High-growth sectors to spur cutting-edge innovations

The Asia Pacific region retains its strong economic performance in 2016 .  Forecast for the region remains positive despite the many challenges countries in the Asia Pacific have to deal with. The World Bank expects the region to grow by 5.5%, outpacing the 3.7% forecast for the world economy in 2016.  The International Monetary Fund also believes that the Asia Pacific region will remain the global leader in terms of economic growth at 5.4% . China will continue to lead despite facing economic challenges.

The plastics industry in the Asia Pacific is expected to sustain its leading position. Asia Pacific is the biggest and fastest growing market for injection moulded plastics, expanding annually by more than 5% up to 2018 and a market share of more than 40%.  It is also the leading plastic additives market of the world due to fast-rising demand as a result of increasing population and improvement in the standard of living.  Asia-Pacific is also the biggest market for automotive composites with market share seen to reach more than 50% in the coming years. In the same manner, the region is seen to account for more than 40% of global demand for packaging products.

The creation of the ASEAN Economic Community (AEC) in 2015 begins to show its impact as member countries prepare for the integration into a single market of 600 million people. The AEC encourages businesses in the ASEAN to implement significant improvement in industrial production and trade of goods.  In this scenario, the plastics industry in Southeast Asia has been posting a reliable 9% average annual growth, riding through the factors that have adversely affected the global market.   

This Special Report contains the insights of industry experts on developments that would impact on their operations and their target markets. It also brings into focus their plans for 2016 and products they intend to highlight to meet growing market demand.

MACHINERY AND EQUIPMENT

Value-adding solutions for efficient processing  

Mr. Heinz Gaub
Managing Director Technology & Engineering
ARBURG GmbH + Co KG
Tel. +49(0) 7446 33-0
Fax  +49(0) 7446 33-3365
E-mail: contact@arburg.com
Website: www.arburg.com

Two trends are currently in evidence among plastics processing companies: On the one hand, the complexity of systems is increasing through the integration of functions in the mould and/or downstream processing steps in automated production cells. There is rising market demand e. g. for components with pleasant tactile qualities, with joints, or with insulating properties. The wide variety of these additional functions is matched by the options for integrating them. The know-how of experts is in ever greater demand when it comes to finding efficient, value-adding solutions. Thus, the customers want a partner who provides them with comprehensive advice and support on the way to new products and innovations. For this reason, Arburg offers individually matched turnkey systems and provides advice throughout the entire value-added chain.

On the other hand, customers are seeking flexible solutions owing to ever faster product changes, increasing variant diversity and, consequently, ever smaller unit volumes per order, down to one-off parts. These requirements can be met, for example, by combining injection molding, additive manufacturing and "Industry 4.0" technologies to individualise large-volume products in order to create single-unit batches in a cost-effective manner using an automated, digitally networked cyberphysical production system. The internet has reached plastic processing.

Flexibly automated systems as thrust
Arburg is transforming itself into a supplier of flexibly automated production systems for integrated production in the digital factory. With automated Allrounders, the central Selogica control system, the Freeformer for additive manufacturing and IT solutions such as the Arburg host computer system, ALS, we are a true supplier of cyberphysical production systems.

The Freeformer, worldwide launched in spring 2015, is still a highlight. There is a definite demand for the production of functional parts from qualified standard granulates without requiring a mould, whether as one-off parts or in small-volume batches. We have already delivered the first Freeformers to the United States and China. At Fakuma 2015 we presented an automated Freeformer communicating via an Euromap 67 interface with a mobile seven-axis robotic system. The solution is truly unique in the world of additive manufacturing.

Efficient, to specific customer needs configured injection moulding solutions are e. g. our new physical foaming process Profoam, which extends our range of processes for lightweight construction. In the context of micro injection moulding, we offer a complete micro production cell. With regard to sophisticated packaging technology, we offer the “Packaging” version of the Allrounder.

Our extended offering in the area of the large full electric Alldrive machines from 2,500 to 5,000 kN will from now on be available in three performance variants in order to cost-effectively and individually adapt the machines to the specific customer needs. Further novelties will be presented in 2016 at the Arburg Technology Days in March and at the K show in October. Our keyword here is "production efficiency".

