Exploring Future Projections with JSW

An Exclusive Interview with Mr. Vijay Mudgal – Managing Director, Prevision World india Pvt. Ltd. with Modern Plastics India (MPI) Magazine A Part of Modern Plastics Global Network

Prevision World JSW is renowned for its all-electric injection molding machines. Can you elaborate on what makes them stand out in the market?

JSW’s all-electric injection molding machines represent a paradigm shift in the industry. Unlike traditional hydraulic machines, which rely on oil for operation, our all-electric models utilize electric servo motors. This not only enhances precision and efficiency but also eliminates the need for hydraulic oil, making them more environmentally friendly and safer for operators.Above all JSW all electric machines are power saving machines as well.

That’s impressive. How does JSW cater to the diverse needs of customers with its range of all-electric machines?

Our product portfolio is designed to accommodate a wide spectrum of production requirements. From small-scale projects to large-scale manufacturing operations, we offer all-electric machines with varying tonnage capacities and capabilities. Whether our client s are producing intricate components or oversized parts, our machines deliver consistent performance and reliability across the board.

Could you provide insights into how JSW’s 4 Solutions for High Productivity are tailoredtoaddress theunique requirements and expectations of its readers in the manufacturing industry?

The incorporation of AD Strong Robust Design ensures that JSW’s injection molding machines are built to withstand rigorous production demands over an extended lifespan. This robust design not only minimizes the risk of machine failure but also reduces the frequency of maintenance interventions, thereby enhancing overall operational efficiency and productivity.

The implementation of AD Stable Ultimate Stability plays a crucial role in maintaining consistent performance and minimizing variations in production output. This stability ensures that manufacturers can achieve high quality molded products with precision and reliability, resulting in reduced scrap rates and improved overall efficiency.

JSW provides AD Support services aimed at reducing molding machine downtime. Through proactive maintenance schedules, prompt technical assistance, and readily available spare parts, JSW ensures that any potential disruptions to production are swiftly addressed, thereby maximizing uptime and productivity.

With our wide service network and Pan India presence, we stand high with our AD support. JSW’s commitment to AD Smart Stable Production through advanced technologies and intelligent control systems optimizes the production process for maximum efficiency and stability. By continuously monitoring and adjusting machine parameters in real-time, JSW’s machines can adapt to changing production conditions, minimize production fluctuations, and maximize throughput. JSW’s holistic approach to enhancing productivity through robust design, stability, proactive support, and smart production strategies has resulted in tangible benefits for manufacturer s , including increased throughput, reduced cycle times, and improved overall operational efficiency.JSW’s holistic approach to enhancing productivity through robust design, stability, proactive support, and smart production
strategies has resulted in tangible benefits for manufacturer s , including increased throughput, reduced cycle times, and improved overall operational efficiency.

How do the various products within JSW’s portfolio, such as injection molding machines and robotic solutions like Sigmax Robot Eye and Campetella Robotics, complement each other to offer comprehensive solutions for manufacturers in the plasticsindustry?

The integration of various products within JSW’s portfolio, including injection molding machines and robotic solutions like Sigmax Robot Eye and Campetella Robotics, creates a synergy that offers comprehensive solutions for manufacturers in the plastics industry.

JSW’s injection molding machines serve as the foundation of the manufacturing process, providing precision and efficiency in molding plastic components. These machines are optimized for various applications, ranging from small-scale production to ultra-large manufacturing operations, ensuring versatility and scalability to meet diverse production needs. In conjunction with injection molding machines, robotic solutions such as Sigmax Robot Eye and Campetella Robotics play a pivotal role in enhancing automation and efficiency throughout the production cycle. Sigmax Robot Eye offers advanced vision systems that enable precise part inspection, quality control, and seamless integration with injection molding machines, ensuring consistent product quality and minimizing defects.

On the other hand, Campetella Robotics provides robotic automation solutions tailored to the plastics industry, including robotic arms for material handling, assembly, and packaging tasks. These robots work seamlessly alongside injection molding machines, optimizing material flow, reducing cycle times , and increasing overall production throughput.

Furthermore, the synergy between injection molding machines and robotic solutions is enhanced by JSW’s focus on innovation and integration. By leveraging technologies such as IoT connectivity and data analytics, JSW enables seamless communication and coordination between different components of the manufacturing process. This integration facilitates real-time monitoring, predictive maintenance, and adaptive control, resulting in enhanced efficiency, reduced downtime, and improved overall productivity.

