Engineering Review December 2013

Volume 13 No.8 A MONTHLY MAGAZINE ON ENGINEERING & ALLIED INDUSTRY December 2013 ` 300 RNI NO. MAHENG/2004/15135 www.engrreview.com

Special

The Innovator of Technology in India Mr. Lalit Seth - C.M.D HPL Electric & Power Pvt. Ltd. Page no. 4-6

IN

FOCUS

An exclusive technology overview of various verticals of manufacturing industry (Refer Pg.2)

Volume 13 No.8

A MONTHLY MAGAZINE ON ENGINEERING & ALLIED INDUSTRY

December 2013 ` 300

The Innovator Of Technology In India Mr. Lalit Seth, CMD, HPL Electric & Power Pvt. Ltd.

04 - 06

FACE TO FACE

09 Vashi Electricals : Visionary excellence & electrified leadership

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100

Dowel Engineering : Cognitive tradition of excellence

Techno Products : Drives to gear up excellence Mr. Murli Srinivasan Director,Techno Products Development Pvt. Ltd.

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124 Corrosion causes incalculable damage to our economy, draining a whopping Rs.50,000 crores annually Mr. J. J. Dias, Chief Executive, Kirloskar Corrocoat Pvt. Ltd.

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Sparsh : A made in India brand revolution

Cognitive heritage of technology excellence

Mr. Sanjeev Sehgal, Managing Director, Sparsh

Mr. Sandeep Deshpande, Managing Director, Gunnebo India Pvt. Ltd.

CORPORATE PORTFOLIO

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Spearheading innovations in industrial automation Albert Miranda Mr. Albert Miranda, Managing Director, Miranda Automation Pvt Ltd

58 Orbital Systems in its new avatar : A global solutions provider for precision assembly automation Mr. Paramjit Singh Seehra, CEO & MD, Orbital Systems (Bombay) Pvt Ltd

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114 Ameya Transmissions : Success through innovation SUCCESS STORY

Walpha Engineering : The honor for technology excellence

Essential Power Transmission : The mark of excellence Mr. Bharat C. Shah – Technical Director, Essential Power Transmission

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C.S.Limaye- Director, Supertech Instrumentation Services (India) Pvt. Ltd

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December 2013

64 ISGEC’s 200T Mechanical Press An engineering marvel

Mr. Ashok J. Sheth Chairman, Solitaire Machine Tools Ltd.

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Peristaltic Hose Pump Showa Best Glove appoints replaced many American, Marvel Gloves Industries Japanese & Italian Pumps as authorized distributor for the region of India Mr. Rakesh Engineer, MONIBA

88 MONORAIL - Overhead Conveyor System : The answer to increasing productivity & tea quality Mr. Rajeev Kapoor Director (Marketing & Export)

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122 Lubi thrives on water pumps & motors

In Pursuit of Excellence in instrumentation - C.S. Limaye 19

61 Solitaire Machine Tools Performance driven grinding solutions

Mr. Farooq Abdullah, Marvel Gloves Industries

PRODUCT SHOWCASE

150 Prolite Autoglo The Guiding Light

ELECRAMA 2014 SPECIAL

COVER STORY

Contents

Mr. Harsha Joshi, C.E.O Prolite Autoglo Limited

.......... 177 www.engrreview.com

FACE TO FACE

HPL : The Innovator Of Technology In India The company has 69 marketing offices across the country with 1,500 authorised dealers and over 18,000 retailers. The group has manpower of more than 5,400 people. HPL has its presence overseas in South-east Asia, the Middle East, Africa and Europe. Products in HPL manufacturing facilities are supervised by its technical team and are the best in terms of technology, quality and design.

This strong & effective presence gives HPL products a respectable share in the market and justifies its brand image that is ‘Technology Brand of India’.

Mr. Lalit Seth, CMD, HPL ELECTRIC & POWER PVT. LTD

Q. HPL India is in the industry for 5 decades, what are the discerning achievements that has been made by the company in the electrical segment?

HPL, a multi product electric equipment company is among the leading players in the electrical industry today. The company has always believed in being technically abreast and keeping a great focus on the design and development of products. That is why, the heart of HPL is the R&D centre, with over 100 engineers innovating, developing and processing to produce the very best in class products for you. The R&D centre is approved by the Ministry of Science and Technology, Govt. of India, which ensures that the products manufactured here are superior in quality, technology and finish.

Q. Please brief us about company’s global reach & what are the global alliances that has been made in order to out-front the competition?

HPL has its presence overseas in South East Asia,

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FACE TO FACE

In Electronic Energy Meters category, HPL is the largest manufacturers of meters in India and among the top few in the world. The strength of this confidence is moving HPL from existing turnover of Rs. 1300 Crores to Rs. 1800 Crores in the next two years. Due to HPL’s unwavering commitment to quality, the products have the markings of Indian and International standards like ISI, CE, KEMA. This dedication to technology has earned HPL the name of ‘The Technology Brand of India’

Mr. Lalit Seth, CMD, Mr. Rishi Seth, JMD, and Mr. Gautam Seth, JMD. HPL ELECTRIC & POWER PVT. LTD the Middle East, Africa and Europe.

The products in HPL manufacturing facilities are supervised by its technical team and are the best in terms of technology, quality and design.

Currently, HPL is on a global expansion policy to expand its business horizons and is looking for marketing alliances for its products from unexplored markets. Exporting its products to Middle East, SAARC and European Countries, HPL is increasingly focused on export-led growth through optimal utilization of its comparative technical advantage vis-à-vis competitors.

Q. What is the market potential for HPL products in India? How do you plan to position these products?

HPL’s product range is divided into four groups – Electronic Energy Meters, Switchgears, Lighting, and Wires & Cables.. Owing to the superior quality and performance of products, HPL enjoys an edge over competitors in the field of low voltage switchgear and protection devices, metering and Energy Management System, CFL Luminaries, Wires and Cables.

Recently, HPL has added modular switches and accessories to its already huge portfolio.

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Q. Is there are any alliances, HPL made recently to strengthen its position in electrical industry?

Co operation with international companies is an ongoing process and we are always open to it as we are committed to bring in the latest technology in India and to our customers.

Q. What are the distinguishing factors which makes HPL, a cutting edge over competition?

A cutting edge factor of HPL products are technology, R&D and quality.

HPL evaluates all these factors while adopting new production techniques.

This enhances the acceptability of products. Due to innovative technology adapted by HPL engineers, the products comprise both technology & durability.

Ultra-modern manufacturing facilities ensure accuracy & reliability of the products.

Q. Please elucidate in brief about the HPL infrastructure & What are the measure that is being taken from the phase of manufacturing to distribution of the products?

The company has 69 marketing offices across the country with 1,500 authorised dealers and over 18,000 retailers. The group has manpower of more than 5,400 people. HPL has its presence overseas in South-east Asia, the Middle East, Africa and Europe.

Products in HPL manufacturing

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year, and we should achieve a turnover of Rs. 1300 crores in this financial year.

The company has a Govt. Approved “HPL R&D centre” with over 100 design engineers, working constantly to upgrade technology in tune with company’s mission. The products in HPL manufacturing facilities are supervised by its skilled technical team and are the best in terms of technology, quality and design.

Q. According to you what is the current status of Electrical equipment sector?

HPL - KUNDLI PLANT OVERVIEW facilities are supervised by its technical team and are the best in terms of technology, quality and design. This strong & effective presence gives HPL products a respectable share in the market and justifies its brand image that is ‘Technology Brand of India’.

Q. Brief about your company’s performance in 2013?

The HPL range enjoys superiority in technology, quality and performance and has an edge over competitors in the field of Electronic Energy Meters and Energy management Systems, low-voltage Switchgear and protection devices, CFL, luminaries, wires & cables and modular switches. HPL has maintained almost 20% growth over last

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The Electrical sector in India has been in the forefront for last few years and now has well matured technology. HPL , a multi product electrical equipment company is among India’s foremost organisation known for its technology & quality .It has always focused on design & development of product to bring the latest in technology.

