Calco Poly Tech­nik sets up new plant, plans to step up ex­ports

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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

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