In summary, the combination of injection molding machines with robotic solutions like Sigmax Robot Eye and Campetella Robotics offers manufacturers in the plastics industry a comprehensive solution that optimizes production processes, enhances automation, and ensures consistent product quality. This integrated approach not only maximizes efficiency but also enables manufacturers to stay competitive in today’s dynamic market landscape.

In what ways does Prevision World foster a culture of continuous improvement and adaptability within its organization, particularly in the context of its “Keys to Development,” to ensure resilience and success in an ever-evolving business landscape?

Customer-Centric Approach: Prevision World fosters a culture of continuous improvement and adaptability by placing an unwavering commitment to the customer at the forefront of its operations. By actively seeking and incorporating customer feedback, the company identifies areas for improvement and adapts its products and services to better meet customer needs in an ever-evolving business landscape.

Prevision World maintains a strong focus on quality, reliability, and service excellence across all aspects of its operations. By consistently delivering high-quality products and services, the company builds trust and confidence with its customers, fostering long-term relationships and ensuring resilience in the face of market fluctuations.

Building Mutual Trust and Condence: Prevision World prioritizes building mutual trust and confidence with both customers and employees. By fostering a transparent and collaborative work environment based on mutual respect and integrity, the company encorage sope and communication , innovation, and continuous learning, driving adaptability and success in a dynamic business landscape.

Commitment to All-Round Excellence: Prevision World is committed to achieving all-round excellence in its operations, products, and services. By setting high standards for performance and continuously striving for improvement, the company creates a culture of excellence that permeates throughout the organization, ensuring adaptability and success in an ever-evolving business environment.

Culture of Innovation: Innovation is a core value at Prevision World, driving continuous improvement and adaptability within the organization. By encouraging creativity, experimentation, and the exploration of new ideas, the company fosters a culture of innovation that enables it to anticipate and respond effectively to changing market trends and customer preferences.

Prevision World fosters a culture of continuous improvement and adaptability by prioritzing customer satisfaction, maintaining a focus on quality, reliability, and service excellence, building mutual trust and confidence, striving for all-round excellence, and embracing a culture of innovation. These key principles ensure resilience and success in navigating the challenges of an ever evolving business landscape.

How does Prevision World collaborate with automobile manufacturers around the world to address their specific needs and challenges, particularly in terms of product development, quality assurance, and supply chain management?

Prevision World collaborates closely with automobile manufacturers worldwide to address their specific needs and challenges in product development, quality assurance, and supply chain management through tailored solutions and strategic partnerships.

Prevision World conducts comprehensive consultations with automobile manufacturers to understand their unique requirements and challenges. By actively listening to their concerns and priorities, Prevision World can develop customized solutions that align with their goals and objectives.

In terms of product development, Prevision World works hand in hand with automobile manufacturers to co-create innovative solutions tailored to their specific needs. This collaborative approach involves iterative design processes, prototyping, and testing to ensure that the final products meet the rigorous standards and performance requirements of the automotive industry.

Prevision World’s collaborative approach, tailored solutions, and strategic partnerships enable it to effectively address the specific needs and challenges of automobile manufacturers in product development, quality assurance, and supply chain management, ultimately driving mutual success and innovation in the automotive industry.

How does Prevision World’s vision for the future align with the evolving needs and expectations of its readers and the broader market landscape, and what strategies are beingimplementedtorealize this vision?

Prevision World’s vision for the future is intricately aligned with the evolving needs and expectations of its readers and the broader market landscape. The company envisions itself as a leading provider of cutting-edge solutions that empower individuals and organizations to navigate and thrive in an increasingly complex and dynamic world.

To align with this vision and cater to evolving needs, Prevision World continuously monitors market trends, technological advancements, and reader feedback. By staying attuned to shifting preferences and expectations, the company can adapt its strategies and offerings accordingly.

Prevision World recognizes the growing demand for personalized and accessible information. To address this, the company is investing in innovative content delivery mechanisms, such as mobile apps, interactive platforms, and personalized recommendations. These strategies ensurethatreaders canaccess relevantand engaging content tailored to their interests and preferences.

Moreover, Prevision World is committed to fostering a sense of community and collaboration among its readers. By facilitating discussions, forums, and networking opportunities, the company creates a dynamic ecosystem where individuals can exchange ideas, share experiences, and learn from one another. This approach not only enhances reader engagement but also fosters a culture of continuous learning and improvement.

In terms of broader market trends, Prevision World recognizes the growing importance of sustainability, diversity, and social responsibility. To address these concerns, the company is integrating sustainability principles into its operations, minimizing environmental impact, and promoting diversity and inclusion in its content and initiatives. By aligning with these values, Prevision World ensures that its vision resonates with the broader market landscape and remains relevant in an ever-changing world.

