PU

PUTodayS e p t e m b e r 2 0 1 1p o l y u r e t h a n e s t o d a y1

PUToday2 p o l y u r e t h a n e s t o d a yS e p t e m b e r 2 0 1 1

Vice Chairman’s MessagePUTodayDear Member,want to thank the executive committee of the Indian PolyurethaneI Association (IPUA) for posing confidence in me and providing me withan opportunity to serve as the Vice Chairman of a dynamic and impactfulassociation. The good news is that the Polyurethane (PU) industry inIndia is still at its infancy in terms of consumption and the future willopen up plenty of good prospects. The current global scenario is volatile& challenging. However, opportunity is there in front of us - as the PUindustry is massive. I am humbled by this election and will strive to domy best to support the growth of the PU industry in India.Dr Mahesh GopalsamudramI strongly believe in continuity and as an enabler in the medium term, theIPUA needs to strengthen its platform through more external and openinteraction with PU and associated industries. A great example of this isthe PUTECH exhibition held every three years. Its increased impact andpopularity is for all of us to see.Other initiatives which we are actively working on and will soon beginto deliver results in are the promotion of insulation in construction andeducation/training of operators and supervisors. As an association, wewill extensively focus on these areas over the next couple of years.In addition to the above, I want us to focus on;• Garnering more active members from the Insulation, footwear andappliance industries• Advocating the cause of the end industry like PU seating in railways,enhancing excise limit for footwear above INR249 and creatingspecifications in insulation applications for improved energyefficiency• Listening, through interaction, with specific sectors to understandconcerns and promote industrial growthOnce again, I am humbled at the recognition of being elected to this officeand see this as a result of the collective contribution of the Dow India(PU, Formulated Systems and leadership) team that rallied behind all theIPUA initiatives over the last several years.Let’s recommit ourselves to contribute more than ever before...Best wishesDr Mahesh GopalsamudramS e p t e m b e r 2 0 1 1p o l y u r e t h a n e s t o d a y3

PUTodayEditorialDear Members,A ‘Change of Guard’ – a time rendered with mixed emotions indeed! Warmwelcome and heartfelt congratulations are extended to the New Office Bearersat IPUA, and a poignant farewell with the very best of wishes to the outgoingmembers after the elections that were held at the last meeting of IPUA ExecutiveCommittee Members in Delhi.There is anticipation in the air though – as the PU Industry waits for the unfoldingof new activities that have been envisioned by the New Guard. A new momentumwill spur its progress a different outlook; a different approach to existing obstacleswill change the pace and the status of things indeed.You will notice a new section has been introduced in this issue – “IPUA Ventures.”We in the Editorial Team felt that the inclusion of this section will enlighten allour members on the various endeavors that IPUA has undertaken in the recentpast – a kind of a summation of their efforts and results therewith. We hope youall appreciate our efforts towards the diffusion of knowledge of various aspects ofour functions, always aimed at benefitting the PU Industry, and to give a voiceto it wherever and whenever necessary to further all our interests as a whole.Do keep abreast with our activities, and participate wherever you can, in orderto make our Association a meaningful entity.Let me inform you of IPUA’s first venture next month: An event sponsored byHoneywell. This will be a workshop on - Next Generation Blowing Agentsfor Polyurethane Foam. This event will bring together global industry expertsand regional colleagues to discuss key challenges in the polyurethane industry.It is also a platform to learn more about energy efficient and cost effectivetransition alternatives in today’s changing scenario. I recommend you do notmiss this half a day’s event on 4th November 2011, beginning at 3pm, at theRodas Hotel in Powai’s famous Hiranandani estate. Of course an added bonusis an opportunity to network amongst Industry members, over cocktails anddinner, following the event!To register, please contact anupama.sachdeva@honeywell.comPhone: +91-124-675 3115There is no cost to attend this conference!Sincerely,4 p o l y u r e t h a n e s t o d a yS e p t e m b e r 2 0 1 1

PUTodayContentsC o n t e n t sPUBLISHED BY THE INDIAN POLYURETHANES ASSOCIATIONEDITORMRS. MEDHA BHUTAEDITORIAL TEAMMR. RAMAMURTHY - SECRETARY IPUAMR. GOVIND GUPTA - DOWMR. PRAVIN MAHAJAN - BASFMR. PRANAV MEHTA - HONEYWELLCOMPILATION & SELECTIONDR. MAHESH GOPALASAMUDRAMMR. G. ANANDDESIGN CONCEPTMR. MUKESH BHUTAGRAPHIC DESIGN & LAYOUTRED SKY DESIGNSPRODUCTION & EXECUTIONMR. RAMAMURTHYIPUA OFFICE BEARERSCHAIRMANMR. RAHUL GAUTAM 0120 4162 220/4162 200 rahul@sheelafoam.comVICE CHAIRMANDR. G. MAHESH 022 67934904 maheshgn@dow.comMr. MUKESH BHUTA 022 2768 0303/0404 mbhuta@expandedinc.co.inTREASURERMR. GIAN JAIN 011 2724 6907/4237 6465 gcjain@karefoam.comVice Chairman’s Message .................. 3Editorial ............................................... 4Credits + Contents ............................... 5Industry Updates ................................... 6International News ............................... 8Product News ....................................... 11Interview .............................................. 15Technical Updates .................................. 18Technical Article ................................... 21IPUA Ventures ...................................... 32Previews & Reports ............................... 37Books & Periodicals .............................. 38Events & Trends ................................... 42SECRETARY GENERALMR. K. RAMAMURTHY 044 2499 5923 admin@pu-india.orgramamurthy_k2@dataone.inIPUA EXECUTIVE COMMITTEE MEMBERSMR. JAGANNATH SARANGAPAN +9140 23704551/3 jagannath@ufoam.comMR. G. ANAND +9122 2778 7396 anand_g@huntsman.comMR. MANDAR JOSHI +9122 6791 7420 mandar.joshi@basf.comMR. DEEPAK T. MEHTA +9179 2630 4652/3/4/5 deepakmehta@tirupatifoam.comMR. M. G. BOHRA +9144 2595 2001/2 mgb@amulpolycure.comMR. H. S. KOCHAR +91120 4080000 kochar@pfeda.comMR. S. RAJESH T. BHARGAVA +912642 247160/61/62 rtbhargava@gnfc.inMR. RABINDRA JHAJHARIA +91332229 8904/2229 5496 multiwynfoams@multiwynfoams.comMR. PRANAYA PRADHAN +9731303238 pranaya.pradhan@shell.comMR. SANJAY SANGHI +91224005 9350/51/52/53/54/55sanjay.sanghi@momentive.comMR. VINOD VORA +9122 413 5141/5889 vnvora@aromaticagencies.comMR. ASHWINI K. SEHGAL +91120 4031000 aksehgal@saanglobal.comMR. ROMESH MADAN +9111 41613643/44/45 rmadan@goodiesons.comMR. ROHIT RELAN +91124 2341258 rohitgrp@ndf.vsnl.net.inMR.AJAY DURRANI +91120 3921199 ajay.durrani@bayer.comMR RAVI MUTHUKRISHNAN +9144 25942830 mravi@manalipetro.comPERMANENT INVITEE & SPECIAL ADVISOR TO THE IPUAMR G RAMACHANDRAN +91 44 24345738 indramu123@gmail.comPERMANENT INVITEEMR. SAMIR ARORA011 26912375/26917758/26831850 samira@airtelmail.in sam@sam3.inS e p t e m b e r 2 0 1 1p o l y u r e t h a n e s t o d a y5

PUTodayIndustry UpdatesHuntsman to scale up India capacitiesBy Malini HariharanUS chemical producer Huntsmanplans to rapidly expand capacitiesand sales in India, a country thathas caught the attention of globalmajors.The blog caught up with thecompany’s President and CEO PeterHuntsman in Mumbai yesterday.“In every one of our businesses,except titanium dioxide, we will bespending money to build or buy inIndia,” Huntsman said. “In textileeffects, we will be doubling capacityin three years and we will also expandthe Laffans facility,” he added.US-based Huntsman recentlycompleted the acquisition of India’sLaffans Petrochemical, which has a60,000 tonne/year ethylene oxide(EO) derivatives facility at Ankleshwarin Gujarat state.“We will first bring Laffans to thesame standards as other Huntsmanfacilities, which should be easy, andwe will then look at expansion,”Huntsman said.He added that details of the expansionwere not yet firmed up but theambition was to complete it in twoyears.The company’s other major expansionwill be in Baroda, Gujarat, where itplans to spend $10m (€7m) to raiseits dyes capacity by 80,000 tonnes/year.“Some of the dyes produced elsewherewill move to India and we will alsobe producing some new products,”Huntsman said.Production would be targeted at theIndian market first and then exports.Huntsman acquired the Barodafacility from India’s MetroChemIndustries in 2009.Earlier this year, the companyannounced plans to build a $10mpolyurethane (PU) systems house inPune, India, by April 2012.However, Huntsman ruled out anIndian investment in methyl di-pphenyleneisocyanate (MDI) in thenear future.“The Indian market is not largeenough to support a worldscale MDIplant,” Huntsman said.“We are going to start with a systemshouse, bringing MDI from the US andChina. We hope we will be the first toproduce MDI locally, but we need tobuild the end-use markets first,” hepointed out.As well as adding capacities, thecompany has budgeted $10m for anoffice complex in Mumbai, which willalso house a technical support centreand laboratory.Huntsman said he expects sales fromIndia, currently $400m, to grow at10%/year, while sales should doubleevery five years.He also expects sales from China togrow at more than 10%/year from thecurrent $1.2bn.“In the next five to seven years, Asia-Pacific will account for one-third ofour sales,” Huntsman said.“Two years ago Europe was our singlelargest market. Within three years itwill be North America, followed byAsia, Europe and Latin America,” headded.Huntsman posted sales of $9.25bnin 2010.Japan prefers India to ChinaThe TelegraphJayanta Roy Chowdhury, October 3, 2011Tokyo, Oct. 2: Wary of doing businessin China, Japanese investors feelIndia is their best bet in the long run.A survey by the Japan Bank forInternational Cooperation for thecountry’s Ministry for Economy, Tradeand Industry shows around 75 per centof Japanese businessmen putting Indiaas “the most promising country” aheadof China, Brazil, Vietnam and the US.“India holds great potential for us(Japanese firms),” said Koji Miyahara,chairman of NYK Line, the 140-yearold shipping firm, which has investedheavily in India.According to Sanjeev Sinha, a Tokyobasedfund manager advising Japanese6 p o l y u r e t h a n e s t o d a yS e p t e m b e r 2 0 1 1