Q.What are your expectations from ‘Elecrama’?

We expect to place our company’s new products on a national & international platform , so the people can share our technology. We also hope to interact with other companies for overall trade development. India is set for a big growth as rural areas are moving towards urbanization, hence we should see a large development in C and B level towns. Therefore the future of electrical sector in INDIA is very bright.

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BUSINESS NEWS

CeMAT brings in customized themes and display categories for Indian MHE companies

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annover Milano Fairs India Pvt. Ltd, a wholly owned subsidiary of two of the world’s leading trade fair organizers Deutsche Messe AG, Germany and Fiera Milano, Italy, announced that CeMAT 2014, world’s largest fair for intralogistics scheduled to happen during May 19-23, 2014 in Hannover, Germany will focus on innovative and energysaving forklifts and industrial trucks, complex fully automated conveyor systems, shelving and warehousing systems or the latest developments in IT – every section of the Intralogistics industry will be represented at CeMAT in Hannover. On the sidelines of the announcement, it also divulges that the Indian material handling industry will be primarily driven by intralogistics with warehousing and logistics becoming the demand drivers. It is quite visible that there is also a growing demand for forklift vehicles in the fast-growing markets of the BRIC countries and the figure is growing in India too.

With a keynote theme of “Smart – Integrated – Efficient”, a

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complete range of Industrial trucks, cranes and hoisting gear, access platforms, shelving systems, factory equipment, pallets, containers, loading equipment, as well as complete plant installations will be demonstrated by the manufacturers and sole agencies at the world’s largest fair for intralogistics, CeMAT. Two new display categories - port logistics and transport logistics along with 5 main clusters of displays are being organized this edition that includes Move & Lift, Store & Load, Pick & Pack, Logistics IT and Manage & Service. CeMAT 2014 will also showcase used industrial trucks from the selected dealers during the fair and has placed an added emphasis on topics like port handling systems, retail logistics, bulk goods, packaged goods, pharmaceuticals, hazardous goods and disposal during the display.

Wolfgang Pech, Senior Vice President at Deutsche Messe said, “The intralogistics industry is highly innovative and global in nature and it requires a flagship fair geared to global market needs and demand.

CeMAT provides this global platform for generating new business every two years. The show’s new topic clusters and expanded range of innovations will further enhance its status within the intralogistics industry.”

Hoshang Khumbatta, President, SIMHEM & Executive Vice President, Godrej added, “The Indian material handling industry which currently stands at INR 900 crore market is still small compared to India’s economic growth but has immense potential. And to create awareness about the benefits of using material handling systems, a common platform like SIMHEM is essential to bring together material handling equipment manufacturers, dealers, suppliers, consultants and others associated with this field. The usage of forklifts is gradually increasing in India as well among other nations and a platform like CeMAT which focuses on used vehicle business is becoming more and more important these days.”

“The MHE industry in India is in its developing stages as compared to the technologically advanced industries of Europe and China.

India’s traditional affinity to manual labour is one reason for this; however the end users of the MHE industry are now starting to understand the importance of automation in factories and warehouses which will enable a tectonic shift in the way goods are moved within a facility in the next 4 to 5 years. There is going to be additional need for set up of ports, airports, warehousing and logistic sectors to support the growth of the manufacturing industry and overall economy”, concluded Mehul Shah, Managing Director, HMF India.

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FACE TO FACE

Vashi Electricals : Visionary excellence & electrified leadership during project planning and our award winning operations team of more than 200 members are capable of delivering intime what we commit.

Consists of General managerSales, General manager marketing, Business managers, Area sales manager, Product managers, 40 members of strong Sales support backend teamPAN INDIA.

2) Store /Logistic Department: Vashi Electricals today has its presence across India to cater to the local project needs of every region. The logistics centre in Bhiwandi boasts of a 2 Lakh square feet area with more than 20,000 different products being stocked to cater to the diversified customer need in time. This is made possible with the help of the state of the art SAP ERP software, System processes and customer portal which supports the backbone of our organization.

Q. Please brief us about company’s infrastructure & achievements?

The Brief Details Of The Company Infrastructure Are As Under: “Vashi Electricals Pvt. Ltd.” Largest Channel Partner of Reputed International Brands of Industrial Products Celebrates 35 Golden Years of Service to Electrical trade.

We are a company of procurement specialist helping customers to lower supply chain cost with increase in efficiency. We provide a basket of products under one roof to meet Project or emergency maintenance requirements under one roof.

The company the team believes it represents the Largest reputed brands more than ten thousand customers with one goal to satisfy their needs in time and be a Customer Delight.

Core Purpose To provide world class solution to our

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entire eco system through innovative system and process, enabling them to save time, money & build inspiring relationships

Brand Promise 100% Customer Delight by offering Electrical Products and Services ahead of time

We Commit ● Timely Deliveries. ● After Sales Services. ● Correct Prices with CENVAT Invoice.

Core Values: 1.Integrity,Ethical and Transparent working.

2.passionate and innovate.

3.Accountability.

4. Communication.

5.Team Work.

1) Sales &Marketing Department: Our strong sales and service team of over 100 members are capable of providing technical expertise required

3) Financial Department: Involving the CFO with a manager accounts, Manager Finance/Credit Control, followed by the Accounting Executive, in a financial department.

4) Human Resources Department: Consists of Directors –HR supported

by HR management consultant and their Executive in the Office for all HR related activities.

Our achievements.

Retained the No. 1 Rank of being the Largest Channel Partner for Siemens Switchgears in India since 1983, Awarded the first runner-up trophy for “Exceptional Operations amongst Family Business - All India by SP Jain Institute of Management and Research and being the Largest Multi Brand Electrical Partner in India over the

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decades.

Milestones ● 2012 : Opening of Vadodara Branch. ● 2012 : Opening of Bangalore Branch and taking over Ownership of Kim Associates - Siemens Bangalore C.P. ● 2012 : Received FMB Award for Outstanding Operations Process. ● 2012 : Appointed Authorized Distributor for Philips. ● 2012 : Appointed Authorized Distributor for Bosch. ● 2011 : Certified ISO 9001:2008 by UKAS. ● 2011 : Opening of North India Regional Office in Gurgaon. ● 2010 : Opening of the State-of-theart Office and Logistics Centre at Bhiwandi ● 2009 : Installation of world renowned SAP ERP software. ● 2008 : Appointed Authorized Distributor for Omron Automation (India) Pvt. Ltd. ● 2008 : Certified ISO 9001:2000 by UKAS ● 2008 : Opening of Centralized Logistics Centre at Bhiwandi ● 2008 : Appointed Authorized Distributor for Maruti Spare Parts for Mumbai ● 2006 : Opening of New Sales outlet and Warehouse at Vasai - Thane ● 2006 : Gross Turnover of Rs. 600 Million ● 2005 : Joined Hands with Ramesh Electric and Trading Company Pune to service Pune belt customers ● 2004 : Started Castrol Lubs Distributionship for Western Mumbai Suburban & Vashi Thane & Raigad Region ● 2003 : Highest Sales Award by Bonfliglioli Transmission for Gear Motor ● 2002 : Silver Jubilee Year. Twenty five years of Glorious business achievement ● 2001 : Gross turnover of Rs. 600 million ● 1997 : Certified by TUV Germany as ISO 9002 company for sale and distribution on industrial electrical products

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● 1994 : Setup large showroom at Andheri (Mumbai) inaugrated by Mr. Pernstich (MD of Siemens) ● 1991 : Setup large showroom at Andheri (Mumbai) inaugrated by Dr. Reinhardht (MD of Siemens) ● 1989 : Appointed authorised stockist for MDS product ● 1988 : Appointed authorised distributor of Finolex Cables Ltd. ● 1983 : Appointed authorised dealer for Siemens India Ltd. ● 1982 : Appointed authorised dealer for Crompton Greaves Ltd. ● 1981 : Opened showroom and office at Andheri (Mumbai) ● 1978 : Started trading business.

