A PROJECT REPORT

ON
“Plastic Industries”

Submitted to
B.V. PATEL INSTITUTE OF COMMERCE
UKA TARSADIA UNIVERSITY

Submitted by

Pranav Patel 202203103110003 B.Com

Heena Shah 202203103110031 B.Com
Rudra Dixit 202203103110033 B.Com
Vansi Dadhaniya 202206100710006 IM.Com

Guided by

Dr. Arpana Patel

April 2024

I
 Table of Content

Sr.no Content Pg.no.

.

1 Profile of the Sector
(a) Introduction
(b) Types
(c) History
2 Size of the Sector and Sub-Sectors
(a) Statistical Snapshot
(i) Present Scenario
(ii) Future Scenario
(iii) Polymer share & sub-sectors
3 Classification
4 SWOT Analysis
5 Applicability with other sectors
6 Case Study
 Summary

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 DECLARATION

We hereby certify that we are the sole author of this project report and that neither any part of this
project report nor the whole of the project report has been submitted for a degree to any other
University or Institution.

We certify that, to the best of our knowledge, the project report does not infringe upon anyone’s
copyright nor violate any proprietary rights and that any ideas, techniques, quotations, or any other
material from the work of other people included in our project report, published or otherwise, are fully
acknowledged in accordance with the standard referencing practices.

We declare that this is a true copy of the project report, including any final revisions, as approved by
the review committee.

Date: April 2024

Place: B. V. Patel Institute of Commerce

Enrolment No. and signature

Pranav Patel 202203103110003

III
Heena Shah 202203103110031

Rudra Dixit 202203103110033

Vansi Dadhaniya 202206100710006

PROFILE OF THE SECTOR

INTRODUCTION

A plastic is a type of ‘synthetic’ or ‘man-made polymer’, similar in characteristics to natural resins found
in trees and plants. Plastics are a modern day innovation wherein Oil and natural gas are the key raw
materials used for manufacturing. The word, plastic, was derived from the word ‘Plastikos’ meaning ‘to
mould’ in Greek. Fossil fuels have compounds containing hydrogen and carbon (hydrocarbon) which act
as building blocks for long polymer molecules. The starting material, called ‘Monomers’, are linked
together into long chains to form a ‘Polymer backbone’. Styrene, vinyl chloride, ethylene glycol,
terephthalic acid are some example of monomers which are chemically bonded into chains called
polymers. Polyethylene, polypropylene and polystyrene are the most common examples of polymers

Plastics encompass almost every domain of life such as household items, automobiles, packaging,
electrical and electronics, among others. Oxygen, chlorine, fluorine and nitrogen are also found in the
molecular makeup of many plastics. For example, Polyvinyl chloride (PVC) contains chlorine. Nylon
contains nitrogen. Teflon contains fluorine. Polyester and polycarbonates contain oxygen.

TYPES

Bakelite

Bakelite is a polymer made up of the monomers phenol and formaldehyde. This phenol-formaldehyde
resin is a thermosetting polymer.We cannot deny the presence of polymers in our lives. We are
surrounded by objects, most of which in some way or the other have a polymer associated with them. The
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ease of molding polymers into different shapes and their relatively low cost of production has been the
main reason for their universal usage. As such, Bakelite is one of the commercially manufactured
polymers that we witness in our daily lives.

Bakelite is the commercial name for the polymer obtained by the polymerization of phenol and
formaldehyde. These are one of the oldest polymers that were synthesized by man. Phenol is made to
react with formaldehyde. The condensation reaction of the two reactants in a controlled acidic or basic
medium results in the formation of ortho and para hydroxymethyl phenols and their derivatives.

Uses:-

Since this element has a low electrical conductivity and high heat resistance it can be used in
manufacturing electrical switches and machine parts of electrical systems. It is a thermosetting polymer
and Bakelite has high strength meaning it basically retains its form even after extensive molding.
Phenolic resins are also extensively used as adhesives and binding agents. They are further used for
protective purposes as well as in the coating industry.

