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Redefining success, epitomizing growth Part – II

Valuable experience for exhibitors

Engineering Expo Ahmedabad showcased the best in terms of engineering innovations & technologies and served as a platform for the business fraternity to grow and gain a competitive edge. Being an all-inclusive engineering show, the event provided an opportunity to exhibitors from various sectors to spread awareness about their products and services. “The event provided a platform to spread awareness about my company, which besides being a Fenner distributor also deals with many other products. I have received good response from customers. Undoubtedly, Engineering Expo is better than any other exhibition on several counts, be it the organization part of it or the products on display,” noted Harsh Jain, Director, P K Transmission Products Pvt Ltd.

The exhibitors received an overwhelming response and generated many leads having the potential to generate revenues. To this, Hardik Panchal, Director, Jekson Machinery Pvt Ltd, said, “Engineering Expo has seen many genuine visitors this time. We have received many enquiries and some of them have already been converted into orders.” Another exhibitor Bhavin Siddhapura, Partner, Macht Exim LLP, added, “The event has turned out to be better than what I expected. It helped customers to know about different companies and their products. Importantly, it conveyed the message to customers that now they can get everything in Ahmedabad and do not have to travel to other places for the same.”

The Expo not only met the expectations of the regular exhibitors but also that of the new entrants. “I am participating in any exhibition for the first time. I have received good response for the gate automation product and sold 10 of them,” opined Major Amitava Mittra, Chief Operating Officer, BGI Engitech Pvt Ltd. To this, Karan D Trivedi, Executive Director, TIMS Internationals, added, “One word that would describe this exhibition is ‘excellent’. The organizers have done a good job.”

Highlighting the long-term fruitful association with the organizers, Vishal Dhandhukiya, General Manager – Operations, Bhavya Machine Tools, said, “Promotional activities are the need of every company and for the same reason we are connected with Engineering Expo since many years.”

Displaying a sense of contentment

The event attracted several visitors from leading industrial centers such as Vadodara, Rajkot, Gandhinagar, among others, who were on the look-out for the latest in engineering solutions for improving their business prospects. Their satisfaction with the show could be gauged from the fact that most of them are eagerly looking forward to the next year’s edition. Abhinav Srivastava, Technical & Marketing Consultant, Asteam Consultants, said, “I have been coming to the exhibition since last three years, as it helps me find potential clients. I am looking forward to come in the future as well.”

Engineering Expo provided a common networking platform for leaders in the industry to showcase their products and this helped the potential customers take better business decisions. “I usually visit such exhibitions with the objective of finding out new potential suppliers, which otherwise are not known to us,” commented Pankaj Pandya, Manager – Purchase, Metso Minerals (India) Pvt Ltd. Another visitor, A K Mehta, Assistant General Manager, General Mechanical Works Pvt Ltd, said, “We manufacture engineering product, and at present, are looking for welding equipment for our factory. Engineering Expo has helped me gather information about various products in this segment available in the market.”

It is not only the organizers who believe that the event has evolved over time, but even regular visitors share this sentiment. Srivastava averred, “With time, Engineering Expo has grown bigger and better. This can be gauged from the fact that every year, new companies are added to the already long list, which truly indicates the signs of growth.” Maintaining the growth trajectory and taking the next step ahead, the upcoming edition of the Engineering Expo will be organized in Pune from November 18- 21, 2011. Don’t miss it.

Source – Modern Plastics Polymers (Infomedia18)
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Redefining success, epitomizing growth Part – I

Gujarat, renowned for its vibrant and buoyant economy, has been at the forefront of industrial growth, thanks to the entrepreneurial culture of its people and strong infrastructure development focus of its policy makers. In this backdrop, Engineering Expo Ahmedabad 2011 proved to be a catalyst in accelerating this growth further by bringing the industry veterans from the manufacturing sector together under one roof and offering ample business opportunities. Meeting the expectations of exhibitors and visitors alike, the Expo completed a decade of excellence in the state and promised to define new horizons in its next edition.

The success story of Gujarat stands out as one of the most dynamic growth stories in India. Recognized for its vibrancy and entrepreneurial spirit, the state has carved a niche among the most industrially developed regions in the country with respect to investment, production value and value-additions in industrial sector. It houses a number of multinational corporations, private sector enterprises and medium & small-scale units. In such a scenario, trade fairs assume great significance as they provide a platform to companies to interact with customers directly, and thus foster business and trade.

Doing exactly this for a decade, in the state where it originated, Engineering Expo organized by Infomedia 18 has emerged as one of the major trade platforms for the industry by catering to the needs of the manufacturing fraternity. Held during October 14-17, 2011, Engineering Expo Ahmedabad was well-organized and offered a plethora of business opportunities to both exhibitors and visitors.