Gross turnover Rs. 4.0 Million

Awards and Rewards ● 2011 : Top Performer of 2010 – Bonfiglioli ● 2010 : Awarded Best Promising Dealer Award – Hindustan Motors ● 2009 : Siemens All India Highest ACB Sales ● 2009 : Siemens All India winner LV Switchgears ● 2009 : Awarded “Best Warehouse Management in Western India” by Maruti MGP ● 2008 : All Time Record Sales in Siemens Switchgear & Motors ● 2007 : Fastest Growing Dealer for Fenner V-Belts ● 2007 : Highest sales for Finolex Cables Mumbai Region ● 2007 : Bonfiglioli All India First Place ● 2007 : Awarded Best Dealer All India for Hindustan Motors ● 2005 : All time record sales in Siemens Switchgears & Motors ● 2006 : All time record sales in Siemens Switchgears & Motors ● 2004 : Siemens Motors Highest Sales Mumbai ● 2003 : Bonfiglioli All India first place ● 2002 : Siemens Switchgears No.1 All India Sales ● 2001 : Best Sales Performance Award

by Siemens All India Basis ● 1999 : Best Sales Performance Award

by Siemens, Finolex & MDS ● 1998 : MDS Best Sales performance

award ● 1997 : Certified by TUV Germany as ISO 9002 Company for sale and distribution on industrial electrical products ● 1996 : Seimens best performance Award No.1 Switchgear Dealer ● 1996: Finolex recognition of excellence for Outstanding sales performance in Maharashtra ● 1995 : Crompton Greaves highest sales western region Award ● 1995 : Siemens Best Performance Award No.1 Switchgear Dealer ● 1994 : Finolex Cables Award for Highest Overall Salesin Mumbai ● 1992 : Best Sales Award for Siemens Switchgear ● 1990 : MDS Outstanding Stockist Award ● 1989 : Crompton Greaves Appreciation Award Bombay Branch ● 1986 : All India Siemens Best Sales Performance Award ● 1985 : All India Siemens Best Sales Performance Award ● 1985 : Crompton Greaves Merit Award Bombay City ● 1983 : Siemens Best Performance Award Thane District

Affiliations Group Co.: ● Purva Vashi Electricals & Services Pvt.Ltd. - Kolkata ● Techno Products Development Pvt. Ltd. - Chennai ● Western Auto Spares & Services ● Western Lube Co

PAN INDIA Presence: HO and Branch Office: Head Office-

Bhiwandi,Mumbai. Branch: Navi Mumbai.Regional Offices: Vadodara, Ahmadabad,Bangalore,Nashik, Pune,Nagpur,Gurgaon.

Joint Venture Companies- Kolkatta, Chennai & Kerala

Q. What are the latest initiatives executed by your company in material handling space? Which are your focus areas?

FOCUS in ACTION : ● Project Focused Approach

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● Centre of Expertise ● E-commerce ● Proposing efficient and Profitable solutions ● Low Energy Lighting ● Integrated Home Automation Solution ● Customer / Enduser Centeric Solutions ● PAN India Presence ● PAN India Rate Contract ● Social Responsibility

Q. What are the market opportunities for your products in India?

How do you plan to position these products?

The Indian market is poised to grow at a compound annual growth rate of (CAGR) of 17.3 per cent over 2010-11 to 2017-18. The XI five-year plan (INR 60,271,000.0 million) and its impact on the growth of heavy industries is expected to spur the growth of Indian Electrical products in India.

Asia-Pacific, with its thriving economies and rapidly expanding manufacturing bases, is expected to experience highest revenue growth during the next five years.

Rising energy prices, stringent efficiency regulations, and increased awareness about advantages of the drives are the factors increasing the demand for VFD.

Vashi Electricals Strategic Plan: To Be filled: Cannot Mention Presently.

Q. What is your marketing strategy for India?

Vashi electrical PVT LTD , marketing strategy for India We are more than just an Electrical Channel Partner, we are a company of procurement specialist helping customers to lower supply chain cost with increase in efficiency. We

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provide a basket of products under one roof to meet Project or emergency maintenance requirements under one roof.

Our strong sales and service team of over 100 members are capable of providing technical expertise required during project planning and our award winning operations team of more than 200 members are capable of delivering intime what we commit. ● Providing customized Engineering solution ● Moving into new market segment and adding up newer products catering to the market need. ● A new all India market coverage by email campaign, products web seminars, products demo in industrial expo, Organizing engineering awareness program at all affiliated Industrial units, Sponsoring Industrial meet by taking part in their marketing programs. ● Marketing activities like Product campaign, DEMO mass contact program, Industrial seminar, Customized on site solution by technical expert engineers. ● To tap the new market growth potentials and growth of different industries. ● Well trained Service Engineers to offer 24x7 technical services, attended in the shortest possible time, to support to our customers.

Our methodology is centered on the following 7 steps: (To be validated) Vashi’s s new Business Model redefined which comprise of the following: ● Select customers in identified, selected areas, markets in territory. ● Define and Differentiate its product offerings ● Create Value for its customers ● Acquire and keep customers with existing and new products group. ● Offer goods and services to suit customer need. ● Deliver timely goods and services in the market ● Organize Sales Promotional

activities in to increase customer base. ● Configure Human Resources to meet market demand. ● Achieve and sustain a high level of profitability ● Grow business by 35% every year till the vision is achieved.

Strategic Selling: Special task Force team working in the field in defined territory, identified market. ● Build confidence in company and Brand ● Build customer demand. ● Secure complete and comprehensive distribution. ● Establish a reputation platform for all products ● Aid salespeople in getting large orders ● Build morale of sales force ● Impress the Trade with scheme and offers.

Q. What is the role of R&D activity? What are the measures that are being taken from the product manufacturing to distribution? ● The first major role of R&D is the development of fundamental knowledge or “enabling technologies” ● The second important function of R&D is to provide support to manufacturing, customers, and business management. ● The third major function of R&D is to develop and implement new technology.

Measurements: ● Analytical task quality elements represents the activities carried out for particular projects or individual analytical tasks. It includes the planning, control and reporting practices recommended at the start of, during, and at completion of R&D work. ● Technical quality elements forms a subset and comprises specific QA elements which apply to the technical activities of the organization, such as policy and procedures for instrument

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calibration and performance checks; use of celebrants’ and reference materials, and; use of statistical procedures. ● Organizational quality elements.

These are quality management structure with a defined role within the organization; a quality system; documented procedures for key activities; a recruitment and training policy for all staff;

Measurement methods ● Prescribe guidelines which are intended to cover analytical testing or measurements. ● Define process of manufacturing and evaluate the deviations. ● Establish the quality audit steps in r3efining the processes and ensure the quality, to increase productivity and minimize the wastage. ● Methods to analyze problem and provide appropriate timely solution.

Q. Brief us about the quality policy for your business?

Vashi Electricals PVT LTD-Quality Policy Our USP is “Dedicated to growth” Committed to service” Vashi Electricals Pvt LTD recognizes that the disciplines of quality, health and safety of employee, and work environmental management are an integral part of its management function. The organization proudly takes this as core responsibility. In addition, we believe that in adopting a quality management system, we are striving to improve our efficiency, work environment, service to customers, and ultimately our profitability.

We will measure or performance by the following objectives: Training Development: To ensure that all that work force, are educated in the detail of our quality standards, and to ensure that quality becomes a part of our business culture at all levels.

Commitment: We wish to ensure that all our staff are fully committed to the principals and customers’ objectives laid out in our quality program.

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Product & Service: Provide industry leading quality in both product and service to our customers, at fair and competitive prices.

Continued Improvement: To ensure that we are continually monitoring our performance in quality and service, and implementing programs to improve our business.

