TECHNOLOGY VISION 2035
TECHNOLOGY ROADMAP MANUFACTURING
TECHNOLOGY INFORMATION, FORECASTING AND ASSESSMENT COUNCIL
MESSAGE
MESSAGE
FOREWORD
Manufacturing is a crucial and critical activity for the robust growth of economy, exports and for substantial job creation in any country. While keeping the basic needs like food, water, healthcare, housing and energy as the topmost priority for Indians in 2035, the importance of associated enablers like manufacturing, materials, ICT etc for the economic growth of our country needs to be emphasized. It is often quoted that, manufacturing sector is the force multiplier and any investment in manufacturing yields four times the effect on GDP growth.
Indian manufacturing sector currently contributes around 16% to the GDP, which amounts to a mere 1.8% of the world manufacturing output and is currently at the crossroads braving more competitive manufacturing means and strategies from other nations. Development of Indian manufacturing sector calls for strengthening and reformulating economic reforms that would reinforce the sector and enable it to grow faster and fuel the engine of inclusive growth.
Another worrisome issue is that India’s machine building capabilities need to be augmented manifold to match with our manufacturing targets. Need of the hour is, therefore, to push the manufacturing sector for its sustainable growth particularly ensuring environmental sustainability through green, lean and energy efficient process technologies with optimal utilization of natural resources.
As per the available statistics, it is expected that the next decade would witness substantial demographic change and uneven expansion of working age population. Hence, manufacturing also assumes a key role especially for emerging economies like India, where the sector can potentially generate large scale employment and meaningfully engage sizable populace in economic activities. India needs a rapid growth of the manufacturing sector not only to meet the rising demand but to accommodate millions of new entrants to the workforce.
In view of its utmost importance, TIFAC has considered the manufacturing sector as one of the 12 key sectors, under its Technology Vision 2035 exercise. This exercise is aimed at taking stock of the progress of different sectors, taking into account, new possibilities and challenges in each of them, that our country would see by the year 2035.
The technology roadmap on manufacturing sector analyses the current status and ecosystem in India, global scenario in manufacturing, technology trends and gaps, drivers to change, future technologies, R&D drivers, anticipated challenges and policy imperatives pertaining to eight key segments namely, leather, textile & apparel, chemical, metal fabrication, food processing, electronics & ICT appliances, metal fabrication, composites and micro nano manufacturing.
I am sure that the analysis and recommendations in this document would facilitate the stakeholders - government, industry, R&D and society to take informed decisions about the transformation in manufacturing sector in India in the next few decades.
Dr. Anil Kakodkar Chairman, TIFAC
PREAMBLE
Manufacturing creates both high and low value job opportunities to the growing population, accelerates wealth creation and makes products available to people, to improve the quality of life. Manufacturing is vital to ensure energy and food security apart from being the backbone of infrastructure development, mobility and healthcare. The superior capability of the country in high technology manufacturing is also critical for national security. The slogan, “Make in India” is very apt in this respect and this roadmap is oriented to identifying the technologies and strategies to improve the manufacturing competitiveness of our country.
Manufacturing encompasses a variety of fields ranging from petroleum to food processing and mining to metal fabrication. To be competitive, manufacturing needs continuous innovation and technology development in academic institutions, R&D organisations and industries, and infusion of technology to design offices and shop floors. Manufacturing, therefore, is one of the priority areas in the Technology Vision 2035 exercise.
In this sectoral roadmap document, eight major sectors of manufacturing have been considered under three categories: manufacturing sectors which are already recognised to have potential to make India a global supplier ( textile, leather, metal fabrication, chemicals), manufacturing sectors in which India lags behind considerably but is very vital for overall development of manufacturing (electronics and ICT, food processing) and sectors which have recently emerged or emerging wherein India could make a significant impact in the global scene (composites, micro nano manufacturing technology). Some sectors which are not explicitly dealt with in this report could be considered as part of the broad sectors included here.
The Indian manufacturing sector for the past two decades has been contributing to about 16% of the GDP of the nation. It is aspired that by 2035, manufacturing sector ably backed by a vibrant innovation ecosystem and frugal engineering capability, would contribute about 30-35% of GDP and lead to products affordable for people without compromises on safety, efficiency and utility.
The roadmap highlights the need for all the above said sectors to imbibe concepts such as use of smart machines and equipment complete with self-diagnostic capabilities, zero waste and zero defect principles. Adoption of concepts of machine to machine communications, product data influenced by big data and data analytics etc would bring about a globally connected manufacturing network. Such a process is likely to promote clusters of investment induced, innovation oriented MSME’s who would bring about a good “made in India” brand. The relevance of appropriate levels of skill development, training of trainers and retraining has also been highlighted.
Prof. P. Radhakrishnan Chairman, Advisory Committee Manufacturing Sector, TIFAC
GENESIS & KEY CONTRIBUTORS
Bringing out technology vision documents is one of the regular activities of TIFAC. Technology Vision 2020 was the first document of its kind. Keeping in mind the fast changing social, economical and technological scenarios both in India and globe, TIFAC has evolved the Technology Vision 2035 document. This document outlines the aspirations of Indians in 2035, the different prerogatives they would be assured of and also the technologies that would enable them to be achieved.
Manufacturing sector, being the backbone of all industries would be undoubtedly playing a critical role, directly or indirectly in achieving the prerogatives. By 2035, manufacturing would expectedly be a major wealth-producing sector in the Indian economy and would be catering to the needs of at least 150 crore consumers then. In addition, manufacturing would be providing important material support for national infrastructure and strategic sectors as well. Hence, manufacturing sector was identified as one of the 12 key sectors based on which the Technology Vision 2035 document has been scripted. Broadly, bottom-up and top-down approaches were adopted in framing the technology roadmap of this sector.
The technology roadmap exercise on manufacturing kick-started with a brainstorming meet in Delhi in end 2011, in which experts from leading industries, R&D institutions and academia participated and deliberated on selecting sub-sectors of focus, specifically in Manufacturing sector. I convey my heartfelt thanks to all the experts who had participated in the brainstorming meet and set the tone for the exercise.
This technology roadmap exercise was effectively steered by the Advisory Committee, chaired by Prof. P. Radhakrishnan, Director, PSG Institute of Advanced Studies, Coimbatore and Dr. Harit Santhanam, (Formerly) Mahindra & Mahindra was the Co-Chair. Other members of the committee include Dr. Pugazhenthy, E.D, ILZDA, Dr. C. Gajendiran, Former Director, CMTI, Dr. K. V. Raghavan , Former Director- IICT, Dr. T. V. L. Narasimha Rao, GM- Sundaram Clayton, Dr. Gautam Goswami, Scientist-F along with Ms. Jancy.A, Scientist-E, TIFAC as Member Secretary. As a result of the various deliberations in the Advisory committee meetings, 8 sub-sectors were shortlisted and authors were identified. Traditional segments such as food processing, textile, leather, chemicals and metal fabrication have been analyzed along side upcoming areas such as composites, micro and nano manufacturing, and electronics and ICT.
Questionnaires focussing on future prospects and technologies in Manufacturing were sent to around 600 professionals across the country and around 100 responses were received. Inputs from them have been collated in the document. TIFAC also had arranged for a platform to document the aspirations of young Indians recently. Aspects of the deliberations specifically related to Manufacturing have also been reflected in various sections of the roadmap.
I express my deepest appreciation and gratitude to all the members of the Advisory Committee for the timeless efforts in bringing this document to its final shape. Special record of appreciation for the unstinting commitment and personal interest shown by Prof. Radhakrishnan during the entire process of framing and scripting this technology roadmap. Thanks for the direction, feedback and assistance provided to us whenever we needed it.
The eight chapters on subsectors have been authored by Prof. P. Radhakrishnan, Dr. K. V. Raghavan , Former Director- IICT, Hyderabad, Dr. T. V. L. Narasimha Rao, GM- Sundaram Clayton, Chennai, Dr. J. Raghava Rao and Dr.J. Sreeram, Senior Scientists from CLRI, Dr.Prakash Vasudevan, Director, SITRA, Dr. Suvendu Bhattacharya, Chief Scientist, CFTRI and Dr. Zacharia Alex, Head, School of Electrical Sciences, VIT. Thanks to all the authors for their technology-
xi enriched inputs and timely cooperation throughout the phase of shaping up this roadmap.
I would like to express my heartfelt thanks to all the members of the National Apex Committee chaired by Dr. Anil Kakodkar, Chairman -TIFAC for the support, valuable insights and guidance in shaping up the Technology Roadmap on Manufacturing -2035.
This document would not have been in this form, without the involvement of our able technical editors, Dr. J. Raghava Rao and Dr. J. Sreeram, Senior Scientists from CLRI . I wish to record my sincere gratitude and thanks for their commitment and pain-staking efforts in finalising the technology roadmap, meticulously in time.
The chapters also have been enriched by value-added inputs from Prof. JP Raina (VIT), Dr.D Chandramouli (CLRI), Mr. S. Sivakumar (SITRA), Dr. Santhanakrishnan & Dr. Kousalya (Avinashilingam University), Dr. Radhaisri (PSG College of Arts and Science), Mr. R Sakthivel (VIT), Prof.VK Jain (IIT Kanpur), Prof. SS Joshi (IIT-Bombay), Prof. VK Suri (BARC), Dr.Dasaratham Yadav, Prof.V Radhakrishnan,(IISST), Mr.S.Devarajan, (Formerly)Sundaram Clayton, Prof. Alagirusamy, Textile Department, IIT (D) and Dr. Apurba, Textile Department, IIT (D). Special thanks to all the key contributors for their value addition and guidance.
I convey my heart-felt appreciation to the dedicated scientists, in Technology Vision 2035 team, Dr. Gautam Goswami, Dr. Neeraj Saxena, Ms. Jancy. A, Dr. T. Chakradhar, Ms. Mukti Prasad, Mr. Manishkumar and Ms. Swati Sharma for their technology insights, value-addition and editorial suggestions in bringing out this excellent document.
Special appreciation to the members of Scenario building team, Shri. S. Biswas, Mr. M. Thamarai selvan and Mr. Suresh babu for their involvement. Several aspects of the scenarios which emerged, have been captured in the roadmap.
I am sure, researchers, academicians, funding agencies, policy makers, manufacturers and entrepreneurs with specific interest in the manufacturing sector of India would find this document very interesting.
(Prof.Prabhat Ranjan) Executive Director TIFAC
VISION 2035 Strengthening the manufacturing base of India through innovation-driven clean, green and lean processes.
EXECUTIVE SUMMARY
Manufacturing sector is the engine of growth for India. It provides for a stable economy, sells goods to other sectors and in turn buys materials and services from them. An analysis of the contribution of this sector to the GDP of the nation would indicate that it has not contributed to its full potential. The growth of manufacturing sector into an economic powerhouse can only be realized when it imbibes technology and constantly updates the same.
Contributors to the sectoral roadmap begin with analysis of the current Indian and global manufacturing scenario leading to the identification of technology gaps, drivers for change and its possible contribution to the GDP of India. Towards this, eight major manufacturing segments where potential for innovation, creation of jobs and contribution to export earnings exist have been looked into.
Traditional segments such as textile, chemicals, food processing, leather and metal fabrication have been analyzed alongside upcoming areas such as micro and nano manufacturing, electronics and ICT products and composites.
Technology needs to meet increasing export and domestic demands, production of coloured cotton, customized apparels, technical textiles, implementing zero effluent discharge and appropriate adoption of technologies for cost reduction and quality improvement is highlighted in the textile and apparel chapter. Economic utilization of raw material and leather through a technology led growth path and adopting innovation driven manufacturing such that leather remains a consumer preference oriented fashion statement is highlight of the chapter on leather.
The requisite level of technology, infrastructure, skill and needs to reduce emissions from the chemical sector through routes including automation and process intensification has been presented in the chemical manufacturing segment. Chapter on food processing indicates that there is a scope to improve quality attributes of food along with simultaneous reduction of spoilage through innovative technologies, improvisation of supply chain and focus on traditional and health food. Chapter on metal fabrication provides a roadmap on how industry in India can grow in leaps and bounds through adoption of technologies crucial for development of machine tools, fabrication equipment, automation & precision and productive manufacturing. The chapters on micro nano manufacturing, composite fabrication and electronic appliances & ICT products highlight how, inspite of being relatively new domains, they posses the potential to revolutionise the manufacturing sector, through development of tools for self assembly, repairs, machining and development of state-of-art fabs for ICT and electronics appliances manufacturing.
Short, medium and long term technology needs for each specific segment has been evolved based on available literature and also based on reports and scenario / trend analysis carried out by specific government departments and those published on the World Wide Web. The document identifies a few grand challenges that manufacturing sector is likely to face by 2035 and also provides a glimpse into possible blue-sky research areas to ensure the sustained global leadership for the sector.
The vision perceived for the manufacturing sector is to create a technology edge that would turn India into a global manufacturing hub, resulting in large-scale job creation and enhanced contribution to GDP. All efforts to provide environmental and economic sustainability for the sector have been envisaged.
xvii The manufacturing sector in India needs to grow through adoption of technology platforms which include nano-engineering, additive and precision manufacturing, adaptive automation, next generation electronics, continuous and sustainable manufacturing. It is perceived that adoption of these would enable the manufacturing sector to meet India’s domestic needs as well as export value added products. Areas requiring development and adoption of technologies for manufacturing of products based on the likely changes in lifestyle and demographic dividend have been identified.
Recommendations that have evolved from this exercise to turn Indian industries as a global hub of manufacturing are a) creating innovation eco-systems at all levels b) developing systems for skill development, upgradation and certification c) emphasis on both economies of scale and scope models based on investment required for technology updation d) making available essential inputs such as raw material and energy at globally competitive rates, e) innovative technologies for frugal utilization of material f) building coalitions and encouraging cluster approach of MSME’s for appropriate investments in R&D, supporting technology acquisition and for design know how.
It is felt that through adoption of the recommendations, the manufacturing sector could ideally contribute 30 - 35% of GDP by 2035. Accordingly, the technology roadmap concludes by highlighting the need for a concerted effort from stakeholders that includes the government, R&D organizations, industries and academia for realization of the Vision 2035. INTRODUCTION
Manufacturing sector which encompasses the entire spectrum covering transportation, energy, health, food, housing, clothing, leather, infrastructure, ICT, entertainment, consumer goods etc is vital and should contribute significantly to GDP of the nation. The competitive industrial performance index places India at a dismal position of 43 amongst 133 countries. Amongst the factors that determine competitiveness, India figures in the top 20 countries only with respect to creating world impact and not so with respect to capacity to produce and export and technology deepening. This has resulted in Indian manufacturing sector contributing only 16% to the GDP as against global best of 30-35%.
The technology roadmap for manufacturing is, therefore, focused on providing employment to the growing population, improving the quality of life, increasing the per capita income to the level of advanced countries, and placing a few Indian manufacturing companies among the top 100 in the world and several hundred Indian products competing globally, successfully in quality, cost and performance with brands from other countries.
By 2035, India should be manufacturing for the world in areas where it has a competitive edge in terms of raw material supply as well as backward and forward integration. This requires both R&D and vastly improved education and massive skill development initiative to increase the productivity of young workforce. There is the need for creating an ecosystem of continuous technology development, upgradation, assimilation and adaptation to make the products competitive.
In order to achieve this vision, it is necessary to scale up through adoption of new manufacturing strategies, creating a broad base of micro, small and medium industries and an effective and efficient ecosystem for transfer of technology from research to business on a scale several fold from the current level of 53 as against global best.
Manufacturing is on the threshold of a massive paradigm change with additive manufacturing, molecular manufacturing, self assembly etc offering the potential of creating new products through unconventional but more efficient routes in addition to developing vastly improved products through environmentally sustainable and new technologies like micro nano technology.
The vision 2035 for manufacturing requires development of innovative products, development of indigenous manufacturing and next generation ICT for clean, green and lean manufacturing. Changes in education system for enhancing creativity and innovation, developing R&D in emerging technologies and providing adequate infrastructure for seamless manufacturing is required. Educational institutions should bring about mindset changes in cultural disposition to use our own hands.
For the manufacturing sector to reach its envisioned goals of contribution to the nation, it is likely to encounter some challenges requiring technology preparedness, sound implementation strategies and favourable policy environment. Grand challenge that this sector needs to resolve would be guaranteeing sustainability through adoption of appropriate global best practices on material, energy and time management.
Indian manufacturing industry would benefit more from innovative utilization of available indigenous material and their transformation into value added products. Industry may need to adopt principles of additive or cloud manufacturing, cluster approaches to meet common needs etc. This would transform Indian manufacturing into one of micro enterprise model that can produce customized goods based on local needs.
xix
SECTIONS
23 37
1. TEXTILES & 2. LEATHER APPAREL
57 79
3. CHEMICAL 4. METAL FABRICATION
95 109
5. FOOD 6. ELECTRONICS & PROCESSING ICT APPLIANCES
123 137
7. COMPOSITES 8. MICRO NANO FABRICATION MANUFACTURING
xxi
TEXTILES & APPAREL
Textile and Apparel industry is the largest in terms of employment potential and has an immense potential for vertically integrated growth. Export as well as domestic demand for quality textile and apparel from India is expected to see marked growth. New technologies like customised apparel production, wearable electronics, technical textiles, zero effluent processes, etc are likely to gain momentum and shall offer a cutting edge advantage to the Indian textile industry. TECHNOLOGY VISION 2035
26 TEXTILES & APPAREL TECHNOLOGY ROADMAP: MANUFACTURING
1.0 INTRODUCTION
Textile industry is one of the oldest INDIAN TEXTILE INDUSTRY CONTRIBUTES TO industries in the world with a rich heritage and is the second largest industry, next only to agriculture in terms of employment potential. The textile and garments sector occupies a significant position in the total 11% 14 % INDUSTRIAL MANUFACTURING volume of merchandise trade across PRODUCTION SECTOR countries. World trade in textiles and clothing amounted to USD 772 billion in 2013.1 Developing countries are the major exporters, which account for a little over two-thirds of the world exports in textiles 4 % 10 % GDP EXPORT and clothing. The per capita consumption of EARNINGS INDIAN textiles throughout the world, including that SCENARIO of the developing countries, has been on the rise over the years and the increased CURRENT INDIAN AND GLOBAL 10 % EXPORT utilization of textile materials in automobile, SCENARIO EARNINGS industrial and other technical areas will only Indian scenario: The Indian textile industry propel it to grow further. contributes about 11 percent to industrial production, 14 percent to the manufacturing The Indian textile industry can legitimately sector, 4 percent to the GDP and 10 percent be proud of its status as being a pioneer in to the country’s total export earnings.3 Approximately, the world owing to its long-standing textile one out of every history and the availability of skilled manpower The fundamental strength of this industry six households since time immemorial. It has remained flows from its strong production base of a in the country predominantly unorganised until globalisation wide range of fibres / yarns from natural fibres depends on this arrived on the scene. The opening up of the like cotton, jute, silk and wool to synthetic / sector, either economy gave the much-needed thrust to man-made fibres like polyester, viscose, nylon directly or the Indian textile industry, which now has and acrylic. Per capita consumption of fibre indirectly, for successfully become one of the largest in the in 2011 for the World taken as a whole was their livelihood, world. Approximately, one out of every six pegged at 11 kg of which cotton was about 3.5 resulting in direct households in the country depends on this kg, representing 32% of the total consumption. employment to sector, either directly or indirectly, for their India’s per capita consumption is about 2/3rd of over 45 million livelihood, resulting in direct employment to the world’s per capita consumption. However, people and to over 45 million people and to another 60 this trend is likely to change in the future years another 60 million million people who are engaged in its allied due to the growing economy and the resulting people who are activities.2 purchasing power in India. The fashion trend in engaged in its India is moving from “need based clothing” to allied activities. “occasion specific dressing” and is projected
TEXTILES & APPAREL 27 TECHNOLOGY VISION 2035
also emerged as exporters of readymade India to be a global leader in the manufacture of value garments not because they have an established textile base, but, on the strength of preferential added textiles and apparel through integration of available tariff arrangement under the quota regime. capacities with state-of-the-art technology, skilled human In so far as the resource-based advantage is resources and best environmental management practices. concerned, it may be said that countries like India, Pakistan, China, Uzbekistan, Turkey and USA have the same in cotton; China, India, to move further to “fashion & detail oriented” Vietnam and Brazil in silk; Australia, China, New dressing. Zealand and India in wool and China, India, Indonesia, Taiwan, Turkey, USA, Korea and a few From environmental point of view, textile CIS countries in man-made fibres. In addition, industry is recognized as a major polluter. It China, India, Pakistan, USA and Indonesia have discharges great amount of water contaminated capacity based advantages in the textile spinning with dyes, finishing chemicals, cleaning and weaving. In spite of all these, India hasn’t compounds, wax and lanolin removed from been able to make optimal capacity utilization natural fibres, and compounds used to produce due to lack of quality awareness and lack of synthetic fibres into rivers, streams, and lakes. professional management as, majority of home Gaseous emission includes excess heat, fly ash, grown textile units are family owned private carbon dioxide, formaldehyde, and sulfurous firms. and nitrous compounds that contribute to acid rain. Excess packaging, discarded cardboard India’s share in global textiles has increased and paper goods, empty metal drums, and by 17.5% in the year 2013 compared to the hazardous and toxic chemicals are deposited previous year. Currently our textiles export is in landfills. Other environmental problems are USD 40.2 billion, with a growth rate of 23% high intensity noise in spinning and weaving as against global rate of 4.7%. Of the textiles rooms and dust and airborne debris in opening export from India, the contribution of apparel and spinning areas. Developing eco-friendly and clothing sector is phenomenal (43%). processes in textile Industry is one of the major challenges in the present scenario. Technical textiles: Technical textiles are specially engineered textiles which the user industries Global scenario: The USA, European Union belonging to wide-ranging segments such as and Canada are the major importers in the agriculture, clothing, healthcare, construction, global textile market while Asian countries have sportswear, packaging, sports equipment, been the major sourcing region for imports automotive, etc. deploy for getting their of textiles and clothing by both USA and functional requirements fulfilled. Current European Union. The next important sourcing market size of this industry in India is around region for USA has been the Latin American USD 14 - 17 billion and is expected to reach countries while the same for European Union USD 32 billion by 2023. have been Central and East European countries. For Canada, the principal sourcing region has DEMAND PROJECTIONS WITH RESPECT been the USA, while Asia finishes at a close TO 2035 second; this obviously points to the fact that India has always been a force to be reckoned there has been a great deal of re-exports with in the global textile industry scenario from USA. As far as the position of individual from early ages. Though country’s fragmented countries in all these markets are concerned, decentralized small and medium scale textile the nations like China, Mexico, Turkey and India industries are currently facing stiff competition India, hopefully, occupy dominant positions. India is one of the from China and such other nations in the will continue to leading suppliers of readymade garments to liberalized global market, the traditional wisdom have a good share USA. In the EU market also, India is a preferred brought about by a rich heritage for quality of global textile supplier for many of the textile products. It is textile materials seemingly not withering away, trade, provided it forecasted that, in a few years from now, Turkey India, hopefully, will continue to have a good gears up for the would emerge as the biggest competitor for share of global textile trade, provided it gears 4,5 challenges in the both India and China. Countries like Mexico, up for the challenges in the times to come. times to come. Caribbean Basin Initiative (CBI) countries, many of the African countries and Bangladesh have Inspite of having the largest loom capacity
28 TEXTILES & APPAREL TECHNOLOGY ROADMAP: MANUFACTURING
production is bound to find the going to be increasingly tough. Having said that, 2014 2020 2035 PROJECTED PROJECTED India’s strength in the manufacture of cloth lies with its labour force adept at
6 producing value added textile materials on account of which the country’s visibility in the world’s quality textile segment may 1.24 1.32 1.54 very much remain a reality.
7.10 7.70 8.60
POPULATION (BILLION) POPULATION Based on the projections, it is expected that the requirement of textile goods
7 in India and across the globe will be increasing constantly.
Overall global demand across the textile 7.5 11.0^ 19.0^ value chain is expected to grow by around PER CAPITA PER CAPITA 3% year-on-year in the coming years.2 11.0 13.9@ 21.7@ CONSUMPTION OF FIBRE (KG) The factors that would affect the projections with respect to consumption 1,2 of textiles and apparels in India are its demography and changes in life style based on demographic dividend existing in 2035. 58 140* 385# This is already reflected in the faster rate of per capita spend on apparel between 662 978$ 2033$ INDUSTRY (BILLION USD) 2012 and 2025 (from USD 36 to 138). SIZE OF TEXTILE AND APPAREL SIZE OF TEXTILE AND APPAREL
GLOBAL INDIA For increase in the spindle speeds and adopting modern processing systems with @Extrapolated at a automatic controls, cotton possessing a set CAGR of 3% of attributes is required. This includes a) 50 67 $Extrapolated at a CAGR of 5% highly clean, contaminant-free, b) stronger & STAPLE FIBRE 58@ SPUN YARN 87@ * (MILLION TONNES) (MILLION TONNES) Extrapolated at a and mature fibres for a given length, c) low 2 CAGR of 11% variability in fibre attributes from bale to #Extrapolated at a 79@ 135@ bale, d) lower short fibre content, e) higher CAGR of 7% from 2021 to 2035 fibre elongation, f) lower fibre neps and
370 145 ^Extrapolated at a seed coat fragments, g) lower organic trash CAGR of 5 % upto and micro dust and h) higher amenability WOVEN FABRIC 473@ APPAREL 189@ 2025 & 3% from (BILLION SQUARE (BILLION PIECES) 2025 to 2035 & to cleaning is required. METRES) includes filament yarn as well 737@ 293@ These developments have grouped &
GLOBAL DEMAND FOR TEXTILE GOODS DEMAND FOR GLOBAL Includes filament yarn as well several of the intermittent processes into 2014 2020 (PROJECTED) 2035 (PROJECTED) a continuous interrelated process, which had led to improved productivity and in the world and the world’s second largest quality. Ability to react quickly to the call of spindleage, India’s export share in global textile the market had been the major driving force market is abysmally low at 5.2% as of 2013. This behind the technological inventions during only points to the dire need for increasing the the 1990s. Improvement in speed and hence quality, productivity, value addition, consistency, the productivity / flexibility was the key target Overall global volume and timely delivery strictly as per the rather than cost reduction measures. However, demand across schedule committed to the buyer. Though, the these technology improvements came attached the textile value overall quality and productivity of the Indian with a premium price tag, which the small and chain is expected spinning mills are good, the fragmented nature medium scale industries could not afford. to grow by and old technology being employed by the around 3% year- Indian weaving industry, in turn, are placing a on-year in the demand for turning out a still higher quality coming years of spun yarn without which the woven cloth
TEXTILES & APPAREL 29 TECHNOLOGY VISION 2035
2.0 TRENDS IN TECHNOLOGY DEVELOPMENT
For increase in the spindle speeds and adopting major driving force behind the technological modern processing systems with automatic inventions during the 1990s. Improvement in controls, cotton possessing a set of attributes speed and hence the productivity / flexibility is required. This includes a) highly clean, was the key target rather than cost reduction contaminant-free, b) stronger and mature fibres measures. However, these technology for a given length, c) low variability in fibre improvements came attached with a premium attributes from bale to bale, d) lower short price tag, which the small and medium scale fibre content, e) higher fibre elongation, f) lower industries could not afford. fibre neps and seed coat fragments, g) lower organic trash and micro dust and h) higher Automation amenability to cleaning is required. Developed countries like Europe and USA saw a case in point towards automating their These developments have grouped several of facilities due to the prevalence of high labour the intermittent processes into a continuous cost in their countries. In India, during the interrelated process, which had led to improved last couple of decades, automation has taken productivity and quality. Ability to react place in almost all the processes related to quickly to the call of the market had been the textile manufacture viz., cotton picking, ginning,
DEMAND PROJECTION FOR DEMAND PROJECTION FOR STAPLE FIBRE (MILLION TONNES) FABRIC (BILLION SQUARE METRES) 2005 41 2005 310 2011 50 2011 370 2016 53 2016 420 2021 59 2021 487 2026 65 2026 565 2031 72 2031 655 YEARS
YEARS 2036 80 2036 760
DEMAND PROJECTION FOR DEMAND PROJECTION FOR In India, during YARN (MILLION TONNES) APPARELS (BILLION PIECES) the last couple 2005 57 2005 120 of decades, automation 2011 67 2011 145 has taken place 2016 77 2016 168 in almost all 2021 90 2021 194 the processes related to textile 2026 104 2026 225 manufacture 2031 120 2031 260 viz., cotton YEARS picking, ginning, 2036 139 YEARS 2036 300 spinning, weaving, processing, and Many technological changes have happened in the textile industry, which can be broadly divided into three phases. even to some From handlooms, high-speed spinning frames and looms, with reduced vibration levels, were extent in garment PHASE 1 developed in the 1950s and early 1960s. making, resulting in enormous gains During late 1960s and 1970s, rotor spinning and shuttle less looms were introduced, which brought PHASE II about a major improvement in the productivity. in productivity and efficiency. Since the late 1970s, changes in the textile industry that have occurred owe their origin to the PHASE III introduction of microelectronics- based technology and the automation of industrial processes.
30 TEXTILES & APPAREL TECHNOLOGY ROADMAP: MANUFACTURING
spinning, weaving, processing, and even to been introduced. Link winder, which has direct some extent in garment making, resulting in feeding of cops from spinning machine to the enormous gains in productivity and efficiency. cone winder, is another major advancement paving way for reduction in manpower Cotton picking: Two types of mechanical engagement. Moreover, online monitoring of harvesting equipment are used: the spindle all the machines is now possible giving the picker and the cotton stripper. The spindle much-needed flexibility in production planning picker is a selective-type harvester that uses exercises. Advancements with respect to tapered, barbed spindles to remove seed improvement of the yarn quality have come cotton from bolls. This harvester can be into being recently which include splicing of used on a field more than once to provide joints and auto piecing in open end frames, stratified harvests. On the other hand, the together with reduction in material handling cotton stripper is a non-selective or once- due to automatic transportation of cans, over harvester that removes not only the bobbins, etc. The ring spindle speeds have gone well-opened bolls but also the cracked and up to 25,000 rpm and in open end spinning, unopened bolls along with the burs and other high rotor speeds of upto 1,50,000 rpm are foreign matter. practicable now-a-days. The latest technology spinning machines like airjet spinning machines Ginning too has been automated to a great can produce yarn 20 times faster than that of extent and futuristic techniques have been ring spinning machines. proposed to take the same to even greater heights; a machine vision-based system for on- Fancy yarn manufacturing is one of the line identification of trash objects commonly important areas where there is significant found in cotton has been shown in action value addition. Electronically controlled which, employing soft computing techniques sophisticated machines are available that like, neural networks and fuzzy inference enables to have better control over the fancy systems could classify trash objects into yarn characteristics. Precise and fast change individual categories such as bark, stick, leaf and of the front roller speed in ring spinning gives pepper trash types with great accuracy. consistent and uniform slub yarn. Electronic clearing of missing, thick, thin pile, electronic Spinning industry has witnessed advancement stop motions, in the chenille yarn are the in the form of newer methods of spinning like, few recent developments in the fancy yarn open – end spinning, airjet spinning and Vortex production machinery. system. The advent of bale pluckers has made it possible to pluck cotton from several bales In the weaving sector, the technology and make a homogeneous mixture of the upgrades have swept across the complete same leading to a reduction in the batch-to- spectrum of automatic shuttle looms and batch variation in spun yarn lots. It is essential automatic shuttle-less looms culminating in that the fibre mat fed to the carding machine higher productivity. The water jet and air jet should be of a high degree of uniformity to looms use, respectively, water or pressurized Fancy yarn ensure consistent opening and carding; this air to transport the yarn with multiple colour manufacturing uniformity is achieved using the chute feed weft insertion. Implementation of electronic is one of the system, which aims at feeding a fibre sheet of control in automatic looms has simplified important areas a uniform packing density and uniform linear operational routines as only the data such as where there density (weight per unit length) to the carding yarn type, weave and width need to be input is significant machine. Stemming out of common sense is for production to proceed optimally. Quick value addition. the realization that the mass uniformity of the style changes have become possible. Electronic Electronically card sliver is an essential criterion for good jacquards enable intricate designs to be controlled subsequent processing; the card auto-levelling produced with ease. Inspection of fabrics on sophisticated system comes in handy on this count by loom, use of optical and laser detection of warp machines are measuring sliver thickness variation on real-time break, reduction in downtime due to higher available that basis, and altering the machine draft so that a levels of automation and quick warp beam enables to high consistent sliver thickness is continuously change have also occurred in the recent past. have better produced. Weft insertion rates upto 2500 mpm are now control over possible, 5 to 10 times faster than what it was the fancy yarn In the case of ring and rotor spinning, the 20 years ago. characteristics. speeds have increased and auto doffing has
TEXTILES & APPAREL 31 TECHNOLOGY VISION 2035
Automation in textile processing has Automation in chemical processing of textiles encompassed the transportation of additionally has resulted in bringing into practice batch trolleys to the respective machines, use of low liquor ratio machines, which are programmable Logic Controller (PLC) based preferred owing to their reduced effluent loads control system for automatic completion of a and less consumption of water and chemicals. process cycle, automatic dispensing / dosing of right quantity of chemicals, dyestuffs, etc., Knitting, embroidery and decorating machinery automated stock control and printing recipe, have seen numerous improvements in the recipe prediction and computer colour recent past. The new computerised flat knitting matching, centralised data collection for all the machines have minimised the need for sewing machines, centralised colour kitchen to dissolve thereby creating the knitwear into a single and dispense the dyes. piece. Knitting technology has seen good
SECTOR / PRESENT TECHNOLOGY PARAMETER TECHNOLOGY INTERVENTION SUGGESTED COTTON Majority dependence on rain Subsurface Drip irrigation (SDI) CULTIVATION ON A ATI N IV D HARVESTING Mostly manual Automation T H L A METHODS U R C V QUALITY Quality declines at the end of Hybrid seeds to maintain E
N S OF COTTON cotton season consistent quality levels
T
O
I N
T STORAGE No proper space On-farm storage T G
O OF COTTON C LENGTH Generally shorter and have wide Produce long staple cottons with OF FIBRES variations consistent quality across farms
GINNING Feeding of cotton to machines Automation done manually
Sizing is done to single warp yarns Eliminate sizing process PREPARATORY for better weave-ability. Operational speeds of weaving Improve the yarn quality suitably to WEAVING loom limited by the strength of increase loom speed warp yarns used KNITT ND IN HUMIDIFICATION The entire shed needs to be To develop chemical or a A G S REQUIREMENT AT humidified to achieve a better technology that can maintain G E C WEAVING performance the moisture levels in the yarn IN T V without resorting to the use of O
A humidification plants. R
E
W Weft knitting is predominantly used Realization of increased speeds, for making apparels adoption of warp knitting technology KNITTING Incidence of defects of major To develop stop motions that will nature is still high result in bare minimum rejections arising out of defects. ENERGY The waste recovery plants, CONSERVATION compressors and humidification Energy efficient systems plants are highly energy intensive
DEVELOPMENT Takes considerable time for Faster design change and quicker OF INTRICATE preparation of the design and to production DESIGNS produce the same
Involves a number of processes for Hybrid seeds to maintain NG SEC PREPARATORY opening and cleaning consistent quality levels NI TO IN R P S Piecing is mostly done manually Automatic Cop content is in the range of 40 Achieving a better package size at RING SPINNING to 80 g. depending upon the count. minimal power consumption. Waste generated is high Less wastage Production rate is limited to 25 m/ Increasing speed of the machine min. / a new technology multi-fold production HUMIDIFICATION Whole preparatory, spinning and Humidification plant integrated/ REQUIREMENTS winding areas are to be humidified free machine designs
32 TEXTILES & APPAREL TECHNOLOGY ROADMAP: MANUFACTURING
improvements during the past decade giving manufacturing. These technologies have room for high speed warp knitting, production minimized the waste, while ensuring increased of seamless garments, slitting of circular knitted production rates with better accuracy. In fabric at the delivery point of the knitting the assembly stage, however, technological machine itself and many more of the kind. change has so far been the incorporation of Image processors and electronic stop motions microelectronic control units to the standard have been characteristic of majority of the sewing machines in order that they are able automations. to handle complex tasks with increased speed and flexibility. During the initial stages of its The earlier innovations in apparel manufacture introduction, the computer based technology have seen development of durable, faster did not pick up due to its high cost of machines, which can carry out specialized tasks, ownership which reflected in increased cost such as, laser cutting machines replacing the of clothing. However, later, as the reliability and hydraulic die cutting machines. The subsequent versatility have become field proven, more modernization efforts involving introduction number of these machinery have been installed. of computer-aided design (CAD), computer Apart from the developments and automations numerical control (CNC) cutting systems, in the apparel making processes, a lot of and computer-aided manufacturing (CAM) innovations have occurred with respect to new have given a new dimension to apparel materials,smart textiles, etc.
SECTOR / PRESENT TECHNOLOGY PARAMETER TECHNOLOGY INTERVENTION SUGGESTED PRE-TREATMENT Preparatory processes involve Develop a combined single step de-sizing, scouring, bleaching, process that will make the fabric ING SE mercerising, etc. suitable for subsequent processes ESS C C TO Predominantly synthetic dyes are Develop more natural dyes / O R DYEING R used and in the case of polyester environment friendly synthetic dyes P / cotton blends, two-step dyeing offering a palette of wide ranging process is followed hues/shades, suitable for use with all types of fibres
Media used for dyeing is water Dyeing using Super critical CO2 or resulting in generation of effluents equivalent and make it suitable for MEDIA USED and rendering the already scarce all of the material variants namely, FOR DYEING commodity, namely, water, much cotton, polyester, viscose, acrylic, scarcer etc. AUTOMATION Automation few; prevalence of Improve the level of automation in IN WET manual work culture high this industry PROCESSING ENT SECT RM O A R G PRODUCTION Labour intensive Automation SYSTEM SMART To develop a variety of smart GARMENTS Use of smart garments is negligible garments for different applications
PRODUCTION Limited to certain designs at To develop machines suitable to OF SEAMLESS present produce numerous designs and GARMENTS patterns
MACHINERY FOR Most of these machines are Cost effective indigenous PRODUCTION imported and are pricey machinery AL T IC EXT RECYCLING OF Used to a limited extent Extraction of fibres of synthetic N IL H E FIBRES origin, from materials consigned for C S E recycling T NANO- Limited Nano cellular foam structures, TECHNOLOGY unique surface structure, soft hand, durability, antimicrobial properties and such other. SMART TEXTILES Limited to passive smart textiles From wearable computing to medical to electronic gadget controls NON-WOVEN Lack of technology for conversion Indigenous machinery FABRICS machines
TEXTILES & APPAREL 33 TECHNOLOGY VISION 2035
India in comparison to several other textile sewing technology and the structure of fabrics, producers has a low cost of production of ring although better technologies are now available spun yarn, woven ring yarn fabric, woven OE for the production of value added garments yarn fabric and the knitted ring yarn fabric.10 like plastisol printed, embroidered and art work The main reason for India’s competitive edge garments.11 In spite of automation in several in woven and knitted fabrics is the ease of of areas of textile processing, indigenous raw material availability and low labour cost. production of machinery for every conceivable However, it is a matter of concern that our segment involved in textile goods manufacture power cost and capital cost (interest and – ginning, spinning, weaving/knitting, processing depreciation) are relatively higher compared to and garment making is lacking. Apparel other countries that could pose a severe threat makers strive to cope up with ever-changing to the textile industries’ competitiveness in the fashion styles by reducing the time it takes to global market. design, produce, and deliver the goods. In this environment, technology to support such needs TECHNOLOGY GAP ANALYSIS have to emerge as an important source of A predominantly labour intensive sector, the competitiveness. Advanced technologies to fulfil textile industry has to adopt automation the extended demand for production, speed, of labour intensive processes like mixing, and quality requirements for the competitive bobbin transport, feeding the auto-winders, export market are required. Technologies such cop segregation, etc. Multi-fold increase in as robotics for automated assembly line in production is possible through changes in garment making, high speed sewing machines, currently practiced ring spinning technology. pressing and fusing techniques etc. need to be With improvements in the strength of cotton made available at affordable costs. The adoption yarns, the operational speed of looms can be of advanced technology seems to be the way increased. The development of technology in forward to improve upon on these areas and cutting and sewing is limited by the traditional meet the export standards.
3.0 TECHNOLOGIES FOR 2035 Technology change in textile and apparel in- per capita spend, c) fashion attributes such as dustry would be driven by two growth drivers simplicity of garment construction, d) customer viz., economic and life style of the consumer. desired features such as breathability, comfort, The economic sub-factors that would drive the water repellence, resistance to spread of flame, technology preparedness are a) increasing retail and anti-bacterial activity. penetration, b) disposable income, c) number of working women, d) nuclear families and e) With increase in disposable income, consumer hospitality and heath care. The life-style factors preferences for customized designs and sized that could bring about a change in the appar- products would replace buying off the shelf. el features include a) increased urbanization, b) ENERGY MANPOWERPLANNING Improved availability of energy/power Training on new range of machinery for the manufacturing units through and developing skilled labour force. adoption of options such as dedicated/ For this adoption of virtual and factory captive power and use of non- based training programs with adequate conventional sources. certification tools is called for.