Substantiating this fact, Nilesh J Dalal, Proprietor, J D Corporation, said, “The event was conducted in a most efficient manner. It was extremely well-planned and everything seemed to be just in the right order. Unlike other events, I received more quality customers here. In present times, events such as this have become important, as otherwise, it would be impossible to reach all customers at one go since they are scattered all over the state.”

Grand opening

The inauguration function was graced by the presence of Chief Guest Ravi Kapoor, Chairman – Gujarat Chapter, Indian Chemical Council, & Managing Director, Heubach Colour Pvt Ltd; Shaileshbhai D Kava, President, Machine Tools Manufacturers’ Association, Rajkot, & Managing Director, Shailesh Machine Tools Pvt Ltd; Hemendra C Shah, Vice President (Commercial) and Chief Financial Officer, Elecon Engineering Co Ltd, along with Sudhanva Jategaonkar, Associate Vice President, Infomedia 18.

Industry veterans not only felt that the event facilitated the growth of the industry, but also believed that the present day events have improved over the years. Kapoor said, “I have been visiting various exhibitions since the last 15 years, so can feel the sea change being witnessed today. Earlier, the number of visitors were not substantial and even the organizers lacked the vision. But now, the exhibitions have become lively and attract many visitors as evidenced at Engineering Expo.”

This mega trade show was seen as an encouraging step by the distinguished guests, from the industry’s point of view. Shah opined, “Engineering Expo Ahmedabad served as an ideal meeting point for exhibitors and customers. While it offered the opportunity to exhibitors for showcasing their products and generating business leads, it also enabled customers to explore competitors’ products at one place; and these further facilitated on-the-spot decisions on their part.”

During the event, exhibition directory featuring the list of all the exhibitors of Engineering Expo Ahmedabad was also unveiled.

Vibrant Gujarat

The state’s economy and overall development have gathered momentum over the past few years, and specifically the engineering industry has witnessed an increase in investments in recent years. “The engineering industry in the state has been registering a growth of more than 22-25 per cent every year. In the wake of automation and new technologies, the industry is growing remarkably well. In such a scenario, events like Engineering Expo act as a catalyst to boost the industry,” said Shah.

Among the emerging sectors in Gujarat, automobile industry holds a prominent place. In this regard, Kava said, “The growth of auto industry in the state is a positive development for the machine tools industry. This has led to setting up of many new companies in Rajkot, solely dedicated to the requirements of this sector. Rajkot is one of largest manufacturing hubs for machine tools, and houses around 600 players in this segment, with majority being the small- and medium-scale enterprises.” He added, “Trade shows like Engineering Expo help customers in getting the actual feel of the products. Further, the exhibitors can compare their products with those of their competitors and take steps for further improvement.”

Source – Modern Plastics Polymers (Infomedia18)
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Offering companies manufacturing advantage with a trading edge Part – II

Upbeat exhibitors

Like always, exhibitors are upbeat about exhibiting their innovative products and demonstrating their manufacturing might to visitors of the Expo. Going by their sentiments, most of the exhibitors are happy with the choice of location such as Rudrapur, Indore and Aurangabad for organizing the Expo, as it offers them access to such emerging manufacturing hubs.

According to one of the exhibitors, B Harish, GM, Micromatic Machine Tools, “Indore is a developing industrial hub and it is the perfect time and place to organize the event. Indore is a very significant market for us. Looking at the potential of the region, we had set up our franchisee here six months ago. As the major cities are getting crowded by the day, people are moving towards tier II & tier III cities. Thus, regions like Rudrapur and Indore have become great options for many leading manufacturers.” he adds, “We feel that by participating in the Expo, we will get a lot more visibility. Moreover, we are also looking at higher sales through the exhibition.”

Seconding his views, Rajesh Ratnaparkhi, Director, Ratnaparkhi Electronics India, avers, “Many exhibitors from Indore and neighbouring areas will be present at the event, which will offer scope for interaction with manufacturers. Indore and nearby areas like Pithampur are fast developing and with Indore being a great exhibition centre, we will have great opportunities to get introduced and present ourselves to our potential clients in the best possible way. During the event, we will be launching two of our products: CNC wire cut EDM machine and portable EDM machine.”

Prabodh Ahuja, Partner, Hi-Tech Engineers, Indore, informs, “I plan to get answers to most of my technical queries at the Expo. Additionally, Indore is a developing business hub and our participation in the Expo will give us recognition in Indore and its nearby areas. Some of our best material handling products will be on display there and interested people can get an idea about the product as there will be live demonstration.”

