Thermoplastic Rubber Compounds

SBS & SEBS BASE COMPOUNDS

By - Ashutosh K. Gupta

SHOE SOLES COMPOUNDS

INDUSTRY
FOOTWEAR AUTOMOTIVE GRIPS WRITING LUGGAGE
INSTRUMENTS
Thermoplastic Rubber Compound : Scope of Study

Regional Coverage: Indian Market is the primary focus of this study with regard to
technology, economics, markets, and industry structure. The Indian TPR industry is
analyzed with respect to SBS resin and compound technology and supplier industry
structure.
TPE Compound Coverage: The target TPRs analyzed in this study are compounds
based on SEBS (and SEPS), SBS, The TPR and PVC interfaces have received particular
attention.
Forward Vision: The primary emphasis of the study is on the analysis and forecast of
likely evolution during the next five years. Previous evolution and snapshots of the current
situation are used as baselines.
Fabrication Process Technology: Emphasis is on processes that will broaden TPE
material substitution potential and reduce system cost.
Compounding Technology/Property Envelope: Relationships between compound
technology/properties/costs are defined in a series of graphs that show property
envelopes and their relationship to markets and value in the marketplace. The cost and
property implications of using recyclate (rubber and TPE) and metallocene-catalyzed
styrenic and polyolefin resins are analyzed.
Thermoplastic Rubber Compound : Scope of Study

Pricing: The current/future dynamics of TPR pricing are identified and analyzed with
respect to such factors as:
- New metallocene/non-metallocene plastomer and elastomer alternatives
- Broadening of the TPR resin supplier structure
- Increased presence of independent compounders
- Globalization of TPR markets
- Increased raw material availability
- Expiration of key TPR compound and resin patents
- The cascade effect toward lower cost TPRs
- A shift in how TPRs reach the market.
Market Sector Structure: All end use market sectors and applications in the TPR target
zone in India have been analyzed and quantified with respect to current TPR use, intra-
TPR and intermaterials competition, as well as supplier structure. The footwear sector
received particular attention due to its size and technological importance.
Thermoplastic Rubber Compound : Scope of Study

Structural Change: Consolidation, partnering,

and market globalization have shifted paths to
market and purchasing patterns. The
implications of the major structural changes
that occurred in this industry in the India are
analyzed. These include:
- Increased numbers of TPR Compounders in
the last five years
- Product line broadening by SEBS, SBS, TPO,
and TPV compounders
- Increase of TPR consumption for Exports
- The shift toward a multi-region business
structure.
Thermoplastic Rubber Compound : Scope of Study

Supplier Strategies: The implications of the greatly expanded SBS & SEBS resin
supply in the U.S., Europe, and Japan are analyzed with respect to demand for SBS &
SEBS compounds and the intermaterials environment in which they must compete.
PVC Substitution Trends: The current and possible future recycling pressures and
PVC-related trends and their likely impact on TPE demand are reviewed. Particular
emphasis has been placed on developing an analysis and forecast of these influences on
European medical, and automotive sectors and the potential impact in other regions and
TPE markets.
Rubber Replacement: The key target rubber markets have begun to be penetrated.
The replacement potential, timing, and requirements for TPE/rubber competition in
roofing, belting and automotive, and building/construction body and glazing seals are
analyzed.
Time Horizon: Demand and market share analysis by TPE base resins and compounds
are developed through 2005.
TPR & TPE COMPOUNDS

THERMOPLASTIC RUBBER COMPOUNDS

These compounds based on the SBS (Styrene-

Butadiene-Styrene) block thermoplastic
elastomer.
SBS thermoplastic rubbers present high elastic
properties

THERMOPLASTIC ELASTOMERS

These compounds are based on Styrene

Ethylene Butadiene Styrene (Block Co-Polymer)
formulations and easy to process, can be
Injection Molded at normal conditions.
Thermoplastic Rubber Compounds

CHARACTERISTICS

TPR compounds are having a wide

range of hardnesses from 40 to 85 Sh
A units. The elastic behavior is
excellent at room temperature and still
very good up to - 40 °C. Maximum
working temperature is + 50 °C. TPR
Compounds is a fully recyclable
material blended both with different
polymers. Provided it is properly
stored, it does not require pre-drying
phases before processing.
Thermoplastic Rubber Compounds

PROCESSABILITY

The technologies which are commonly used for TPR & TPE processing
are injection molding and extrusion - the later only for the production of
rands. The injection process can be carried out with the extruder type,
controrotating screw extruder type or transfert type machines. Using the
proper machine it is possible to inject soles composed of 2 or 3 colours
and/or inject directly onto upper.