Work Environment: Make sure that we have a safe, healthy, and comfortable work environment for our field and office staffs.

Supply Chain: Ensure that our customers are satisfied with timely & speedy delivery to meet and exceed a defined level of quality standards thereby ensuring that our quality standards are support by our suppliers, vendors and customers.

Q. What is your vision for your company in near future?

As a Company we are working very strongly at being a one stop solution provider for project requirement. Some of the major developments that you will see from our side in the next few years will be in providing automation solution to our Customers. “Green Energy” is no longer a wish, it is the need of the hour.

We realize our responsibility and are adding more energy efficient products to our basket.

Q. What are the best possible remedies you can advise in order to maintain the high profitability in the shrinking margins market of India? ● Reduce Inventory and prepare proper planning on stock management. ● Prefer to put in system to monitor market trend and accordingly procure material Just in time. ● Proper enquiry generation by understanding exact need of the customer and service them with required products and services at appropriate time. ● Procure materials back to back (against the order) and supply against Performa. ● Increase demand of the products and reduce inventory. ● Focus on the market need based products & fast moving products and service. ● Increase profitability to increase volume focusing on project orders. ● Reduce credit limit and define suitable credit policy depending on the value of the purchase and customer profile. ● Market segmenting, customer profiling, product segmenting to sell what is needed at right time.

Q. How far the factors like government norms, excise duty, taxation, exim policies are affecting your business? ● Exposed to more global competition. ● The Uncertainty in invoicing, billing with different Tax system creates additional accounting procedure adding to tedious operations. ● Pay due attention to cost reduction, improvement in quality, delivery schedule and after sales services. ● Globalize our business by increasing the quality standard. ● Given opportunity to import machineries and raw materials on liberal terms.

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BUSINESS NEWS

Atlas Copco’s very 1st energy efficient VSD compressor - A work horse clocked 100,000 plus hours in automotive sector in Chennai

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stablished in 1998, India Piston Limited (IPL) – Ring Blank Unit in Chennai maintains its leadership position in the automotive sector in India, by the installation of the very first unit of Atlas Copco’s GA 50 VSD in 1998. The partnership of India Piston Limited and Atlas Copco India reached 15 yrs.

P. A. Jayaraman – General Manager at IPL, said “In the inception stage, we wanted to go for an energy efficient compressor, which will not give maintainance problems and as a team we decided to go for Atlas Copc’s VSD Compressor.”

GA 50 VSD Compressor A simple, energy efficient and user friendly machine for the maintenance and production teams. “Plus point of this compressor is energy efficiency.

We have saved nearly 40% of energy cost by operating this compressor”, P. A. Jayaraman commented.

This has surpassed the traditional expectation of 35% energy savings by Variable Speed Drive technology over Fixed Speed Drive technology.

At IPL Chennai, by installing GA50 VSD 114000 kWh of electrical

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power have been saved, meaning an amount of 10.3 MINR in energy savings and a reduction of 1600 metric tonne of carbon-dioxide over the past 15 years which is equivalent to a 5000 trees plantation.

Prasanna Kulkarni – Business Line Manager Industrial Air, said, “Truly GA50 VSD with Variable Speed Drive technology is saving the electrical power as well as has become friendlier with the environment.”

This innovative product is a tribute to the partnership between extraordinary organizations India Pistons Ltd. and Atlas Copco. This partnership further shows the capability of Atlas Copco to covert it’s values and believes into action. Atlas Copco committed to sustainable productivity.

Atlas Copco is an industrial group with world-leading positions in compressors, expanders and air treatment systems, construction and mining equipment, power tools and assembly systems. With innovative products and services, Atlas Copco delivers solutions for sustainable productivity. The company was founded in 1873, is based in Stockholm, Sweden, and has a global reach spanning more than 170 countries. In 2012, Atlas Copco had 39 800 employees and revenues of BSEK 90.5 (BEUR 10.5).

Atlas Copco (India) Ltd. started operations in 1960, and has 22 offices across India, the registered office being at Pune. In 2012, Atlas Copco (India) Ltd. had about 2 500 employees and in the period from 1st April 2012 to 31st March 2013, revenues of INR 2 600 cr (MEUR 400). Atlas Copco’s Compressor Technique business area provides

industrial compressors, vacuum solutions, gas and process compressors and expanders, air and gas treatment equipment and air management systems. It has a global service network and offers specialty rental services. Compressor Technique innovates for sustainable productivity in the manufacturing, oil and gas, and process industries.

Principal product development and manufacturing units are located in Belgium, Germany, the United States, China and India.

Industrial Air is a division within Atlas Copco’s Compressor Technique business area. It develops, manufactures and markets oil-injected and oil-free air compressors, vacuum pumps, gas generators, air treatment solutions and compressor controls and monitoring under several brands.

In addition to serving a wide variety of industries, dedicated solutions are also available for marine, railway and oil and gas customers.

The division’s focus and main drive is to further improve its customers’ productivity. The divisional headquarters and main production center are located in Antwerp, Belgium.

For more information Web: www.atlascopco.com www.atlascopco.in

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BUSINESS NEWS

BoostStar Hydro - Pneumatic System - meeting water flow challenges head on!

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fficient water flow management in conditions of varying water pressure and fluctuating demand has always been a challenge. It is an even greater challenge to manage flow while optimizing energy consumption. Amongst a host of systems that are currently available in the market, the ‘BoostStar’ hydropneumatic (HyP) pressure boosting system from A.T.E. wins hands down as it combines efficient water management and optimum energy consumption.

‘BoostStar’ is designed and engineered to manage the water flow of high-rise apartments, townships, bungalows / villas, commercial buildings such as malls, hotels and office buildings and also for industrial applications.

What is unique about BoostStar is that it provides the highest level of intelligence and automation. It has the most advanced inbuilt features such as configurable time-of-day and day-of-week demand patterns, pumps auto-cascading and rotation for prolonged pump durability, Q/h runtime graphs, advanced protection, data and fault logging, BMS connectivity and remote alerts & notifications via SMS. A.T.E. BoostStar HyP systems are engineered using the most stringent quality and testing standards. At the heart of the BoostStar HyP systems are the world’s leading brand of centrifugal pumps manufactured by Ebara, Japan, and instrumentation and control systems built using

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| DECEMBER 2013 | ENGINEERING REVIEW

the best components. The scalable design of the BoostStar HyP systems enable a variety of configurations, ranging from basic fixed speed systems to advanced and fully automated variable speed systems.

The BoostStar HyP systems are available in a wide-range of configurations of pumps (vertical, horizontal, submersible), frames (MS/GI, SS304/SS316), and with varying levels of automation and intelligence, without compromising the reliability and efficiency of the system. ‘BoostStar’ systems are also designed for the lowest total cost of ownership over the product life.

A.T.E., which has introduced the BoostStar HyP system, has over 3 decades of experience in the field of flow technology. With a strong legacy of over 75 years, A.T.E. is a diversified engineering group with business interests in textile engineering, clean technology, flow technology and print and packaging solutions.

The BoostStar HyP system is emerging as a preferred choice for many leading customers, not only because of its rich features and proven performance, but also because it comes from the house of A.T.E., a synonym for quality, reliability and service.

For more information E-mail : flowtech@ateindia.com

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INDUSTRIAL AUTOMATION SECTION

Read it.

Don't Scan it.

High Performance - Low Cost Barcode Readers Meet the DataMan 50L. The tiny barcode reader that brings big performance to food, beverage, consumer products & Pharmaceutical industry.

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The new DataMan 50L is a powerful upgrade for applications that use small laser barcode scanner systems.

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Cognex, Cognex.com, DataMan and the Cognex logo are registered trademarks of Cognex Corporation.

Cognex Sensors India Pvt. Ltd., Regus Level 6, Pentagon Towers P II, Magarphatta City, Hadapsar, Pune - 411 028. INDIA. Mobile: +91 98814 66003 • email: vaggu.sunil@cognex.com

BARCODE READINg AND INSPECTION Complete traceability solutions from handheld scanners and barcode readers to vision systems and advanced lighting.