We see great potential offered by the combination of injection moulding and industrial additive manufacturing using Industry 4.0 technologies. By applying an individual DM code on an injection moulded part the product itself becomes, from this moment on, a data and information carrier and its own website. Using the code, the part-specific web page can be retrieved at any time and from anywhere in the world using a mobile device – even after several years. This plays an important role, for example in the traceability of safety-related parts, such as airbags for the automotive sector and implants for medical technology. This type of traceability is also the basis for just-in-time production. Moreover, different work processes can take place at different times and locations.

Today, Arburg is the only manufacturer in the industry that enables its customers to produce individual plastic parts in lot size 1 or enhance mass-produced parts in order to create added value. It is therefore possible to exploit new market potential for individual components that were previously not economically viable.

Cost savings, increased efficiency, conservation of resources and reduction of CO2 emissions: lightweight design as a "problem solver" is a key topic for the future in numerous industries. The aim is to reduce part weights, while maintaining or improving mechanical properties. Innovative injection moulding processes are required for this purpose. Arburg offers e.g. Profoam for the physical foaming as well as overmoulding of thermoplastic organic sheets, Fibre Direct Compounding (FDC)  and particle-foam composite injection moulding (PCIM).

Expansion in Asia
We have successfully expanded our activities in Asia in recent years and will continue to intensify these in the future. At the forefront is China, where business is progressing satisfactorily for us. Arburg is particularly interested in customers who have a long-term vision and who are looking for high-quality, reliable machine technology.

With our subsidiaries in Hongkong, Shenzhen and Shanghai as well as a machine warehouse close to Shanghai we provide the customers of the Chinese injection moulding market with intensive support. Here, the Allrounders produced in Lossburg are temporarily stored and can be locally adapted to the individual customer requirements. We also deliver machines directly from our Shanghai warehouse to Indonesia, Singapore, Thailand or Malaysia, for example.

High-performance blown-film lines

Mr. James Murphy
President & CEO
Davis-Standard LLC
Tel: +1-860 599 1010
E-mail: jmurphy@davis-standard.com
Website: www.davis-standard.com

As global economic uncertainties continue, capital investment will be impacted. Davis-Standard will continue to focus on offering high quality products that provide a rapid return on investment. We will also focus on the excellent opportunities for upgrading existing lines and providing 24/7 aftermarket services. Specific to Asia, we anticipate the food packaging market to continue to grow by 10 to 15 percent.

Our line of dsX™ products are doing very well in the marketplace due to their exceptional value, high performance and fast delivery, and we expect this to continue. Examples of this include our dsX s-tretch™, dsX flex-pack™ and dsX flex-film™ lines.  

The dsX s-tretch™ cast film line is the first in-line pre-stretch machine to provide exceptionally strong, thin film that can be run at higher speeds. It can produce three-, five- or seven-layer conventional or pre-stretched films with greater efficiency and consistency.  The dsX flex-pack is engineered for cost-sensitive flexible packaging applications where fast and reliable production is essential. It features an adaptable machine configuration to support converters, printing companies, multinational companies and start-ups.

The dsX flex-film™ is engineered for applications from one to nine layers for the blown film industry’s core market. This includes laminating and converting, bag making shrink film, hood shrink film, collation film, multi-unit packaging films, roll stock and surface print films.   

Extrusion systems in general will remain strong for us as will cast film and extrusion coating, and in this area we will continue our bid to innovate.

Expansion in ASEAN
We will continue to see growth in developing nations across the ASEAN region and India. Manufacturing continues to grow due to government incentives and we continue to expand our team and geographic capabilities and service accordingly.

Davis-Standard also recently acquired blown film leader, Gloucester Engineering, giving our customers access to the industry’s premier blown film technology and aftermarket services under one roof. This will be a significant benefit in 2016 as it will provide a significant advantage in blown film for our customers throughout Asia. This addition strengthens all areas of our blown film operation including engineering, installed base and aftermarket capabilities – all geared to improve processing and profitability for our customers.