Industry UpdatesPUTodayfirms in India, “The top managementof Japanese firms recognise India’sstrategic importance as an investmentdestination (which is backed by)commitment from the politicalleadership starting from the PrimeMinister down.”More than 1,200 Japanese firms haveinvested in India. A second wave ofinvestment by small and mediumenterprises as well as major players hasstarted this year. The Delhi-MumbaiIndustrial Corridor, funded by Japaneseloans, is expected to attract moreJapanese companies.“The Delhi-Mumbai Industrial Corridoris going to be a game changer for theeconomic ties with Japan,” said RaviMathur, India’s ambassador to Tokyo.Backing the shift in investment patternis the Japanese government, which isalarmed by aggressive Chinese navalmoves in the East China Sea, whereit disputes Tokyo’s control over theSenkaku islands. The island nationhas been advising its firms to lookwestwards to India.The two main political parties ‘ theLiberal Democratic Party, which ruledJapan for more than 40 years since1955, and Democratic Party, whichrules it now ‘ have both agreed on theneed for closer ties with India.According to Takeshi Iwaya, the LiberalDemocratic Party’s shadow defenceminister, “Threats surrounding Japanare increasing. China is expanding itsmilitary technology and capacity at aferocious speed. Japanese alliance withthe US will remain our cornerstone(but) we have to work out commonstrategic objectives and economicagenda with India.”However, the government’s fiatsto businesses do not always work.“Japanese firms politely listen andignore the government’s advicewhen it does not suit them,” saidMasanori Kondo, who teaches at theInternational Christian University andadvises Japanese firms in India.In this case, the Japanese firms havestarted to feel they have over-investedin China and there is a pressing need to“put their eggs in other baskets”.Japanese CEOs are worried over“possible collapse of the Communistone-party rule and the bursting ofChina’s bubble economy”, YasukaniEnoki, former ambassador of Japan toIndia and a visiting professor at SokaUniversity, said.Rupee falls 3rd day as risk aversion gripsOctober 4, 2011MUMBAI (Reuters) - The rupeeweakened on Tuesday [Oct 4th]for a third session as concerns ofgrave injury to the world economyfrom Europe’s debt imbroglio hitrisk appetite, sending stocks downand the dollar surging against majorcurrencies.“Heightened risk aversion triggeredby Greece debt concerns is gettingreflected across asset classes,” saidPramod Patil, senior foreign exchangedealer at State Bank of Mauritius.“The dollar index is getting strongerby the day. In such a bearish globalscenario, the rupee will have tosuffer.”Global stocks fell to a 15-month low onTuesday and the dollar was supportednear a 9-month high as growingdoubts over Greece’s ability to avoiddefault fuelled fears of global financialturmoil and recession.The 30-share BSE, which is one of theworst performing indexes this year, wasdown 0.2 percent in choppy trade.Traders said the rupee could fall morein coming days because of a worseningcurrent account deficit and fears offiscal slippage from the government.Data released last Friday showed Indiareached 66 percent of its full-year fiscaldeficit target in just five months, andthe current account deficit widenedto $14.1 billion in the June quarter,compared with $12 billion in the sameperiod a year ago.The rupee, which has fallen 11 percentfrom its July peak, is unlikely to breacha 28-month-low of 49.90 reachedon Sept. 23, traders said because ofexpectations the central bank wouldintervene.“Inflows are trickling into the countryfrom corporates. Exporters too havebeen selling dollars,” said a dealer ata private sector bank.The Reserve Bank of India, whichsteps in to smooth excess volatility,is suspected to have intervened inSeptember when the rupee hadtouched 49.90.The euro was at $1.3216, lower than$1.3340 at the end of rupee trade onMonday, while the index of the dollaragainst six major currencies was at79.459 points from 78.946 previously.(Reporting by Aditya Phatak; Editingby Ranjit Gangadharan)S e p t e m b e r 2 0 1 1p o l y u r e t h a n e s t o d a y7

PUTodayInternational NewsHuntsman Joins EU R&D Project Exploring newComposites for Automotive ApplicationsEverberg, Belgium (July 25, 2011)– The polyurethanes division ofHuntsman Corporation (HUN:NYSE)today announces its involvement inan ambitious European collaborativeresearch project focused on advancingcomposite materials technology, tobring it closer to mass-production forautomotive applications.HIVOCOMP is a consortium of worldleading automotive manufacturers,materials scientists and academicsthat have joined forces to increasethe use of composite materials in theproduction of vehicles. HIVOCOMPstands for: advanced materialsenabling HIgh-VOlume road transportapplications of lightweight structuralCOMPosite parts.Project partners include three largeautomotive OEMs (VW, Daimler,Fiat Research Center); luggagemanufacturer Samsonite; highlyspecialised suppliers in the fieldof composite materials and theirapplication; and six leading universitiesat the cutting edge of compositematerials research in Europe.Over four years, HIVOCOMP partnerswill work together to significantlyspeed up the composites productionprocess, a key factor for theestablishment of plastics in thecommercial vehicles market. Theywill develop two material systemsthat show unique promise for costeffective,high-volume productionof high performance carbon fibrereinforced plastic (CFRP) parts:advanced polyurethane (PU) thermosetmatrix materials; and thermoplasticPP- and PA6-based self-reinforcedpolymer composites with continuouscarbon fibre reinforcements.The performance, production costand recyclability of new CFRP materialsystems will be thoroughly tested andbenchmarked to ensure the resultsreach and exceed cost, safety andenvironmental targets. Validateddemonstrator parts will be producedin 2013.Although HIVOCOMP focuses primarilyon passenger cars, including hybridand fully electric platforms, spin-offapplications in other transport-relatedsectors have also been identified.HIVOCOMP is funded under thetopic NMP-2009-2.5.1 “Light highperformancecomposites” of the 7thFramework Programme for Researchand Technological Development.Project partners include: VW, Daimler,Fiat Research Centre, Samsonite,K.U. Leuven, University of Leeds,University of Perugia, T.U. Munich,E.P.F. Lausanne, Fraunhofer ICT-A,Huntsman Polyurethanes, AirborneComposites, ESI Group, Benteler SGL,Propex Fabrics and Bax & WillemsConsulting. Project coordinator isProf. Ignaas Verpoest of KatholiekeUniversiteit Leuven.For more information aboutHIVOCOMP, please visit www.hivocomp.eu or email: info@hivocomp.euAbout Huntsman:Huntsman is a global manufacturerand marketer of differentiatedchemicals. Our operating companiesmanufacture products for a varietyof global industries, includingchemicals, plastics, automotive,aviation, textiles, footwear, paints andcoatings, construction, technology,agriculture, health care, detergent,personal care, furniture, appliancesand packaging. Originally known forpioneering innovations in packagingand, later, for rapid and integratedgrowth in petrochemicals, Huntsmanhas approximately 12,000 employeesand operates from multiple locationsworldwide. The Company had 2010revenues of over $9 billion. For moreinformation about Huntsman, pleasevisit the company’s website at www.huntsman.com.Forward Looking Statements:Statements in this release that arenot historical are forward-lookingstatements. These statements arebased on management’s currentbeliefs and expectations. Theforward-looking statements in thisrelease are subject to uncertaintyand changes in circumstances andinvolve risks and uncertainties thatmay affect the company’s operations,markets, products, services, pricesand other factors as discussed in theHuntsman companies’ filings withthe U.S. Securities and ExchangeCommission. Significant risks anduncertainties may relate to, but arenot limited to, financial, economic,competitive, environmental, political,legal, regulatory and technologicalfactors. In addition, the completionof any transactions described inthis release is subject to a numberof uncertainties and closing willbe subject to approvals and othercustomary conditions. Accordingly,8 p o l y u r e t h a n e s t o d a yS e p t e m b e r 2 0 1 1

International NewsPUTodaythere can be no assurance that suchtransactions will be completed orthat the company’s expectations willbe realized. The company assumesno obligation to provide revisionsto any forward-looking statementsshould circumstances change, exceptas otherwise required by applicablelaws.China Warns of Trade war if U.S.bill passesOctober 4, 2011By David Stanway and Aileen WangBEIJING (Reuters) - China warnedWashington it is “adamantlyopposed” to a proposed U.S. billaimed at forcing Beijing to let itscurrency rise, saying its passagecould lead to a trade war betweenthe world’s top two economies.In a coordinated response, the Chinesecentral bank and the ministriesof commerce and foreign affairsaccused Washington of “politicising”global currency issues.The bill to be debated in the UnitedStates this week violates World TradeOrganization rules and forcing theyuan to appreciate would weakenjoint efforts to revive the globaleconomy, the foreign ministry said.“By using the excuse of a so-called‘currency imbalance’, this willescalate the exchange rate issue,adopting a protectionist measurethat gravely violates WTO rules andseriously upsets Sino-U.S. trade andeconomic relations,” foreign ministryspokesman Ma Zhaoxu said in astatement posted on China’s officialgovernment website (www.gov.cn) onTuesday.“China expresses its adamantopposition to this.”U.S. lawmakers, eyeing 2012elections, said the undervaluing ofChina’s currency had cost Americanjobs and that a fairer exchange ratewould help cut an annual trade gapof $250 billion.S e p t e m b e r 2 0 1 1Ma urged U.S.legislators to“proceed fromthe broaderpicture ofSino-U.S. tradeand economiccooperation”and “forsakeprotectionism”.If the bill did clearboth chambers,it would presentPresident BarackObama with atough decision on whether to signthe popular legislation into law andrisk a trade war with Beijing, orveto it to pursue a more diplomaticapproach.“My colleagues, both Democratsand Republicans, agree that China’sdeliberate actions to devalue itscurrency give its goods an unfaircompetitive advantage in themarketplace,” said Senate MajorityLeader Harry Reid.China has routinely denied claimsthat its policies are responsible fortrade imbalances and a high rate ofunemployment in the United States,saying that structural problems wereto blame. Ministry of Commercespokesman Shen Danyang said theUnited States was trying to pass onthe blame for its own failings.Shen said any move by the UnitedStates to force the yuan to appreciateAn employee counts yuan banknotes at a branch of the PudongDevelopment Bank in Hefei, Anhui province May 3, 2010. REUTERS/Stringer/Fileswould undermine joint efforts torevive global economic growth,which took another blow on Mondaywith data showing that globalmanufacturing shrank in Septemberfor the first time in over two years.U.S. critics of the bill also warned ofthe risk of a trade war with China --one of the fastest-growing markets forU.S. goods -- just when weak globaleconomies can least afford it.The Emergency Committee forAmerican Trade called the bill “ahighly damaging unilateral approachthat will undermine broaderefforts to address China’s currencyundervaluation.”It also said the bill was unlikelyto pass muster at the World TradeOrganization and would open thedoor to Chinese retaliation “to thedetriment of U.S. exports and jobs.”(Additional reporting by ChrisBuckley; Editing by Neil Fullick)p o l y u r e t h a n e s t o d a y9

PUToday10 p o l y u r e t h a n e s t o d a yS e p t e m b e r 2 0 1 1

Product NewsPUTodayIndian state rolls out red carpet for carmakersOctober 4, 2011By Anurag KotokySANAND (Reuters) - Along a dusty,traffic-choked road in Gujaratlies what may be India’s industrialfuture.As labourers work under a blazingsun to widen the highway, auto giantsFord Motor Co and PSA PeugeotCitroen prepare to spend nearly $2billion to build new plants in Sanand,a sparsely populated collection ofvillages about 40 kilometres west ofAhmedabad.More automakers and suppliers areexpected to follow, taking advantageof the state’s business-friendlypolicies, including comparativelylittle bureaucratic red tape and,crucially in crowded India, ease ofacquiring land.An employee works inside the newly inaugurated plant for the Tata Nano car at Sanand inGujarat June 2, 2010. REUTERS/Amit Dave/FilesRelated Quotes“You have a pro-business environmentfrom the Gujarat government focusedon getting companies like us to comein,” said Michael Boneham, whoheads the Indian operations for Ford,which will open its plant in Sanandin 2014.The Indian auto industry, which grew30 percent last fiscal year before arecent slowdown, is a key growthengine for India’s underdevelopedindustrial sector. New Delhi wantsto lift manufacturing’s share of theeconomy to 25 percent over the nextdecade from about 16 percent now,a daunting target.While car sales have skidded in recentmonths on rising interest rates andprices, the industry is expected togrow 10-12 percent for the yearending March 2012. The longer-termpotential is vast in a country thatsold 1.9 million cars in its last fiscalyear. China sells that many in sevenweeks.By rolling out the red carpet tomanufacturers, Gujarat is takingon existing Indian auto hubs,including Chennai, known as “India’sDetroit.” Executives and investorshope the competition betweenstates ultimately results in improvedbusiness conditions across India.“When more states compete forinvestments, then more states willbecome states where people wantto go. This is a good thing,” said R.C.Bhargava, chairman of Maruti Suzuki,India’s dominant carmaker.Maruti, which is 54 percent ownedby Japan’s Suzuki Motor and hasbeen plagued by labour trouble at itsplant near New Delhi, will decide bythe end of October where to build itsnext factory and is widely reportedto be leaning towards Gujarat for aplant with capacity of one millioncars a year.S e p t e m b e r 2 0 1 1p o l y u r e t h a n e s t o d a y11

