Author: V. Vasu4bk

My self plastic engineer, From INDIA. Currently selling High Quality with Latest technology plastic machines, Caring About environment. THus in the plastic field. To know more about me, Just give a whatsapp text on +91 97677 93971

Buying Extruder?? Make Right Choice-1

Few days back a friend called me, from Rajkot regarding to machinery. He is already in plastic industry since 5 years and currently planning for installing Plastic waste reprocessing unit and plastic film extrusion unit. From our discussion one can conclude that he is very much confused about which supplier to trust and what major aspects to consider before purchasing machine. And this I think is a biggest concern for those who are completely fresh in the business.

There are major two reasons for these confusions, Many often it happens that buyer is not that much technically sound being new comer in the industry and another reason is sometimes sales people of machine create confusion in between what is and what is not PERFECT for buyer in term of equipment / technology.

So, there are few things for everyone should be knowing before making investment in machinery because it is a long term decision and you don’t want to spend more after purchasing machine.

SCREW DESIGN

Since last 20 years or so, plastic industry has grown manifold with speed of light. In terms of quantum and in terms of quality as well. Constant and continuous inventions in the industry led to sophistication in design of screw barrel compatible to particular resins. Just by altering screw design with technical considerations, one can get 2 to 3 times more output than 25 years ago on the same screw size.

Scre Desing

An Ideal screw, which we can call STANDARD SCREW is a single stage with single flight. By altering one(or more) of following we can perfectly compatible screw with comparing resin or end product

  • L/D Ratio
  • Channel Depth
  • Compression Ratio
  • Helix Angle

L/D Ration

It is the ratio of the flighted length of the screw to its outside diameter. The ratio is calculated by dividing the flight length of the screw by its nominal diameter. By increasing L/D ratio following changes are observed

  • More shear rate can be uniformaly generated in the plastic without degradation
  • Generate opportunity for mixing resulting in better homogeneity of the melt.
  • Greater the residence time of the plastic in the barrel possible permitting faster cycle of larger shots.

COMPRESSION RATIO

The ratio of the channel volume in the feed zone to channel volume in the meter zone is refereed as the compression ratio. It typically ranges from 1.5 : 1 to 4.5 : 1 for most of the thermoplastic resins.

The higher the compression ratio the greater the resulting and….

  • Shear heat imparted to resin
  • Heat uniformity to melt
  • Potential of creating stresses in some resins.

HELIX ANGLE

It is angle of a screw flight relative to a plain perpendicular to the screw axis. Although the helix angle is not commonly altered from the standard square pitch such a change can have majority impact on processing.

A reduced pitch is very common in screws that have short L/D ratio, Two stage screw design or developing mixing section.

A change to a smaller helix angle, hence more flight turns per diameter

  • Increases the axial melting length
  • Conveys stiffer resins with greater ease and requires less troque
  • Reduces the rate at which resin is conveyed

CHANNEL DEPTH

Channel depth in the meter zone of the screw is determined according to the resin to be processed. The channel depths of Feed and Transition zones are depended upon the selected compression ratio and screw profile.

It influences the degree of shear heat developed by the screw and the throughput of the screw. For ex. A Shallow Screw Channel……..

  • Increase exposure of plastic to heated barrel.
  • Increases the shear heat imported to the resin structure
  • Reduces the potential throughput of screw

Deep screw channel would have just the opposite effect helping reduce the shear heat and potentially increasing the throughput of screw.

Normally screws are made of Nitrated Steel. But in easily processed material like LDPE / PP screw can perform well and durable while for engineering material such as Nylon-Glass Filled it might be opposite results. So considering resin / durability it can be hardened in many ways. It can be chrome plated after polishing or It can be Bi-metalised or it can be flame hardened etc.. Definitely the cost is also varied depending upon post treatment is selected.