TRANSPORT AND TECHNOLOGY INFRASTRUCTURE ACQUISITION Strengthening of major international Encouraging purchase or merger with gateways and corridor infrastructure foreign machinery brands. crucial to the exports and imports of products and resources.
34 TEXTILES & APPAREL TECHNOLOGY ROADMAP: MANUFACTURING
RAW MATERIAL WATER Improving quality of the cotton fibre, Placing less demand on water through production of organic and coloured innovative machines together with cotton through mechanized cultivation exploring measures for the recycling and development of high performance and reuse of water, wherever possible. fibres for applications in the The said technologies have to be re- automotive textiles, healthcare textiles, engineered to make it affordable for and personnel protective garments. small and medium scale industries.
WEAVING AND SPINNING SECTOR KNITTING SECTOR Even though traditionally strong and Developing cost effective indigenous advanced, continuous improvements to weaving and knitting machines, reduce down time, labour dependence improving versatility of air jet looms, and energy consumption are required. methods to determine optimum Spinning technology to enable multi- production speed for a given kind of fold production with better quality a fabric meant for a particular end attributes, such as introduction of application. Technologies such as warp chute feed, continuous carding and knitting need further development and drawing, automatic bobbin transport, tuning to maximize productivity and auto doffing at draw/fly/ ring frames, variety. open-end spinning and auto-winders. Use of vortex/ air jet/ rotor spinning need to gain momentum.
TECHNICAL PROCESSING SECTOR TEXTILES SECTOR Massive technology upgradation Nanotechnology initiatives to to bring in appropriate waste transform textiles into application- management technologies, in house oriented products such as protective practices such as reduction in garments, medical implant carriers, processing steps, continuous rather composites and the like needs to than batch processing, waterless be adopted. Indigenous machinery, dyeing, natural and sustainable dyes capable of working with wide-ranging / chemicals and automatic dye fibres, for the production of nonwoven dispensing system. Facilitators for fabrics having different structures this process include setting up of would need to be made available at a processing parks, fabric-tracking relatively cheaper cost. systems such as bar coding devices, automated loading, transport, folding and packing, etc.
GARMENTS SECTOR Automation in unit production, cutting Technology of fusing of fabrics, garment and stitching needs to be developed. Use printing, garment dyeing and washing should of CAD to optimally utilize the fabric and be elevated to higher platforms as they minimize the wastage of the same is an help in production of a particular design in urgent requirement. The art of producing very small lots and thereby permit quick seamless garments need to be perfected style changes. Technology for manufacture to produce garments of all sizes. Increased of recyclable garments is likely to gain demand for customized apparel would momentum. Technologies for developing lead to development of garments made smart/sensor-engineered textiles would be of non-woven with very short lead times. required in a large scale.
TEXTILES & APPAREL 35 TECHNOLOGY AND PROCESSES SHORT TERM (2013-2018) Increase the productivity of cotton To develop machines with integrated Zero effluent / liquid discharge in textile cultivation by adapting drip irrigation in humidification thus minimising the energy wet processing majority of the area under cultivation. required to a great extent. Automation to be done at ginning unit to minimise material handling
MEDIUM TERM (2018-2028) Hybrid seeds that give consistent and Automatic piecing of yarn in ring spinning system Design and develop marine outfalls to uniform cotton quality from first to last Technologies to reduce the number of processes discharge industrial effluents in a safe picking. involved in cotton spinning system. manner. Eliminate the sizing process by improving the weavability of yarns. Perfection of production of seamless garments to produce garments in varying sizes Smart clothes, through embedded wearable electronics New technology machines for the weaving and knitting sector which can help in quick style change.
LONG TERM (2028 -2035) Production of coloured cotton with a good Evolve a new spinning technology with multifold Cost effective waterless dyeing suitable for consistency in colour and in a wide range of production and optimum quality. all the materials like cotton, polyester, colours and eliminate the necessity to dye Fully automated technology for production of viscose, acrylic etc. the materials to a great extent. tailor-made garments with a customization possibility to suit individual requirements.
4.0 RECOMMENDATIONS AND IMPLEMENTATION STRATEGY
KEY RECOMMENDATIONS • Training farmers in using a range of improved and increasing development and use of agronomic practices including to prevent boll indigenous machinery, with emphasis on worm infestations innovation and local manufacture • Precision agriculture for productivity • Progress towards zero emission from the improvement industry through systematic adoption of clean • High-yielding cotton varieties process techniques, including development of machines that are less water intensive • Contract farming and accessibility to decision making tools • Set-up good infrastructure for textile designing and strengthening institutional • Capacity building in raw material and support to the garment industry manpower resources including skill upgradation and development of modern • Establishment of R&D centers for textile and innovative tools for education machinery development so as to develop textile machinery, which will address the • Produce organic cotton of consistent quality specific problems and necessities of Indian • Develop seeds for long staple fibres that can textile industry. be available throughout the year • Develop coloured cotton in variety of hues POLICY ORIENTED RECOMMENDATIONS • Implement an Indian certification system • Draw up a dynamic and strategic that offers traceability right from cotton infrastructure for efficient transport system cultivation to sale of end products as a means that is essential for handling ever-increasing of ensuring credibility at International level. volume of exports and imports. • Encouraging modernization of machinery • Consolidation of supply chain leading to vertically integrated manufacturing
36 TEXTILES & APPAREL TECHNOLOGY ROADMAP: MANUFACTURING
Hybrid seeds, which can give consistent cotton quality throughout the year Invention of a new spinning and the fibres with technology with multi-fold least possible natural production and better versatility as variations. compared to ring spinning.
Garments made of non- woven fabrics with a lead time of less than a week – a break-through that will result Increased delivery package size in in production of garments ring frames without increasing the on mass scale catering, at the power consumption and with the same time, to customized same yarn quality. style requirements. BLUE-SKY Zero effluent RESEARCH processes
Reducing the number of processing steps involved in spinning.
Waterless To develop a chemical or a technology dyeing for natural that can maintain the moisture levels and synthetic fibres. in the yarn without the need for humidification plants.
REFERENCES 1. World Trade Organization International Trade Statistics 2013 2. Ernst & Young’s attractiveness survey Turkey 2013, The shift, the growth and the promise 3. Productivity and competitiveness of Indian Manufacturing sector: Textiles and garments by National productivity council 4. A brief report on textile industry in India, May 2014 5. Final compendium Textile and Apparel 2012 –Technopak 6. Demographic Trends, Policy Influences and Economic Effects in China and India Through 2025, available from www.rand .org (accessed on 13.3.2015) 7. Golden decade for India’s textile and apparel industry (2014), available from www. alokind.com (accessed on 13.3.2015) 8. Technical textiles market by technology – global industry analysis, size, share, growth, trends and forecast 2012-2019, available from www. www.transparencymarketresearch. com/technical-textiles-market.html (accessed on 13.3.2015 9. Discover smart textiles, available from www.smita-iitd.com/discover-smart-textiles (accessed on 13.3.2015) 10. Compendium of International Textile Statistics - 2009-10, available from www.txscindia. gov.in (accessed on 13.3.2015) 11. Measuring competition for textiles: does the US make the grade? Available from www. ageconserach.um.edu/bitstream/34616/sp04ly01.pdf (accessed on 13.3.2015)
TEXTILES & APPAREL 37
LEATHER
Leather processing has remained world over as a tradition interwoven with technology activity driven mostly by market forces and consumer preferences. Science, research and innovation have by and large been undergoing changes in their own isolated spaces. Technology vision 2035 for leather foresees greater interplay of innovation driven manufacturing and leather emerging as a fashion statement. TECHNOLOGY VISION 2035
40 LEATHER TECHNOLOGY ROADMAP: MANUFACTURING
1.0 INTRODUCTION
CURRENT INDIAN AND GLOBAL hides and skins, tanning industry, product sector, SCENARIO technology trends, trade and policy. Leather and leather product industry might undergo transformational changes during the Global scenario: In the present context, next couple of decades. Technology trade tanning industry is largely concentrated in coupling is bound to increase many fold from Asia and to an extent in Latin America. the current levels. India with a share of about There are indications of industry growing 10-13% command on global supply of raw much faster in Africa, which is emerging as materials currently could foresee an untapped major sector. Countries like Brazil, Argentina opportunity in leather sector. The value and South Korea are fast moving out of the addition to raw material through technology, tanning segment. It is predicted that Africa innovation and brand building is predicted to might account for 20% of heavy leather (1% undergo major changes by 2035. Currently, as of 2013), 30% of light leather from bovine the trade value of leather is five times of that (2%) and 40% of light leather (10%) by 2035. of meat. Doubling of the global trade value of This trend will be associated with global level leather to meat during the next two decades changes such as China and India investing in is a likely challenge. Opportunity for value Africa, converting them into manufacturing / addition through technology will increase. trading partners. Conversion of leather into value added products would still remain an activity of small The net effective recovery rate (after and medium enterprises offering opportunities deduction of non-recovered hides/skins) is for high volume employment for relatively low generally employed as marker for hide/skin investment into capital goods (namely Rs. 0.5 availability. The supply of raw hides and skins Conversion of mil/job/year). Leather product sector would remains constant over time but prices are leather into value remain an industry, which connects manpower impacted by demand for leather products. added products with purchasing power. While sources of buffalo and goat appear would still remain to be promising in the next 20 years, only an activity of An integrated RAW MATERIAL AVAILABILITY TRENDS small and medium approach with enterprises clear-cut short (10 offering year frame) and opportunities long (20 year frame) for high volume term goals needs CATTLE BUFFALO GOAT SHEEP employment for to be developed to relatively low effectively couple 2012 24 MILLION 32 MILLION 94 MILLION 31 MILLION investment into technology with 2025 24.6 MILLION 38 MILLION 102 MILLION 33 MILLION capital goods trade. Hence, the (namely Rs. 0.5 foregoing analysis 2035 25 MILLION 42 MILLION 109 MILLION 34 MILLION mil/job/year) covers livestock,
LEATHER 41 TECHNOLOGY VISION 2035
a marginal growth is seen with respect to in growth to the tune of 40 mil pcs over a cattle and sheep. Net effective recovery is 20 year period, the growth rate is not as expected to go up as the current proportion of appreciable as goat skins. The major suppliers slaughtered - 75% for hides and 98% for skins1- are China, India, Australia, New Zealand, Iran will go up due to decrease in natural mortality and Turkey. Recent trends indicate that even rate, owing to better health care. Slaughter in Oceanic countries, supplies are dwindling. rate increase is also expected due to better The forecast is that there will be an increase access to meat outlets and pruning of stocks of supplies in the next years to the extent of at farmer’s level. India could also benefit from another 50 mil pcs by the year 2035. exploring other sources of raw material such as rabbits, emu birds, ray fish skins etc. INDUSTRY AND INDUSTRIAL PRACTICES Processing Industry: This industry had been Availability of quality hides and skins in India marked by a co-existence of artisanal and can be improved by adoption of promotion organized processing units. Mechanization and methods for a) stall fed goat and sheep farms, modernization adopted by the organized sector b) buff calf rearing and fattening farms, c) from time to time has resulted in improved streamlining meat industry, d) establishment quality. Ethnic footwear manufacturers of of carcass recovery centres at potential/ideal Rajasthan and Maharashtra, who account for locations, e) reducing manmade defects through less than 5% of the production, are the only better curing. dominant manufacturers in the artisanal sector today. The leather produced from Indian As possessing of raw material reserves can no leather industry today, is estimated to be 2100 longer be considered as an advantage for any mil. Sq.ft (1800 mil. Sq.ft from domestic and 300 country, an assessment of the global availability mil. Sq.ft from imported raw material/wet blue). of hides/skins is also essential. Organized tanning is predominantly in clusters Estimated current global production of hides is located in the states of Tamil Nadu (Chennai, 322 mil pcs as of 2011.2 Much of the growth of Ranipet, Ambur, Vaniyambadi, Erode and raw hides and skins supply has originated from Dindigul), Uttar Pradesh (Kanpur, Unnao), developing countries in Latin America, South West Bengal (Kolkata) and Punjab (Jalandhar), Asia, and Africa etc. A substantial reduction together accounting for close to 95% in the (fall of 26 mil pcs during the last 20 years) in country. 3 Cluster approach has the advantages the supply from developed countries has been of skilled labour, machinery capacity sharing, recorded. In particular, Europe recorded 12 mil common effluent treatment plants, ease of pcs decline from 1992.2 These trends indicate chemicals and accessory availability, service that developing countries would witness engineers etc. growth in availability of hides in the next 20 years. Overall forecast could be that developing The pace of modernization has been tardy, regions may hold higher share in the years in spite of having access to best technology ahead though the world supplies will not go and trained manpower owing to the present up significantly. The marginal increase is largely operation and management system. One of through buffalo hides from Asian region. the positive aspects of this industry is its ability to convert relatively poor quality material In the case of production of goat skins, global into best quality leathers through appropriate production is estimated as 434 mil pcs which technology. States like Andhra Pradesh are recorded a growth of 185 mil pcs over looking forward to the establishment of mega As possessing period of 20 years.2 Nearly 95% of the global leather clusters complete with environmental of raw material production of goat skins is from developing safeguards – an initiative to be considered as a reserves can countries of Asia and Africa. Asian countries major step forward for this industry. no longer be such as China, India, Pakistan and African considered as Countries consisting of Nigeria, Ethioipia and Product Industries: Major products made an advantage for Sudan have significantly contributed to the out of leather are footwear, leather garments, any country, an supply. It is anticipated that goat skin supply leather goods consisting of handbags, wallets, assessment of the would go up in the next 20 years. gloves, harness and saddler, upholstery etc. It global availability is footwear that consumes almost 50% of the of hides/skins is In regard to sheep skins, about 547 mil pcs leather produced in the world. also essential. are produced annually, of which developing countries account nearly 67%.2 With increase The manufacture of leather products is
42 LEATHER TECHNOLOGY ROADMAP: MANUFACTURING
systematically promoted in India as there is a especially after the decline of fur coats based value addition of 4 to 5 times over the raw on endangered species. Indian specialization material. In fact, value addition is taken as the in leather garment manufacture through principle goal for exports and to introduce export oriented clusters in Chennai, Noida, a series of incentives and disincentives for Mumbai and Bangalore (production capacity exports. of 16 million pieces) has been considered advantageous. Domestic market in leather Footwear sector currently exists in traditional garments is negligible as more than 90% is as well modern sectors at varied levels of currently exported. Leather garment probably operation. Domestic market is largely served would become a high value product with a low by traditional/decentralised sector with sandals, volume production. As of 2014, 120 million chappals and ethnic footwear. Footwear clusters pieces are manufactured and traded globally of are located in Agra, Kanpur and Kolkata. In which more than 66% is priced at less than US$ the case of exports, production emanates 35. This market segment will further diminish from modern units with varying capacities. and technology and unique customer values An assembly line system which is employed would start dominating. By 2035, main market as the style of production, throws open large for leather garments would be the fashion employment avenues for women workers in industry. South India with 90% of total labour in modern shoe factories, thus contributing significantly to Leather goods are a very broad category with social development of region. Of the 909 mil. a mix of utility and fashion products. India also pairs of leather footwear currently produced produces leather upholstery – sofa seat covers, (2013-14 data), 150 mil. pairs go for exports, car seat covers etc. Production segments are mostly in the form of shoes. Leather footwear in Kolkata, Delhi and Chennai, with production consumption in India is predominantly in capacity of 63 million pieces annually, of the form of chappals and sandals, ethnic which 80% goes for exports. Sub-contracting products such as Kolhapuri and Jutis. Per capita of leading global brands, which enable the consumption of footwear is likely to go up enhancement of value, is the mode of from 2 to 3 pairs in the next 10 years and to operation. With the infrastructure created for 4 pairs by 2035. Compared to non-leather fashion goods, India is becoming a major design footwear, the market share of leather footwear base for catering global market, particularly in domestic trade is quite low and this trend taking the advantage of ethnic designs. is expected to widen in the future. There are Production of upholstery is likely to strengthen indications that this trend would prevail globally. in the years ahead.
Comparison of the trends in the global scene Major categories not included above are indicates that as of now, lower segment of the the gloves and saddlery. Gloves include all market is dominated by China, while premium categories like fancy/fashion gloves, sports segment is dominated by Italy. Vietnam is fast gloves, and industrial gloves. India is the fourth catching up at global level as major contract largest exporter with annual production manufacturing country for reputed global capacity of about 52 million pairs for industrial brands. Consumption of leather footwear at gloves itself. India is positioned as the third global level may not go up significantly going by largest exporter of saddlery and harness to the the current trends. Non-leather footwear with world, accounting for a share of 9.01% in the variety may take a center stage in the years global saddlery import of US$ 1224.94 million ahead. There is a need to develop materials as of 2012. This sector is not likely to grow in for this sector. The increase in the market the long term. will be largely contributed by Asia and Africa, Technology and where income and population are rising. Use A comparison of the global trends indicates innovation content of footwear (leather plus non-leather) is likely that China, Italy and France are major players. in the manufacture to double in the next 20 years at global level. Market is likely to witness changes giving way and marketing of In this growth, leather footwear may not gain to high fashion articles rather than cheaper leather goods is much share. Leather footwear is likely to retain products. Leather accessories form a class of likely to increase mostly high priced segments only and slowly products with a potential for growth of market significantly during emerge as a premium product. demands. Design features of these products the next two offer unique opportunities for value creation decades Garment is a highly leather intensive of the consumers. Unit value realization from commodity, global market share has increased, leather as accessories is likely to increase much
LEATHER 43 TECHNOLOGY VISION 2035
higher than other products including footwear. as Brazil, Argentina, India, Australia and USA Technology and innovation content in the are less prominent with respect to share in the manufacture and marketing of leather goods global trade. is likely to increase significantly during the next two decades. Countries like India which has Based on the analysis, the goals set for Vision a large SME sector stands to gain through 2035 are: advanced research and design capability. • Establishment of integrated leather clusters and green parks linked to raw material TRADE OF INDIAN LEATHER SECTOR sources and valued added product units Trade involves two angles, viz., domestic needed and export. With dominance of non-leather • While footwear consumption will double, footwear, complexity of domestic market is leather will get hardly 10% of the share, likely to change. Premium footwear is likely therefore current growth profile based to find opportunities in the years to come. on men’s footwear and specific European Growth projections of this industry are markets need to change dominated by export market. The level of • Domestic market for leather products will exports is around USD 5.91 bil for the year grow 2013-14. Except for a few years in recent • Leather goods, foot care products, children past, export from leather sector in India has footwear, upholstery to become niche witnessed a consistent growth and in the value products year 2011-12, recorded close to 23% over • India to become hub of ethnic design the previous year.4 The industry, thanks to the products technology support, has transformed from • Technology backed growth of leather raw material exporter to an 80% finished industry in India should be seen as an product exporter. 20-25% of the export is advantage accounted by finished leather and footwear components – materials that have a huge value DEMAND PROJECTIONS FOR 2035 AND addition potential. Indian leather importers METHODOLOGY FOR ROADMAP are significantly located in Europe and China. A detailed roadmap based on current and Germany is a consistently major trading partner future trends on raw material and products for India, with a share of 15%. However, one has been put in place. This includes a) of the major concerns of India, is the share technology pathway to enforce and comply in global market, which is as less as 4% as with environmental regulations that may come of 2013-14 (USD 170 bil. of global market). from time to time, b) reducing the carbon India is finding it difficult to compete on cost footprint of the industry through development with China and on brand image with Italy. The and adopting of appropriate technologies, combined share of China and Italy is around c) adopting an economy of scope model of 40%.4 Other competitors for India are Brazil marketing to ensure technology based value and Vietnam. The model of operation of Indian addition to leather, d) technology for developing leather industry is the focus on medium various products and thus be in a position to segment of the market, wherein efforts to provide a new product mix, e) technology to consolidate the base and exploring new market develop products which would not only meet avenues is being progressively attempted. consumer preferences but also enthuse in them newer needs, f) ensuring highest level While the industry exports finished leather of compliance to animal rights and protection products, it imports hides/skins, leather, through new technologies, g) technology for chemicals, machinery etc. However, the meeting regulatory norms and finally h) wading advantage in favour of this industry is that the the competition from non-leather. imports are hardly 15% of the exports, while the same in China and Italy is around 40-50% These technology drivers are detailed below. (in value of exports). This is because, Italian leather industry imports leather for value Enforcement and compliance to addition prior to export. The import of hides/ environmental regulations: By 2035, it is skins by Indian leather industry, in spite of expected that enforcement of environment favourable policies is not significant. Resource regulations and compliance to strict emission poor nations such as South Korea, Italy and norms would force changes in technologies Turkey had become important players in adopted in leather processing. leather trade while resource rich nations such
44 LEATHER TECHNOLOGY ROADMAP: MANUFACTURING
Technology vision 2035 for leather foresees a transformation of a byproduct of meat sector into a technology driven industry, where S&T led innovations, for the first time in its long history, are likely to drive the next paradigm of change and those who enjoy access to technologies and innovations would emerge as leaders. There is an opportunity for the rise of India in global leather sector.
Carbon footprint of leather sector needs tanning industry supported by technology to to be assessed in terms of the emissions of suit environmental regulations might derive greenhouse gases at the time of storage of advantage of technology preparedness. materials, manufacture of leather and products, International brands of leather products waste management as well as the global could sustain their brand value only when transport of materials. Literature on carbon manufacturing is made without compromises footprint from leather footwear indicates a to environmental regulations. Finishing activity is wide range from 10 to 100 kg, leaving enough likely to shift from tanneries to leather product scope for technology aided reduction, such as units. Global leather processing activity would enhancing energy economy of the processes. demand environmental viability. Therefore, Cost of not processing hides and skins into leather processing activity is likely to shift to leather in the form of carbon footprint might large and medium scale manufacturing units also form a consideration. Carbon footprint with economies of scale and ability to comply analysis of global leather trade is likely to affect with regulatory norms. trading and marketing more than even leather processing technologies. On the other hand, conversion of leather into leather products is likely to derive advantages Models of marketing: Currently, global leather from economy of scope. Small and medium trade includes marketing through both enterprise in manufacturing and marketing merchandising and branding segments. By 2035, would gain through branding and formation the share of merchandising market segments is of marketing companies. India, which currently likely to decrease. Terms like labour arbitrage is operates both economy of scope and economy likely to yield way to technology and expertise of scale, with technology driven products arbitrage in global trade. Segments of global such as ladies and children footwear, safety PRIORITIES FOR 2035 ARE LIKELY TO INCLUDE
Technology simplification coupled with economic gains so as to i. Enhancing the atom and ensure adoption of in-plant control over end-of-pipe treatment energy economy of the methods process, so as to reduce 1 liquid, solid and gaseous Assisted and/ or aided transport of chemicals and auxiliaries into wastes, leading to the skin or hide doubling of weight of leather 2 obtained per ton of raw material (currently 350 kg New methods of cross-linking and long term preservation as of leather is obtained from 3 alternatives to chrome tanning 1000 kg of raw material) Conversion of solid wastes generated in leather processing units, ii. Shifting away from the meat industry and product industries into value added products, “Do-Undo” principle including amino acids, cosmetic and pharmaceutical products etc. of leather processing 4 through rationalization of Eliminating nitrogenous and sulfide gases through shift from unit processes and unit chemical to bio-processing and incorporation of aqueous operations 5 finishing to eliminate volatile organics iii. Technology simplification Adoption of appropriate technologies to reduce wastes from coupled with economic gains chemicals employed for aesthetics and value addition by shifting so as to ensure adoption of such process to product industry rather than process industry in-plant control over end-of- 6 pipe treatment methods Adoption of processes, where biodegradability of leather products can be ensured under set conditions so as to avoid iv. Waterless processing or 7 solid wastes from used products solvent recycling LEATHER 45 TECHNOLOGY VISION 2035
and occupational shoes, smart upholstery and that time. India could foresee a special status garment leathers, high end utility gloves etc. is in the new technology paradigm of 2035, likely to adopt the economy of scope model. by investing judiciously into a) research, b) Under such circumstances, the translation of technology development, c) expertise build-up, the industry from tradition based to knowledge d) compliance to global ecological and social and innovation driven is likely to happen. norms, e) building national capacity for design Leather product export market would then be innovations and f) brand building. independent of access to market. It is foreseen that technology niche would drive the Indian Consumer preferences: Likely to be dominated leather export. by fashion, utility, safety and ethics, the market for customers who would want unique product Product mix: Global leather trade currently definitions will dominate leather. Customization consists of both high volume with low value as of product features is expected to be the well as low volume with high value segments. norm of the future. This would then require the Volume segment with low value is likely to lose leather product manufacturers to innovatively to the products from non-leather materials. build products with properties that were Share of non-leather footwear is likely to ‘hitherto unknown’, so as to create a need increase from the current levels by at least rather than cater to a need. Health care sector, 50-70%. It is estimated that 1.7 billion square with footwear for specific health conditions, meters of upper materials are required for garments which can deliver drugs, monitor covering the human feet of the world as of health condition etc. would be another area for 2010. Of this need, leather is able to meet leather to dominate. currently only about 45-50%. It is not unlikely that the share of leather as upper materials Pressure groups fighting for animal rights used might decrease to less than 25% by 2035. protection are likely to mount and exert Products where low levels of expertise and influence on global leather trade. It is innovation are required seem to be a major true that there is an increasing trend of product mix of the global industry today. The vegetarianism in developed countries, but the compliance to various regulatory norms is likely meat consumption is unlikely to decrease. to push-up the cost of manufacture of leather. With improvements in purchasing power Therefore, unless leather processing industry, in developing and emerging countries, meat through new technology paradigms is able to consumption might undergo little changes. Even, gain high economic returns from by-product if vegetarianism increases in the world, death industries, it is likely that non-leather would of domesticated animals cannot be overcome. replace leather from the low priced market As long as human civilization continues to rear segments. Products, which conform to the domesticated animals, there would be supply use of processes that meet the highest levels of hides and skins and it would remain as a of ethical norms, environmental and social by-product of the livestock industry. The by- stipulations, and are declared safe for use for product nature of the leather industry alongside children and elderly alike, would dominate. the growing market and value realization from Innovation and design driven products such as leather is likely to increase value for hides women’s footwear, children shoes, and safety and skins. Slaughter of animals for hides and products will need to dominate the market. skins from reared animals is likely. This is likely Innovation driven products for aerospace, to meet several social objections. Organized intelligent garments, upholstery with smart animal farming for skins and hides from non- properties will need to be developed. conventional sources might emerge as an industrial activity in some countries. Application Leather sector is likely to undergo a major of modern techniques like stem cell for growing transformation from a material and market skin like materials in industrial environments driven industry to a technology and innovation may be considered by 2035, if the value driven sector. Expertise and innovative ability realization from leather as a fashion statement of human resource capable of transformation becomes high enough. are likely to gain high importance. Newer programs at the undergraduate and graduate For the safety of mankind, any material that level such as those on design innovation, fashion is subjected to mass production is likely to intelligence, strategic material forecasting etc. encounter regulations relating to health and would be required to provide a new generation safety, solid, liquid and gaseous discharges of manpower ideally suited for the industry at etc. By 2035, technology for production of
46 LEATHER TECHNOLOGY ROADMAP: MANUFACTURING
niche products, which are customer specific, is mandatory. expected to be coupled with environmental technologies to avoid discharge of any Non leather: By 2035, several conventional kind. In-plant processes for optimal use of uses of leather would have been replaced chemicals, raw material etc. will also be in by non-leather. This is likely on account of a) force. As products are meant for an elite class inelastic supply of raw hides and skins to meet of customers for whom the highest level of new market needs and bulk demands b) higher ethical and regulatory compliance is mandatory, costs of production than those of synthetic it is expected that industry would switch equivalents and replacements and c) ability of over to voluntary compliance than regulatory. synthetic materials to meet leather-like features. Technology for innovative products will be Challenges from synthetics can be met through coupled with technology for waste-less process. a) combination with other natural fibres such Biodegradable leathers, which do not leave as jute etc. and b) technology/innovation driven wastes after product usage, are likely to be products which are unique of hides/skins.
2.0 TRENDS IN TECHNOLOGY DEVELOPMENT
GLOBAL AND DOMESTIC TRENDS AND of the forthcoming technologies would be TECHNOLOGY GAPS the synthetic analogues to vegetable tanning Livestock: Leather industry takes birth from materials. Other organic tannages such as those livestock/ animals.5 One of the major challenges based on aldehydes will be phased out owing in analysis of livestock and subsequent to reported toxicity of the aldehydes. availability of fallen carcass for the leather The 100oC factor for shrinkage still remains industry arises from the decentralized character elusive for most tanning agents. One of the of the animal farming process in the country. options considered ideal by researchers is the Simplification of existing technologies such as mixed metal tanning systems, wherein the use those of radio frequency identification currently of chromium(III) (as oxide) can be reduced to adopted for endangered species would lead less than 25%, so as to be just good enough to to its adoption in the case of domestic animals provide desired shrinkage temperature. Mixed as well. Such technology application would metal oxides of chromium with zirconium, provide details such as animal stock availability, phosphonium and iron8 have been reported feeding and maintenance patterns, information and can be expected to lead way, as they not on the eventual death/slaughter, thus making only reduce the use of chromium but also the process of collection of raw material provide for fullness, natural colours etc. easier, quicker and above all transformation of predominant part of livestock into raw material There are also reports that chromite ore for the leather industry. processing residues9 generated by the chromite beneficiation industries, which currently are Tanning chemicals: Consumer preferences for immobilized in secure landfills will force the softer products and their ever-growing concern chromium industries to be phased out. This for safety and environment have resulted in a has also led to an increase in the price of basic call for change of tanning system away from chromium sulfate. A major segment of the chromium. Technologies for replacement of market seems to have adopted manufacture of chromium by other mineral tanning materials or basic chromium sulfate from waste products natural products have not been forthcoming.6 such as spent chrome tanning liquors. This is Such replacements by 2035 are not likely. also an indication for the leather industry to With the growing period for vegetable tanning adopt chrome free tanning where-ever possible. materials such as wattle being close to 10 years,7 genetically modified products will be By 2035, technologies for conversion of leather required to reduce the growth periods and be into leather products might opt not to deploy in a position to meet even 10% of the global heat-setting methods and therefore demands demands on tanning materials. Issues such as of shrinkage temperature above 100oC might deforestation also need to be addressed. One decrease.
LEATHER 47 TECHNOLOGY VISION 2035
GLOBAL AND INDIAN TREND IN Nanotechnology has paved way for LIVESTOCK POPULATION targeted drug delivery by way of drug encapsulation within defined matrices, 2014 2020 2035 which carry target specific binding sites. This technology can lead to metal ions (which are toxic) giving way to naturally found metal oxides encapsulated
within polymeric matrices that can CATTLE 200 206 210 specifically bind to collagen active sites, thus providing for an enhancement 1228 1390 1501 of thermal and mechanical stability.10 Research also would lead to modifications to skin collagen itself, such that enzymes involved in collagen degradation pathways cannot recognize 11 collagen, thus leading to enzymatic BUFFALO 110 127 147 stability of collagen – one of the objectives of tanning. 84 162 139
Consumer preferences and eco-norms are expected to go hand in hand in the future. There are calls for developing biodegradable leathers. Research in GOAT India and elsewhere indicate that the 144 157 169 vegetable tanned leathers are hard to 777 874 957 biodegrade, followed by chromium. This also calls for changes to tanning methodologies, so as to provide leathers, which are easy to biodegrade under given conditions. Dialdehyde-
polysaccharide combinations are SHEEP expected to perform well under such 52 56 59 12 conditions. 1026 1059 1195
In essence, research in tanning has equipped the leather industry with a basket of technologies ready for end OTHERS INDIA use. Consumer preferences as well as cost and other ecological considerations might favour the non-chromium based constraints. In a similar manner, leather tanning technologies by 2035, but it is not likely processing methods, which generate or use that cationic mineral systems will be replaced neutral salts would have to be phased out, by organic tanning agents including natural so as to avoid creating salinity to river and vegetable tanning materials. soil. Leather auxiliaries such as those used in re-tanning of leather containing neutral salts Leather Auxiliaries: Classified as bulk will have to undergo process modifications and specialty products, this industry is a to ensure salt free products. Leather as a predominant driving force of the manufacturing commodity is expected to undergo a vertical sector. Increasing knowledge on the fact that split in trade, with one segment focusing bulk chemicals contribute to emission loads on bulk products for common use such as and specialty products to presence of harmful footwear and garment and the other on substances, which are constantly, brought specialty niche products such as gloves, saddlery, under various import bans has forced the women wallets and upholstery. Lifestyle auxiliary industry to adopt changes. A large leathers such as those used in hiking, biking amount of bulk chemicals would be replaced etc. will also find niche markets. These high with robust enzymes, such as in the case of performance leathers are reported as the unhairing and fibre opening.13 This shift would pinnacle of technical achievement, with auxiliary be predominantly due to environmental manufacturers putting their best R&D efforts to
48 LEATHER TECHNOLOGY ROADMAP: MANUFACTURING
provide for properties hitherto not found with need to develop technologies to ensure the leather. absence of banned substances, or would generate toxic substances such as Cr(VI) on Smarter leather, which can act as power supply usage. carriers, deliver drugs etc based on smarter auxiliaries is expected to occupy premium Preservatives currently employed in the initial leather trade. Leather is a product of an stages of leather manufacture as well as during intelligent material – skin, which when present finishing would find constraints relating to their on the animal had performed several intelligent toxic effects. Biocides and natural product based functions such as temperature control.14 There anti-fungals are likely to dominate this part of will be an increasing trend to ensure that these the industry. intelligent functions, which involved a large number of nerve connectivity to the brain is Wastes: Two major constraints faced by either preserved or is externally provided to the global leather industry are low levels the leather through auxiliaries. of technology changes and secure and cost effective management of wastes. In the case of bulk leather, cheaper auxiliaries that can meet the demands of fullness and Zero liquid discharge methods, which are softness will be required. With customer slowly becoming mandatory, would undergo demands on knowing what chemicals go change towards zero liquid discharge through into their leather, as well as a need to meet in-plant control methods alone, rather than REACH or similar norms, there will be a trend in-plant control and end-of-pipe treatment. to classify such chemicals as generic products. The compliance is expected to change from These products would be simple enough for a statutory to voluntary as cost of water as large tanner or a cluster to produce in-house, a raw material will be high. Technological preferably using wastes generated in the options, which have currently remained at the tannery employed as raw material. There will laboratory level such as process integration; also be a niche market for one-shot auxiliaries, reversed leather processing etc. will have to be such as those, which provide multifunctional adopted by the tanners. property of re-tanning with fatliquoring. Safety at the workplace will gain relevance. Dyes are expected to dominate the auxiliary Odour abatement, control over VOC and trade. Products, which have good fastness and other gaseous emissions, noise etc. will gain can withstand user dictated usage conditions prominence. In fact the release of greenhouse will be predominant. This includes the use of gases and sludge from the waste treatment reactive dyes. Green-mark, which is expected plants itself will be an issue to tackle. to dominate consumer minds, would pave way for the use of natural dyes in leather, similar to Atom economy in leather processing being the case of textiles. Usage of pigments would low,15 tanners who adopt such processes be predominantly for lower end products as with a very high atom economy, will end niche products would require leathers to show up occupying the heights of the profit table. off their natural hair pattern and blemishes. Choice of chemicals, their compatibility to Pigments and finishing auxiliaries, which are each other, process machinery, which promote transparent and yet can cover defects, as well as better diffusion etc. will become critical. With that can provide specific functions such as cool biological processes reported to provide for factor, camouflage properties, thermo-chromic a higher area yield compared to conventional effects etc. are likely to dominate both fashion processes, tanners will be prompted to adopt and smarter leather product markets. such methods as leather is sold by area rather than weight. Chemistry of fatliquors could find a change from sulfonation. Products, which are amphoteric, are Technologies for conversion of the wastes likely to be preferred. Consumer demands for (650 kg per ton of raw material) into value flame retardance, water resistance etc. would added products are currently available. Tanners lead to a new range of fatliquors. Though quite will either have to turn to producers of such young, nano-emulsions could occupy a small value added products or will have to integrate portion of the leather lubrication products. themselves with such producers. Biological disintegration of wastes in the tannery premises, In all these auxiliaries, manufacturers would leading to generation of bioenergy for use in
LEATHER 49 TECHNOLOGY VISION 2035
tanneries itself will be one of the options to look skin or hide. Economics of survival could force ahead. tanning sector to explore technologies for fuller realization of other by-products of skin or hide. Other matrix components of skin or hide: It Life Cycle Analysis concepts could promote is widely known that potential economic values the global leather industry to adopt closed of several minor matrix components of skin cluster or network, where animal husbandry or hide are not being realized in the manner systems, chemical manufacturers, tanners, in which skin or hide is processed in tannery product manufactures and by-product utilization sector. Leather processing sector has operated industries could co-exist. This provides for with a mindset of a by-product of meat industry newer approaches to management of chemicals, and had not focused in gaining values from raw material and wastes, thus leading to zero high value and minor matrix components of discharge clusters.