According to Yogesh Mantri, Managing Director, Automation and General Electric Co, “The event will be a kind of mini ELECRAMA. It is good to have such an event in one of the developing areas. It will offer a platform for everybody – the industry, traders and OEMs. We hope to interact with more customers and showcase our products during the event. We will be displaying the Universal Enclosures of Schneider make.” In contrast, Manish Matta, Manager, Electronic Appliances, avers, “People are always on the move and do not have the time to see all the products & solutions available. Events such as this come as a one-stop solution for all. Also, Indore is not what it used to be five years ago. It is fast developing, and, at this point, organizing such an event will be beneficial for everybody.” He adds, “We are into trading, manufacturing and are solution providers and will be displaying 10-15 solutions that we launched last year.”

Growth ahoy!

While many opportunities exist, there is still much more scope for companies who want to make Indore and the surrounding regions their preferred investment landscape. According to Gautam Kothari, President, Pithampur Audhyogik Sangathan, “To make the state a prominent export hub, a special corridor has been recently sanctioned by the government, which will be linked with the Delhi-Mumbai Industrial Corridor. Also, many other railway projects are in the pipeline. Kothari adds, “Regions in & around Indore have the potential to attract many pharmaceuticals companies, be it formulations or biotech, but due to the absence of regulatory bodies in Indore, many pharma companies have shifted their base from the region. However, with the decentralization of the Food & Drug Administration Authority to Indore from Bhopal, many pharma companies are flourishing around the region. Along with this, the recently launched single window system & single application systems in the industrial policy will act as trade enablers.”

With such promising prospects ready to be leveraged & capitalized on, exhibitors and visitors at Engineering Expo Indore Edition can be sure of getting the biggest bang for their buck. Be there on January 6, 2012, to capture the immense opportunities waiting to be tapped…

Source – Modern Plastics Polymers (Infomedia18)
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Offering companies manufacturing advantage with a trading edge Part – I

Sensing the pulse of the customers and offering them the best of opportunities has been the notion and intent of Engineering Expo ever since its inception. With the aim to equip companies with the best networking as well as product demonstration platform, the fourth edition of Engineering Expo Indore will kick-start from January 6, 2012. Perched for profits, this year’s edition promises to offer companies a manufacturing advantage with a trading edge. A preview…

Welcome to the heart of India where possibilities are endless and opportunities unlimited! Madhya Pradesh, by virtue of its central location, has become a strategic hotspot for setting up logistical activities and a burgeoning trade hub. Notwithstanding is the fact that its major cities such as Indore, Bhopal, Gwalior and Jabalpur are also gaining major traction owing to the state’s inherent advantages. Abuzz with all the success ingredients such as strategic positioning, logistics hub, proximity to major ports, low cost of land & labour, availability of talented manpower and the entrepreneurial spirit of people are driving businesses in these cities.

Since years, Indore has been known as the trading hub of central India. But owing to these promising advantages and proximity to emerging manufacturing hubs such as Pithampur and Dewas are offering the city manufacturing advantage with a trading edge. Is it not the perfect mix to progress and prosper? Taking these thoughts forward and keeping up with the growth momentum is the fourth edition of Engineering Expo Indore that promises to offer exhibitors and visitors a dual opportunity.

Slated to be held between January 6 and 9, 2012, the Expo aims at offering companies a networking platform for enhancing their business prospects. Elaborating on this, Sandeep Khosla, Chief Executive Officer – Publishing, Infomedia 18, informs, “With the intent to offer our exhibitors the dual proposition of exploring manufacturing opportunities along with an inherent trading edge, we decided, in 2009, to select Indore as the location to organize Engineering Expo. I am delighted to share with you that the past three editions have proved to be successful in terms of generating enviable business leads. I am sure that the upcoming edition will offer our exhibitors much more opportune prospects. For visitors, it is going to be a great networking platform to forge deals and get updated on latest products & services. All in all, it is a win win scenario for all.”

Opportunities unlimited

The geographic location of the state makes it a prominent business destination for companies vying to get a logistical advantage over their competitors. It can give companies an upper hand in establishing inter-state trade. The major advantage it offers investors is the low establishment cost of business as compared to its neighbouring states. Justifying the same, Ashok Jaiswal, President, Association of Industries, Madhya Pradesh, informs, “Apart from low transportation cost to every corner of the country, the state offers basic requirements such as land, water and skilled manpower for at lower cost. The state also allows industrial units and their ancillaries to have captive power plants to produce power as per the requirement.