So Final selection should be made only on the basis of direct practical experience with with the design in the question or on the basis of manufacturer’s guarantee of performance

(PART 2  on 30/12/2017)

Survey : Results

Being actively involved in Plastic Recycling Industry as well as plastic machinery industry we, at BK PlastiX once decided to know CURRENT SITUATION or, we can say CURRENT STAND of people who are directly linked with plastic recycling industry. Thus we tried to conduct a survey with few questions such as,

  1. Which type of material do you recycle?
  2. Does your machine have die face cutter?
  3. Your opinions about die face cutter
  4. Does your machines have forced feeder?
  5. Your opinions about forced feeder
  6. How do you see potential of plastic recycling industry in India.
  7. How GST affected plastic recycling industry of country.
  8. According to you which is best company in India for plastic recycling machines
  9. Why Indian plastic industry is still depended on outdated technology. Why recycling industry is not upgrading technically.

We have ran survey from 2nd November to 27th November and for which we have got 172 responses for which I would like to thank members of whatsapp groups as POT / Plastic Spare Parts / RP GROUP / Virgin RP Granules / ALL INDIA POLYMERS GROUP / Plastic Professionals / World Of Polymers / Scrap Deal  for participating and expressing facts and opinions.

Even though we have got these much responses I do not think one can estimate complete scenario of current times from these results but at least we can say this somewhat describes status/situation of (Recycling)Industry.

So in response we got to know that out of these 172

50% in Commodity material  /  6 % In Engineering Material /  44% BOTH

Material

16% have machine with Die Face Cutter / 84% Does not have.

On asking opinion on Die Face Cutter technology, it is so unfortunate and upsetting as only 98 recyclers mentioned any answer and out out of those 98, 7 responses claimed to have no knowledge.

Die Face Cutter

That somewhat means that out of 172, 64 does not have clearly aware about DIE FACE CUTTER TECHNOLOGY, but positive thing is that 43 recyclers (25%) are very much optimistic about it and planning to equip one with their existing machine or want to go for new machine with this technology.

 

23% have machine with forced feeder / 77% Does not have

From 172 recyclers, 40 posses recycling machine equipped with extruder, and from remaining, 26 responses were as It is not required because they are working with high density waste such as Injection molded articles waste / blown article waste / sheet waste / pipe waste etc. In these cases, normal gravity feeding is fulfilling their purpose satisfactorily and do not require to upgrade in that terms. From total of 87 responses, around 50% (43) appreciated the technology, 18 recyclers mentioned as they are not well familiar with the concept and technology and the questioned remained untended  85 times.

Forced Feeder

About the potential of Plastic Industry in India, We at BK are very pleased that we got total 124 responses, of which 93 mentioned as industry have very bright potential and huge scope of opportunities as growth where 9 recyclers are completely uncertain and 22 are in doubt because of policies of Indian Government. Though it is practically imposiblle to mention all the comments but 2 comments which got attention were

Potential of Industry

 

“Future of Plastic Industry in India in doubt, due to ignoring nature of government”

“It is going to be extremely superb, Packaging is increasing day by day and innovations are always coming up”.

 

About question No 7 and question No 9, which are respectively about Effect of GST in Plastic Industry and reason for not upgrading plastic industry in terms of technology, I would request and insist to all the readers to shout out your opinions in the comment section below, because these topics are matter of detailed discussion but what we got from our survey is that the highest responded question was about GST with total of whooping 148 responses. of which 115 claiming it bad for the industry, 11 don’t have much idea about it while 22 responses claimed GST is positive reform happened and will bring sophistication to the industry. Few eye-catcher comments were…………

Effects of GST

“Recycled Plastics are being costly due to GST, Rates should be lowered down for recycled plastics & goods made from it”

“GST Will hugely affect unorganized units, Not organized players”

“It made industry standstill”

Disappointing is that we got only 31 responses out of 172 about why industry is not upgrading technically, that is why i am leaving it to the readers and share your point of view on the subject. Few of comments were as


“Unviable nature because of non-availability of scrap in volumes. Competitive nature of market which kills sourcing volumes. Corrupt nature of dealers of scrap even at Industrial scrap source which also makes it unviable. Unethical practices used in the industry for orders and payment…. etc., are some of the reasons.”


