“NEW DEVELOPMENTS &

BUSINESS OPPORTUNITIESIN IN

ROTOMOULDING”

Product Application & Research CentreRIL & IPCL

Contents

• Company profile-RIL/ IPCL

• PARC

• International Rotational Moulding Market Scenario

• Indian Rotational Moulding Industry• Indian Rotational Moulding Industry

• Salient Features of Rotomoulding Grades Polyolefins

From Reliance Industries Limited

• Innovative Products

• New Business Opportunities

Corporate Profile Corporate Profile

• Manufacture and market internationally competitive Polymers

• Strive to develop the service, technical expertise and creativity toaddress all our customers’ problems and concerns

• Commit to total Customer Satisfaction in terms of Quality & Services forall our products

Our Mission…….

• Ensure sustained Profitability and Growth in our business operations

• Build an organization in line with our continued commitment toexcellence and innovative efforts to stay as market leaders

• Continuously upgrade our product and delivery systems to provide theright product for every customer

Total Customer Satisfaction – a Reliance commitment…

Reliance Group - BusinessesTextiles

PolyesterPlastics

PetroleumProducts

Oil & Gas

Infrastructure

NarodaPatalganga

Hazira

Materials and energy value chains and infrastructure

HaziraJamnagar

Bombay HighSuiting PSF LLDPE/HDPE LPG Crude Oil Power

Shirting PFY PP Gasoline Natural Gas Telecom

Furnishings POY PVC Naphtha Port

Pillows P. Chips MEG ATF Roads

Fabrics PTA Ethylene Kerosene OFC

PX Propylene Diesel

LAB VCM Petcoke

EO Sulphur

Ducts

About RIL

• RIL : The fastest growing private sector company

• RIL : Amongst world’s top ten producers inpetrochemicals

• RIL : Gross turnover Rs. 75,518 crores(US$ 17,022 billion) (2003 - 04)

• RIL : First Indian company in Fortune Global 500 list

Reliance’s Polymer Business

Capacity (KTA) Global Rank

PE 1000 14th

PP 1300 7thPP 1300 7th

Polyolefins 2300 10th

All Polymers 2820 10th

……… Largest PP producer in Asia….

Post IPCL acquisition

Total Capacity FY2002: 4,200 kTA

500 PVC

GAIL

HPL16%

Others6%

RIL- IPCL – Largest Polymer Producer in India

1160

780 PE

PP

with plans for major expansions

RIL+IPCL

71%

GAIL7%

About IPCL

• IPCL : Pioneer petrochemical company now managed by

RIL

• IPCL : Heralded the growth of petrochemical industry in

IndiaIndia

• IPCL : Total production of 1 million metric tons of

polymers, synthetic fibres and chemicals

• IPCL : Second largest petrochemicals company in India

in terms of sales, assets, net-worth and profits

• RIL and IPCL rank amongst tenth largest polymer

producers in the world and caters to approximately

70% of Indian market

About RIL & IPCL

• In PP alone, it has a market share of 85%

Reliance & IPCL -Manufacturing Facilities

India

Naroda - GujaratTextile manufacturing

Hazira - GujaratPetrochem & Polyester

Jamnagar - GujaratRefinery & Petrochem

IPCL - Baroda, GujaratPetrochem

Strategically located facilities in western India. I N D I A N O C E A N

ARABIANSEA

BAYOF

BENGAL

I N D I A N O C E A N

Patalganga-MahPolyester & Intermediates

Panna Mukta & TaptiOil & Gas

Petrochem & Polyester

IPCL - Gandhar, GujaratPetrochem

IPCL - Nagotahne, MahPetrochem

IPCL : Polymer Manufacturing Facilities

• IPCL manufacturing locations at :

• Baroda - LDPE / PVC / PP

• Gandhar - PVC / HDPE• Gandhar - PVC / HDPE

• Nagothane - LLDPE / HDPE / MDPE

PolymersFiber

IntermediatesChemicals

Fibers

Textiles

Reliance Group - Vertical Integration

Ducts

Oil & Gas E & P

Petroleum Refining

Olefins Aromatics

Fully integrated value chain from well head to fabrics.