Enhanced benefits of inspections systems

Mr. Wanbin Chen
President - SIKORA Asia
SIKORA AG
Tel: +49-421 489 000
Fax: +49-421 489 0090
E-mail: sales@sikora.net
Website:  www.sikora.net

Quality standards in the plastic manufacturing and processing industry will further rise in 2016 and accordingly this high standard creates the need to inspect and analyse the plastic material before it enters the production process and the final product.  Contamination, colour anomalies and inhomogeneities have to be detected reliably. This trend of achieving excellence in end-product quality has pushed SIKORA to develop solutions to meet the diverse and strict requirement of compounds, masterbatch, and recycling industries SIKORA offers an innovative portfolio of systems for inspection, analysis and sorting of plastic material. The SIKORA systems contribute to increase quality, optimize processes and reduce costs during the manufacturing and processing of plastic materials.
 
For 2016, SIKORA will put great emphasis on technological solutions for inspection, analysis and sorting of plastic material.  One highlight in 2016 will be the Purity Scanner, a system for 100% online inspection and automatic sorting of plastic material. Equipped with X-ray technology and an optical inspection system the Purity Scanner detects contamination down to a size of 50μm inside and on the plastic pellet. Contaminated pellets are sorted out.

Moreover, with the innovative models of the Purity Concept Systems SIKORA provides modular designed systems for on- or offline inspection and analysis of pellets, flakes and films/tapes. Depending on application, the systems are equipped with X-ray technology (X), Infrared technology (IR) or optical sensors (V) to be used during the production or for sample testing and detect contamination from 50μm. SIKORA will present these innovations among others at the Chinaplas in Shanghai and at the K Show in Düsseldorf in 2016.

Quality is greatest concern
We see a general trend towards increased quality of plastic materials all over Asia. From discussions with customers, we notice that greater focus is placed on process optimisation, increased productivity and cost saving. The aim of plastic producers and processors in Asia is to remain competitive in the global market.
 
Hence, we see great potential in the Asian market for our systems which guarantee the  highest material quality due to the integration of latest technologies and the possibility to be used for diverse applications - tailored to the requirements.
 
The models of the PURITY CONCEPT Systems are used for inspection and analysis of pellets, flakes and films/tapes based on different technologies (X-ray, optical, infrared technology). Thanks to the modular design, the systems can be used for various applications.  

As we move on in 2016, we will further introduce the benefits of our technology to the  Asian market in particular, the compounding, masterbatch and recycling industries where we see promising prospects.  
 


Compatibility and flexibility in injection moulding operations

Mr. Joseph Lung
General Manager
Shine Well Machinery Co., Ltd.
Tel: +886-6 356 0081  
Fax: +886-6 356 0082
E-mail: info@shinwell.com.tw         
Website: www.shinwell.com.tw
 

In the year 2015, Shine Well was able to sell the CX series products to customers in various countries and received positive feedback. In 2016, we will import other novel technologies to improve equipment performance while lower users’ cost.

We are also keen on automation since manpower resources have become more expensive around the world. Production of plastics machinery needs to keep up with the automation trend. For plastics injection sector, manufacturers of injection machinery have to design their products in the way that is compatible with various peripheral equipment.

Customers request for products and quantity, and we machinery suppliers have to generate the most economic design that can generate the highest productivity. Now suppliers cannot survive if we offer only machinery, so we have to integrate all other peripheral equipment, together with our services.

Speaking of the business growth, Shine Well gains benefit from the Indonesia market which is relative good compared to other Asian nations. The company is stepping ahead towards Industry 4.0 by adjusting its IML system integration, as well as multi-axis robotic arm installed on injection moulding machinery. Shine Well  also aims to promote its products in the Southeast Asia and Africa markets in 2016 as part of its goal.  
 

Gearboxes of the future

Mr. David Lo
Sales & Marketing Manager
Sun Lung Gear Works Co., Ltd.
Tel: +886-6 384 3678
Fax: +886-6 384 3858
E-mail: david@slgear.com.tw
Website: www.slgear.com.tw
 

In the year 2015, Sun Lung Gear Works Co., Ltd. benefited from the Japan market as there are many Japanese extrusion line manufacturers purchase Sun Lung gearboxes. The business in the Japan market has grown by 200% in 2015. In this regard the  development of single and twin screw gearboxes are crucial in the business.