“Because of the market demands, its highly waving “


“Due to financial problem small industry is not able to invest largely on new technology .Further local machines are available cheap.Further local cheap labour is easily available so people are not upgrading technology.”


“Lack of trained operator, availabilty of spare parts, technician for repairs not trained enough.


About the best recycling machine manufacturing company in India I must say all the machine manufacturers have huge competition in the market. We got total 85 responses with name of total 28 different companies.

Please leave comments and mention your stand about all the questions mentioned.

& please do not forget to like & Follow us on FACEBOOK by clicking HERE

Know something about PLASTIC ROADS

Roads of PLASTICS!! !! !!

WASTE MANAGEMENT and ROAD NETWORK of a county effects each and individual citizens within. Because waste management is directly related to health of society and Roads matter for connectivity, transportation and availing resources which are not present in particular locality.

What if I say, Both the problems can be curbed by 1 solution. Yes. That’s right, Making roads from PLASTICS. And not from virgin plastics, but from plastic waste which we generate as lamination films, biscuits / chips /chocolates’ wrappers, carry bags, disposed containers etc.. ..

road

The technology goes back to 20th century, Polymer modified asphalts became popular in late 1970s in Europe.  At the initial stages only virgin plastics were used for making these types of polymer-asphalt compounds which resulted to non viability in practical use.

Making roads from Plastic scrap is kind of newer technology, thus there are no any particular methodology to it. Many companies using different methods to achieve desirable results.

The PLASTIC MAN of India Prof. Rajagopalan Vasudevan who invented very low cost method for plastic roads and he implemented use of plastic waste in road in 2002 at his collage campus. According to him method is as follows.

Inspiration-from-R-Vasudevan-Plastic-Road-5
Plastic Man of India. Prof. Vasudevan
  • STEP 1 : Segregating plastic waste from the solid waste.
  • STEP 2 : Than shredded into small pieces using industrial plastic shredders.
  • STEP 3 : Shredded plastic waste is heated at upto 165 Deg. Cel. temperature and transferred to mixing chambers
  • STEP 4 : Bitumen, heated at 160 Deg. Cel. is mixed with plastic melt and mixed thoroughly
  • STEP 5 : Lying road with tempreature range between 110 Deg. Cel to 120 Deg. Cel. with used roller of 8 tonnes capacity.

Main advantages plastic roads offer are Long Durability, Water Resistance, Reducing Voice Pollution, Can withstand high temperature as well as high loads and we get to save some resources too… !!!!

According to Prof. Vasudevan


THE ADVANTAGES OF USING WASTE PLASTICS FOR ROAD CONSTRUCTION  ARE MANY. THE PROCESS IS EASY AND DOES NOT NEED ANY NEW MACHINERY. FOR EVERY KILO OF STONE, 50 GM OF BITUMEN IS USED AND 1/10TH OF THIS IS PLASTIC WASTE. THIS REDUCES THE AMOUNT OF BITUMEN TO BE USED. PLASTIC INCREASES THE AGGREGATE IMPACT VALUE AND IMPROVES THE QUALITY OF FLEXIBLE PAVEMENTS. WEAR AND TEAR OF THE ROAD IS DECREASED TO LARGE EXTENT”


Plastics roads are highly versatile too.  Many cities are using plastic roads as per their particular requirements.

For example Illinois use them for High Traffic Truck Roads, Washington State use them for voice reduction purpose,  In rural Orianto  they are used to prevent crackings on the roads after harsh winter. In southern India, State of Tamilnadu use them for long durability of the road.

Thus, being Eco-friendly solution, many counties are starting to pave the way forward with plastic roads,

In UK engineer named Toby McCarthey has first introduced plastic road replacing bitumen with pieces of plastic waste. As a results those roads were 60 % stronger than conventional bitumen-tar roads. Netherlands are also in the list using ocean waste in road infrastructure. Ghana / Bhutan have also adopted the Eco-friendly technology, But India is performing quite impressively.