About PARC About PARC -- RILRIL

Total TechnologyTotal TechnologyTotal Technology

&

Business Solution Provider !

Total Technology

&

Business Solution Provider !

PARC

Established in 1990 , this centre committed to deliver value

addition to polymer business by

� Providing technical service,

� Constant product up gradation and

� Market development

With the sole objective of total customer satisfaction

• Between business enterprises and their vendors

• Converting basic needs into commercially viable

technology

• Helping produce useful products

WE believe in building strategic relationships

Research Institutions

Polymer Processors

End Users Machinery Manufacturers

PARC

Bureau of Indian Standards -Representations

• Plastics Containers PCD 21

• Test Method on plastics Containers

PCD 21.1

• Crates for Veg. & Fruits PCD 21.P1

• Method of testing of Plastics PCD 23

• Cement & fertilisers TX 23

• Textile Materials Polyolefins TX23

• Polyethylene Pipes CED 50

Member of 18 committees

• Food Packaging PCD 12.12

• Thermoplastics PCD 12.3

• Moulded Luggage PCD 12 P2

• Recycling PCD 12.17

• Plasticizers PCD 12.10

• Multilayer Films PCD 12.16

• Polyethylene Pipes CED 50

• UPVC pipes CED 50

• PVC CED 50

• Irrigation and Farm Drainage FADC 54

• Sprinkler Irrigation FADC 35-P!

PARC

• Doctorates

• Polymer Engineers

Biggest asset - People

• Polymer Engineers

• Industrial Designers

• Polymer Chemists

• Technicians

Total Manpower : 43

Presentations

Houston

- SPO ‘97

Vancouver

ISO TC/61

London

- PVC ‘98

China

-PPS

Germany

- PE ‘97

Netherland

- PPS-15

Japan

- PPS-14

Antec 2001

Addcon

2003

PPS 20

- SPO ‘97

Singapore

- WCC

Delhi

Polymer’99

International conferences

National conferences

Presentations to OEMs

Customer Meet

Enviormental Meetings

Papers published - 75

PARC Facilities

ROTOMOULDING MARKETS

NORTH AMERICA MARKET:

�U.S. rotational mouldingmarket place is unique inso far as fully 20% of itsannual output consists of

O t h e r s

2 0 %T o y s

2 0 %

annual output consists oftoys(Little Tikes and Step 2)

�Agricultural and industrialtanks are the secondlargest market for NorthAmerica.

T a n k s

2 0 %

R e c r e a t i o n a l

P d t s

2 0 %

A u t o m o t i v e

2 0 %

ROTOMOULDING MARKETS

EUROPEAN MARKET :

�European moulders areinvolved in design conceptsand products.

�The largest segment is the

Leisure Time

5%

Toys

6%

Others

11% Automobile

18%

�The largest segment is thefood and agriculture marketat 32%.

�In Europe, the rotationalmoulding industry makes theprocess fit the desireddesign.

�In North America, however,the trend is to make thedesign fit the process.

Material

Handling

10%

Food &

Agriculture

32%

Lawn &

Garden

10%

Highway

8%

ROTOMOULDING MARKETS

SOUTH AFRICA MARKET :

� It is estimated that there are 40

companies involved in rotational

moulding. Tanks dominate the

market (56%), although a very

broad range of products are

Others

4%

Leisure

5%Mining

2%Industrial

7%

Material

Handling

8%

broad range of products are

manufactured.

�The need for building products

such as septic tanks has been a

big driving force.

�The mining industry and the

expanding automotive sector

has also created a demand for

higher performance of

rotomoulded products.

Construction

12%Tanks

56%

Automobile

6%

ROTOMOULDING MARKETS

INDIAN MARKET :

� Over 150 rotomoulders

� Annual consumption about 35,000 MTA

� 85% fo the market is Water

Others

15%

� 85% fo the market is Water storage tanks

� Rotomoulders have initiated developments in various industries like Automotives, Diary, Material handling .