3.0 TECHNOLOGIES FOR 2035
TECHNOLOGY DRIVERS, CHALLENGES AND manufacture of chemicals and meat industry, INTERVENTIONS which can provide hide/skin as green/chilled Any industry would want to maximize its profits. will obviously be the way forward. Industry will In the case of leather industry, value addition also have to implement adequate measures to the raw material, which will continue to be for reduction of gaseous emissions and adopt procured by weight and sold by area, would technologies, which will enable them to obtain depend on technology employed to upgrade high atom economy and low carbon wastage. the available raw material, conversion of any Highest level of operational health and safety will type of material into premium products and also have to be implemented. above all maximizing the area yield. Technologies that will enhance the area of leather, such as Creation of green technology parks and its biotechnology oriented techniques for operations linkages to innovation hubs would be required prior to tanning and mechanical operations after to be ahead of time in technology advancements crusting will have to be employed. for the industry. These parks should have facilities for proper sourcing of collagenous wastes of One of the key concerns of a modern leather the leather sector, process them and forward factory of 2035 would be the time of processing. to pharmaceutical / cosmetic industries which Current schedules of a minimum of one week for can convert them into value added products. processing would need to be reduced to a day or Direct linkage between these two industries, so so through appropriate adoption of technology as to churn out collagen product industries, as and mechanization/automation. With availability by-product utilizers of tanning industry would of quality manpower on the decrease for such be required. In essence, these green parks will wet-end operations, a complete automated implement a cradle-to-grave approach for leather. tannery with adequate in-process quality control measures would be required. Tanneries and One of the major challenges that the leather product manufacturers will also benefit from industry would encounter to reduce its carbon clustering, where leather manufacturer can credits is to find adequate use for its non- understand the property requirements of the collagenous organic matter. An analysis of the product manufacturer and work accordingly. technology related challenges, and a roadmap to overcome such challenges over a period of time The transition from a by-product of meat so as to be ready with an industry implementable industry into an industry making value added technology by 2035 has been analyzed. For this products comes with challenges on the ethnic technology solutions to current problems, which front as well. Leather industry will have to work can be achieved in the next 5 – 7 years have on its carbon credits. been classified as short, 10 – 15 years as medium (do-how and show-how period) and around 20 Clustering of the leather industry in areas where years as long (technology upscaling, do-how and forward and backward linkages to auxiliary show-how period) . manufacturers who utilize their wastes for
50 LEATHER CHALLENGES AND TECHNOLOGY SOLUTIONS SHORT TERM
CURRENT TECHNOLOGY SOLUTION
Challenge Technology Drawbacks Short term Medium term Long term Leads
Salt for preservation Alternative chemicals/ Cost reachability to Mobile chillers Low cost chemical - Integration of flaying to Chilling farmer alternatives leather clusters - Process green
Salted hides Mechanical desalting Disposal of salt Disposal to sea Avoidance of salt Process green
Lime and sulphide Enzymatic process -Cost -Robust enzymes Drum based systems, One enzyme systems for -Enzyme robustness -Enzyme delivery Area yield enhancement unhairing, flesh removal, -Skin looseness vehicles – short hair removal and nanotechnology degreasing
Salt in pickle Salt free pickling Avoids added salt alone RO based treatment of Salt free tanning - Synthetic vegetable wastewater agents tannin analogues Recycling - Partial replacement of Cr
Chromium in tanning - Chrome-other metal Shrinkage temperature - Wet whites - Product recycling for - Synthetic vegetable tanning provided by alternatives - Low chrome tanning Cr recovery tannin analogues - Vegetable tanning - Recovery of Cr from - Complete recovery in - Mixed metal (Cr Free wastes tanneries and product tanning) industries - Waterless tanning Chromium in tanning - Chrome-other metal Shrinkage temperature - Wet whites - Product recycling for - Synthetic vegetable tanning provided by alternatives - Low chrome tanning Cr recovery tannin analogues - Vegetable tanning - Recovery of Cr from - Complete recovery in - Mixed metal (Cr Free wastes tanneries and product tanning) industries - Waterless tanning
REACH norms for Compliance, avoidance Short product life cycle Generic products for Leather waste based Integration of auxiliary auxiliaries of banned chemicals conventional products auxiliaries units to leather clusters
RO Rejects None Storage of reject Low salt – compliant Efficient utilization of - Salt free processes salt friendly RO systems generated salt - Waterless processes
Competition from synthetics Low cost Quality Phasing out of low cost Niche footwear Footcare rather than footwear leather footwear footwear
Value addition Finishing/post tanning Cost, Not customer Lifestyle/aesthetic Enhanced value Customer preferred based preferred products from lower addition through niche products from end products and low cost lower ends through production multifunctionality, smart features Cost reduction through product finishing rather than leather finishing
Products – competition Technology and stature Cost Leather plus natural Smart products Niche products with from synthetics preference products – preferred technology superiority, ethnicity natural product advantage, devoid of
ethical and social issues TECHNOLOGY ROADMAP: MANUFACTURING
Solid wastes Landfills, low cost Feasibility in the long Value addition to Better recovery and Atom economy to products run waste generation of value ensure complete added products utilization of raw including amino material acids Integration of by- product industry to tannery clusters TECHNOLOGY VISION2035
CHALLENGES AND TECHNOLOGY SOLUTIONS MEDIUM TERM
CURRENT TECHNOLOGY SOLUTION
Challenge Technology Drawbacks Short term Medium term Long term Leads
Salt in auxiliaries RO treatment, solar Cost Phasing out of products Liquid products to Encapsulation of active evaporation high on salt avoid neutral salts on ingredient in polymeric drying matrices and delivery
Gaseous emissions Scrubbers Cost Enzymes in beamhouse - Odour and gas Atom economy to Monitoring scrubbers in drums ensure complete devices - Avoidance of avoidance of gaseous compounds releasing emissions gaseous emissions
Value for leather Finishing and post Short life Cost reduction through - Cost reduction through New raw materials tanning processes for in process control and avoidance of end-of-pipe and raw material value addition monitoring treatment independent products - Customer and lifestyle preferred products from low end raw material
Machinery None Not optimized - Ultrasound and other - Newer solvents for In process control, for improved technologies to aid enhanced penetration fuzzy logic based fault diffusion penetration - Nanoproducts diagnosis, reduced - Machinery optimized for improved time for penetration, for clean recovery of diffusion enhanced recovery wastes of solid, liquid and gas wastes for value addition None Not optimized - Ultrasound and other - Newer solvents for In process control, for improved technologies to aid enhanced penetration fuzzy logic based fault diffusion penetration - Nanoproducts diagnosis, reduced - Machinery optimized for improved time for penetration, for clean recovery of diffusion enhanced recovery wastes of solid, liquid and gas wastes for value addition
LONG TERM
CURRENT TECHNOLOGY SOLUTION
Challenge Technology Drawbacks Short term Medium term Long term Leads
Ethical and Social issues Major level Limited to few Regulatory compliance Niche markets Products based on compliance tanners to norms meets indirect provides voluntary available raw material, ethics and social rather than regulatory integrated processing compliance compliance clusters, niche products and niche markets
Process duration None Limited by Diffusion chemistry Fixation chemistry to be Product size not be chemistry to reduce process innovatively managed a limiting factor to duration to reduce process diffusion Fixation times through coordinate and covalent linkages with faster kinetics
Human resource - Workforce Limited to skill of Adequate training of Robotics for work Reduced dependence driven operation workforce, gained new manpower on management, non on intuitions. Skill - Guided by their only through areas such as machinery, destructive and online dependence only for skill and intuitions experience design, quality testing facilities innovation in process assessment and product space
TECHNOLOGY ROADMAP: MANUFACTURING
These organic materials will also have to be leather sector to survive as there are no other adequately transformed into value added good options for disposal of raw skins/hides products. Forward linkage with industries who at a premium price. Industry would need a can convert these wastes into products is corporate environmental commitment. The best essential. option forward for the industry is to gain global acceptance through better environmental and In short, tanning industry of the future will be quality management. an integrated enterprise with linkages to raw material supplier and solid waste utilizer, one External factors: Synthetics, economy and time which has a zero discharge policy for water – would be three major issues to deal with. These completely dependent on inplant methods and are directly related to the disposable income where no gaseous emissions occur. available to the consumers. The category of leather and leather products is promoted as an TECHNOLOGY INTERVENTIONS export commodity for India, as the disposable Property related: where a constant innovation income available with the consumer in India to provide consumer preferred properties is not high enough to afford premier quality from available raw material rather than raw of leather products. India, today adopts both material of choice would be the focus. With the ‘economy of scope’ and ‘economy of scale’ growth rate of cow and sheep the ideal raw models, where high value niche products are material for several applications not in favour exported and low value products such as of India, Indian leather industry would need to common footwear are domestically traded. either import raw material of choice either as Even in the case of footwear, technological hides or skins or as leather for conversion into intervention to produce leather and footwear products. Under such circumstances, the price at a price economically acceptable and within of the final product would be dependent on minor variations to that of synthetic (non- the supplier rather than the leather producer. It leather) footwear would be required. would be ideal for India to innovate processing methodologies such that any leather can be The likely situation by 2035 could be analyzed produced from any material, especially when from three scenarios of disposable incomes. a dearth of raw material is not envisaged for First scenario would be that of disposable India. incomes of consumers remain as that of 2013 whereas human population continue to rise In the product arena, the growth of footwear on the projected lines by 2035. Given the into foot-care and personalized products social pressures, environmental regulations would bring in cross fertilization of ideas and would continue to be stringent and even methods of uplifting the hidden properties of more in the years ahead. Tanners will have to hides/skins for such products will have to be adopt technologies for in-house or end-of- worked up. This would enable India to capture pipe treatment of wastes, leading to cost of the niche market as the normal footwear manufacture of leather remaining high. This market is expected to give way to synthetics. would lead to leather occupying spaces of niche Concentrating on intelligent products and consumer demand and the market for the niche markets such as upholstery is needed. same would be in regions where the disposable Upholstery for aircrafts, waterproof leathers income available with the consumer is good for aviation industry are some of the niche enough to afford leather products. It means that products with high value. export focus will continue with low/poor off take in the domestic market. It is quite unlikely Cost-benefit ratio:In spite of fluctuations in scenario. trade, the most innovative tanner would be one who is able to enhance his benefits at reducing The second scenario would be that of costs. Innovations in chemical and raw material disposable income available with the Indian utilization (reducing their cost contribution consumer increases, say by 25% from to overall cost), environmental management, the current. Under such circumstances, manpower etc. will be more prevalent. niche leather footwear would find market domestically, while export market would Societal: Country would want the industry to still continue. Non-leather footwear may survive, more so as a large number of people dominate the day-to-day use footwear markets. are dependent on this industry indirectly. The mindset of the consumer to procure Animal husbandry systems would want economically viable products for day-to-day use
LEATHER 55 TECHNOLOGY VISION 2035
and high end products for once in a while use, the ethical and other social norms. Going by would retain the consumer requirements of the current assessment of population increase leather footwear to less than 2 pairs per year and rise in the disposable incomes by 2035 in per person. Under such circumstances, leather India, the market for leather products is quietly footwear would move into niche use segments likely to take the shape of second scenario as rather than common use footwear. envisaged above.
The third scenario is that of the disposable Manpower: Wet processing involving a large income increases by 50% from the current. amount of hands on work is classical of leather Indian leather industry would move into the processing. Availability of shop floor workers ‘economy of scope’ model rather than the for such activities would continue to diminish. ‘economy of scale’. Under such a situation, Industry may have to adopt automated systems niche/ technologically superior leather products for bulk activities like initial preparative steps will find significant market in India, particularly and devote quality manpower for areas where for elite and enlightened consumers of India. the aesthetics and value of leather is amplified. These products may have to be in the form Products like footwear would benefit from high of ‘personalized to the end user’ and satisfying level automation.
4.0 RECOMMENDATIONS AND IMPLEMENTATION STRATEGY
DIRECTIONS FOR STAKEHOLDERS (present) to access of creation of consumer It is a recognized fact that the future of values through applications of knowledge and wealth creation in global economy is innovation is envisaged. Specialty products, connected to knowledge creation system. For which enable the “elite” to distinguish instance, innovation in processing or product themselves as special owners, is a key element manufacture is directly connected to how to creation of consumer values. Indian leather well one can overcome competition. In the industry while enhancing its current strengths years to come, the ability of leather industry in areas such as raw materials, human capital, to wade away competition from synthetics will expertise base, R&D base, institutional strength, crucially depend on its ability to take forward environmental preparedness, fashion forecasting its science, technology and innovation skills. This and design forecasting needs to venture into could be for performance upgradation or even areas such as gaining access to low cost capital, cost reduction in a normal product. Amongst hardware support to adopt innovations, labour the global players in leather, it is foreseen productivity, technology culture in tanning that domination of countries that have access and product industries, creativity linked to to materials and market will be reduced if customer preferences, brand image and finally countries that do not have such access adopt ability to create an innovation driven product knowledge dependent economic growth profile. market. A conscious decision on whether to remain as an industry for mass market or move Challenge to the leather industry would be completely into a niche market needs to be source ‘all that is available’ rather adopting made. While mass market will be determined the ‘all that is made available’ format. Leather by the economy of scale, the niche market industry may need to intervene and integrate would operate on an economy of scope model. with meat producers and organized livestock In the economy of scale model, R&D would farmers to move origin of hides/skin supply need to focus on cost reduction, through a) from farmer lands to convenient organized cutting down the cost of hides/skin to less locations. than 25% of the final leather, b) reducing the cost of chemicals, water, energy etc. through A shift in economy drivers from access of raw appropriate management, which enhances the materials (past) to access and control of market atom and energy economy and adoption of in
56 LEATHER TECHNOLOGY ROADMAP: MANUFACTURING
house made generic products, c) reducing the STRATEGIES AND POLICY cost of waste treatment by adopting newer INTERVENTIONS technologies, and generation of energy and Strategy for development is carried out value added products from wastes – essentially through programs, which are largely funded a process of continuous innovation to enhance by government agencies. The programs cover the value per square feet of leather, through infrastructure development, human resource cost reduction. In the economy of scope model, development, support to artisan sector, an understanding of customer preferences to modernization, promotion leather cluster/ smarter products, adopting innovative elements complexes, funding common effluent systems to lead the customer to new products carrying etc. R&D is the backbone for all the efforts, properties hitherto not imagined by the which is provided through the activities of consumer, reducing the time from conception Council of Scientific and Industrial Research. to release in market and adopting changes Trade related efforts are handled by Council frequently is needed. For both these models for Leather Exports. The thrust of the policy to be successful, trained technologists and is to make leather industry strong, vibrant and innovators need to gain command of global operate on balanced growth of all sectors. leather sector. There are two dimensions for the policy POLICY CHANGES AND ETHICAL ISSUES framework. These are industrial and trade India has invested significantly into leather policies. Industrial policy pertains to balanced sector through promoting polices, developing growth of all regions and all segments of the technologies and human resource and exploring leather sector. To cite an example, various new market linkages. Leather is perhaps one categories of leather products were reserved of the few sectors in which India commands a for small scale sector till recently so as to ensure global respect as a technologically- advanced the balanced growth. In the case of trade country with large untapped potentials. When policy, it relates to exports and imports. Entire a forecast is made that technology-trade orientation of export policy is to promote coupling is likely to increase significantly, there is value added products for export. Towards this an opportunity for India to emerge as a major goal, there were bans, quota restrictions, duties player in leather sector. on the exports of low value raw materials etc. To promote value added products, series of The Council of Scientific and Industrial incentives such as cash compensatory support, Research, through its Central Leather Research duty drawback, airfreight subsidy, Rep licenses, Institute, which can network with expertise tax concessions have been offered. In the available in other laboratories generally, current context, with the emergence of WTO, develops technologies that are 5-10 years many of these restrictions / incentives have ahead of its need so as to be in a position to been taken off. However, the policy continues meet the exigencies in time. to promote fully fabricated products. Imports of raw materials and leather are allowed free of duty to spur the growth of export segment, while imports of chemicals and machinery are allowed at concessional rates of duty to support the growth.
THE SCOPE Product type and There would be a global properties would induce Niche customized Raw material dependence scouting for newer and customers rather than products for women and for product variety will cheaper resources customer inducing product children will gain turn out to be negligible
Movement to economy Indian S&T strength will stand ‘Natural’ will be the key of scope would prompt good for transformation of word in finishing industry to gain ethical leather industry into one which is clearance knowledge and innovation driven
LEATHER 57 TECHNOLOGY VISION 2035
ENVIRONMENT PRODUCTS PROCESSING RAW MATERIAL • Environment management • Products to be developed • Removal of hair and flesh without A significant amount of to be needed only for from crust leathers, finished in removal of pigmenting substances, so research will have to go in biodegradation of used product making units as to retain the natural colouring areas such as leather products as process according to the expected pattern methodologies in tanneries value in market chain – • Ensuring skin quality, and product units to resort incorporating elements of • Utilizing the natural fat and sweat gland defectless surfaces (especially to zero waste process intelligence to the product build up to provide thermostatic from diseases), enhancing techniques function substance • A constant innovation to think ahead of consumer dreams • Processing through methodologies that • Biological changes to the skin about a leather product. can be integrated to save on cost, matrix to delay putrefaction water etc. Methodologies to ensure processes by several • Fashion oriented products to zero build-up of neutral salts, enhanced hours/days be developed from unfinished atom economy and energy efficiency / non-pigmented products • Management of fibre • Finishing processes to consist of structure, orientation etc. so
rather than heavily pigmented material transparent coating to ensure coverage as to ensure better utility of post-mortem defects, while value • Design innovations to highlighting natural pre-mortem optimize material usage, blemishes. • Stem cell research to create lower cost and convert lower skin like fabric ex vivo, which ends into lifestyle, aesthetic • Leather finishing systems to be made ensures compliance to all and fashion preferred more intelligent to incorporate above as well as to issues of consumer products elements of consumer desire, device ethics in animal slaughter etc. integration etc. • Zero waste (liquid, gas, solid) processes to become a norm • On line process monitoring systems, non-destructive testing methods, test methods for banned / sensitive chemicals without the need for derivatization, sensors for odour, harmful substance release in tanneries and ETPs. • Though industry would move into economy of scope model, modifications to processing methods leading to reduction in process time from raw to finish to less than a day from current 7 days is needed
58 LEATHER TECHNOLOGY ROADMAP: MANUFACTURING
REFERENCES 1. Report of All India survey on raw hides and skins, Vol. 1, CLRI 2005 2. World statistical compendium for raw hides and skins, leather and leather footwear, 1992-2011, FAO, Rome, 2011 3. Directory of tanneries in India, CLRI (under publication) 4. Industry at a glance available from www.leatherindia.org (accessed on 13.3.2015) 5. Estimation and prediction of livestock population, CLRI under preparation 6. Sreeram et al., Encyclopedia of Metalloproteins, Springer, 2013 7. Ashish et al., Energy Education Science and Technology, 2007, 19, 37-44 8. Nishad et al., Chapter under preparation, Technoscience publication (Jaipur) 9. Sreeram et al., Resources conservation and recycling, 2003, 38, 185-212 10. Selvam et al., Colloids and Surfaces B – Biointerfaces, 2012, 100, 36-41 11. Punitha et al., Journal of Physical Chemistry B, 2009, 113, 8983-8992 12. Kanth et al., Process Biochemistry, 2009, 44, 869-874. 13. Thanikaivelan et al., Critical reviews in environmental science technology, 2005, 35, 37-79 14. Fathima et al., Proceedings of the 8th AICLST, Kolkata, 2010 15. Pradeep Kumar et al., Journal of American Leather Chemists Association, 2011, 106, 113-120
LEATHER 59
CHEMICAL
Technology has played a decisive role in enhancing the global competitiveness of industry and to improve the life cycle of processes and products in the chemical value chain. This section highlights the past and current technological trends in three important segments of chemical industry viz., basic, specialty and knowledge intensives and the technological outlook for 2035 considering the likely growth drivers and inhibitors with reference to infrastructure, human capacity building and consumer expectations
TECHNOLOGY ROADMAP: MANUFACTURING
1.0 INTRODUCTION
The chemical industry is a major provider of future manufacturing challenges, through better basic building blocks for general consumer, operation scales, process intensification use of healthcare, construction, textiles, food, defence alternative energy/feedstock. and other vital sectors of national economies.1 Global demand growth for the chemical History shows that the technology has industry is better than the annual GDP growth played a decisive role in various subsectors in several countries including China and India. of chemical industry worldwide as well as in Technological advances will provide the main India to enhance its global competitiveness driving force to transform the manufacturing and to improve the life cycle of its processes processes in three major segments viz., basic, and products in the overall value chain.2 This specialty and knowledge intensives of the report highlights the current and emerging chemical industry for better environmental and technological trends in basic, specialty and consumer acceptability. The fastest commercial knowledge intensive chemical areas and the growth areas lie in specialty and knowledge technological outlook for 2035 considering intensive chemicals. the likely growth drivers and inhibitors with reference to infrastructure, human resource Indian Chemical industry plays a critical capacity building and consumer expectation. role in boosting the manufacturing sector. It contributes approximately 15% to the OPTIMISTIC PROJECTIONS FOR overall GDP of INDIAN CHEMICAL INDUSTRY IN 2035 manufacturing BASIC SPECIALITY KNOWLEDGE sector. The CHEMICALS CHEMICALS CHEMICALS chemical manufacturing 2009 2020 2035 2009 2020 2035 2009 2020 2035
technologies Turnover 30.0 48.0 95.0 12.0 22.0 56.0 22.0 40.0 99.0 in 2035 will (USD Billion) (47%) (44%) (38%) (19%) (20%) (22%) (34%) (46%) (40%) be driven by Production 59 106 210 10 18 47 1 2 3 environment, (MMTPA) energy and Exports Indian Chemical new consumer as value 25500 35700 60000 15500 27900 50000 48500 61400 140000 industry turnover demands. in Crores INR is expected to Export The inherent to import 0.6 4.6 1.6 0.7 5.0 2.0 0.8 6.0 3.0 reach USD 250 strengths of ratio billion by 2035 chemical, bio and R&D from the 2009 expenditure 1000 2880 8550 280 1584 6720 6600 14400 44550 nanotechnologies in Crores INR level of USD 64 will be leveraged billion to meet their RDI% 0.74 0.8 5.0 1.0 1.2 6.0 1.5 2.0 7.5
CHEMICAL 63 TECHNOLOGY VISION 2035
workers in chemical manufacturing plants to INDIAN AND GLOBAL SCENARIO produce much more sophisticated chemical Indian Scenario: Indian Chemical industry products to the global markets. Indian turnover is expected to reach USD 250 billion chemical manufacturers will use a variety by 2035 from the 2009 level of USD 64 billion. of biomass-based resources from non- The share of knowledge intensive chemical edible sources like straw, plant products sector will increase to 40% level, almost on and those containing polymers derived par with basic chemical sector. The chemical from plant cell walls. The enabling biological production will reach 260 MMTPA by 2035 sciences viz., genomics, proteomics, synthetic with an overall growth of 75-80% during 2010- biology, metabolic engineering, fermentation 20. In terms of chemical exports and imports, processes and high efficiency downstream the Indian chemical industry will be export separations will be of great value to make oriented with an overall growth lead provided equivalent chemical products in a sustainable by the specialty and knowledge intensive fashion. chemical sectors. The R&D expenditure is expected to touch Rs 60,000 crores per The three Es viz., environment, energy and annum by 2035 from both public and private efficient manufacturing processes are likely sectors. The basic chemical sector is expected to make deeper impact on Indian chemical to maintain an annual average growth of industry during 2020-35. The impact of 5-6% during 2020-2035. The share of Indian international treaties on Indian chemical chemical exports is likely to reach 50% of industry will be much more deeper. They their production. Factors like enhanced per include Montreal Protocol, CWC-1997, capita chemical consumption, higher export the Stockholm Convention on Persistent competitiveness, more focused growth of Organic Chemicals (2004), Kyoto Protocol on specialty and knowledge intensive chemicals greenhouse gases and Registration, Evaluation and employment of state of art manufacturing and Authorization of Chemicals (REACH) technologies will provide the necessary policy of EU. Their perceived effects are more positive push. India will be employing an stringent process / products safety regulations, additional 10 million skilled workers in chemical shift from end to middle of the pipe strategy manufacturing sector by 2035. The Indian for evolving clean technologies, use of catalysis chemical sector will invest an additional USD and allied tools for process intensification, 125 billion by 2020 and USD 150 billion during advanced process control and optimization 2020-35. It will reach 3% of global chemical and recycle or utilization of wastes. Chemicals turnover as compared to around 2% registered with unfavourable environmental footprints now. particularly with reference to ozone depletion and greenhouse gas effects will be phased out. Indian chemical industry will witness and Typical examples are CFCs and HCFCs. experience following major events during 2020- 35: Global scenario: The global economy is • Though naphtha will continue to be one of expected to grow by 4+% per annum till 2035. the important feedstocks for petrochemicals, It will be driven mainly by the rise of Asian and efforts to integrate with cellulose-based South American countries and the growing industry will be intensified. The green clout of middle class in almost all developing branding of products and processes will be countries.3 The global chemical industry is a major driving force for gaining enhanced divided into basic, specialty and knowledge global market share and for new technology intensive chemical segments based on their applications in Indian chemical manufacture. process and product differentiation, physico- The use of low carbon energy will gain chemical characteristics, user market structures, The main focus of priority in energy intensive segments of management practices and technological the global chemical chemical industry viz., petrochemicals, factors. Their total turnover may cross USD industry in the fertilizers and inorganic / organic chemicals. 5 trillion by 2020 and USD 8 trillion by 2035. coming years will be It is expected that by 2035 nearly 20% of The share of Asia Pacific countries in global to create minimum the fuels in these sectors will be low carbon chemical production will cross 60% by 2020. environmental energy based. A 38% increase in fossil fuel energy demand footprints and • Demographic advantage to India in terms of is expected from global chemical industry maximum resource growing productive population in 25-35 years by 2035 in spite of energy conservation and utilization efficiency. age group will enable Indian chemical industry lower carbon and renewable energy usage to employ significant number of knowledge by it. The USA will continue to be the largest
64 CHEMICAL TECHNOLOGY ROADMAP: MANUFACTURING
chemical consuming market in the world with the latter category. The phase out of several the share of European countries declining and chlorine compounds will gather momentum in Asia Pacific countries increasing. The global coming years due to international restrictions economy is expected to grow much faster from on their use. CFCs and organochloro pesticides 2014 onwards. Non-conventional feedstock (including DDT) have already been phased and energy resources will create significant out in several countries. Following are on their technological and economic opportunities way out: a) chlorinated and brominated flame- for chemical industry growth.4 Demand-pulls retardants; b) chlorinated solvents (methyl are anticipated in Asia Pacific countries for chloride, carbon tetra chloride, trichloroethane, polystyrene, nylon, polycarbonates, polyester perchloro ethylene and trichloro ethylene); c) fibres and polyethylene terephthalate. Benzene polychlorinated biphenyls; d) chlorine containing production is likely to diminish with crackers dry-cleaning fluids; and e) wood preservatives shifting to lighter feedstock. Lower priced (penta chloro phenol). methane is likely to be available from shale gas. The main focus of the global chemical industry Though international efforts are being made in the coming years will be to create minimum to develop alternatives to PVC, its phase out environmental footprints and maximum in major developing countries will take much resource utilization efficiency. longer duration. Their phase out strategy would be based on case-by-case examination of Growth impacting factors: The future environmental impact, restricting their usage population growth, ageing and urbanization and seeking alternatives. By 2035, the chlorine trends, resource shortages, shifting economic tree will become much leaner on account of power to Asia Pacific countries and climate deletions of several chlorine compounds. change will reshape the chemical industry in the world. By 2035, the chemical industry will More pronounced role of biotechnology: A deliver a new mix of basic chemicals from wider range of bio-catalytic processes will be more renewable resources than at present and employed for chemical manufacture employing higher value added specialties and knowledge a variety of enzymes. The characterization of intensives with much less adverse health and their biodiversity is still a challenge. Extreme environmental impact. Structurally, the chemical environment surviving biological precursors are industry of 2035 is expected to be a much expected to perform better under industrial tighter integrated network of large, medium process conditions. The major chemical and small-scale plants with flexibility to use a subsectors that will employ biotechnologies on wider range of feedstock in a more inclusive a wider scale are pharmaceuticals, cosmetics, innovation ecosystem. The global regulations detergents, food additives, surface coatings, based on Montreal Protocol for ozone agrochemicals, polymers/fibres and organics. depletion, Kyoto protocol for greenhouse The future prospects for biotechnology gas reduction, chemical weapons convention application in chemical sector will lead to 40% for regulation of dual purpose chemicals and reduction in cost, 80% reduction in the use of REACH stipulations of European Union will non-renewable resources, 50% reduction in shape the future product technologies of the volatile organics and 65% reduction in water chemical industry. pollution. Their commercial potential will be gradually enhanced as the integrated bio- The basic chemical sector will witness increased refinery concept gains wider acceptance. The per capita consumption of petrochemicals, implementation of lingo-cellulosic biorefinery fertilizers, polymers and plastics in China, India concept will facilitate the production of and Brazil by 2035. platform chemicals viz., lower alcohols, diols, polyols and dicarboxylic acids through Growth inhibiting factors: Globally, 85% of fermentation and hydrogenation processes. chloroalkali and knowledge intensive chemicals The production of aromatics through bio- particularly, pharmaceuticals and pesticides are catalytic processes is still a challenge. One being manufactured from chlorine containing of the options is to produce butadiene precursors. Chlorine tree is highly expanded from bioethanol and later convert it into and based on nearly 42 MMTPA of chlorine aromatics. Ethylene and propylene production produced in the world for generating end from bioethanol still requires a chemical products and intermediates containing transformation step. chlorine as well as no chlorine. Polyurethanes, polycarbonates and epoxy resins belong to The polymers / plastics most of which are
CHEMICAL 65 TECHNOLOGY VISION 2035
currently synthesized from petrochemical sources (starch, sugar and cellulose) will pick up feedstocks will face more environmental by 2020 to reach an annual production level of concerns due to low biodegradability, high 3.5 million tonnes. Their current consumption GHG emissions and disposal problems. Their is around 1 million tonnes, which is 0.4% of global demand may touch 0.5 billion tonnes global plastics consumption. In recent years, by 2035 with LDPE, HDPE, PP, PVC and PET bioplastics are being favoured in consumer constituting two thirds of their total market. electronics, automotive interiors, housing and The production of bioplastics from renewable industrial components.
From a manufacturing perspective, environment, energy and new consumer preferences will greatly impact the chemical technologies that leverages the inherent strengths of chemical and biotechnologies appropriately to promote eco-friendly and innovative products and processes. The Indian knowledge intensive chemical sector will be driven by innovation to shift away from “Me Too” type of approach for novel molecular entities with high biological activity. The chemical manufacturing industry thus will be driven by stronger science and engineering aimed at embracing innovation.
2.0 TRENDS IN TECHNOLOGY DEVELOPMENT
Manufacturing technologies have played a reforming, isomerization, aromatization, vital role in the growth of Indian chemical cyclization, dimerization and polymerization. industry. It has successfully adopted globally The major unit operations include distillation, competitive processes with advanced control solvent extraction and stripping. There is and automation for a wide range of market a complex linkage between upstream and relevant products. It has made consistent downstream products.5 The ethylene and efforts to improve process and product propylene have the highest weighted growth. efficiencies by tapering down material and Inspite of the tremendous advances made in energy consumptions and by curtailing the petrochemical synthesis, potential still exists process steps. It has made very effective use of for improving product yield and quality, better chemistry and enabling disciplines like catalysis, gas/vapour – solid/liquid separations, more biotechnology and material science and process innovative regeneration and recycle options design/ modeling. Chemical manufacture is and energy / material optimization.6 The ability highly research intensive with R&D becoming of petrochemical manufacturing companies the single most driver of process / product to respond quickly to constantly growing innovations. environmental and market demands determines their sustainability in the coming decades. BASIC CHEMICALS Some of the emerging petrochemical are based The Indian basic chemical sector will witness on CO2 as the feedstock for hydrogenation, environment, energy and ecofriendly resource dehydrogenation reforming Fischer Tropsch driven changes in the coming years. Process type synthesis and allied unit processes. Some intensification will be one of the major tools to of them are biotechnology driven. be employed for enhancing the efficiency and selectivity of concerned chemical reactions. The Future developments in biorefining in India major unit processes involved in petrochemical with multiple biomass-based feedstocks will synthesis viz., steam, catalytic fluid and hydro provide a wider product base from renewable cracking, hydro-treating, coking, alkylation, resources for the Indian petrochemical oxidation, dehydrogenation, steam and catalytic sector.7 Long term prospects exist in India
66 CHEMICAL TECHNOLOGY ROADMAP: MANUFACTURING
for the natural gas substitution with EMERGING PETROCHEMICAL TECHNOLOGIES synthetic natural gas obtained from PROCESS REACTANTS/ PRODUCT biomass gasification, ethylene with bio ethylene, traditional plastics with bio substitutes viz., PET with OXIDATIVE ETHYLENE, PLA (poly lactic acid), HDPE with DEHYDROGENATION poly hydroxyl alkonates (PHA) OF ALKANES PROPYLENE and Nylon with polytrimethylene terephthelate (PTI). Bio-polymers can also be produced from starch and cellulose by fermentation followed DIRECT CATALYTIC METHANE by conventional polymerization or HYDROGENATION OF CO2 through the microbial technology to synthesize biopolymers directly. Typical examples are polyols from xylose and arabinose, conversion of glucose with 1,3-propane (GT) diol by genetically DRY REFORMING OF SYNTHESIS HYDROCARBONS EMPLOYING GAS modified microorganism and CO2 polymerization to 3GT and succinic acid from sugars.
Fertilizer manufacture: The TRI-REFORMING OF METHANE SYNTHESIS fertilizer manufacture represents (REFORMING + PARTIAL GAS OXIDATION) one of the most energy intensive operations. The major unit processes include catalytic oxidation and reforming, methanolation and acid METHANOL neutralizations. The unit operations DIRECT SYNTHESIS OF AND CO2 AS cover absorption, distillation, DIMETHYL CARBONATES REACTANTS evaporation, solvent extraction, crystallization and drying. Mechanical operations like size reduction / enlargement, particle segregation DIRECT SYNTHESIS OF EPOXIDES and bagging are also involved. POLYCARBONATES AND CO2 AS (COPOLYMERIZATION) REACTANTS Future Indian efforts will focus on improving the efficiency of their energy utilization through appropriate process technology interventions and modernization of its utility systems. GASOLINE, CO2 BASED GAS TO LIQUID The future Indian fertilizer applications (CO2 – GTL) TECHNOLOGY DIESEL, JET FUEL may be effected through controlled release solid formulations. They unlock a new realm of opportunities for minimizing fertilizer losses. Long METHANOL, BIOMASS GASIFICATION AND DMF, chain urea formaldehydes, coarse SUBSEQUENT CRACKING ETHYLENE, isobutylidene diurea and specific PROPYLENE polymer coated formulations are likely to be employed for new controlled release systems. The energy efficiency MIXED revamp of Indian fertilizer plants BIOMASS PYROLYSIS XYLENE, FOLLOWED BY BIOREFORMING NAPHTHA- installed during 1970-90 will receive (BIOCATALYSIS) LENES priority to make them more cost competitive. The Indian plants installed after 1990 have better standards in energy consumption. With respect to OLEFINS new product compositions, substantial BIOPLASTICS FROM STARCH, ETC., LDPE, HDPE, PVC changes are not likely to emerge SUGAR AND CELLULOSE REPLACEME NTS before 2035. However, modified
CHEMICAL 67 TECHNOLOGY VISION 2035
products like higher phosphates containing include nitrophosphates and their mixtures; DAP/MAP, granular urea and ammonium compound NPK products and triple super nitrate that are harder than prills are likely to phosphate. find commercial acceptance. Urea ammonium nitrate in liquid form is likely to be favoured in Urea synthesis involves two steps viz., ammonia
the future for drip-irrigated crops. and CO2 reaction (fast and exothermic) to carbamate formation and its dehydration At global level, ammonia synthesis technology (slow and endothermic) to urea. The reactants has undergone evolutionary changes resulting are stripped from urea solution and recycled in downward energy consumption from 20 back. The carbamate liquor is pumped back to less than 7 g cal/tonne. Ammonia is equally to the synthesis section through a series of important for petrochemical and fertilizer loops involving carbamate decomposition at sectors and it accounts for more than 20% progressively lower pressures or employing of the total energy employed. The Indian a stripping process. Future manufacturing ammonia plants are designed to produce up processes for urea production will be based to 3000 TPD employing steam reforming of on recycle-stripping operations employing natural gas. Partial oxidation of heavy fuel or a vertical submerged carbamate condenser, residual oils is an alternative option. The steam primary and secondary urea reactors and a reforming based ammonia process consists vertical falling film type stripper. In future, a of desulphurization, primary and secondary single train urea plant with 4500 TPD capacity
reforming, shift conversion, CO2 removal by can be operated on a medium pressure recycle reactive absorption, methanization to remove without a separate ammonia loop. They are CO and ammonia synthesis. In India, major cost effective with minimal high-pressure steam technological changes in this sector are likely consumption. The use of membrane reactor in to occur in isobaric manufacture with super urea production will facilitate water removal active catalysts, significant reduction in recycle in situ and the process is reported to have a gases through the employment of ultra high lower energy demand, significant reduction efficiency absorption systems and more efficient in ammonia and urea emissions, drastic cut in intra-reactor ammonia separation.8 Increased process cooling water requirement and less concerns on the contribution of green house toxic wastewater quality. gases to global warming will re-ignite the Global potash fertilizer capacity is projected to prospects for replacement of steam by CO2 as the reforming agent. The process is referred grow beyond 60 million tonnes per annum by to as dry reforming. It is a highly endothermic 2035. The fertilizer grade potassium chloride is reaction to be carried out at high temperature extracted from the mined ores with impurities and lower pressure employing a Cu/Ni/MgO/ consisting of non-clay and clay minerals. Froth flotation technology is employed for heavy ZrO2 catalyst to achieve maximum conversion. Coke deposition on catalysts is another major media separations and crystallization operations. issue, which requires new catalysts with limited Major developments in its processing are carbon formation and avoiding any major anticipated in terms of coarse particle flotation, structural changes at elevated temperatures. product screening and final compaction. In India, there is no strong resource base for The currently employed phosphatic fertilizer potash fertilizer manufacture. Current efforts product mix in India is found to be most cost are directed towards its extraction from sea
effective at farm level. More than 70% of P2O5 bitterns, the salt concentration and purification. is derived from wet phosphoric acid. Though A novel integrated process for the recovery phosphatic fertilizer production technologies of potassium sulphate (SOP) from sulphate are simple, they have been encountering rich sea bitterns has been developed. Kainite increasing level of environmental concerns. The type mixed salt is obtained by the fractional conventional tank reactor used in phosphatic crystallization of the bitterns and is converted fertilizer plants may be replaced with a pipe to schoenite, which is subsequently reacted reactor, which can be operated at higher with muriate of potash for its conversion to phosphoric acid concentration, and its outlet SOP. End liquor from Kainite to schoenite can be directly inserted into a granulator. The conversion is desulphated and supplemented
increase in concentration of melt in the reactor with MgCl2 from end bittern. will lead to drying cost reduction by 70-80%. There are likely to be some changes in the Chloroalkali manufacture: The Indian product mix of phosphatic fertilizers. They chloroalkali industry manufactures caustic
68 CHEMICAL TECHNOLOGY ROADMAP: MANUFACTURING
soda, chlorine and soda ash as the backbone chlorine as the only product. Such a technology constituents with their application in paper, will be favoured if chlorine manufacture has to soap, detergents, PVC and healthcare sectors. be delinked from caustic soda. The inorganic chemical sector produces sulphuric, nitric and hydrochloric acids, carbon Solvay process is widely employed for soda black, aluminium fluoride and others. Fuel cells ash manufacture. Ammonical brine is reacted
are likely to be introduced in caustic soda with CO2 to produce bicarbonate, which is and chlorine manufacture to utilize hydrogen then calcined to produce sodium carbonate. for their DC power generation. The phasing The process requires a large amount of steam. out of mercury cells will continue in the next Significant efforts are foreseen for optimizing decade. More serious efforts are foreseen in energy fluxes of the system. The other optimization of electrolysers with reference potential improvements that can be made in
to current consumption. Other options are solvay process are a) utilization of excess CO2 the use of modern coatings for anodes for from ammonia process for soda ash production
enhanced operating life and current densities. and b) better heat and mass transfer in CO2
In order to delink caustic soda manufacture absorption and NaHCO3 precipitation zones. from chlorine, a membrane cell based
electrochemical technology for conversion of Inorganic acids: The inorganic acids like H2SO4,
sodium carbonate to 35% sodium hydroxide HCl, HNO3 and HPO3 play a dominant role in will receive attention. Future electrolysis plants fertilizer and industrial chemical manufacture. will have more advanced cell controls for Their manufacturing processes have not short circuit elimination and anode protection. undergone much change since their discoveries. Significant level of revamping of chlorine However, number of scientific and engineering handling systems including compressors, modifications has been made from time to time refrigeration systems and hot gas bypass units to make them more commercially acceptable. is anticipated. A new technology for chlorine The future developments in manufacture of manufacture based on oxygen-depolarized sulfuric acid will be through direct conversion
cathodes is under development in Germany of strong SO2 gases coupled with more efficient with substantial potential for energy savings waste heat recovery. They will have advanced (440-530 kwh per ton of caustic soda).9 It intelligent controls. employs HCl instead of brine to produce
POTENTIAL BIOREFINERY PLATFORMS
WET BIOMASS BIOMASS SYNGAS BIOGAS C6/C5 SUGAR PLANT ALGAE OIL LIGNO- BASED OILS (GRASS, CELLULOSIC PYROLYSIS CEREALS)
Methanol, Methane, Furfural, Xylitol, Glycerol, Bulk Carbohydrates, Ethanol, Lignin, Pyrolysis Ethanol, DME, Bio Fuel Isoprene, Propylene, Glycol, Chemicals, Proteins, Chemicals Oil And Ft-Diesel, Glutamic And Epichlorohydrin, Biofuel Amino Acids, Downstream Ethylene Levulinic Acids, 1,3-Propane Organic Acids, Producs Sorbitol, Adipic Diol, 3-Hydroxy Hormones, Acid, Lysine, Propionaldehyde, Enzymes Lactic And Acrylic Acid, Citric Acid, Propylene, Bio Caprolactum, Diesel Cellulose, Hemicellulose, Lignum
CHEMICAL 69 TECHNOLOGY VISION 2035
EMERGING ORGANIC CHEMICAL TECHNOLOGIES The basic chemistry of the nitric acid process has not changed in the last PROCESS REACTANTS/ PRODUCT 100 years, though several process refinements have been introduced since then to make the nitric acid CATALYTIC VAPOUR PHASE AROMATICS synthesis less energy consuming. The AMMOXIDATION (SINGLE TO NITRILES STEP) current technology for nitric acid production is by ammonia oxidation in the presence of a metal catalyst. Mono and dual pressure options are CHLORPYRI- employed. The latter was developed SINGLE POT HECK REACTION DINE AND N-BUTYL to accommodate more stringent ACRYLATE environmental pollution control requirements. Single plant capacities up to 1500 TPD could be achieved in a single train configuration. A low ASYMMETRIC TRANS OR EPOXIDATION TRISUBSTITUT- temperature process for the combined ED OLEFINS (SHARPLES OR SHI) removal of N2O and NOx efficiently has been reported.10 Future Indian nitric acid manufacture plants will be built on vertical orientation concept PROPANE OLEFIN METATHESIS FOR CONVERSION with minimum land, equipment volume REARRANGEMENT OF C-C TO ETHANE and cost. DOUBLE BONDS AND 2 BUTENE Carbon black and TiO2: The Indian carbon black industry may face FUNCTION- the prospect of replacement with SUZUKI CROSS COUPLING ALIZED precipitated silica for automotive tyre REACTION POLYOLEFINS AND manufacture. The next generation STYRENES carbon black technologies are likely to be based on hydro treatment of the feedstock to lower their SOx and AMINE, NOx content and incorporation of ORGANIC CARBAMATES ALKYL NOx burners in the tail gas furnaces FROM CO2 HALIDE AND CO2 of the pellet drying section.
The global production of TiO2 has crossed 4 million tons mark. There
CONTINUOUS HYDROGENA- FURFURYL are very few TiO2 producers in the TION OF FURFURAL IN ALCOHOL world who employ proprietary SUPERCRITICAL CO2 chloride and sulphate process technologies. Intense R&D efforts are being made worldwide to develop
DYES FOR new pigment grade TiO2 with special LIQUID ELECTROLYTE AND SOLAR CELL optical properties. There are no THIN FILM TECHNOLOGIES SENSITIZATION reported substantiative novel pollution prevention and control techniques for either chloride or sulphate process
employed for TiO2 manufacture <100 NM nor an alternative technology to NANOECOLOGICAL DYE PARTICLE TECHNOLOGY SIZE these processes. However, following developments are important for India: • Pressure oxidation eliminating the absorption and desorption of FOR chlorine in CCl prior to recycling in STUBBORN 4 POLYMERIC DETERGENT GREASE chloride process. SYSTEMS STAIN • Continuous digestion, fluid bed REMOVAL calcinations, osmosis of strong and
70 CHEMICAL TECHNOLOGY ROADMAP: MANUFACTURING
weak acid filtrates from pre and post leach efficiencies. The impact of greener solvents operations, solvent extraction of sulphate will be quite significant on organic chemical metals and hydrometallurgical options to segment in terms of phase out of chloroorganic achieve a product with better crystal size and other environmentally less friendly solvent distribution in sulphate process. systems.