However, Rajesh Prasad, Factory Head – Pithampur, Jyothy Laboratories, opines, “Indore is fast emerging as a transportation hub due to its easy accessibility. However, ancillary industrial development is still at a nascent stage in the state. This offers new entrants trying to establish their base in the state an added advantage. Areas like Delhi and NCR are getting saturated, and Madhya Pradesh is proving to be a preferred destination for setting up ancillary units due to the advantages such as low production and transportation cost, which it will offer investors.” Testifying this, Sameer Golwelkar, Managing Partner, Orion Wire Ropes, says, “The presence of major industrial units has given way to the establishment of ancillary industries. Moreover, the cost of production in smaller cities, such as Indore, is less as compared to other big cities. Second, the state’s proximity to Gujarat is an added advantage. Many ancillaries have developed in Madhya Pradesh to cater to the larger industries in Gujarat.” Multinational companies setting up their manufacturing units in Madhya Pradesh have also led to the growth of ancillary industries in the state.

Ravindra Pujari, Managing Director, Unique Saws & Machineries, says, “Madhya Pradesh houses five Original Equipment Manufacturers (OEMs) and more than 100 auto component manufacturing facilities the market size of which is about $ 306 million. In addition, many major industry players have plans to set up plants in the state. Pithampur offers tremendous potential and promises to be one of the leading auto-based clusters in India.”

Source – Modern Plastics Polymers (Infomedia18)
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Enthralling engineering enterprises Part – II

According to Goyal, since 2009, Tamil Nadu has become the major hub for most of the manufacturing industries. “The Engineering Expo has become an ideal place for companies in various manufacturing sectors to showcase their product strength. It extends its purpose to both buyers and sellers of engineering products. On one side where the sellers can cater to a large potential client group, even the buyers are made aware of the latest technological changes, which, in turn, help them choose the best product. Second, considering the level of competition in cities like Chennai where most of the companies have entered a price war, platforms like Engineering Expo are the best way to invest in marketing and reach out to a larger clientele,” he adds.

Sandeep Khosla, Chief Executive Officer – Publishing, Infomedia 18, states, “The last three editions of Engineering Expo have contributed immensely to the engineering and service industries from this part of the country. Besides, it has significantly benefited the small and medium enterprises in spreading their wings, as the event provided an ideal platform to connect the buyer and the seller. As we look forward with further value additions for even better experience and reach to the target audience, we welcome all large, medium & small industries in manufacturing & servicing sectors to be a part of the fourth edition of Engineering Expo in this exciting journey. We are sure that the Expo will catalyze the business prospects of the manufacturing community significantly.”

The Chennai advantage

With its strong base in MSME, Engineering Expo Chennai offers a unique advantage by not only providing new opportunities for enhancing the business, but also for augmenting the existing process with cost-effective technologies. Though it is a common phenomenon, MSMEs are the worst affected due to the rising cost of finance and volatile raw material prices.

There are options for these enterprises to become competitive. In order to stay afloat, it is necessary to look for innovative technologies to reduce the cost of manufacturing while satisfying the customers’ specific requirements. In this scenario, Engineering Expo Chennai gains significance as its helps connect buyers and sellers of affordable technologies.

One-stop destination

More than 175 exhibitors, from diverse engineering and service industries are expected to participate in Engineering Expo Chennai. To be held in Chennai Trade Centre, which is about six kilometer from Chennai airport, the event will have participants from several industrial segments including machine tools and accessories, hydraulics and pneumatics, instrumentation, light & medium industries, automation, electrical & electronics, material handling equipment and process plant machinery and equipment.

Major industrial associations including Tools & Gauge Manufacturers Association of India, Tamil Nadu Small and Tiny Industries Association, Electroplaters & Metal Finishers Association of Tamil Nadu, and Tamil Nadu Chamber of Commerce and Industry will participate in Engineering Expo Chennai. Visitors are expected from varied industrial segments including automotive, Fast Moving Consumer Goods (FMCG), pharmaceuticals, process equipment, light & medium engineering and a large student community.

The third edition of Engineering Expo held in March this year generated a business worth about ` 34 crore. The exhibition saw machinery movement of over 87,000 kg and generated about 5,500 business leads. Just like the past editions of Engineering Expo, the forthcoming event will also provide an ideal breeding ground for collaborations between companies with significant growth in terms of exhibitors, visitors and innovative technologies displayed.

Source – Modern Plastics Polymers (Infomedia18)
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Enthralling engineering enterprises Part – I

Tamil Nadu continues to be a favoured destination for investments not only for the service sector, but also the manufacturing industry due to several factors like availability of abundant talent pool and the infrastructure facilities including sea, air, rail and road network. Catalyzing growth to the next level is the fourth edition of Engineering Expo Chennai, scheduled from December 8-11, 2011. This edition will further augment the industrial activities that are synonymous to the competitive spirit of Engineering Expo and the state as well.

Japan has identified Tamil Nadu as one of the most potential states for investments recently, and towards this, the Japanese Ministry of Economy, Trade and Industry (METI) has signed a bilateral economic cooperation agreement with Tamil Nadu. The agreement is a feather in the cap for the state as it has been identified as a potential investment destination by none other than an industrially advanced country like Japan. It is estimated that about 240 of the 725 Japanese companies are already in Tamil Nadu and many more investors are looking at the state as an attractive investment destination.

