteristics of post-consumer milk jugs Lindner can customise the line using new components for high efficient washing. Combination of Floater and Twister, a highly efficient friction washer from Lindner washTech where any paper label residue and other contamination are detached The final results are clean, dry HDPE flakes for direct further processing in a recycling line. from the plastic, is the right solution for this specific All pictures: © Lindner washTech material. To achieve requested size of flakes, material is size-reduced on specially designed Wet Grinder. Here, a jet of We had the fortune of planning our water is directed onto the rotor so that the friction arising during recycling plant from scratch. The key the grinding process can be used to detach remaining dirt partiaspect here was to ensure a high level cles. The amount of water can be regulated to ensure uniform and of sustainability through the particularly controlled material discharge. The particle size is ideal for the next efficient use of water, heating cleaning stage in the Graviter, where heavier plastic fractions such and energy power, as well as lowas PET, ABS or PVC are removed. maintenance operation, maintenanceThis is followed by careful drying of the cleaned material in a friendly design and a high nominal Lindner Loop Dryer with a rotor diameter of 48”, a rotor length throughput in long-term operation. of 78” and a 120 HP motor before the still remaining fines are separated in an air-wash system. The material can be transferred Chad Rassi, Process Engineer at Poly-Wood directly to octabins / Big Bags or to storage Silo before entering recycling line. optimised the washing unit in close cooperation with Poly-Wood and Lindner washTech. He adds: “Two important factors providExperience brings rapid success ed us with the basis that enabled us to comply with Poly-Wood’s Tomas Kepka, Vice President of Lindner reSource America LLC, requirements quickly and completely. Firstly, the Lindner systems have a modular structure. This enables us to meet a wide variety of different demands simply through the clever combination of standard and new components. Secondly, we benefit from our long-lasting cooperation with main suppliers of plastics recycling machineries. As a result, we are very familiar with their demands made on the input material for their recycling process. From this experience, we know without extensive preliminary trials how we must configure our systems to provide them with a clean, shredded and dried material optimised for these machines.”

Rassi sums up: “In the meantime, we know that our decision to accept the offer from Lindner was absolutely correct. The complete system went in operation in September 2016 after a lead time of only six months. Water and energy consumption are even lower than expected and the performance and end product is outstanding!”

The single-shaft Micromat Plus 2000 pre-shredder from Lindner is fed by conveyor belt with the non-returnable HDPE milk containers compressed into bales.

Source: Lindner washTech

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INNOVATION

Development of key components for water pressure booster KNOW MORE ABOUT HOW GRUNDFOS REPLACED METAL IN ITS KEY COMPONENTS IN SCALA2 DOMESTIC WATER PRESSURE BOOSTER WITH PLASTIC.

Q

uadrant Creative Moulding & Systems has proved to be an important partner of Grundfos in the development and production of important components for the new SCALA2 domestic water booster pump.

Grundfos made its heavy-duty industrial pumps almost entirely out of cast and machined metal. For the SCALA2, it needed a partner who could help it in designing components that could be produced in high volumes using plastics injection moulding. Quadrant Creative Moulding & Systems (Quadrant CMS) was chosen for its experience in metal-toplastics transitions projects, as well as its know-how in design for manufacturing.

Quadrant CMS is a fully-integrated manufacturer of injection-moulded systems-critical polymer applications and sub-assemblies. It prides itself on delivering customized design, tooling, moulding and assembly from a single source. The company’s main manufacturing operation is in Tielt, Belgium, and it has additional operations near Budapest, Hungary.

When the development project for the SCALA2 began several months ago, Grundfos was aiming to introduce a compact water booster pump for households where mains water pressure is low and/or variable. Most of the critical internal parts in this new development needed to be made in plastics instead of metal (mostly cast aluminium) because Grundfos wanted to create a pump that made so little noise that it could be located close to— and even inside—the house.

Injection moulding would also enable Grundfos to create more complex parts than is possible with metal casting, and so allow it to design a pump that was more compact than any it has produced to date.

What followed once the companies agreed to work together was a period of intensive cooperation between the development teams within Grundfos in Denmark and the project team at Quadrant CMS, including CAD- and quality engineers in Belgium.

All parts designated for co-development needed to be engineered for molding in high volume series, using thermoplastics capable of withstanding high pressures and which were also approved by national authorities such as WRAS, NSF and ACS for contact with drinking water.

Quadrant and Grundfos together developed various parts, including components for the water inlet and outlet and for the non-return valve system, as well as for the housing for the turbine

that is at the heart of the booster compartment. For the most critical parts, prototype injection molds were produced, while for others, functional prototype parts were created using laser sintering, a form of 3D printing that creates parts with characteristics close to those of injection molded parts.

Later on in the development project, the two development teams were joined by members from the Grundfos New Product Introduction (NPI) team at its production plant in Serbia, where the SCALA2 was due to be produced, together with a team from Quadrant CMS Hungary, where the serial production of the parts would be carried out.