PUTodayProduct NewsRAMPF Giessharze to present firstBIO electro casting system at Productronica 2011RAMPF Dosiertechnik presents accelerated curing with CODGrafenberg, Zimmern 4 October2011 – Visitors to Productronica,the world leading trade fair forinnovative electronics production,will be able to see two highlights fromRAMPF live and in action at Stand260 in Hall A3. With the developmentof a two-component BIO electrocasting system made of polyurethane,RAMPF Giessharze is respondingto the market’s growing awarenessof ecological issues. RAKU-PUR®21-2499 casting material has beendeveloped based on renewable rawmaterials. Thanks to the COD (CuringOn Demand) equipment integrated intothe DC-CNC low-pressure system fromRAMPF Dosiertechnik, the materialcures after just three minutes. The BIOsystem is suitable for casting electricaland electronic components.to the European RoHS directive2002/95/EC. The use of non-abrasivefillers means the green casting resincan be processed on all commerciallyavailable two-component mixing anddosing systems. The standard pot lifefor processing the system is 10 to 15minutes. At Productronica, RAMPFDosiertechnik will be giving a livedemonstration of accel-erated curingof the casting material using CuringOn Demand, a contactless method ofintroducing energy into the castingmaterial. Infrared radiation is usedto heat the material to 90° Celsius.The high temperature speeds up thereaction of the pol-yurethane castingmaterial and it cures in a maximumof three minutes. The COD system wasdeveloped by Swiss company VulkanAG, which manufactures tailoredheating technology solutions for theindustrial sector, and made availableto RAMPF Dosiertechnik for use withBIO electro casting materials. CuringOn Demand has already becomeestablished in the automotive suppliersector as a method for speeding upthe curing process when bondingplastic parts. A casting material willbe cured using COD for the first timeat Productronica.The compact DC-CNC dispensing cellis the optimum solution for the 2Dor 3D ap-plication of casting, sealingWith a mix viscosity of 3,200 mPa*s,solvent-free RAKU-PUR® 21-2499makes the casting process easy. TheBIO electro casting system offersexcellent thermal con-ductivity of0.6 – 0.7 W/mK and good resistanceto temperatures and fluctuationsin temperature (from -40 to +130°C). Due to its low exothermicity,it demonstrates low shrinkage andstress during curing. Even withthin layers of 6 mm, the productrange complies with fire protectionclass V0 in accordance with UL94,extinguishing a flame within 10seconds. During the developmentprocess for this material, the ex-pertsfrom RAMPF completely eliminatedthe use of flame retardants containinghalogen. This ensures the twocomponentsystem also conformsTwo-component polyurethane BIO electro casting system from RAMPF Giessharze12 p o l y u r e t h a n e s t o d a yS e p t e m b e r 2 0 1 1

Product NewsPUTodayand adhesive systems. The basic setupof the fully en-closed DC-CNC isequipped with an integrated controlcabinet and a two-componentmaterial conditioning system.Further features include the modularcontrol solution incorporating aSiemens Sinumerik control system,and integrated process control forcontinuous monitoring of pressure,fill level and speed. The mixing anddispensing system can optionally beequipped with a high-pressure rinseagent recycling system, high-pressurewater rinsing or various items ofautomation equipment dependingon the application in question.Once again, companies in the RAMPFGroup are demonstrating how theywork hand in hand as system suppliersof reaction resins and machinesystems. RAMPF Gies-sharze is oneof the leading companies in the fieldof reactive casting resins for sealing,casting, bonding and designing.The plastics specialist has beenmanufac-turing casting materialsbased primarily on polyurethane inits laboratories since 1980. RAMPFGiessharze works with its sistercompany RAMPF Ecosystems todevelop polyols based on renewableraw materials. In order to expand thepotential applications of renewableraw materials in the productionof polyurethane plastics, RAMPFEcosystems has been modifyingand functionalising renewable rawmaterials since 1999. The Pirmasensbasedcompany focuses primarily onnative plant oils such as rapeseed oil.Known as Recypols, these materialsflow back into the polyurethaneproduction chain.“Our formulations are developed torespond to the needs of our customersand offer customer-specific systemsfor new markets, too,” explains Jean-Michel Pouillaude, Key TechnologyManager Electro Casting Resins atRAMPF Giessharze.www.rampf-giessharze.deRAMPF Giessharze GmbH & Co. KG,the nucleus of the RAMPF Group,is headquartered in Grafenberg,Germany. The company has specializedin the development, productionand sale of resin systems made ofpolyurethane, epoxy and silicon since1980. Its product portfolio includesDC-CNC low-pressure system from RAMPFDosiertechnikliquid and thixotropic sealing systems,electro and engineering casting resins,edge and filter casting resins andtwo-component adhesives. RAMPFGiessharze offers solutions for all keyindustries around the globe.www.rampf-dosiertechnik.deWith 2,200 system solutions on themarket worldwide, RAMPF Dosiertechnikfrom Zimmern o.R., is one of the leadingmanufacturers of low-pressure mixingand dispensing systems. As a supplier ofinnovative systems for processing one-,two- and multi-component reactionresin systems, RAMPF Dosiertechnikserves customers in the automotive,electrical, household appliance andfilter industries. Part of the internationalRAMPF Group since 2003, the ace upthe sleeve of RAMPF Dosiertechnik is itsbroad-ranging product portfolio. Thisstretches from simple manual systemsall the way through to fully automatedproduction plants. RAMPF Dosiertechnikhas carved out an outstanding namefor itself on an international stage.With a global service network andnumerous branches in France, Spain,Eastern Europe, the United States, Chinaand Korea, the company has a stronginternational presenceS e p t e m b e r 2 0 1 1p o l y u r e t h a n e s t o d a y13

PUToday14 p o l y u r e t h a n e s t o d a yS e p t e m b e r 2 0 1 1

InterviewPUTodayAn Interaction with Mr. G. Ramachandran –Manali Petrochemicals Ltd.PU Today has the pleasure of presenting excerpts of an interaction with Mr. G. Ramachandran[Managing Director – Manali Petrochemicals Ltd. (Retd.)]BRIEF RESUME OFG.RAMACHANDRAN:Mr. G. Ramachandran is aChemical Engineer and a PostGraduate in Business Administration.He worked with the SPIC group ofcompanies in various capacitiesfor the past 38 years. He has richexperience in Operation, Design,Construction and Commissioning ofPetrochemical and Fertilizer plants.He retired in September 2011 fromManali Petrochemical Ltd afterserving as its Managing Director for11 years.He worked with Manali Petrochemicalsince its inception in 1986 and tookover as Managing Director in theyear 2000. He was instrumentalin the development of the projectwhich produced PO, PG and Polyolfor the first time in the country.He also successfully expanded thecapacity of PO, PG and Polyol plantsusing internally developed processdesigns thus reducing the cost ofproduction significantly. A 4.2 MWbiomass fired Captive Power Plantwas also added.PU TODAY: Mr. Ramachandran,Congratulations on your havingcompleted a successful inningsin the PU Industry, over aperiod of almost 25 years!Your own perceptions on thisIndustry over that time spanwould be a valuable read forour Industry members, so dogive them to us.Mr. Ramachandran: I was fortunateto be associated with PU Industry ofIndia since 1987 and participated inits step by step development whenMPL began production of Polyol inIndia in 1990.It has been an exciting experienceand travel - from the downs thatthe industry faced between 1993and 1995 when we struggled to selleven 200 MTs of Flexible Polyol inthe month due to L/C limitationsfor importing TDI. MPL did its bit inexpanding the market during the timeby importing TDI for use of foamers.PU TODAY: What were thefactors that influenced “thedowns” that you mention - thathindered the Industry alongthe way?Mr. Ramachandran: At first, thereservations, high taxes, dutiesdid not allow the industry to grow.These limitations slowly got removedduring the last decade.Over the period of the past twodecades, we witnessed the dramaticfall of customs duties from 240% levelto the current near 0% levels. Thedifferential duties between Polyoland Isocyanate vanished. The adventof Modvat/Cenvat regimes with VAThelped unplug and streamline theMr. G. RamachandranManali Petrochemicals Ltd.business. The rate differences ofcompeting products of differentorigins, and for the same productdifferent taxes in different states, etc.,slowly vanished into the oblivion.PU TODAY: So what wouldyou say are the conditionsprevailing now – conditionsin which you are leaving theIndustry?Mr. Ramachandran: The last decadehas been a wonderful experience,with markets always moving updemand – which has so far beenmore than production; and the pricesare commensurate with the cost ofproduction and efforts for all thesegments of the market, leading toa quick growth of the Industry.PU TODAY: Apart from thisgrowth oriented marketconditions, what other factorswould you credit with thiswonderful experience that theIndustry has enjoyed?S e p t e m b e r 2 0 1 1p o l y u r e t h a n e s t o d a y15

PUTodayInterviewMr. Ramachandran: Newer andnovel applications of Polyurethanesalso surfaced, which helped theentrepreneurs to take up formulationsof the newer products for diverseapplications like gaskets, sealants,coatings, fish floats, roof panels & cartrims besides the conventional largevolumes of insulation, refrigerationand automotive seating’s sectors.PU TODAY: What would youhighlight as the most excitingaspect of this Industry’sdevelopment?Mr. Ramachandran: Our experiencewith the automotive seatingapplication is the most exciting. Thecountry uses systems with manomericMDI, TM/MT mixes. From moulds onthe floor with make shift heatingsystems, the industry developed insteps, initially moving to rotatablecarrousels to semi automated linesand finally to automated systemswith robotic pouring and continuousconveyors to transport the productfor curing and further processing. Itwas a quantum leap that the industrysaw, and several excellent ‘state of theart’ units were subsequently installedin India - in line with the autorevolution that the country saw.PU TODAY: What were thehighpoints in the other sectorsthat enhanced PU’s journey inIndia?Mr. Ramachandran: T h erefrigeration industry saw the adventof “PUF” insulated refrigeratorsduring 1988 and 1989, which slowlyand steadily made in roads into thetraditional closed glass wool insulatedrefrigerators. Because of its inherentmechanical strength, PU acted as the“bone” which revolutionized designof the refrigerators with thinner sheetmetal covers, HIPS/ABS inner liners,clean backs, flexi trays, sporty looksand what not. The industry sawgrowth from a few hundred units aday to more than 5000 units a daywith multiple design, colors, etc.The panel industry also saw spectaculargrowth from a troubled beginning in1990 to many automated continuouslines manufacturing products up tointernational standards.PU TODAY: What are thePU Industry’s steps towardsthe International policy - tobring about a CFC/HCFC freeenvironment?Mr. Ramachandran: During the midnineties, the efforts of indigenousPolyol manufacturers helped thecountry to eliminate the use of R 11 infoam manufacture completely. Priorto that, the Flexible Foam Industryitself, on its own agenda, eliminatedR 11 in the production of flexiblefoam way ahead of schedule. Weare now planning for the balanceelimination of HCFCs from all othersegments, to meet the target of 2013for Phase I target.To summarize: from a mere 5000tons per year of the Polyurethanes’market in 1990, it has already crossed300,000 MT per year and the growthrate in the last decade is too good tobelieve, and is worth going throughall over again!PU TODAY: If you were to giveus a very brief overview of thePU Industry – as in “A SWOTANALYSIS,” it would be?Mr. Ramachandran:SWOT ANALSYSIS1. STRENGTHSStrong technology orientedBroad product rangeDiverse marketsDiverse locationsDriven by owner technocrats2. WEAKNESSES1. No value for quality2. Dwindling margins3. Too many players4. Difficult branding5. Restricted distribution channels6. Too price sensitive markets3. OPPORTUNITIESExpanding marketsNewer applicationsTechnical and chemical packagesCommitted markets4. THREATS1. Corporates entry2. Preferences of OEMs3. Markets swing with experienceelsewhere4. Fire propertiesPU TODAY: What are yourpredictions for the Indian PUIndustry in the near future?Mr. Ramachandran: The slabstockmarket will continue to grow atthe rate of 15 to 20% for another5 years, before slowing down.Polyester foams will also come intoprominence.The automotive market is expectedto grow at the current rate, and thisis a highpoint of the PU spectrumand will be of interest to manyIndustry members. However, themarket growth may be from exportof cars rather than from internalgrowth. The car manufacturers areexpecting to treble their productionin the next 5 years and let us hopeit comes true!The refrigeration industry willdefinitely continue to grow, but the16 p o l y u r e t h a n e s t o d a yS e p t e m b e r 2 0 1 1