JAMBULINGAM Street of Nandangakkam area of City, Chennai( State:Tamil Nadu) is one of the earliest plastic road projects in India. Those “PLASTIC TAR” made road have not developed any potholes or rutting or raveling even after 4 years of age. Since than India leaned towards this approach with higher seriousness

In India about 39,000 Kms ( Approx 21000 Miles) of roads have already by used Plastics waste. Out of which roughly half are in the southern area of state Tamil Nadu. Mostly are in the rural areas. Small numbers of roads with plastics are in Chennai and financial capital Mumbai as well. Remaining are in Jamshedpur, Himachal Pradesh, Bangalore etc.. .. ..

In eastern India, The JAMSHEDPUR UTILITY & SERVICES COMPANY (JUSCO) a subsidery company of TATA Steel has unique patented technology of these types of roads.  JUSCO has constructed around 15 Km roads in STEEL CITY, Jamshedpur  and widened 22 roads using this technology.

Mr. Gaurav Anand, Senior Manager (Quality Assurance) JUSCO, who is also and environmental engineer has said that there are no maintenance cost for first 5 years. He also said that for every Kilo metre and four metre wide road using this technology one tonne of Bitumen is saved. Worth 50,000 Rs. The bitumen use is reduced 7% since JUSCO has taken this initiative. Anand said, longevity of these types of roads are two times better than conventional bitumen roads.

According to Times Of India The National Highwy Authority of India (NHAI) is planning to utilize solid waste from Ghazipur landfill site in construction of Delhi-Meerut expressway. This will be in line with Prime Minister Narendra Modi‘s direction for utilizing waste in productive ways

As current BJP Government of India has allocated 13,948 Crore Rs. on ‘Swachchh Bharat Abhiyan’ (Translate as : “CLEAN INDIA MISSION) and multi-million km of Indian road network, Industrialists and environmentalist are expecting more projects to be announced for Plastic waste Roads.

Do you think this alternative can help us get rid of Plastic Waste????

Please feel free to drop comments.

PLASTIC / PEOPLE and MONEY

“It is expected that worth of global plastic market will be more than 655 Billion USD”

It is so young and powerful. Isn’t it????

Just been about more than 65 years, look around. I bet you would find it so hard to have sight without plastic. Many experts claim it to be the most wonderful material ever found, where many believe that plastics is solely responsible for environmental disaster. I also have my own opinion which I mentioned in previous posts SAY YES TO PLASTICS and WHO IS RESPONSIBLE?? .

business-management

Being a businessman, There is third angle I am looking at plastics and its about ECONOMY, REVENUE and EMPLOYMENTS because PLASTIC STREAM holds vast area of PRODUCTION INDUSTRY as well as RECYCLING INDUSTRY providing employments to hundreds of thousands people. Helping going by to everyday life.

According to IBEF.Org INDIA have more than 2000 exporters all over the country. Export of PLASTICS Products/Machinery was 7.65 Billion USD in financial year 2015-2016. With the biggest importer being US (898.45 Mil. USD) followed by China (489.25 Mil. USD), UAE (422.74 Mil. USD), Germany (290.03 Mil. USD), UK (287.68 Mil. USD). Beign non developed country in terms of Industry,

Nepal somewhat depends upon India when it comes to fulfilling plastic demands of the country. In 2015-16 Nepal imported plastic good worth more than 160 Mil. USD.

Around 85-90% organizations associated with plastic industry are Small / Medium scales, and more than 70% of are processing under UN-organised sector thus, it is really difficult to get exact data about total numbers of units in India, yet many reports suggest that around 30,000 processing units are in the country with 40,000,00 people employed to the industry.   4 Million People!!!!!! Amazing. Isn’t it?

Still if we look at the consumption aspects, India is not that much forward. Per capita consumption of plastic in India is just around 11-13 Kg where for US and China it is more than 100 kg.

India expect 20 Million Metric Tonnes consumption annually by 2020. With per capita consumption of 20 kg.

