Total polymer consumption in automobile sector in pune region appl industries pune by mrinal khajuria marketing

A Project Report On Total Consumption Of Polymer In Automobile Sector In Pune Region With Special Reference To APPL.. CERTIFICATE OF SUMMER TRAINING COMPLETION This is to certify that

A Project Report

On

Total Consumption Of Polymer In Automobile Sector In Pune

Region

With Special Reference To

APPL Industries Limited, Pune

Submitted To Vishwakarma Institute Of Management, Pune

In Partial Fulfillment Of The Requirement For The Award Of Degree Of

Master Of Business Administration

By Mrinal Khajuria (2004-06)

Under The Guidance Of

Mr Yuvraj Lahoti

(Professor, VIM)

CERTIFICATE OF SUMMER TRAINING COMPLETION

This is to certify that Project Report titled Total Consumption Of Polymer in Automobile

Sector In Pune Region has been completed satisfactorily in partial fulfillment of Master Of

Business Administration course for the academic year 2004-2006 by Mrinal Khajuria, Student of Vishwakarma institute of management pune-37

Place: Pune Director,

3

This is to certify that Mr Mrinal Khajuria student of Master of business administration course

with specialization in Marketing, for the session August 2004- July 2006 prepared project report

entitled Total Consumption Of Polymer in Automobile Sector In Pune Region at Aalekh

I wish him all success in life

Prof Yuvraj lahoti (Marketing)

I take the occasion to thank Aalekh polymers private Limited for giving me the opportunity to work on this project, which has immensely helped in gaining & developing my knowledge & experience I would like to thank my institute VIM as well as Director sir Dr Sharad L Joshi to provide me such a wonderful opportunity

I especially thank my project guide Mr.Yuvraj Lahoti (professor, VIM) for his valuable guidance, co-operation & encouragement throughout the project

I am also Grateful to Mr.Arun Sharma (senior head marketing) and Mr.Inder Jain (CEO) for providing their valuable thoughts and inputs throughout the project & kindly accepting the suggestions & recommendations given by me

I am very thankful to god as well as my family who really helped me during the project work without there ally and support it its not possible to study here in a very pleasant atmosphere

Lastly I would like to specially thank the subordinates & their superiors for their co-operation and also would like to thank to all the respondents of the survey, members of the faculty & all my other fellow summer trainees for their co-operation & co-ordination in the project along with me

Place-Pune

Mrinal Khajuria

3) What are the prices at which injection moulding companies are buying raw materials from other manufacturers

4) To know the availability of substitutes and grade of polymers in Pune region 5) To find out the awareness of the product in the market

6) To know the strengths and weaknesses of the companies 7) To know various parameters whatever the business rivals of APPl are following:

1) There is no problem in the availability

2) Its trends do not vary

3) It is cheaper then metal

4) Properties are more or less same as of metals

5) The weight is lesser then metals which helps in increasing average of the vehicle

Recommendations: -

The company should increase sales The company should try to reduce the cost of production Growth opportunities in public transport and commercial sectors Material handling

Sourcing of materials Proper inputs from customer Trend analysis

Limitation of the study: -

Sometimes consumers are not aware of the new product

Due to limited sample representation population may not be that much accurate

I, here by declare that this project report entitle Total polymer Consumption In Automobile

Sector with special reference to APPL Industries Limited Pune, Which is the outcome of the

summer training undergone by me from 15 th June 2005 to 30 th July 2005 The empirical finding

of the study is entirely based on the data collected by myself

9

INTRODUCTION

History and significance of polymers

Plastics are polymers What is a polymer? The simplest definition of a polymer is something made of many units Think of a polymer as a chain Each link of the chain is the "mer" or basic unit that is made of carbon, hydrogen, oxygen, and/or silicon To make the chain, many links or

"mers" are hooked or polymerized together Polymerization can be demonstrated by linking strips

of construction paper together to make paper garlands or hooking together hundreds of paper clips

to form chains

Polymers have been with us since the beginning of time Natural polymers include such things as tar and shellac, tortoise shell and horns, as well as tree saps that produce amber and latex These polymers were processed with heat and pressure into useful articles like hair ornaments and jewelry Natural polymers began to be chemically modified during the 1800s to produce many materials The most famous of these were vulcanized rubber, gun cotton, and celluloid The first synthetic polymer produced was Bakelite in 1909 and was soon followed by the first semi- synthetic fiber, rayon, which was developed in 1911