The processing temperatures ranging from 140 -175 °C in the first zone to
160-190 °C in the last zone. The runners should be round-shaped, the
shortest possible and with gradually narrowing sectional areas of flow. A
round-shaped injection point is suggested
Thermoplastic Rubber Compounds

TPR Applications
• Shoe Soles
• Automotive Components
• Luggage

TPE Applications:
• Power tool grips
• Hand tools
• Garden tools and equipment
• Kitchen utensils
• Industrial paint brushes and scrapers
• Trowels
• Razors
• Toothbrushes
• Hairbrush handles
• Writing pens/pencils
• Bumpers
Thermoplastic Rubber Compounds

Applications:
Footwear
In-soles, out-soles, uppers, motifs, heel
counters, top pieces
Electrical
Moulded plugs, welding cables, wire
harnesses, flexible cords
Appliances
Handle grips, knobs, seals, stoppers, body
parts, rollers
Toys
Wheels, belts, semi-rigid toy components
Automotive
Interior gaskets, grommets, seals, shift boots,
pedal covers
Plastic Modification
Compatibiliser, impact modifier, ugrade regrinds
- olefinic & styrenic
Thermoplastic Rubber Compounds

Market Potential

Total consumption of TPR & TPE compound in footwear

industry is estimated at 16,000 MT per annum.
TPR & TPE Compounds consumption depends on Export
orders
Total Demand for TPR compounds is estimated at 18500 MT /
Annum.
Approximately 13,400 MT / annum is manufactured by the
Indian Compounders and balance 5100 MT/annum is being
imported.
TPR & TPR Compounds are also used in Automotive
applications, but cost wise costlier to PVC compounds.
Black Colour TPR compound for major demand. The other
colours mostly used are Red, Blue, Green, Yellow, White,Grey
and Honey.
Now New Grades like Translucent, Transparent and Crape
finish TPR compounds are in demand.
Thermoplastic Rubber Compounds
OTHER TPE APPLICATIONS
Thermoplastic Rubber Compounds

INDIAN TPR MANUFACTURERS

Following are the major compounders producing TPR
& TPE compounds.
Some of the prominent Players are :
Sales (MT/Annum)

M/s SPERRY PLAST 14800

M/s KLJ PLASTALLOYES 4400
M/s SBJ VON 1800
M/s PLASTIC EXTUSION 2800
M/s GAJENDRA PLASTICS 1000
M/s NIKHIL INDUSTRIES 1200
M/s TECHNO VINYL 800
Total 26,800
Thermoplastic Rubber Compounds

IMPORTED TPR COMPOUND

Following are the major Overseas Suppliers producing

TPR & TPE compounds.
Some of the prominent Players are :

Exports to INDIA (MT/Annum)

M/s CENTERPLAST srl 180

M/s TCT 200
M/s GOITER 180
M/s ADVANCE ELASTOMER 480
M/s TECHNOFILM 1000
M/s SO.F.TER 800

Total 2,840
Thermoplastic Rubber Compounds

M/s SPERRY PLAST LTD. have major share in the

market. They have outplaced M/s. SBJ VON,
Ahmedabad from the first place.

KLJ PLASTALLOYES LTD. Recently entered in to

TPR compounds and doing very well, producing
approx. 4400 MTS/annum.

SBJ VON COMPOUNDERS now diversified

themselves into Automotive sector, In Footwear
sector they supply only to BATA, India.

NIKHIL PLAST is also coming out with new plant

and added one MARIS Twin-screw machine recently.
Thermoplastic Rubber Compounds

Price of some of the Indian manufacturers

are given below:

Colour Basic Prices

Black Compounds 60,000 to 88000
Color Compounds 70,000 to 105000
Honey Compounds 90,000 to 110,000
Transparent Compunds 90,000 to 102,000
Crape Compounds 90,000 to 102,000

Credit offered varies from 45-90 days.

Duties/ Taxes are Extra.