The future opportunities for silicon carbide SPECIALTY CHEMICALS (SiC) manufacture in India will be driven by Indian specialty chemical sector will be more the demand for semiconductor electronic knowledge driven to pursue an accelerated devices and circuits to perform effectively growth path.12 Currently, the demand is mostly under high temperature, high power and high driven by the growth prospects of end use radiation conditions. This is due to the fact industries. Indian export of specialty chemicals that SiC crystals consist of 50% carbon atoms to developed countries is based on its ability to covalently bonded with 50% silicon atoms with leverage its low cost of production and quality each crystal type having its own distinct set of talent pool. Innovation and sustainability will electrical semiconductor properties. be the major factors for its future competitive performance at global level.13 Organics: Most of the organic chemical reactions take place at moderate temperatures, Product development approach: The involving catalytic processes and requiring 3 or progressive replacement of non-renewable 4 process steps. The transition from fossil to feedstock and energy resources will present biomass based processing is likely to make a real challenges to Indian specialty chemical reasonable level of impact on the future organic manufacturers after 2020 while developing chemical technologies in India. Incidentally, the alternative products with good market biorefinery concept will reach a tipping point in acceptability. Biomass and biotechnology the coming years.11 The important driving forces driven products and processes with less for its development are high fuel oil prices, energy consumption will be favoured for the consumer preference to greener products, manufacture of higher end surfactants, personal corporate commitment and government care products and fine chemicals. Specialty policies and support mechanisms. The platform elastomers and adhesives will switch over to biochemicals are growing substantially during biobased C3-C5 hydrocarbons feedstock. The 2012-17. The organic chemical segment will achievement of a specific optical activity through be one of the main beneficiaries of the future asymmetric / raceimic switching will receive developments in this area. The technologies will greater attention in case of fine chemicals. percolate into the fast developing countries Nanotechnology application has good potential like China, India and Brazil in the next 10 to 15 in personal care products and food processing years. sectors. Controlled release and encapsulated delivery systems will be favoured in perfumery Indian organic chemical sector will attempt and cosmetics manufacture to improve their improved value chain integration and functional properties and application safety. environmental sustainability. Catalytic and From environmental considerations, the biochemical process technologies will find phase out of highly toxic specialty chemicals favor in downstream product segment. For and development of more ecocompatible example, adipic acid synthesis from benzene is alternatives is foreseen in subsectors like dyes likely to be replaced by cyclohexane oxidation and intermediates, paints and surface coatings with 30% H2O2 employing a tungsten catalyst and chemical auxiliaries. or by employing a biocatalytic method using D-glucose. Similarly, the traditional method Process development approach: The future of maleic anhydride synthesis from benzene growth drivers will be efficient process through air oxidation with vanadium pentoxide routes for producing specialty chemicals to catalyst will be replaced by greener option reduce their current environmental burden of n-butane oxidation employing (VO)2P2O5 to contribute to higher investments, lower catalyst. operating costs and minimal plant inventories. The focus will be on atom efficient synthesis, Most of the future organic synthesis will be selectivity and yield maximization, recovery catalytic processes. Their effectiveness will and recycle of unconverted precursors and be enhanced by process intensification for byproduct utilization. There are bright prospects improved mass and heat transfer and reaction for the employment of heterogeneous catalysis
CHEMICAL 71 TECHNOLOGY VISION 2035
in reactions, which are currently inefficient. intermediate market accounts for larger A typical example is the solid acid catalysed value. The future technology thrust will be aromatic nitrations replacing mixed acid towards: a) environment friendly natural dyes; nitrations with cumbersome acid recovery b) industry – academic joint initiatives on process. More proactive industry-academic process intensification; c) innovative product engagement is anticipated in supporting green development; d) energy minimization and chemistry initiatives. Significant reaction and conservation; e) project engineering for process engineering inputs are foreseen in expansions and new ventures. A whole new development and design of specialty chemical range of dyes and pigments may enter the processes, which are currently the sole domain Indian market in nonconventional application of the synthetic organic and industrial chemists. areas. They include liquid crystal display The study of reaction mechanisms, mass / systems, polarizer and colour filters, optical heat transfer limitations, multiphase mixing, discs, solar energy (PV) capture, dye sensitized separation engineering and hydrodynamics polymers in digital and holographic data storage of process systems will be addressed by the devices etc. The dye-sensitized solar cells (>10% chemical engineers in a much more focused efficiency) are emerging as one of the cheaper way. alternatives to silicon solar cells. Future efforts will be to enhance their functional efficiency Dyes and pigments: This segment has to by employing novel sensitizers and improved respond more proactively to the colouring device architecture. In case of pigments, the needs of a much wider range of user new areas include plastics and special paints, industries due to the manufacturing capacity decoration of natural pearls and transparent shift from Europe and North America to metal oxide coatings. Asia pacific countries. The inorganic pigment market segment represents the largest Adhesives and sealants: The Indian adhesives component in volume terms while dyes and and sealant industry is expected to achieve Rs.
FUTURE GROWTH AREAS IN DYE/ PIGMENT MANUFACTURE
Petrochem, Organics, Inorganics, Biomass
FEEDSTOCK SOURCES
Organic, Inorganic, Product Recipe, Analytical Chemical/ INTELLECTUAL KNOWLEDGE Mechanical Engineering, Process Knowledge PROPERTY INPUTS Instrumentation, Micro Electronics DYES & PIGMENTS
DYES PIGMENTS Sulfur: é Metallic1: é EXPECTED Textile/ Leather/ Plastics/ USERS Reactive: é Organics2: Limied TRENDS Paper/ paint/ Electronics/ Direct: Stable Solar Energy Disperse2: é Azo: ê
1- At the expense of direct and VAT dyes; 2- Higher demand in Automotive Furnishing
72 CHEMICAL TECHNOLOGY ROADMAP: MANUFACTURING
Their growing importance in South EMERGING PERSONAL CARE PRODUCT / Asia and Asia Pacific countries will PROCESS TECHNOLOGIES create new manufacturing base PROCESS REACTANTS/ PRODUCT in India for products to suit these new customers. They include silane- terminated products; hot melt NANOSILVER, NANOTECHNOLOGY FOR CADMIUM, formulations, new building blocks SUNSCREENS AND SHAMPOOS TITANIUM, for reactive systems and advanced SILICON, ZINC ETC., versions of pressure sensitive additives. The future adhesive and sealant formulations will be the enablers of lightweight composites PERSONAL PHASE CHANGE MATERIALS CARE for structural applications. In terms of PRODUCTS manufacturing technologies for broad- spectrum adhesives and sealants, increased preference will be for state of art technologies with higher level of automation and process control. UNILAMELLAR CARRIER COSMETIC SYSTEMS ACTIVES The future regulatory push in India will be to limit the use of solvent based adhesives and sealants particularly based on acrylic, HIGH polyurethane, polyvinyl acetate, SUGAR STRUCTURED SURFAC- EFFICIENCY TANT SYSTEMS DETERGENTS epoxies, styrenic block, ethylene vinyl acetate, silicones and others. Currently, adhesives and sealants are formulated in India by compounding VESICULAR TRANSFERO- the base material with fillers, pigments, NOVEL DELIVERY SYSTEMS SOMES, stabilizers, plasticizers and other FOR COSMOCEUTICALS ULTRASOMES, IOSOMES additives. New alternatives will be ETC., developed to achieve enhanced bond strength, elongation capacity, durability and environmental acceptability. NANOSTRUCTURED LIPID HIGHLY Natural substances like starch, dextrin, CARRIERS AND HYPER SPECIALIZED BRANCHED POLYMERS COSMETIC natural rubber and novel proteins SYSTEMS will find more favour. Though the consumption of low to medium performance adhesive and sealant formulations is quite sizeable but DOUBLE LAYERED ENCAPSULA- FRAGRANCE TION TECHNOLOGY WITH FILLED their future marketability may not PROTECTIVE MICROSPHERES SPHERES be very strong. The demand for hot melt adhesives is expected to grow faster since they are amenable to high speed bonding processes. New 5000+ crores turnover by 2017.14 At present, products are expected for use in civil it is relatively small as compared to its global and metal construction and aerospace industrial counterparts. Seven major end uses define segments in India. Indian adhesives industry viz., construction, packaging, transportation, rigid and non-rigid Personal care products: The current global bonding, consumer products and tapes. The market for personal care products is around first three sectors drive the domestic market. USD 350 billion with Asia pacific and Latin Neoprene, starch and silicone based adhesives American countries providing the emerging are important for Indian market. Their markets. The young consumers all over manufacturing processes consist of mixing and the world are looking for more natural kneading the ingredients into a uniform paste/ ingredients in shampoos, cosmetics and solution or powder. The Indian made sealants creams. Accordingly, the future technologies are mainly used in automobile manufacture. for their preparation will be from natural
CHEMICAL 73 TECHNOLOGY VISION 2035
lipids like soyabeans and others. The addition to introducing alternative product emerging technologies are enzyme-catalysed workup techniques. Recovery / abatement of
functionalization, biocatalysed lipid modification NOx, HCl, Cl2, HBr, NH3, SOX, cyanides and and algal biomass conversion by thermo or hazardous particulates will receive high priority. biochemical means. The petrochemical products such as polyethylene glycol and petrolatum The global linear alkyl benzene (LAB) industry are likely to be phased out. The future cleaning is currently experiencing depressed margins products will be based on biocompositions and feedstock shortages. Nearly 98% of LAB like levulinic ketals, which can be extended by production is used for linear alkyl benzene transesterification. 1,3 propane-diol will most sulphonate (LAS) manufacture. The global likely be made from fermentation of corn sugar demand is projected to grow at 2.7% CAGR for application in cosmetic lotions and creams. until 2020. There is likely to be a shift in consumption pattern of synthetic detergents Consumer driven innovation provides the main since liquid detergents are gaining better driving force for development of new and foothold. Future efforts will be to base them novel personal care products. The customer on oleochemicals, fatty alcohols and their friendly qualities introduced in personal care ethoxylates, sulphates sand amines. The new products are fortification of body defences, oil resources like cuphea, jojoba and other nitrification of skin and beautification of body. nonedible oils will receive attention, since LAS is They include color cosmetics, shampoos, bath considered as environmentally less acceptable. and shower gels, toilet soaps, skin creams, These developments will have major bearing on deodorants, baby products, after shave lotions, Indian synthetic detergent manufacture.16 specialty ingredients and fragrances used in air fresheners, bleaches, detergents, washing The dirt repellent clothing lines based on powders, fabric softners, anticrease products nanotechnology will have some impact on etc. Indian synthetic detergent industry by 2025. Better strains of enzymes will be developed Essential oils and aromatic chemicals are as washing aids for synthetic detergents with building blocks for fragrances. A range of aroma a wider pH spectrum, stability and quicker chemicals like amyl salicylate, eucalyptus, hexyl action. The Indian synthetic detergent industry acetate, phenyxol and tetra hydro mycernol are will be reinventing its product and process in the market. technological strategies mainly to overcome environmental and consumer oriented Future developments are anticipated in challenges. nanoscaled encapsulation for controlled delivery of active constituents to the targeted Lipid based specialities: Lipid process areas, in designing multifunctional formulations technologies provide a range of products and with improved sensory characteristics and in intermediates needed for nutrition, health, evolving new range of special use cosmetics personal care, specialty chemical sectors. In based on multipersonal care aids.15 Alkylation, recent years, transesterification is employed for hydrolysis, esterification, saponification, the preparation of biodiesel from nonedible ethoxylation, sulphation and steam splitting vegetable oils. Methanol or ethanol is are important unit processes employed in employed as the transesterification agent. The this sector. Cleaner concepts, better process transesterification technology is also employed control and minimization of non-renewable for the synthesis of fatty acid esters of material and energy inputs will be the key carbohydrates, which can be used as non-ionic factors for technology upgradation. biodegradable surfactants.
Fine chemicals: Dye intermediates are by far Knowledge intensive chemicals: The future the major customers of fine chemicals. As in growth of Indian knowledge intensive chemical other specialty chemicals, Asia Pacific regional sector will be driven by the need for novel demands will dominate the fine chemical and more specific human, animal and plant market. The key environmental concerns are health care systems. Serious efforts will be volatile organic emissions, wastewaters with made to rationalize their product and process nondegradable organics / inorganics, spent portfolios based on new advances in science solvents and nonrecyclable solid wastes. Given and technology. Producing safer and greener the diversity of this sector, a wide range of ingredients will be the major drivers for future abatement technologies will be employed in process technologies in this sector.
74 CHEMICAL TECHNOLOGY ROADMAP: MANUFACTURING
Drugs and pharmaceuticals: More than 2400 separation processes) provides several Active Pharmaceutical Ingredients (API) from attractive options for intensification of bulk drug chemical synthesis are being employed in the processes to make them more efficient and pharmaceutical industry. They are all small clean.18 Recent successes in reactive extraction molecules (<550 MW) and more than 90% of L-phenylalanine and penicillin G provide of them contain a nitrogen atom and an the necessary incentive for its extension to aromatic ring and nearly half of them are chiral other bulk drug processes. Transformation of in nature. Their synthesis is predominantly batch to continuous processes will gain more modular convergent in nature based on simple importance from cost reduction, downsizing construction from precursor fragments. process facilities, and reduction of energy consumption, better solvent utilization and In spite of impressive product development improved process control considerations. advances made in this sector, the E-factor Microreactor technology will also receive viz., the total mass of waste generated per a great deal of attention in case of highly unit mass of a bulk drug still lies in the range hazardous pharmaceutical manufacture.19 of 25 to 100 due to multistep and non- optimal synthesis routes employed with low Pesticides: The pesticide manufacturing requires overall product yields. The following changes a series of unit processes and operations, are anticipated in Indian pharma process executed in batch or semibatch mode to technologies: a) employing more ecocompatible generate desired quality technical product along alternative feedstocks / solvent replacements with release of significant level, of unwanted air, and process re-optimization; b) intensification water and solid pollutants. Volume of volatile for cleaner processes employing catalytic organic constituents (VOCs) in pesticide biocatalytic / chemo-enzymatics options synthesis is quite low in comparison with other c) non-reactive and reactive separations chemical processes.20 d) continuous / microprocessing and e) zero discharge driven waste management. Future pesticide manufacturing technologies Use of ecofriendly feedstocks for its core will be more atom efficient, inherently safer, manufacturing activities is not expected to endowed with much less number of process take place on a large scale before 2020 due steps, employ minimum solvents or use to lack of viable green alternatives. However, ecofriendly solvents, use some feedstocks employment of alternative solvents, their derived from renewable resources and quantity optimization and minimization of their consume minimum energy. As in the case of losses through reuse/recycle will receive priority. bulk drug technologies, options like single The use of aqueous media, employing one of pot synthesis, reactive separations, catalytic the reactants as a solvent, direct use of same processes, continuous processing and micro solvent in subsequent batches etc., are some reactor application will receive attention in of the preferred options that will be explored. the coming years. Chemically, the solvents Future prospects are bright for their large scale employed in pesticide manufacture may be classified as aliphatics covering halogenated deployment of supercritical CO2, water based systems and ionic liquids. hydrocarbons, alcohols, acids, anhydrides, nitriles and aromatics covering halogenated In recent years, water based reaction media compounds, heterocyclics, aldehydes, ketones, have been employed in pharmaceutical amines and amides. They account for 60-70% synthesis on a limited scale in Mannich, Michael of mass utilization and play a dominant part cycloaddition, asymmetric aldol synthesis and in achieving the desired toxicity profile of a carbon-carbon bond forming reactions.15 Single formulated pesticide. pot synthesis in place of 2 or 3 reactions in series is likely to pick up in future for insitu Sustainable pest management depends on the generation of witting intermediates, oxidation phase-in and phase-out strategies adopted and other processes. Use of catalysis for less for various categories of pesticides based efficient noncatalytic reactions is likely to be on their environmental performance. Such tried on a wider scale in the coming years. developments provide necessary directions to the future growth of Indian pesticide industry. Integration of chemical reactions with mass transfer operations like distillation, adsorption, Bioproduct manufacture: Bioproducts crystallization and extraction into a single manufacture, such as carbohydrates, fat operation (generally referred to as reactive derivatives, steroids, peptides, amino acids,
CHEMICAL 75 TECHNOLOGY VISION 2035
secondary alcohols, nucleotides and chiral level of product differentiation. For example, compounds need highly efficient process newer varieties of therapeutic proteins viz., technologies. The enzymes used for their native, recombinant and fusion types and a synthesis can be oxidizing or reducing cells, wider range of peptides and antibody products oxido-reductases, transferases, hydrolases, lyases, will be manufactured in India through microbial isomerases and others. The unit processes fermentation. They will be recovered from the like acylation, hydrolysis, reduction, reductive fermentation broths or intracellular, periplasmic, amination, oxidation and other regioselective soluble or inclusion type of biomass. The reactions will see more biotechnology downstream purification operations have to be applications. Automated batch, semibatch, more robust and scalable. fedbatch and continuous (plugflow or stirred tank) reactors are employed. The current At present, recombinant DNA technology is advances in enzyme immobilization can be employed on a laboratory scale to identify, extended to cell and tissue components for use map and sequence a variety of genes and as biocatalysts for converting electrochemically determine their function. rDNA probes are unreactive compounds into new range of now being extensively used for analysing gene bioproducts. More efforts are anticipated expression within individual cells and tissues of in the future to employ newer varieties of whole organisms.23 There are bright prospects immobilized enzymes for developing novel drug for the Indian manufacture of recombinant delivery systems, tumour location analysers and human insulin from non-animal sources, human biosensors. Bioresource engineering will grow growth hormones, blood clotting proteins from faster to explore new biomass sources, to treat non blood sources and hepatitis B vaccine more complex biological wastes and to analyse from yeast cells and HIV diagnosis agents the aerobic and anaerobic digestion options, obtained from molecular cloning. Even though microbial growth processes and enzymatic the probiotic concept has been around for catalysis.21 more than a century, its application in Indian pharmaceutical and bio-products has been Fermentation will continue to be the major somewhat limited. The recent developments in process route in India for the synthesis of their therapeutic applications have brightened antibiotics and other biomolecules. However, the prospects for developing new range of the use of new knowledge in molecular and probiotic products. The neutraceutical field will genetic biology will enable its application in also be enriched with the modern probiotic the synthesis of newer types of biomolecules manufacturing technologies. Probiotic health including new pest control agents based on supplements based on super high quality strains genetic modification.22 They will enable higher will receive greater attention in India in the
3.0 TECHNOLOGIES FOR 2035
S&T RELATED ISSUES FOR CHEMICAL changes under the direct and indirect influence MANUFACTURE IN 2035 of the national and international regulations. New technology and control packages: An More emphasis will be placed on adopting near attempt is made to examine the current zero emission manufacturing concepts involving manufacturing technologies in the Indian cleaner process options to minimize air, water chemical sector to identify a) knowledge gaps and solid waste discharges. Environmentally which need to be attended to by the research more robust technologies are likely to be and academic institutions, b) productivity adopted during chemical manufacture. deficiencies to be taken care by the industry and c) policy / regulatory initiatives to be taken care by the concerned authorities.
By 2035, the Indian Chemical manufacture will undergo major structural and operational
76 CHEMICAL TECHNOLOGY ROADMAP: MANUFACTURING
PROBABLE IMPLEMENTATION TARGETS TECHNOLOGIES Short Term Medium Term Long Term
Vertical orientation concept in Nitric acid plants for process intensification and improved catalytic basket design
Nanotechnology in personal care products
Higher mass intensity process routes for producing specialty chemicals
Environment friendly natural dyes
Dye Processes for Liquid crystal display systems, optical discs, solar energy (PV)capture, dye synthesised polymers in digital and holographic data storage devices
Pigment technologies for transparent metal oxide coatings
Adhesives and sealants as enablers for light weight composites for structural industry
Natural lipids (soyabeans and others) for manufacture of personal care products such as shampoo, cosmetics and creams
Bio-nano-microemulsion technologies for personal care products
Nano scaled encapsulation for controlled delivery of active constituents to targeted areas and for multifunctional formulations with improved sensory characteristics
Synthesis of better enzymes strains as washing aids for synthetic detergents
Manufacture of petroleum based surfactants by genetic engineering technologies
Single pot synthesis for insitu generation of witting intermediates, oxidation and other processes
Microreactor technology for hazardous pharmaceutical processes
Recombinant human insulin from non-animal resources & hepatitis –B vaccine from yeast cells
Probiotic manufacturing technologies for Nutraceuticals
Production of Biobased polymers (Bio plastics) from renewable sources- starch and cellulose
Substitution of fossil fuel feedstocks with bioderived ones in petrochemical sector
Usage of ultra high efficiency systems for ammonia reactor engineering
CHEMICAL 77 TECHNOLOGY VISION 2035
PROBABLE IMPLEMENTATION TARGETS TECHNOLOGIES Short Term Medium Term Long Term
Shift conversion with membrane facilitated reactive separation
Immobilized enzymes for novel drug delivery systems, tumor location analysers and biosensors
Application of molecular and genetic biology for synthesis of new pest control molecules
Intelligent automation and process controls for specialty chemical processes
Starch, dextrin, natural rubber and novel proteins for adhesives and sealants
New processes for high performance materials for chemical sector
Ligno-Cellulosic Biorefinery for production of platform chemicals (lower alcohols, diols, polyols and di carboxylic acids)
Biologically engineered algae to replace naphtha as feedstock
Microbial fermentation for therapeutic proteins (native, recombinant and fusion types), peptides and antibody products
Dry Reforming of Hydrocarbons with CO2
Oxidative Dehydrogenation of Alkanes
CO2 based gas to liquid conversion
Olefin Metathesis for C-C bond rearrangement
Polymeric Detergent Systems
Usage of pipe reactor in Phosphaticfetiliser plants, to be operated in higher phosphoric acid concentration
Recycle-stripping operations in Urea Plants, leading to significant reduction in process installation size, energy consumption, water consumption, toxic waste water etc
More advanced cell controls for anode protection in Eletrolysis plants
Advanced intelligent controls in Sulphuric acid plants
Condensing acid vapours without emission of acid mist, cooling of vapours and spontaneous homogenous nucleation and heterogenous condensation in Sulphuric acid Plants
78 CHEMICAL TECHNOLOGY ROADMAP: MANUFACTURING
4.0 RECOMMENDATIONS AND IMPLEMENTATION STRATEGY
TECHNOLOGY RELATED CHALLENGES Control of Pollution) Act-1981 amended in FOR 2035 1987, the Water (Prevention and Control of Technology management, consisting of skilling Pollution) Act 1974 amended in 1988 and and capacity building, addressing environmental Environment (Protection) Act -1986 amended challenges, stakeholder responsibilities, policy in 1991 and Hazardous Wastes Management and ethical issues, requires in depth analysis and Handling Rules – 1989 (amended in prior to adoption of new technologies. 2000 and 2003) are the flagship Acts of Government of India to control pollution in Human resource capacity building: The chemical manufacturing and allied activities. National Skill Development Corporation Indian chemical industry also participates in (NSDC) of India had brought out the human nonregulatory voluntary programmes like resource profile of Indian chemical sector Responsible Care, Corporate Responsibility including pharmaceuticals but excluding food in Environmental Planning (CREP), ISO processing. It shows that less than 6% of 14001, OHSAS 18001, ISRS and ISI and ECO skilled personnel are employed in R&D and Marketing systems. Their footprints on future knowledge intensive activities. The estimated Indian chemical technologies will become more personnel requirement for Indian chemical intense. industry is around 1.9 million by 2022 with demand predominantly from knowledge The Ozone Depleting Substances (Regulation intensive chemical sector. A perspective study and Control Rules 2000) related to Montreal by the Indian National Academy of Engineering Protocol, the Hazardous Waste Management (INAE) has broadly examined the specific and Handling Rules-2003 of Basel Convention features of R&D manpower deployment on the Transboundary Movement of Hazardous in basic, specialty and knowledge intensive Wastes and their proposal, the Chemical chemical sectors. The R&D manpower in Weapons Convention (CWC)-1997 on basic chemical sector is to be well equipped the prohibition of development, production, in dealing with green processing, alternative stockpiling and use of chemicals with weapons feedstock selection, energy minimization, potential, the Stockholm Convention on process intensification and biorefining has Persistent Organic Pollutants (POPs) – been stressed. The specialty chemical sector 2004 and the Registration, Evaluation and requires qualified personnel with good Authorization of Chemicals (REACH) of EU expertise in product and process development Countries -2007 are the major international and an understanding of business and market regulations which already have strong dynamics. The human resource skills for R&D footprints on Indian chemical regulations. The in knowledge intensive chemical sector have Kyoto Protocol on green house gas emission to be based on discovery and development reduction will have greater impact on Indian abilities since market value creation in this chemical sector after 2020 to adopt lower sector is through the exploitation of tacit carbon emission technologies. knowledge. Along the important value chains of chemical The increasing complexity of future chemical manufacturing industry, process intensification technologies requires highly skilled personnel and green chemistry applications have to be with ability to innovate. Special tools are made to moderate the adverse environmental required to evaluate professional competency impact on process technologies. Replacement of such personnel. of fossil fuel based energy with renewable energy alone may not suffice to correct the Minimizing environmental footprints: The energy demand – supply imbalances in the Indian regulatory framework for storage chemical manufacture. The process operations handling, processing, transportation, export have to be more efficient to reduce the overall / import and disposal of chemicals is quite energy demand. comprehensive. The Air (Prevention and
CHEMICAL 79 TECHNOLOGY VISION 2035
Addressing stakeholder related issues: The commercialization and drop in registration of concept of community engagement has been patents being filed in Indian chemical sector widely employed in chemical industry worldwide as compared to overseas registration. The to minimize the adverse impacts of chemical concern is also on the slow pace of technology processing on people’s safety. For effective use upgradation being undertaken in the basic of new products and process technologies, the and specialty chemical sectors with reference direct and indirect stakeholders play a vital role. to environmentally cleaner processing. The The chemical industry is endowed with multiple stakeholders from Indian and global chemical stakeholders viz., academic / research community, markets are concerned with the slow manufacturers, employees and their associations, response of Indian chemical sector to the governmental and non-governmental agencies, consumer preferences in Asia Pacific countries regulatory bodies, consumers, market leaders, as compared to those form European and traders and distributors, exporters / importers American continents. and media. Their combined resolve to promote economically and environmentally sustainable POLICY CHANGES AND ETHICAL ISSUES chemical products and processes greatly Policy changes: The need to earn the public contributes to the long term stability of the confidence on chemical product and process chemical industry. The heterogeneity of Indian safety and increased use of renewable resources chemical industry will introduce a high level has to be the principal theme of chemical of complexity in developing the foresight of management policies in India. They have to be multiple stakeholders who are also sectorially based on the concept that safety is a shared divided. MSMEs whose number exceeds 1.11 responsibility between government, industry, the lakh units in the country, and operating in value chain and the consumers as well as the organised and unorganised sectors in 20 states, users of the technologies. Various developed pose the maximum challenge in introducing countries and geographical regions are evolving technology interventions. They employ more new policies for better chemical management than 600,000 people of various levels of skills. for quick adoption of improved technologies. Such policies have to be evolved in India in The future directions for the stakeholders can the coming decade to minimize technological, be evolved through a multilevel interaction and economic and societal risks of chemicals and sensitization process involving various segments processes. They include: of stakeholders. The process is quite complex, a) Manufacturing companies to generate more labourious and time consuming but is extremely chemical and process safety information to important for promoting innovation, global enable consumers to appreciate safe use market competitiveness and technology driven determinations growth of Indian chemical industry. Development b) Risk consideration to reflect on prioritizing of shared vision between manufacturers, their chemicals for safe use employees, customers and regulators to identify c) Separate consideration to be given for technological priorities for achieving medium population vulnerable to chemical exposure and long term chemical product and process d) Encouraging technological innovations sustainability. and generation of globally competitive technologies by driving innovation towards Sensitization of the stakeholders of Indian greener and more sustainable product or chemical sector on technology development process options needs to be pursued periodically for long e) Fiscal incentives for the development and term sustainability. The stakeholders of deployment of greener and energy / material chemical industry from manufacturing domain efficient chemical products and processes favour long-term stability with reference to f) Expedited regulatory process to incentivize environment and economic factors. They adoption of renewable feedstock, cleaner would like to see minimum impact of global production and sustainable product options uncertainties on Indian chemical manufacture. g) Strong support to research and development Their main concern has been the adverse by universities, R&D institutes, industry and economic impact of global environmental other stakeholders regulations like REACH on Indian chemical h) Special support to training and education manufacture. The concerns of government, of chemical industry scientists, engineers academic and R&D agencies pertain to and technicians in renewable and greener poor industry linkages, lack of adequate technological options financial resources for process scale up and
80 CHEMICAL TECHNOLOGY ROADMAP: MANUFACTURING
The future Indian policy framework for • Commissioning of new ventures with a chemical manufacture will not only address the strong industry – R&D base human safety concerns adequately but also • Developing new expertise in novel product encourage the continued flow of new useful development in knowledge intensive areas chemicals from time to time. • Human Resource Development in R&D, scale up and commercialization of new Ethical issues: Ethics in chemical manufacture chemical processes and products. forms a subset of transparent chemical business practices. It is meant to ensure that the chemical manufacturing activities are not damaging to the consumer or the society in general. Ethical problems also arise out of new manufacturing technologies that may contribute to unknown effects on human health, safety and environment. The cost efficiency of many technologies can sometimes be achieved at the cost of quality and product safety. The ethical dilemmas occur in manufacturing processes caused by the involvement of unsuitable manpower, improper working conditions and fast depleting resources. In case of specialty and knowledge intensive chemicals, ethical issues mainly arise in case of user’s right for information and product developer’s intention of non disclosure. As chemical manufacture becomes more and more regulated from quality and safety considerations, it has to rely more heavily on a code of ethics in its everyday practice. There may not be a common global standard on the code of ethics for chemical manufacturers, but every organization has to evolve a set of guidelines on ethics.
EVOLVING AN ACTION PLAN Though it is extremely difficult to evolve a precise action plan for taking the Indian chemical sector to reach a position of adequate global strength by 2035, the general contours for such a plan need to be evolved with focus on following: • Industry foresight development on emerging technologies to meet national and global demands • Establishing appropriate mechanisms to strengthen industry – academic linkages to pursue sponsored research of industrial relevance. • Motivating R&D institutions to undertake product/process development in emerging areas with focus on greener chemistry and engineering • Preparing project engineering companies to develop basic and detailed engineering packages for setting up commercial ventures • Exploring Investment Opportunities in new technology areas for setting up large-scale demonstration and full-fledged commercial ventures.
CHEMICAL 81 TECHNOLOGY VISION 2035 AND PHYSICS BIOLOGY CHEMICAL Big data molecule discovery applications in new bioactive new bioactive BIOLOGY CHEMICAL molecule optimization approach drug corrections ------Disease modeling cells for genetic cells for from viruses into Insertion of DNA transportation Cell penetrating ------AND peptides for drugpeptides for CHEMICAL ENGINEERING COMBUSTION enhancement phenomena – Forest fire smoke smoke Forest fire New algorithms AND PHYSICAL ORGANIC CHEMISTRY clusters – dynamics and Gas phase nano PLASTIC PAPER AND PAPER structure, chemical structure, catalytic synthesis catalytic TECHNOLOGIES molecules from plastic Smart paper ORGANIC CHEMISTRY Self systems construction of Synthetic tools for Synthetic tools for small stained ring ------disproportionatio n of enantiomers ------CHEMICAL from very simple Synthesis of Indigo ENGINEERING organic molecules Graphene isotopes separation of membranes for helium 3 and 4 PHYSICS CHEMICAL in the regime to manipulate Organic Optical Tweezers Optical Tweezers single molecules femtosecond femtosecond ------Nonlinear Optical RFID circuits (NLO) techniques ------electronics for TV, electronics TV, for integrated PV and CHEMISTRY ATMOSPHERIC chemical Reactivity of troposphere intermediates in
82 CHEMICAL TECHNOLOGY ROADMAP: MANUFACTURING AND PHYSICS BIOLOGY CHEMICAL Big data molecule discovery applications in new bioactive new bioactive BIOLOGY CHEMICAL molecule optimization approach drug corrections ------Disease modeling cells for genetic cells for from viruses into Insertion of DNA transportation Cell penetrating ------AND peptides for drugpeptides for CHEMICAL ENGINEERING COMBUSTION enhancement phenomena – Forest fire smoke smoke Forest fire New algorithms AND PHYSICAL ORGANIC CHEMISTRY clusters – dynamics and Gas phase nano PLASTIC PAPER AND PAPER
structure, chemical structure, REFERENCES catalytic synthesis catalytic TECHNOLOGIES
molecules 1. Management Centre Europe (MCE), Chemical 13. R. Rajagopal, Sustainable Value Creation in the Fine from plastic Smart paper Industry (2010), The Executive Issue 36/Quarter 1 and Specialty Chemicals Industry (2014), ISBN: 2. Chemical Industry Vision 2030: A European 978-1-118-53967-5, Wiley, UK Perspective (2012), available from www.atkearney. 14. Green adhesives and sealants to be a Rs 5,540 com (accessed on 13.3.2015) cr industry by 2017, available from http://www. 3. Global Chemical Outlook Towards Sound constructionupdate.com/News/16512 (accessed Management of Chemicals, UNEP Report (2012) on 13.3.2015) (ISBN: 978-92-807-3275-7) 15. Arora et al., International journal of pharmaceutical ORGANIC
CHEMISTRY sciences and drug research, 2012, 4, 168-182 Self 4. America’s New Energy Future: The Unconventional
systems Oil and Gas Revolution and the US Economy, Vol 16. Technology in Indian linear alkyl benzene (LAB) 1; IHS Report (2012), available from www.energy industry, available from http://www.dsir.gov.
construction of xxl.org (accessed on 13.3.2015) in/reports/techreps/tsr155.pdf (accessed on Synthetic tools for Synthetic tools for small stained ring 5. Frost & Sullivan, Future Evolution of the 13.3.2015) ------disproportionatio n of enantiomers Petrochemicals Industry – Overview (2012), 17. Lombardo et al., Current opinion in drug discovery ------CHEMICAL from very simple
Synthesis of Indigo available from www.frost.com/prod/servlet/ and development, 2010, 13, 17-32 ENGINEERING organic molecules Graphene cpo/221887219 (accessed on 13.3.2015) isotopes 18. Tsoka et al., Green chemistry, 2004, 6, 401-406
separation of 6. C. Marcilly, Journal of catalysis, 2003, 216, 47-62 19. Pelleter et al., Organic process research and membranes for helium 3 and 4 7. Biobased chemicals – Value Added Products development, 2009, 13, 698-705 from Biorefineries (2013) available from www. 20. Development of national emission standards leabioenergy.com (accessed on 13.3.2015) (NES) for pesticides manufacturing industry, PHYSICS
CHEMICAL 8. Challenges and Innovations in Technology of available from http://www.cpcb.nic.in/upload/
in the Ammonia Urea Plants (2008) available from NewItems/ NewItem_101_NewItem_101_ regime http://125.19.12.220 (accessed on 13.3.2015) contents.pdf (accessed on 13.3.2015) to manipulate Organic 9. Assessment of energy use and energy savings 21. Bisaria et al., Bioprocessing of renewable resources Optical Tweezers Optical Tweezers single molecules femtosecond femtosecond potential in selected industrial sectors in India to commodity bioproducts, Wiley, 2014 ------Nonlinear Optical RFID circuits (NLO) techniques (2005), available from www.eetd.lbl.gov (accessed 22. Biochemical conversion: using enzymes, microbes
------on 13.3.2015) electronics for TV, electronics TV, for and catalysts to make fuels and chemicals, available integrated PV and CHEMISTRY 10. Uhde EnviNOx® Technology for NOX and N O from http://www.energy.gov/sites/prod/files/ ATMOSPHERIC chemical 2 abatement – A contribution to reducing emissions 2014/04/f14/biochemical_four_pager.pdf (accessed Reactivity of from nitric acid plants (2009), available from www. on 13.3.2015) troposphere thyssenkrupp-industrial-solutions.com (accessed intermediates in 23. Shanks et al., Current opinion in biotechnology, on 13.3.2015) 2000, 11, 169-170 11. Morais et al., Sustainable Chemical Processes, 2013, 24. Probiotic food: 2008 update Part VIII: 1:18 Nutraceuticals & supplements, available from 12. Indian Specialty Chemical Industry worth US$ http://www.thenibble.com/reviews/nutri/probiotic- 38 billion in 2017, available from www.process- food8.asp (accessed on 13.3.2015) worldwide.com (accessed on 13.3.2015)
CHEMICAL 83
METAL FABRICATION
Metal fabrication covers a wide range of activities – from general welding, forming, casting and cutting to highly specialized additive manufacturing concepts and is an important link for industrial competitiveness. Metal fabrication involves both the demand for raw materials and intermediate components, such as financial services, transportation, software and many other services within a national economy. It is an industry concerned with the skills and creativity to manufacture complex, high specialisation products.
TECHNOLOGY ROADMAP: MANUFACTURING
1.0 INTRODUCTION
Metal fabrication is a value added process to propel it to the development of machine that involves the construction of machines tools of the latest technology to compete with and structures from various raw materials. the best from abroad. The absence of this R&D The main function of the metal fabrication has resulted in the industry losing nearly 70% industry is to produce component metal of the domestic market for machine tools to parts that will fit in along with other parts, to foreign companies. form larger machinery. In this way, the metal fabrication industry proves to be an essential CURRENT INDIAN AND GLOBAL section of the entire global metal industry SCENARIO as it produces minute spare parts of larger Technology development is critical to a heavy machinery and equipment, which cannot country’s efforts in improving productivity, be manufactured simultaneously with the efficiency and competitiveness of its industrial manufacturing of the heavy machines. This sector. Cost advantages are being replaced sector represents a critical component of by technology related factors such as zero- the economies of many developing countries defect product quality and international including India. Development of this sector certification of firm’s quality assurance systems will have implications for other areas of (e.g., ISO 9000) in determining international national development of non-metallic minerals, competitiveness. Central to maintaining construction, information and communication competitiveness is the ability of producers to technology, energy, tourism and the distributive respond quickly and effectively to the changing trade. demands of the international market.
The Indian machine tool industry has come Technological capabilities can be best described a long way during its 65 years of organized in terms of three levels: development. India now ranks 16th in world • Basic level involves the ability to operate production and 11th in consumption as per and maintain a new production plant based the Annual Report (2013-14) of the Indian on imported technology, Machine Tool Manufacturers Association • Intermediate level consists of the ability (IMTMA). There has been a negative growth to duplicate and adapt the design for an due to the-then prevailing manufacturing imported plant and technique elsewhere in The industry scenario in the country. It has the capability to the country or abroad, has good design manufacture the whole range of machine tools, • Advanced level involves a capability to strength and all its especially Computer Network Controlled undertake new designs and to develop new current products (CNC) machines. The industry has good production systems and components are the result design strength and all its current products of the industry’s are the result of the industry’s own design There are very few firms close to the own design and and development efforts over the last two international frontier in terms of product development decades. Nevertheless, the industry suffers design capability and process technology; efforts from the lack of strong R&D, which is required technological capabilities of most players are
METAL FABRICATION 87 TECHNOLOGY VISION 2035
MANUFACTURING SECTOR SIZE AND GDP SHARE a booming services sector, which contributes 62.5% of the GDP. These statistics clearly 9000 16.2 indicate that while manufacturing has not been 8000 16.0 the engine of growth for the Indian economy, it 7000 now needs to grow at a much faster rate. The 15.8 6000 growth in metal fabrication sector is dependent 5000 15.6 on the investment climate. 4000 15.4 Global Scenario: Technology acquisition 3000 15.2 has traditionally been viewed as a source of 2000 techniques necessary for initiating production 15.0 1000 and hence was considered as substituting 0 14.8 domestic R&D. In the absence of the inflows of FYO5 FYO6 FYO7 FYO8 FYO9 FY10 FY11 new and advanced technologies, however, there has been little incentive, direction and capability Manufacturing sector to update the existing technologies. Technology Source: RBI, Aranca Research (size in INR billion, constant prices) Share in real GDP(%) continues to be sourced from other nations, extremely limited due to growing technological but the firm-level technology absorption is low. obsolescence, inferior quality, limited range and This is in sharp contrast to firms in Japan and high costs. This adversely affects the ability of Korea, which absorb sourced technology and the organizations to respond to the challenges, improve upon it. High quality human resources of increasing international competition from and rich stock pool of engineers and scientists other low-wage countries like China. Most is necessary for innovation. The availability of Indian metal fabrication firms appear to be engineers and scientists determines the ability stuck at the basic or intermediate level of of a nation to develop competitiveness through technological capabilities. Though Indian metal differentiation. In terms of availability and quality fabrication industry has mastered standard of scientists and engineers (2014-15 data), India techniques, it has remained dependent for scores highly. highly expensive and complicated technologies. INTERPRETING THE VISION STATEMENT With this report, we set out to predict the The industry has summarized its goals and model for the metal fabrication industry for the objectives for the year 2035 in the preceding year 2035. Technology and scientific resource vision statement. The vision statement also availability in current technology status, suggests that metal fabrication will not be seen technology development initiatives and future as an impediment to a smooth manufacturing imperatives have been identified to propel process. Rather, it will be integrated into Indian metal fabrication industry to achieve high product design such that development and growth rates. fabrication will be a primary contributor to the superiority of Indian products. In order A decade ago, India and China had almost the to compete with other technologies, the same GDP per capita. India’s GDP is only about quality of fabrication must continue to match half of that of China and is growing only at 6% the significant improvements being made by compared to China’s 10%. Currently, India’s the competing technologies. Products must manufacturing sector contributes about 16% to approach zero defects, eliminating the need the GDP, and its share in world manufacturing for repairs and re-handling, and ensuring is 1.8%. This is in stark contrast to China; where cost-effectiveness. The vision also states that manufacturing contributes 34% to GDP and is the Indian metal fabrication industry of 2035 13.7% of world manufacturing - up from 2.9% will have a world-class workforce. Although a in 1991. India’s growth has been on the back of present concern is that today’s industry is not
CAPACITY FOR INNOVATIVE RANKING
SWITZERLAND USA ISRAEL GERMANY FINLAND SWEDEN UK CHINA INDIA 1 2 3 4 5 6 8 28 48
88 METAL FABRICATION TECHNOLOGY ROADMAP: MANUFACTURING
INDIA’S GLOBAL RANK (WEF GLOBAL COMPETITIVE REPORT) RANK
RANK 48 52 30 INDIA’S 50 61 45 GLOBAL
RANK PARAMETER Quantity University Government Availability Capacity of Scientific Company Industry Procurement of Scientists for Research Spending Collaboration of Advanced and Innovation Institution on R&D on R&D Technological Engineers PARAMETER Products
attracting as much talent as it needs to ensure ROADMAP APPROACH its future viability, several steps can be taken This report is constructed by interviewing to change this. A cleaner, more automated experts from diverse back grounds such as factory will ensure a healthier and safer working entrepreneurs, academicians, researchers environment. and industrialists from leading institutes and industries across the globe. Respondents answered questions regarding the way they expect to do business in 2035 in the areas of Metal fabrication would turn out to be a flexible, forward- research and development, technology, supply chain and logistics, and sales and marketing, looking cost-effective operation producing superior- and how this compares with their current performing products, through appropriate sustainable operations. Based on the responses and various brain storming sessions with experts from technologies thus enabling the sector to be globally various fields and current industry trends, we competitive. have drawn a picture of what metal fabrication will look like in another two and half decade time and where companies will need to focus if they are to succeed going forward.