InterviewPUTodaygrowth rate will be slower than whatwas experienced in the last decade.New applications: small volume highend applications, suitable for smallentrepreneurs, will emerge and willthrow open many opportunities andchallenges for the industry.PU TODAY: Finally, is there aword of advice from you to themembers of the PU Industry, asyou retire?Mr. Ramachandran: It has beena wonderful experience ever sincewe started the PU Association. Ithas been a learning experience andat the same time helped many ofus to contribute significantly forbetterment of the industry and lifeof many. Together, the things weachieved in the last 10 years areThe automotive marketis expected to grow atthe current rate, and thisis a highpoint of the PUspectrum and will be ofinterest to many Industrymembers. However,the market growthmay be from export ofcars rather than frominternal growth. Thecar manufacturers areexpecting to treble theirproduction in the next 5years and let us hope itcomes true!tremendous which is why, we couldhost PUTECH three times successfully.The industry is growing and manymore are expected to join and anexcellent business opportunity is herefor us to enjoy. Let us stay togetherand contribute to the well being ofthe industry and the Association andbe a part of this wonderful, evolvingPU Industry in India.PU TODAY: Mr. Ramachandran,thank you for sparing timefor this interaction. We aresure that our members will beinterested in reading aboutyour successful innings in thisfield, as well as have youradvice for guidance. We wishyou a long and happy retiredlife ahead with your lovedones. Thank you.S e p t e m b e r 2 0 1 1p o l y u r e t h a n e s t o d a y17

PUTodayTechnical UpdatesLFI composite panels with 3D paintingA Technical presentation on LFI PU composite with 3 dimensional paintingBackgroundDue to the striving demand inIndia for the fuel economyof rigid polyurethane systemand chopped glass fibre strands.The proportion of PU and glassfibre is determined by the loadto the exposed surface instantlywithout any external pressure. Thenthe component is passed throughhot air oven for curing.Base primer + transferLFIcommercial & passenger vehicles,composites with good surface finishwill be the definite alternates forsheet metals. The expectations fromOEM’s are light weight, durabilityand uncompromised surface finish.Polyurethane composites likeLFI-Long fibre injection draw theattention of Indian OEM’s to suit thistechnology for various applications.Recently we have done a researchto skip our existing in mold coatingdecoration on LFI componentsand demonstrated transfer painttechnology which is so called 3Dpainting on LFI surface. The transferfilm is directly applied on LFIwithout barrier coat wherein barriercoat is the intermediate surfacebetween paint and LFI in the currentIMC process. The basic agenda ofdeveloping this surface finish withLFI is to meet interior requirementswith good strength. The technologywill impart both functional andaesthetic enhancements. It can alsobe used for exterior panels whereverrequired with better UV resistanceproperties.characteristics of the end product.The molding process is an openmold process in which PU and glassstrands are wetted and poured asa slurry mixture. There are manyprocessing factors in LFI processto decide the surface quality andstrength. The molded componenttaken out of the mold is subjectedto next process called transferpainting. It is an offline process.The component is dipped in awater medium which contains awater soluble PVA film coated withpigmented patterns or grains.TheLFI surface needs to be cleaned withIPA and primed before it is taken fortransfer painting.The PVA film is getting dissolved inUniqueness of the productVariable densities ranging from 800to 1600kg/c.m can be offered with3dimensional painting for bothinterior and exterior applications.Both glossy and matt finish can begenerated. There is no intermediatecoating required between finallacquer coat and LFI.The finalcomposite properties are isotropic,UV resistive and load bearing. It canbe a replacement for sheet metal,SMC, DCPD and thermoplastics.ApplicationsFront Anterior band of a tractorExterior applicationConstitutionThe LFI composite is comprisedwater medium at around 50-60degC, and the grains get transferredInterior application18 p o l y u r e t h a n e s t o d a yS e p t e m b e r 2 0 1 1

Technical UpdatesPUTodayBenefitsHat rack panel of bus luggage rackLess cycle time –higher outputsNo VOCECO friendlyDevelopmental cost is lessInnumerable finish can be offeredfor the same profile100% reworkableP U T o d a y A d v e r t i s e m e n t T a r i f fAdvertisement 1 Issue 2 Issues 4 IssuesBack Cover 16,000.00 15,000.00 14,000.00USD 355 USD 335 USD 310Inside Front Cover 12,000.00 11,000.00 10,000.00USD 265 USD 245 USD 225Inside Back Cover 12,000.00 11,000.00 10,000.00USD 265 USD 245 USD 225Full Page Colour 10,000.00 9,500.00 9,000.00USD 225 USD 215 USD 200Half Page Colour 6,000.00 5,500.00 5,000.00USD 135 USD 130 USD 125Quarter Page 4,000.00 3,500.00 3,000.00USD 90 USD 80 USD 701/8th Page 2,000.00 1,750.00 1,500.00Sponsored Feature (2 pages ) Rs 12,000 (USD 270)Each Additional Page Rs 4000 (USD 100)Service Tax is applicable at the rate of 10.30% as per Government rules. The Inside Front & BackCovers And Back Cover are already booked for the next four issues.Technical Details of the AdBleed Size: 8.5 In X 11 In (21.59 Cm W X 27.94 In H) (Letter Size)Print Area: 7 in x 9.24 in (17.8 cm W x 29.50 cm H)YOU HAVE TO SEND THE MATTER IN A PDF FILE OR EPS OR TIFF FORMATSALL MATTER TO BE SENT TORamamurthy KSecretaryINDIAN POLYURETHANE ASSOCIATIONFlat 7, III Floor, Shakti Mahal, New 24, Old 41, First Main Road, CIT Colony,Mylapore, CHENNAI 600 004. Tel/Fax: 044 2499 5923, H/P: 94440 55923Email: ramamurthy_k2@dataone.in admin@pu-india.org ramapu42@gmail.comS e p t e m b e r 2 0 1 1p o l y u r e t h a n e s t o d a y19

PUToday20 p o l y u r e t h a n e s t o d a yS e p t e m b e r 2 0 1 1

Technical ArticlePUTodayHousehold Refrigerator:Low GWP Blowing Agent Performance UpdateAbstractReported to the industry in2010, the low climate changeimpact refrigerators built in 2009,utilizing Solstice Liquid BlowingAgent, exhibited 1.5 – 2.0% energyefficiency improvement, comparedto baseline HFC-245fa. This currentstudy builds on the initial workwith an optimized Solstice LBAformulation that demonstrates energyefficiency improvement exceeding 6%compared to HFC-245fa baseline,exceeds the current DOE Energy Starlabel by 9.5%., continuing to define theapplication and performance morebroadly across the appliance industry.Solstice LBA, in this commercialhousehold refrigerator/freezerplatform exceeded the proposedDOE 2014 energy standard.As with all new materials, prior toadoption, the industry requires anunderstanding of factors beyond theinitial polyurethane performancecharacterization. These analysesinclude quality measures such asdimensional stability and adhesion toliner and exterior case. In all ancillaryassessment related to a householdrefrigerator/freezer, met or exceededall requirements. Solstice LBAregulatory approvals are in processin major markets, encompassingexcellent properties of ultra lowGWP (GWP < 7), non flammability,and anticipated to be non-VOCCommercial manufacture of SolsticeLBA is estimated by late 2012.DisclaimerAlthough all statements andinformation contained herein arebelieved to be accurate and reliable,they are presented without guaranteeor warranty of any kind, expressed orimplied. Information provided hereindoes not relieve the user from theresponsibility of carrying out its owntests and experiments, and the userassumes all risks and liability for use ofthe information and results obtained.Statements or suggestions concerningthe use of materials and processesare made without representation orwarranty that any such use is freeof patent infringement and are notrecommendations to infringe onany patents. The user should notassume that all toxicity data andsafety measures are indicated hereinor that other measures may not berequired.Development SummaryA key raw material in the production ofhigh performance, rigid polyurethaneinsulation foam is the blowing agent.Although many blowing agenttechnologies are available to thefoam formulation chemist, the useof fluorocarbon blowing agents hashistorically resulted in foams with thehighest insulation performance, bestphysical properties, safest and simplestprocessing characteristics, and bestvalue in use. The use of fluorocarbonblowing agents began as early as themid-1950s with the introduction oftrichlorofluoromethane, or 11. Thisblowing agent became the industrystandard until the mid 1990s, whenconcerns over ozone depletion ledto the development of a secondgeneration of high performance foamblowing agents, the HCFCs. For therigid polyurethane foam industry,the most commonly used HCFCwas 1,1-dichloro-1-fluoroethane, or141b. Although conversion to HCFC-141b reduced the ozone depletionpotential of the blowing agent by90%, subsequent regulation requiredthat these HCFC blowing agents alsobe phased out and a third generationof high performance blowing agentswas developed, the HFCs. The mostcommonly used HFC blowing agentin rigid polyurethane foam is 1,1,1,3,3-pentafluoropropane, or 245fa. Thismaterial satisfied the requirementsof ozone depletion regulation while,at the same time, retained the highperformance and non-flammabilityrequired in many foam applications.In many parts of the world,conversion from HCFC technology toHFC technology is complete while, incertain other regions, this conversionis now occurring.In recent years, concern over climatechange is driving the development of afourth-generation fluorocarbon, onethat meets the requirements of bothozone depletion and climate changeregulations, current and anticipated.Honeywell, formerly AlliedSignal, hasbeen the leader in the developmentof fluorocarbon blowing agents andis now leading the development ofthis fourth-generation fluorocarbontechnology. Honeywell has developedtwo such fourth generation products:HFO-1234ze(E), a gaseous blowingagent; and a proprietary liquidblowing agent called SolsticeLBA. Both products successfullyincorporate required environmentalproperties, while maintaining thenon-flammability, non-VOC, and highS e p t e m b e r 2 0 1 1p o l y u r e t h a n e s t o d a y21