Even with these developments, it was not until World War II that significant changes took place

in the polymer industry Prior to World War II, natural substances were generally available; therefore, synthetics that were being developed were not a necessity Once the world went to war, our natural sources of latex, wool, silk, and other materials were cut off, making the use of synthetics critical During this time period, we saw the use of nylon, acrylic, neoprene, SBR, polyethylene, and many more polymers take the place of natural materials that were no longer available Since then, the polymer industry has continued to grow and has evolved into one of the fastest growing industries in the U.S and in the world

Every polymer has very distinct characteristics but most polymers have the following general attributes

1 Polymers can be very resistant to chemicals

2 Polymers can be both thermal and electrical insulators

3 Generally, polymers are very light in mass with varying degrees of strength

4 Polymers can be processed in various ways to produce thin fibers or very intricate parts

As a leading manufacturer of engineered thermoplastic compounds having largest capacity in India with multilocational compounding base, thus providing the complete solutions for Automotive and Appliances Industries

Research and Development

Manufacturing is fully supported by a team of dedicated Research and Development officers A laboratory scale Extruder very similar to the production machines has been installed in our R & D department This ensures that the scale up is smooth from R&D to production In house R&D also helps us to develop new materials in the shortest time period to meet our customer's new and exacting requirements R & D department is well dedicated to upgrade our material time to time

as per customer's requirements

Company Profile

About APPLAPPL Industries Limited, which has been formed by the merger of three groups of companies Aalekh Polymers (P) Limited, Aalekh Industries (P) Ltd., and Prateek Enterprises, is one of the leading compounder of engineered thermoplastics in India We have been providing material solutions to our customer for over 15 years Today, we offer precoloured compounds based on Polyolefin s and engineering plastics modified with minerals, glass fiber/beads, wood flour, flame retardants etc We also offer blends and alloys of various plastics, colour concentrates and additive master batches

Article I APPL Facilities

Production units at multiple sites - strategically located to meet customer's requirements

Latest fully Computer controlled state-of-the-art compounding systems from Germany, Japan offer Advanced Materials Technologies

International standard Quality Control Laboratory

APPL has established highly sophisticated Polymer Compounding units at IMT Manesar near Delhi and at Pune in Maharashtra with a total installed capacity of 30,000 MTA, and by the end of

2006, APPL will set up its third compounding unit at Hosur, Tamil Nadu with additional 10,000 MTA capacities

APPL PROCESS

Twin Screw Super Compounders Co-rotating and counter-rotating type Gravimetric Loss-in-Weight feeders from Brabender Technologies, K-Tron Automation of material handling

Our production equipment and its variety allow us to match each product to the right process, highest and consistent product quality in shortest lead-time

1990: - The Company was established at New Delhi to manufacture Color Concentrate

1995: -Manufacturing Plant dedicated for Black Masterbatch was set up at Rajasthan

1998: - Two compounding line from Japan were installed at Delhi for PPAM compounds

2001: - Two state-of-the-art compounding line from Theysohn Maschinenbau, Germany were installed at pune

2002: - Commissioned IMT - Manesar plant with two lines from Japan and two more Compounding Lines from Theysohn, Germany

2003: - Obtained ISO - 9001:2000 accreditation

2003: - Automated Feeding system was installed at IMT Manesar Plant

2004: - Appointed as consignment agent of Ciba Speciality chemicals for plastics additives for Eastern India

2005: - Accelerated Weather meter instrument was set up at Pune plant

2005: - Two state-of-the-art compounding lines from Coperion were installed at Pune and IMT Manesar plant

2005: - Two Research & Development purpose compounding lines from Coperion were installed

at Pune and IMT Manesar plant

2006: - One Counter Rotating Twin screw extruder from Japan was installed at Pune

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SEGMENT DESCRIPTION TRADE NAME

Advanced Polypropylene

Compounds APPCOM

Advanced Styrenic Compounds APPSTRON Advanced Colour

Masterbatches APPCOL

Engineered Plastics based on Commodity Resins

Speciality Additive Masterbatches APPLENE

Polycarbonate Compounds APPNATE

Alloys APPLOY PBT Compounds APPET

Engineered Plastics based on Advanced Plastic Resins

Nylon Compounds APPLON

Engineered Plastics based on Commodity Resins

A product may start with homopolymer, copolymer, TPO (rubber-modified alloys) The application may require UL recognition, special stabilizers for improved weatherability, and extra heat stabilizers for under the hood applications The type, particle size and amount of filler can be adjusted as per requirement for their aesthetics and mechanicals For improved impact, impact modifier can be incorporated We can provide pre-colored materials as well as natural colour materials A complete product listing, incorporating all would be too long to list

Our ABS and HIPS compounds have been developed specifically to meet the requirements of major customers These grades are the cost-effective answer for purchasers These grades are available as per customer-specific colours Our ABS compounds offer excellent processability, good heat resistance and show good balance between impact resistance and rigidity