Further, Bakelite has been used for making the handles of a variety of utensils. It is one of the most
common and important polymers that are used to make different parts of many objects.

Polystyrene

Polystyrene is a hard, brilliantly transparent, stiff resin. It is produced by the polymerization of

styrene and is the most widely used plastic. At room temperature, the thermoplastic polymer is a solid but
when heated above 100 °C it flows. It becomes rigid again when it cools down. Polystyrene is insoluble
in water.

Polystyrene is compound that is non-biodegradable with a couple of exceptions. It is easily dissolved by

many aromatic hydrocarbon solvents and chlorinated solvents. It is widely used in the food-service
industry as rigid trays, containers, disposable eating plates, bowls, etc.

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 Uses:-
 Medically it is used for sterilizing test tubes, diagnostic components, and other medical devices.
 It is used to manufacture car parts which include knobs, instrument panels, sound dampening foam, etc.
 Polystyrene foodservice packaging keeps the food fresh for a longer period of time and is less expensive
than alternatives.
 It is used in packaging consumer goods such as DVD cases, and egg cartons, to protect against spoilage
or damage.
 It provides thermal insulation and is used in refrigerators, freezers, etc.
 Used in housing in all IT equipment such as Television, computer, etc.

Polyethylene terephthalate
Polyethylene terephthalate is a clear, strong, and lightweight plastic widely used for packaging foods and
beverages. The essential elements of PET are ethylene glycol and terephthalic acid, combined to form a
polymer chain.
PET was first created in the mid-1940s by DuPont chemists attempting to develop new synthetic fibers.
DuPont later labeled its PET fiber as "Dacron." Now, more than half of the world's synthetic fiber is made
from PET. Polyethylene terephthalate is called polyester when used as a fiber or fabric. When used for
packaging or other applications, it is called PET or PET resin.

Uses:-
Polyethylene terephthalate is used for textiles, packaging, and other applications. Almost all single-
serving and two-liter bottles of carbonated soft drinks and water sold in the U.S. are made from PET. It is

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 also commonly used for packaging salad dressings, peanut butter, cooking oils, mouthwash, shampoo,
liquid hand soap, window cleaner, and tennis balls. Special grades of PET are used for carry-home food
containers and prepared food trays that can be warmed in the oven or microwave.

Polypropylene
A synthetic resin built up by the polymerization of propylene. One of the important family of polyolefin
resins, polypropylene is molded or extruded into many plastic products in which toughness, flexibility,
light weight, and heat resistance are required. It is also spun into fibres for employment in industrial and
household textiles. Propylene can also be polymerized with ethylene to produce an elastic ethylene-
propylene copolymer.

Propylene is a gaseous compound obtained by the thermal cracking of ethane, propane, butane and
the naphtha fraction of petroleum. Like ethylene, it belongs to the “lower olefins,” a class
of hydrocarbons whose molecules contain a single pair of carbon atoms linked by a double bond. The
chemical structure of the propylene molecule is CH2=CHCH3. Under the action of
polymerization catalysts, however, the double bond can be broken and thousands of propylene molecules
linked together to form a chainlike polymer (a large, multiple-unit molecule).

Uses:-

Polypropylene is a right, semi-crystalline thermoplastic that is used widely in a range of domestic and
industrial applications. Some of the common uses of polypropylene are:

 Plastic packaging, such as yogurt cups, water bottles, ketchup bottles, etc.
 Plastic parts for machinery and equipment.
 Fibres and textiles for home furnishings, clothing and sports.
 Disposable nonwoven fabrics for diapers and medical applications.
 Nonwoven fabrics for ground stabilization and reinforcement in construction and road paving.
 Rope and cordage.
 Straws
 Automotive parts.