PUTodayTechnical Articleperformance characteristics that havedifferentiated fluorocarbon blowingagents as the best choice for highperformance rigid foam insulationapplications. These two fourthgenerationblowing agents are alsoideal for those applications where aflammable blowing agent is unsafe,too costly to use, or fails to providethe desired foam performance. Thesenew high performance materials,while they contain fluorine, alsocontain an olefin structure, and aretherefore referred to as haloalkenes.Because of the presence of a doublebond in the molecule backbone,these haloalkenes are a separate anddistinct class of materials from theirpredecessor HFC materials, resulting ina much shorter atmospheric lifetimethan their predecessor fluorocarbons,thereby resulting in a much lowerglobal warming potential, or GWP.Environmental AndRegulatory StatusAlthough current activity is limited,the United States government isconsidering various approaches toaddress climate change, particularlyregulatory-driven changes., whichwhile still too early to predict thefinal structure and language, will inall probability impact high globalwarming potential materials to somedegree. In anticipation of theseregulations, and in response tosimilar regulatory initiatives globally,industry is preparing solutions tomeet current and future climatechange regulations. Honeywell countsamong this group of industries withits low GWP development program,including, in addition to blowingagents, refrigerant gases and otherfluorochemicals.The European Parliament and theCouncil of the European Union havecommitted the Community and itsMember States adoption of the KyotoProtocol in reducing anthropogenicemissions of greenhouse gases listedin Annex A to the Kyoto Protocol by8% compared to 1990 levels in theperiod from 2008 to 2012.To this end, the F-Gas Regulationas outlined in (EC) No 842/2006(OJEC L161 of 14.06.2006) prohibitsthe use of fluorinated greenhousegases with a 100-year GWP of 150or greater, which include certainHFCs (hydrofluorocarbons), PFCs(perfluorocarbons), and SF6 (sulfurhexafluoride) as listed in Annex I (EC842/2006). The EU F-Gas Regulationwill be reviewed in 2011, which mayresult in additional use restrictionsfor high GWP fluids (Article 10, F-GasRegulation).Honeywell’s 1234ze(E) and SolsticeLBA are both in full compliancewith the EU F-Gas regulation, withrespect to two matters: (1) they arenot listed in Annex I as a fluorinatedgreenhouse gas, and therefore notcovered by the provisions of the F-Gasregulation, and (2) the GWP of thesematerials is more than an order ofmagnitude less than 150. Since thepurpose and intent of the EU F-GasRegulation is to control emissions ofhigh GWP materials, 1234ze(E), with aGWP of

Technical ArticlePUTodayis submitted to the EPA, together withan application for a Pre ManufacturingNotification (PMN). Approval of thePMN, includes the material’s listingon the Toxic Substances Control Act(TSCA) inventory. Further, materialsto be used as blowing agents or incertain other applications must havelisting as an acceptable substitute forozone depleting substances under theSignificant New Alternatives Program(SNAP). PMN approval and listing onthe TSCA inventory is a requirementfor all new chemical materials. SNAPlisting is a requirement for all materialsin applications that have historicallyused chlorofluorocarbons (CFC).Upon completion of these regulatoryrequirements, new materials can becommercialized in the United States.Additionally, these materials maybe regulated at the federal, state, orlocal levels to comply with volatileorganic compound (VOC) regulations.1234ze(E) has completed both thePMN and SNAP process and is nowapproved for commercial sale inthe United States. For Solstice LBA,filing for SNAP and PMN has beencompleted and is currently under U.S.EPA review.In the European Union, REACH[Registration, Evaluation,Authorization and Restriction ofChemicals, (EC) 1907/2006] regulationhas, effective June 1, 2008, replacedthe notification provisions of directive67/548/EEC. Under REACH, eachmanufacturer or importer of asubstance over 1 metric ton per yearis obliged to submit a registrationfile, including a chemical safetyassessment for volumes greater than10 tons. For volumes over 100 and1000 metric tons, additional datamust be submitted. Moreover, forthese volume bands, the registrantmust submit proposals for animaltests needed to obtain certain (eco)toxicological data points. The goalof the latter provision is to prevent,as much as possible, (duplication of)animal tests. In many cases, waiversfor such tests can be proposed.The registration should indicatethe intended uses for which thesubstance is notified. Use outsidethese registered uses is prohibited,unless a downstream user submits aseparate registration file for that use.1234ze(E) has been notified underREACH at the >1,000 metric ton level..REACH Registration of Solstice LBAis in progress.For Japan, the requirements forcommercialization of new chemicalsrequires submission of toxicologicaland environmental data to theJapanese Ministry of Health, Laborand Welfare (MHLW), the Ministry ofEconomy, Trade and Industry (METI),and the Ministry of the Environment(ME) for compliance with the ChemicalSubstances Control Law. 1234ze(E) andSolstice LBA registration in Japan iscomplete, allowing for commercialsales in Japan.Other regions of the world,individually, have requirementsfor toxicology assessment andenvironmental impact assessmentprior to commercialization of newmaterials. Honeywell is committedto obtaining the necessary regulatoryclearances for sampling and eventualsales of both 1234ze(E) and SolsticeLBA globally. This registration processis in progress for both 1234ze(E) andSolstice LBA in several countries,including China, South Korea,Australia, Canada, and others.Toxicity AssessmentAt the writing of this paper, Honeywellhas made significant progress towardscompleting risk assessment for useand commercialization of SolsticeLBA, as might be anticipated by theU.S EPA SNAP and PMN submissions,as well as the EU notification leveldiscussed earlier.Blowing Agent PropertiesTable 1 lists the properties of lowGWP blowing agent compared to245fa and other commonly usedblowing agents. Note that SolsticeLBA blowing agent exhibits certainkey physical properties, such asboiling point and flammability,similar to HFC-245fa and superior tothose of cyclopentane. Note that theglobal warming potential (GWP) ofSolstice LBA is 7, and is more thantwo orders of magnitude lower thanthat of currently utilized HFCs, and ismore than one order of magnitudelower than the present limitationsin the EU F-Gas Regulation.Beyond the excellent insulationperformance that 1234ze(E)and Solstice LBA imparts topolyurethane foam, it is distinctlydifferent from hydrocarbonblowing agents in flammabilitycharacterization. 1234ze(E) andSolstice LBA shipment, storage,handling, and processing doesnot require flammability riskmitigation, as is the case withflammable blowing agents suchas cyclopentane. Solstice LBA isnonflammable by ASTM E-681 testmethod and has no limitation onhazards classification. SolsticeLBA is further distinguished fromcyclopentane and other hydrocarbonblowing agents by the low potentialto contribute to ground level smogformation, and is anticipated to beclassified as a non-volatile organiccompounds (VOC). Flammabilityand VOC mitigation may contributesignificantly to the OEM’s cost ofadoption and use and in some cases,such as spray foam, prohibit theiruse due to safety considerations.S e p t e m b e r 2 0 1 1p o l y u r e t h a n e s t o d a y23

PUToday24 p o l y u r e t h a n e s t o d a yS e p t e m b e r 2 0 1 1

PUTodayS e p t e m b e r 2 0 1 1p o l y u r e t h a n e s t o d a y25

PUTodayTechnical ArticleTable 1. Liquid Blowing Agent Comparative PropertiesProperty Solstice LBA 245fa CyclopentaneMolecular Weight 130.5 134 70Boiling PointºC 19.0 15.3 49.3ºF 66.0 59.5 120.7Flashpoint°C None None - 7ºF None None 19LFL/UFL None None 1.5 – 8.7(Vol % in air)GWP, 100 yr [1] < 7 [2] 1030 11 [2]PEL [3] 300 [3] 300 6001) 2007 Technical Summary. Climate Change 2007. The Physical Science Basis. Contribution of working Group 1 to the Fourth AssessmentReport of the Intergovernmental Panel on Climate Change. (Except where noted)2) Solstice LBA: Measured value. Cyclopentane: generally accepted value3) Manufacturers’ literature, except where noted, Solstice LBA: Honeywell internal OEL.Low Climate Change ImpactHousehold Refrigerator /FreezerHoneywell has reported in variouspapers and proceedings on thecommercial development of LGWPblowing agents in the variouspolyurethane (PUR) applications,including appliance foams. PUR foamproperties of thermal conductivity(also known as lambda or k-factor),compressive strength, anddimensional stability derived fromcharacterization of hand mix foamsor foam panels prepared by means ofa high pressure foam machine haveevidenced efficacy in comparison to245fa foams. This type of effort todevelop baseline data is necessaryto estimate the performance inthe commercial manufacture ofrefrigerators, refrigerator/freezers,and freezers. However, untilcommercial refrigerator producthas been manufactured underindustrial conditions, and assessedfor energy performance and ancillaryperformance, for example, linercompatibility, adhesion to liner andmetal cabinet and doors, freezestability, and other quality aspects,an OEM cannot make a prudentdecision that a commercially viable,‘real world’ solution is available.Honeywell reported in thePolyurethanes 2010 TechnicalConference the performance ofhousehold refrigerators/freezersmanufactured utilizing SolsticeLBA blowing agent, compared tobaseline 245fa blowing agent in thesame refrigerator platform. Furtherassessment has been performedutilizing an Solstice LBA appliancepolyurethane system optimizedfor thermal conductivity, for whichthe resulting assessment will bediscussed and contrasted to theprior reported data. To that end, afull scale trial, utilizing HoneywellSolstice LBA blowing agent, withan optimized polyurethane system,in a commercially available 623 liter(22 ft³) household refrigerator/freezer[bottom freezer, counter-depthplatform] was undertaken. Thesethirty refrigerator cabinets, withassociated door sets, were foamedto investigate:• Lambda (k-factor) performancein various locations of therefrigerator• Liner compatibility with HighImpact Polystyrene (HIPS)• Dimensional stability• Freeze stability at target density• Compressive strength• Adhesion to plastic liner materialand metal case• Foam closed cell content• DOE (Department of Energy)Energy Performance• Energy consumption with 134arefrigerant working fluid• Reverse Heat Leakage (RHL)assessment was additionallyperformed on this new set ofrefrigeratorsThe baseline comparison for these lowclimate change impact refrigeratorsis the same commercial household26 p o l y u r e t h a n e s t o d a yS e p t e m b e r 2 0 1 1

Technical ArticlePUTodayrefrigerator/freezer product utilizing245fa blowing agent and 134arefrigerant (unmodified compressorsystem). It should be noted that theSolstice LBA was substituted for245fa at an equal molar level in thePUR foam formulation.Polyurethane FoamFormulationAs discussed previously, thepolyurethane formulation comprisedcommercially available materials, andwas supplied by a major PUR systemshouse, with Solstice LBA equalmolar substituted for 245fa. Thefoaming process conditions includingmachine temperatures and pressure,were identical to the conditions forthe 245fa baseline cabinets anddoors. The polyurethane processparameters are illustrated in Table2. Those familiar with refrigeratorfactories and scale will observethe scale of foam through-put isconsistent to scale found in NorthAmerican world-scale factories, andis consistent with the size refrigeratorsmanufactured in this trial.Table 2. Appliance Process ParametersComponent 245fa Solstice LBADoor Foam Rate: kg/min (lbs/min) 40.8 (90) 40.8 (90)Cabinet Foam Rate: kg/min (lbs/min) 95.2 (210) 106.6 (235)B-Side Temperature °C (°F) 18.3 (65) 18.3 (65)A-Side Temperature °C (°F) 21.1 (70) 21.1 (70)Gel Time (sec) 17.0 17.0Tack Free (sec) 24.0 24.0Injection Pressure MPa (psi) 10.4 (1500) 10.4 (1500)freezer compartment were assessedfor lambda (k-factor) performance.PUR foam thermal conductivitycan and will vary throughout therefrigerator/freezer due to foamflow characteristics and associateddensity variation. Chart 1 illustratesthe average lambda (k-factor)performance measured in varyinglocations of the refrigerator/freezer.Solstice LBA lambda performanceis approximately 8% improvement to245fa baseline.designs and freezers. Differingliner materials (except steel) exhibitvarying compatibility to PUR foams.Liner compatibility is dependentupon a wide variety of variablesincluding, but not limited to, plasticthickness, extrusion conditions ofthe plastic sheet, thermoformingor vacuum forming conditions,and not the least, the blowingagent. Chlorofluorocarbons (11),hydrochlorofluorocarbons (141b,Solstice LBA processed very similarlyto 245fa, and no modifications weremade to the PUR foaming equipmentor process - effectively, conventionalexisting PUR equipment, existing inthe factory, accommodated SolsticeLBA.Additionally, characterization of theSolstice LBA versus 245fa foamedcabinets and doors suggest nodifferences in minimum fill weightor over pack conditions.Lambda (k-factor)PerformanceFoam samples from various locationsin the fresh food compartment andChart 1. Average lambda measured across various refrigerator/freezer locationsPlastic Liner (HIPS)CompatibilityPlastic liners, either high impactpolystyrene (HIPS) or acrylonitrilebutadiene styrene (ABS) are currentlyutilized in household refrigerators/freezers, though, steel liners areused in some specific refrigerator142b, and 22), and hydrofluorocarbons(245fa and 134a), as well ashydrocarbon blowing agents allexhibited quite varying compatibilitywith either HIPS or ABS liner material.Liner compatibility to PUR foamscontaining new blowing agentsis a consideration, as correctingliner compatibility, while not anS e p t e m b e r 2 0 1 1p o l y u r e t h a n e s t o d a y27