According to a senior State Government official, the joint Steering Committee of METI and the State Government have identified several infrastructure development & maintenance in the state. He added that the government has plans for establishing a Japanese industrial cluster near Chennai.

Fostering development

Acting as a key enabler in propelling the growth of the manufacturing and service sectors in the state is Engineering Expo Chennai organized by Infomedia 18. The fourth edition of the Expo to be held in Chennai will be a conducive platform in amalgamating the capabilities of the state with the specific needs of the industries. “The paradigm of Engineering Expo participation has grown beyond expectations and become the hub for all engineering activities like manufacturing, designing, construction and Engineering, Procurement and Construction (EPC) projects,” states Abhishek Goyal, Marketing Executive – Transformer Division, Electrotherm India.

Countries like Korea, Japan and Thailand have evinced interest in investing in the state, particularly regions close to the major ports. Tamil Nadu has a unique distinction of having three major ports – Chennai, Tuticorin and Ennore. It also boasts of having the first corporatized port – Ennore – in the country.

“Opportunities are abundant in the areas of power, including renewable energy; roads and minor ports development; water augmentation; wastewater treatment; logistics and industrial parks,” asserts M Velmurugan, Executive Vice Chairman, Guidance Bureau, Industries Department, Government of Tamil Nadu.

The State Government is facilitating investments through exclusive industrial estates for industries from these countries. With Chennai emerging as the hub of international investments, the government is concentrating on improving the urban infrastructure. According to the industrial development authorities, the government will launch two special programmes – Chennai City Development Mission that will include the suburban areas with an allocation of ` 500 crore; and an Integrated Urban Development Mission for other cities and towns at an investment of ` 750 crore.

A separate project for the industrial development of the southern districts is also in the pipeline involving creation of a self-sustainable industrial growth corridor on the Madurai-Tuticorin highway. A detailed project has been prepared with locations identified for creating clusters of investment regions for manufacturing, agricultural business, knowledge hubs and tourism. These projects will be implemented through public private partnership, the government sources reveal.

Growth catalyst

The State Government, apart from large industries, is also looking at accelerating the growth of Micro, Small and Medium Enterprises (MSMEs) with additional incentives. The first step will be a three per cent interest rebate on loans provided by the Tamil Nadu Industrial Investment Corporation. Tamil Nadu Small Industries Development Corporation has identified over 2,256 acre in 25 locations to promote industrial clusters for MSMEs. The government is also revamping land pricing policies to simplify the processes.

Source – Modern Plastics Polymers (Infomedia18)
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A buyer’s guide

The market for used industrial equipment is a big one with many sellers out there. Any purchase decision regarding used machinery must be made after considering various factors as even in the secondary market for machinery, the costs are high and significant investment is required. Here are some pointers that would help potential buyers of used machinery make a good deal.

Due to wide global acceptance and use of plastics, the market for used plastics processing machinery is a global industry today, with market leaders having manufacturing & engineering locations worldwide. The machinery manufacturers that will dominate this price-sensitive market in the future will be those currently focusing on further automating their machinery offerings. Hence, buyers of such machinery must understand the process flow at the manufacturing base and remaining useful life of the equipment, and how it will add value to their business

Here are some factors to consider when purchasing used machinery:

1.Budget

The budget will dictate many things including the brand and model type that can be purchased. The buyer should have a clear breakup of costs associated with the purchase decision. These include cost of additional space required, if necessary; cost of transporting machines to the factory; dissembling & reassembling the machines; cost of machines and various duties applicable, etc.

2.Partnering the right people

Given the global nature of this business, it is not possible for a buyer to be aware of the best deals in terms of cost and quality. This is where brokers come in; a good broking company can present the buyer with multiple options and help him select the best used machinery for his/her needs.

3. Visual inspection

Internet has made communication easy and buyers can conduct much of business communication online, but there is no alternative to physically inspecting the machinery one is going to purchase. Used machinery is usually not warranted; one must know the extent of refurbishment and state of the machinery. It is advisable to insist on a test run and observe signs of machine ill health, e.g., unusual vibrations or noise, and also find out about the state of maintenance & look for worn out parts.

4. Trade fairs

Businesses, whether big or small, benefit immensely by regularly visiting used machinery trade fairs. Learning acquired and contacts made at such trade fairs can often prove invaluable when the buyer gets down to making purchase-related decisions.

5. Negotiation

The physical observation of the machinery empowers the buyer to negotiate with the seller or the broker. One should not hesitate to name a price that he/ she feels is fair for the machine. They should try and get favourable terms of delivery, e.g., getting the machine delivered free to their site, transportation charges borne by the seller, etc.