APPL also offer SAN compounds, which have high heat resistance and chemical resistance It

has a wide range of applications in electrical/electronic parts, automotive parts, office consumables and so on

An engineered plastic based on commodity resins includes: -

ADVANCED POLYPROPYLENE COMPOUNDS: These compounds are used in

manufacturing bumpers, instrumental panel, door trims, speedometer housing, speedometer body cover, seat side balance, household items, case heater of air conditioner, automotive filters, refrigerator body parts, foot rest paddles etc

ADVANCED COLOUR MASTERBATCH GRADES: These resins are used in

manufacturing Cover Inner of Two Wheeler Sector, Washing Machine Body Part, Tray for Washing Machines, Hood Meter Cluster

ADVANCED ADDITIVE MASTERBATCH GRADES: These resins are used in

manufacturing Blown Film

ADVANCED STYRENIC COMPOUNDS: These resins are used in manufacturing

Washing Machine Body Parts, Hood Meter Cluster, UPS Body Parts, Blower for Conditioner, Two Wheeler Front Cover, Seat and Door Handle, UPS Housing

Engineered Plastics based on Advanced Plastic Resins

We at APPL are offering various grades of mineral filled, glass reinforced, fire retardant

polycarbonate compounds, and their alloys, compounds of PBT and nylon Our R & D department is constantly working in this wide spread Engineering Plastics field

Polycarbonate and its alloys e.g PC/ABS, PC/PBT, PS/ASA characterized by their unique balance of impact strength, heat resistance and high mechanical properties are the right choice for a multitude of applications including automobile, medical equipment, optical, electrical and electronics, home appliances and various other sectors

Polybutylene Terephthalate (PBT) resin with its combination of heat, chemical resistance, and outstanding electrical properties deliver unique design advantages with exceptionally good processability & surface appearance PBT compounds find application in electrical/electronic connectors, automotive components, telecommunication enclosures & so

on

Nylon is the most versatile plastics-easy to process; easy to modify to meet specific needs, environmentally responsible in production Due to their outstanding properties these materials have become indispensable in almost all fields of engineering for the wide variety of components and machine parts, as high-quality electrical insulating materials and for many special applications

Nylon grades are exceptional for their high mechanical strength, rigidity & thermal stability

Engineered Plastics based on Advanced Plastic Resins includes:

-POLYCARBONATE COMPOUNDS: These resins are used in manufacturing Head

Lamp Reflector, Door Handle, Electrical/Electronic Body Parts

ALLOYS: These resins are used in manufacturing Wheel Cover, Inverter Housing, Cub

Panel & Exterior Automotive Body Parts, Exterior Automotive Body Parts, Tail Light Housing

PBT COMPOUNDS: These resins are used in manufacturing Garnish, Louvers, CFL

Housing

NYLON COMPOUNDS: These resins are used in manufacturing Chain Cover, Heater

Cover, Handle Window Regulator, Roof Clip, Radiator Fan, Handle, Ash Tray

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OBJECTIVES OF THE STUDY

1 To know the total polymer consumption in the automobile sector

2 How many injection moulding companies are using polymers for automobile industry in Pune Region?

3 What are the prices at which injection moulding companies are buying raw materials from other manufacturers

4 To know the availability of substitutes and grade of polymers in Pune region

5 To find out the awareness of the product in the market

6 To know the strengths and weaknesses of the companies

One more important aspect is transportation related issues: - incidents like chemicals get contaminated during transportation process due to: -

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Research Methodology

RESEARCH APPROACH

a) In this research report survey method is used Survey is the method of gathering of primary data by asking the questions to the customers about their usage and requirements

a) Telephone b) Personal interviews c) E-mails

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NAME: Yuvraj Sadashiv Marath DESIGNATION: Owner

ORGANISATION: PLAST O MECH

Bharat Electronics

P B

T

PP + FILLER

HI

PS

PC AB

S

PC PB

PP + FILLER

HI PSPCABSPCPBTGPPS

PRODUCT NAME: Pulsar mud guard, Caliber mud guard

P B

T

PP + FILLER

HI

PS

PC AB

S

PC PB

PP + FILLER

HI PSPCABSPCPBTGPPSNY+ 30% GFACRYLICHDPE

From the above information we come to know that SPS plastics use 80% of polypropylene + filler

as compare to other polymers The company is using the polymers in manufacturing the products

like mudguards for two wheelers

NAME: Ashok G Chavan

ADDRESS: 5/4, Nagar Road, Pune - 14

P B

T

PP + FILLER

HI

PS

PC AB

S

PC PB

PP + FILLER

HI PSPCABSPCPBTGPPSNY+ 30% GFACRYLICHDPE