Production moulds were designed by Quadrant and built to its specifications, either in-house or at approved mould makers.

All fine-tuning was carried out within Quadrant. Production of the first final parts, all of them in a polyphenylene ether/polystyrene blend, began in early 2016. The SCALA2 was launched on numerous markets around the world over the course of the year.

“With the engineering teams from the two companies working very closely together on the development of the SCALA2 pump, we have been able to achieve a perfect result,” says Grundfos Department Head Mikkel Essenbæk. “We have been able to balance product and production process demands to an extremely satisfying level.”

Source: Quadrant CMS

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SUSTAINABILITY

Bottled up for a cause THE WORLD’S TWO LARGEST BOTTLED WATER COMPANIES HAVE JOINED FORCES WITH A STARTUP TO DEVELOP AND LAUNCH AT COMMERCIAL SCALE A PET PLASTIC BOTTLE MADE FROM BIO-BASED MATERIAL.

T

he world’s two largest bottled water companies - Danone and Nestlé Waters - have joined forces with Origin Materials, a startup based in Sacramento, California, to form the NaturALL Bottle Alliance. Together, the three partners aim to develop and launch at commercial scale a PET plastic bottle made from bio-based material, i.e. 100 percent sustainable and renewable resources.

The project uses biomass feedstocks, such as previously used cardboard and sawdust, so it does not divert resources or land from food production for human or animal consumption. The technology represents a scientific breakthrough for the sector, and the Alliance aims to make it available to the entire food and beverage industry.

100 percent bio-based bottles “Our goal is to establish a circular economy for packaging by sourcing sustainable materials and creating a second life for all plastics,” declared Frederic Jouin, head of R&D for plastic materi-

The exclusive use of renewable feedstocks which do not divert resources or land from food production is the Alliance’s main focus area. als at Danone. “We believe it’s possible to replace traditional fossil materials with bio-based packaging materials. By teaming up and bringing together our complementary expertise and resources, the Alliance can move faster in developing 100 percent renewable and recyclable PET plastic at commercial scale.”

Danone and Nestlé Waters are providing expertise and teams, as well as financial support, to help Origin Materials make this technology available to the entire food and beverage industry in record time.

This next-generation PET will be as light in weight, transparent, recyclable and protective of the product as today’s PET, while being better for the planet. The exclusive use of renewable feedstocks which do not divert resources or land from food pro-

duction is the Alliance’s main focus area. The R&D will focus initially on cardboard, sawdust and wood chips but other biomass materials, such as rice hulls, straw and agricultural residue could be explored.

“Current technology on the market makes it possible to have 30 percent bio-PET,” noted John Bissell, Chief Executive Officer of Origin Materials. “Our breakthrough technology aims to reach 100 percent bio-based bottles at commercial scale. With the help of our Alliance partners, Origin Materials will be able to scale up a technology which has already been proven at the pilot level.”

A packaging revolution for all The NaturALL Bottle Alliance partners consider that everyone should benefit from this new material, so the technology will be accessible for the entire beverage industry. This unique approach demonstrates the allies’ commitment to open innovation and sustainable business.

“It’s incredible to think that, in the near future, the industry will be able to use a renewably sourced packaging material, which does not compete with food production and contributes to a better planet,” commented Klaus Hartwig, Head of R&D for Nestlé Waters. “It therefore made perfect sense for us to join forces through this Alliance to develop this innovative technology in a large scale and in the shortest time period possible. This is an exciting journey and we are proud to be part of it.”

A packaging revolution in record time Origin Materials has already produced samples of 80 percent biobased PET in its pilot plant in Sacramento. Construction of a “pioneer plant” will begin in 2017, with production of the first samples of 60+ percent bio-based PET to start in 2018. The initial volume goal for this first step is to bring 5,000 metric tons of biobased PET to the market. Thanks to their complementary skills and shared vision, the NaturALL Bottle Alliance aims to develop the process for producing at least 75 percent bio-based PET plastic bottles at commercial scale as early as in 2020, scaling up to 95 percent in 2022. The partners will continue to conduct research to increase the level of bio-based content, with the objective of reaching 100 percent.

Source: Nestlé Waters

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PRODUCTS

I

In-house recycling for leading PE/PP plastic bag producers

n Indonesia (Solo, Magelang and Jakarta), POLYSTAR has been working closely with the leading PE and PP bag producers for their in-house recycling requirements. In total, seven POLYSTAR recycling lines have been installed in three of the largest HDPE and PP film/bag manufacturers in Indonesia.

The top three bag producers, who sell most of their products in the domestic market, combine for a monthly production of over 8,500 tones. The seven POLYSTAR machines are now processing nearly 1,000 tonnes of post-industrial waste per month.

