polypropylene :trends and ... · pdf filepolypropylene :trends and...
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Polypropylene :Trends and Developments in PackagingDevelopments in Packaging
Dr. U. K SaroopVice President- Reliance Industries Limited
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June 30, 2011
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Contents
• Polypropylene Versatile Polymer
• Clarified PolypropyleneClarified Polypropylene
• Polypropylene Products by various Methods• Extrusion Blow Moulding (EBM)
• Injection Stretch Blow Moulding (ISBM)
• Thin Wall Injection Moulding (TWIM)
• Trends in Bulk packagingTrends in Bulk packaging• Leno for Fresh Produce
• Woven Sacks for Sugar / Food Grains / Tea
R il P k i• Retail Packaging
• Speciality Packaging
• RIL Partnership
2
• RIL Partnership
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Polypropylene Versatile Polymer : Designer’s Choice
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The Polypropylene Journey
• Year 1957 – The journey began at Ferrara,Italy
• 50+ and growing strong by leaps and bounds50+ and growing strong by leaps and bounds.
• Unbounded growth from few gm then to 44 MMT now.
• 2nd largest plastic consumed in the world.
• Prof. Ziegler & Natta received Noble prize for Catalyst development in 1963
Prof Natta Mr. John Paul Hogan Mr. Robert L BanksMr Ziegler
PP-The Most Invented Invention…!!!
David B Sicilia co author of The Entrepreneurs: An American Adventure 1986
4
-David B. Sicilia co-author of The Entrepreneurs: An American Adventure, 1986
Yet young and the journey continues
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PP - A Versatile Polymer…With the widest Performance Envelope
O ff600
Izod impact at RT, J/m2
Optimum impact-stiffness balance600
400
200
0 2000
5Flexural modulus, MPa
1000
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Global PP Demand
MMT
60
4151
40
4120
PP CARG 3 7%
02005 2011
6
PP - CARG 3.7%
Source – CMAI 2011
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Polypropylene – India Growth Opportunities
P P C o n s u m p t io n 2 0 0 5
IM3 6 %
B O P P8 %
E x t r u s io n3 %
F & F5 %
T Q1 6 %
PP Consumption 2011 (Proj)
R a f f ia s3 2 %
IM35%
Extrusion7%F & F
8% 35%
BOPP9%
8%
Raffia32%
TQ9%
7Journey from 1.3 MMT to 3.2 MMT by 2011
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Polypropylene for Packaging
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Packaging –Revolutionizing Classical 4 “P” Model
9Polypropylene in Packaging – Adding the 5th Dimension
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Clarified Polypropylene
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Characteristics of Clarified PP
Glass like transparency
E ll t i t b i & Ch i l i t• Excellent moisture barrier & Chemical resistance
• Higher continuous use ambient temperature
H t fill( t 8o C) R t t bl & Mi bl • Hot fill(upto 98o C), Retortable & Microwaveable
• Excellent balance of stiffness , flexibility
Li Hi t• Live Hinge property
• Excellent ESCR property
C t ff ti• Cost effective
11Clarified Polypropylene (cPP) ideally suited for Modern Life Style
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cPP Consumption
India vis-à-vis Global Average7.5 %
3.1 %
12Strive to Meet Global Average
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PP Random Copolymer
Incorporation of Ethylene in PP
• Chain regularity disturbed.
• Decrease in crystallinity and rate of crystallization.
• Restrict the size of crystalline aggregates.
B tt l it• Better clarity.
Use of Clarifier (Nucleation)( )
• Large number of crystallites having size less than wavelength of light.
• Effect : Better clarity and high stiffness.
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Nucleated vs Clarified PP
Nucleators and clarifiers induce
formation of smaller spherulites
that scatter less light.
Inorganic Nucleators: Larger than the wavelength of lightInorganic Nucleators: Larger than the wavelength of light.