Polyvinyl chloride

A synthetic resin made from the polymerization of vinyl chloride. Second only to polyethylene among
the plastics in production and consumption, PVC is used in an enormous range of domestic and industrial
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 products, from raincoats and shower curtains to window frames and indoor plumbing. A lightweight,
rigid plastic in its pure form, it is also manufactured in a flexible “plasticized” form.

Vinyl chloride (CH2=CHCl), also known as chloroethylene, is most often obtained by reacting ethylene
with oxygen and hydrogen chloride over a copper catalyst. It is a toxic and carcinogenic gas that is
handled under special protective procedures. PVC is made by subjecting vinyl chloride to highly
reactive compounds known as free-radical initiators. Under the action of the initiators, the double bond in
the vinyl chloride monomers (single-unit molecules) is opened, and one of the resultant single bonds is
used to link together thousands of vinyl chloride monomers to form the repeating units
of polymers (large, multiple-unit molecules).

Uses:-
Polyvinyl Chloride is an economical and Versatile thermoplastic polymer it is widely used in the building
and construction industry to produce door and window profiles. Other uses of PVC include:
 Drinking and wastewater pipes
 Wire and cable insulation
 Medical devices
 Plumbing
 Electrical cable insulation
 Flooring
Bioplastic:-

These modable plastic material made up of chemical compounds that are derived from or synthesized by
microbes such as bacteria or by genetically modified plants. Unlike traditional plastics, which are derived
from petroleum, bioplastics are obtained from renewable resources, and some bioplastics are
biodegradable.

Plastics are polymers—assemblies of identical chemical subunits, called monomers, that are linked
together in the form of a chain. The properties of a plastic, like those of all polymers, are defined by the
monomers in the chain and by the number of links and cross-links in its structure. Cross-linking of the
monomers increases a polymer’s rigidity and thermal stability. As their name suggests, plastics can
readily be molded into various shapes. Plastics such as polystrene (polymerized styrene, CH2=CHC6H5),
polyethylene (polymerized ethylene, CH2=CH2), or polypropylene (polymerized propylene, CH2=CHCH3)
are molded into a wide variety of everyday and specialized products—for instance, eating utensils, coffee
cups, synthetic fabrics, park benches, automobile parts, and surgical implants.

Since the early 20th century, there has been an explosion in the development and use of plastics, and their
utility and importance have become so great that it is difficult to imagine modern life without them.
Virtually all current plastics are derived from petroleum through chemical extraction and synthesis.
Because petroleum-based plastics are generally not biodegradable, plastic refuse is very durable, and
disposing of it has become a serious problem. Despite efforts to encourage and support recycling, landfills
are becoming filled with plastic refuse, which also accumulates in the environment. An additional
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 problem with petroleum-based plastics is that petroleum resources are being used up; conservative
sources estimate that at current rates of consumption, all known sources of petroleum on Earth will have
been depleted before the end of the 21st century. Given that modern life is dependent on plastics, that
petroleum is a non-renewable resource, and that petroleum-derived plastic waste fouls the environment, a
sustainable solution for the longer term may be found in bioplastics.

Uses:-
Bioplastics are used in variety of industries and markets. Some of the most common uses for bioplastics
include:-
 Disposable utensils, straws, and bottles
 Bin liners and shopping bags
 Disposable food packaging and containers
 Mobile phone cases
 Toothpaste tubes
 Laundry detergent sheets
 Sunscreen
 Medical devices
Bioplastics are also used in biomedical products, electrical products and structural materials.

HISTORY

Parkesine, invented by Alexander Parkes in 1855 and patented the following year, is considered the first
man-made plastic. It was manufactured from cellulose (the major component of plant cell walls) treated
with nitric acid as a solvent. The output of the process (commonly known as cellulose nitrate or
pyroxylin) could be dissolved in alcohol and hardened into a transparent and elastic material that could be
molded when heated. By incorporating pigments into the product, it could be made to resemble ivory.
Parkesine was unveiled at the 1862 International Exhibition in London and garnered for Parkes the bronze
medal.