6.Get everything on paper

This is a very important step in buying used machinery. Getting everything on record, from the first formal quotation, the details of machines, accompanying accessories, delivery terms, mode of payment, extent of buyer liability, seller liability, etc. This step ensures authenticity to the deal.

Source – Modern Plastics Polymers (Infomedia18)
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Optimizing cost through waste reduction

The plastics processing industry often faces heavy criticism for causing environmental damage and industrial pollution. Processors are now taking this issue seriously and making efforts to ensure that production techniques do not result in heavy waste and high energy utilization. Avani Jain puts forth some of the best manufacturing practices to help reduce waste and optimize cost.

Waste is defined as any aspect of operations that fails to add value. It is a significant hidden cost for many plastics manufacturing companies and includes the costs associated with energy & maintenance, solid wastes, inefficient utilization of water, hydraulic oil and emissions into the atmosphere.

Increasingly, companies and organizations are taking an interest in waste reduction, which thereby results in optimizing cost. Rohan Shrikant Shahane, Regional Director-South East Asia, Machine Point Consultants SL, notes, “With rising energy costs, soaring raw material prices and the impacts of climate change, the need to monitor energy consumption and reduce waste is more important than ever. As with most industries, controlling costs is critical to sustainability and profitability. In order to remain competitive a business must adopt effective energy management process and waste reduction methods.”

Waste reduction strategies

Right from polymer processors to plastics processing machinery manufacturers, it seems that the industry is aware of their due diligence and is adopting various steps for reducing waste. M M Biswal, Business Head-Polymers, Loxim Industries Ltd, details, “In order to reduce waste, one has to have an appropriate system in place, as it helps in improving the overall efficiency of the company. In our company, the water consumed during manufacturing of engineering thermoplastic compounds is recycled and used for watering our plants in the garden. We also have a rain water harvesting plant as it is a low lying area and a lot of water accumulation happens.” He continues, Thus, we not only reduce waste but consume it as well. For example, we offer to our customers an eco range, which is made of recycled products. We believe that atomization and training of people is important because if the people are trained well, they would contribute more towards operating efficiencies.”

Reducing waste does not merely mean managing the solid and liquid waste, but also means preventing excessive energy use. “Energy efficiency is possible only through a good set of machinery that demands adequate investment. Cutting cost on infrastructure, in turn, would increase the cost of efficiency, so we always believe that investing in right machinery is important. The right machinery will result in cost and operating efficiency as well as waste reduction in the long run. At the same time, the product quality will be good,” Biswal opines. Apart from the plastics processing machinery manufacturers, the ancillary equipment manufacturers have realized the need for waste reduction.

The plastics processing machinery manufacturers have also started adopting novel methods for waste reduction. Earlier, in the injection moulding segment, hydraulic machines ruled the market, but now the all-electric machines with better energy efficiency are being employed. Shahane notes, “The use of all-electric injection moulding machines helps in substantial reduction in maintenance cost, as these eliminate the need for hydraulic oil. Further, a shorter product cycle makes these more productive than the hydraulic machines. These machines reduce losses by using high-speed servo motors to drive the processes.”

Supporting acts

The rotomoulding industry is also continuously adopting various strategies for reducing waste and energy. Bharat Mistry, Partner, Ash Win Engineers, says, “We make machines that help in reducing plastic wastes. For example, plastic wastes like the entire plastic tanks are cut into small pieces by a scrap cutter; these pieces are then fed into a solid granulator where their size is further reduced to 10 mm. These are then put into a recycling extruder in which fine plastic granules are obtained; these granules are used to make an entirely new product. Thus, we are not only making the machine, but also reusing the plastic waste.”

Mistry adds, “Further, as a responsible company we have taken a number of steps. First, while making moulds of different sizes, we are particular about the quantity and size of raw material used, which, in this case, is stainless steel. We ensure that we procure only that quantity of material that will be needed for the job because if the requirement is low, then the remaining steel roll will go waste. Second, we produce extremely energy efficient oven chambers, i.e., furnace that runs on Liquefied Petroleum Gas (LPG) as against diesel or petrol. This results in energy efficiency and reduction in the production cost.” He continues, “Third, we use standardized frequency drives of European origin for the rotation of the mould. It ensures jerk-free operation, which otherwise may lead to variation in thickness, thus causing wastage. For example, if 100 tanks are made and there is weight variation, then it is not acceptable and they go waste.”