PUTodayTechnical Articleinsurmountable problem, can resultin added cost to the OEM.Unfortunately, there is no confidentmethod of assessing refrigeratorliner materials without buildinga refrigerator, subjecting therefrigerator to thermal cycling, andsubsequently assessing the liner forblistering and cracking. High impactpolystyrene (HIPS) liner material wasutilized in this refrigerator trial.Thermal cycle testing for linercompatibility was conducted usingfour refrigerator/freezers withdoors. The units were placed inand environmental chamber andexposed to 54 ºC (130 °F) for 10hours, followed by an exposure to-34°C (-30 ºF) for 10 hours. This cyclingwas repeated continuously for fiveconsecutive days, after which theliners were observed for blisteringor cracking.Upon completion of the five daysthermal cycling protocol, the HIPSliners did not exhibit, and were freeof, blisters, cracks, or any visualdegradation.These first trial refrigerators thatwere reported in 2010, were builtin 2009, and continue to exhibitno degradation of the HIPS linermaterials after two years.DOE Energy AssessmentThe U.S. Department of Energy (DOE)established, in July 2001, a standardfor the maximum energy consumptionof household refrigerators. Insimplified terms (Federal Register10CFR 430 for more detail) thestandard allows a maximum energyusage by refrigerator internal volume,adjusted for various accessories,such as through-the-door waterand ice dispensers. In addition, theDOE provides for the Energy Starlabel for refrigerators, refrigerator/freezers, and freezers, which, as ofMarch 2008 is DOE Standard minus20% energy consumption. Further,presently the DOE is in the processof establishing, for promulgationin 2014, a revised and presumablymore stringent energy standard forhousehold refrigerators, refrigerator/freezers, and freezers.Lambda (k-factor) assessments aside,meeting the DOE energy standardis the only criteria that determineswhether a refrigerator meets theenergy requirements to be sold inthe U.S. The refrigerator/freezersmanufactured in this trial not onlymet the DOE Standard, not onlymet the DOE Energy Star label,but exceeded the Energy Star labelrequirements. Five refrigerator/freezers utilizing Solstice LBAblowing agent in an optimizedPUR system / 134a refrigerant wereassessed by the DOE Energy Star testmethod. Five refrigerators/freezersutilizing 245fa blowing agent in anoptimized system / 134a refrigerantwas the baseline comparison. Forcomparative illustration, the SolsticeLBA refrigerator/freezer ‘drop-in’ and245fa ‘baseline’ from the 2009 trial isincluded in Chart 2.Effectively,the 2011refrigeratorscontainingSolsticeLBA in anoptimizedPUR systemexceededt h eproposedD OE 2014E n e r g yChart 2. Energy Efficiency Performance.Standard, without employmentof further energy solutions to theplatform, such as vacuum insulationpanels or compressor modification.Summary: HouseholdRefrigerator EnergyPerformance utilizingSolstice LBA Blowing AgentCommercially manufactured in 2009and reported to CPI Conference2010, 710 liter (25 ft³) householdrefrigerator/freezers with SolsticeLBA, equal molar substituted for245fa, in a commercially available245fa appliance PUR formulation,exceeded the DOE Energy Starperformance criteria, and, exceededthe 245fa baseline performance.Commercially manufactured in2011, 623 liter (22 ft³) householdrefrigerators, utilizing an optimizedSolstice LBA PUR system supplied byBayer MaterialScience, LLC exhibitedan energy efficiency improvementto the baseline 245fa refrigeratorsexceeding 4%. Further, this 623liter refrigerator/freezer platformexceeded the ‘proposed’ DOE 2014Energy Standard for this platform.Solstice LBA, in all ancillaryassessment related to a householdrefrigerator/freezer, met or exceeded28 p o l y u r e t h a n e s t o d a yS e p t e m b e r 2 0 1 1

Technical ArticlePUTodayall requirements, including, linercompatibility, compressive strength,dimensional stability, and freezestability.Reverse Heat Leakage (RHL)AssessmentAssessment of reverse heatleakage for cold storage, such ashousehold refrigerator/freezers, is amethodology to isolate and assessthe insulation performance. WhileRHL is not utilized in the U.S. forenergy efficiency standards testing,the method has continued use inother regions of the world, andfor those regions with unreliableelectricity supply and distribution,provides some indication of the‘time to food spoilage’ in the event ofextended electrical disruption.Prototype Solstice LBA refrigeratorsfrom this trial were assessed forRHL, along with baseline 245farefrigerators. The Solstice LBArefrigerators exhibited a reduction(in total) RHL exceeding five percent(5%), illustrated in Chart 3. Notethat while refrigerator size andwall thickness directly impact heatleakage, these refrigerators were adirect comparison from baseline245fa refrigerators.Chart 3. Reverse Heat Leakage ComparisonFurther, the reverse heat leakageimprovement correlates to theseparate DOE energy consumptionimprovement, a validation of theefficacy of Solstice LBA in anoptimized PUR system.Commercialization StatusHoneywell has successfullycommercialized 1234ze(E) in theEU in several foam applicationscoinciding with the implementationof the EU F-Gas Regulationconstraints on the use of high GWPmaterials. Commercialization of1234ze(E) in Japan and the U.S. is wellunderway with several successfulmajor customer trials completed andadditional trials planned. Recently,Honeywell announced plans to builda commercial 1234ze(E) commercialmanufacturing plant at Baton Rouge,Louisiana, USA – the plant is expectto be in operation in 2013.With respect to U.S. commercializationof 1234ze(E), the EnvironmentalProtection Agency’s SNAP officehas added 1234ze(E) to the list ofacceptable substitutes for ozonedepletingsubstances in certain foam,refrigerant, aerosol, and sterilant gasapplications. That notice appearedin the Federal Register/Vol. 74/No.188 on Wednesday, September 30,2009 (p. 50132) and Federal Register/Vol.75/No.115 on Wednesday, June16, 2010 (p. 34039 ff). 1234ze(E) PMN(Pre Manufacturing Notification) hasbeen approved by the U.S. EPA.In the EU, Solstice LBA is in theREACH Registration process, and hasbeen approved for commercial salesin Japan under the Japan ChemicalSubstances Control Law. In the U.S.,Honeywell has completed SolsticeLBA SNAP and PMN filings and theU.S. EPA is currently reviewing thesefilings. Solstice LBA developmentis significantly underway, withmajor successful customer trialscompleted or underway in all majorapplications.ConclusionsAn optimized Solstice LBAformulation has demonstrated a4% system level energy efficiencyimprovement in householdrefrigerator/freezers compared toHFC-245fa baseline, exceeds thecurrent DOE Energy Star label by 9.5%.Solstice LBA, in this commercialhousehold refrigerator/freezerplatform exceeded the proposedDOE 2014 energy standard.As with all new materials, prior toadoption, the industry requires anunderstanding of factors beyond theinitial polyurethane performancecharacterization. These analysesinclude quality measures such asdimensional stability and adhesionto liner and exterior case. In allancillary assessment related to ahousehold refrigerator/freezer, metor exceeded all requirements.Solstice LBA regulatory approvalsare in process in major markets,encompassing excellent propertiesof ultra low GWP (GWP

PUToday30 p o l y u r e t h a n e s t o d a yS e p t e m b e r 2 0 1 1

Technical ArticlePUTodayflammability, and anticipated to benon-VOC Commercial manufactureof Solstice LBA is estimated by late2012.With the global attentionto climate change, andpotential restrictionson the use of high GWPblowing agents andrefrigerant gases in thevarious regions of theworld, Honeywell andWhirlpool have validatedthe energy efficiency ofSolstice LBA low GWPblowing agent in thecontext of a second NorthAmerican design platform[623 liter (22 ft³)].With the global attention to climatechange, and potential restrictions onthe use of high GWP blowing agentsand refrigerant gases in the variousregions of the world, Honeywelland Whirlpool have validated theenergy efficiency of Solstice LBAlow GWP blowing agent in thecontext of a second North Americandesign platform [623 liter (22 ft³)].Further, this work demonstratedimproved energy efficiency to theinitial design platform [710 liter(25 ft³)] through the use of BayerMaterialScience optimized SolsticeLBA PUR system. This highly energyefficient household refrigerator/freezer utilizing an ultra low globalwarming potential (GWP < 7) blowingagent was demonstrated to meetthe requirements of ‘proposed’DOE 2014 energy standard withoutemployment of further energysolutions to this refrigerator/freezerplatform, such as vacuum insulationpanels or compressor modification.Honeywell’s intent is continuedcommercialization of lowenvironmental impact solutionsfor the appliance industry, as wellas other industries requiring highperformance, cost effective energysolutions.AknowledgementsHoneywell acknowledges thesignificant contributions by theWhirlpool Corporation for theircollaboration in providing themanufacturing site and refrigerators,as well as the Bayer MaterialScience,LLC in providing the polyurethaneformulation utilizing Solstice LBA.Referencesv. James M. Bowman, David J.Williams, and Samuel F. YanaMotta: “Low Climate Change ImpactSolution: Household Refrigerators/Freezers”, CPI Proceedings 20102. James M. Bowman and PaulSanders. “ A Novel, EnvironmentallySustainable Blowing Agent”, UtechMarch 20093. James M. Bowman and DavidJ. Williams. “ HFO-1234ze(E)Commercial Status and LGWPAdvancements”, CPI Proceedings20094. J. M. Bowman and S. F. YanaMotta. “Advances in EnvironmentallySustainable Blowing Agents andRefrigerants”. EEDAL Proceedings2009BiographiesJ. M. Bowman, P.E.Jim holds a B.S. degree in ChemicalHoneywell’s intentis continuedcommercialization of lowenvironmental impactsolutions for the applianceindustry, as well as otherindustries requiringhigh performance, costeffective energy solutions.Engineering from Iowa StateUniversity, Ames, IA, a M.Eng. degreefrom McNeese State University, LakeCharles, LA, a MBA from NorthernIllinois University, DeKalb, IL, and isa registered professional engineerin the State of Louisiana. Jim joinedAllied Corporation (AlliedSignal, nowHoneywell) in 1984 and has workedin sales, marketing, commercialdevelopment, and technical servicecapacities. He is currently a seniorprincipal engineer in Honeywell’sBlowing Agent Technical Serviceand Development Group withprimary responsibility for applianceindustry applications of fluorocarbonproducts.Yordani SinagaYordani holds a B.S degree inChemical Engineering from theIndonesia Institute of Technology,Indonesia and a M.S degree inManufacturing and IndustrialTechnology from Western IllinoisUniversity, Macomb, IL. Yordanijoined Maytag, now Whirlpool in1998, and is currently a SeniorEngineer in Materials Technologygroup for Whirlpool Corporation,where he has been actively involvedin product and developmentof polyurethane insulation forhousehold refrigerators.S e p t e m b e r 2 0 1 1p o l y u r e t h a n e s t o d a y31