In 1893, French chemist Auguste Trillat discovered the means to insolubilize casein (milk proteins) by
immersion in formaldehyde, producing material marketed as galalith. In 1897, mass-printing press owner
Wilhelm Krische of Hanover, Germany, was commissioned to develop an alternative to blackboards. The
resultant horn-like plastic made from casein was developed in cooperation with the Austrian chemist
(Friedrich) Adolph Spitteler (1846–1940). Although unsuitable for the intended purpose, other uses
would be discovered.

The world's first fully synthetic plastic was Bakelite, invented in New York in 1907 by, Leo
Baekeland, who coined the term plastics. Many chemists have contributed to the materials science of
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plastics, including Nobel laureate Hermann Staudinger, who has been called "the father of polymer
chemistry,” and Herman Mark known as “the father of polymer physics.”

After World War I, improvements in chemistry led to an explosion of new forms of plastics, with mass
production beginning in the 1940s and 1950s. Among the earliest examples in the wave of new polymers
were polystyrene (first produced by BASF in the 1930s) and polyvinyl chloride (first created in 1872 but
commercially produced in the late 1920s). In 1923, Durite Plastics, Inc., was the first manufacturer of
phenol-furfural resins. In 1933, polyethylene was discovered by Imperial Chemical Industries (ICI)
researchers Reginald Gibson and Eric Fawcett.

The discovery of polyethylene terephthalate is credited to employees of the Calico Printer’s

Association in the UK in 1941; it was licensed to DuPont for the US and ICI otherwise, and as one of the
few plastics appropriate as a replacement for glass in many circumstances, resulting in widespread use for
bottles in Europe. In 1954, polypropylene was discovered by Giulio Natta and began to be manufactured
in 1957. Also in 1954 expanded polystyrene (used for building insulation, packaging, and cups) was
invented by Dow Chemical.

Plastic industry started growing in India since the late 1950s. It gained momentum with the economic
liberalization of 1990s. Raw material production beginning in mid 1990s gave a further impetus to its
growth. Today, it has grown into a multi-billion dollar industry. However, India is a net importer of
plastics today. Reliance Industries Ltd., Gas Authority of India and petrochemicals are major producers of
polymers in India. The key organised sector players include VIP Industries, Nilkamal Plastics Limited
and Supreme Industries Limited.

SIZE OF THE SECTOR AND SUB-SECTORS

STATISTICAL SNAPSHOT – PRESENT SCENARIO IN INDIA

Annual polymer consumption

Employment Formality
in India
 Close to 4 million  70% of the industry is
 16 million metric tonnes
people across the held by unorganized
in 2019 (MMTPA)
country players as opposed to
 (90% - Plastic, 10%-
only 30% organized.
Non- plastic)

Per capita consumption Country ranking in terms of Share of India’s plastic

consumption products industry
 An Indian consumes
13 kg annually versus  3rd largest consumer  0.5% of India’s GDP
27kg globally globally after USA and
China

Growth rate Size of the plastic industry

X
 11% annually over the  INR 144000 crores in
years 2018
 STATISTICAL SNAPSHOT- FUTURE PROJECTIONS FOR INDIA

The plastic industry in India is poised to grow and contribute to employment, demand and development in
the coming years.