As mentioned, per capita consumption of Plastics in USA is more than 100 Kg. as per PLASTICNEWS, USA Plastic Stream is third largest manufacturing sector after GAS EXTRACTION and AUTOMOBILES. In 2016 US alone demanded for plastic worth of around 295 Billion USD, which is always expected to be increasing.

Going since back in 1999 USA employed more than 1.25 Million people to plastic industry, which turned to 8,70,000 jobs in 2008 due to recession. In 2016 employment grew 1.4% from 2015, Reaching 9,54,000 jobs which is expected to cross million mark again in 2017 reports. (Surely I will be coming with more data in future on the same)

While looking at The Great Britain, BEF mentioned as annual turnover of plastic industry in Britain is 23.5 Billion Pounds (Approx 30.80 Billion USD). About 6,200 firms are engaged in plastic industry out of which 5,200 are manufacturers of plastic products with employing 1,70,000 people.

BTW Thanks to UK for INVENTING POLYTHENE in 1933

China represents largest market for plastics & significant driver for industrial growth. Recent economic slow down impacted the industry. Largest plastics & rubber machinery to china saw its exports drop 4% in 2016 on top of than 19% drop in 2017.

Still comparing internally, Chinese plastic industry have really handled situation. In 2016 plastic machine manufacturing  amounted 5.69 Billion RBM ( 0.85 Billion USD) showed 14% growth from previous year. Where export value amounted to 9.05 Billion RBM ( 1.35 Billion USD) which was 7% higher than previous year.

So, overall China is recovering internally and I am certainly sure that in 2018 report chines plastic industry will be way much better than current or previous ones.

The point is…….

As plastic have already dominated our lives. Plastic also is very much important in our nation’s economy, financial growth, employment numbers.

It is just an angle. It is not about Plastic is GOOD or BAD or something like that.

Please feel free to drop your thoughts on comment box.

WHO IS RESPONSIBLE…….. PLASTIC WASTE or OUR WASTE MANAGEMENT????

 

THE GREAT PACIFIC GARBAGE PATCH IS LOCATED IN THE NORTH PACIFIC GYRE OFF THE COAST OF CALIFORNIA AND IS THE LARGEST GARBAGE SITE IN THE WORLD, THIS FLOATING MASS OF PLASTIC IS TWICE THE SIZE OF TEXAS, WITH PLASTIC PIECES OUT NUMBERING SEA LIFE SIX TO ONE”

“100,000 MARINE CREATURES IN A YEAR DIE FROM PLASTIC ENTANGLAMENT AND APPROX 1 MILLION SEA BIRDS ALSO DIE BY CONSUMING PLASTICS”

World already was facing environmental challenges and waste  management issues and than plastic came into the picture. In 1950, Commercial production of started and just in under 70 years plastic has truly dominated out 24 Hours. Look around you, You will get at least 25 examples.

Garbage Patch.jpg

In 2014 world produced 320 Million Tons of Plastics

UNITED STATES generates approx 258 Million Tons of Garbage each year. Of which Million Tons is recycled, 33 Million Tons used for energy recovery and whooping 136 Million Tons goes to landfills. An average person in US consumes more than 100 Kg of plastic each year. In 2012, Only 9% of Post Consumer plastic waste has been recycled. Remaining 32 Million Tons discharged into landfills or finds way into ocean via leakages. Due to higher per capita consumption,US has to take some serious steps towards the managing plastic garbage.


If present trends continue, by 2050, there will be 12 Million Tons of plastic in landfills. That amount is 35,000 times as heavy as the Empire State Building


 

Being second highest populated country in the world, India generates 1,33,760 Tons of waste every day ( 1 Million Tons in just 10 days) out of which plastic contributes to 15,342 Tons . Out of total garbage only 68% Of waste is collected. Means more than 40,000 tons of garbage is being littered to land or sea. Only 26% garbage from total is recycled or treated and remaining goes to Landfill. Speaking of Plastics from 15000 Tons generated waste, 9000 Tons were collected while remaining 6000 remains littered. India is listed 12th in top 20 Countries who contributed highest in polluting oceans