Prevision World’s vision for the future is grounded in a deep understanding of its customer’s needs and the broader market dynamics. Through strategic investments in community building, and sustainability initiatives, the company is actively working to realize its vision and maintain its position as a trusted source of knowledge and insight around the world.

www.previsionworld.com

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Efficiency Redefined: Rollepaal’s Innovation Boosts Productivity

An Exclusive Interview With Mr. Patrick Van Bezouw, Sales Director Rollepaal Pipe Extrusion Technology With Modern Plastics India (MPI) Magazine A Part of Modern Plastics Global Network

Could you provide an overview of Rollepaal and its position in the market of pipe extrusion technology?

Rollepaal has established itself as a trusted name in the pipe extrusion industry. We offer a broad range of solutions from standalone machines to complete plastic pipe extrusion lines. Our strategic partnerships, such as the one initiated in India with Sintex – part of the globally recognized Welspun World conglomerate, show our commitment to global reach and localized solutions.

We’ve seen companies in the manufacturing industryproviding40%ofthe exportmarket and growing significantly. Do you see a good future for this sector?

We see a very promising future for the sector. As for our own company, we are not just supplying goods in India, but also exporting from our facility in India and our Head Quarters in The Netherlands to all continents across the globe.

We’ve seen companies in the manufacturing industryproviding40%ofthe exportmarket and growing significantly. Do you see a good future for this sector?

We see a very promising future for the sector. As for our own company, we are not just supplying goods in India, but also exporting from our facility in India and our Head Quarters in The Netherlands to all continents across the globe.

How would you compare the market in Europe to the Indian market?

The market in India is accelerating much faster than in Europe. The European market, of course, is a very good market for us but quite stable, unlike India where everything is growing at a swift pace. It is a melting pot where everything is bubbling and evolving, clearly different than in Europe.

In what ways does Rollepaal stay ahead ofemerging trends and technologies in pipe extrusion?

We have an ever-evolving range of products and services aimed at meeting the varied needs of our customers, which helps us and our customers to stay ahead in the market. We are committed to exploring new digital offerings, developing the best material saving solutions such as PVC-O technology, our unique multilayer die heads, and more to stay on top of emerging trends in the industry.

We noticed that you use technology quite a lot. Can you share any special thoughts on new technology or products that you’re currently working on?

Of course, let me give a bit of a backdrop first. We have been on the market for 60 years, headquartered in the Netherlands but had our manufacturing unit operating in India since 2 0 0 3 . We lead this fi e ld by differentiating our products. Primarily, our solutions are focused on material-saving options for pressure and non-pressure pipes. This helps our customers save on materials and is gaining more recognition in our ever more sustainable world.

How does Rollepaal integrate Quality System 4.0 principles into its manufacturing processes to ensure the highest standards of quality and efficiency in its extrusion lines and stand alone machines?

Quality is a top priority for Rollepaal. We employ Quality System 4.0 principles that offer enhanced controls for quality assurance and efficiency. They help ensure the performance and longevity of our extrusion lines and standalone machines, contributing to seamless operation for our customers. Since we have a lot of pipe processing knowledge in house, we can use that to support our customers to optimize their production process.

Could you outline some of the sustainable practices integrated into Rollepaal’s pipe production processes, emphasizing how these initiatives contribute to resource conservation, waste reduction, and environmental responsibility Sustainability is a standard we uphold in our practices. We believe that efficient use of resources and was te reduction are intertwined with advanced technology and quality, and we aim for our products and services to reflect that belief. Our cost saving solutions go hand in hand with sustainability since all of these developments are aiming at using less and also recycled material to create a perfect end product.

In light of Rollepaal’s global footprint, how does the company foster collaboration and knowledge sharing among its diverse teams worldwide to drive innovation, exchange best practices, and maintain a competitive edge in the rapidly evolving pipe extrusion market?

Our team members and agents across the globe are our most important assets and  our success. We aim to cultivate an environment that encourages and enables knowledge sharing and collaboration. We acknowledge that these practices are integral to maintaining our competitive edge and to keep innovating in the industry.

Can you provide insight into Rollepaal’s long-term strategic goals and initiatives for driving growth, sustainability, and market leadership in the evolving landscape of pipe extrusion technology?