2.0 TRENDS IN TECHNOLOGY DEVELOPMENT
APPLICATIONS 7. Plastic Components: Home equipment, There is wide spectrum of applications in the writing instruments, moulded furniture metal fabrication sector. The major consumers 8. Packaging: Plastic containers, metal cans, glass are automotive and general engineering bottles, caps and closures applications. Some of the major applications are 9. Computing: Monitors, cabinets, modems, listed: printers, keyboards 1. Automotive: Passenger cars, commercial 10. Others: Defence, railways, ship building, vehicles, two wheelers medical equipment, bath fittings, hardware 2. Auto Ancillary: Transmission & steering, engine, suspension & braking, body parts & MODERN MACHINE TOOLS chassis The main requirements from modern machine 3. Communication: Mobile phones, switching tools are productivity, precision and reliability. All equipment, transmission R&D efforts by the most reputed machine tool 4. Electrical: Switch gears, cables and wires, builders are targeted at achieving substantial switchgears, wires, motors, transformers, UPS improvement in these aspects of machine tools. and lighting Several new machine design concepts and 5. General Engineering: Construction functional improvements have been evolved equipment, textile machinery, engines, boilers, as a result. The developments of machine tools turbines, bearings, valves in India must likewise be oriented towards 6. Consumer Durables: Washing machines, air- achieving major gains in the above three areas. conditioners, refrigerators, microwave ovens TECHNOLOGY VISION 2035
CONSUMPTION BY APPLICATION (IN PERCENTAGE)
KITCHEN SHIP ELECTRICAL AUTO UTENSILS BUILDING RAILWAYS EQUIPMENTS ANCILLARY OTHERS
2 2 2 4 4 5 6 9 15 23 5 23 5% 6% 9% 15% 23% 5% 23%
OFFICE CONSUMER CONSTRUCTION ENERGY AUTO GENERAL EQUIPMENTS DURABLES AND POWER ENGINEERING
DEMAND PROJECTIONS WITH RESPECT TO institutional infrastructure, these institutions 2035 generally fall short of quality when compared The Indian Metal fabrication sector in the to those in industrialized countries, putting upcoming years is estimated to grow at a India at a comparative disadvantage. The CAGR of 6, 7.5 and 9% and is expected to role of national laboratories in designing and generate revenue of 10 Lakh Crores by 2035. innovations varies from industry to industry. The main determinants of success of national R&D institutes appear to be the nature and extent of laboratory-industry interaction, the extent of market orientation of products and accessibility. Since most of 500000 700000 900000 300000 100000 the R&D effort is limited to specialized institutes, rather than in-house, market 800000 400000 600000 0 1000000 200000 orientation is a weak link.
The range of activities of R&D institutes 936526 9 includes education/training (both academic
2035 and practical), research and development (academic, practical, product, process and input material related), provision 793888 7.5 of information services, and provision 2025 of services like testing & inspection etc. Although the range of activities undertaken by these institutes is quite wide, resource 672600 constraints with respect to budget, staffing 2020 6 and equipment limit their effectiveness in both quantitative and qualitative terms. 570000 4.2
2013 Some of them are located in areas away from the industrialized zones like Mumbai, Delhi etc. Apart from R&D institutes, a 0 1 2 3 4 5 6 7 8 9 10 number of engineering colleges –provide a steady stream of engineering graduates, MARKET PROJECTIONS Market Projections while the Bureau of Indian Standards IN INR CRORES CAGR% (BIS) is responsible for activities related The Indian Metal to the development, promulgation and fabrication sector maintenance of industrial and other in the upcoming standards. years is estimated The demand and the expected industry size The culture of collaborative research involving to grow at a for major user segments of metal fabrication different institutes has not been promoted CAGR of 6, in 2035 are estimated. This is to emphasize in past and the limited resources are not 7.5 and 9% and the opportunity available for Indian metal pooled through networking to develop core is expected to fabricators to seize upon. technologies in sectors where Indian industry generate revenue has potential. Another vital link missing of 10 Lakh RESEARCH AT ACADEMIA AND INDUSTRY is the isolation of universities from R&D. Crores by 2035 Although Indian organizations are served by a network of national laboratories and While universities are the major research
90 METAL FABRICATION TECHNOLOGY ROADMAP: MANUFACTURING
MARKET PROJECTIONS FOR 2035 obsolescence or simply falling behind, a constant threat. Metal fabrication firms are pressured to be innovative, and technologically up-to-date with limited capital resources.
0 50000 100000 150000 200000 250000 300000 350000 Intensified global competition: For the Indian metal fabrication industry, global competition AUTOMOBILES refers to more than the competition from foreign firms—it refers to all firms and AUTOANCILARY industries that seek to offer an alternative to ELECTRICAL metal fabricated components. This includes component manufacturers who employ PLASTIC COMPONENTS different methods of metal processing as well as those who use different materials (e.g., plastics). COMMUNICATION MARKET ESTIMATES As traditional competitive advantages erode, IN INR CRORES GENERAL ENGINEERING the industry will experience increasing price pressure and a greater risk of commoditization. 2013 CONSUMER DURABLES 2020 Increasing customer demand: The industry 2028 OTHERS 2035 must deal with a customer who is more demanding in terms of price and quality and of new functionalities and applications. Increased customer demand puts a premium on both centres in almost all developed countries, continuous improvement and continuous especially Germany, Taiwan and Korea, in India innovation. Metal Fabricators are pressured they are isolated from scientific research to provide components that maintain the and advancements. This is largely because traditional benefits of strength, reliability, government funding of the research institutes durability, and at the same time offer new does not goad them to seek funding from benefits and new functionality. industry and industry associations through fees and royalties charged for work performed. This TECHNOLOGY GAP ANALYSIS results in low commercial orientation. Challenges faced by Indian metal fabrication industry require support from both ANALYSIS OF INDIAN METAL FABRICATION government and industry. Therefore, to improve INDUSTRY overall competitiveness (cost and quality), we An analysis has been carried out in order to have to improve national as well as firm level understand the industry’s situation, from which competitiveness. Listed below are the gaps of a diagnostic report was obtained for decision Indian metal fabrication industry benchmarked making in the sector. The factors identified gave against the global best. This has to be bridged in rise, according to their degree of development, order to reach global level competitiveness to positive implications and at the same time • Energy intensive operating mechanisms issues inhibiting progress. Understanding the • Low level of customisation dual nature of the factors allows a deeper • Low level of automation analysis of the degree of momentum necessary • Capability to manufacture versatile products to trigger a positive impact in the sector. but inexperienced workforce • Low technology innovation TRENDS • Lack of focus on core competencies and This framework is created to cope up with the poor process capability following trends Metal fabrication • Poor product design capability Accelerated technological Change: Metal is a technology- • Low focus in reverse engineering fabrication is a technology-dependent dependent • Poor product life cycle management business that can be drastically affected by business that can • Low level of flexibility, agility and reusability scientific breakthroughs and innovation. New be drastically • Limitations of inter-operability (systems advancements can present new threats or affected by integration, interface with ERP/ MRP/ new opportunities, making the future less scientific production controls systems, and software) predictable. Technological change has a breakthroughs • Lack of recognized universal standards for disruptive influence that increases the risk and innovation performance specifications attached to R&D investments, and makes
METAL FABRICATION 91 TECHNOLOGY VISION 2035 THREATS Increased demand for raw Increased demand for materials in other developing China) leading to countries (e.g. upward pressure on prices and shortagessupply energyUncompetitive costs Emergence of China and production other low-cost centres Global economic downturn reduce the demand which may exports manufactured for Impact of trade liberalization on products and non-competitive industries Dumping of products that do acceptable not meet minimum standards safety OPPORTUNITY Expansion potential for local Expansion potential for raw materials local Joint purchasing by manufacturers European Ease of access to US, and Far Eastern shipping routes techniques to increase Available through raisingcompetitiveness productivity equipment and Available re-tooling processes for liberalization providing Trade enhanced access to export markets Increasing reach of Internet marketing/e-commerce WEAKNESS Poor supply chain management supply Poor local manufacturersby procurement networks Weak Inconsistency in quality and of domestic raw supply materials product Insufficient knowledge development Lack of support services (e.g. environmental maintenance, services etc.) systems Out-dated processes, and work organization existing productivity Low existing capacity utilization Low Limited application of clean technology in production Limited economies of scale of external knowledge Weak and technology, consumers, marketing trends to match Limited innovation marketevolving trends of matching Inadequate levels health environmental, quality, and packaging standards STRENGTHS Current availability of high Current availability quality raw materials Strong international supply relationships Reduction of duties on imported raw materials Largest contributor to GDP of all goods-producing sectors enterprisesWorld-class in several manufacturing subsectors and industries high quality Ability to make products Numerous small and diverse for production facilities allowing a range markets of focussed and products Attractive Brand India appeal marketsEstablished and products DESCRIPTION Raw MaterialRaw Production Marketing
92 METAL FABRICATION TECHNOLOGY ROADMAP: MANUFACTURING Potential increases in cost of Potential capital Alternative unregulated as diversion vehicles investment in of capital from investments Manufacturing sector Brain drain of skilled persons work attitudes Poor Lack of trust and social capital Intense international adoption foreign of new technologies by competitors Impact of international as potential laws environmental barriers to trade impact of natural and Potential man-made hazards on sector
Strategic cross-border alliances and partnerships from reduced growth Potential interest rates Manufacturing skills readily transferable to other subsectors waste Existing technologies for optimization Opportunity to transfer technology from foreign investors and suppliers demand for Growing environmentally-friendly products
Lack of low cost capital to fund Lack of low expansion capital and Lack of venture start-ups for incentives and MSMEs Limited entrepreneurial spirit of skills Limited availability necessary viable to build including: businesses worker motivation Low Inadequate plant systems and new technologies Mismatch of market trends/ needs and technical applications utilization of Quality Low Management Systems (QMSs) linkages to R&D Weak resources (private and academic) product innovation Weak Limited use of environmentally friendly/clean production technologies Lack of use waste as a resource utilization of Environmental Low Management Systems (EMS) Equity investments in Equity investments more manufacturing relatively attractive of labour Large employer of trainable workforce Pool of people Innovativeness use Some plants significantly modern technologies Use of CAD/CAM tool in all areas of Metal Fabrication raw ‘green’ of some Availability materials Finance Human Resource Technology Environment
METAL FABRICATION 93 TECHNOLOGY VISION 2035
3.0 TECHNOLOGIES FOR 2035
DRIVERS performance axes drivers; motors, drive Economic Drivers: The process of globalization controllers and CNC that form the core has enabled sourcing capital where it is of machine tools, coupled with a strong cheapest, producing where it is most efficient, R&D is essential. and selling where it is most profitable. The Automation & Mechatronics: An important markets could be for products or for factors of component of modern machine tools, which production, such as capital, labour or enterprise. needs strengthening through R&D. The integration of markets takes place basically due to the removal of restrictions, both in Precision: terms of price barriers. Thus, countries have Thermal control: In machine tools, thermal to compete in global goods market mainly behavior determines the long-term accuracy. in terms of quality and price. India has a Benchmarking against the best such as use competitive cost-price advantage in mass of epoxy-granite structural material for consumption goods involving (cheap) labour. improving thermal resistance, using thermal It also has an advantage in IT and niche sensors at critical points to get information engineering sectors, where it has established leading to ability to compensate thermal quality competitiveness from this base, it deviations, multiple cooling circuits to carry could move up to product differentiation away heat generated, ensuring internet and technologically sophisticated product connectivity so as to adopt ‘internet of development to convert the challenges posed things’ and technologies like MT-connect by globalization into opportunities for machine-to-machine and machine-to- supervisor controls. Intellectual Property Rights (IPR): India Static and dynamic properties: Obtaining requires a better institutional set up for high precision also requires machines to protecting IPRs and a greater awareness about be designed with high static and dynamic the issues involved. properties. Materials such as epoxy-granite to realize high damping of structures, use Productivity: of sandwich structures with metal foam Multi Tasking Machines: In order to reduce to damp vibrations, using fibre reinforced set-ups and component handling, machine composites etc. are to be investigated upon. tools have more functions built into them Active vibration cancel systems to push so that they can handle different machining metal removal rates higher and thus improve tasks on one machine. Such machines accuracy and finish on the component are are highly productive, but require several some of the best practices. Lighter structures spindles, tool turrets/tools and work- for higher acceleration and faster traverse holding features built into one machine. rates without lose of dynamic rigidity and Typical examples are turn-mill machines. static stiffness is another approach. Indian machines must be built with similar capabilities for niche applications Reliability: in petroleum, defense, automotive and Reliability modeling: Using CAD/CAE tools aerospace industries. to built machine tools that can deliver 98% High speeds: The application of high spindle uptime, 5000 hrs MTBF and minimum MTTR speeds and traverse/feed rates are very is a way forward. This requires reliability to common to achieve high productivity by be engineered in at the design stage itself. reducing idle times. While Indian machine So R&D into the subject is of importance. tools have recorded some improvement, It should generate a model of the machine R&D into machine static and dynamic and be able to predict failure modes, behavior, vibration and thermal control is probabilities, cost etc. using data on the required to meet global benchmarks. individual elements going into the design. Cutting tools and tooling: Indigenous R&D Smart machines: Incorporate sensors for so as to develop cutting tools to achieve machine tool condition monitoring which high productivity is essential. Machine tool triggers suitable response during operation electronics: Indigenous development of high and also when repair/replacement of
94 METAL FABRICATION TECHNOLOGY ROADMAP: MANUFACTURING
items is required. Such sensors also permit Measuring systems: All modern machine self-diagnosis and correction and extend tools use very accurate rotary and linear autonomous working of machines. Smart measuring devices for position feedback. machines and controls that “know”, “learn” These are usually based on optical and “improve” are the machine tools of the transducer technology such as encoders future. Being a nascent field, India can enter and linear scales. World-wide, just two or this R&D field with some advantage. three companies have monopolized this technology. All control manufacturers also Technical Drivers: The current roadmap buy from these sources. Along with the contains the following sections: development of machine tool electronics, • Materials technology the development of such measuring • Manufacturing technology systems should also form part of the R&D • Design program. Other systems: The development of other For each of the areas listed above, the critical systems such as high pressure coolant pumps trends and driving forces affecting it, the and filtration systems, balancing systems, performance targets given in the beyond 2035, smart machines with sensors for monitoring the technical and other barriers preventing the and autonomous operation etc. are also industry from achieving these performance important components of machine tool targets, and the research and development technology R&D. activities that the industry has recommended for overcoming the barriers have been ENABLERS provided. Other than the above technical drivers, the rise of additive manufacturing and the mandatory Others: need for green manufacturing initiatives also Machine tool elements: Like electronic drives the goals which have to be worked upon systems, the machine tool industry depends till 2035. Also the enablers to achieve the above entirely on imports for its requirements mentioned technical targets are listed below of aggregates like antifriction bearings, before going into goals for the future. guideways and ballscrews. These are the • Lean Manufacturing –Processes and “mechanical heart” of the machines. The procedures to remove non-value creating industry needs to develop manufacturing activities and items while reducing waste in facilities for these components, which calls operations. for intensive R&D.
ANALYSIS OF TECHNICAL DRIVERS GOAL TARGET PRIORITIES • Effective use of • Develop dimensionally To establish materials stable materials MATERIAL material and • Higher value • Develop tools with TECHNOLOGY quality components longer life integration • Non-destructive • Virtual library of techniques material property
•Increase overall productivity Continuous improvement in metal fabrication • New cost effective MANUFACTURING •Reduce average lead times processes, process control technologies TECHNOLOGY •Reduce energy mechanisms, material for • Modelling technology Consumption per unit tools, and energy efficiency value
Effective use of the •Use of software’s for Improve speed and design and analysis design and simulation of accuracy of design tools available to all metal fabrication DESIGN and simulation increase ability to process software construct a concurrent •Use of smart tools for design fast and intuitive design TECHNOLOGY VISION 2035
TECHNOLOGIES FRAME-WORK
IMMEDIATE INTERMEDIATE LONG TERM
• Elimination of distortion and residual • Avoid post weld heat treatment • Joining at cryogenic temperatures stresses in weldment • Adaptive welding techniques • Welding techniques without heat • Robust sensors and controls suitable • Accurate fast and reliable Non- affected zone for hostile environments destructive testing to qualify defect • Rapid die manufacturing technologies • Influence of squeeze in die casting free products • Recyclable and disposable moulds • Examine emerging technologies and • Design consideration for semi solid assess material properties • Automatic set forming machines to Rheocasting and lost core processes • Advanced die materials with improved save time thermal conductivity • Advanced post casting processes • Ultrasonic plastic assembly using robotics and other automatic • Eliminate need for lubrication in metal • Welding of micro-plastic parts processes forming processes and develop dry • Metal cutting operations of • Heat treatment response alloys for machining process miniaturized components having pressure die casting • Develop direct quenching in tolerance range in nanometres controlled cooling environment • Safe and silent forming machines • High speed additive manufacturing which are maintenance free • Efficient heating and furnace systems techniques • Real time defect sensing equipment • Computer based system to organize • Develop new materials that have and manage tools • Tools to address root cause of process properties comparable to composites unreliability in welding • Bi-cycle frames and high-end sports • Develop harsh environmentally • Tool to evaluate metal forming process car panels using Hydroforming parameter effect on end service life tolerant sensors to measure 3D • New generation of statistical process stresses • Capability of predicting distortion control for weld applications and understanding effects of residual • Development of interface between stresses • Development of model based process model and design to use in concurrent control • Model turbulence in castings for defect engineering reductions • Develop design-for manufacture tool • Develop computer design tool to • Solid Lubrication technology and that is easy to use move from a part design to a metal alternative for Graphite • Models that accurately predict weld fabrication design • Integration of various machining joint performance • Develop software to simulate casting operations in single head center • Develop fast and intuitive mold design processes and casting service under • Welding filler materials to improve tools various conditions productivity and reduce sound and • Smart molds for continuous • Weldable alloys that eliminate pre & smoke monitoring post weld heat treatment • Improvements in dissimilar metal • Advanced concept to promote • Establish a casting design book that joining wetting during welding relates properties and types of tests to • Determine alloy requirements expected part performance (compositions) for thin-wall castings • Impact of simulation on shop floor performance • Develop improved dies new die • Develop lighter weight casting alloys materials, better coatings • Develop corrosion- and creep- • Welding non-metallic for high resistant magnesium alloys temperature environments • Solar welding feasibility • Forming of composite materials • Determine castability and cast • Develop easily disposable tool • Forming of hard to work materials properties of new wrought alloy materials like Inconel, Niobium, Tantalum and chemistries • Incentives for renewable energy and Molybdenum etc. • Quantify the effects of primary alloying green buildings • Methodologies to deal with elements and tramp elements on • Setting up green science parks composition sensitive materials existing pattern shapes • Basic research to replace Cr and Ni • Filler materials in welding to reduce
96 METAL FABRICATION TECHNOLOGY ROADMAP: MANUFACTURING
IMMEDIATE INTERMEDIATE LONG TERM
sound and smoke • Look at novel alloys (e.g., rare earth • Develop environmentally stable and • Micro machining of glass elements in aluminum alloys) and their recyclable tool materials • Fume free fusion welding effect on ductility and strength • Develop lower-cost, process-insensitive • Conduct energy audits (water, waste & • Eco-friendly machines to reduce waste alloys energy) regularly in all industries and toxicity • Welding process and filler materials • Develop emission database for • Develop low cost highly thermal efficient that will not hamper ability to recycle industries to use in educating environment friendly heating source components regulatory bodies (Infrared heating) • Supplier - customer collaboration • Mandatory use of foundry sand • Develop technologies to utilise low through cloud reclamation process by all foundries grade heats across India • Water jet machining of composite parts • Finishing of Aluminium foams • Rapid manufacturing of turbine • Mandatory use of closed loop water system by all manufacturing industries component using Electron Beam Melting • Use of unconventional machining in medical devices • Develop environment friendly lubricants for all processing technologies • Real time energy management • 5-axis ultrasonic CNC machine design • Machine interaction with humans through ubiquity of mobile devices, monitoring and diagnosis • Adaptive and smart manufacturing devices, components and machines • Control technologies; cognition-based intelligent features within machinery and robots • Nano-manufacturing using unconventional manufacturing techniques • Advanced metal fabrication processing of composite parts • Fuzzy logic controller for advanced metal fabrication processes
• Predictive Equipment Failure Methodologies organizations will be looking for improved – Through data mining and analysis, systems, equipment and processes which organizations can determine the health of will allow for improved energy efficiency assets through identifying data patterns that and reduced costs. With specific reference tend to be associated with common machine to equipment, demand for more energy faults. This technology has the ability to efficient machinery will cause machine eliminate unplanned machine downtime. manufacturers to incorporate logic, software, • Visualization tools usage – Visualization tools and improved functionality geared toward have the ability to display high-level machine energy management. data in a simple and intuitive format so that • Smarter Materials – Super materials for problems and under-performing areas can be tools with high thermal conductivity, high identified at a glance, thus reducing costs and corrosion resistance, ductile as well as improving efficiencies. strong at the same time cost effective to be • Energy Consumption – Rising energy invented as tools are the back bone of all the prices have created the need to reduce metal fabrication processes. energy consumption and costs. Accordingly, • Improved chemistry technology - Enabling
METAL FABRICATION 97 TECHNOLOGY VISION 2035
manufacturers to carry out simple and that even if every factory, power plant, car complex chemical transformations faster, and aeroplane is shut down, the average more efficiently, with fewer processing steps, global temperature would still increase by while offering reduced cost and lower 0.6°C in this century. ‘Green Manufacturing’ environmental impact. or sustainable industrial activity is now the • Additive and direct manufacturing need of the hour and no more an empty processes - Convert raw materials (such as slogan. metal, ceramic or plastic) more directly to • Industries that adopt green practices finished products without many intermediate benefit not only through long–term cost steps, using fewer materials and minimizing savings, but equally importantly, from brand waste. enhancement with customers, better • Light Weighting- That provides high regulatory traction, greater ability to attract performance and multi-functionality allowing talent and higher investor interest. manufacturers to make products with less • Smart/Intelligent Machines – Machines materials and lower overall weight without having self diagnostic, healing and mending sacrificing performance. Materials can be capabilities along with capability of informing designed or treated to impart desired potential and real failures, greasing etc. properties such as being biodegradable, recyclable or re-engineered after the In order to meet the targets set forth in product’s end-of-life phase. the previous section, the metal fabrication • Sophisticated packaging method - Extend community must be able to hurdle certain the shelf life of products barriers, or “Competitive Challenges,” in • Green Manufacturing -The sector must the following areas: Materials, Manufacturing use energy and resources efficiently, and Integration, Workforce Integrity, and Quality. minimize generation of waste. It is estimated
Roll-to-roll Mass production of manufacturing multifunctional miniature systems Faster additive manufacturing techniques capable of assembling products by area or by volume rather than by Machine for layering materials as is self-assembly done today of parts
Free form fabrication techniques Biologically inspired nano scale-fabrication processes
Advanced and custom-designed materials, developed using improvaed Develop noise free metal computational methods fabrication processes and accelerated Self-reconfigurable experimental techniques robotics
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4.0 RECOMMENDATIONS AND IMPLEMENTATION STRATEGY In addition to the technological interventions Strengthening institutional architecture given earlier, other measures that need attention are as follows. Building coalitions, relationships, etc., with Investment inducement stakeholders through clusters
Communication and Support for promotion of industry technology transfer and Establishing metrics value and needs modernisation
Strengthening of certification and Skill development standardisation support
Reframing and refocusing industry to promote new ideas, new ways of thinking, and new frames of reference
REFERENCES The Future of Manufacturing Opportunities to 13.3.2015) drive economic growth, available from http://www3. The Manufacturing Plan Strategies for Accelerating weforum.org/docs/WEF_MOB_FutureManufacturing_ Growth of Manufacturing in India in the 12th Report_ 2012.pdf (accessed on 13.3.2015) Five Year Plan and Beyond, available from http:// Trends in manufacturing to 2020 – A foresighting planningcommission.gov.in/aboutus/committee/ discussion paper, available from http://www.cemi.com. strgrp12/str_manu0304.pdf (accessed on 13.3.2015) au/sites/all/publications /CEMI_DP1301_Mazzarol_ The 2012 World Machine-Tool Output & 2013.pdf (accessed on 13.3.2015) Consumption Survey, available from https://www. Metal Casting – industry of the future, available from gardnerweb.com/cdn/cms/uploadedFiles/World%20 http://www.nrel.gov/docs/ fy01osti/29612.pdf (accessed Machine%20Tool%20Output.pdf (accessed on on 13.3.2015) 13.3.2015) Indian manufacturing in a global perspective: setting the Metal Forming and Machinery Industry in India, agenda for growth, available from http://drona.csa.iisc. available from www.imtma.in (accessed on 13.3.2015) ernet.in/~nv/9DTT_DR_ISBNYUPurdue_ Summit_ Indian Machine tool Industry Vision Document & Nov05a(1).pdf (accessed on 13.3.2015) Perspective plan 2010 – 2020, available from http:// Quick Estimates Of Index Of Industrial Production www.imtma.in/userfiles/file/vision_&_pp_report-ref.pdf And Use based Index For The Month Of July, 2014, (accessed on 13.3.2015) available from http://pib.nic.in/newsite/PrintRelease. Hassan El-Hofy, Advanced Machining Processes: aspx? relid=109624 (accessed on 13.3.2015) Nontraditional and hybrid machining processes, National Manufacturing Policy, available from http:// McGraw Hill, 2005 dipp.nic.in/english/policies/national_manufacturing_ The Global Competitiveness Report 2013-2014, policy_25october2011.pdf (accessed on 13.3.2015) available from http://www3.weforum.org/docs/WEF_ Vison for welding industry, available from http:// GlobalCompetitivenessReport_2013-14.pdf (accessed www.aws.org/library/doclib/ vision.pdf (accessed on on 13.3.2015) 13.3.2015) Wheer to approach for R&D funds?, available Forging Industry Technology Roadmap Update, from www.nitt.edu/home/icsr/funding_agencies.pdf available from https://www.forging.org/system/files/ (accessed on 13.3.2015) resources/public/pdf/Roadmapws.pdf (accessed on
METAL FABRICATION 99
FOOD PROCESSING
Food processing is composed of food preservation, manufacturing, nutritional need and socio-economic factors in addition to providing a nation with healthy people. Scope exists to improve the quality attributes of food along with simultaneous decrease in spoilage through innovative technology intervention with a focus on traditional and healthy food.
TECHNOLOGY ROADMAP: MANUFACTURING
1.0 INTRODUCTION
Food has many roles; the primary purpose achieving a nation with healthy people. being to supply the energy and nutrition required to grow and maintain a healthy This present chapter mentions the status human life. After these basic requirements of the current scenario and development are achieved, food also serves various other of this technology both in India and abroad, purposes, which include social, socio-economic and attempts have been made to identify the and cultural issues. The overall status is that technological gaps, which as of today are quite food is a highly complex subject where considerable in India. The areas, which need to science, technology of manufacturing, religion, be addressed and focussed, are also indicated regional choice and feeling, belief, culture, and in a brief manner. The technology scenarios knowledge obtained from earlier generations in 2035 in several fields of human endeavour and followed practices are involved and that will be impacted by food processing important. The production and consumption of and preservation technologies have been food products also depend on the availability incorporated. The document also outlines the of raw materials in the neighbourhood and approach to develop indigenous know how to the process of converting to an edible form. make India a global player in this field by 2035. The area of food processing is also dependent on other allied areas like agricultural practices, Being a complex technology depending on dairy industries, and fish, meat and poultry many aspects of other areas, it is somewhat production. Hence, all of these areas have difficult to make an intelligent forecast significant roles in the manufacture of about the market potential for the products processed food and their consumption pattern. manufactured using these technologies. The overall It is also worth mentioning here that food However, an attempt has been made to status is that processing also includes food preservation, indicate the trend based on available data, food is a highly packaging, and appropriate measures for waste appropriate prediction and optimistic future complex subject disposal. thought. where science, technology of It is thus desirable that a near future prediction CURRENT INDIAN AND GLOBAL manufacturing, is made now to understand the sector of food SCENARIO religion, regional processing and preservation. Such an exercise The current scenario can be discussed in the choice and feeling, will be useful in attaining the targets for food context of manufacturing in developed and belief, culture, security and safety. Production of food also developing countries. The developed countries and knowledge links with direct and indirect employment of are able to provide adequate quantity of obtained from many people wherein there is a good scope food, which is safe from the point of hygienic earlier generations to popularise Indian food in other countries and microbial status. However, these food and followed to boost export initiatives and convey the are not necessarily healthy for consumption practices are message of healthy life style. The vision as a number of food are fried, and contains involved and document also discusses the expected food high levels of calorie and fat. In addition, the important. requirement, strategies needed for meeting consumption of higher quantity of food than the requirement and other related issues for is actually needed by body often ends with
FOOD PROCESSING 103 TECHNOLOGY VISION 2035
can be described as a socio-economic problem where low income of people is the real cause. Developing a technology backed food-processing industry On the other hand, the problem of diabetes, to provide adequate quantity of safe nutritional food for over-weight and obesity is on the rise for a all the citizens of India along with a marked increase in significant section of people who possess a better financial status. The reasons attributed employment opportunity and export. to these problems are overeating, sedentary life style and continuation of non-healthy food habits. overweight and obesity, and associated health problems like cardiovascular diseases (CVD). Concerning the sector of food manufacturing, The existing technologies presently used are this industry ranks fifth in the country and the different conventional thermal treatment employs about 1.6 million people who processes such as baking, frying, canning comprise about 19% of the total industrial and drying, low temperature processes like labour force; it accounts for 14% of the total refrigeration and/or freezing, etc while newer industrial output with 5.5% of the GDP. Its preservation/processing technologies that are in turnover is estimated to be at Rs. 1,44,000 the R&D stage include the newer processes like crore of which Rs. 1,11,200 crore comes from the use of ozone, microwave, radio frequency, the unorganised sector.2 A large proportion of high pressure processing, Ohmic heating, food arising from the unorganised sector may infra-red processing, membrane separation, not be necessarily manufactured maintaining etc. A few attempts are also made to use the the hygienic practices. The growth rate for the irradiation technique as a commercial process Indian processed food is expected to touch a of food preservation but the success is limited very high level of 13% per annum. The country’s to a few commodities only in a few countries/ presence in the global food trade of 3% at places. present can be significantly increased to 10% by the year 2035. There is a good potential in In India, the situation is however different. India to build profitable businesses in the sector Lack of enough quantity of food for a large of food processing. There is a need to have population is existing. The FAO report a fresh look at the existing technologies with indicates that 15.2% people in India were an orientation towards the implementation of undernourished during 2012-2014 period,1 newer technologies that are energy economic which ideally should be zero by 2035. There and environmental friendly. are serious efforts to combat the malnutrition problem through government funded FOOD REQUIREMENT FOR INDIA nutritional intervention programmes like The vision document emphasises the primary mid-day meal programme for school children, goal of the food security for all citizens of India subsidised raw food materials through public and availability of adequate quantity of healthy distribution system, etc. However, still the food+. Based on the expected population problem of malnutrition is continuing which growth by 2035, the requirement of major
PRESENT AND PREDICTED PRODUCTION OF MAJOR RAW FOOD MATERIALS FOOD GRAINS VEGETABLES MILK FRUITS
265.57 162.89 132.43 88.97 The vision 394.25 336.05 230.45 165.55 document emphasises the primary goal of the food security for Production all citizens of India (2013-14) 32.74 19.78 9.04 5.92 and availability of Predicted production adequate quantity 2035 53.54 32.57 16.07 15.47 of healthy food. In million tonnes OIL CROPS PULSES FISH MEAT Source: Ministry of Agriculture, Govt. of India (2013-14); 2035 data – TIFAC estimate
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food commodities like cereals, pulses, oilseeds, and 2011), the projected Indian population in fruits, vegetables, meat, fish, and milk have been 2035 is 1530 million.3 It is hoped that the spread worked out. It is obvious that the sectors like in education and better understanding of the agriculture, dairy, fishery, poultry and meat societal duties, the increase in population rate preservation and processing industries have may come down. The requirements of major to ensure the availability of these essential raw food commodities in 2035 have been arrived materials and processed food. based on per capita consumption for the year 2011. As India is already deficient in edible oils Based on the census data (683, 846, 1023 and and pulses, there exists a serious concern about 1211 millions in the year of 1981, 1991, 2001 the increase in production of these items.
2.0 TRENDS IN TECHNOLOGY DEVELOPMENT
GLOBAL AND DOMESTIC TRENDS with the raw material and the A number of manufacturing practices/ required final product. It is desirable that all the technologies is used for developing products technologies are upgraded in the coming years of commercial interest.4 The type of food is with simultaneous improvement in the design shown under different raw materials like (i) of machinery to meet the requirements of the cereals, pulses and oilseeds, (ii) fruits, vegetables Indian food industries as well as matching with and spices, (iii) animal products obtained from the international standards. diary, meat, poultry and fisheries, and (iv) consumer food (snacks, biscuits, ready-to-eat TRADITIONAL INDIAN FOOD products and non-alcoholic beverages, etc). The traditional food of India are possibly as old The common technologies for all these cases as her civilisation and are an integral part of the are initial cleaning (to improve the safety of culture. Some of these traditional food are also the product), drying (to reduce the moisture known internationally while a major fraction content for achieving stability and increasing remains largely unknown to the rest of the the shelf life of raw material and product) and world due to lack of propaganda and scientific packaging (to improve the shelf life of product, understanding. The facts and the vision plans on avoid contamination and increase consumer traditional food are as follows: acceptance). However, other technologies vary
PRESENT STATUS OF TECHNOLOGIES EMPLOYED IN FOOD MANUFACTURING INDUSTRIES
Cleaning, infestation control, grading, Cleaning, grading, water washing, shorting, milling to remove inedible peeling, removal of inedible portions, drying, size reduction, portions, cutting/slicing/shredding/ extrusion cooking, isotope based pulping, gelling, drying, pickling, irradiation, hydrothermal treatment, pasteurisation, sterilisation, aseptic extraction processes, baking, puffing, FRUITS, processing, hydrothermal treatment CEREALS, PULSES frying, roasting, toasting, flavouring, including blanching and canning, VEGETABLES AND OILSEEDS fortification, fermentation, bulk and extraction processes, drying, osmo- small packaging AND SPICES concentration, fermentation, packaging
Cleaning, grading, water washing, Cleaning, removal of impurities, removal of skin, bone and other size reduction, dough preparation, inedible portions, icing, refrigeration, moulding, refrigeration, mixing, drying, freezing, cutting/mincing, smoking, baking, agglomeration, instantisation, drying, salting, pasteurisation, frying, extrusion, hydrothermal ANIMAL sterilisation, canning, aseptic processing, CONSUMER treatment, extraction processes, PRODUCTS hydrothermal treatment, extraction FOOD puffing, frying, roasting, toasting, [obtained from diary, processes, osmo-concentration, [Snacks, Biscuits, Bread, flavouring, coating, fortification, meat, poultry and fermentation, pickling, packaging Ready-to-eat products fermentation, retorting, packaging fisheries] and Non-alcoholic Beverages, etc]
FOOD PROCESSING 105 TECHNOLOGY VISION 2035
The limitations of many traditional food are the products. Among these products, highest poor quality due to unhygienic processing, low scope exists for instant beverage products shelf-life leading to fast quality deterioration, such as instant tea/coffee/cocoa/instant milk, suitability for production only in the household nutritious (health) drink, coffee creamer, or small scale processing centres, and lack of chocolate drink, ready-to-drink fruit juice and scientific investigation/data concerning their easy reconstitution powder, and high density processing, storage and quality characteristics. compacted food.