PUTodayIPUA VenturesIndian Polyurethane AssociationA Report Of The Annual General Body Meeting – 2010-11Venue: Silver Oak 2, IndiaHabitat Centre, LodiRoad, New Delhi.Date: 23rd September2011Time: 1515 Hrs.Attendance: 50 Ipua MembersPresent.Welcome By Chairman. TheChairman Mr Rahul Gautam reviewedthe Indian Scenario and likelyprospect for our Industry and alsoreviewed and informed membersof the Associations Activities andplans.1. Mr Deepak Mehta Tirupati Foam, Ahmedabad2. Mr M G Bohara Amul Polycure, Chennai3. Mr R T Bhargava GNFC, Bharuch4. Mr.Jagannath iSarangapan U Foam, Hyderabad5. Mr.Rabindra Jhajharia Multiwyn Foams, Kolkata6. Mr Vinod Vora Aromatic Agencies, Mumbai7. Mr Sanjay Sanghi Momentive Performance, Mumbai8. Mr Gian C Jain Panama Poly Products , Delhi9. Mr H S Kochar Pfeda Synthetics, Noida10. Mr G Anand Huntsman Polyurethanes11. Mr Mukesh Bhuta Expanded Polymer Systems, Mumbai12. Mr Mandar Joshi BASF , Mumbai13. Mr Rahul Gautam Sheela Foams14. Mr Ashwini K Sehgal Saan Global, NoidaSecretary General’s Report 2010-11. The Secretary General submittedthe report – attached herewith. Itwas proposed to be adopted by Mr RJhajharia and seconded by Mr SanjaySanghi and adopted unanimously.Treasurers Report 2010-11. TheTreasurer submitted the auditedannual report and balance sheet(attached) for discussion andadoption. He answered queriesraised by the members. The motionto adopt and approve the same wasproposed by Mr Deepak Mehta,seconded by Mr Romesh Madan andadopted unanimously.Election 2011: The Secretary Generalinformed the members of the electionto the Executive Committee for theperiod 2011-13.The Returning Officer informed themembers that on completion of theprocess the following candidates hadfiled their nominations and that thesewere scrutinized and found in order.The candidates are as below:-Since there were 14 positions and 14candidates – the above candidateswere declared elected to the ExecutiveCommittee of the IPUA for the period2011-13. This was ratified by theAGM.The AGM concluded with fellowshipand high tea.Subsequently the 14 elected membersdecided to co-opt 6 members as perthe rules and regulations of theIPUA.The 6 members co-opted were1. Dr. G Mahesh2. Mr. Rohit Relan3. Mr. Ajay Durrani4. Mr. Ravi Muthukrishnan5. Mr. Romesh Madan6. Mr. Pranaya PradhanThe 20 members then elected thefollowing office bearersMR. Rahul Gautam – ChairmanMr. Mukesh Bhuta – Vice ChairmanDr. G Mahesh – Vice ChairmanMr. G C Jain – TreasurerIt was further decided to requestMr. G Ramachandran to be theSPECIAL ADVISOR TO IPUA andpermanent invitee to the Ex Com.Mr. Samir Arora to be a SPECIALINVITEE for all Ex Com Meetings andassist in the HPMP Program.The new Executive Committee thendrew up the action plan and thrustareas for the coming years.It was identified that Insulationand Education (Meeting Manpowerrequirements of the Industry) werethe core thrust areas and a detailedaction plan is being drawn up forthese activities.K.RamamurthySecretary General32 p o l y u r e t h a n e s t o d a yS e p t e m b e r 2 0 1 1

IPUA VenturesPUToday17th International Day for the Preservationof the Ozone LayerAddress by Shri Rahul Gautam, Chairman, Indian Polyurethane AssociationHon’ble Minister, Smt. JayanthiNatarajan ji,Dr. T. Chatterjee,Shri J. M. Mauskar,Dr. B.P. Nilratana,And of course Dr. A. Duraisamy,Representatives of Industry, Ladies& Gentlemen & Members of thePresss,On this august occasion of the“17th International Day for thePreservation of the Ozone Layer”,it is my privilege to be among thisdistinguished gathering along withthe “Future of India” – the youngchildren. Greetings to you all.The celebrations today would surelyhelp us to refocus our attention andaction on this very important issue ofthe protection of the Ozone Layer. Iam indeed thankful for being invitedto as the Chairman of IPUA to sharethe thoughts of the industry.We all know what the Ozone layerin the atmosphere is and how itprotects us from Sun-burns, Eyediseases, Low immunity etc. If itdepletes, we all become vulnerableto excessive UV radiation. Foodproduction goes down and marinelife is threatened. In fact the wholeweb of life is endangered. Obviouslyall of us strongly desire it to bemaintained. However there are somesubstances which deplete it andI must confess that our industry– The Polyurethane Industry wasalso using some chemicals whichreduced this atmospheric layer. Aswe all know the atmosphere doesnot have any national boundaries,so all the countries, both developedand developing had to work together- and that they did to evolve theMontreal Protocol in 1987. India alsobecame a signatory to it in 1992.The Indian Government through theMinistry of Environment & Forestsgave this special responsibility to the“OZONE CELL”.Our Association interacts regularlywith the “OC” and let me say itwith confidence and with deepsatisfaction that the OC has donean absolutely outstanding job. Ithas exceeded its targets of bothadvancing completion dates andgoing beyond its call of duty to helpand support neighbouring countries.Both the “OC” and Dr. Duraisamyhave been very often conferred withawards by the international fora fortheir achievements. Let’s hav a biground of applause for them.The India Polyurethane Industry isrepresented by IPUA . The membersform a very wide base right fromthe raw material suppliers to theprocessors and then the actualusers. We recognize that to supportthe good work of the Ozone Cell,some corrective steps have to betaken. Technologies need to changeand chemicals used need to change.Let me assure all of you that theIndustry is committed to phasingout all substances which are notenvironmentally friendly.. We haveconducted awareness programs andare now ready to usher in the newtechnologies and substances.Many years back, we used CFC-11–commonly known as Freon,which was successfully phased outby a transition material - HCFC. HCFCmay have a low ODP but is high onGWP. Our industry recognizes thenon-sustainability of HCFC. To us,sustainable development shouldmeet the needs of today withoutcompromising the ability of futuregenerations to meet their own needs.Hence the process of phasing out ofHCFC has already begun and on behalfIndian Polyurethane Association, Iassure you that all targets will bemet, if not exceeded.Today we celebrate the “Ozone Day”.This provides us an opportunity torenew our commitment for a betterenvironment for the entire world. Iam delighted to note that the MOEFin cooperation with the UN is pushinghard in implementing this year’sobjectives. I also appreciate that theindustry participation is very vibrantand continues to play an importantrole in a sustainable developmentof India.Allow me to conclude by wishingthe MOEF every success in its nobleendeavours towards making ourMother Earth a better place to livein now and in the future.Thank youS e p t e m b e r 2 0 1 1p o l y u r e t h a n e s t o d a y33

PUTodayIPUA VenturesSecretary’s Report 2010 – 2011Dear Members,It gives me great pleasure to submitbefore you my report for thefinancial year – 2010-11.At the outset, I would like to expressmy sincere thanks to all the Chairman,Vice Chairman, Treasurer, ExecutiveCommittee Members, and Membersfor all the assistance and guidancegiven to me during the year.PU TECH 2011A detailed report of the event hasappeared in our newsmagazinePOLYURETHANES TODAY – June 2011issue. This event exceeded all theexpectations of all the Exhibitors,Speakers, Dignitaries and has becomean event that the entire PU GlobalFraternity looks forward to. The GalaEvening appears to be the right topupfor the event..Our sincere thanks to all theExhibitors, Sponsorers, ConferenceFaculty and all Visitors in makingthis event a grand success from allview points.PublicationsOur quarterly newsmagazinePOLYURETHANES TODAY continues tobe a comprehensive communicationand information tool for all of usand is also gaining internationalrecognition. Our Thanks to theEditorial team headed by MsMedha Bhuta We wish to thank theadvertisers for their support. Thanksare also due to Red Sky Designs andMs Citiprint for their assistance inthis regard.I would again request all membersto avail of this oppurtunity toadvertise in the magazine and getmaximum coverage in the Indian PUindustry. Technical contributions andsponsored articles are also invited forpublication.WebsiteOur website is gaining increasingpopularity and we have had around1500 clicks this year.. The enquiriesgenerated on the website have beenpassed on to the concerned membersduring the year. Since this mediumof communication is fast givingpopularity, I would request membersto advertise in this, so that theirproducts get worldwide attention. Iwould also like to place on record theprompt response and services of ourwebhoster Ms Cherrytec Solutions.MembershipWe have enrolled around 40 newmembers this year and the totalmembership now stands at 245. Ofthe 245 members – 3 are life membersand 71 A Category Members. Therehave been about 40 drop outs duringthe current year – the total numberof dropouts has now reached analarming figure of 100 - and I wouldrequest your cooperation to seethat dropouts are minimized andthe membership drive taken up sothat we cover the entire Indian Puindustry.CIIWe continued to be associatemembers of the CII. Our ExecutiveCommittee Members are attendingthe ASCON – CII meetings andparticipating in the deliberations.We have also furnished data requiredby CII.Ozone Cell: HPMP ProgramThanks to the pioneering efforts ofour Vice Chairman Mr Mukesh Bhuta –we are now a recognized integral partof the HPMP Program for HCFC Phaseout in our sector. We have conductedthree awareness workshops and haveparticipated in their meeting as wellas the INDO-US Joint meeting. OurChairman Mr Rahul Gautam recentlydelivered the keynote address on theOzone day with the Hon Minister ofEnvirnonment present.We are actively working out a roadmap for implementation of the GOICommitment and Mr Mukesh Bhutawill apprise you of further details.We would like to express our sincerethanks to all members of the IPUA/HPMP Committee for their untiringefforts in generating/collating datafor presentation to the Ozone Celland UNDP.A sponsored program on new blowingagents by Ms Honeywell is slated forthis year.VAT IMPLEMENTATION ON PU FOAMPRODUCTSWe have made several representationsto the Government of India and thevarious State Governments regarding34 p o l y u r e t h a n e s t o d a yS e p t e m b e r 2 0 1 1

IPUA VenturesPUTodaythe VAT sales tax and have beensuccessful in bringing the VAT rate toon Pu foam to 4% in several states. Thismatter is being vigorously pursued inthe balance states and all membersare requested to cooperate so thatwe can get an uniform equitablerate across the country which willencourage growth further.Manpower Requirements OfThe IndustryMembers will recall that we hadconducted brief two day orientationprograms to enhance skill of theoperating personnel. This programcould not be conducted this yeardue to preoccupation with PUTECH2011.We are also trying to work withthe National Skills DevelopmentCorporation and GNFC to evolvetraining programmes so that skilledmanpower needs of the industryare met.Energy ConservationAs you are all aware, PU plays animportant part in energy conservationand green buildings. To carry thismessage further – your Associationintends to conduct two half dayprograms in Delhi and Chennai tohighlight this aspect in collaborationwith the Bureau of Energy Efficiency.This is one area we all need to workupon unitedly since this promisesimmense potential and also servesnational interest.CPI / PUCHINAThe Secretary attended these eventson your behalf. You will be gladto note that your Association hasgained international recognition. Iwould like to thank the Chairman,PU plays an importantpart in energyconservation and greenbuildings. To carry thismessage further – yourAssociation intends toconduct two half dayprograms in Delhi andChennai to highlight thisaspect in collaborationwith the Bureau ofEnergy Efficiency. This isone area we all need towork upon unitedly sincethis promises immensepotential and also servesnational interest.Vice Chairmen and Treasurer for theiruntiring efforts in this regard.Global Working GroupYou will also be glad to note that aGlobal Working Group consisting ofrepresentatives from the CPI, ISOPA,Korea Pu Society, Thai Pu Society,China Pu Industries Association,Japan Polyurethane and yourAssociation has been formed tointeract and exchange notes onaspects of Safety, Environment andProduct Development, We have had ameeting in New Delhi during PUTECH2011 and are planning the next oneduring UTECH Europe next March.Members views on the activity planat these meetings is requested.CondolencesDuring the year under review, twoof our members Mr Bhushan Jain (ofEnkay Foam) and Mr N C Garg (CrystalFoam) passed away. Our Heartfeltcondolences to the family and teammembers of both these members.The undersigned has also beenregularly attending meetings ofthe Plastics Export PromotionCouncil, Indian Plastics Institute,CIPET, etc., so that the presence ofour Association gets establishedin trade / government circles. Weare planning to strengthen all theactivities mentioned above and alsoadd on new activities as per yoursuggestions. Your continued supportand guidance is a must to make asuccess of the activities and theseare required on a daily continuousbasis.I would like to once again expressmy sincere thanks to the Chairman,Vice Chairmen, Treasurer and allthe Executive Committee Membersfor the continued guidance theyhave given me in the past year. Inaddition to the above my specialthanks to Ms. Lalitha (Sheela Foam),and Mr. Mangal Chand, (Panama PolyProducts)for all the assistance givenduring the year.The strength of any Association liesin its members – we need your activeparticipation and guidance – pleasedo not hesitate to contact me or anyof the Ex Com Members.I wish that all of youAchieve & Exceed Your GrowthAspirations with Green InspirationsWith Best Personal Regards,K.RamamurthyS e p t e m b e r 2 0 1 1p o l y u r e t h a n e s t o d a y35