Sorbitol-based Clarifiers form a fibrous network within the resin that makes the crystallites smaller than the wavelength of light.(Source: Milliken Chemical)
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Polypropylene morphology
Nucleated PPStandard PP
100 micronsPhotomicrographs - cross-polarized light
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Photomicrographs - cross-polarized light
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Polypropylene morphology
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Clarified PolypropyleneIndian Perspective
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cPP – Diverse Process Technologies
Processing Techniques
Moulding Extrusion
TWIM IM ISBMEBM
Sheet& TF
RTE / RTS Containers
Housewares , C bl
Pharma & B Cosmeceuticals Disposable
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Containers Consumables & Medicare
Beverages Cosmeceuticalscontainers
Partnership with Machinery mfrs. – Key to future Success
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cPP Growth avenues : India
IM & EBM
ISBMTWIM
400
450
IM &
TF
A
250
300
350
TF ISBM TWIM
IM & EBM
mpt
ion
in K
TA
100
150
200
TF
IM & EBM
ISBM
Con
sum
0
50
2005-06 2008-09 2012-13
ISBM
TWIM
19Infusion of new technologies (ISBM & TWIM) to fuel growth
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Clear Business Opportunities by Clarified Polypropylene
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Malt Milk Food : Commercialized Application
OEM’s : GSK, Heinz, Cadbury, GCMMF
Total Current Market: 85 KTA
• 50% is Packed in Bottles & 50 % in Refill Pouches
• Market is growing at 15 %
GSK t l 70% M k t• GSK controls 70% Market
21Complete Market Acceptance of cPP Containers
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cPP Beverage Analysis
Oxygen Sensitive
22
yg
cPP is the Winner – Strategy to substitute glass & Tetra-Pack
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Dairy: Flavored Milk
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Dairy: Flavored Milk Contd…
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Manufacturing Process
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Dairy: Flavored Milk Contd…
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Dairy: Flavored Milk Contd…Industry Scenario
• 80 Dairies - 300 KL / Day - Growing @ 25 %
• Requirement - 45 Cr Bottles per AnumRequirement 45 Cr Bottles per Anum
• PP Business Potential - 13 KTA
Major Playersj y
• Amul – (Leader, Mkt share of 60 %)
• Mother Dairy / Verka / Prabhat /Aavin / Cavine Kare
D S R i Down Stream Requirement :
• Amul alone needs 600,000 Bpd
• ISBM Machines with 12 Cavity Mould : 7 Nos
• Capital Investment : Rs 12 Crs
26Successful Completion to Open New Avenues in other beverages
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Hot Filled Fruit Drink
Target Market : Low Juice Content Fruit Drinks
Existing Material : Glass, HR-PET, Tetrapak
Status :
• Trend Changing towards Health Drinks
• Government emphasis on Processed food sectorGovernment emphasis on Processed food sector
cPP Offers :
• Hot fillability upto 98 deg C
• High Filling Temp -> lower Preservative Requirements
• Lower Bottle Weight Vis-à-vis PET
27cPP Finding rightful place in Hot Filled Products
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Drinking / Flavoured Water
OEM’s : Bisleri, Pepsi, G.C. Beverages, National Foods, Railways
Existing Material: PET
Total Current Market: 85 KTA
• High Growth market ( 30 % annually)
• PP offers Weight advantage apart from Soft touch and noAcetaldehyde Generation
• Contact Clarity same as glass
• Bottle & Cap both from PP – Ease of recycling
35 % Lower Density than PET : Commercial USP of cPP
28Water : Promising Market for cPP
y
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RTE Food
Target Market : RTE Food / Mithai Packaging
Existing Material : Paper Cartons / Trays
E d UEnd User : RTE Outlets, Food-Courts, Mithai Shops, MealVendors, Local Sweet and confectionary shops
Status :
• TF Containers are in use for select Mithai Pkg.
• Meal Trays are also being used by few selected vendors
• Glasses & Cups are being used for liquid / creamy foods
Market Overview :
• Ethnic Food Mkt is 2.9lakh TPA
• Organized Mkt marginal – Growing@15%Organized Mkt marginal Growing@15%
• Demand for Attractive high end packaging is growing
• Possible to Pack Hot Foods
Mi bl P k i
29
Changing Food Habits : Driver for Disposable Containers
• Microwavable Packaging
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On-Going Projects : Jam and Honey
Target Market : Fruit Jams, Honey, Bread Spreads
Existing Material : Glass,
cPP Offers :
• cPP Bottles can be Hot Filled – an importantrequirement for Jam Filling
• No Breakage – Ease of handling
• Lower Weight
30cPP Finding rightful place in Hot Filled Products
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Optical Media : DVD Boxes
• Infotainment Industry - India is catching up very fast with global trend.
• Optical Media a major growth area for Infotainment.