The solution to these limitations is that, there FOOD PACKAGING is a need to have a comprehensive research Packaging of food provides technological efforts and database concerning processing advantages such as protection, easy to carry details, specification and standardisation of the and transport, resistance to tampering, and products, shelf life, and mechanisation of the special requirements like reducing physical, product preparation including packaging. This chemical or biochemical changes. It also will help to develop processing lines of selected contains other legal requirements including traditional food, large-scale production, and price, composition, ingredients used, use of possibility of export and popularisation of those permitted preservatives, net weight, date of selected food in other countries. manufacture, safe date of use and nutritional facts.6 IMPORTED FOOD Several unwanted foreign food have entered The earlier concept of using rigid containers the Indian market, and they are freely sold of glass bottle for food packaging has changed throughout the country, and people of younger over the years though rigid containers are still generation are mostly attracted to those food. in use with several modifications. In addition, Strict quality control measures are required as the flexible packaging employing different per the existing law or by amending the laws, thermoplastic polymers and biopolymers and permission is to be provided only after are also employed for convenience, technical passing the test/specification.5 There is a need suitability and cost reduction. The design of to discourage imported food with high fat and/ food packages depends on several factors or sugar content, and if needed, higher tax may including the reactivity of the material towards be imposed for such items. environmental factors, moisture sorption behaviour, and attractive features to draw NEW LIFE STYLE PRODUCTS consumer attention, cost of packaging material More consumption of convenience food and the shelf life needed. Active packaging is in ready-to-eat/ready-to-prepare/ready-to- another concept, which is getting popular at cook form, or as convenient mixes, instant present. Edible films/coatings are manufactured food, beverages based on fruits, health drinks using edible biopolymer ingredients like (including milk and milk products), water with proteins, polysaccharides and lipids. Modified health benefiting ingredients, ready meals for atmosphere packaging of fruits, vegetables breakfast/lunch/dinner, ready-to-eat snacks, and agricultural products, and animal products and specialty ingredients for industries will be are the other areas where researches are matching the fast life style of people in the continuing at present. In addition, newer future. packaging materials are in the process of The instant development for minimally processed food products, which Instant food can be classified based on the including microwavable food, high pressure are going to match raw materials used such as cereals, pulses, processed food, etc. the future life vegetables, instant products of animal origin, style of people, beverage products, dairy products and The concept of intelligent packaging (IP) is an are basically miscellaneous instant products. The instant emerging area of technology, which has drawn to provide products, which are going to match the future considerable interest among researchers convenience to life style of people, are basically to provide and consumers. It is an alternative to the people in terms convenience to people in terms of saving ongoing packaging methods as monitoring of saving time of time of food preparation, avoiding drudgery and maintenance of the safety of products food preparation, and for offering nutritional benefits. Several throughout the supply chain are possible avoiding drudgery process technologies are going to be employed in addition to increasing the shelf life of and for offering of which the technologies like instantisation, products. The IP system includes indicators nutritional benefits agglomeration, wet heating and quick drying (time-temperature indicators, integrity or is to be the common technologies for various gas indicators and freshness indicators), bar
106 FOOD PROCESSING TECHNOLOGY ROADMAP: MANUFACTURING
PROCESSING METHODS FOR FUTURE LIFESTYLE FOODS
CEREALS Mixing, agglomeration, hydration, steaming, puffing, flaking, conditioning, extrusion cooking, pelleting, dry milling
PULSES Extrusion cooking, boiling in water, enzymatic treatment, drying, roasting, agglomeration, coating, blanching, size reduction, sieving, blending
FRUITS AND VEGETABLES Heating, stirring, pasteurisation, canning, blending, drying, mixing, freezing, refrigeration, size reduction, agglomeration, granulation, drying
PRODUCTS OF ANIMAL ORIGIN Heating, mixing, thermal treatment, freezing, refrigeration, drying, moulding, size reduction, drying
BEVERAGE PRODUCTS Moistening, pasteurisation, canning, mixing, sizing, compaction, homogenisation, enzymatic treatment, extraction, filtration, distillation, instantisation, concentration, decreaming, freeze drying, granulation
DAIRY PRODUCTS Pasteurisation, sterilisation, agglomeration, drying, coating, homogenisation, gelling, fermentation
MISCELLANEOUS INSTANT PRODUCTS Size reduction, mixing, autoclaving, drying, agglomeration, instantisation, crystallisation
codes and radio frequency identification tags nanoparticles in food packaging. (RFID) and sensors (biosensors, gas sensors, fluorescence-based oxygen sensors).7 UPCOMING TECHNOLOGIES FOR WASTE UTILISATION Machinery for packaging plays a key role for the Food preservation and processing generates manufacture of food products. The selection of large quantity of wastes, which are basically packaging machinery depends on the type of organic in nature, and arises from raw materials food to be packaged apart from its cost and from the processing of meat/poultry/fishery, capacity. There is a need to have high capacity dairy and agricultural raw materials. These packaging machine systems at an affordable wastes are in the form of liquid (waste water) price. and solid wastes. The high moisture content (even upto 95%) allows the materials to Disposal and reuse are the other issues related degrade faster, which is more severe in the to food packaging and environmental factors. case of a tropical country like India where the The use of biodegradable food packaging environment is seriously affected. The high The wastage requires reduced packaging system and humidity (70-90%) also promotes wastage in of fruits and appropriate reuse of packaging materials are a short time. However, some waste materials vegetables, and also the need of the hour. The manufacture may be considered as a by-product (meaning grains is the of food packaging machinery in low, medium that they often possess some market value) highest in the (1000 packets/hour) and high capacities provided appropriate process technologies are food sector; a (10000 to 100000 packets/hour) are needed employed. tentative estimate in addition to complete process lines for says it is about Rs liquid food like milk, beverages, etc. The The wastage of fruits and vegetables, and grains 44,000 crore per blue-sky research areas are the completely is the highest in the food sector; a tentative year in India. biodegradable packaging material for the estimate says it is about Rs 44,000 crore per protection of environment, and the use of year in India. The main reasons for this food loss
FOOD PROCESSING 107 TECHNOLOGY VISION 2035
are the lack of cold chains and the inadequate antioxidants, natural colours and protein number of cold storage facilities. However, isolates. several products of commercial importance can be prepared from the wastes such as candied TECHNOLOGY GAP ANALYSIS peel, oil, pectin, alcohol, vinegar, reformed fruit There exists a considerable technological gap pieces, etc from the waste available from fruit between India and the developed countries processing industries. at present. The solution to this problem lies in import and assimilation of technologies The conventional method of handling waste wherein development of technologies needs a fresh look for their appropriate through R&D efforts within India are also disposal or reuse. The technology of anaerobic encouraged. The assimilation of these imported fermentation, generation of biogas, and technologies to suit products to Indian people energy generation with biogas production is also includes detailed assessment of the said an interesting feature in several places. The technology in addition to understanding the wastes coming from fish/meat, fruit and spent science and subsequent training wherein grains can be used for the production of food the industrial applications are of prime ingredients like dietary fibers, polyphenols, importance.
3.0 TECHNOLOGIES FOR 2035
Food processing can be categorised as ongo- often overlap, and thus a fresh grouping has ing conventional food processing and advanced been introduced under the headings of existing, food processing, which will be implemented in near future and future technologies. the coming years. However, these two systems
EXISTING, NEAR FUTURE AND FUTURE TECHNOLOGIES
EXISTING NEAR FUTURE FUTURE TECHNOLOGY TECHNOLOGY TECHNOLOGY
• Drying Existing technologies (shown Existing and near future • Size reduction in column 1) in addition to the technologies (shown in • Material handling: Solid, liquid following items: columns 1 and 2) in addition and semi-solids like doughs, • Electron beam irradiation to the following items: gels, batters, concentrates, etc for extension of shelf life • Application of radiowave • Extrusion cooking • Micronization and and ultrasonics • Isotope based irradiation for encapsulation • Nanotechnology in food extension of shelf life • Flavouring and coating • High pressure processing • Thermal processing • Instantisation and • Ozone processing • Osmotic dehydration agglomeration • Pulsed electric fields in • Extraction processes • Fortification and food including filtration, impregnation practices • Ohmic heating sedimentation, solvent • Membrane processing • Automation and robotics extraction • Microwave technology • Baking • Ultraviolet and infrared • Frying treatments • Roasting and toasting • Flavouring • Fortification • Refrigeration and freezing • Fermentation
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ENERGY EXPENDITURE plant-based nutrition healthcare, clinical food The energy sector needs a special mention as technology and food allergies will be the focus it is an integral part of any food processing and of research in coming years. preservation method. The energy usage may be conveniently divided into two major sectors DRIVERS like rural and urban sectors. The depleting It is desirable to identify the drivers that help resources of wood and fossil fuels are going India to become a leading food processing to be a serious concern by another 10 or 15 country. years, particularly for domestic cooking. In other I. Set the objectives clear, and a clear vision words, there is going to be a huge shortage concerning the need of the country. of cooking fuel in urban areas and for food II. Research innovations and scientific preservation/processing industries wherein understanding, which come out of individual, the answer lies in the use of electrical energy academia and research organisations in the sources obtained from nuclear reactors. The field. It should come out with a number of limited petroleum based fuels can be made machines, and technologies and/or products available only to rural sectors. that may be feasible in future. III. Scale-up where a number of concepts may It is desirable that the rural community cooking be screened to find their suitability for large- is encouraged to reduce energy expenditure scale production. The available machineries using the concept of centralised kitchen where are to be used whereas the gap can be a person can bring the raw materials and identified to develop specialised machinery, cook there in an energy efficient manner as which is necessary for large-scale production. centralised cooking facility has been proved Understanding of multi disciplinary science to be energy economic system particularly based requirements needs coordinated for firewood stoves which are still in use in research involving several institutions at this rural sectors and may continue in future in phase. isolated places. Mass cooking in urban areas IV. Standardisation of technology after successful can also ensure completely mechanised meals scale-up, ascertaining the quality and at an affordable price. This can also generate acceptance of the product, and commercial adequate number of urban jobs in addition to viability. This phase needs coordination with safe food ensuring healthy practices. industries for large-scale manufacturing, and NGOs/self help groups for cottage The present vision document does not and small-scale production wherein the encourage the unregulated use of low availability of demonstration facilities is temperature processing and unnecessary mandatory. refrigeration/freezing systems as we live in a V. Release of developed technologies, and tropical country. It is rather desirable that dried consequent manufacturing for consumption food/ingredients/ready-to-process food are in India and abroad. made available which do not need any low temperature storage or processing. This practice The drivers are: is also an energy saving system. a) Mass communication for people • The need for healthy food and NEED FOR INNOVATIVE THOUGHTS AND maintaining good food habits. MASS PRODUCTION OF SELECTED FOOD • Avoidance of high sugar or high fat Innovative concepts are the perquisites to containing food particularly the fried introduce societal benefits for a society having products. limited purchasing ability. An appropriate • Maintenance of hygienic conditions in strategy is required to adopt the practice of all food processing operations including developing cost-effective products for mass domestic sector. feeding and societal requirement and the required research initiatives. b) Appropriate disposal and reuse of waste
NEWER AREAS ON NUTRITION RESEARCH c) Web linked items under awareness The future basic nutrition studies will programme include micronutrients, nutritional physiology, • The school curriculum wherein younger nutrition and aging, nutrigenomics, lipidomics, minds (6 to 10 years) will be advised to personalised and molecular nutrition, and health have healthy food assuming that a large diet and lifestyle. In addition, the new areas like
FOOD PROCESSING 109 TECHNOLOGY VISION 2035
NEED FOR INNOVATIVE THOUGHTS AND MASS PRODUCTION OF SELECTED FOOD TYPE OF FOOD NEEDED JUSTIFICATION
Convenience food Rapid urbanisation, more time spent during travel and at workplace, and more people in job require quick or less cooking type of food such as ready-to-eat and ready-to-serve food
Food for elderly people Specialty food (soft in texture and energy dense) are needed for senior citizen
Baby Food Low cost baby food including milk powder are needed
Children (pre-school and Protein rich (minimum 15% protein content) food with adequate school going) quantity of energy, minerals and vitamins are needed
Food for baby born with Import substitute and cost effective low weight
Persons under medical Help to reduce the price and act as an import substitute treatment
Persons with diabetic The enormous rise in diabetes patients needs specific food to problem control the sugar level in blood
Sports persons There is a lack of food for sports persons who need very high energy intake
On special duties Easy-to-carry homely food, which are also not monotonous [like police, duty on border and for armed forces in remote places like hilly terrains, ships, and during travel]
Working force The large number of working forces in urban and rural sectors need [Like Labourers] high calorie containing food that are safe, low in cost and are tasty
Lactating mother This requirement is meant for social cause where the health of both mother and offspring is to be protected
Research Low cost nutritious food Required for the people with low income groups innovations for all and scientific proportion of the school teaching will POLICY ISSUES understanding, be through the computer network in the • Taxation on food products which come out future. • Food for selling in the Indian market need of individual, • If a university/individual develops a new to be taxed under three categories academia process at a small scale, the inventor(s) • Healthy food with low fat content (less and research can declare the innovation in the website than 5%) are to be taxed at the lowest organisations for the purpose of scale-up and large level. Example of such food includes bread, in the field. It scale processing by others including whole-wheat flour, flaked rice, puffed rice, should come out government and private bodies with and raw and roasted cereal/pulse flour. with a number mutually agreed terms. • Neither healthy nor unhealthy food need a of machines, and • Another website is required to develop moderate taxation where the fat content is technologies and/ where the R & D requirements of between 5 and 10%. Examples of such food or products that the country are reflected with active are biscuit, less fat containing snacks, etc. may be feasible in participations from industries, academic • Non-healthy food, having the fat content future. institutions, exporters and researchers. of more than 10%, are to be discouraged.
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NEW CONCEPT NEEDED/NEW AREAS OF RESEARCH FOR TECHNOLOGIES BASED ON INNOVATIONS ITEM/ISSUE JUSTIFICATION
Bumper crop of fruits, For providing appropriate value to the producers and for saving vegetables, tuber crops, etc national resources
Reduction in the wastage Innovative and new process technologies are to be developed of perishable food thorough R&D efforts commodities
Traditional food Understanding the science and developing process technologies to make large scale production possible. The specific traditional food to be focussed are jilebi, gajak, idli, gaja (jibe gaja), dhokla, sohan papri, seasoned roasted dhal mix, etc having increased shelf life
Novel ingredients and raw For meeting specialty requirements including slow digesting complex materials carbohydrates, lipids with health benefits, linking food with health protective features, avoidance of health hazards, replacement of medicines with appropriate food items, and substitution of oil/fat with other ingredients
Macro- and micro-nutrient Attractive food with macro- and micro-nutrients for health benefits, enriched food and for increasing the shelf life of these nutrients
Food processing Energy efficient and cost effective machines are needed which include machinery the processing of traditional food, and common equipment like dryer, grinder, extruder, evaporator, etc with the quality matching the international standards for domestic use and for export purposes
Carry away meal packets Convenient meal packets at affordable price and for convenience
New process technology Development of new processing systems that is economically viable for application in industries
Examples are high fat containing cookies dry chapati, emergency ration, low fat The future of and pastries, fried food like potato chips, baked products, compacted bars, etc) food processing etc. These food are to be taxed at the that are to be stored in these centres depends on highest rate. may be processed through different several factors • The North Eastern Region, the Hilly States welfare schemes and should have shelf including existing (J&K, HP and Uttarakhand), the Islands life of at least one year. If not needed practices, life (A&N, Lakshadweep) and the Integrated or used within this time, they can be style requirement Tribal Development Projects (ITDP) distributed after nine months of storage and changes, the areas in the country need to be given to the same welfare group persons/school success of newer fiscal incentives like excise duty/sales tax children under nutritional intervention technologies concessions and tax holidays only to the programme to avoid food wastage. A and the changing units established in those areas. website indicating the name and quantity choice of food • Food for emergency situation of food under storage should be made by people. • Natural calamities like cyclone, earthquake, available to people so that the time of However, there flood and draught are common in India searching and preparation of food during are possibilities every year. It thus desirable to have five such emergency are avoided/omitted. It of several centres where long shelf life emergency becomes more relevant as the number of interesting food are kept appropriately for meeting voluntary organisations to do this type of and disruptive the emergency needs. The locations social activity is expected to reduce in the technologies may be in the north, east, west, south coming years. emerging in and north-east regions of the country future. where good road and air connectivity are available. The specific food (such as
FOOD PROCESSING 111 TECHNOLOGY VISION 2035 Applications of automation and robotics. Specialised foods for for Specialised foods body disorders like cardio diabetes, etc. vascular diseases, Incorporating of health benefiting new ingredients and molecules for foods. healthy Food products with a long shelf of 5 years.life Health food Health food replacing medicines.
112 FOOD PROCESSING TECHNOLOGY ROADMAP: MANUFACTURING
4.0 RECOMMENDATIONS AND IMPLEMENTATION STRATEGY Applications of automation and robotics. Uniform syllabus on food technology/processing/ engineering/preservation throughout the country at the graduate and post-graduate
Mechanisms for encouraging Implementation of food courts health, safe and long shelf-life in urban areas to supply Specialised foods for for Specialised foods body disorders like cardio diabetes, etc. vascular diseases, safe and low-cost food, and food through appropriate laws centralised kitchen facilities in and measures. rural areas. Incorporating of health benefiting new ingredients and molecules for foods. healthy Open web source complete with all data required for Rate of increase in population understanding the merits of needs to be checked seriously Encourage Indian food to a such technologies and products, to avoid shortage of food including those based on Indian global exposure. Food products with a long shelf of 5 years.life particularly the protein rich food traditional food, needs to be and cooking oils. created.
Develop process lines for Zero tolerance on the aspect selected popular traditional of food adulteration. food.
Establishment of appropriate facility for low cost storage facilities for farmers, entrepreneurs, traders and consumers.
REFERENCES 1. The state of food insecurity in the world, available from http://www.fao.org/3/a- i4030e.pdf (accessed on 13.3.2015) 2. Awasthi et al., A manual for entrepreneurs: Food processing industry, available from http://smallb.in/sites/default/files/knowledge_base/ best_practices/ AmanualforentrepreneursFoodProcessingSector_opt.pdf (accessed on 13.3.2015) 3. World population 2012, available from http://www.un.org/en/development/ desa/ population/publications/pdf/trends/ WPP2012_Wallchart.pdf (accessed on 13.3.2015) 4. Potter et al., Food Science, Springer, 1995 5. Report of working group Food processing industries for 12th five year plan, available from http://planningcommission.gov.in/aboutus/committee /wrkgrp12/wgrep_fpi.pdf (accessed on 13.3.2015)
Health food Health food 6. G.L. Robertson, Food Packaging: Principles and Practice, CRC Press, 2012 7. Lee et al., Intelligent packaging for food products. In: Innovations in Food Packaging, 2014, 171-209. replacing medicines.
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ELECTRONICS & ICT APPLIANCES
India has the ambiance to emerge as a leading global manufacturing hub in Information Communication and Electronic Technologies le- veraging the availability of young, knowledgeable Science, Engineer- ing and Technology manpower A joint effort between Government, Industry and Academia would make India realize its potential in the area of ICET products and services.
TECHNOLOGY ROADMAP: MANUFACTURING
1.0 INTRODUCTION
Electronics industry is one of the largest and The demand for electronics in the Indian fastest growing industries globally. The industry market is growing rapidly. Growth of demand in India is also on an upswing. Even during for telecom products such as mobile the economic downturn, the consumption of phones, computer and IT products, auto electronic goods in India witnessed moderate electronics, medical, industrial and consumer growth, predominantly due to increasing electronics is likely to bring in investments demand for consumer goods and mobile to augment Indian manufacturing capacity. devices. With the global economy showing India is also an exporter of a vast range of strong signs of recovery, this growth is electronic components and products for expected to continue in the long term. Though many segments4,5 with the help of foreign not on par with consumption, local production investment in India. of electronics has also seen a boost, influenced by IT, wireless handsets, and communication The impressive growth of Indian economy equipment production in the last decade with offers excellent opportunity to electronic foreign investment and technology. These players worldwide. In consumer electronics, segments collectively hold a share of 80% of major global players have made commitments, total electronics market revenue in the country. by establishing large manufacturing facilities and In the last couple of decades, semiconductor now enjoy a significant share in the growing chip design has grown rapidly in India. With market for products such as televisions, many of the top 25 companies in the global CD/DVD players, audio equipment and semiconductor business setting up design other entertainment products. The global houses in India, the country is progressing semiconductor industry is dominated by USA, towards being a global semiconductor design South Korea, Japan, Taiwan, Singapore and hub, with Indian talent pool as the human European Union. Worldwide semiconductor resource. The progress in design segment has growth in recent years have been largely not translated into manufacturing as the top driven by increasing demand for consumer manufacturers have established facilities in electronics and telecom products such as their countries of origin. This situation is likely mobile phones, FPD TV, notebooks, portable to change due to favourable governmental music players, mobile phones etc. During the policies.1-5 global recession, sales in Asia Pacific remained flat, whereas that in America and Europe CURRENT INDIAN AND GLOBAL witnessed a steep decline.6-11 By 2020, the SCENARIO Indian share The electronic industry, more so consumer By 2020, the Indian share of the chip market is of the chip electronics, in India is growing fast. A market expected to be US$ 50 to 60 billion. Over the market is value of US$ 400-480 billion (US$ 340 billion last two years, chip consumption has increased expected to from consumer electronics alone) is forecasted 61.44% to $8.25 billion. Right now, India adds be US$ 50 to for 2020, which is only a miniscule (1.44%) of value by way of design, accounting to a modest 60 billion the forecasted global production of US$ 1.8 $2 billion. Value addition to this design comes trillion. in the form of chip manufacturing to the tune
ELECTRONICS & ICT APPLIANCES 117 TECHNOLOGY VISION 2035
It is essential to build facilities for assembly, India would become a major player for low volume high testing, and packaging for the manufactured chips, Embedded/real-time software to run critical technology and high volume less critical technology these chips, a supply chain to cater to all the to meet needs of manufacturing of a large electronic critical equipment and chemicals12 is considered ideal. A concerted effort between government, product mix. industry and academia is required in areas of training technical human resources to run and manage fabs, study the market trends, analyzing of $20 billion worth in countries like Taiwan, and adopting business models, develop China and Korea, based on chip design work relationships with supplier and customer base, done in India and finished electronic goods develop appropriate policy support mechanism worth US$ 60 billion plus based on these and carry out cutting edge R&D. Some efforts chips. India needs to have a large number of are already in place through the Department of fabrication facilities, for which investments to electronics and information technology, GOI. the tune of US$ 4 – 6 billion is required for every fabrication facility. Augmentation by way DEMAND PROJECTION 2035 of R&D investments every 18-24 months for Electronics, reported at US$ 1.75 trillion worth technology updating is also needed. Compared production now, is the largest and fastest to dismal number of chip fabrication units or growing manufacturing industry in the world. semiconductor chip manufacturing foundries for Demand for electronics in the Indian market large scale production, domestic manufacturing is expected to grow from US$ 45 billion to facility is required to manufacture chips to US$ 400 billion by 2020 and US$ 3200 billion be used as audio/video/ general purpose by 2035 at a growth rate of 15%. The export processors, microcontrollers, memories, etc. market is likely to move from US$ 4 billion
NEED FOR DOMESTIC MANUFACTURING Projected demand-supply gap in Electronics Industry 900 Production level electronics industry may reach with favorable policy environment 500 750 400
Gap between current and 250 expected domestic production, 320 250 offering significant opportunities for improvement 125 85 45 104 Production level electronics 20 42 industry will reach with current 0 environment FY09 FY14 FY20 FY35
Total Demand Domestic Production [Largest] Domestic Production [at current CAGR]
EXPECTED DOMESTIC DEMAND FOR FY09 45 ELECTRONICS IN INDIA [In USD Billion] FY14 125 22% FY20 400
FY35 Source: Industry Estimates 1700
118 ELECTRONICS & ICT APPLIANCES TECHNOLOGY ROADMAP: MANUFACTURING
to 80 billion by 2020. With setting up of new touch $1200 Billion by 2050. The imports are manufacturing facilities, export contribution more than what we can export in electronics. of US$ 800 billion by 2035 should be aimed This is not favourable for GDP, CAD and for. The trend of imports/exports needs to be Nation debts. The graph shown in Plate 1 and 2 reversed. This scenario may improve and may gives the projected demand- supply gap.13-15
Demand estimates for key segments in US$ Million
8.1 16.7 29.5 2.7 155.5 CONSUMER 17.8 54.4 7.8 AUTOMOTIVE ELECTRONICS/ INFORMATION TELECOM INDUSTRIAL TECHNOLOGY ELECTRONICS/ ELECTRONICS OTHERS
45.02 175.0 210.0 10.5
2014 2020 Targeted 2035 Targeted
2.0 TRENDS IN TECHNOLOGY DEVELOPMENT
Among numerous great inventions made in the evolve further for around a decade and their 20th century, electronics has played a dominant importance will taper off in future giving way to role. According to a recent survey,15 Electronic new emerging technologies to meet the needs End Equipment’ has become the base of all of the present intelligent society. political and economical activities and staked a share of the world’s total GDP of about PRESENT DAY STATUS OF THE USD 30,000 billion. Almost everything related SEMICONDUCTOR INDUSTRY to human needs, such as power generation, Semiconductor manufacturing today is a mature transportation, communication, entertainment, technology, with global revenue of US$300 medical care, economic activities like stock billion and manufacturing facilities in over 20 market, financial transactions are now provided countries. It is the cornerstone of global IT and controlled by electronics. Semiconductor, economy, supporting a $2 trillion market in being the key component of the Electronic electronic products and an estimated $6 End Equipment, is a strategically important trillion in service industries across sectors technology for all countries. The electronic ranging from health care and transportation circuit development has been accomplished to banking and defence. The dominant through down scaling of component size manufacturing process used today for digital brought out by the replacement of vacuum electronics is called the complementary metal tubes with transistors 40 years ago. Circuit oxide semiconductor (CMOS) process. performances have benefited a lot from the downsizing. It is now possible to integrate With the establishment of manufacturing- millions and billions of CMOS transistors in the independent design rules for integrated circuits, nano scale in a silicon chip of few centimeters IC designers no longer need to be co-located square. Right now, the operation speed of the with the manufacturing side of the business. This latest microprocessor has already reached decoupling led to the creation of the electronic 3 GHz and is expected to increase further17 design automation industry. Semiconductor although recent trends indicate that increase manufacturing ecosystem today has mostly of clock frequency may gradually saturate. bifurcated in to fabrication-less (fabless) The CMOS integrated circuits as well as their companies, which design their products and core device technologies are expected to outsource the manufacturing to a third party,
ELECTRONICS & ICT APPLIANCES 119 TECHNOLOGY VISION 2035
and foundries, the companies that provide a and utility infrastructure are considered noncompetitive manufacturing facility for fabless favourable points for India, where as of now no companies. A few manufacturers who design operational wafer fabrication units exist. Indian and manufacture their own products in house, presence in the semicon industry, a key driver to called as integrated device manufacturers, entire electronic system chain, has been limited (IDMs) also exist. Today, Japan, Taiwan and Korea to four government units. The establishment of have an established position in the industry, a fab city in Hyderabad with 14 manufacturing with China slowly ramping up its foundry units is expected to create 1.4 million jobs capabilities. While U.S. companies have led the through 200 odd ancillary units. Many of the microprocessor market, Japan has historically drivers for semicon industry, such as, the cost led in memory products. In recent years, competitiveness, talent pool, IP protection, however, Korea has taken the lead in memory proximity to APAC countries etc. are favourable products, as well as the mobile devices industry. to India. China with appropriate policy support from government is attracting foreign manufacturers The current day electronic manufacturing to set up foundries there, with end effect of its requirements could be understood from the semiconductor industry occupying 11% of global Frost and Sullivan study that indicates that of industry in 2009 as against 2% in 2000.18,19 the 25 high priority electronic products, which account of 82% of overall consumption of The industry is now reaching the basic physical electronics in India, the top 5 alone accounts limits to linear CMOS scaling. To avoid leakage for 60% of the consumption. These products current, manufacturers now scale down the are communication networks and switching device at constant voltage (approximately equipment such as mobile phones (38.85%), one volt), which has effect of exponentially FPD TV (7.91%), Notebooks (5.54%) and increasing the power emitted when the desktops (4.39%); solar cell panels, storage transistor operates at high speeds. With the heat devices and associated devices; power generated by a processor already exceeding electronics/supplies; LCD displays; memory that of a hot plate, further reduction is not a and PCB. The report also suggests that 69% of viable option. The continued ability to achieve the local consumption of the top 25 priority full benefits of scaling is thus diminishing as products is currently met through imports.20 manufacturers are being forced to trade-off between transistor density and performance The future requirements could be next (speed) to avoid excessive increases in power generation products like smart TV with density of the chip. There is growing interest in FHD and UHD resolution display and studio technologies that would carry the industry past equipment, also with digital network alliance the scaling limitations. Exploring technologies to features, quantum computers capable of improve chip performance via increased system- delivering extra fast performance for tasks level functionality, in what is called the system- requiring long and complex computation, on-chip concept is one of the major areas of machines which can recognize emotions, industrial R&D. Other researchers are actively Industrial robots for different applications engaged in the development of new devices, like underwater, Medical, Surveillance and new physics, new material that can function at intervention, Edutainment, etc. MEMS and much lower voltages and could allow continued NEMS for automotive, aerospace, medical, miniaturization beyond the limits now imposed Defence, require the manufacturing facilities by the CMOS transistor. There is a trend to use with latest technology nodes. FINFETs as the new option replacing CMOS. The next generation power electronics, which TECHNOLOGY GAP ANALYSIS convert and control electrical power across India is well known for its software power. On the grid and is in a growing array of products the hardware front, the progress is rather slow used by industry, consumers, military and with approximately 50 electronics manufacturing other utilities, will be using Wide Band Gap services (EMS) and original design manufactures (WBG) semiconductors, which will improve the operating (both indigenous and global players) efficiency of industrial motor system, consumer in India. Further moves by international players electronics and data centers, conversion of are expected to add production in India in the renewable power etc. Some of these could be coming years. Low labour cost, fast growing done with low end technology with low risk and domestic market, excellent education system, low investment but has advantage of meeting a technology parks and improvements in transit specific demand sector.
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3.0 TECHNOLOGIES FOR 2035
Forecasts indicate that most of today’s key and system architectures such as parallel semiconductor and electronic packaging processing architecture and system-on-chip technologies are not capable of meeting the (SoC), optimized interconnect; can also make needs of the industry in 2019. Technologies the integrated circuits to perform better. It is for the future should address these challenges expected that the overall performance of our with innovative solutions, to strengthen the electronic system could be enhanced further viability of the electronics manufacturing at least down to the generation of 20 or 10 industry13. Even though further scaling of CMOS nm gate lengths as consequences of both the semiconductors has many difficulties, they are improved device technology and the new expected to be in the market beyond 2020 system structures. for low-end solutions. International Technology Roadmap for Semiconductors (ITRS) has ROADMAP FOR THE SEMICONDUCTOR made predictions relating to future scaling for INDUSTRY 10 years up to 2018, when the physical gate Technology planning and R&D in the length is expected to be 7 nm16-19. Gate oxide semiconductor industry is a large-scale, thickness should be two orders of magnitude long- term, and multi billion dollar operations, smaller than that of the gate length. From the which has to be largely collaborative. To keep present 1 - 2 nm thick oxynitride film being electronics industry vibrant and growing, used in production, it is expected that the technology planning may be as follows - near silicon dioxide equivalent thickness (EOT) will term technology (More Moore) , medium term be reduced to 0.5 nm in 10 years time. MOS technology trends (More than Moore or System transistor with 1.5 nm6-7 or the recent 0.8 nm8 on Chip) and long term technology (beyond may face challenges during the construction of CMOS /beyond Moore). large-scale integrated circuits with such thin gate insulators. It is believed that the CMOS device It should be emphasized that these technology downsizing is approaching the physical limit. The developments are not sequential but occur ultimate limit of the scaling is the distance of in parallel with advances in one feeding into atoms in silicon crystals (0.3 nm),17,19 when the another area. Each of these trajectories gate leakage will reach unmanageable limits. will require substantial changes in design, architectures, system integration models, and New Technological Options: Performance process technologies. enhancement can be achieved and further downscaling may be proceeded with the NEAR-TERM TECHNOLOGY TRENDS introduction of new technologies and (“MORE MOORE”) materials at least for another 10 years and This category includes modifications in design furthermore with that of three-dimensional and materials in the current manufacturing structures.17 New materials and processes processes to compensate for the limitations for sub-100 nm device manufacturing such in linear scaling and extend the benefits of as elevated source/drain, plasma doping with the CMOS process to the maximum possible flash or laser annealing, NiSi silicide, strained Si extent.16,17 channel for mobility enhancement, silicon on insulator (SOI), three-dimensional structure Device and Materials Continued Scaling: high dielectric constant (high-k) gate insulator, Continued scaling of transistor dimensions metal gate, and low dielectric constant (low-k) results in extreme heat dissipation at the limits interlayer insulator for interconnects have been of high performance. Manufacturers now explored recently. These measures are already seek to improve chip performance using a on schedule for future technology nodes.17 combination of continued dimensional scaling, FinFET is another contender. However, some to the extent feasible and cost effectiveness. unexpected device parameter degradations Towards this, “Equivalent scaling,” that is, changes were reported with the new materials. High-k in materials, design, and process that combine gate insulator is an example. Fortunately, to give a performance improvement equivalent scaling is not the only solution for performance to scaling down the chip (e.g., introducing new improvement. The improved circuit structures materials such as high-K dielectrics in place of
ELECTRONICS & ICT APPLIANCES 121 TECHNOLOGY VISION 2035
the traditional silicon dioxide insulator) and electronics eras”.14 using three-dimensional transistors such as the FinFET and the tri-gate transistor18 is becoming Transmission: Silicon photonics are being increasingly relevant. Design-equivalent scaling, developed to enable integration of optical such as, use of multi-core architecture, general transmission systems onto the chip, overcoming purpose graphical processor units (GPGPUs) the constraints of today’s copper interconnects. and different modes of low power design to This would result in faster and more energy- drive improved performance is yet another efficient chips than are possible using option. Though only marginal improvements are conventional technologies. Silicon photonics gained, all these methods utilize the parallel- circuits have recently been demonstrated instruction capability of multi-core processors and are a few years away from commercial to achieve speed-ups. production. In future in circuit optical interconnects will be using 3-D, nanophotonic In the areas of memory and storage, research solutions. has focused on unifying hard-disk memory and chip-based memory into a single unifying Manufacturing Process: Lithographic patterning non-volatile memory. Technologies such as is critical for defining lateral dimensions on the the phase-change memory, ferroelectric RAM chip and translating design into product.19 There (FeRAM), and magnetoresistive random access is currently a pressing need for next-generation memory (MRAM) are under development as lithography (NGL) technologies for nanoscale potential replacements for the universal flash printing, and leading equipment manufacturers memory.21 are in a close race to bring future lithography techniques such as extreme ultraviolet (EUV) Materials: Several materials are being lithography to market.18 EUV Lithography has researched and characterized for their potential its own limitation and is not a cost effective insertion into CMOS devices (replacing the technology and new emerging technologies are channel) to improve performance, as well as plasmonic lithography, which can overcome the form the basis of new “beyond CMOS devices.” limitations of EUV lithography. The materials attracting the most attention are graphene22, carbon nanotubes, and compound As emerging devices scale down to nanometer semiconductor nanowires. As the silicon- and very low-end nanometer levels, robust based CMOS process has been a technological and efficient methods for atomically precise juggernaut for the past four decades, there placement and solutions for intelligent fault is enormous resistance to the integration of tolerance are becoming essential. At simulation new and old materials—including compound level, new paradigms are emerging for quantum semiconductor materials and germanium as mechanics based modeling and characterization they are not compatible with the existing of process compatible designs. On the manufacturing processes.17 factory- floor, globally distributed production systems need to become increasingly scalable, Integration: During integration of various circuit flexible, and extendable. Improving all these blocks on same chip there is a problem of characteristics for improving process control is interconnect delays that limit the performance essential. Further, as manufacturing systems are of any IC. New strategies of interconnect such increasingly automated and subject to remote as CNT interconnects and three-dimensional control, information security and cyber-security integration of circuits are being explored. In become essential. 21 Future low-end nano three-dimensional integration of circuits two or technology solutions may need self-assembly at more layers of active electronic components the large-scale production. are vertically integrated into a single circuit using through-silicon vias (TSVs), which will MEDIUM-TERM TECHNOLOGY TRENDS dramatically reduce interconnect lengths and (“MORE-THAN-MOORE” OR “SYSTEM- ON- thus transmission delays. Three-dimensional CHIP”) integration for stacking memory and logic This methodology involves incorporating components provides a higher memory density analog devices (such as sensors, actuators, at lower power for mobile applications.16 This RF devices, audio and video power circuits concept of moving system integration to the and passive components), which are typically third dimension has been called “the largest integrated at the system board level, to be shift of the semiconductor industry ever, one placed directly onto the chip (also called that will dwarf the PC and even consumer system-on-chip, or SoC).16-18 A compact system
122 ELECTRONICS & ICT APPLIANCES TECHNOLOGY ROADMAP: MANUFACTURING Baseline CMOS Memory RF HV Power Passives Sensors Actuators Biochips Fluidics MOORE MOORE MORE THAN MOORE MOORE HETEROGENEOUS INTEGRATION System on chip (SoC) and System in Package (SiP)
“MORE-THAN-MOORE” HETEROGENEOUS INTEGRATION OF FUNCTIONALITY ON THE CHIP with heterogeneous functionality will drive the Manufacturing Process: SoC system will proliferation of integrated circuits for improving combine digital and non-digital (sensing, communications systems, bioelectronics, and audio/video sub-systems, power supplies, transportation. communication, and fluidics) elements on the same platform; thus, suitable materials The United States leads in these technologies, integration of such sub-systems on the but Korea and Taiwan are highly competitive. same foundry floor must be found for the new applications23, 24. These will have to be Device and Materials: “More-than-Moore” or integrated into the CMOS manufacturing “System-on-Chip” is the idea of integrating technology. While leading manufacturers are in heterogeneous components onto the silicon a competitive race to ramp up heterogeneous- platform to increase the functionality of the integration methodologies for the silicon chip itself.1 platform, incorporating new functionality will need cross-disciplinary work and new As against the present method, wherein learning for the industry. More automation and processor is connected to other system standardization will be needed for the new components such as power source, external processes introduced. Manufacturers of SoC memory, RF chips, sensors, etc. on the and three-dimensional integrated products will motherboard, using wires made of copper, in an initially be more vertically integrated, which SoC paradigm, these system components would will cause big shifts in the highly modular migrate directly onto the silicon platform. At and globally dispersed ecosystem of the first the system components would be vertically semiconductor manufacturing industry. Further, separated and as manufacturing processes processor- packaging technologies (flip-chip evolve they would be eventually stacked bonding) would be replaced with three- vertically. This would optimize performance dimensional packaging technology. at the system level and extract much larger improvements in system performance than Three-dimensional packaging saves space by linear scaling alone is able to do. The first SoC stacking separate chips in a single package, manufactured would likely integrate processor, making it more economical for low-cost memory, and communication chips; eventually, manufacturing but issues such as cross-talk, MEMS, sensors, and biologics would also be removal of heat amongst various layers of the integrated. Advances in three- dimensional circuits and optimum layout planning is required. integrated circuits and silicon photonics, would feed into SoC technology. There will be an LONG-TERM TECHNOLOGY TRENDS increasing emphasis on field-programmable (“BEYOND CMOS/ BEYOND MOORE”) gate arrays (FGPAs) and a shift away from This trajectory includes research on emerging application-specific integrated circuits (ASICs) devices and materials, focused on a “new as chip technology becomes more for general switch,” which will initially supplement the purpose. This would also open up possibilities functioning of the current CMOS and for mass customization of chips, produced eventually supplants it. These devices and inexpensively and programmed at the software memories are anticipated to use new state level such as for embedded system designs.18 variables (such as electron spin, magnetic spin,
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SCIENCE AND TECHNOLOGY STRATEGY / ROADMAP
2000 2005 2010 2015 2020 2025 2030
PLAN A: Extending Si CMOS R R PLAN B: Subsystem Integration R R Non-Si FET PLAN C R R&D Beyond FET
molecular state, etc.), which allow functional integrating with the CMOS process, to allow scaling substantially beyond that attainable by insertion into heterogeneous or hybrid systems, “scaled CMOS.” Examples include carbon- thereby enabling a smooth transition to a new based nano electronics, spin-based devices, scaling path. These goals are driving research ferromagnetic logic devices, atomic switches, in graphene, carbon nanotubes and nanowires, and nano electromechanical-system (NEMS) among other materials. While many ideas switches16-19 etc. are being pursued, a representative sample (based on demonstrated feasibility)21 would Device and materials: The limits of CMOS include a) field-effect transistor (FET) devices scaling have also infused an urgency into that can operate at lower voltages, such as band- the vision of discovering new, highly scalable to-band tunneling FETs, b) nanomagnetics and concepts for information processing and spintronics,18 which exploits the spin properties memory functions to enable orders-of- of electrons (both individual and collective magnitude higher miniaturization than that is oscillations), c) resistance-based memory devices possible using silicon CMOS devices. These or conductance devices (resistive random concepts could be based on a new “token” access memory, or ReRAM), d) single electron (such as electron spin or molecular resistance) transistors and d) molecular devices. to represent electric charge as a means to represent information. Quantum Information It would be interesting to note that recent and computing systems will be round the corner. advances based on magnetic spin properties include products like MRAM, which could be The change to a new information-processing a key component in defence systems that technology will likely be accomplished in require radiation-hardened devices and non- two phases: in the first, the potential new volatile memory. Metal-based spintronics are technologies would have to be integrated with likely to reach commercialization first, using a existing CMOS processes to extend chip phenomenon called spin-torque transfer for functionality beyond what would be possible storage and applications (called STT-RAM). with CMOS alone, such as a hybrid technology. Semiconductor-based spin devices are still The second phase would see the evolution to very much in the research stage. The resistive completely new, multifunctional and scalable memories will be very dense and easy to stack. technology platforms.16 This second phase is Non-volatile memory integrated with logic is at the basic stages of research, and it will likely also being explored. The spin electron transistors continue past the 2035 time frame. are switching devices that use tunnelling mechanisms to transport single electrons from The new devices being explored for “Beyond source to drain. While these devices hold CMOS” technology may perform processor the potential of ultra- low-power electronics, or memory functions or in some cases, a significant obstacles remain in the noise margins, combination of both functions in a universal control of meta-stable states before SETs can device. They should ideally show significant be used in large-scale circuits. Molecular devices advantages over ultimate scaled devices in are based on molecular switches that switch power consumption, frequencies of operation, reversibly between two or more positions. The and density. They should also be capable of
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use of molecular switches as programmable storage and management of increasing volumes diodes is the core technology underlying of data while addressing integrity, safety, security, projected applications. Logic, memory, and and privacy concerns, f) Influx of biological interconnect functions have been demonstrated devices based design, architecture, and concepts, using molecular assemblies, but integration onto ultimately aiming for massively parallel, fault- a circuit is still a long-haul research goal. tolerant neuro-morphic systems, Cumulatively, these trends would enable advances in Manufacturing Processes: Bottom-up powerful and intelligent electronic products manufacturing processes such as directed self- as well as enhanced modes of human-computer assembly of molecules (currently shortlisted interaction.25 on the international roadmap for further investigation) will start being incorporated Printed electronics is another promising area into the existing CMOS platform for building to play a dominant role in the next generation heterogeneous devices and eventually play electronic products manufacturing, with market a larger part in improving process control for printed, flexible and organic electronics at lower costs.18 Currently, self-assembled growing to USD 76.79 billion by 2023. Printed structures of diblock copolymers are being used electronics may enable new markets for large- as an alternative to photoresists for sub-10 area, flexible or low-cost disposable devices. nm features in design patterns. However, the Using printing to fabricate electronic devices scale and scope of investment in the current promises lower manufacturing costs because manufacturing methods is such that a full shift to of the additive, non-vacuum nature of the bottom-up manufacturing is predicted to be a technology and the advantage of roll-to-roll or decade away. large-area processes.