PUToday36 p o l y u r e t h a n e s t o d a yS e p t e m b e r 2 0 1 1

PUTodayBooks & PeriodicalsThe Chinese market for thermalinsulation productsIAL Consultants has recentlypublished a new, fully updatededition of its report entitledThe Chinese Market for ThermalInsulation.With the enforcement of energysavingpolicies in China, a boomingstandards and measures.• There are about 40 billion squaremeters of buildings in China currently,of which 75% to 80% are high energyconsuming buildings. The Chinesegovernment focused on transforming165 million square meters of existingChinese Market for Thermal Insulation2010 (133,239,000 M 3 )will provide significant opportunitiesfor the thermal insulation materialindustry over the next five years.• Improvement in incomes and livingstandards will further boost demandfor thermal insulation, as heating andair conditioning in homes becomemore popular.The Chinese Market for ThermalInsulation is available to purchasein one comprehensive volume andincludes both data for 2010 andforecasts to 2015 for the followingproduct categories:Source: IAL Consultantseconomy and fast-growingconstruction sector, the market forthermal insulation materials in Chinahas remained buoyant despite theglobal economic recession. In 2010,total Chinese demand for thermalinsulation reached some 133 millionm³, equivalent to approximately 4million tonnes and valued at RMB65 billion.• By 2020 the Chinese governmentis determined to reduce its energyconsumption by 50% from that of2005, which will provide a significantboost for the growth in thermalinsulation material demand inChina.• To achieve the energy saving targets,the government has implemented aseries of compulsory energy savingbuildings in the 11th Five Year planperiod (2006-2010), and will continueto reinforce the transformation ofthe remaining buildings into energyefficient buildings.• Commercial and public buildingswill be the focus in the 12th FiveYear Plan period (2011-2015); this• Mineral Fibre: Glasswool& Stonewool• Expanded Polystyrene (EPS)• Extruded Polystyrene (XPS)• Polyurethane Foam• Phenolic FoamMarket data split by region andby end-use application is alsoprovided.For more information or a brochureon this study, please visit www.ialconsultants.comEnd-use Sector 2010 (m³) 2015 (m³) (% Growth pa)Domestic & Commercial Building 67,217,100 119,617,800 12.2Cold Stores 3,948,600 7,130,500 12.5Agricultural Storage 1,991,100 3,277,700 10.5Total Building 73,156,800 130,026,000 12.2Pipe Lagging 9,465,700 21,224,000 17.5Domestic Appliances 13,812,000 22,244,000 10.0Transport 9,743,800 17,332,000 12.2Process Plant 27,060,700 40,466,500 8.4Total Industry 60,082,200 101,266,500 11.0Grand Total 133,239,000 231,292,500 11.738 p o l y u r e t h a n e s t o d a yS e p t e m b e r 2 0 1 1

Books & PeriodicalsPUTodayA Global overview of the thermoplasticPolyurethane (TPU) marketIAL Consultants has recently published the third edition of its report titled Global Overview ofthe Thermoplastic Polyurethane Market.Despite accounting for less than5% of the total production ofpolyurethane products, TPUs representone of the fastest growing and mosthighly versatile parts of the industry.TPUs are supplied as a fully reactedmaterial that is processed in twomain ways (injection and extrusion) tomanufacture a huge range of productsfor many industries.The TPU industry is highly fragmentedindustry and it is a relatively mature inthe Western hemisphere while stronggrowth prospects remain in SouthEast Asia.Asia is the largest TPU market inthe world. The production is mainlyconcentrated in China and Taiwan,where there are approximately 30major manufacturers. The Asianregion leads the global TPU with225,610 tonnes produced in 2010,thereby accounting for almost 60%of the world demand of 378,550tonnes.Source: IAL ConsultantsGlobal production of TPU is expectedto increase by 5.6% per year between2010 and 2015. The largest increasewill be seen in Asia with 7.9% growthpa.The versatility of TPUs continues todrive investment in their developmentand commercialisation around theworld. The growth of the Asian marketand cheaper manufacturing costs hasresulted in many Western companiesincreasing theirpresence in the Asian continent,especially mainland China. Thistrend is expected to continue inthe future, with more footwear andengineering operations moving tolower labour costs countries such asThailand and Vietnam. The majoruse of elastomeric fibres in all typesof clothing, footwear, and especiallyin the area of sportswear, means thatTPU applications will move more intohigher value-added areas.Global TPU Production by Region, 2010(%)There is an increasing global interestin bio TPUs. In 2009 Spanish companyMerquinsa launched PearlthaneEco, a plant derived and recyclableTPU made from renewable carbonresources and successfully marketedworldwide. The company serves allmajor TPU markets, but its mainactivity is in the adhesives market(principally used in the footwearindustry), where it claims to holdover 45% of the global market for TPUprimers. Accounting for nearly 20% ofglobal market share, Bayer MaterialScience (BMS) is the leading producerof thermoplastics polyurethanes andtechnical films made from TPU.Following the EU REACH regulationsand the WEEE Directive (WasteElectronic Electric Equipments),recyclability is becoming the keywithin the plastics industry. Across allmarkets many of the TPE applicationshave been developed throughconversion from traditional rubbermaterials. This is because TPEs offerimproved recyclability and theyoften present more options in termsof parts integration, manufacturingcost reduction, colour and designdifferentiation. This has a particularimpact on the automotive andelectronic sectors.On the consumption side, TPUsrepresent a relatively maturemarket and continue to face strongcompetition from other thermoplasticelastomers, especially thermoplasticolefins (TPOs) in film and sheet use.The main advantage that otherS e p t e m b e r 2 0 1 1p o l y u r e t h a n e s t o d a y39

PUToday40 p o l y u r e t h a n e s t o d a yS e p t e m b e r 2 0 1 1

Books & PeriodicalsPUTodaythermoplastic elastomers have overTPU is their more competitive price.Therefore TPUs are often used inspecial applications where theyoutperform any other material.In Asia-Pacific, demand is dominatedby the sports and leisure segments,reflecting the extent to whichproduction for sporting goods (i.e.soles for soccer shoes) and leisurewear has almost entirely movedto this region. It is estimated thatvolume growth is approximately 8%per year in Asia-Pacific, significantlyhigher than the 1.7% growth ratesanticipated in the Americas and 2.4%in EMEA.China’s market is growing at almost10% per year because it still deliversseveral TPU grades to customersacross the Asia-Pacific region, whereasother emerging markets, such asMalaysia and Vietnam, are enhancingtheir domestic production.In Europe, the Russian automotiveindustry is emerging as one of themost competitive and dynamic inthe world. Government initiativesand incentives are filliping theSource: IAL ConsultantsAs a result of some Asianeconomies benefitingfrom the transfer ofmanufacturing operationsfrom more matureeconomies, growth inthe Asian TPU market isplaced at 8.2% pa, dueto the booming housingmarket and the largestfootwear industry in theindustry and attracting the foreignplayers, with new opportunitiesfor TPU. On the other hand, thedecline of the automotive sectorduring the recession in both Easternand Western Europe has put morepressure on those governments thathave tried to help their automakersas the economic crisis continues tohurt the region’s motor industry.Global TPU Consumption by End Use 2010(%)world.The global demand for TPUis expected to increase by 5.9%annually until 2015; however growthforecasts for the global TPU varyconsiderably depending on theregion. Projected growth for theEMEA markets is placed at about 2.5%per annum over the period 2010-2015 whereas in the Americas this isseen at around 1.9% pa. NeverthlessSouth American economies remainbuoyant, especially Brazil, whereconsumer demand is growing fastand much hope rests upon theFootball World Cup in 2014 and theOlympic Games in Rio de Janeiro in2016.In both of these regions a furthercontraction of the footwear sector isforeseen, while the automotive sectoris expected to grow steadily.As a result of some Asian economiesbenefiting from the transfer ofmanufacturing operations frommore mature economies, growthin the Asian TPU market is placedat 8.2% pa, due to the boominghousing market and the largestfootwear industry in the world. PVC,rubber and metal replacement arecontinuing to boost the market andthis is expected to continue in thefuture.Overall demand has been driven bythe partial recovery in the automotiveand insulation material industries.After three quarters of growth in2010, the outlook for 2011 is one ofstabilisation. We should see furthergrowth this year but not as muchas in 2010, when a knock-on effectoccurred after the global economicdown-turn.For more information about thereport please contact Cathy Galbraithat cgalbraith@brggroup.comS e p t e m b e r 2 0 1 1p o l y u r e t h a n e s t o d a y41

PUTodayEvents & TrendsEvents CalendarINTERNATIONAL25 - 29 Oct 2011IPF Japan 2011International Plastic FairAssociationTokyo01 - 02 Nov 2011Polyurethanes: An Introduction– Science, ApplicationsSmithersShrewsbury, UK02 - 03 Nov 2011PFA General Business Meetingand Technical ProgramPolyurethane Foam AssociationPhoenix, Arizona, Usa16 Nov 2011Polyurethane CoatingVincentz Network GmbH & Co.KGAmsterdam17 - 20 Nov 2011Putech Eurasiartkim Fuarcilik Tic. Ltd.Istanbul29 Nov - 01 Dec 2011Fire Resistance in Plastics 2011Applied Market Information LtdCologne06 - 07 Dec 2011Polymers for ImplantableMedical DevicesSmithersDublin01- 06 Feb 2012Plastindia 2012Plastindia FoundationNew Delhi21 - 22 Mar 2012Plastics In AutomotiveEngineering 2012Vdi Wissensforum GmbhMannheimOrlando26 - 29 Mar 2012Polyurea DevelopmentAssociation Annual ConferencePda Polyurea DevelopmentAssociation15 -17 Apr 2012Adhesive And Sealant Council2012 Spring ConventionThe Adhesive And SealantCouncil, Inc.Denver17 - 18 Apr 2012Utech Europe 2012Crain Communications LtdMaastricht18 - 21 Apr 2012Chinaplas 2012Adsale Exhibition Services LtdShanghai07 - 10 May 2012American Coatings Show AndConferenceVincentz Network Gmbh & Co.KgIndianapolis08 - 12 May 2012Plast 2012Fiera Milano InternationalMilan14- 17 May 2012Plastvision Arabia 2012Expo Centre SharjahSharjah16 - 23 Oct 2013K 2013Messe Düsseldorf GmbHDUSSELDORF42 p o l y u r e t h a n e s t o d a yS e p t e m b e r 2 0 1 1

PUTodayS e p t e m b e r 2 0 1 1p o l y u r e t h a n e s t o d a y43

PUToday44 p o l y u r e t h a n e s t o d a yS e p t e m b e r 2 0 1 1FOR PRIVATE CIRCULATION ONLY. Edited by Ms Medha Bhuta Published by K. Ramamurthy for Indian Polyurethane AssociationPrinted by citiprints | 94449 42151 | www.citiprints.com