We also noticed that for practical applications in the China market, demand for extrusion lines with better energy consumption rate, higher productivity, and enhanced accuracy is on the rise. As the electricity supply issue becomes more critical in China, energy consumption rate is more important than before. Under this premise, productivity and accuracy cannot be compromised. As a result, Sun Lung has adjusted its gearbox product designs in order to keep up with the market demands. Since energy consumption is related to motor mechanisms, Sun Lung adopts novel servo motor system to develop its gearbox design and yield higher torque.

Promoting energy-efficient gearboxes
Accordingly, in the year 2016, novel gearboxes with lower power consumption feature is the primary consideration in Sun Lung’s promotion of its products in the world market. Besides China market, ASEAN members are also Sun Lung’s target customers. The company has sold its products to Indonesia, Thailand, Philippines, Malaysia, and Vietnam. In the future, the Sun Lung also recognises India as a growing export destination.

Looking forward to the application in which business are good in 2015, compounding, masterbatches, and pelletising are three sub-sectors in the plastics industry that are booming. In 2016, the company will expand its sales market, making the world its customers. Expanding market share is the 2016 goal, and so in the K2016, Chinaplas 2016, and Taipei Plas 2016, we intend to participate to promote our products.  


RAW MATERIALS AND COMPOUNDS

Sustainability focus to yield green innovations

Mr. Rob T. Bindner,
Vice President, Asia
PolyOne Corp.
Tel+86-21-6028 4888
Fax +86-21-6028 4999
E-mail jennifer.huang@polyone.com
Website www.polyone.comWebsite: www.polyone.com

 
The most important trends in the plastics industry will still be sustainability, high-performance and customer-focused solutions. Regarding sustainability, it will be primarily focused on those green innovations which are not only efficient for business but helpful for development of our end users who benefit from our solutions.  PolyOne is also committed to meeting the needs of the present without compromising future generations’ ability to meet their needs. We also have established the “PolyOne Sustainable Solutions” certification to denote those products or services that meet defined standards for sustainability in areas such as renewability, recycle-ability, reusability, eco-conscious composition, or resource efficiency.

PolyOne offers a number of engineered materials solutions that help to promote these emerging technologies. For example, PolyOne, Xindao and XD Design developed all of the molded plastic casing components for their charger from PolyOne’s reSound™ biopolymer, which Xindao estimates will reduce the CO2 footprint for this product by as much as 35 percent compared to alternatives. Using reSound, a durable, eco-conscious material that offers the same functional and aesthetic behavior as conventional engineering polymers, enabled XD Design to reach both performance and sustainability goals.

On the other hand, the regional plastics manufacturing industry is highly competitive. The competition is based on many factors including technology innovation, production capacity, product improvement, service networking, product delivery, marketing insight etc. Our competitors range from large international companies with broad product offerings to local independent custom producers whose focus is a specific market niche or product offering. Against these, we believe the strength from our brand and reputation, diverse solutions portfolio, speed to market, efficient and fast delivery, coupled with the quality of products and agility of our distribution network, will allow us to differentiate and grow.

PolyOne’s customer-focused business units are distinguished by the breadth and depth of their materials, services and technologies. Our businesses serve a diverse array of end markets and hold leading industry positions.  Inspired by our customers’ challenges, we are featuring advanced solutions that help solve the toughest issues in material selection, distribution, manufacturing, colourants and design.  

Giving customers the right solutions
We offer many families of materials to help solve the demanding application needs of our customers. Our solutions are the right choice for customers who want to achieve profit and growth with innovative products, enter new markets, expand globally and much more.  

In the next year, we will still be featuring advanced solutions that help solve the toughest issues in material selection, distribution, manufacturing, colourants and design. And besides production capability and marketing development, we are also investing in the local market. For example, our new Asia Innovation Center in Shanghai reflects the voice of the customer and gives us unique footprint from which we can better serve regional customers by consolidating research activities in Shanghai. In the future, we will continuously enhance our knowledge within the region to create greater opportunities to collaborate with customers to enable us to be better equipped to understand their unique needs.