Incorporating new materials onto the silicon platform in ways that their functionality can be fully exploited Beyond CMOS is yet another challenge. This trajectory includes research on emerging devices and materials, focused on a “new switch,” which will initially supplement the functioning of the current CMOS and eventually supplant it. These devices and memories are anticipated to use new state variables (such as electron spin, magnetic spin, molecular state, etc.), which allow functional scaling substantially beyond that attainable by “scaled CMOS.” Examples include carbon-based nanoelectronics, spin-based devices, ferromagnetic logic, atomic switches, and nanoelectromechanical-system (NEMS) switches.
DOMINANT TRENDS IN TECHNOLOGY AND MANUFACTURING The next two decades would witness technology trends such as a) low-power and low-energy systems, which will be needed as more devices (especially those with integrated sensors, SoC, MEMS etc.) have to integrate seamlessly with the environment, b) increasing wireless capability and connectivity, particularly as cloud computing needs escalate, c) convergence of computation, storage, sensing, and communication functionality on the chip by integrating heterogeneous materials and components, d) increasing use of nanoscale processes in device fabrication; slow but eventual transition from top-down to bottom-up manufacturing will be necessary, e)
ELECTRONICS & ICT APPLIANCES 125 TECHNOLOGY VISION 2035
Nano-photonics
Spintronics
Bio-Electronics Molecular Electronics, Plasmonics Quantum Electronics and Quantum Computing
Carbon Electronics/ Graphene based
Electronics
Meta Materials
Single Electronics
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4.0 RECOMMENDATIONS AND IMPLEMENTATION STRATEGY • Setting up of manufacturing units for industries that would benefit from these low- very low cost (low risk) and ultra high end fabs are those relating to renewable energy, performance (high risk) electronic solar panels, silicon and hybrids, inverters, UPSs, products through FDI wherever possible automotive electronics, Micro-controllers, or with real national effort in mission analog, mixed-signal, FPGAs, MEMS and audio mode. equipment. Another major segment that would • Creating ITI’s offering training in high-tech benefit from these lower end fabs are the ICT products and centres of excellence in health care industries comprising of sensors, electronics and other emerging domains. mobile/wireless diagnostics and treatment • Policies to support flexibility for industry equipment, industrial level electronics and to adapt to new product chains as future automation and FMCGs. If more fabs are directions of Electronics are always in flux needed over and above mentioned existing and are dynamically changing from time to Indian Industries they should only be set up time. under private sector only and Govt. of India’s • The established SMEs should be able to involvement should be minimum except meet the ultra high precision requirements provide licenses. This has to take into account of current day electronic manufacturing the past mistakes. and also cope up with new challenges. Once the manufacturing ecosystem is set up, Some major recommendations for setting up and is a successful as a business model (viz. fabs for meeting domestic needs are market, customers, revenues, growth, etc.) • N-3 or more through FDI or large scale for Indian conditions – it will yield a platform expansion of existing fabs, which could be (and confidence) to go for high technology mandated to produce devices for low end manufacturing technology nodes and meet the power electronics type demands • establishing ITI type training institutes that have high end skills, which the leading Industries of India can utilize for taking up manufacturing of low end and high end device and systems • mandating educational institutions, R&D organizations and other Govt. agencies to take up problem solving for emerging domains of technologies, along side training of manpower to handle such problems when employed by the industry • technology up-gradation should be the prime goal of industry who want to be major players and • major investments and handling of high end technology should be made by the industry, in tune with practices followed in US, Japanese and Europe.
It is expected that the adoption of these recommendations could have advantages such employing cost effective technologies, equipment, infrastructure etc. to produce products with lower global market share but is able to support large local industries. The
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REFERENCES 1. An overview of opportunities in electronics available from http://iesaonline.org/ manufacturing in India, available from http:// downloads/MVAtre_BITES_Guest_Editorial_ www.igovernment.in/opinion/20122/an- April2013.pdf (accessed on 13.3.2015) overview-of-opportunities-in-electronics- 13. India a hub for Global electronics manufacturing-in-india (accessed on manufacturing? Available from http:// 13.3.2015) iesaonline.org/presentations/A_Gururaj.pdf 2. Market research India, available from http:// (accessed on 13.3.2015) www.euromonitor.com/india (accessed on 14. Handset manufacturing Value Chain, available 13.3.2015) from http://cmai.asia/pdf/Cover%20Story.pdf 3. Indian consumer electronics market (accessed on 13.3.2015) outlook 2015, available from http://www. 15. International Technology Roadmap for researchandmarkets.com/reports/2516245/ semiconductors 2013, available from www. indian_consumer_electronics_market_ itrs.net (accessed on 13.3.2015) outlook_2015 (accessed on 13.3.2015) 16. Future of silicon integrated circuit technology, 4. a. Frost & Sullivan, Does India’s available from http://ieeexplore.ieee.org/ Semiconductor Policy need an extension?, stamp/stamp.jsp?arnumber=4579241 available from www.frost.com/prod/servlet/ (accessed on 13.3.2015) cio/197194030 and b. Market Analysis 17. Emerging Global Trends in Advanced Report: China’s Electronics Industry, Manufacturing, available from http://www. available from http://www.export.gov.il/ wilsoncenter.org/sites/default/files/Emerging_ uploadfiles/03_2012/marketelectronics.pdf Global_Trends_in_Advanced_Manufacturing. (accessed on 13.3.2015) pdf (accessed on 13.3.2015) 5. The Indian electronics industry, available 18. 2013 research priorities, available from from http://www.calce.umd.edu/ general/ http://thor.inemi.org/webdownload/2013/ AsianElectronics/pref_ind.htm (accessed on Research_Priorities.pdf (accessed on 13.3.2015) 13.3.2015) 6. ICT sector overview opportunity for 19. Bernstein et al., Proceedings of IEEE, 2010, 98, US firms, available from http://www. 2169-2184 exportwashington.com/Documents/Tractus- Sector-Overview-India-ICT-2012-07-30.pdf 20. The Global Information Technology Report (accessed on 13.3.2015) 2008- 2009: Mobility in a Networked World, available from http://www.weforum.org/pdf/ 7. Value addition and employment generation in gitr/2009/gitr09fullreport.pdf (accessed on the ICT sector in India, available from http:// 13.3.2015) mospi.nic.in/mospi_new/upload/val_add_ ICT_21june11.pdf (accessed on 13.3.2015) 21. Cavin et al., Journal of Nanoparticle Research, 2005, 7, 573-586 8. Digital planet 2010 – Executive summary, available from www.witsa.org (accessed on 22. Roadmap for making India a global ESDM 13.3.2015) Hub, available from http://iesaonline.org/ downloads/Snayak_IT_biz_Oct12.pdf 9. Productivity and competitiveness of Indian (accessed on 13.3.2015) manufacturing: IT hardware and electronics, available from http://nmcc.nic.in/pdf/ 23. The Global Information technology Report ithardware_03july2010.pdf (accessed on 2012-Living in Hyper-connected World 13.3.2015) available from http://www3.weforum.org/ docs/Global_IT_Report_2012.pdf (accessed 10. Report of task force to suggest measure on 13.3.2015) to simulate the growth of IT, ITES and electronics hardware manufacturing industry 24. A Snapshot of Australia’s Digital Future in India, available from http://deity.gov.in/sites/ to 2050 avialable from http://www-07.ibm. upload_files/dit/files/Task_Force_Report- com/au/pdf/1206_AustDigitalFuture_A4_ new_21211(2).pdf (accessed on 13.3.2015) FINALonline.pdf (accessed on 13.3.2015) 11. Boosting India’s manufacturing exports, 25. Speech by ITU Secretary-General, Dr available from http://planningcommission.gov. Hamadoun I. Touré available from http://www. in/aboutus/committee/wrkgrp12/wg_mfg.pdf itu.int/en/osg/speeches/Pages/2013-05-13-3. (accessed on 13.3.2015) aspx (accessed on 13.3.2015) 12. Semiconductor manufacturing in India,
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ELECTRONICS & ICT APPLIANCES 129
COMPOSITES FABRICATION
Attractive characteristics such as light weight, high strength, high stiffness, good fatigue resistance and good corrosion resistance make it easy to fabricate structural parts using composites. India in 2035 should be able to realise the innovations in composite manufacturing, which has to produce results in rapid, high volume, cost effective and energy efficient composite manufacturing processes which will expand commercial and industrial utilisation.
TECHNOLOGY ROADMAP: MANUFACTURING
1.0 INTRODUCTION
Composites will materialize tomorrow’s during 2013 and is projected to grow sustainable future. Innovation in composites at a CAGR of 22% over the next four is of great importance to face the upcoming years. Today, total demand for composites global challenges by providing safe and products in India is more than USD 240B engineered materials with specific properties, In 2013; the Indian Composites Industry new lean and precise processing technologies recorded a growth of 15.6%. and novel recycling pathways in order to • Most of the major players are capture the full value of waste. strengthening themselves by opening new facilities and sales offices to tap future INDIAN SCENARIO potential of one of the fastest growing • In India, the first composites industry economies. began in 1962. With the development • Capacity expansion either through of various industrial sectors, the Indian building new capacity or JV/acquisition composites industry started growing. The to meet growing market demand. Joint Indian composites industry is currently venture between OEMs and composite expected to produce 320,000 metric tons material suppliers in automotive Industry per annum accompanying a market size of and long term contracts in aerospace approximately USD 130B. Industry • With respect to its turnover the • R&D projects across supply chain to composites industry offers greater gradually shift composites from high end employment opportunities. It is currently to high volume applications employing 150,000 people either directly • Emerging composite applications in or indirectly. The composites industry growing aerospace, and automotive. in India manufactures around 35,000 implements. GLOBAL SCENARIO • Statistics reveal that composites produced • In 2010, the global composites industry in India is equivalent to approximately 3 was valued at USD 17.7 billion. This is % of the worldwide output and 6 % of expected to rise to USD 27.4 billion in Asia’s output 2016, thus growing by approximately 55%. • Improvements in technology in the Indian Similarly, the end composites industry is Improvements in composites industry have accelerated its estimated to increase to USD 78 billion in technology in the growth. This has facilitated India’s ever- 2016 from USD 50.2 billion in 2010 thus Indian composites growing presence in the global composite attaining a growth of 55.3% industry have market. • The confidence shown by the consumers accelerated its • Over the past decade, India has been able towards the use of composites in the growth. This has to maintain a steady Compound Annual automotive industry has catalysed the facilitated India’s Growth Rate (CAGR) of 18%, further composites industry to surge ahead. ever-growing indicating the demand for composites in • Global Automotive Composite Materials presence in the the country. market was estimated to be around USD global composite • The industry recorded nearly 20% growth market.
COMPOSITES FABRICATION 133 TECHNOLOGY VISION 2035
Indian composite industry to be a sustainable, technology driven, resource efficient and high productive manufacturing sector for delivery of a wide range of quality products
CurrentCurrent trends trends and and Technology Technology Strategies WHEREcomparecompare with with globe globe WHERE WHAT IS Know-hows Targets WHAT Implementation StrengthStrength and and Skill levels Framework ARE DO YOU Awareness STOPPING NEEDS WEweaknessweakness WANT US GETTING Infrastructure TO BE Government TechnologyTechnology gaps gaps Funding and Policies NOW?FinancialFinancial Situation Situation TO BE? THERE? Finance DONE TO OVERCOME THE BARRIERS?
2.9 billion in 2013, forecast to reach USD For each stage, after gather each input are 5.7 billion by 2020 @ CAGR of approx. then clustered under common topics and 8%. generally arrives at a consensus of opinion. Priorities are given to what are considered METHODOLOGY ADOPTED the most important issues for the last three The procedures typically used for writing this stages of the road mapping process, enabling a vision document are stated. People from diverse key priority list to be established for each step. backgrounds are consulted to arrive at a broad The final outcome is a list of priority items that picture about the future of the Composite need action in order to enable the industry to fabrication industry. Experts are asked to progress in a more dynamic and competitive provide their thoughts and opinions for the four manner. main stages of the road mapping process.
PENETRATION OF COMPOSITE MATERIALS IN VARIOUS INDUSTRIES AS OF 2014
0 0 0 0 70 10 70 10 70 10 70 10
60 20 60 20 60 20 60 20
50 30 50 30 50 30 50 30 40 40 40 40 AUTOMOBILES MARINE AEROSPACE PIPELINES 3.6% 68% 10% 7%
0 0 0 70 10 70 10 70 10
60 20 60 20 60 20
50 30 50 30 50 30 40 40 40 CONSTRUCTION WIND ENERGY CONSUMER GOODS 4% 38% 14%
COMPOSITE PENETRATION %
134 COMPOSITES FABRICATION TECHNOLOGY ROADMAP: MANUFACTURING
DEMAND PROJECTIONS (2035) Composite materials, which is evaluated to be MARKET PROJECTIONS IN INR CRORES 15K crores in India is expected to grow steadily and reach approximately 46K crore in 2035. The CAGR which is currently 15.6% is going to
sustain its growth up to 2020 and from there 500000 700000 900000 300000 grow aggressively until 2035 and the demand 100000 800000 400000 600000 0 1000000 projections in KT for 2035 is estimated to be 200000 Strategies around 1123 at a increasing CAGR from 15-25. • India’s continuous use of composites in WHAT Implementation Framework applications such as rockets, satellites, missiles, NEEDS 9 Government light combat aircraft, advanced light helicopter 936528 TO BE Policies and trainer is identical to that of the developed 2035 DONE TO countries. • The 3 emerging sectors in India for the usage OVERCOME of composite materials are Marine(31%), Wind 793668 7.5 2028 THE Energy(28%) and Railway(20%) BARRIERS? • There is scope for further usage of composite materials in the building and construction 672600
sector. Rapid technological developments 2020 6 in the aerospace and defence sectors have been achieved with the use of composites. For instance, NAL and HAL have developed 570000 4.2 several components for the aerospace 2013 structural components using composites. This shows the ever growing presence of composites in modern projects. 0 1 2 3 4 5 6 7 8 9 10 • The Indian Automobile sector built on composites is expected to grow to USD 53.4B Market Projections in 2035 from USD 32.5B in 2013 thus growing CAGR% at a rate of 64.3%
2.0 TRENDS IN TECHNOLOGY DEVELOPMENT INDIAN TRENDS energy costs are some of the major • The Indian chemical industry is greatly requirements of this industry. dependent on composites as certain • Adequate support for building an IPR requirements cannot be met by using portfolio, skill development in design, traditional materials. Backed by a good developing indigenous machinery for chemical industry base this sector is manufacture, developing design data and characterized by its ability to tailor tools, and specialized repair facilities are also properties within a given part and develop essential for the growth of this industry. Composite complex shapes by employing low pressure materials, which tools. GLOBAL TRENDS is evaluated to • The increasing demand for developing • Automotive market has shown a positive be 15K crores in indigenous materials for defence applications, growth after a setback in 2009, Significant India is expected possible two fold increase in non interest shown by Automotive OEMs in to grow steadily conventional energy usage, automobiles, developing carbon fibre applications and reach railways and textiles is likely to aid the • The key growth drivers are automotive and approximately growth of this sector. aerospace applications, although demand 46K crore in • Technology for recycling, avoiding high profile from wind power and engineering sectors is 2035. component failures, meeting increasing also expected to increase
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APPLICATIONS OF COMPOSITES (PRESENT TREND IN USER SEGMENTS)
150
125 34.56 117.72 100 92.16 75 54 50 30.96 25 34.56 10.8 9 0
Energy Transportation Wind Energy Aerospace
Defence Pipe and Tank Construction Others
• To complement the rise in the use of composite materials in India. Automotive composites in manufacturing, a 30% applications of composite materials in India reduction in the cost of components is are limited due to productivity concerns which expected. However , process improvements , are because of non-mechanized manufacturing with a cost reduction of 40%, are more likely processes used. The skill level required in to increase cost savings manufacturing of composite is high and • Different technologies and components from therefore the Indian composite industry with its various engineering segments – primarily limitations is unable to compete with steel or from plastics machinery, textile machinery, aluminium. machine tools in addition to the automation and handling systems need to be integrated Some of the technological gaps that the Indian to ensure the development of corresponding composite industry lacks when compared to chains. This will reduce the transition period global players are listed below: between process thus improving cost savings. • Currently limited to low manufacture with • Mostly, the firms are oriented towards high labour content. improvement and fine-tuning in current • High raw material cost and lack of availability practices, in view of the market size. of materials • No rapid automated production lines TECHNOLOGY GAP ANALYSIS available The Indian composite industry manufactures • No cost effective recycling strategies has only FRP’s and GFRP’s in which almost 98% been developed for composites of the suppliers use hand-lay up or filament • Less skilled labour winding techniques. The applications are limited • No standards or database available for to aerospace and wind turbine blades due to materials Technology the high manufacturing cost. The availability • Lack of knowledge in understanding for recycling, of raw materials for glass fiber has increased composite supply chain avoiding high the growth of GFRP’s. Other fibres such as • No awareness among sectors for introducing profile component carbon and aramid are imported for higher composites failures, meeting costs. Although there is a steady growth for • Carbon fibre manufacturing & supply ( increasing energy Indian composite industry for the last ten years Mostly imported and therefore costly) costs are some the total volume of production is very low • Lack of knowledge in design of products for of the major compared to other developed countries. The composite manufacturing requirements of high cost of raw materials, lack of availability of • Integration of metals, thermosets, this industry. many critical materials and obsolete technology thermoplastics and other hybrids. for manufacturing has increased the cost of • Quality and testing facilities used are not up
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to the global standards and processes. • No experience in analyzing composite • The industry has historically used steel and material performance in high corrosive, high there is a lack of relevant performance temperature and high pressure environment information, reference values or standards • There is a reluctance to try out new for composites to facilitate design and technology in this sector, delaying or even simulation. preventing the adoption of new materials
3.0 TECHNOLOGIES FOR 2035
DRIVERS FOR COMPOSITE INDUSTRY robots, and lowering reject and repair rates - Trend to life-style vehicles - Lower weight and emissions Process Technology: Enhance the use of - For the high volume end the trend is towards composite technology by developing state of including crash performance (compatibility) the art composite technologies and disciplines, - Towards hybrids for lighter weight and fuel at the engineering level and also at the economy operational level. - Trends towards multi-functionality - Replacement of metal Materials Technology: Develop newer - Trends to move to modular construction composite materials and fibres
STRATEGIES FOR 2035 Quality Technology: Through the use of Cost/Productivity/Markets/Applications modelling, systematic process selection Reduce the average cost of composite part by and procedure development, and NDE one-third, by providing better process selection technologies, assure that composite technology guidance, increasing the use of automation and is standardised and reduce rejections
SECTORIAL DRIVERS The general trends and drivers in four main application areas (automotive, aerospace, wind energy and engineering) of composite materials are
• Weight reduction and lower fuel economy FOR AUTOMOTIVE • Current applications are limited to areas in motor sports and premium/super premium segments
• Increased composite usage in structural components for new aircraft types. • Airbus A380 and Boeing B757 to carry almost 50% composite body structure. FOR AEROSPACE • Interiors with high GFRP share • State of the art helicopters and combat aircrafts
• Rotor blades are exclusively made of GFRP’s FOR WINDPOWER • Trend towards longer blades and high stiffness
• High number of relatively small niche applications with varying requirements FOR ENGINEERING • Use of high performance applications under extreme conditions
COMPOSITES FABRICATION 137 TECHNOLOGY VISION 2035
Composite Industry, at every level, enabling Energy & Environment: Reduce energy them to make decisions that will result in use in by 50% through such productivity utilization of the best technology for each improvements and enhanced recycling of application composites
STRATEGIES FOR 2035 TECHNOLOGY AND PROCESSES AUTOMATION IMMEDIATE MID TERM LONG TERM Make 80-90% of equipment Use of sensors and other Use systems technologies to compatible (“plug and play”) by innovations from computer integrate the process upstream developing an industry standard industries and downstream
NEW TECHNOLOGIES IMMEDIATE MID TERM LONG TERM Orient fibres using draping, tow Developing Reconfigurable Induction heating is used to placement and nesting mould that uses a liquid/particle selectively heat the mould for Introduction of hollow structure media contained by membrane rapid cycling and low energy use pultrusion processes that solidifies against a master compared to conventional shape. The media can be heating Computer controlled filament re-liquefied and re-solidified, and winding machines can potentially be sculpted to Press forming of long net shape with a CNC machine. discontinuous fibres Robotic thermoplastic ATP machine Co-curing of large structures in RTM
DESIGN IMMEDIATE MID TERM LONG TERM Evaluate composite techniques Conduct virtual qualification of Develop software to simulate at design phase Composite designs. Development manufacturing processes and of computational modelling tools part service under various which are important to assess life conditions cycle impacts of composites
EDUCATION AND TRAINING ENCOURAGING MORE STUDENTS TO PURSUE CAREER IN COMPOSITES AND IMPART QUALITY TRAINING IMMEDIATE MID TERM LONG TERM
T Significantly increase number of Keep present stake holders in Double number of engineering Strategies faculty and students in this composites community aware of programs focused on discipline (>50%) state-of-the-art technologies and Composites and substantially processes increase composite-related Objectives information in the manufacturing - engineering curriculum Technologies for 2035 TECHNOLOGY ROADMAP: MANUFACTURING
QUALITY AND MATERIAL TECHNOLOGIES REDUCE REJECTIONS IMMEDIATE MID TERM LONG TERM New generation of Statistical Tools to address root cause of Develop harsh environmentally process control for Composite process unreliability tolerant sensors manufacturing Self-contained moulding system with a rapid heat up/cool down system
ROBUST SIMULATION TOOLS IMMEDIATE MID TERM LONG TERM Development of Model based Tool to evaluate composite Mapping of Impact of simulation process control manufacturing process parameter on shop floor performance effect on end service life of part
ADVANCED MATERIALS IMMEDIATE MID TERM LONG TERM Develop a Composites material Develop long-lasting, reliable, Increase product design property virtual laboratory to corrosion- resistant materials community’s understanding of determine the materials The durability of natural fibres, science of metallurgy, stimulate properties needed particularly their resistance to development of product designs Production of Industrial grade moisture, requires more and of new technologies and PAN Precursors investigation, e.g. high performance materials for composites treatments to reduce moisture uptake and resistance to fungal attack Prepreg materials are being developed to enable curing and acceptable properties without the capital investment for an autoclave
MARKET AND APPLICATIONS INCREASE GLOBAL DEMANDS OF COMPOSITE MATERIALS BY 50% IN 2035
CONTINUOUS Capture the demand for wind energy and auto segments for Asian markets; develop technology to ensure use of composites in airplanes; increase welding markets in engineering industries and also sustain development in aerospace industries
ENVIRONMENTAL REDUCE ENERGY BY 50% AND ENSURE SAFETY AND HEALTHFUL ENVIRONMENT FOR WORKERS
IMMEDIATE MID TERM LONG TERM Conduct energy audits and Renewable energy Incentives, Model all composite fabrication T develop emission database for Green buildings Incentives processes to identify and Strategies composite industries and Setting up green science parks minimize environmental benchmark with global industries for composites problems in both design and production stage Objectives Applications of recycled fibres for composite production Technologies for 2035
COMPOSITES FABRICATION 139 TECHNOLOGY VISION 2035
COST ACHIEVE COST EFFECTIVE OPERATIONS
IMMEDIATE MID TERM LONG TERM Conduct “up-front” design and New conversion technologies Enhance simulation of development (modeling, that can heat fiber directly comprehensive techniques of process/materials databases) to through the use of microwaves production processes achieve a greater market share or a combination of microwaves and plasma to be developed INCREASE PRODUCTIVITY
IMMEDIATE MID TERM LONG TERM Automate all the process from Reduce curing time for matrix Eliminate inspections, testing, and prepeg placement to Filament materials by snap-cure reworking as quality improves winding techniques Quick cure without thermal Tape Lay - a technique used to effects. Need radiation shielding produce flat shapes through and resins designed for this placement of wide prepreg tape process accurately onto a tool. The lay-up (stack of tape) can be subsequently formed to a 3D shape. IMPROVE PROCESS AND PRODUCT
IMMEDIATE MID TERM LONG TERM T Joining techiniques such as Multi material design and Superior methods of simulating Strategies bonding,adhesives, rivets and Optimisation production processes open up clinches Use automatic curing process additional areas of potential Objectives Reconfigurable mold surface for like ‘out of auto -clave’ rapid prototyping or repairs. Curing of composites using Technologies for 2035 electron beam
COMPOSITE RECYCLING fluidised bed, solvolysis are some of the prominent With versatile application potential on one recycling process of composites. However, side, composites possess very limited scope mechanical grinding and pyrolysis have proven of recyclability on the other hand, due to their to be commercially viable world wide. Recycled inherent structural complexity. However, in case glass fibres through mechanical grinding find major of composites where thermoplastics are used, applications in roofing industry while carbon fibres recycling is possible through re-melting. recycled through pyrolysis is used for electrostatic applications. Mechanical grinding, pyrolysis, cement kiln route,
OVERVIEW OF RECYCLING OF DIFFERENT TYPES OF COMPOSITES TYPE OF RECYCLING TECHNOLOGY COMPOSITES METHODS FEATURES Thermoplastic- Remelting and No separation of matrix from the fibre matrix composites remoulding Regrinding – compression or injection molding/extrusion – compression molding In case of Product as pellets or flakes for molding composites where Fibre breakage – property degradation thermoplastics are Chemical recycling Dissolution of matrix used, recycling is Fibre breakage – property degradation possible through Thermal processing Combustion or incineration for energy recovery re-melting (option for old scrap)
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TYPE OF RECYCLING TECHNOLOGY COMPOSITES METHODS FEATURES Thermoset–matrix Mechanical Comminution – grinding – milling composites recycling Products: fibres and fillers Degradation of fibre properties Thermal recycling Combustion/incineration with energy recovery Fluidized-bed thermal process for fibre recovery Pyrolysis for fibre and matrix recovery
Chemical recycling Chemical dissolution of matrix Solvolysis (supercritical organic solvent)/ hydrolysis (supercritical water) Product of high quality fibres, potential recovery of resin Inflexibility of solvent and potential pollution
Metal–matrix Re-melting – Direct-cast scrap: direct re melting – casting composites casting Foundry scrap: direct re melting with (dry Ar) cleaning Dirty scrap: re melting – fluxing – degassing cleaning Very dirty scrap: metal recovery only – remelting and refining to separate reinforcement from Al (alloy)
4.0 RECOMMENDATIONS AND IMPLEMENTATION STRATEGY
TECHNOLOGY • Create new coursework that places more • India should extensively use composites in emphasis on composite manufacturing niche areas of the automotive, aerospace technologies and on 3D design without the and marine industries. limitations of traditional manufacturing • Thermoplastic composite structures have the potential to replace metal ENABLING INNOVATION parts but more attention is needed to better • Establish national level composite processing and automation. manufacturing strategy • Close attention needs to be given to the • Increase R&D funding for cross cutting repair infrastructure, and the use of smart composite technologies materials for damage assessment and • Establish national network of composite correction. fabrication institutes • Recycling issues for composites need to be addressed, with issues such as identification, ENHANCING CAPABILITIES bonding and de-bonding, and re-use needing • Establish technical competencies that development work. facilitate and accelerate the adaptation of progressive technologies, including rapid SKILLS design and development, solid modeling, for • Significantly increase number of faculty composite manufacturing and students in composite manufacturing • Provide resources at a reduced rate to technologies help new companies get off the ground. • Double number of engineering programs This will help offset the high capital cost of focused on composites and substantially equipment and operating expenses for start- increase composite related information in up companies manufacturing – engineering curriculum • Develop global standards for composite • Need for improved competence in manufacturing processes computer-aided engineering, in crash, • Identify critical emerging technologies with durability, and cost models. transformational impact and capacity in
COMPOSITES FABRICATION 141 TECHNOLOGY VISION 2035
Sialon ceramic based composite materials
Self-healing Braided composite material composite tube fabrication fabrication processes
Dome forming of Non-crimp Microwave fabrics curing of resins
Intelligent RTM, VaRTM systems
translating these technologies into products IMPROVE BUSINESS CLIMATE and businesses for the market • A set of specific tax reforms should be • Support pre-competitive research and enacted that “level the playing field” for proprietary technology and product domestic composite manufacturers. research, with a strong intellectual property • Streamline regulatory policy for smarter (IP) protocol that favors manufacturers regulation on composite manufacturing • Establish distributed manufacturing support • Effective and efficient legislative and centers throughout the region to assist SMEs regulatory frameworks that want to adopt new technologies • Modify FDI policy to ensure transfer of • Provide a variety of business services such as technology by giving preference to JVs design, digital manufacturing, prototype and instead of 100% foreign owned companies test services for composite materials • Incentivize/mandate foreign players to • Involve quality assessments, accurately increase value addition in India gauging worker skills • Preference in PSE/Government purchases • Focus on energy efficiency and conservation for products having higher local content • Focus on composite recycling processes • Improve cost competitiveness with traditional engineering materials
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REFERENCES 1. S.V. Hoa, Principles of the manufacturing of %20 for% 20the%20Composite%20Industry%20 composite materials, DEStech Publications, Inc. 2011-2023.pdf (accessed on 13.3.2015) 2009, available from www.tnu.edu.vn (accessed 7. Growth Opportunities in Global Composites on 13.3.2015) Industry, 2012 – 2017, available from www. 2. The use of composite in aerospace: Past, Present lucintel.com (accessed on 13.3.2015) and Future Challenges, available from https:// 8. Plastics and composites Outlook 2020, avaloncsl.files.wordpress.com/2013/01/avalon-the- available from www.plasticvision.be (accessed use-of-composites-in-aerospace-s.pdf (accessed on 13.3.2015) by European plastic converters on 13.3.2015) association 3. Composites Manufacturing Technologies: 9. Series Production of High strength Composites, Applications in Automotive, Petroleum and Civil available from http://www.rolandberger.com/ Infrastructure Industries, available from www.atp. media/pdf/Roland_Berger_Series_production_ nist.gov (accessed on 13.3.2015) of_high_strength_composites_20121008.pdf 4. Technology Roadmap for Composites in (accessed on 13.3.2015) Automotive Industry, available from www.ngcc. 10. H. Ishida, Interfacial Treatment and Its org.uk (accessed on 13.3.2015) Characterization of High Perfoarmance 5. Yang et al., Chemical Engineering and Processing, Composite Materials,” H. Ishida in “High 2012, 51, 53-68 Performance Polymer Composite Materials, 6. A Forecast for the Composites Industry 2012 Society of high polymers, 1990 – 2023, available from http://nccef.hubble-2. 11. F.C. Campbell, Manufacturing Processes for titaninternet.co.uk/Portals/0/Documents/ Forecast Advanced Composites, Elsevier, 2003
COMPOSITES FABRICATION 143
MICRO NANO MANUFACTURING
Micro Nano Technology applied to manufacturing is an emerging field that enables production of several new innovative products in a wide spectrum of areas with vastly improved functionalities at much smaller scales of size and at considerably less cost. The micro nano manufacturing technology will have significant impact on improving energy harvesting, healthcare, water purification, sensors, environment remediation etc.
TECHNOLOGY ROADMAP: MANUFACTURING
1.0 INTRODUCTION
Micro / Nano Manufacturing is defined as the the development of micro and nano machines. manufacture of components and products in Already, the lithographic processes have moved the sub-micrometer to a few-millimeter range on to sub 30 nm thick wafers and thinner with micro / nano size feature characteristics wafers are on development. of high accuracy and precision in a wide range of engineering materials by non- There are many fields of micro manufacturing. lithography based processes. The idea of Rajurkar et al have given an interesting micro/nano manufacturing was necessitated overview of micro nano machining.1 They by the development of parts to be used in can be broadly classified as: a) Mechanical bio medical engineering, miniature sensors, micro-manufacturing, b) Electro physical aerospace and automotive equipment, optical and chemical micro-machining, c) Energy and electronic equipment etc. The meso scale beam micro-machining, d) Near net shape parts are manufactured with various processes micro-forming and micro-forging, e) Additive like electrolytic in-line dressing (ELID), Electro- micro-manufacturing processes (including chemical machining (ECM), die sinking electro micro-casting), f) Micro-joining (including discharge machining (EDM), wire cut electro micro-welding, micro-soldering, micro-brazing). discharge machining (WEDM), milling, turning etc. While lithography based techniques are Micro-manufacturing has been the topic the most common for micro electronics of research for quite some time. Process manufacturing which cover a wide spectrum modeling, optimization, technology of products encompassing the entire ICT development and machine building have spectrum, micro and nano fabrication could been going on for three decades and more be considered as an extension of conventional and several commercial applications are in manufacturing in a limited sense. As the size of place now.2-5 Nano scale manufacturing is the the products becomes increasingly smaller and newly emerging area of manufacturing and the the market for micro and nano scale parts is capability of several conventional machining Nano scale on the increase, the previous non-lithographic processes has been extended to nano scale manufacturing processes are required to be employed at manufacturing. Emerging processes under this is the newly the micro and nano scales. However, new category are: a) Chemical vapour deposition, emerging area nanofabrication techniques are evolving in the b) Physical vapour deposition, c) Molecular of manufacturing laboratories that are capable of creating nano beam epitaxy, d) Atomic layer epitaxy, e) Dip and the capability structures and it is a matter of time before pen lithography, f) Nano imprint lithography, g) of several these become part of regular manufacturing Roll to roll processing, h) Self assembly conventional on shop floors. During the last decade, the machining applications of nano technology in the form Some of these processes are additive in processes has of incorporating nano scale features on macro nature and will make additive manufacturing a been extended parts like lenses, mirrors and bearings and strong challenger to subtractive manufacturing. to nano scale nano scale devices for applications like drug According to Cientifica, the market potential manufacturing. delivery and other health related applications of nano manufacturing is likely to cross several have emerged. These factors have motivated trillion marks during the next few years.
MICRO NANO 147 TECHNOLOGY VISION 2035
Micro Nano Manufacturing technologies have the potential to create economic growth in all India to be a technology leader in Micro Nano developed countries of the world, particularly Manufacturing by 2035, leveraging its strengths in in India. Over the next 10-20 years, projections by several organizations estimate that the global precision engineering and backed by smart skilled workforce. market for products will vary between US $ 2.6 Trillion to US $ 3 Trillion. This estimate is based on the optimistic assumption that these technologies have the potential to change every product in the market today. Based on Together with micro manufacturing, nano an assumed CAGR of 12-15 %, the market for manufacturing is likely to be a major segment of micro nano manufacturing technology based future manufacturing. products will be around US $ 8 Trillion. USA and European countries dominate much of the CURRENT INDIAN AND GLOBAL current market. If we give the right push to this SCENARIO technology through support for indigenous Micromachining research was initiated in applied collaborative R&D, manpower most of India’s premier institutions about 10 development and appropriate policy initiatives, years ago. A couple of attempts to develop India could have a good share of global market. indigenous machines have been reported. A single point diamond turning machine METHODOLOGY AND APPROACHES was successfully developed in India. Micro FOLLOWED TO FORMULATE THE manufacturing received a fillip in India through ROADMAP National Program on Smart Materials (NPSM) The roadmap has been prepared on the basis and National Programme on Micro and Smart of interaction with all major researchers and Systems and Structures (NPMASS). NPSM seminars on micro nano manufacturing and helped to create facilities in many institutions. advanced schools conducted in the country. NPMASS is focused on delivery of products. The draft roadmap was communicated to The Nano initiatives of the Government experts in the field in India. A few experts of India funded major facilities, education in India and abroad were contacted to elicit programmes and research projects in many views on the forecast for future. The responses universities across the country. This has helped received were incorporated in the roadmap. in increasing the number of publications. Synchrotron facility established in the country has enabled micro nano fabrication.
While substantial work is going on in laboratories, technology transfer from lab to industry is yet to be achieved.
Globally, all major industrialized countries have been investing heavily in micro and nano manufacturing technology. During the last twenty years, a number of micro machines for drilling, milling, turning and electric discharge machining (EDM) have been developed and are already commercially available. A few machines Micro Nano have been developed for nano manufacturing. Manufacturing Physical vapour deposition (PVD) and chemical technologies have vapour deposition (CVD) machines of several the potential to configurations and types are available for create economic additive manufacturing operations. Focused growth in all ion beam machines are used for chipping developed away materials at nano level. 3-D printers are countries of the available with micro level accuracy. Some 3-D world, particularly printers with nano level accuracy have been in India. reported from laboratories abroad.