PerCapitaConsumption

China wins the contest. In every aspect. CHINA is biggest country in generating garbage. China is solely responsible for 30% of plastic pollution clogging the oceans. Every day china generates about 5,20,000 Tons of garbage. Julie Makinen wrote in the Los Angeles Times, “China has surpassed the United States to become the world’s GarbageToOceanslargest trash producer, churning out more than 260 million tons a year. Beijing’s 20 million residents generate about 18,000 tons a day, most of which goes to landfills. With household trash volume rising at least 5 percent annually, according to the city, authorities are building new incinerators, though that’s caused concern about further dirtying the capital’s already smoggy skies. ” .  With having per capita consumption of Plastic around 40 Kg and highest population on earth, Managing plastic garbage as especiallly Plastic Waste is one of the top most challenge for china. To overcome,  china have banned import on foreign garbage. On 18th July, China Notified the WTO(World Trade Organization) that it would stop accepting shipments of rubbish such as Plastic / Paper as a part of campaign against “FOREIGN GARBAGE” .

GarbageToOceans

Iserael also could not score good grades in Waste management. According to reports, 5.4 Million Tons of solid waste is generated in Isarael each year. Of which plastic contributes 41% by volume (2.21 Million Tons). From total garbage, Isarael is able to recycle 25% while remaining 75% finds way to either landfills or oceans.

Russia also is running out of space for more landfills. Russia generates about 60 Million Tons of waste each year out of which 30% of garbage is of Plastics. From the total garbage Russia is able to recycle only 11-15%. Even though having low recycling rates, Russia dumps not more than 20 Million tons to landfills, They act smart. They just export garbage to other countries like Sweden / China.

Speaking of Sweden, I think it is only country which can impress us considering waste management. RECYCLING REVOLUTION actually has happened in Sweden. In 1975 Only 38% of house hold garbage was recycled. In 2014 Sweden imported 2.7 Million tons of garbage just to keep recycling industry running.

Garbage USed

Sweden recycle it’s 47% of garbage. 52%

 

used in energy conversion thanks to that, 9,50,000 homes are heated and 2,60,000 homes are electrified. Only 1% of Garbage goes into landfills.

I don’t mean to target any government or private body for the messed up Waste management all over the world, What I want to convay is, Plastic is not Bad material. How we use it is important. Properties of Plastic of having flexibility / long durability / easy to process made it prominent are the same properties which made it one of the most hated topic on internet. Because we, The people could not handle.

As a common man in a country we can not change whole waste management systems. But what we can do is,  we can control generation of waste. Natural Home Brands, Suppliers of Eco Friendly Kitchen Tools / Health & Beauty products, Have made an amazing list of 22 Ways to reuse plastic. Click Here. I am sure you will love it.

If you loved or Hated the article than please. Feel free to drop comments.

Also don’t forget to read the previous post SAY YES TO PLASTICS

 

Sources :

MARINE DERBIES https://marinedebris.noaa.gov/sites/default/files/GPmap_2012_NOAAMDP.jpg

TIMES OF INDIA  http://timesofindia.indiatimes.com/india/india-generates-100000-metric-tonnes-of-waste-per-day/articleshow/57917862.cms

CLLECTIVE RESPONSIBILITY http://www.coresponsibility.com/chinas-plastic-waste-epidemic/

REUTERS https://uk.reuters.com/article/us-china-environment/china-says-it-wont-take-any-more-foreign-garbage-idUKKBN1A31JI

NATIONAL GEOGRAPHIC http://news.nationalgeographic.com/2017/07/plastic-produced-recycling-waste-ocean-trash-debris-environment/

Say Yes To Plastics

By searching blogs of PLASTICS one can find hundreds post related to subject.
Of those more than 90% content is blaming plastic as one of the biggest pollutant. Which may be true in some cases but we need to step back and think about it once.

different-plastic

Just ask yourself a question “from waking up in the morning till sleeping at night, can I live without plastics for a single day?” (more…)