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SUCCESS STORY

In Pursuit of Excellence in instrumentation C.S. Limaye The changes in technology are very fast. And every development brings in some benefit. We must accept and adapt ourselves to these changes to derive the benefits, says Mr. C.S. Limaye whose contribution to the field of Instrumentation & Automation is immense.

THE JOURNEY OF SUCCESS

Agrochemicals and Rubber Chemicals plants with DCS, up-gradation of MCC and PCC systems, new projects in Pharma at Thane and Agrochemicals at Himmatnagar.

Business

C.S.Limaye- Director Supertech Instrumentation Services (India) Pvt. Ltd, A leading company providing Automation Solutions in Process Industries.

Education He was born in 1954 in a family with educational background at Nagpur, where he completed his education up to B.Sc. He moved to Pune in 1974 for studying Instrumentation Engineering at College of Engineering Pune.

After graduation in Instrumentation Engineering in 1977 from Pune University, he moved to Thane to pursue a career. After two years of experience in Industry, he completed part-time Diploma in Management Studies from Mumbai University.

Service He started his career in 1977 at NOCIL as a Trainee Engineer. At that time NOCIL was one of the most modern and automated petrochemicals complex situated at Thane Belapur Road. The rich experience laid a strong foundation.

After NOCIL, he joined J.K. Chemicals manufacturing chlorine, SO2 and

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textile intermediates. His next job was at Godrej Soaps, Mumbai, manufacturing fatty acids, soaps and detergents.

After Godrej, he joined Bombay Dyeing DMT plant at Patalganga. He was responsible for instrumentation during set up of DMT plant imported from USA. In 1984, he joined Herdillia Chemicals, another petrochemical company manufacturing Phenol, Acetone, Phthalic Anhydride and allied chemicals. He was responsible for maintenance of instrumentation and project for upgrading the automation system from pneumatic to DCS. In 1989, he joined Bayer India Limited, a German company manufacturing Agrochemicals, Rubber chemicals and Pharmaceuticals. He was responsible for projects and maintenance of instrumentation and electrical systems. He visited company’s headquarters and various plants in Germany in 1992. During his tenure he has handled Major projects such as up-gradation of automation systems in

After 18 years of service in responsible positions, he entered into his own business in 1995, Supertech Instrumentation Services (I) Pvt. Ltd. along with Mr. M.G. Ranade, an old associate and friend. Supertech was already established as a reliable Instrumentation Contractor.

Mr. Limaye added services of Design & Detailed Engineering and Systems Integration. An alliance was made with Schneider Electric for their Automation and Drives products. Subsequently the alliance was strengthened with addition of Electrical switchgear for Intelligent MCC, metering products, APC Industrial UPS and MES solutions. Supertech started providing cost effective turnkey automation solutions in a wide range of process industries such as resins, paints, polymers, API, pharma intermediates, specialty chemicals, food & beverages, agrochemicals, lubricating oils etc.

Most of these industries involved batch processes and hence Supertech developed special expertise in automating batch processes. With this experience, Supertech developed “SUPERBatch”, a comprehensive Batch Management software package based on ISA S88 Batch Standard. The package is tightly integrated with Schneider PLC/ SCADA and DCS, but can also be used with other PLC/ SCADA and DCS systems. There are over 25 successful installations of SUPERBatch. In order

ENGINEERING REVIEW | DECEMBER 2013 |

19

SUCCESS STORY

to expand the business and to be able to cater to a wider range of industries, Supertech has recently entered into an alliance with ABB for their DCS systems with focus on verticals such as specialty chemicals, pharmaceuticals, food & beverages.

Supertech also specializes in Historian and MES based solutions which involve sourcing the process data from disparate automation systems (PLC, SCADA, DCS) and archiving in open database such as MS SQL Server. By querying this data using special tools, different types of management information reports and dashboards are generated. The solutions also extend upto integration of Automatation system with ERP systems such as SAP, Oracle.

Another area of focus for Supertech is Intelligent MCC. With increasing level of automation, the number of motors in a plant is increasing. These motors are required to be operated automatically from a PLC/ DCS. Intelligent MCC allows soft connectivity with PLC/ DCS through an industrial bus (such as Profibus, Canopen, Modbus) and eliminates the need for PLC I/O and wiring. It provides warnings and extra protection for the motors against disturbances on both load and power supply side.

It greatly increases the availability of motors. Supertech provides end-toend Intelligent MCC solutions with advanced products from Schneider Electric. Supertech also offers energy monitoring SCADA and a unique Asset Management system for motors.

Valuable Clients Supertech’s valuable clients include highly reputed names in process industry such as Asian Paints, Kansai Nerolac paints, Akzo Nobel, BASF, Bayer, Colgate Palmolive, GSK Foods, Cadbury, Fine Organic, Torrent Pharma, Associated Capsules, Piramal Healthcare, Ranbaxy, Dr. Reddy’s Laboratories, Wockhardt, Watson Pharma, Sandoz, Glennmark, US

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| DECEMBER 2013 | ENGINEERING REVIEW

Vitamins, Reliance Life Sciences, Megafine Pharma, IOCL, Tide Water Oil, Fuchs Lubricants, Syngenta, Huntsmann, Asian PPG, Godrej, Clariant, Novartis, Pfizer, Avestha Pharma, S.D. Fine, Grasim, Indo Rama, Finolex, Supreme Petro, Garden Silk, Birla Cellulosic, Esteem Industries, Gharda, Indofil, Sabero Organic, Gharda Chemicals, Sudarshan Chemicals, Laxmi Organics, Lanxess, VVF, MCF, Garware Chemicals, Firmenich, Tytan Organic, SEYA Industries, Makwell Plasticizers etc. Supertech has also supplied Automation systems and services in Dubai, Sharjah, Iran, Singapore, Nigeria, Kenya, Democratic Republic of Congo and USA.

Professional Work He is a senior member of ISA (International Society of Automation) for 28 years and has served ISA in various capacities including the District Vice President of the ISA Asia-Pacific District, Chairman of ISA India Region and the President of ISA Maharashtra Section. He has organized various ISA seminars and exhibits for ISA Maharashtra Section and India Region.

He had the opportunity of interacting with global leaders in the field of instrumentation through his work in ISA and participation in six ISA President’s meetings from 1998 to 2005 in various parts of USA and Canada. He has played a key role in the formation of ISA Asia Pacific District and opening of various ISA sections at Delhi, Bangalore, Hyderabad, Kolkata, Surat, Pune, Shahjanpur, Ambernath, Thane and about 30 ISA students sections all over India. He also has several technical papers to his credit.

Polytechnic, Thane and currently a member of their Governing Council.

He was Chairman of the Courses Committee – Electronics Group constituted by MSBTE for Curriculum development of new semester pattern Diploma Courses in Maharashtra. He was also a member of the Academic Council of MSBTE. He has actively contributed to revision of curriculum in Instrumentation Engineering for Shivaji, Pune and Mumbai Universities.

A subject on Batch Process Automation was introduced in the B.E. Instrumentation curriculum of Mumbai University in 2010. He provides opportunity to instrumentation students for carrying out their final year projects and internship at Supertech.

Beliefs & Values Mr. Limaye believes that honesty, hard work and dedication to your profession are the key elements of success. The changes in technology are very fast, but you must be willing to absorb the changes. Every development in technology brings in some benefit that improves the quality of human life.

One must see how fast you can adapt yourself to the changes and derive the benefits.

Through his long experience in process industry, he has lived through the evolution of automation technologies from mechanical to pneumatic to electronic to microprocessor based to present day level. He has also had hands on experience in a wide range of process industries. He specializes in providing cost effective automation solutions to process industries using advanced automation technologies, with special emphasis on batch process industry.