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2.0 TRENDS IN TECHNOLOGY DEVELOPMENT
DOMESTIC TRENDS into existing markets, emerging markets and In the case of India, micro nano manufacturing consumer markets. can be considered as an offshoot of the need for the strategic industries dealing with The technology has a number of enablers, precision fabrication. All along, the strategic some of that are already available (needs industries depended on machines manufactured further developments) and others need to be by a few industries to manufacture precision developed through R&D. Some of the current components at macro and meso scales. application areas of this technology include Indian machinery manufacturers were either sensors, energy materials and devices for technologically incapable of reaching this level hybrid solar energy, fuel cells, ultra capacitors, of precision or were not interested in R&D electronics industry, pharmaceuticals, drug to extend their manufacturing in this range delivery, smart, innovative and functional textiles, because of likely poor return from market. The safety and security equipment, biomedical reluctance of Indian industry to enter areas of engineering, automotive and aerospace industry. product development like high-tech biomedical devices, sensors and precision instrumentation, TECHNOLOGY GAP ANALYSIS could be considered as another factor Evidently, there exists considerable gap between which retarded the growth of this sector in micro nano technology in India compared to India, though educational institutions, R&D advanced countries in Europe, USA, Korea, organizations etc. have been actively involved Taiwan and Japan. Nanotechnology has been in the promotion of this sector. Successful given a big push through the Nano Mission of translation of technology to market has not the Govt. of India. However, the focus so far is been substantial. on manpower development and development of science and technology. The semi conductor GLOBAL TRENDS electronics where nano technology made a All major industrialized countries are investing significant impact does not have any significant heavily in micro and nano technology. footprint in India. We are also lagging behind Considering the future potential of micro nano in utilizing nanotechnology in health care and manufacturing many countries have invested energy. Printed electronics and organic thin film heavily in R&D in these areas. based solar PV is still in the laboratory level. However, the country is yet to see a viable and Micro and nano manufacturing has been the commercially successful engineering product focus of attention during the last 15 years. yet. The application areas can be broadly classified
APPLICATION AREAS AND ENABLERS
• New engineered materials • Improved white and brown goods EXISTING CONSUMER • Agriculture, food, commodities MARKETS • Widespread introduction of sensors, MARKETS Electronics • Textiles, Apparel, Personal accessories
• New manufacturing equipment and • E-Mobility, Batteries, Engines automation techniques, micro and nano EMERGING • Healthcare robots, Photonic machines ENABLERS MARKETS • Environmental - water, energy • Additive manufacturing • Nano-Bio-Info integration with digital • Smart personal and home devices knowledge based tools
MICRO NANO 149 TECHNOLOGY VISION 2035
technology development in the laboratories PVD, will be directionless. As such, there is a CVD considerable gap in the technology in India compared to technology elsewhere. Flame Pyrolysis, PECVD bio-mimetics, Self Mechanical Alloying This scenario is seen in the development assembly Ultrasonic of micro machine tools too. There is just Micro Wave, Milling, Grinding Mechano-Chemical one manufacturer of multi-function micro Electro-Deposition, PRODUCTION Synthesis machine tool in India. Their output is also less Electro-Spinning OF because of the lack of support infrastructure. NANO-PARTICLES Though there are a number of indigenous developments, industry has been lukewarm in converting these technologies into viable Solgel, Electro Explosion, products. Colloid-Chemistry, Laser Ablation, Hydro - Thermal, Plasma Synthesis Nano fabrication can be classified under Organic Synthesis four categories: Nano particle manufacture, Manufacture of Nano surfaces, manufacture of Micro Nano components and Multi-scale PRODUCTION OF NANOPARTICLES System Integration. As far as manufacture of nano particles is concerned the technology As far as MEMS micro machining is concerned, gap is narrowing between India and advanced India has established fabrication facilities and countries. manpower development programs under the earlier NPSM project. The successor project Many of the R&D labs and universities have set NPMASS has a focus on product development up the facilities for nano particle manufacture as and a few products are now marketed. Apart a stage one of the development. Some of these from a few organizations involved in the (carbon nano tubes, nano wires, silver nano development of sensors, the industry as a particles etc.) are also available commercially. whole is yet to embrace micro machining in a big way. Micro moulding and manufacture The second stage of development is the of micro parts by metal injection moulding production of nano surfaces. The capability have been reported. Unless there is a vibrant in India in this area is improving with the ecosystem of development of technology acquisition of several machines recently in products and its rapid commercialization, different research labs across the country. The
PRODUCTION OF NANOSURFACES Barrier
Hydro Phobicity
Nano Corrossion Layering Resistence BASED ON DESIRED PROPERTIES Additive Nano Heat Reflection manufacturing Clustering and roll-to-roll manufacturing BASED ON Etch are disruptive TECHNIQUE Nano Resistence technologies, Texturing which are likely Scratch to challenge many Resistence of the existing processes in Nano future. Coating
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indigenous manufacturing capability is in CVD, There exists considerable technological gap PVD, and microwave assisted CVD. between India and developed countries at this level. Additive manufacturing and roll-to- The third level of development is manufacture roll manufacturing are disruptive technologies, of products with micro nano fabrication which are likely to challenge many of the technology. There are four specific areas existing processes in future. of development, viz., a) manufacture without product-specific tools as in additive Nano composites are important materials manufacturing, b) micro tooling for subtractive which are the used for manufacture of manufacturing, c) components with integrated components. It must be noted that there are functionalities like lab-on-the-chip and d) many more applications already implemented functional micro nano structures on meso and or emerging. macro parts (Multi Scale Integration). Micro stereo lithography, single point diamond turning The fourth stage of micro nano based product etc. is also picking up. development and manufacturing is multi-scale system integration. In a majority of cases micro
MANUFACTURE OF MICROCOMPONENTS
Manufacturing Without Product - Additive Manufacturing Specific Tools
Micro Tools For - Micro RDM Replication - Micro Machining etc Manufacturing MANUFACTURE OF MICRO
COMPONENTS - Micro Injection Molding Replication - Micro Embossing Technologies - R2R - Micro Forming
Products With Integrated - 3D Direct Manufacturing Functionalities
NANOCOMPOSITES NANOMETRIC PARTICLES TRADITIONAL [Nano clay, MATERIALS SMA Nanofibres, [Polymers, MULTIFUNCTIONAL COMPOSITE MATERIALS Carbon Nano Ceramics and Tubes, Metal and Metals] Ferromagnetic Clusters]
Carbon Metal Adaptive Piezo NanoTube Nano Particle Surfaces Composites based Nano based Nano Composites Composites
MICRO NANO 151 TECHNOLOGY VISION 2035
MICRO NANO MANUFACTURING- CHALLENGES OF INTEGRATION
Flexible Tooling MICRO NANO Integration of Machine/Process Knowledge MANUFACTURING Process Perturbations Modular Production Systems PROCESSES
Process Results Product Properties Performance Parameters
nano components form part of a system, micro nano manufacturing. An entire spectrum which has macro and meso scale components. of engineering activity needs to be developed Packaging and integration are major to convert the science and technology from technological challenges here. Typical example the laboratories. This involves equipment design, is implants for rehabilitation purposes where a contamination control, cleanliness standards, nano meter level surface finish is needed. process simulation software, clean room technologies, shop floor data gathering and Scientists of Fraunhofer Institute in Germany control, factory automation and optimization. have summarized the challenges to overcome in
3.0 TECHNOLOGIES FOR 2035
Micro and nano manufacturing technology manufacturing and self-assembly scientists and Using molecular is of recent origin and newer and newer engineers will be able to manipulate materials manufacturing developments are reported frequently from at the atomic level to build the smallest possible and self-assembly R&D laboratories around the globe. It is difficult electromechanical devices, given the physical scientists and to envision what will be the driving technology limitations of matter. It is expected that much of engineers will be in micro nano manufacturing two decades the mechanical systems that is known today will able to manipulate or more lately. However, it can be safely be transferred to the molecular level as some materials at the assumed that quantum computing, molecular atomic analogy. atomic level manufacturing and self-assembly could be to build the the technologies which will have a profound As envisioned by Drexler of MIT, as well as smallest possible influence in manufacturing sector in future. many others, this may lead to nano computers electromechanical no bigger than bacteria and nano robots devices, given the Molecular manufacturing deals with the design and nano machines which could be used as physical limitations and manufacture of extremely small electronic a molecular assemblers and disassemblers of matter. circuits and mechanical devices built at the to build, repair, or tear down any physical or molecular level of matter. Using molecular biological objects. Nano-robots will be able to
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carry out drug delivery, artery cleaning, removal expensive. Some of the examples of application of cancerous cells, surgical operations of the are: eye etc. • Manufacturing of energy-related micro- devices In essence, the development of nanotechnology • Micro channels, micro fluidic ducts in foams, is to have tools to work on the molecular level micro structured reactors etc. analogous to the tools we have at the macro • Fabrication of ceramic and metallic foams level. Nano-machines will enable us to create a • Catalyst-coating techniques plethora of goods and increase our engineering • Micro heat transfer devices, heat pumps abilities to the limits of the physical world etc. Used in computers, laptop, and other mini devices Two major challenges, which need to be addressed for the development of micro nano In the long term, micro nano manufacturing manufacturing technology in India, are: technologies are unlikely to have a significant i. Creating adequate capabilities for nano impact on the environment or on energy costs. structuring, coating, replication and characterization in India Reduction of energy consumption: ii. Developing, manufacturing and Micro nano technologies help to reduce characterization equipment at an energy consumption by better insulation affordable cost. systems, by the use of more efficient lighting or combustion systems and by use of lighter Several products, which we use today, are likely and stronger materials in the transportation to be manufactured better with more advanced sector. Light bulbs presently used convert only and efficient performance features. Many of approximately 5% of the electrical energy the silicon devices, which we use today, may into light. Nano-technological approaches be replaced using printed electronics. Roll to like light-emitting diodes (LEDs) or quantum- roll printing is likely to add a new dimension caged atoms (QCA) could lead to low energy to additive manufacturing, enlarging the scope consumption for illumination. of additive manufacturing to the production of low cost electronic components, RFID tags, Increasing the efficiency of energy production: batteries, antennae etc. The following sections Micro fabrication technologies have helped to give an insight into how this technology will improve the efficiency of power production. impact manufacturing in future. Only a few Nano technology has further helped to push applications are mentioned here as micro the efficiency envelope and reduce the cost. nano technology spans the entire spectrum of The best solar cells manage to use 40 percent materials and manufacturing. of the sun’s energy in spite of layers of several different semiconductors stacked together to ENERGY absorb light at different energies. Commercially The supply of energy is one of the great social available solar cells have much lower efficiencies challenges of the twenty-first century, at the (15-20%). Tetrad-shaped nanoparticles when global level, where alternatives to fossil fuels applied to a surface instantly transform it into are needed, and also at the local level, where a solar collector. Nanotechnology could help batteries often supply energy. Local energy to increase the efficiency of light conversion by supplies are becoming increasingly important using nanostructures with a continuum of the for applications such as environmental band gaps. monitoring with wireless sensor networks, implantable medical devices, tyre pressure The degree of efficiency of the internal sensors and traffic control systems. combustion engine is about 30-40%. Micro and nano Nanotechnology could improve combustion fabrication The most advanced nanotechnology projects by designing specific catalysts with maximized technologies related to energy are i) storage, ii) conversion, surface area. have helped the iii) improving manufacturing processes by energy systems reducing material content and improving More environment-friendly energy systems: to be more and processing speeds, iv) energy saving by better Environment-friendly form of energy is the more compact, thermal insulation, and v) enhanced renewable use of fuel cells powered by hydrogen, which efficient and less energy resources. Micro and nano fabrication is ideally produced by renewable energies. expensive. technologies have helped the energy systems to Important nanostructured materials in fuel cells be more and more compact, efficient and less are the catalyst/support materials consisting
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of carbon-supported noble metal particles helped to improve filtration efficiency. Influence with diameters of 1- 20 nm. Suitable materials of Nano chemistry on wastewater treatment, for hydrogen storage contain a larger number air purification and energy storage devices is of small Nano sized pores. Development of on the anvil. Mechanical as well as chemical many nanostructured materials like nanotubes, methods can be used for effective filtration zeolites or alanates is under research. techniques. Nano porous membranes (may Nanotechnology can contribute to the further be composed of nanotubes) with extremely reduction of combustion engine pollutants small pores smaller than 10 nm are suitable by nano porous filters, which can clean the for a mechanical filtration. Nano filtration is exhaust mechanically, by catalytic converters mainly used for the removal of ions or the based on nano scale noble metal particles or by separation of different fluids. The membrane catalytic coatings on cylinder walls and catalytic filtration technique is named ultrafiltration, nanoparticles as additive for fuel. which works down to particles of size 10 to 100 nm. One important field of application of It is possible to develop both secondary and ultrafiltration for medical purposes is in renal primary batteries with high-energy densities, dialysis. By making use of magnetic separation high capacities using nanomaterials. It is also techniques, magnetic nanoparticles offer an possible to achieve high rate charge/discharge effective and reliable method to remove heavy cycles. metal contaminations from wastewater. Nano particles increase the efficiency to absorb the Nanotechnology is poised to make significant contaminants and this method is inexpensive improvements in solar energy harvesting. Use of compared to traditional precipitation and hybrid solar energy devices, flexible solar films, filtration methods. use of nano tubes and nano wires to increase the efficiency of electron transport etc. have INFORMATION AND COMMUNICATION opened up new possibilities.zz Nanotechnology Micro technology has contributed to the rapid can also better the performance of growth of ICT. In high technology production conventional batteries too. process, the introduction of nanotechnology has already made a mark. The gate length of CHEMISTRY AND ENVIRONMENT transistors used in CPUs and DRAM is at the Micro technology is closely associated with nanoscale especially the critical length scale the fabrication of several chemical sensors. of integrated circuits used in them. Wafer Chemical catalysts and filtration techniques thicknesses are now at sub 30 nm levels. are the areas in chemistry in which micro Eventual replacement of silicon with carbon is and nanotechnology play an important role. emerging as a distinct possibility. The synthesis provides novel materials with tailored features and chemical properties Memory storage: Electronic memory designs like nanoparticles with a distinct chemical in the past have largely relied on the use of surrounding (ligands), or specific optical transistors. Research of crossbar switch-based properties. In this aspect, chemistry is to be electronics had provided an alternative using considered as a basic Nano science. Chemistry reconfigurable interconnections between will provide novel “nanomaterials” in short term vertical and horizontal wiring arrays to create and superior processes such as “self-assembly” ultra-high density memories. Two types of will enable energy and time-preserving memory storage are: strategies in the long run. i. A carbon-nanotube-based crossbar memory called nano-RAM. Catalysis: Catalysis is important for the ii. The use of memristor material as future production of chemicals. Chemical catalysis replacement of flash memory benefits from nanoparticles, due to the large surface-to-volume ratio. The application of the Novel semiconductor devices: Novel Metallic micro nanoparticles in catalysis is from fuel cell to semiconductor devices are based on nano filtration catalytic converters and photo catalytic devices. spintronics. The dependence of the resistance systems are being of a material (due to the spin of the electrons) increasingly tried Filtration: Micro channel based filtration is on an external field is called magneto resistance. out in water becoming widely adopted in several cases. This effect can be significantly amplified purification Metallic micro nano filtration systems are being for Nano sized objects. This giant magneto systems. increasingly tried out in water purification resistance (GMR) effect has led to a strong systems. Micro fabrication techniques have increase in the data storage density of hard
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disks up to gigabytes. The tunneling magneto over-specified systems, and for approximate resistance (TMR) is similar to GMR and based analysis of combinatorial intractable problems, on the spin-dependent tunneling of electrons including mathematical theorems, etc. through adjacent ferromagnetic layers. Both GMR and TMR effects can be used to create a Quantum computers: New approaches for non-volatile main memory for computers, such computing use the laws of quantum mechanics as magnetic random access memory (MRAM). for novel quantum computers, which enable the use of fast quantum algorithms. The quantum Novel optoelectronic devices: In modern computer will have quantum bit memory communication technology, traditional analog space termed qubit for performing several electronic devices are increasingly replaced by computations at the same time. optical or optoelectronic devices due to their large bandwidth and capacity, respectively. Two MICRO AND NANOTECHNOLOGIES IN areas of importance are photonic crystals and MEDICINE quantum dots. Micro fabrication has been used for many applications in biology and medicine. These i. Photonic crystals are materials with a applications fall into four domains: tools for periodic variation in the refractive index molecular biology and biochemistry, tools for with a lattice constant that is half the cell biology, medical devices, and biosensors. wavelength of the light used. They offer a Micro fabricated device structures have selectable band gap for the propagation of significantly enhanced performance with respect a certain wavelength and they resemble to conventional devices. Micro fabrication can a semiconductor, but for light or photons enable devices with novel capabilities. These instead of electrons. enhancing and enabling qualities are conferred ii. Quantum dots are nano scaled objects used when micro fabrication is used appropriately to for the construction of lasers. The advantage address the right types of problems. Extending of a quantum dot laser over the traditional the scale to nano level, biological and medical semiconductor laser is that their emitted research utilized the unique properties of wavelength depends on the diameter of nanomaterials for various applications like the dot. Quantum dot lasers are cheaper contrast agents for cell imaging and therapeutics and offer a higher beam quality than the for treating cancer. Biomedical nanotechnology, conventional diodes. bio-nanotechnology, and nanomedicine are the other nomenclatures for this hybrid field. Displays: The production of displays with low Functionalities can be added to nanomaterials energy consumption is possible using carbon by interfacing them with biological molecules nanotubes (CNT). Carbon nanotubes can or structures. The size of nanomaterials is be electrically conductive and can be used as similar to that of most biological molecules field emitters with extreme high efficiency for and structures. Because of this property, field emission displays (FED) due to their small nanomaterials can be useful for both in vivo and diameter of several nanometers. The principle in vitro biomedical research and applications. of operation is like the cathode ray tube on a The integration of nanomaterials with biology much smaller length scale. has led to the development of diagnostic devices, contrast agents, analytical tools, physical Nano logic: Nano scale devices exhibit therapy applications and drug delivery. dominant nonlinearities that prevent their use as two-state devices in digital computers. The Diagnostics: Point-of-care (POC) diagnostic idea behind Nano logic is to exploit these instruments typically employ a disposable Micro fluidics nonlinearities instead of suppressing them test cartridge in conjunction with a sensitive and bio MEMS to implement functions that correspond to reader. Given the requirement for quantitative are accepted mathematical sets like interval numbers, disjoint measurements with reduced sample volumes, technologies intervals, fuzzy numbers, fuzzy sets, etc. simple micro fabrication technologies are emerging in medical Nano electronic circuits can be designed that as the prime means to deliver the required diagnosis. Lab can represent sets and set operations, and an measurement precision. Micro fluidics and bio on chip concept array of such devices constitutes a universal MEMS are accepted technologies in medical has become a mathematical processor, able to solve any diagnosis. Lab-on-the-chip concept has become reality with micro problem that can be expressed in set theory. a reality with micro fabrication. Nanotechnology fabrication. Nano logic will help to solve problems involving has further advanced lab-on-a-chip technology. uncertainty, ambiguity, error, under-specified and Biological tests measuring the presence
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or activity of selected substances-become Tissue engineering: The fast growing field of quicker, more sensitive and more flexible when regenerative medicine promises significant certain nano scale particles are put to work progress in the treatment of several ailments as tags or labels. Some specific applications of like arthritis, joint wear, cardiac ischemia, liver nanotechnology in diagnostics are: disease, and spinal cord injury. Key to its success i. Magnetic nano particles, bound to a suitable will be the ability to engineer tissue safely and antibody can be used to label specific reliably. Nanotechnology can help to reproduce molecules, structures or microorganisms. or to repair damaged tissue. This “tissue ii. Gold nanoparticles tagged with short engineering” makes use of artificially stimulated segments of DNA can be used for detection cell proliferation using suitable nanomaterial- of genetic sequence in a sample. based scaffolds and growth factors. Tissue iii. Multicolor optical coding for biological assays engineering might replace conventional has been achieved by embedding different- treatments like organ transplants or artificial sized quantum dots into polymeric micro implants. Advanced nanotechnology-based beads. tissue engineering can also lead to longevity iv. Nano pore technology for analysis of nucleic of life in a matter of years. But, the concept acids converts strings of nucleotides directly of tissue engineering is a matter of debate on into electronic signatures. ethical grounds like that of human stem cells.
Drug delivery systems: In recent years, Biomaterials including implants and devices considerable research and development for rehabilitation: Manufacture of biomaterials, has taken place in the field of novel micro implants and artificial limbs require extensive fabricated and nanofabricated devices for application of Micro Nano Manufacturing drug delivery. Such devices seek to develop technologies. a platform of well-controlled functions in the micro- or nano-level. They include Nano LARGE SCALE MANUFACTURING particulate systems, recognitive molecular An inevitable use of nanotechnology will be in systems, bio sensing devices, and micro large-scale manufacturing. fabricated and microelectronic devices. The drug dosage as well as side effects of the drugs Aerospace: Lighter and stronger materials will can be reduced by depositing the active drug be of immense use to aircraft manufacturers, in the diseased tissues only, thereby reducing leading to increase performance. Spacecraft, the need of higher doses. This target-oriented where weight is a major factor, will also benefit. approach saves time and money and reduces Micro and nanotechnology thereby primarily human suffering. helps to reduce the size of equipment used. Aerospace systems will benefit from micro Nanotechnology-oriented implantable drug fabrication technology due to reduced size, delivery system is preferable to the use of mass and power requirements for many injectable drugs. Injectable work on first-order standard functions. Micro fabrication can also kinetics namely the blood concentration goes enable precise control of surfaces and fluid up rapidly, but drops exponentially over time. dynamics. This will increase drug toxicity, and drug efficacy is unpredictable as the drug concentration falls There are several reported applications of Micro nano below the targeted range. nano technology in aerospace engineering. fabrication Through the use of nanotech materials, the has helped in Some specific applications in drug delivery weight of hang-gliders is reduced considerably improving several systems are: while increasing their strength and toughness. automotive i. Dendrimers and Nano porous materials Nanotechnology helps in lowering the mass of systems like could hold small drug molecules, super capacitors that are used to give power to ECU, sensors, transporting them to the desired locations. assistive electrical motors for launching of hang- lubrication etc. ii. Applications based on small gliders. In addition, nano technology offers new Lighter and electromechanical systems such as NEMS types of thin coatings for aircraft for protection stronger materials are researched for the active release of against corrosion as well as for specific military will be useful drugs. Important applications of this include, applications. for creating the treatment for cancer with iron nanoparticles vehicles, which are or gold shells. Construction: Nanotechnology can make faster and safer. construction faster, cheaper, safer and more varied. Automation of nanotechnology
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TECHNOLOGIES FOR 2035
UPTO 2020 2020-2030 2030-2035
Sensors, cardiovascular and in vitro diagnostic devices, Controlled drug delivery cardiovascular clot removal systems, Engineered replacement Artificial organs, bones, self catheters, medical implants, tissues, artificial skin and hair assembled organs BIO-MEDICAL targeted drug delivery systems
Novel materials, Materials with enhanced properties Tailor made materials Self assembled parts MATERIALS
Energy harvesting from unconventional sources, Batteries Hybrid solar energy, hydrogen Widespread adoption of with efficient charging and energy, Efficient fuel cells, micro- decentralized energy harvesting discharge characteristics, ultra scale fuel cells using devices made by additive ENERGY capacitors manufacturing
Large scale bacterial water Filtration devices purification ---- WATER
Foldable displays, miniaturization, Quantum computing, Computing new memory devices based on nano tubes ---- COMPUTING
Shelf life enhancement, sensors for quality monitoring ------FOOD PROCESSING
Wearable electronics, specialty textiles ------SMART TEXTILES
Micro nozzles for high- temperature jets, dust resistant ------coatings AEROSPACE
Use of nano fibres for reinforcement Energy harvesting glass, brick ---- INFRASTRUCTURE
Sensors for internal and external monitoring, waste heat Sensors for driverless vehicles converters, wireless devices for Energy harvesting paints AUTOMOTIVE vehicle to vehicle communication
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construction can allow for the creation of improved the smoothness and heat resistance. structures from advanced homes to massive skyscrapers much more quickly and at much Optics: The sunglasses using protective and lower cost. Use of carbon nano tubes has antireflective ultrathin polymer coatings are helped to improve the strength of reinforced available. For optics, scratch-resistant surface concrete. Micro and nano technology has coatings based on nanocomposites are used. applications in clinker production, improving Nano-optics could allow for an increase in wood and glass, specialty coatings, fire precision of pupil repair and other types of protection and detection equipment etc. laser eye surgery.
Primary metal manufacture: Processes that Textiles: The use of engineered nano fibres produce materials such as steel and aluminium makes clothes water- and stain-repellent or will be able to remove any impurities wrinkle-free. Textiles with a nanotechnological in the materials with the application of finish can be washed less frequently and at nanotechnology. lower temperatures. Nanotechnology has been used to integrate membrane containing tiny Vehicle manufacture: Micro nano fabrication carbon particles and guarantee full-surface has helped in improving several automotive protection from electrostatic charges for the systems like ECU, sensors, lubrication etc. wearer. Modern textile products are winkle- Lighter and stronger materials will be useful resistant and strain-repellent. Soon, clothes will for creating the vehicles, which are faster and become “smart”, through embedded “wearable safer. Combustion engines will also benefit from electronics” parts that are more wear and heat resistant. Automotive systems will benefit from micro Cosmetics: Especially in the field of cosmetics, and nano engineering technology due to products incorporating nano particles have a reduced size, mass and power requirements promising potential. The traditional chemical UV for many standard functions. Better tyres can protection approach suffers from its poor long- be developed using nano technology. Nano term stability. A sunscreen based on mineral technologies also help to promote sustainability nanoparticles such as titanium dioxide offer and safety. several advantages. Titanium oxide nanoparticles have a comparable UV protection property Consumer goods manufacturing: as the bulk material, but lose the cosmetically Nanotechnology is making an impact in the field undesirable whitening as the particle size is of consumer goods, providing products with decreased. novel functions ranging from easy-to-clean to scratch-resistant. 3-D Printing: 3-D printing is emerging as one of the manufacturing technology of future. Food: Nanotechnology can be utilized in the Manufacture of several products in plastic production, processing, safety and packaging printed electronics, hybrid solar energy, low cost of food. Nano composite coating process sensors and functional textiles will increasingly could improve food packaging by placing anti- make use of 3-D printing technology more microbial agents directly on the surface of the likely to be in the form of roll to roll printing. Manufacture of coated film. Nano composites could increase Multiscale manufacture using 3-D printing several products and decrease gas permeability of different opens up enormous opportunities to develop in plastic printed fillers as is needed for different products. They products with enhanced functionalities. electronics, can also improve the mechanical and heat- Manufacture of nano structures using fiber laser hybrid solar resistance properties and lower the oxygen is being pursued in many laboratories and will energy, low cost transmission rate. Research is being performed be commercially exploited in large scale in the sensors and to apply nanotechnology to the detection of near future. functional textiles chemical and biological substances for sensing will increasingly biochemical changes in food. DRIVERS make use of In order to achieve the vision of India becoming 3-D printing Household appliances manufacturing: The one of the leaders in micro nano manufacturing, technology more nanotechnology applications in the household it is necessary to identify the drivers which will likely to be in the items and equipment aim at self-cleaning or provide the necessary impetus for development form of roll to “easy-to-clean” surfaces on ceramics or glasses. of the science, technology and engineering roll printing. Common household equipment like flat irons connected with product development in this when made with nanoceramics particles has field.
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I. Innovation, which should happen in - A government industry consortium for a synergetic manner in academia and understanding and identifying current and industries. Micro nano manufacturing future applications and funding support. technologies span a wide spectrum of industries. Micro Nano manufacturing POLICY ISSUES technology being a multi scale technology, Since micro manufacturing is critical to many innovation can lead to several novel sectors of manufacturing and in particular to products. Textile, energy, water, food national security and defence, energy and health processing, mobility, materials, biomedical care, encouragement to develop this sector is devices etc. are critical segments and a joint important to improve our manufacturing base. academia/industry innovation initiative will be The following policy initiatives are suggested helpful to promote product development. to promote R&D leading to commercially II. Research is necessary to carry out extensive successful products. research to assess the impact of scaling laws a. Micro manufacturing should be a priority on manufacturing process and equipment. R&D area Research is also needed for continuous b. Industry-university-government partnerships assessment of science, gaps, deficiencies, in S&T should be promoted and the need for fundamental knowledge. c. A decisive role by the government Understanding of multi-disciplinary science is important in funding machinery based requirements needs coordinated development projects in this area. Equally research involving several institutions. important is the development of cost III. Technology. Miniaturization in manufacturing effective metrological equipment as it is not needs new approaches and knowledge in possible to manufacture unless it can be equipment design, work handling, simulation measured. and optimization. Bridging between macro- d. Large-scale collaborative research projects to meso- to micro- to nano- requires with focus on product development could extensive fundamental and applied research. be launched in specific areas like health care, It is also necessary to make available proof defence, nutrition and food, energy, water of concept test beds for accelerated product purification and environmental remediation. development. e. Since nanoscience and nanotechnology is IV. Standardization. If a healthy industry is to be multi-disciplinary, it is necessary to develop developed it could be done only through the an integrated approach for developing development of standards for processes and manpower covering disciplines like physics, products. chemistry, bio, composite materials, V. Commercialization. The economics of electronics etc. into one single training micro and nano scale manufacturing has umbrella and more focus is needed in the to be carefully assessed. Societal benefits educational system to train the students to and broad based impact of miniaturization handle manufacturing of nanotech materials have to be weighed against the attendant and products. Special vocation educational risks of adopting this technology. Possibilities programs, specialized training programs are Development of creation of disruptive manufacturing some of the suggestions of micro nano technologies are also being considered in f. Government funding should be focused on manufacturing this context. developing skilled manpower in micro-and technology nano manufacturing and service sectors now requires Challenges related to human resource and since the fruits of investments in R&D will development of capacity building start yielding results. knowhow for In order to achieve the objective of promoting g. Tie-up between industry and R&D manufacture of micro nano manufacturing technology, the institutions is another method of transferring nano materials, following challenges should be addressed: the research outcome in nanotechnology processing - Lack of adequate research infrastructure to industry. The manpower of the industry equipment, - Lack of adequately trained researchers could be trained to handle nanotech metrology - Lack of indigenous processing, characterizing processes in production by R&D institutions. equipment, and metrological equipment h. Continuous training and retraining is development - Lack of design, modeling, simulation and required in the nano domain to keep the of indigenous optimization know how. employees updated with the latest inputs. machinery for - Need for more academic programs in fabrication etc. science and engineering pertaining to this BENEFITS FOR STAKEHOLDERS field The developments in micro nano manufacturing
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will improve the industrial base and diversify the development of indigenous machinery for manufacturing activities in a high priority area. fabrication etc. New technology industries will be set up and • Acquisition: While the country has moved Indian industries can aspire to get a share of ahead with capacity building in MEMS related the emerging global market apart from meeting technologies, we may need acquisition the local demand. In addition, the investment in of knowhow in terms of ink preparation micro nano manufacturing will lead to several for additive manufacturing, 3-D printing benefits like technology, energy materials, photonics to - additional job creation name a few. - improvement of quality of life • Adaptation: Many micro nano-manufacturing - availability of energy at lower cost issues can be handled through technology - cheaper electronics and display products adaptation. This involves using the technology - cheaper and more efficient measuring/ available in public domain to solve country monitoring devices, sensors, drug delivery specific problems. For instance, decentralized systems, lab on chip devices energy harvesting could be carried out - value added textiles covering smart textiles, through use of indigenous dyes as well as wearable electronics, anti microbial clothing, earth abundant coating materials available in anti wetting clothing etc. India. • Substitution: Micro nano manufacturing TECHNOLOGY INTERVENTIONS technology is heavily material dependent. There are several ways of technology Globally competitive manufacture needs interventions that can be pursued the development of alternative materials for • Development of micro nano manufacturing applications related to energy harvesting, technology requires development of healthcare, batteries, fuel cells, biomedical knowhow for manufacture of nano materials, and strategic applications. processing equipment, metrology equipment,
4.0 RECOMMENDATIONS AND IMPLEMENTATION STRATEGY
POSSIBLE TECHNOLOGY OPTIONS – working parameters DIRECTIONS TO STAKEHOLDERS • Equipment for safe transport of nano Micro Nano manufacturing is still at the materials beginning of a long journey. Micro nano manufacturing is perceived to be an important For manufacturing micro and nano surfaces: enabling technology along the innovation • Robust surfaces with controlled shape and The manufacturing chain. The manufacturing challenges include size challenges various issues covering production of nano • Optimized functionalities of surfaces for include various materials, micro and nano scale surface finishing, better performance issues covering micro nano integrated components and their • Higher flexibility and capability for textured production of integration in products, industrial solutions and nano finishing for self-assembly nano materials, services and societal challenges. micro and nano For manufacturing micro components: scale surface Considering the scenario of development • Extending the range of micro-fabrication finishing, micro in other countries, the following activities capabilities in terms of materials, geometry nano integrated are proposed for the development of this and accuracy components and technology in India. • Compatible manufacturing processes for their integration For manufacturing nano materials: single and multi-material micro components in products, • Continuous energy efficient flow of raw • New production methods for near industrial solutions materials to bulk nano material production monolithic integration and services and without any in process leak • Bridging the gap between mechanical ultra societal challenges. • Standardized control system with optimized precision fabrication and MEMS and IC
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fabrication and storing of nano particles. • Multi scale integration in new products e. Promote breakthrough research with a strong focus on innovation. For system integration in micro and nano f. Focus on growth and value creation. manufacturing: • Knowledge based micro and nano ACTION PLAN manufacturing platforms Five focal areas are identified for a coordinated • Simulation systems for integrated meso, action plan. These include building momentum micro and nano platforms in R&D, development of infrastructure, • Design tools, test beds and equipment for human resource development, developing an low cost modular miniaturized equipment ecosystem to promote innovation and finally (desk top factories) carrying out all the activities with the right • Meso, micro and nano integrated process, amount of emphasis on the societal dimension supply chain, logistics and materials covering risk to humans and environment. The management action plan in each of these areas is briefly • Multi-function integration capability outlined in the subsequent section • Traceability • Building momentum in R&D in Micro • Management of toxicity Nano manufacturing technologies: To reach the forefront of nano sciences and RECOMMENDATIONS nanotechnologies, India should identify this a. Form a national group of R&D as a core technology for future. organizations, industries, and possible - Substantially increase public investment end users of micro and nano enabled in nano sciences and nanotechnologies components and devices. in a synergic and coordinated manner b. Develop standards for testing and - Promote excellence in nanoscience qualification. and nano technology by extending c. Embark upon a program for the generous funding to a few hundred manufacture of equipment for Micro and engineering colleges and arts and Nano research and development including science colleges to create basic scaling up from prototype to lot and mass facilities for research. This research production. support should be for manpower, d. Develop standards for handling, disposing, and allow them to use the fabrication
Next Generation Photo Voltaics Hydrogen Energy Fuel Cells Efficient Batteries Ultra Capacitors Medical Applications Consolidation of MEMS Market Sensor Fusion Sensor Networks M i c r o fl u i d i c s for Agriculture, for diagnostics Food Processing, Hybrid Solar Energy Transportation and Self Assembly Functional Textiles Storage, Defense and Disaster Management Nano Robots Tailored Materials for drug delivery Innovation Textiles Know how for and treatment Replacement of producing Nano Quantum part of Subtractive Particles, Surfaces, Computing Structures and Manufacturing by Multiscale System Additive Manufacturing Molecular Manufacturing Integration New material Design
2014 2020 2030 2035
MICRO NANO 161 TECHNOLOGY VISION 2035
Nano robotics for water purification Self-Assembly for making artificial organs
Molecular manufacturing Communities with their own energy harvesting systems
Computing with carbon nano tubes Carbon as a competitor to silicon
and characterization facilities set up in and start-ups the premier institutions expanding the - Accelerate progress in micro and scope and funding nanotechnology manufacturing, in - Boost R&D in nanotechnologies with a particular, interdisciplinary R&D; view to wealth-generating applications - Set up more micro nano technology with emphasis on the involvement of manufacturing institutes in the country SMEs to meet industry requirements - Maintain a concentration of R&D • Developing human resources: This can be activities in the next few years in order both extension of the scale of existing to create critical mass and synergy technologies as well as a new field in some between the developments of nano respects. Human resource development can sciences, nanotechnologies, and related therefore be carried out by: engineering and safety aspects - Incorporating in the existing - Ensure effective coordination among manufacturing programs various agencies funding R&D programs - Designing new educational programs • Infrastructure development: World-class infrastructure (“Centres of excellence”) This can be achieved by is crucial to ensure that India improves • Identifying the educational needs its competitiveness in micro nano • Encouraging the definition and manufacturing technology R&D. This requires implementation of new courses and the following actions: curricula, teacher training and educational - Develop a coherent system of R&D material for promoting interdisciplinary infrastructure, taking into account, the approaches to nanotechnology both needs of stakeholders, in particular, and at graduate and postgraduate levels as developing synergy with education. micronano manufacturingtechnology is - Take measures in order to maximize multi-disciplinary and product development the added value of existing requires considerable modeling and infrastructure taking into account the simulation knowhow most of which are not needs of industry, in particular, SMEs, available in public domain
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• Integrate complementary skills into - Proactive support mechanisms to enlarge Nano robotics post-graduate and life-long training, e.g. and strengthen the seed funding and for water entrepreneurship, health and safety issues at capital base for innovation in micro purification Self-Assembly for work and patenting nanotechnology manufacturing. making artificial • Create national level competitions and - The government must put in place an organs awards that would contribute towards affordable IPR framework to promote encouraging the interdisciplinary and technology transfer and innovation. entrepreneurial spirit of researchers - Emphasis must be placed on equipment • Introduce skill development programs to development both for manufacture and train manpower to operate clean rooms metrology, and development of necessary Molecular and equipment standards for product specifications and manufacturing • Developing an eco-system to promote performance. Communities entrepreneurship: The vision of making with their own India a major player requires a coordinated Foresight Institute has done excellent energy approach to stimulate innovation and work on nanotechnology ethics, including harvesting entrepreneurship based on micro and technical standards and policies. The Centre systems nanotechnology. The following steps are for Responsible Nanotechnology has been recommended: formed to advance the safe use of molecular Computing • Societal issues related to micro nano nanotechnology and the Nano ethics Group with carbon technology and environmental impact: focusses on the ethical and social implications of nano tubes Carbon as a Micro and nano manufacturing, latter nanotechnology. competitor to in particular involves considerable risk in manufacture, storage, transport, REALISING THE ROADMAP silicon handling etc. The environmental This roadmap is drawn up to make India a impact is yet to be fully understood or dominant player in micro nano manufacturing assessed. It is therefore necessary to: technology. Leveraging our known strengths • Focus on public awareness and in precision manufacturing, the large pool of confidence; scientific and engineering manpower and good • Be committed to ethical principles in R&D and academic institutions, we will be in the use of micro nano manufacturing a good position to be a global leader in about technology two decades. • To identify and address safety concerns regarding risk to health of On one side, we must look at basic users and workers and environment manufacturing technologies and on the • To generate data on toxicology and other side the support mechanisms and the ecotoxicology technologies needed to be developed and The future of mastered. nanotechnology POLICY CHANGES is completely Policy changes: A multi institutional program uncharted with significant amount of funding should be territory. It is launched with the objectives of development almost impossible of products in areas of national priorities to predict related to energy, water, sustainability, defense, everything that infrastructure, and shelter. nanoscience will bring to the Other support mechanisms, which should be world considering put in place, are: that this is such - Technology business incubation support in a young science. this area However, there - Encouraging industries and their are possibilities associations to engineer these products for of several commercialization under PPP mode interesting - The Government of India may adopt and disruptive conditions that promote investment in technologies R&D by industry and new innovative emerging in enterprises based on micro nano future. technology.
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GLOBAL LEADER Safety in storage, transportation in use, India to be Global Leader in Micro Nano Technology by 2035 Risk assesment
Nano particles, Nano surfaces, Nano structures System integration 2035
2030 Self auto adaptive intelligent, self controlling process
Mass production of intricate nanoscale structures 2025
Defined standards for hardware and software 2020
Intelligent adaptive systems and platforms TODAY 2013
REFERENCES REFERENCES MATERIAL FOR FURTHER READING 1. Rajurkar et al, CIRP Annals-Manufacturing • www.kern-microtechnic.com Technology, 2006, 55, 643-666. • www.fanuc.com 2. Liu et al., Journal of Manufacturing Science and • www.nano.gov.nanotech-101 Engineering, 2004, 126, 666–678. • http://www.cientifica.com/research/market-reports 3. Alting et al., CIRP Annals - Micro engineering, 2003, • http://www.minamwebportal.eu 52, 635-65. • http://www.nano.fraunhofer.de/english/ 4. N. Taniguchi, CIRP Annals-Manufacturing Technology, competences_instituts.html 2008, 573-582. • http://www.nanotechnologist.com/misc/ 5. M. Tanaka, Riken Review, 2001, 34, 46–49. • http://www.minamwebportal.eu • http://www.nanowerk.com • http://www.foresight.org/nanodot/?p=2993
164 MICRO NANO RECOMMENDATIONS
• Vibrant ecosystem needs to be in place to incubate the new technologies into industries, leading to high value jobs for a large number of young Indians by 2035
• Reinventing the current manufacturing practices by ushering in new technologies and employing green manufacturing processes
• ICT and adaptronics needs to be exploited to produce a structural change for sustainable manufacturing systems in the country.
• Target to achieve world class level in terms of quality, supply and cost in materials (both raw and processed), energy, water, supply chain, automation (including software), skilled and productive manpower
• New technologies for supporting the driving factors for competitive manufacturing like reduction in investment and space, high flexibility and modularity, low life cycle cost production systems, high strength, high performance, multi functional and bio-inspired materials coupled with lean manufacturing concepts
• Cohesive linking of academia, government and industry is required. Linking manufacturing hubs to research institutes and universities with a mandate to create technologies to ensure global competitiveness and develop productive and skilled human resources is essential.
• Efficient and seamless integration of manufacturing processes, micro/nano technologies, mechatronics, process control, production planning, resources and materials management, simulation technologies, efficient logistics and short supply chains, knowledge modelling and management, efficient exploitation of information and networking technologies needs to be ensured
• Research on key enabling technologies to generate new production scenario and futuristic automation systems is essential
• Widespread implementation of distributed manufacturing using 3-D printing technologies and enlarging the technological envelope of manufacturing in traditionally strong fields like textiles and leather, chemicals, pharmaceuticals and high precision fabrication forms the core of the technology vision for manufacturing.
• India should strive to be a global leader in composites for general engineering, automotive and aerospace industries, micro/ nano manufacturing with focus on health care and energy harvesting and create infrastructure for a global standard ICT to support manufacturing and develop food processing to meet local needs and needs of ever growing Indian Diaspora.
• The immediate need in the next ten years is to train a breed of manufacturing engineers who can turn research output into marketable products and services.
• At present, manufacturing sector lacks capacity building in machine building/equipment fabrication, which requires immediate attention.
• Our educational institutions should become nurseries of innovation than from being mere degree-awarding factories, and challenge our students to think and work innovatively during their education. Universities and higher educational institutions should be rated based on their contributions/output on innovations
• A conducive environment for mentoring innovations and encouraging technology start- ups in this sector, is the need of the hour. KEY CONTRIBUTORS
ADVISORY COMMITTEE
Prof. P. Radhakrishnan Chairman Director, PSG Institute Dr. H. Santhanam Dr. T. V. L. Narasimha Rao Dr. K. V. Raghavan of Advanced Studies, COIMBATORE Co-Chairman, Member Member Member - TIFAC General Manager, Vice-President Governing Council M/s. Sundaram Clayton, Indian Society for CHENNAI CHENNAI Technical Education (ISTE) HYDERABAD
Dr. C.Gajendiran Dr. Gautam Goswami Mrs. Jancy. A Member, Member and Head Member Formerly CMTI, Technology Vision 2035 Secretary - TIFAC BANGALORE TIFAC
CONTRIBUTORS
Prof. P. Radhakrishnan Dr. K. V. Raghavan Dr. T. V. L. Narasimha Rao Dr. Prakash Vasudevan Dr. J. Raghava Rao Chairman Member Member Director, Chief Scientist Director, PSG Institute Vice-President General Manager, South India Textile Central Leather Research of Advanced Studies, Indian Society for M/s. Sundaram Clayton, Research Association Institute (CLRI), COIMBATORE Technical Education (ISTE) CHENNAI (SITRA), COIMBATORE CHENNAI HYDERABAD
Dr. K. J. Sreeram Dr. Suvendu Bhattacharya Dr. Zacharia C. Alex Prof. J. P. Raina Dr. Sakthivel Principal Scientist, Chief Scientist, Professor, School of Director, Associate Professor, Central Leather Research Food Engineering Dept. Electrical Sciences Centre for School of Electronics Institute (CLRI), Central Food VITU, VELLORE Nanotechnology Engineering CHENNAI Technological Research VITU, VELLORE VITU, VELLORE Institute (CFTRI), MYSORE CONTRIBUTORS TECHNICAL EDITORS
Mr. Sivakumar, Mr D Chandramouli Shri. S. Devarajan Dr. J. Raghava Rao Dr. K. J. Sreeram Head - Incharge Retd. Chief Scientist Sr. Engr, (Former) Chief Scientist Principal Scientist Textile Chemical Division Central Leather Research M/s Sundaram Clayton, Central Leather Research Central Leather Research The South India Textile Institute (CLRI), CHENNAI Institute (CLRI), Institute (CLRI), Research Association CHENNAI CHENNAI CHENNAI (SITRA), COIMBATORE
TIFAC TEAM
Prof. Prabhat Ranjan Dr. Gautam Goswami Dr. Neeraj Saxena Mrs. Jancy. A Dr. T. Chakradhar Executive Director Scientist F & Head - TV 2035 Scientist-E Scientist-E Scientist-C
Ms. Mukti Prasad Mr. Manish Kumar Ms. Swati Sharma Scientist-C Scientist-B Scientist-B