16% 55% 1 million

8-10% 3%
Capacity Additional
Targeted share in
Expected CAGR Plastic utilization of the manpower
the global export
consumption plastic industry requirement by
till 2025 market by 2025
expected in 2023- 2023-24 in the
growth per annum which is currently
24 over 52% of technical cadre in
in the future 1%
2020-21. the process industry

STATISTICAL SNAPSHOT –POLYMER SHARE & SUB-SECTOR

1. Polypropylene and Polyethylene Terephthalate accounts for over

Share 50%End
of Key of India’s polymer of
Use Sub-sectors
consumption for plastic products (2018-19). Plastic Usage
Sectors
2. Flexible packaging has the highest share among end-users of plastics. This demand isShare (2019)
poised to remain
high in the future due to the numerous advantages such as convenient handling and disposal, price
advantage and portability.
Packaging (Rigid + 59% (17% +
Flexible) 42%)
Building & 13%
Construction
Agriculture 9%

Household (FMCG, 7%
Furniture, Luggage,
etc..)
Electricals and 7%
Electronics
Automotive 7%
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Others (Sports, 3%
medical, industrial
machinery)
 POLYMER CONSUMPTION
SHARE

Polypropylene (PP) 38%

Sources:-:
https://www.teriin.org/sites/default/files/2021-
Polyethylene 15% 03/Circular-Economy-Plastics-India-
Terephthalate (PET) Roadmap_0.pdf

High density 14%

polyethylene
(HDPE)
Linear low-density 11%
polyethylene
(LLDPE)
Polyvinyl chloride 10% CLASSIFICATION OF PLASTIC INDUSTRIES
(V or Vinyl or PVC)

Low density 2%
polyethylene
The classification discussed here is not very
(LDPE)
rigid. Industries operating in the plastic
Polystyrene (PS) 2% manufacturing and processing often fall into
several classes and hence overlapping.

A. Plastic production industry classification: On the basis of plastic type produced

Thermoplastics are generally defined as plastics which soften when

heated.
It broadly caters to commodity and engineering sector
THERMOPLASTIS Covers 70% of the plastic market.
Polypropylene (PP), Polyethylene (PE), Poly vinyl chloride (PVC),
Polystyrene (PS), polyethylenetheraphthalate (PET) and
polycarbonate (PC).

Thermosetting plastics are completely infusible and are generally

made from two reactive components which harden or "cure" during
the reaction. Thermoset materials include unsaturated polyester (UP)
and phenol-formaldehyde (PF)
THERMOSETTING
Used in plywood adhesives, furniture/bedding, building &
construction, automotive, consumers products and electronic.
Covers the rest 30% of the market.
Polymers include epoxy, silicon, polyurethane and phenolic.
B. Plastic processing industry classification: On the characteristics of plastics used

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 Low price, non durable, without the use of additive,
reinforcing fillers, fibres or polymer blends, used in high
volume and wide range of applications, relatively low
mechanical properties. Used as film for packaging,
COMMODITY photographic and magnetic tape, clothing, beverage and trash
PLASTICS containers and a variety of household products. It comprising
of Polyethylene (PE), Polypropylene (PP), Polyvinyl Chloride
(PVC) and Polystrene account for bulk of the plastic
consumption in India. 80%-85% of all thermoplastics are
commodity, balance is engineered.
Consumer
Goods
Robust in their properties, more expensive, used in niche and
demanding applications./Lifestyle
Engineered plastics used for durable
ENGINEERED goods, have better mechanical properties or "special property".
PLASTICS It comprises of Acrylonitrile butadiene styrene (ABS),
Polyethylene terephthalate (PET), polycarbonates (PC) and a
range of polyamides or nylons.

C. Plastic processing industry classification: On the basis of end user/downstream industry

Automotive & Infrastructure

Packaging Agriculture
Transportation & Construction

Electrical & Healthcare &

Textile
Electronics Pharmaceutical

D. Plastic processing industry classification: On the basis of industry formalisation

ORGANISED
Share of organised players has increased from 45% five years ago to 56% in 2017

UNORGANISED
Share of unorganised player is 45%. Maximum msme fall into this category.

Packaging, industrial products and pipes partially Packaging industrial products and pipes
partially are B2B businesses whereas consumer products and pipes are B to C businesses

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E. Plastic processing industry classification: On the basis of processing method employed

EXTRUSION
Most commonly used (64%) in India. Mechanical heat, hot sidewall metal and
die/opening used to mould.