Thermoplastic Rubber Compounds

MAJOR INDIAN CUSTOMERS

FOOTWEARS (TPR)
Mirza tanners Ltd. 150 MTS/month
Enkay HWS India ltd. 120 MTS./month
Farida Leatherware pvt. Ltd. 140 MTS/month
Dyechem India Ltd. 50 MTS/month
Bata India Ltd 50 MTS/month

AUTOMOTIVES (TPE)
Sun Steering Wheels 2000 kgs/month
HP Bajaj Pelzer 2000 kgs/month
Anand Motors Ltd. 3000 kgs/month
Other OEM’s 5000 kgs/month
Thermoplastic Rubber Compounds
Thermoplastic Rubber Compounds

MAJOR INDIAN CUSTOMERS

WRITING INSTRUMENTS (TPE)

Rotomac Pens Ltd. 4000 kgs/month
Luxor Exports Ltd. 2500 kgs/month
Rashmi Writing 2500 kgs/month
Jineshwer writing 2200 kgs/month

LUGGAGE (TPE)
VIP Industries 5000 kgs/month
Aristocrat 1800 kgs/month
Thermoplastic Rubber Compounds

TPR & TPE Compounds should follow SATRA

(U.K.) standards and physical Properties also dully
tested and passed by FDDI, NOIDA.

In TPR & TPE Compounds Colors specifically

matched as per the customers specimen. Color
matching in TPR & TPE compounds is difficult process.
Sampling and Batch wise supplies should match in
terms of Quality and Color.

Black TPE compounds are having larger share in the

market in comparison to Color compounds.

Color Compounds bring loyalty among customers as

once color is approved by their buyer. Customer will buy
from the approved source.
Thermoplastic Rubber Compounds

Existing market of Shoe Sole Compounds &

automotive Compounds.

Increasing demand in Shoe Sole Compounds

New applications found in Automotive

Components & Writing Instruments and
Luggage Industry.

Volume is increasing as the new applications

found in Automotive, Wire & Cable & Additive
industries.

New age TPE compounds are developed in

form of Engineering Plastic Alloys and other
specialized compounds.
Thermoplastic Rubber Compounds

SupplyChain
Supply ChainValue
ValueCreating
Creating

physical processess
Business processes

Customer Support

Infrastructure

Facilities and
Supply chain
Organization

Technical &
Sourcing

TPRModular
TPR ModularSupply
SupplyChain
ChainMnagement
Mnagement
The six founding layers
- Raw Material Sourcing
- Finished Goods
Sourcing
- Process Organization
- Grades Performance & Measurement
TPR
TPRModular

- Communication
Organization
ModularSupply

Supply
SupplyChain
- Manage orders
- Produce goods
- Distribute goods
Business
SupplyChain

ChainValue
Process
- Customer Support
- Technical Issues & Trials
ChainManagement

ValueCreating

- Product Info.
Technical & - After Sales Support
Customer Support
Creating
Management

- Network Optimization
- Production Strategy
Supply chain - Distribution Channels
Infrastructure

- Material Handling Strategy

- Warehouse Management
Facilities and - Material Handling Systems
physical processes - Robotics
Thermoplastic Rubber Compounds SUPPLY CHAIN
MANAGEMENT
and supply chain management

With intelligent Supply Chain

Information flow
Management the product cost WAY Material flow
can be optimized. Supply Chain
Simulation
With smart design, plan and
ASP
control the intra- and inter-
company supply chain without Trade company
bottlenecks and wastage can
be managed and the
optimization of the resources Transportation
can be done for the maximum
advantage: Factory Customer
¬ 100% deadline compliance
¬ productivity increase in
two-digit gains Warehouse

¬ reduction of throughput Developement

time up to 50%
¬ reduction of stocks up to
the half of the capital tied-
up Supplier Sales
 INDUSTRY
Thermoplastic Rubber Compounds

OVERVIEW OF THE INDIAN FOOTWEAR INDUSTRY

The Footwear Industry is a significant segment of the Leather

Industry in India.
India ranks second among the footwear producing countries
next to China.
India produces more of gents’ footwear while the world’s major
production is in ladies footwear.
The industry is labour intensive and is concentrated in the small
and cottage industry sectors. While leather shoes and uppers are
concentrated in large scale units, the sandals and chappals are
produced in the household and cottage sector.
In the case of chappals and sandals, use of non-leather material
is prevalent in the domestic market.
The major production centers India are Chennai, Ranipet, Ambur
in Tamil Nadu, , Mumbai in Maharastra, Kanpur in U.P. , Jalandhar
in Punjab, Agra and Delhi. The following table indicates
concentration of units in various parts of the country:
Thermoplastic Rubber Compounds

SUPPLY CHAIN
MANAGEMENT

DEMAND & RAW MTRL.

SUPPLY STOCKS
PRODUCT DEVELOPMENT

FUTURE LOGISTICS
DIVERSIFIC & LEAD
ATION TIME
OUTSOURCING
&
PURCHASING

TECHNICAL CUSTOMER SUPPORT