According to reports, the global plastic industry is expected to grow at a CAGR of 3.4 percent till 2028. India exported approximately $3.26 billion worth of plastic raw material in the financial year 2021 (IBEF, GOI). Estimates pitch the market size of the plastics industry to grow at a CAGR of 8 – 10 percent until 2025. The Indian plastics industry employs about 40 lakh workers and comprises around 30,000 processing units and 2,000 exporters. According to the Indian Brand Equity Foundation (IBEF) of the union government, around 85-90 percent of the processing units are small and medium-sized enterprises (May 2021).
The key factors that are driving the market growth are the increasing plastic consumption in the construction, automotive, and electrical & electronics industries, and growing population coupled with rapid urbanization and industrialization in emerging economies. Machino Plastics is making its presence felt in all kinds of plastics injection parts market in automotive & non-automotive segment. Auto parts includes Exterior, Interior and Under Hood part ranges. The company is uniquely placed in industry with its capability to make large, high volume parts to small precision parts. Making of prototype parts culminates designer’s concept to reality which is Machino niche area.
The company has a young, dynamic and experienced people’s team. In totality, Machino has around 300 staff and 800 associates. The design & manufacturing team in mould making is trained with Plakor South Korea. “Machino has technical support from Plakor for current projects. With vast experience in plastic part moulding and with gained good experience in Injection moulding tools, it has a bright future coming ahead”, mentions Aditya Jindal, Managing Director, Machino Plastics.
The Growth Story
Machino Plastics was established in 1987 with Gurgaon plant for plastic moulding, later expansion was done at Manesar with new plant in 2008. Manesar plant has moulding unit and most modern plastics injection mould making unit. Recently, Machino has expended. It has set up new moulding and mould making plants at Becharaji, near SMG plant in Gujarat. Facilities at Gujarat ensure same range of services to customers as in its flagship company in Haryana. For catering to aftermarket requirement, company has 1.20 lacs square feet of warehouse at Manesar. Company has a warehouse at Pithampur, MP to meet customer’s just in time requirement.
To adopt new technology and for backward integration, Machino in 1995 set up engineering plastics company, which is now headed by another branch in family, for manufacturing plastics compound to reduce import dependence. “We have set up most advanced commercial mould manufacturing plant in Manesar for injection moulding tools. It has latest equipment and state of art technologies in tool room to produce world class quality injection moulds. Additionally, one new tool manufacturing plant is set up by the group in Becharaji in Gujarat. It also set up a brand new moulding unit near Tooling Plant in Gujarat”, says the MD.
The company is always eager to adopt latest technology and all equipment’s bought for moulding & moulds are aligned with market demand. It leverages latest technology to come up with best quality products and world class moulds which give it an edge over the competition.
Operational Excellence
Machino takes pride in its plastic injection part manufacturing. It produces all size of parts from one gram to 14000 gram. Company also produces micro, small, Nano functional parts requiring very high quality standards. The company processes virtually all kind of thermoplastics such as PP, LDPE, LLDPE, HD, PS, HIPS, ABS, Nylon 6, Nylon 66, and PC. These material are plain and mostly with fillers. It deploys many post moulding processes such as vibration welding, ultrasonic welding, robotic assemblies. The firm has also deployed all electric Japanese Injection Moulding machines, robotic pickup arms. It ensures high quality product for customer. It meets customer’s high expectations of Cost, Quality and Delivery. We deliver just in time to our main customer.
The company has one of the most advanced tool room in India to make plastics injection moulds from small to large moulds for Injection Machines up to 3500 tons such as Bumpers for passenger vehicles. It makes small tools for very high quality precision parts and complex raw material composition. It is in the process of making moulds at fraction of cost of moulds from technically advanced countries in West or like Japan or Korea. Its moulds are cost competitive to China. The company has all mould manufacturing facilities in house. This is a huge step toward Atmanirbhar Bharat reducing dependence on imported plastic injection moulds. It is sure that the facility will reduce new product development cost to auto OEM and others. Prototype parts making is its forte.
Machino is doing new mould manufacturing from scratch including complete mould design, mould flow analysis, retooling through reverse engineering from existing parts or mould and doing refurbishment of moulds which have broken down or outlived its useful life by adding more life to it. “We do emergency repairs of moulds, in case of mould breaks down that may hinder mass production of end user and may cause them enormous loss. Our capabilities and competencies are source of great comforts to our customers. In order to give priority to our non MSIL customers in mould and moulded part business, we have set up two new mould making and moulded parts facilities at Becharaji similar to our facilities in Gurgaon and Manesar for mid-size moulds and parts. This will ensure that our all customers are given equal priority”, says Aditya.
Machino is producing and supplying parts to the biggest OEM Maruti Suzuki since 1988 without any major concerns in terms of part quality. It has multiple check points defined to ensure product quality & mutually agreed with customers. Its multiple testing equipment ensures good quality products. “Further, we defined the development test requirement & periodical test requirements as per OEM. Development test are being done from third party lab for the first time and later periodical test in-house. Our customer level rejections are much lower being less than 50 parts per million. This speaks volumes about our quality controls”, adds the MD.
Machino Plastics have set up the most advanced commercial mould manufacturing plants in Manesar and Gujarat for injection moulding tools for IMM up to 3500 Tons CF, with all kind of complexities. It has the latest equipment and state of art technologies in the tool room to produce world class quality injection moulds.
Looking at the Future
Machino was the first company to develop plastic bumpers in 1988 for Maruti Suzuki. Earlier all OEM’s were using steel bumpers. Bumpers made of plastics were un-thinkable. Since inception, Maruti Suzuki is its biggest customer. Later, as demand increased by Maruti Suzuki, 2nd plant developed at Manesar to fulfil the increased demand. At the same time, Machino added multiple Tier-1’s and white goods customers from Manesar plant to sustain a continuous growth. As per market demand and make in India project from Government, it decided to start Mould/Tool plant at Manesar. Later, in order to cater Gujarat demands in terms of plastic parts as well as Moulds, it placed two plants in Becharaji, one for moulding and 2nd for Moulds/tools.
Machino is one of the growing company in automotive plastics segment and now expanding its presence majorly in White goods products too. “We expect double digit growth in 2022-23 with respect to previous years. The growth is not only in Plastic part moulding but also in injection moulding tools. We have taken target to cross 500 crore by 2027. As told earlier per person plastics consumption is much lower in India as compared to West and development nations. It has enormous potential for future and enough space for competition. Plastics as told are replacing other conventional material. When it replaces wood it saves de-forestation”, concludes the MD.
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