INJECTION MOULDING
Second most commonly used (25%). High pressure used to force molten plastic
into a cooled mold.

BLOW MOULDING
Helps produce hollow shapes without having to join two parts.

ROTATIONAL MOULDING
Uniform coating by using rotation around the axis..

Strengths
Accelerated globalization,
Growing consumerism,
Significant public investments due to its quickly expanding market size,
Growing demand for affordable packaging,
Low entry barriers,
Supportive government schemes,
Rapid urbanization to increase the demand in consumption

Weakness

Deficit to the tune of 13% to the plastic industry.

environmental myths, lack of advanced technology , limited infrastructure,
High fragmentation due to low capital intensity and low technological barriers,
High volatility in feedstock prices,
Non-availabilityt of skilled and formally trained workforce in the form of
machine operators, maintenance technicians, quality supervisors,

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 Opportunities

Ever increasing consumption trend,

In country and export demand due to disruption from China,
Trend of shift from metal to polymer based parts due to low weight and durability,
Govt focused to help synergize production capacities,
Threats
Automation through computer controlled production to change the employment
dynamic sooner or later,
Volatility in exchange rates,
Volaitility in feedstock prices

APPLICABILITY OF THE OCCUPATION WITH OTHER SECTORS

 Plastic industry is dependent on various supply side industries as well as a supplier to several downstream
industries.
 Hence professionals working in plastic industry can find linkages and contribute their skills and expertise
in these sectors.
 Alternatively, professionals from these sectors can find synergy in the plastic industry.

Power Additives
Polymer research
[Enter saving [Stabilizer, anti-
and development
solutions, green oxidants,
growth] pigments]

Waste Machinery
Technology
management and XV
transfer [Product &
recycling
polymer]
 CASE STUDY

Plastics recycling in Romania

The Romanian recycling business Expert Recycling offers numerous services around the disposal and
recycling of post-consumer and post- industrial plastic waste. A W5.18 single-shaft shredder from
WEIMA is used for processing PET, PP, PS, PE, DHPE and PELD material streams. With its help, the
company produces high-quality regranulates, films, and waste bags, which it then sells itself.
Expand.

Nowhere else in the European Union is so little waste produced annually per capita as in Romania. Also
true is that the country’s recycling rate is only just ahead of Malta, which is in last place. Expert
Recycling, located two hours north of Bucharest, has recognized this need to catch up since it was
founded in 2007 and, according to its own figures, has processed over 7,000 tons of waste to date.

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Achieving the Zero Waste goal with strong partners

The circular economy is the focus for Expert Recycling. Together with strong partners, the Zero Waste
ideal goal for Romania is to be achieved. Owner Dan Ana explains how:

“We want to make an important contribution on the way to a circular economy. One person’s waste
should be another person’s raw material. Expert Recycling wants to support a society focused on
sustainability with state-of-the-art technology that is not only safer but also more efficient than before.
Ultimately, we need to significantly increase the recycling rate.”

To achieve these ambitious goals, Expert Recycling relies on shredding technology from WEIMA in
Germany – distributed by the Romanian dealer Chorus Engineering from Bucharest and co-financed by
funds from the European Union.

In the first step of the recycling process, the WEIMA W5.18 plastic shredder W5.18 processes a wide
variety of films, packaging and more to a homogeneous flake size, which is ideal for further processing.

WEIMA shredder as the central component

The WEIMA shredder as the central component of the recycling line has a working width of pprox..
1,800 mm, with a rotor diameter of pprox.. 500 mm. It is driven directly by a Hägglunds Bosch Rexroth
hydraulic power drive train, without gearbox or frequency converter, which allows consistently high
throughput rates to be achieved. The drive is extremely robust with regard to foreign objects and features
variably adjustable rotor speeds with constantly high torque – even under full load.

