Polytetrafluoroethylene (PTFE) is a material of great commercial value. The polymers unique property has earned its special recognition and has revolunized the plastic industry. Best known for its non-stick properties, it can be used to solve a variety of design challenges including preventing build-up of contaminants, corrosion and bacteria; reducing friction or sticking between parts that come into contact; and even used as an ingredient in heavy wear, high-load applications.
The Chemical Processing Industry has largely benefited with the introduction of PTFE lined pipework when used for handling a full range of corrosive chemicals at elevated temperatures. PTFE lined pipework has proved to be the most ideal and economic choice to handle corrosion related problems. That being said, in India, multiple processors have now entered the lined pipework business with limited polymer processing knowledge & techniques only to offer a low-cost product quality and by not qualifying their product.
PTFE lined products need to be considered as a highly engineered industrial product and should be procured to written specifications thereby ensuring that products manufactured comply to materials, workmanship, dimensions, design, fabrication, working pressures and temperature, test methods, Qualification requirements and markings as stipulated in the designated ASTM F 1545 specification. The final product supplied must bear the designated ASTM code. In this hour of need, an experienced processor with a customer-centric attitude can help the clients be on par with the requirements of quality, price and delivery time. This is where Horizon Polymer Engineering comes in.
With more than 35 years of expertise, Horizon Polymer Engineering has evolved into an industry leader in the design, development, and production of a wide range of High Integrity PTFE lined pipes, fittings & valves satisfying every sector/ segment in the chemical processing industry for over the last three decades. The machines used for lining the metal housings are well supported to carry out lining activity in accordance with technology and process know-how acquired by Horizon.
The products manufactured by Horizon are in full compliance with the requisite ASTM STD. “At Horizon Polymer Engineering, our undivided commitment has always been to offer clients viable solutions and services related to handling corrosion problems and deliver quality products aided by technology know-how processing methods resulting in an assurance for enhanced product performance. Our products are known to have given long years of performance which makes us to be the most preferred processor", says Gerard. E. Pinto, President at Horizon Polymer Engineering.
Quality Assurance Procedure
Since its inception, Horizon has been stringent about the quality of the products delivered to its clients. Very recently, to re-assure our customers , the four sets of qualification tests prescribed in the ASTM comprising of High Temp Test, Low Temp Test, Steam –Cold water cycle test & Full Vacuum test were carried out in the presence of TUV INDIA who have witnessed all the tests and have issued us certification which can be shared with our customers. Product Code compliance is fulfilled only when the manufacturer conducts these stipulated tests and qualify their product.
The independent QC team at Horizon adheres to a prescribed QAP which includes inspecting all raw materials and reviewing material certifications. Pipe and fitting fabrication is performed by trained and qualified welders to approved weld procedures. Every batch of PTFE liners produced are internally checked forTensile, elongation and specific gravity results before they are issued for lining. Additionally, only Horizon performs 'Roll-Test' on all PTFE liners as an additional check to detect cracks and or other defects. All final
products produced are tested in accordance with the ASTM requirements for which full certification is provided to customers with traceability.
“The quality assurance procedures were initially laid down by our overseas collaborators which are strictly followed with requisite changes made based on customer feedback or complaints. All required tests for lined products both in-process and final product are all carried out in-house as per our QAP and if a customer wishes to witness any or all of the checks we have an agreed Inspection test plan in place which is followed", mentions Pinto.
Horizon has in place all necessary latest certifications pertaining to Quality systems ISO 9001- 2015 & OHAS, EU-PED -Product certifications for CE markings when required on valves and also for compliance to Fugitive Emission norms as per ISO: 15848-2015 AMD -1-2017.
As a mark of recognition for adapting proven processing methods and for maintaining high quality standards, Chemours, earlier called DuPont continues to retain Horizon Polymer as their preferred processor and Partner under the Teflon Licensing Partner” (TLP) program for which a trade mark agreement signed by both parties continues to be in place and Horizon are officially authorised to use the Teflon logo.
Technology Driven Entity
“At Horizon Polymer technology drives everything that we offer. It is what our customers value us for. We will continue this tradition of harnessing technology to achieve our goals and reach new heights of success", adds Pinto.
Horizon came into the market with a proven technology and know-how and with the ability to provide technical support and offer solutions to customers with back up support from its overseas collaborators.
Horizon Polymer Engineering now has a state-of-the-art manufacturing facility that is equipped with a range of advanced machineries. Starting with two independent fluoropolymer processing divisions for Extrusion (PTFE) & Injection Molding (PFA/FEP), Horizon also has advanced fabrication facilities that are following approved weld procedures and welding performed by qualified welders.
Moreover, the Pipe lining facilities at Horizon are also equipped with special equipment and include special purpose injection molding machines, for lining all types of fittings &valve bodies. For valves CNC/VMC machines are more utilized for machining and to eliminate human errors we have in place a self developedmechanized valve assembly equipment with an automated testing system. On the flip end, the manufacturing facility of the firm also contains — shot blasting and painting facilities, stores for incoming raw and in-process material, and stores for finished products and dispatch.
Robust Growth Trajectory
Incorporated in 1987 under a technical know-how collaboration agreement, the initial 2000 sq. yards manufacturing unit of horizons was restricted to producing lined pipes and limited fittings. This was followed by the setting up of special purpose injection moulding equipment for processing fluoropolymers such as PFA/FEP/PVDF/PP to internally line cast fittings and valve bodies.
In the last phase and as a part of backward integration the extrusion facilities were set up for producing PTFE Liners – a direct import substitution. All liners are 100 percent produced in-house by using only approved grades of PTFE resin material. Also, proven processing methods & techniques are applied which ensures in producing an 'OPTIMUM' Liner.
Further expansions took place beginning from 2010 – A separate unit with a built-up area of 1500 sq. yards was set up only for producing a variety of lined valves. In the same year an independent new satellite unit in Hyderabad was set up mainly to cater to the pharma industry located in south India.
Horizon for the last seven years has kept acquiringnew additional units more to increase its capacities and to improve deliveries. The expansion in production capacities planned in advance and the new additional space which was kept on acquiring has now paid off well since the company is now able to maintain a sizable inventory of raw materials, semi-finished/finished goods, which is giving them the benefit to offer finished goods in a matter of few days or weeks.
Future Road Ahead
Horizon Polymer Engineering has been diligently working to continually upgrade itself in terms of technology adoption and quality standards. “We strive to provide a complete guarantee to our clients, and ensure product reliability with a promise of performance and extended life", shares Pinto.
Today Horizon operates at a pan India level with its corporate Office located in Mumbai and branch sales offices in Delhi, Kolkata, Mumbai, Vadodara, Chennai and Hyderabad. Shedding light at the customer end, the firm looks forward to Increasing its customer base with an undivided focus in meeting customer’s short delivery requirements.
The market forecast in India for lined pipework appears to be very promising at least for the next 2/3 years as many large organizations have earmarked and planned for continuous investments in new projects and expansions with some current projects already under execution and commissioning.
At Horizon, we stand committed to our Vision and Missionand our aim is to become the most preferred processor for all the pioneers engaged in the chemical processing industry concludes Pinto.
Proficient Team of Experts with Customer-centric Approach
In order to keep a personal touch with end users and consultants, Horizon has always had a well-organized and skilled sales crew. As a result of the company's own sales offices in Delhi, Kolkata, Vadodara, Mumbai, Chennai, and Hyderabad, many of its clients are now served locally. The Horizon team has further strategized to retain its current customers at all costs and is also working to grow the existing customer base; as a result, the company has grown significantly over the last ten years despite extremely fierce competition from new entrants offering low-cost products.
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