As a part of our long-term strategic initiatives, we continue to strengthen partnerships, diversify our product lines, and invest in cutting-edge technologies to provide the best products and services for our customers for them to meet their market’s requirements. We intend to uphold our position as a trusted partner in pipe extrusion, sharing process knowledge, build high quality machinery, and develop material saving solutions.

www.rollepaal.com

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Be the First to Know: Dive into The World of Cosmo First

An Exclusive Interview With Mr. Pankaj Poddar, Group CEO, Cosmo First Ltd With Mr. Satnam Singh, Associate Editor, Modern Plastics India (MPI) Magazine A Part of Modern Plastics Global Network

What is the strategy behind launching a new business division Cosmo Plastech?

For the past four decades, Cosmo First has proudly pioneered industry-first solutions. As the demand for FMCG items grows, so does the desire for new packaging solutions. With the establishment of Cosmo Plastech, we want to provide cutting-edge rigid packaging solutions to our clients and consumers while maintaining our steadfast commitment to sustainability. The strategic decision to develop Cosmo Plastech is ideally aligned with our aim of delivering a comprehensive variety of packaging solutions and sheets to our valued partners for a wide range of FMCG, electronic, and other industries, hence improving supply chain efficiency. This is a huge step forward in our quest for a greener future since positive changes in the packaging sector pave the way for circular economy.

Is there any specific hi-end product range to be introduced under the new business division?

Cosmo Plastech looks forward to catering to the industry’s changing expectations in an environmentally conscientious manner. Currently, our packaging containers are made from high-quality materials to ensure durability and reliability using injection moulding and thermoforming techniques. Our expertise in rigid packaging solutions combined with state-of-the-art machinery ensures that the products are moisture resistant and tamper-proof. This makes the solutions of Cosmo Plastech an alternative to traditional packaging practices. Our containers are round, rectangle, oval square, and many other shapes with special anti counterfeiting solutions box containers which are the products with most demand.

Other Cosmo Plastech’s products are:

• TF Cups, available for storing beverages, dairy items, ice cream, jams, sauces, etc.
• TF Trays used for sweets and food packaging.
• Thinwall for food packaging containers
• Sheets for freezer grade, antistatic, ESD (Electrostatic discharge), hot film
• Other electronic industry packaging etc. Going forward, as per industry demand and expectations, we may look at introducing more products and ranges.

What revenue the new business division expected to add in the next three years?

We are targeting INR 100-150 crores (US$ 12 Mn – 18 Mn) in the next three years.

When did the company rebranded as Cosmo First?

We rebranded from Cosmo Films to Cosmo First in July 2022. The company aspire to be the first choice for all its stakeholders and will strive hard to always stay ahead of the curve to industry-first solutions.

What are the objectives of the rebranding and how it impacted the Cosmo profile in the Indian and international market in positive manner?

Over the last few decades, we have established ourselves as the most sought after global brand for value-added films. The strategic choice to rename stems from our company’s expansion of business operations beyond films into specialty chemicals, coating, adhesive, masterbatches, and D2C Pet care. The rebranding reinforces Cosmo’s value and strengthens our emphasis on creating a better life for people, the globe, and the society we live in, based on trust,empathy, compassion, and our core practice of putting people, employees, and our customers first. Today, we are a four-decade old Indian corporate conglomerate widely known for our reliance on innovation to create value in a variety of emerging areas as polymer. Further, we have also into BOPET, shrink films, and CPP lines, and have introduced new business verticals and products like Cosmo Sunshield (window films) and Cosmo Plastech (rigid packaging).

Share the details of the various sites, location along with production in terms of volumes

Our manufacturing sites in India are in Waluj (Aurangabad), Shendra (Aurangabad), and Karjan (Vadodara). We also have sales and distribution centres in Canada, the US, Korea, Japan, Germany, and the UK.

PRODUCTS EXISTING UPCOMING

BOPP Films 2,00,000 TPA 15,000 TPA
CPP Films 9,000 TPA
Thermal Films 30,000 TPA
Coated Films 20,000 TPA
Metalized Films 30,000 TPA 8000 TPA
Rigid Packaging 10,000 TPA
BOPET 30,000 TPA
CSP 10,000 TPA
PET-G 14,000 TPA
Sheets 4000 TPA 10,000 TPA

Cosmo First has been consistently introducing new products in the film vertical, share details of the products launched recently and in the pipeline in the near future?

We have launched several new specialty films including shrink for packaging and non packaging applications. A few other specialty films from non-packaging applications are also in the pipeline and should hit the market i n t h e c o m i n g q u a r t e r s . H a v i n g commercialised our specialised BOPET line in September 2022, we are in the process of launching several new specialty products including window film, security film, and PETG film. While our new companies are still in their infant stages, we are increasing our capacity for speciality films. Some of the recent products that we have introduced in the market are susceptor films, scuff free lamination films, polyester-based thermal lamination films, ID card map & match films.