Water Tanks

85%

� The process comprises of the following :

• Loading the resin in the mould

• Heating fusion of the resin

ROTATIONAL MOULDING PROCESS

• Heating fusion of the resin

• Cooling and unloading the mould

� Unlike other processes, no pressure is involved and

the plastic material is heated / melted and cooled in

the mould.

• Flexibility.

• Moulds inexpensive. Less lead time.

• Moulds of quite different size and shapes may be run

simultaneously on the same equipment.

ADVANTAGES OF ROTATIONAL MOULDING

simultaneously on the same equipment.

• Articles with undercuts and intricate contours can be

produced

• No weldlines or sprue marks

• wall thickness uniformity

• Inserts can be easily incorporated

• surface textures such as wood grain, leather grain etc. can

be achieved with comparative ease

ATTRIBUTES OF HOLLOW PARTS PROCESSES

Rotational Moulding Extrusion Blow

Moulding

Twin-Sheet

Thermo - forming

Shape complexity 10 8 7

Maximum size 10 5 8

Manimum size 10 9 7

Thickness uniformity 10 6 5

Moulded-in inserts 10 4 1Moulded-in inserts 10 4 1

Material choice 6 8 10

Material scrap factor 10 8 6

Material cost 8 10 6

Machine cost 10 7 9

Mould cost 10 7 9

Labour input 6 10 7

Production rate 7 10 8

10 = Best or most common, 5 = Worth considering, 0 = Normally not done

PLASTICS IN ROTATIONAL MOULDING INDUSTRY

• Polyolefins (mainly PE) dominate the market

• Readily converted from

granules to the powder form

• Stability to withstand

long heating period

Others

5%

LLDPE

61%

LDPE

2%PVC

13%XLPE

8%

HDPE

11%

• Liquid, fine powder or small pallet

• Optimal processing performance

• Proper stabilization

RESIN REQUIREMENTS

• Proper stabilization

• Good physical properties

• Impact

• ESCR

EMERGING APPLICATIONS

RECLAIR O35042

�Reclair ER-19 is a Octene Conomoer based medium

density Polyethylene grade designed for Rotational

Moulding applications with optimum loading of UV

Stabilizer

�Processing similar to Butene grades

�Excellent toughness and ESCR.

OCTENE ADVANTAGES

TYPICAL PROPERTIES

Property Unit Test Method ValueProperty Unit Test Method Value

Butene Octene

Tensile Strength at Yield M Pa ASTM D368 14 15

Flexural Modulus M Pa ASTM D790 480 500

Izod Impact Strength J/m ASTM D256 144 650

Indothene LL 36RA045

Reclair O35042

� automotive components,

� fuel tanks,

� underground tanks (septic tanks, manholes)

� insulated crates

APPLICATIONS ( O 35042)

� insulated crates

� pallets.

WHY POLYPROPYLENE (PP) ?

In order to expand into new markets, the rotational moulding

industry needs materials offering good surface hardness and high

temperature stability.

• Excellent chemical resistance

• Autoclavable

• High heat distortion

• Better stiffness

• Better abrasion resistance.

TYPES OF POLYPROPYLENE (PP)

•Three basic types of PP :

• HOMOPOLYMERS :• Fibres, carpet backing, caps etc.

• RANDOM COPOLYMERS :• RANDOM COPOLYMERS :• Clarity, house wares,• Clear / see through

applications

• IMPACT COMOPOLYMERS :• Automotive, bumpers,• Luggage

POLYPROPYLENE (PP) AS A ROTATIONAL MOULDING RESIN

• Toughness is a very major

requirement for Rotomoulded

products.

• Due to inherently low stiffness of • Due to inherently low stiffness of

LLDPE, Polypropylene is considered.

• With the advent of high activity

catalyst technology, PP impact

copolymers exhibit an excellent

property balance of stiffness to

impact resistance.

• Parts requiring autoclaving / sterilization

• Medical bio-technology

APPLICATIONS ( PP)

• High temperature applications

• Housings of appliances -

• Automotives, Furniture.