Disseminating Knowledge Coming from an educational family background, Mr. Limaye has a passion for teaching and contributing towards education in his field. He was a visiting faculty in Control Engineering at VPM’s

For more information E-mail: cs.limaye@supertech.co.in

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Instrumenta on Services (I) Pvt. Ltd.

New

• • • • • • • •

•

Advanced Batch Solu ons ISA S88 Based Batch Management Modular Design User Friendly Plant Editor Flexible, Open Recipe Based Opera on Operator Guide Messages Planning & Scheduling of Batches On-line View & Recipe Changes Analysis & Repor ng of Batch Informa on

Enterprise Solu ons

•

Sourcing Data from Disparate Automa on Systems in Historian Data Archiving Excel & Web Based Repor ng Tools Manufacturing Execu on Systems (MES) Advanced Reports, Dashboards, KPI for Top Management Informa on Customized So ware Solu ons

• • • •

Intelligent MCC Panels VFD & So -starter panels Energy Monitoring SCADA Energy Saving Solu ons

• • • •

Trusted Name in

Automation Solutions in Process Industries

Energy Efficiency Solu ons

Supertech Instrumentation Services (I) Pvt. Ltd. 12-13, Vardhaman Industrial Complex, Old Mumbai Agra Road, THANE- 400601 (Maharashtra) India Ph: +91-22-41550100 Fax: +91-22-41550178 e-mail: automation@supertech.co.in website: www.supertech.co.in

ENGINEERING REVIEW |

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| December 2013

• • • • • • • •

Turnkey Automa on Solu ons Design & Detailed Engineering Advanced Process Automa on Systems Sensors, Transmi ers, Valves Instrument Erec on Material Installa on & Calibra on of Instruments Intelligent MCC, VFD & So -starters Energy Monitoring SCADA Historian, MES, Integra on with ERP

Areas of Specializa on

• • • • • • • •

Industrial Resins Paints Polymers Specialty Chemicals Pharmaceu cals (API) Food & Beverages Lube Oil Blending Agrochemicals

• • • •

On-line UPS Systems (APC Brand) Bumpless Transfer 3-Phase, 415 V, 50 Hz Supply Upto 800 KVA Single Unit

Secure Power Solu ons

PEOPLE AT THE HELM

Spearheading innovations in industrial automation – Albert Miranda We give world class automation solution for food and confectionary industry – Albert Miranda

Mr. Albert Miranda Managing Director Miranda Automation Pvt. Ltd.

W

e can very well call Mr. Albert Miranda the Biscuit Technologist of India.

He richly deserves this sobriquet for his pioneering efforts in automating the manufacture of biscuits in this country so that they are available for an economical price.

Miranda Mania

The history of Miranda mania dates back to 1971 when Mr. Albert Miranda came out of IIT Bombay with his Masters in Chemical Engineering. Of course he worked in the industry for some time, but the fire in him to do something on his own in the field of automation

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| DECEMBER 2013 | ENGINEERING REVIEW

In today’s competitive world we just cannot survive without automation says, Mr. Albert Miranda, Managing Director of the Navi Mumbai based Miranda Automation Pvt. Ltd. The company is engaged in design, development and manufacture of automated food handling and processing systems, harnessing PLC, and SCADA based industrial automation. Mr. Miranda an M. Tech (Chemical Engineering) from IIT Mumbai, has had several years experience in reputed MNCs before starting Miranda Engineering way back in 1991.

Mr. Miranda has pioneered and specialized in offering one stop customized solution to the customer in the field of industrial automation, bulk materials handling, process equipment, plant utility, and energy conservation. He has received a number of awards from the confectionary industry in particular for spearheading technological innovations. Mr. P. K. Balasubramanian spoke to Mr. Albert Miranda the man at the helm at MAPL to understand the strength of the company and its future thrust. made him restless. It was in 1991 that his dream came true when he started Miranda Engineering Pvt. Ltd. He had a penchant for biscuits, and he went deep into studying its ingredients and its process of manufacture. The engineer in Mr. Miranda experimented, designed and came up with an unique biscuit making plant that automated the entire process of biscuit making starting from sourcing the inputs, mixing the ingredients, handling of sugar granules, flour handling, pulverizing sugar, liquid dozing, preparing the syrup, adding minor ingredients, continuous mixing and so on. It did not take long for the biscuit industry to take advantage of this new system and the benefits of automation. To simplify to the end user the very nature of his expertise he started Miranda Automation Pvt. Ltd. in 2002 and since then has continued to push the barriers of innovation and technology.

Today Miranda Systems are churning out tonnes of biscuits in more

than 100 locations and customer places like Britannia, Parle, Anmol, Priyagold and so on. The have also gone beyond the shores of India to Bangladesh, Africa and the Gulf countries. The industry has appreciated and accepted the innovations spearheaded by Mr. Albert Miranda and acknowledged the benefits of automation like improving the mixing quality, ensuring consistency in quality, minimizing wastage, consuming minimum energy and using bare minimum manpower.

No wonder MAPL has won awards and appreciation from big names in confectioneries like Britannia, Parle, Pepsico, Anmol and Priyagold for its contribution towards automation spanning over two decades.

Mr. Albert Miranda doesn’t take full credit for his inventions. He says, “My sons Joel and Daniel, the former an IT expert and the latter a Mechanical Engineer, who joined the business alongwith a team of professionals have contributed immensely to these www.engrreview.com

PEOPLE AT THE HELM

HORIBA ( Process & Environmental Segment) Contributing to the global environment protection, Since 1945.

Stack Gas Analyzer–ENDA Series/ Portable Gas Analyzer- PG 300 Series.

-ENDA> NOx/SO2/CO2/CO/O2/Data acquisition systems.

- Uses Special Horiba Cross Flow Modulated NDIR Technique.

- PG> Portable Gas Analyzer with CH4 gas also and having feature of SD memory.

- Compact & easy to operate. A good auditor for CEMS performance.

The first of its kind: Miranda’s precision engineered Continuous Mixing System

developments.”

Tasting success in biscuit making, MAPL soon widened its horizon and started applying automation to the entire gamut of confectioneries.

The World’s Best

The spices & minor ingredients dosing system is a recent addition to the range of MAPL’s futuristic products. Today all chefs are using volumetric basis for adding ingredients. It can vary from time to time. There are so many readymade spices available in the market. But you do not know their quality and freshness. The aroma of spices will be natural if they are freshly ground. There are millions of recipes available for processing food. At the press of a button you can select the recipe and get it ground automatically.

MAPL has now developed a completely automated system to dispense correctly weighed quantities of different ingredients such as chilli flakes, black pepper, turmeric, cumin seed, coriander, etc. The dispenser will weigh each ingredient in correct quantity in grams and dispense and discharge the quantity required into the mixer grinder. Along with correct quantity water/vinegar and oil. When the ground paste is ready, an alarm will go off. This paste can then be added to meat or vegetables. Thus you need not have a qualified chef to manage the show.

The same machine can be used for ayurvedic medicines or cosmetics. One can feed in the ailment and the machine will choose the recipe and prepare the concoction including boiling or powder or paste. This machine can be remotely operated using mobile connectivity!

Narrating the development of a continuous mixer for Sone Papdi, Mr. Miranda says the system makes best use of the ‘just-in -time’ principle. The mixer has all the tools & tackles and it does everything on time. Hence there is less power consumption, optimum use of space and there is no www.engrreview.com

Multi- Component Gas Analyzer, VA Series/ Ambient Air Quality Analyzers & Stations, AP Series (USEPA Approved) .

- VA> Multi Component Gas Analyzer is capable of Simultaneous measurement of maximum 3 gas components such as CO, CO2, O2, NOx, SO2, CH4, N2O and other gases.

- AP> Ambient CO/SO2/NOx/THC/Ozone/H2S/NH3 analyzer with intelligent data acquisition systems.

LAQUA Laboratory F-70 Series/ Laqua Twin B-700 Series.