The material is fed via infeed conveyor belt. The compact swing-arm ram installed inside the shredder
presses the material to be shredded against the rotor in a load-dependent and fully automated manner. Due
to the wide opening of the inspection flap, the removal of any impurities or the maintenance of the cutting
geometry is conveniently possible at any time.

After shredding, the flakes are washed, followed by extrusion using a solution from Erema. The products,
various regranulates and film products, are of the highest quality, confirms Dan Ana:

“We collect or buy post-consumer as well as post-industrial plastic waste from our numerous partners. All
our products, granules, household waste bags and films, are made of 100 percent recycled material and
comply with all EU regulations, including CE marking for full transparency in national and international
markets. At Expert Recycling, we have a comprehensive technology park for end-to-end recycling. This
includes sorting, separating, washing, shredding, baling and extruding. And we’re pretty proud of that!”

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 Plastics Manufacturer, Scandinavia

Leading plastics manufacturer uses live process data to optimize production, saving time and materials
One of Scandinavia’s leading plastics manufacturers has chosen DataHub software from Cogent Real-
Time Systems (a subsidiary of Skkynet) to extract data and interact with their state-of-the-art plastic
manufacturing equipment. The firm can now access any desired process data for the purposes of
engineering analysis and enterprise-level resource planning. DataHub software was the only additional
piece of software required to realize substantial savings of time, materials, and production costs.

“The DataHub application is exactly the kind we needed,” said the project coordinator. “Our system is
extensive, and we need to visualize a lot of production parameters. We looked at other solutions but they
were too expensive and more complicated.”

When the company installed new equipment recently, the necessary system integration grew very
complex. Progress was slow. After almost a year they were facing a deadline and had little to show for

XVIII
their time and effort. The goal was to pull together data from 15 machinery units, and feed it in real time
into the company’s business processing systems. And if possible, to enable plant engineers to view and
work with the live data as well. When they found DataHub software they were pleased to learn that most
of the work had already been done.
The first test was to connect a DataHub instance to an OPC server and put live data into ODBC databases,
Excel spreadsheets, and web browsers, as well as to aggregate OPC servers and tunnel data across a
network. DataHub technology proved to be easy to use and reliable, and it performed remarkably well.
The next step was to set up a test system.

The test system connected all of the OPC servers for the plant’s plastics production machines to a central
DataHub instance. Another DataHub instance at a network node in the engineering department is
connected to the central instance by a mirroring connection, for tunnelling data across the network. This
second DataHub instance is then connected to an Excel spreadsheet to give a live display of the data in
real time. When a piece of equipment machine starts up on the production line, the chart comes to life—
cells spontaneously update values and bar charts spring into existence.

The engineering department was able to develop a custom TCP application that uses the DataHub C++
API to make a direct connection from the DataHub instance to their SQL Server database. Once
connected that database gets updated in milliseconds with any change in the plastic-manufacturing
machinery. From the SQL Server database the data is accessed by the company’s ERP and accounting
software. Using DataHub software in these ways allows the company to:

Aggregate the data from all machinery into one central location.
Distribute the data across the network to various users.
Do decimal conversions of the data as it passes through the DataHub instance.
Put selected subsets of data into Excel for engineers to view and run calculations on.
Feed values into a SQL Server database in the company’s IT and business processing system. The OPC
points are read-only to ensure a clean separation between the management and production areas.

“This system pays for itself,” said a company spokesman, “and we save money in many ways. We have
seen substantial gains in productivity and performance because we can monitor our processes far more
effectively. Our accounting and planning departments have, for the first time ever, an up-to-the-second
record of actual production variables and statistics. At the same time, our engineering staff can use real-
time data in their calculations, and feed the results directly back into the process.”

DataHub technology also saved substantial programming costs. The time alone saved on development
work has paid for the system many times over. With a single tool the project coordinator has met the

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various needs of both the engineers and company managers. “The software is easy to install and it works
well,” he said. “It’s at the correct level for our needs.”

SUMMARY

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