Calco Poly Technik sets up new plant, plans to step up exports
Calco Poly Technik, part of the diversified Calco Group and a global player in the field of high performance engineering plastics for the automotive, electrical and electronics industry, is setting up a new plant at Sonepat in Haryana to extend its present range with new polymer compounds in PPS, PEEK, ASA, POM. Expected to be on stream by the end of 2018, the plant will have a production capacity of 20,000 tonne and this will be one of the biggest capacities in India for high performance polymer.
“This unit is designed to run at high production speeds that can handle materials with integrated automation systems. It will be very energy efficient and has a solar power generation system,” Varun Gupta, Director, Calco Poly Technik, said. With the increasing adoption of environment-friendly polymers, the conventional heavy metal parts would be rapidly replaced by plastics that can raise productivity and lower cost of production.
Calco has 2 manufacturing facilities focused on colour solutions and high-performance polymer respectively in Delhi and Haryana with a combined capacity of 30,000 tonne a year. The plants have state-of-the-art equipment from Korea and Germany. The plants are designed to meet small order quantities as well as bulk lots with automated packing units. The company has a world class R&D laboratory to innovate continually for new solutions.
“We have also established strong network in Europe and South Asia / South East Asia to promote our products with the local corporates in these countries. We hope to meet 20% of our sales revenue from exports in the short term and over 50% in the long-term.” he said.
Recently, Calco has appointed Bangla Chemicals as its sole authorised distributor in Bangladesh to come closer to its customers to provide innovative and costeffective solutions to leading OEM’s of Bangladesh. Calco exports its wide range of products to SAARC, South East Asia and European countries.
Calco which started in 2000 as a single location-single machine factory focusing on calcium carbonate-filled Master batches for the packaging industry. Understanding the growing expectations of the consumers and high performance of conventional polymers, the company forayed into colour and additive concentrates. For the first decade, Calco defied industry average and grew strongly to an installed capacity of 10 KTPA and colour formulations of over 5000 shades. From the beginning, the company adhered to its key strategic principles of ‘Innovation’, ‘Sustainability’ and ‘Continual Growth’.
“Our constant endeavour is to innovate with niche solutions kept pushing us to different market verticals. We were the first company in India to give scratch resistance solutions to dash boards in the automobile industry. In 2010, as a part of our commitment to environment, we acquired rights to green plastic technology. It is India’s only patented technology successfully commercialised to fight menace of waste management and disposal. In 2011, we expanded with Calco Poly Technik, catering to high performance engineering plastic focusing on providing efficient and innovative solutions in specialty domain. Since then, both the business units are running independently, complementing each other’s strength,” Gupta said.
Calco Poly Technik has a team of experienced polymer and chemical engineers having extensive experience in different product applications. They bring with them over 50 years of rich experience in product testing and innovation. Equipped with all latest technology, they work with their application development team and customers to identify opportunities on how components can be made lighter without compromising on quality and safety features.
“As a part of our commitment to environment, we are investing continuously in developing responsible materials for the current and future generations. We have acquired rights to commercialise indigenous technology. We were the first company in India to give scratch resistance solutions to dash boards in the automobile industry. We believe that our indigenous technologies and professionalism will help us align with Global OEMs and we can see positive outflow of raw material business being served from India.” he said.
India is a small market in the $67-billion global high performance plastics industry. Thus, all raw materials for high performance plastic are imported. Several multinational companies have started their commercial activities by having local office in India and are planning to manufacture in India. “Calco is poised to provide innovative solutions for challenges with regards to using plastics in the automotive industry,” Gupta said.
Innovation and new technologies will drive Calco at every market vertical. Consumer expectations are evolving, and companies globally are innovating to create solutions, meeting challenges of mobility, sustainability and connectivity. “We see this as an opportunity to create viable and affordable solutions with our indigenous technologies. New reinforcement materials create opportunities to replace metals and thermoset. Eco-friendly polymer and flame retardants help to meet strict regulations and social responsibilities. Engineering plastics will help facilitate new design and accelerate growth in automobiles, electrical & electronics and consumer goods. Plastic, indeed is a magical material that has transformed many industries. For automotives, its use is beyond just the look and feel of the vehicle. From material perspective, the selection of material is very critical and should happen at a very early stage of product development, Gupta said. Plastics has many advantages for the automotive manufacturer and consumer as they contribute to light weight reduction and allow weight of new safety equipments. “We ensure that the plastics and composites used are corrosion resistant, so that their application can prolong vehicle life. Also from the design point of view, they offer the designer greater flexibility, reducing the constraints that other materials often impose on shapes and packaging,” he said. High-performance plastic gives the products and equipment aesthetic appeal with colour, gloss and feel. It is mouldable to innumerable shapes and patterns. It gives strength with reinforcement materials for durability, in heat sensitive applications like lighting these materials give excellent thermal conductivity. “In short, we help make your life beautiful, safe and strong,” he said.
Increasing development in infrastructure has made India a favourable destination for investment, creating path for investments and subsequent demand for raw materials. The country is the biggest two-wheeler market in the world now. For four-wheeler capacity India is behind only the US and China. With increasing exports, this volume will go up even further. Increasing urbanisation and popular measures taken by central government will surely lead to huge demand for engineering plastics.
India has had a long tradition of entrepreneurial success and the Indian entrepreneurs have contributed immensely to the country’s economic progress and international standing. Recently, Calco Poly Technik won the D&B SME Business Excellence Awards 2017 in the Manufacturing Sector for ‘Plastics & Plastics Products’ category. Gupta has been recognised as CEO of the Year – India (2017-18) by CV Magazine, UK, for Redefined Leadership and Management at Calco Poly Technik, as it is moving forward with enhancements in innovation, marketing, finance, employee engagement, skill development and technology. Calco Poly Technik has also won The Economic Times ‘Best Brands for the Plastic and Polymers Industry 2018’.
Varun Gupta, Director, Calco Poly Technik