At present, the company has employed some techniques, but in future it will also adopt novel measures for waste reduction. Mistry claims, “We are developing machines that ensure high production. These machines will have the capacity to produce 30-35 products in one and a half hour. They will have advanced oven chambers, with temperature sensors inside the mould. The machines will reduce the cost of production, improve speed and ensure quality production. In future, we also aim to use Programmable Logic Controller (PLC)-based microprocessor control, which will ensure repetitive production with exact thickness and, thereby reduce wastage.”

Understanding responsibilities

With the elimination of waste, the quality improves while production time and cost are reduced. Keeping in mind the ongoing efforts by various companies, the future of the plastics industry is to become more environment-friendly; further, with the latest machinery and methods making inroads to the country, energy efficiency and waste reduction will be yet another achievement by this industry.

Source – Modern Plastics Polymers (Infomedia18)
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Adopting sustainable practices

The increasing use of plastics in industrial & consumer applications, growing consumer awareness on solid waste recycling and low cost of recycled goods has led to an increased demand for recycled plastic resin & products. But recycling of plastics must not harm the environment. Anwesh Koley underlines that guidelines must be implemented to achieve the desired results.

In order to understand the requirements for recycling plastics, it is important to look into the chemical structure of plastics, whereby, it can be successfully reused without causing any environmental damage. The government regularly comes out with measures to ensure efficient recyclability of plastic bottles, and the industry also has started contributing towards this measure.

India recycles approximately 3.6 million tonne of plastics every year. There are about 3,500 organized and 5,000 unorganized recycling units employing 6 lakh people directly and 10 lakh indirectly. The major types of plastics recycled are Polyethylene (PE), Polypropylene (PP), Polyethylene Terephthalate (PET), Polyvinyl Chloride (PVC), Acrylonitrile- Butadiene-Styrene (ABS), Polystyrene (PS), nylon, Polycarbonate (PC), High-Impact Polystyrene (HIPS), Poly (Methyl Methacrylate) (PMMA) and other engineering plastics.

Nature of plastics in PET

All plastics are synthetic polymers, which are high molecular weight chemical compounds made up of linked molecules called monomers. The process of combining of monomers to form a polymer chain is called polymerization. PET is a common plastic material used as an ingredient in beverage bottles. Like most plastics, PET bottles are non-biodegradable and will just sit in landfills if not recycled on time. PET is made of petroleum, so a more efficient recycling of used PET bottles would help reduce dependence on oil.

Recycling is an efficient concept, but often the recycling process ends up wasting more energy in reprocessing the recyclables rather than gaining it. Besides, the industry is yet to find a cost-effective means of recycling food containers into new food containers. Although there is a demand for recycled bottle-grade PET, the high cost of cleaning post-consumer beverage bottles, strict Food and Drug Administration (FDA) requirements and outmoded technology have favoured the use of virgin PET over recycled PET in manufacturing of beverage bottles. This has resulted in most beverage bottles collected for recycling being reprocessed into non-food products such as fiber and strapping.

Industry-government efforts

Nearly all types of plastics can be recycled; however, the extent to which they are recycled depends on technical, economic and logistic factors. Innovations in plastics separation, sorting, washing and de-contamination technologies equipment have made it possible to efficiently collect, separate and recycle mixed rigid packaging plastics. Amit Kalra, Director, Hindustan Plastic and Machine Corporation (HPMC), says, “The National Plastics Waste Management Task Force of the Ministry of Environment and Forests, Government of India, has recommended a strategy and action programme of plastics waste management in India. Also, the Bureau of Indian Standards (BIS), New Delhi, has issued guidelines on recycling of plastic waste. All responsible manufacturers of plastic recycled products adhere to the safety rules and regulations laid out by the government.”

The government has formulated several rules and regulations so as to cause minimum environmental damage. These rules fall under Environment Protection Act 1986. According to the Act, all recycling of plastics shall be undertaken strictly in accordance with the BIS specification: IS 14534: 1998, entitled ‘The Guidelines for Recycling of Plastics’. Manufacturers of plastic products also have to incorporate markings and codings. These markings indicate type of plastics and also whether it is virgin or recycled. Apart from regulations, The Plastics Industry Association, through its member units has to undertake self-regulatory measures to protect the environment.

Modern technology for recycling plastics

Most bottles are made of PET. PET containers are identified by a resin identification code imprinted on the side or bottom of the container. After collection, the bottles are forwarded to recycling locations where they are run through grinders that reduce them to flake form. The flakes then proceed through a separation and cleaning process that removes all foreign particles such as paper, metal and other plastic materials. Among the recently developed technologies, the automatic PET washing system that requires less capital and energy cost is useful for the Indian market.