• DVD a very fast growing application while VCD a declining market• DVD a very fast growing application while VCD a declining market.
• Global DVD production estimated to 30 Bn in 2005.
• USA, Europe & China account for 95 % of global market.
• India’s share is < 1 %
31~ 12 % MADE IN CHINA
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Optical Media (DVD Boxes)
Target Market : Movie Houses
Existing Material : StyrenicsExisting Material : Styrenics
Status :
• Sony has completely switched over to cPPDVD Boxes
• Presently they are importing all theirrequirements from China
Total Disc production (CD/DVD) :1 Bn
• DVD Market is growing at very high speed
Pc/YrDVD market Growth rate 92%
32Catering High-Tech with HDD & Blue Ray Formats
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Pharmaceutical
Target Market : Pill Vials, I.V. Fluid Bottles, Ayurvedic Cough Syrups
OEM’s : PDPL, GSK (Pharma), Pfizer, Alpha
Status :
d f ll• New Grade SR20NS SuccessfullyEstablished
• Requisite Pharmacopeia certificationObtainedObtained
33India becoming favored destination for Multinational Pharma Industry
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PP – Airtight Containers
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Moisture Barrier and Adequate Transparency :cPP Containers find larger acceptance day by day
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Polypropylene :Extrusion Blow Moulding (EBM)
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EBM : Freedom of Design including Transparencyp y
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Polypropylene :Thermoforming
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Thermoformed Products
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Polypropylene :Thin Wall Injection Moulding (TWIM)
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TWIM Products
Retailing to require large quantities of TWIM Containers for RTE Foods Items
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Retailing to require large quantities of TWIM Containers for RTE Foods Items
Presently no Real TWIM Downstream in India
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Trends in Bulk Packaging
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Leno Bags – The Ideal Choice for F & V
• It is a form of weave in which adjacent PP warp tapes are twisted around
consecutive weft tapes to form a spiral pair, effectively locking each weft in
l
42
place.
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Advantages of Leno Bags
• Excellent breath ability, good tensile and burst strength.
U d f i li bb b b i j l d • Used for onions, potatoes, garlic, cabbage, beet root, brinjal, carrot and coconuts.
• Can be printed and labeled.
• Available in wide range of colours.
• Light in weight & cost effective compared to jute bags.
• Does not impart odour to packed contents
• Capacity : 1 to 50 Kg
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• Capacity : 1 to 50 Kg.
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Leno Bags for Potato Storage
• India 3rd largest producer of potatoes.
• Most suitable for Cold Storages –due to better aeration, leno
bags reduces power consumption by 30%.
• Leno and CIPC – to create synergy for storage packaging • Leno and CIPC to create synergy for storage packaging.
• No sweating of potatoes hence lower wastage
• Ideal for sweat less potatoes due to controlled sugar level in
potatoes.
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Woven Sack for Bulk Packaging
Agri-Horticultural Produce
• Sugar / Food Grains
• Fruits & Vegetables
• Tea & CoffeeTea & Coffee
India is 2nd Largest producer of Horticulture Produce, Sugar and Food grains
45World choice for Agri & horticulture produce packaging
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Food grains & Sugar Packaging
Packaging and storage of Food grains and g g g g
Sugar is a challenging job.
Both are hygroscopic and thermally active.yg p y
Ideal Packaging System should have :dea ac ag g Syste s ou d a e :
• Adequate Mechanicals.
• Sustain the quality on long term storage
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Field Trials- PWS for food grain Packaging
• 100% satisfaction in Sugar and Foodgrain applicationg g pp
• No deterioration in grain/sugar quality
• Reduced need for prophylactic treatmentHandlingHooking
• Stable stacks, free of bulges and burstings
• No infestation due to rodents, birds, etc.
• No moisture gain/loss
HandlingHooking
• No moisture gain/loss
• Hygienic and compatible with Edible Items
• Hooking & Worker Friendly
Certification Received from HAFED, Drop Test
47PP Woven Sacks meets all the functional requirements
,NAFED, NSI, IARI etc.
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PWS for food grain packaging – ISO
48PP Woven Sacks meets all the functional requirements
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PP Woven Sacks for Packaging of Auction Tea
IIP Study report synopsis :
Sh lf lif l ti i t t t d l ti • Shelf life evaluation on moisture content and organoleptic
properties of tea stored in PP Woven Sacks also found to be better
than in jute bags.