“We fell in love with the compact design of the POLYSTAR line at first sight. The machine looked robust and the design is simple and user-friendly,” said Hendrix, Production Manager of Solo’s largest HDPE film producer. “High and stable output, superior pellets quality is the reason why we’ve continued to work with POLYSTAR,” he said. The company has purchased its second POLYSTAR in 2016 after having worked with the first one since 2014.

“The POLYSTAR recycling machines are extremely easy to operate, which is ideal for our workers to process all the in-house waste,” said Pandhika, Manager of the renowned T-shirt and garbage bag maker located in Jakarta. “The output of the machines

are incredibly high and stable and we’ve already been running the machines for years.” The company is now equipped with 2 sets of POLYSTAR HNT-120V recycling machine. Known for it’s premium quality of plastic bag products in the market, the Indonesia-based producer has been using high quality recycled pellets processed by POLYSTAR machines back into film extrusion lines, and continues to produce one of the best quality film in Jakarta.

Source: POLYSTAR

INNOVATION

High-quality surfaces in automotive interiors

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onsumers appreciate a personalized vehicle interior with a premium feel and appealing design. The automotive industry and its suppliers are therefore focused on design freedom, but also want to reduce the energy consumption, logistics effort and costs associated with the production of the components. Covestro is offering a solution for all these desires that is DirectCoating.

This technology enables the efficient production of coated com-

ponents with tremendous design freedom in regard to appearance and haptics.

Today plastics dominate the automotive interior. Components are typically injection-moulded from a thermoplastic and then, in a second step, coated on a coating line at a different location to create the desired appearance and haptic properties.

The DirectCoating process produces a component in just one step. After production in the injection mold, the plastic substrate is then transferred to a second, minimally larger cavity, into which the coating system is injected via a reaction injection molding (RIM) mixing head. This creates a polyurethane (PU) coated component with outstanding properties that requires virtually no post-processing.

“Compared with the conventional process, the integrated process offers substantial savings potential with respect to logistics effort, energy consumption and space requirements,” said automotive coatings expert Dr. Jan Weikard. “All you need is an injection molding machine and a RIM system.”

The component itself can be transparent, translucent or opaque. Its surface can be coated in various colors, decorated with a matte or high-gloss finish or protected with scratch-resistant functional coatings. There are also various haptic and surface structuring options.

Source: Covestro

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PRODUCTS

3D print material for food technology

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LUBRICATION-FREE AND MAINTENANCE-FREE IGLIDUR I150 TRIBO-FILAMENT CERTIFIED ACCORDING TO EU REGULATION 10/2011

he 3D print material iglidur I150 developed by motion plastics specialist igus has now been approved for food contact according to EU regulation 10/2011.

By the certification of this Tribo-Filament that has a versatile use, customers can now print their custom-made parts which are approved for direct contact with food or cosmetics in moving applications. The material is lubricationfree and maintenance-free and can be used even on 3D printers that do not have a heated printing plate.

With the certified iglidur I150 Tribo-Filament, lubrication-free special parts for movement in the food industry can be produced quickly and cost-effectively. iglidur I150 can be processed on any 3D printer where the nozzle temperature can be set to 250°C. Since the high-performance plastic has a very low shrinkage, it can also be processed on 3D printers that do not have a heated printing plate. In this case, the igus adhesive film is recommended as the base for the print bed in order to ensure good adhesion.

iglidur I150 can be processed on any 3D printer where the nozzle temperature can be set to 250°C. Since the highperformance plastic has a very low shrinkage, it can also be processed on 3D printers that do not have a heated printing plate. In this case, the igus adhesive film is recommended as the base for the print bed in order to ensure good adhesion.

iglidur I150 is extremely versatile and therefore also interesting for many other industries.

Tom Krause, Product Manager for Tribo-Filaments at igus

Lubrication-free wear parts easily printed In addition to iglidur I150, the polymer specialist igus has five other lubrication-free and maintenance-free iglidur Tribo-Filaments for a wide range of applications – for example, where permanent load or chemical resistance is required. Common to all is that they are characterised by high abrasion resistance and are up to 50 times more wear-resistant than standard materials for the 3D print. The 3D print with the tribo-filaments from igus is a good option especially in the production of complex moving “iglidur I150 is extremely versatile and therefore also interparts subject to wear in jigs and fixtures, in small batches and speesting for many other industries,” explains Tom Krause, Product cial machine construction. For customers who do not have their Manager for Tribo-Filaments at igus. “It is very tough and the own 3D printer, igus offers a 3D printing service for wear parts, easiest Tribo-Filament to work with. The material has an impresmade from both the iglidur Tribo-Filament and sively high wear resistance at surface speeds of its own laser sintered material iglidur I3. Cusup to 0.2 m/s.” In the igus test laboratory, igliFor more information, contact tomers can upload their data, choose the matedur I150 showed a much higher abrasion resistigus (India) Pvt Ltd rial, calculate prices and order their individual ance compared to classic 3D printing materials E-mail: nitin@igus.in www.igus.in wear parts directly online. for a large number of different test parameters.

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