VALUE ADDITION FROM RECLAIR LLDPE

• FR compounds for Rotational Applications

• Crosslinkable LLDPE for achanced performance

• Value addition -PE Foamed products

• Tailor-made compounds for niche markets

FR compounds for Rotational Moulding

• Requirements-

-Antistatic properties

-V-0 rating, UL -94

• FR compounds for different

flammability ratings as per UL 94 .

• Applications: Defence, Packaging,

Dust-bins, Automotive.

CROSSLINKABLE LLDPE

• Alters performance of base resin

- Increase Service temperature

- Improvement in ESCR- Improvement in ESCR

- Increase in Toughness.

• Applications: fuel tanks,

Chemical tanks

CROSSLINKABLE LLDPE

� Crosslinked materials showed encouraging results

Property Unit Reclair R35042 Crosslinked R35042

Tensile Mpa 16 17Tensile Mpa 16 17

Elongation % 260 210

Flexural MPa 710 740

Mod.

Izod Impact J/m 60 240

ESCR hrs 50 >400

PE- FOAMED PRODUCTS

• Reduce Weight -Strength ratio

• Improve Rigidity

• Thermal insulation

-Eliminate post-moulding-Eliminate post-moulding

-Better bonding ( Skin& core)

-Ease Recyclable

• Applications: Insulated

containers,Automotive components

PE- FOAMED PRODUCTS

• In-house trials have given

encouraging results

-Consistent & uniform cell

structurestructure

-Increase in rigidity

-Good insulation

PE - FOAMED PRODUCTS0

• Development of insulation containers for fishery Industry

TAILOR- MADE COMPOUNDS FOR NICHE MARKETS

• Development of compound for Automotivecompound to match Impact - Rigidity balance.

• Compound was designed as per the requirements ofthe End user.

• In-house trials were conducted to evaluate• In-house trials were conducted to evaluate

- Process ability

- Product properties

UNDERGROUND ROTOMOULDED MANHOLE

Manhole Developed for RelianceTelecom junctions.

Total weight of the product is

100 Kgs, as compared to the

conventional Concretemanhole of 7 tons.

TESTING OF THE MANHOLE STRUCTURE

• The manhole was installed underground and soil wascompacted around the structure.

• The pre-fabricated concrete frame and lid weighing1.2 tonnes was placed on the Manhole.

• Various vehicles were moved on this Manhole assembly, tosimulate actual loading conditions.simulate actual loading conditions.

• This test was carried out with different soilconditions.(Compacted, loosely packed, Dry / Wet.)

• The various Vehicles tried were :

» LMV(Car) 1.5 Tonnes

» HYDRA 4.0 Tonnes

» HMV(Truck) 10.0 Tonnes

TESTING OF ROTOMOULDED (UNDERGROUND) MANHOLE.

UNDERGROUND SHELTERS

Underground Shelter for

Defence from

Reclair LLDPE

Visualisation On ID Software

ROTOMOULDED BUS STOP SHELTER AT JAMNAGAR

• For visualising the concepts, Industrial Design(ID) Software is used.

• ID Software are highly useful for developing new products since designing can be totally freeform based without any basis of dimensions

• Here, standard mannequins (life sized human dummies) are available to check/design ‘Ergonomics’ (Human factors viz.. Access, reach, comfort etc).

Left : the approved concept Right: Same shelter visualised for Cycle stands

FEA - Finite Element Analysis

•Any creative concept should ultimately meet certain performance conditions

•Loads applied on the model for testing and modifying the design

ROTOMOULDED BUS STOP SHELTER AT JAMNAGAR

and modifying the design

Top left: Meshing, boundary conditions applied

Bottom : Test results are displayed as colored plots with values on scale

Actual Product

ROTOMOULDED BUS STOP SHELTER AT JAMNAGAR

Reliance Industries Limited - PARC

won the Plasticon Award 2000 for the above

rotomoulded product

POTENTIAL APPLICATIONS

POTENTIAL APPLICATIONS: (AUTOMOTIVES/ APPLIANCES)

POTENTIAL APPLICATIONS

APPLICATIONS

APPLICATIONS

New Development Support from RIL

� Development of new grades.

� Technical assistance- Application development.

� Customer support- Testing and Processing .

� Coordinate with OEMs and nodal agencies for

approvals.