• Chemical quality of tea stored in jute & PP Woven Sacks were
comparable.
M h i l ti f PP W S k f d t b b tt th • Mechanical properties of PP Woven Sacks found to be better than
jute bags.
• Transport worthiness and stackability found to be comparable to
that of jute bags.
49Cost effective functional solution to bulk tea packaging.
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Retail Industry (Reliance Initiatives)
Target Market : Hot Filled Juices, Pickles,Trays for Biscuits , RTE-Meal & Tea Bags
Status :
• Very High demand for packaging of variousconsumable food items
• RTE ( Ready to Eat), RTD ( Ready to( y ), ( ydrink), RTC ( Ready to Cook) Take awayFoods, Processed Foods
• Trays and Punnets for Confectionery,Fresh Fruits Pastries, Tea Bags.
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Key Projects
Breathable Films:
E d h lf lif f h fl d• Extend shelf life, preserve freshness, flavor and
reduce the need for preservatives.
• Equilibrium respiration rate for extended shelf life
• Use in: Leafy vegetables, Fruits
PP in core layer in a 3 layer structure:
• Enhanced clarity, gloss and moisture barrier
• Superior strength and stiffness
• Use in: Salt, sugar, candy/toffee, preservatives
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Key Projects
Multilayer Thermoformed Trays:
M ltila e the mofo med t a s to ithstand cold• Multilayer thermoformed trays to withstand coldtemperature (-19°C) & ambient temperature (40°C).
• Enhanced Aesthetics
• Use in: Liquid concentrates / Instant Meals / Soup /Noodles
• Products: 5
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Plastic Bubble Guard Cartons- Advantages
• Light Weight & Easy to Handle
• Good Aesthetics excellent printability• Good Aesthetics , excellent printability
• High Strength & Durability
• Safe & Hygienic
D i Fl ibilit• Design Flexibility
• Easy availability
• Maintenance Free & Washable
• Dimensional Consistency
• Eco-friendly
• Value Addition to the Product
• High Salvage Value
• Reusable & RecyclableAbove all …
Moisture Resistant so..Reduction in Wastages
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Reduction in Wastages
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PP – Caps & Closures
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PP – Paint Pails
55PP Containers for Water Based Paint Pails
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f i h l l Manufacturing Technology Envelop to cater all the customer needs
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RIL Technology LayoutRIL Technology Layout
Location ~> HaziraJamnagar
DTAJamnagar
SEZBaroda Nagothane
Licensor Dow Chemicals Dow Chemicals Dow Chemicals Basell Basell
Capacity (KTA) 430 1050 900 170 115
StartupLines/ Plants ~ 1 1996 1999 2009 1987 1996 ~ 2 1996 1999 2009 1996 ~ 3 2000 ~ 4 2005
~ HP ~ HP ~ HP ~ HP ~ HP~ RCP ~ RCP ~ RCP~ ICP ~ ICP
Strengths
MFI Capability0.7 - 65.0 2.0 - 35.0 2.0 - 35.0 0.3 - 65.0 1.5 - 35.0
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RIL Partnership
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Role of Business Development Group
• Evolution of conceptEvolution of concept
• Explore / Identify new market
• Identify Modern technology
• Id tif E t / I t• Identify Entrepreneur / Investor
• Downstream development
• Nurturing new application / Promotion / Market extension
• Securing Approvals From Testing Agencies & End-user
• Regulations / Mandation for driving Growth
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A Vital link amongstM/c Mfg. - Business - Converter - End User
MachineryMachinery
/ g
Machinery Manufacturers
Machinery Manufacturers Extensive support fromExtensive support from
• PARC – technical support
• Nodal Agencies
• PARC – technical support
• Nodal Agencies
BDoda ge c es
• Govt. Agencies – for Spec in
oda ge c es
• Govt. Agencies – for Spec in
End Users ProcessorsProcessors
60Concept to Commercialisation
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In short…...
Mould Maker / Machine mfr • Concept Marketing
d d ifi iExisting Customers
New Entrepreneur
• Product Identification
• Market Survey
• Feasibility Studies
RIL p
State Ind. Dev. Corp.
• Development
• Implementation
• Supply chain
OEM / End Users
Standard / Specs
• Nurturing new
development
Standard / Specs.
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360° Support - Complete package of Value Added Services to Customers & Entrepreneurs
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