- F-70> Designed to measure pH, mV (ORP), ION, Conductivity, Resistivity, Salinity and TDS. Touch Panel operation.

- B-700> Designed to measure pH, Conductivity, Sodium, Potassium, Nitrate, Calcium and Salt. IP 67.

Oil in Water & Oil on solids Analyzers – OCMA Series / Multi Parameter Water Quality Analyzer –U5X Series/ W-2X Series.

- OCMA> Simply inject the sample & solvent, Push the button and get the results - U-5X/ W-2X> Measurement up to 13 parameters like pH/ ORP/ Cond/ Salinity/ TDS/ DO/ Turbidity/ Temp/ depth/ Sea water specific gravity and various Ions with GPS connectivity.

Online Direct COD Analyzer, Model CODA-500/ Online TOC Analyzer, HT-110.

-CODA> Online COD analyzer based on Potassium Permanganate method with less running cost of reagent.

- HT> Online TOC analyzer for Pharmaceutical water production.

- Confirms to USP <643> TOC measurement.

HORIBA India Pvt. Ltd. Delhi - 246, Okhla Industrial Estate, Phase III, New Delhi-110020, Tel:011-4646 5000, Fax:011-4646 5020.

Pune - 502, Purushottam Plaza, Baner Road, Baner, Pune-411045, Tel:020-4076 6000, Fax:020-4076 6010.

E-mail : pe.hin@in.horiba.com Website: http://www.horiba.com/in/process-environmental/

ENGINEERING REVIEW | DECEMBER 2013 |

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PEOPLE AT THE HELM

material degradation. Plus the quality is at its best.

Describing the company’s approach to new developments, involving customization, Mr. Miranda says his team first studies the product and its operation and views it from different angles, work out different solutions and try them out in in-house R&D before proposing the final set-up.

In the continuous mixing system we have implemented ‘just-in-time’ with proper time frame, requirement of power, space, controlled usage of fresh materials, etc.

MAPL has designed and supplied an automated confectionery manufacturing unit to Sweet s of Oman, Muscat. “This plant is totally Maintained by us using web connectivity”, reveals Mr. Miranda. “It is so user-friendly that even a technician can operate the machine. No one has such a system in the whole world.”

MAPL has customized equipment for automation in the paint industry, ayurvedic manufacture and in pharma industry too. The company has three manufacturing units in MIDC/TTC Industrial Area, Rabale, Navi Mumbai.

It has applied for six patents so far.

there is no corrosion. Comparing the functioning of the equipment to human body, Mr. Miranda says by virtue of JustIn-Time and continuous processing the energy requirement is minimum.

Every stage is utilized and there is no idle time anywhere. Maximum utility of the product is achieved in terms of taste, efficacy and dispersion.

MAPL is dealing with giants in the industry like Parle, Britannia and others. On asked how the company could maintain the wavelength, Mr. Miranda says, ‘Our continuous effort to innovate new techniques to solve individual problems has kept us together and they trust us on all our activities because we have not failed in any venture.

Talking of automation, Mr. Miranda says, ‘Anything and everything is possible, if there is a limitation it is in our imagination. We have even added materials handling to the system wherever required this is for powder handling of granules and then there is a conveyor to move the finished product.

The level of automation is such that you require just one person to press the button and activate the system.

The rest is taken over by the machine.’

The challenges in automation in the domain of confectionery manufacture are manifold. The foremost thing is the accuracy of dosing of ingredients, the other is high temperature to be controlled for cooking products.

Sophisticated SCADA systems ensure these parameters.

Furthermore the equipment is designed as per GMT, so that there is minimum holdup in the system and then there is CIP (Cleaning & Processing). It is a totally enclosed system untouched by human hand so hygiene is 100%. The equipment is made of stainless steel so that

To know the latest coming out of this crucibles? Moving from Masala Dosing, MAPL has come out with a Body Massager which will be a boon to Spas and health centers. It is designed to massage the body from top to bottom in lying position. A set of rolls will do the massaging. Then there is hammering action, pressure control by the pneumatics. This ensures proper blood circulation in all parts of the body.

The entire process takes only 10 mins.

It is so soothing that the person gets complete relaxation and goes into deep sleep! Miranda Automation is also working on a new project sponsored by

The Challenges Ahead

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| DECEMBER 2013 | ENGINEERING REVIEW

The latest

an NGO attached to the Sion Hospital (MNT Group) to address malnutrition in children. ‘Both IIT Mumbai and IIT Kharaghpur have joined hands with MAPL in designing and developing a suitable automated system’ .

Mr. Miranda feels that automation is not for eliminating people but for using the manpower for better utilization elsewhere. His machines are fully automated. In order to ensure optimum productivity and fast realization of ROI, we have to ensure continuous uptime of these robust machines. Even five percent of idle time would mean a sizable loss of productivity and revenue he cautions.

Mr. Albert Miranda has ambitious growth plans. ‘We have been stagnant for 3-4 years because of the upheavals in the industry we have survived because of our innovations. We are now looking up. Armed with a number of innovative products and services for automation we shall be able to achieve 50 crores turnover in the next 5 years. Export is certainly a thrust area for us. A major part of our present turnover comes from exports. This will be stepped up by another 10 % in the coming year’, envisions Mr. Miranda.

We always look at problems out of the box and give our heart and soul to solve them adds Miranda. R&D and people are our major strength.

With our kind of education, experience, industry exposure, and engineering acumen we can achieve anything, of course with God’s grace, declares Miranda.

For more information E-mail:editor@engrreview.com

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TECH TRENDS

AUTOMATION

Avians Innovations Technology Pvt. Ltd. : Innovation is the key to our Success

A

vians Innovations Technology Pvt Ltd along with its parent company “A Mathurbhai & Co” has a rich history of serving the best companies in India for last 40 years. A professional engineering dynamic enterprise offering innovative door solutions to its customers is what Avians Innovations Technology is!!

“Innovation is key of our success”.

Situated in the core hub of industrial area of pune, the company is the makers of the finest automatic products in India today.

Back up with world leading door manufacturer TECKHENTRUP Gmph & Albany Door Systems, Germany makes us one of the leading players in the door automation market in India.

Why Avians?

By choosing Avians as your preferred partner for door automation means a minimal investment, Maximum return on the product and efficient service across India.

Besides assuring finest quality products & flexibility in the development of customized solutions, the company also provides comprehensive customer service / AMC package.

Product Basket: Avians offers wide range of Automatic doors products like High speed door, Sectional Doors, Folding Doors, Sliding Doors, Fire Rolling shutters/Fire Sliding Doors, Motorized rolling shutters, sliding / cantilever /Telescopic

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| DECEMBER 2013 | ENGINEERING REVIEW

gates, Rising Bollards, Dock levelers & shelters. These doors can be used for various types of opening from Small to wide or extra large openings areas with Simple construction and robust in design. This includes on site customer care, fast delivery, product & installation support across the country.

A perfectly matched drive and control system is the foundation of modern technology doors & entrance systems. Exclusive dedicated controller designed to accept all modern activation control and safety features...

Conclusion The company can provide door solutions for practically any challenging & complex door requirement at the site as from the initial concept to Design & to final execution, everything occurs under just “one roof”.

State-of –the- art engineering process and production systems guarantee continued progress and success ensuring a promise of cost effective & quality door solutions to you!!

For more information Web: www.avians.co.in www.engrreview.com

of ...