“The latest PET washing/grinding/drying systems incorporate heated pre-wash stage to remove labels from whole bottles before grinding, a wet grinder/crusher to reduce bottles to flake, followed by a succession of small wet-washing units – hot and cold – that use intensive friction,” adds Kalra. Each washer is followed by a friction dryer to strip off dirty water. It also uses density separators and metal detectors both before and after washing. Density separation is followed by two friction dryers, one for the polyolefin that ‘floats’ and second for PET ‘sinks’. PET is air-classified for removing fines, labels and nylon barrier material from bottles. The last stage is the drying stage, where flakes are thoroughly dried by friction dryers. After being cleaned according to market specifications, the recovered PET is converted into a variety of useful products such as carpet fiber, strapping, moulding compounds and non-food containers.

An eye on the future

The need for an effective means to recycle PET bottles has urged both the industry and policy makers to look into the problem, with particular focus on energy efficiency and reusability of PET. With more companies becoming involved in research to develop better means of recycling PET, the condition is expected to improve both globally and in India. Till then, a better understanding of the chemical structure of PET would make it easier to recycle it.

Source – Modern Plastics Polymers (Infomedia18)
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Surpassing excellence in energy efficiency

Energy efficiency and space management are key concerns troubling the plastics industry today. Though manufacturers are getting government support at the policy level, the infrastructure needs to be stepped up for improving output quality. Anwesh Koley analyses the efforts required for conserving energy and achieving efficiency in the plastics manufacturing space.

A typical blow moulding manufacturing unit involves the use of various components, which heavily require electricity to function proficiently. A major challenge for manufacturers is to reduce the time taken across various blowing steps within the process. Since the process involves alternate heating and cooling of preforms, it is important to ensure that the time taken for each is gradually reduced over the production process in order to save energy.

The process

In the Stretch Blow Moulding (SBM) process, the plastics is first moulded into a preform by using the injection moulding process. These preforms are produced with the necks of bottles, including threads on one end. The preforms are packaged and later fed into a reheat stretch blow moulding machine after cooling. In the SBM process, the preforms are heated using infrared heaters above their glass transition temperature, then blown using high-pressure air into bottles using metal blow moulds.

The blow moulding equipment space has witnessed numerous innovations over the years, as manufacturers had to adapt to changes according to growing customer needs. This has resulted in increased innovation in the plastics moulding industry. Srikanth Padmanabhan, Managing Director, Motan-Colortronic Plastics Machinery (India) Pvt Ltd, says, “There is huge scope in the field of blow moulding machines, as a major segment of the plastics industry wants to switch over from the basic manual moulding machines to modernized Programmable Logic Controller (PLC) controlled ones with advanced hydraulics and energy saving machines.”

Technology to enable efficiency

With more advanced features that manufacturers incorporate in their machines are options for connectivity with Wi-Fi and SCADA solutions through which all machines can be connected with a single computer or the mobile, through which they can access their machine production and status from anywhere in the world.

Today, the emphasis is more on energy-efficient, maintenance-free and high-response machines. The current lot of machinery comes fitted with servo motordriven pump instead of normal induction motor, which saves energy of 20-60 per cent, and this depends on the cycle time and other conditions. “Also, due to the availability of advanced hydraulics and energy-efficient solution, the hydraulic clamping machine is adopted more than the toggle-type clamping machine, due to its low maintenance and long life,” adds Padmanabhan. The equipment designed today are digitally controlled, more precise, fast, compact and easily compatible with machine controls. Manufacturers are modernizing their plants and equipping them with latest CNC machines and design-related software for producing quality product and competing in the international market.

Cost control and environment safety

Lowering costs through better quality, reducing inputs, less wastage and less labour has been the focus in the blending and conveying systems. “User-friendly networked controls reduce the time taken to understand the operations. The current trend is towards graphic, menu-driven touchscreen controls. Different parts of the system can communicate with each other through CANbus or Ethernet protocols,” says Padmanabhan.

While manufacturers have to ensure that the above requirements are met during the process, another area of concern for blow moulding equipment is environment-friendliness. This is managed by companies through the use of consumables, which are recyclable or environment-friendly.

Achieving the desired results

Manufacturers are developing equipment that have higher productivity and consume lesser space within the plant. Another important measure is to reduce all forms of waste resulting from operational rejections, waste heat and spillage. “A specific problem in India is that although labour is relatively cheap, most are unemployable and without intensive training. Also, the attrition rate of trained personnel is high. This has led to increased automation and user-friendly and data-recordable systems,” says Padmanabhan.

Automatic blow moulding machines that are not labor-intensive might reduce time in the plant with efficient use of robotics, but not all manufacturers can afford it. Thus, small- and medium-scale blow moulding manufacturers need to find a means to increase production efficiency with the available resources. The blow moulding industry is working on reducing time to meet the demand from both domestic & global customers and with the latest technology, quality will not be compromised either.

Source – Modern Plastics Polymers (Infomedia18)
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