Some high-performance products will be further contributed to the market. For example, PolyOne’s soft-touch GLS™ thermoplastic elastomer (TPE) material provides smooth, silky texture for comfort, the innovative FiLIP™ 2 wearable phone and locator for children can stand up to the demands of active kids during outdoor play and sports, staying bright and maintaining material performance attributes.

InVisiO Color Inspiration 2016, a collection of four influential and emerging colours. These four palettes help stimulate the creative minds of designers to incorporate up-and-coming color trends into their designs.  ColorMatrix™ Select, a new service combines advanced liquid colourants, Web-accessed software, and automated dispensing technology to offer a complete package that enables companies and designers to take greater control of their colour development and supply chain. Percept™ Authentication Technologies present a full-spectrum portfolio of formulations and consultative services that employ covert, overt and forensic techniques. With these solutions, manufacturers can reduce potential risks and loss of revenue from counterfeits in consumer goods, medical devices, packaging, and consumer electronics markets.

Exploring bigger Asian markets
First of all, we are proud and excited to be expanding in Asia in support of our customers and our dedicated PolyOne associates who serve them. Even among the global economic recession, we are still keeping cautiously optimistic for Asia especially the dynamic China market, our commitment to customers in Asia has never been stronger. We continue to invest in Asia so that our customers can innovate and grow.  

In this region, the China market is very important to us and there is much potential for the sales performance growth here. As companies continue to widen their global manufacturing footprints, the demand for advanced technologies, especially in healthcare packaging, premium food packaging and consumer electronics sectors is on the rise. We are also confident about Southeast Asia market performance, especially Indonesia, Thailand and Vietnam. We are optimistic with the regional markets and believe that we can achieve more from these countries if they maintain a stable political situation and increasing domestic spending power.
 

Development of new materials for improved product quality

Mr. Vincent Wang
Marketing, Regulatory & MARCOM Manager, Asia-Pacific
Milliken Chemical Division
Tel: +86-21 6145 5505
Fax: +86-21 6145 5558
E-mail: Vincent.Wang@Milliken.com
Website: www.millikenchemical.com  

Though China market has been a bit soft due to the weak oil price and the mega-economic environment, but still we see strong growth in packaging segment for cPP, as well as product upgrade in BCP and ICP segments.

Our growth in China is again strong this year. Our clarifier Millad NX8000 is strengthening its leadership in the industry, cPP becomes ultraclear with Millad NX8000 and are able to replace a lot of the engineering plastics. There are a lot of new inter-material-replacement applications developed this year, such as GPPS replacement in appliance, TRITAN and PC replacement in sports bottle and food containers and etc. In order to help TF market improve its product quality, we launched NX UltraClear SE340B specifically for this market and its gaining momentum in microwavable food trays in convenient store and next step we will be working with on-line ordering O2O business establishing standard on environmental friendly material of cPP for convenient food packaging.

Localised technologies
In 2016, we will launch highly localized PP nucleating technologies for Chinese BCP and ICP industry. It will help the whole industry upgrade the quality and features of the products, as well as HCPP.  

We believe cPP in packaging will be the next revolutionary opportunity for the whole PP industry, here I am talking about thermo forming and thin wall injection moulding packaging. In EU, Japan and Australia, TWIM is very popular but in China, it is still very small but has huge potential. EBM in China and Asia, is also small now could be a promising market as well, where we have very neat technology in improving the quality of the product.

Overall in Asia, we are growing in almost all the market. China will still be leading the growth with the huge new capacity added. ASEAN is also the fast growing area where we see the market is prosperous. In developed market like Korea and Japan, we are focusing on new development of IMR, this will fuels the growth and provide great success developing example for China and other emerging market.

With our leading market position, we will still be focusing on capture new opportunities, developing new markets, adding value to our customer and the whole supply chain of the polyolefin industry. The fast growing, consumer focused market will be our target. We have great technology and unique business model that will help us win these opportunities.