We have successfully developed a new transparent printable biaxially oriented polypropylene (BOPP) film named “TeploR” which has higher heat resistance as compared to conventional BOPP films. The film has been engineered to work as a printing layer replacing BOPET film in multi layer laminates for various packaging applications in both food and non-food segments. The thermally stable films have excellent s lip properties and good machinability and have good performance on high-speed VFFS and HFFS machines. This film has good thermal stability (no shrinkage) upto 185˚ C as compared to conventional BOPP films of 145-155˚ C.

To stimulate expansion in specialty chemicals, we plan to introduce label adhesives, and coating chemicals for our existing B2C customer base this year. Alongside, as part of our product expansion strategy and to cater to industry demands, we have also introduced.

Any new site planned or expansion planned, if yes, share details

Yes, we have our expansion plans for our film business in line. We look forward to commissioning our 10th BOPP line by 2025 & 3rd CPP line by 2024. Further, we are planning one more site in Maharashtra. We will be focussing on our sheets for the rigid packaging business as well.

What is the company turnover in 2022, annual growth rate despite challenging business scenario and growth target for fiscal 2023?

The BOPP & BOPET business had an excess supply in FY23 due to the bunching of numerous new manufacturing lines. Although demand continues to rise, the bunching of supply reduced margins and impacted the whole sector. Cosmo First, with more than two-thirds of our sales from specialised films, resisted margin pressure and outperformed the industry substantially.

Our consolidated revenue increased marginally to INR 3,065 crores (USD 368 Mn) in FY’23 from INR 3,038 crores (US$ 364 Mn) in FY’22, after expanding at a CAGR of more than 13.3% from FY18 to FY22 (speciality film sales increased at a CAGR of 18% over three years). Despite a hard economic situation, our EBITDA for the year stood at INR 434 crores (US$ 60.76 Mn) demonstrating the resilience of speciality films. ROCE (Return on Capital Employed) and ROE (Return on Equity) were 16% and 20%, respectively. We are aiming for a top line of roughly INR 5,000 crores (US$ 600 Mn) in the next 3-4 years, with new businesses accounting for 15-20% of sales.

Do Cosmo introduce any new products in the US market?

In the US, we have multiple sales and distribution centres at different locations and carry slitting for local needs. For the products, in the US market, we have introduced the thermal lamination films which is one of our flagship products. We are strategizing for the high-margin films in the US market. All our products are available in the US market.

Comments on the evolving Indian market and how Cosmo aspired to achieve its goals and objectives?

The Indian market has been steadily growing in recent years. The demand for film and  packaging solutions has been on the rise, driven by various factors, including increased consumerism, e-commerce expansion, and a growing middle-class population. We have recognised this growth and have strategically positioned ourselves to leverage the opportunities presented by this upward trajectory.

In recent years, India has well positioned itself as a global market hub and Cosmo has emerged as one of the leading players within the Indian market. We have not only catered to domestic demand but also successfully penetrated international markets. Our ability to provide high-quality film and packaging solutions has made us a preferred choice for clients not only in India but also across the world. This expansion reflects our ambition to be a key player in the global supply chain.

Further, with ongoing changes and uncertainties in the China market, many businesses are actively seeking alternatives. We have ensured to keep our supply chains running and stand as a strong and reliable alternative to the Chinese market for our customers. Our commitment to quality, competitive pricing, and a customer-centric approach have attracted businesses looking for dependable sourcing options. This strategic positioning aligns with our long term goals to become a leading player in the global film and packaging industry.

We plan to raise our entire film capacity by approximately 50% by FY’26, at a cost of around INR 500 crore (USD 70 Mn), and our film income will increase by approximately 50% by FY’27. Our diversification into new industries including specialty chemicals and pet care has progressed as planned. Bothsegments are growing and contributing to the company’s long-term wealth generation potential. Future goals in the pet care area include expanding the experience centres to 100+ in a few years and pushing the online business.

What are the flagship products of the Cosmo?

Year-on-year we have introduced several industry-first solutions for our valued customers and partners, susceptor films, face stock films, and heat resistance films are some of the flagship products that we have introduced in recent years. Cosmo synthetic paper is a direct replacement for pulp-based paper in situations where durability is required. It is a white opaque co-extruded polypropylene-based synthetic film that resembles ordinary paper.

A few other flagship products that we manufacture are:
• Self-adhesive/ Face stock film
• Lidding film
• Thermal lamination films
• Heat resistance films for printing
• Shrink Films
• In mould label films
• Packaging adhesives
• Think wall containers
• Metalized container Films

www.cosmofirst.com