Tradition

Innovation

Service

Reliability

Product Range

Precision Quality

Rotary & Linear Encoders, Draw Wire Systems, Inclinometers, Counters, Hour Meters, Process Displays, Process Controllers, Slip Rings, Optical Fibre Module, Connection Technology

Elevators Solar

Packaging

Steel Wind

Well established service team for support & setup to repair fieldbus encoders Application engineering team for solution support

Heavy Cranes

State of the art Assembly plant at Pune, India Regional Offices: Ahmedabad | Bangalore | Delhi Kolkata info@kuebler.in | service@kuebler.in www.kuebler.in

Mobile Automation Drive Technology

Kuebler Automation India Pvt. Ltd. Head Office & Factory: # 677, S. No. 269/3, Bhugaon, Paud Road, Pune â&#x20AC;&#x201C; 412108, Maharashtra, India Phone: +91 (0) 20 6790 1200 Fax: +91 (0) 20 6790 1232 Mobile : +91 99701 22299, 8600 147 280

TECH TRENDS

AUTOMATION

Defect-free parts in 360 degrees

A

demanding market place needs the right vision systems for quality inspection Meccancotecnica Umbra manufactures seals for pumps for the circulation of the anti-freeze liquid in combustion motors. The production cycle runs at about three turns per every eight hours. The automotive sector is a demanding one. Parts destined for the marketplace need to be 100% without defect and capable of standing up to difficult working environments.

Meccanotecnica Umbra realised that they needed a reliable and confirmed quality control solution for the inspection of their parts while in the production phase. After trying various vision suppliers they finally found the solution they needed in the InSight速 5000 vision system from Cognex.

The search for the right vision solution In the automotive sector every

component must be capable of withstanding difficult environmental conditions (vibrations, variations in temperature, wind, rain, etc.) Generally different types of pump are used which need to support about 3 bars worth of pressure in order to guarantee the perfect workings of the entire vehicle.

So, it makes sense that manufacturers would seek a top of the range quality inspection before the pieces leave the factory floor.

Meccancotecnica Umbra decided to use a vision system in order to satisfy the demanding standards of quality required by the market.

Having chosen a particular vision company they started testing vision systems. After an initial testing phase it was necessary to admit that for various reasons including system limitations and a lack of support from the supplier led to it never getting past the testing phase. The quality inspection of the production cycle was thus continued manually by personnel with all of the limitations this kind of manual inspection can imply.

In-Sight 5400 for the inspection of automotive components Luckily, soon after, technical experts at Meccancotecnica participated in a Cognex vision seminar and afterward explained their requirements to Cognex asking for a feasibility study for a potential project for quality inspection to check each product passing through their production lines.

The solution was developed

by TEC, a partner system integrator Continue on page no.30

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TECH TRENDS

Continued from page no.28 (PSI) of Cognex for central Italy.

The PSI network is specially selected and trained by Cognex to deliver turnkey solutions for vision and identification applications.

They proposed they use the InSight 5400 from Cognex as well as two Cognex In-Sight 5401 readers.

Every seal; depending on the type and the dimension, is made up of nine components of a different nature such as carbon, steel springs, silicon, etc. which are then mechanically assembled on an automated line.

After the assembly phase, before the pieces are sent to be stacked for distribution, they are sent to three different inspection stations.

A 360째 inspection in just a few seconds At the first inspection station, an In-Sight 5400, takes 24 snapshots of each fully rotating piece in only two seconds in order to verify the external profile of the seal in a complete 360째 inspection.

The second inspection post continues the inspection of the still rotating piece using ten snapshots learned by the camera checking the surfaces of the various parts that make up the seal and verifying their functional aspects.

The third station performs two inspections on the seal which is no longer rotating. In the first, the internal part of the same seal is inspected in about 250 milliseconds and in the second, it is checked whether the product is properly stamped with the model number, the lot number, the company logo and the production date. This is done in less than 600 milliseconds.

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AUTOMATION

Quickly installed and easy to use The application was developed and installed by TEC in record time; in only 20 days it had been confirmed that the system was capable of working correctly on the prototypes. The installation in the factory was done within a week plus the time it took for the training of the personnel in the use and maintenance of the entire system.

production and exports. For several years, the percentage of exports has been around 40% of total revenues, distributed throughout 50 countries, where high-level competitive recognition was attained for the products in an increasingly global market.

In-Sight readers for optimal production inspection The reliability of the In-Sight vision systems, their capacity to adapt to the varying environmental conditions as well as the powerful vision tools available for Cognex vision systems allowed TEC to establish a long lasting relationship with the client. Considering the advantages, Meccanotecnica has already shown their intention to adopt similar solutions to optimize the quality of other productive processes.

About Meccanotecnica Meccanotecnica Umbra was founded in 1966 and in October 1992 took the legal form of a joint stock company. Since its conception, its production has been based almost exclusively on the manufacture of mechanical face seals for electro-pumps, initially for home appliances and for diverse and light industrial appliances.

A few years later, MTU entered into the automotive field, manufacturing seals for pumps for the circulation of the anti-freeze liquid in combustion motors.

The development of the company over time has been characterized by the continuous growth of its

For more information Web: www.cognex.com

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All Gigabit modular design | Up to 24 port connections | Robust remote monitoring DIN rail and rackmount models | Smart plug-and-play operations | Hot-swappable modules

N-Tron NT24k The next level of industrial Ethernet switching is here.

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NT24k-DR16 DIN Rail Gigabit Ethernet Switch

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Mix and Match Copper, Fiber, Fast Ethernet and Gigabit Modules

Red Lion, the trusted name in automation, now offers Ethernet and M2M networking. +91 - 9844876540 I asia@redlion.net I better.redlion.net Connect, monitor and control virtually anything, anywhere. Visit better.redlion.net now. Š2013 Red Lion Controls Inc. All Rights Reserved.

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| December 2013

TECH TRENDS

AUTOMATION

Gandhi Automations offers automatic industrial overhead doors – the ideal solution for all industrial needs • Best use of transit openings • Weather resistant • Maximum safety

T

heir compact size leaves more available space both inside and outside the premises.

Gandhi Industrial Overhead Doors ensure a better use of inside space as the side runners vertically move the door along the wall and parallel to the ceiling. The doors are installed above the opening, thus ensuring a better use of the transit opening.

Easy and practical to open and operate - As these doors slide vertically, stopping in the proximity of the ceiling, they blend in with the architectural features of the building. Their compact size ensures more available space both inside and outside of the premises. The doors are also easy and practical to use.

More environmental control – Heat insulation and soundproofing ensured by heat-insulated panels

improve working conditions on the premises and ensure energy savings. Light and aesthetically pleasing environments – The panels can also be manufactured with the addition of practical portholes or full aluminium sections featuring polycarbonate or unbreakable glass panels, wire meshing or air grilles.

They add value to the premises and meet all requirements - the design and different solutions offered ensure the door to be aesthetically pleasing and perfectly suited in any architectural environment – from modern and traditional industrial buildings to fine commercial buildings. The doors can meet any industrial and commercial requirement and add value to the building they are installed on. These doors are built to ensure the highest ease and flexibility of use which, in turn ensures a quick, hassle free and accurate replacement of old doors.

Reliability - all products are affixed with a CE mark.

For more information Gandhi Automations Pvt Ltd 2nd Floor, Chawda Commercial Centre Link Road, Malad(W) Mumbai – 400064, India.

Tel : +91-22- 66720200/66720300 (200 lines) Fax : +91-22-66720201 Email :- sales@geapl.co.in Website : www.geapl.co.in

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TECH TRENDS

AUTOMATION

Chainflex M - service life guaranteed for one million double strokes The new cable range from igus guarantees reliability and high quality at a favorable prices for the machine tool industry

W

ithin the context of the “savfe campaign” – reliable components which help to save costs – the igus presentation at the EMO revealed a new, complete range of cables for use in the machine tool industry: igus has developed arange covering all types of cables from control, motor, servo and measuring system cables through to data and bus cables – chainflex M – which guarantees reliable low-cost cables. chainflex M stands for a service life guaranteed for one million double strokes. The name speaks for itself.

This means, the specialist for moving cables is the first supplier on the market to link lowpriced cables with a guaranteed service life in the energy chain. igus can make this reliability promise because their cables and systems are subjected to permanent simulated-reality tests.

These tests are undergone within the company’s own testing laboratory, which has 1,750 m² of floor space. Two billion test cycles are run every year at 180 test

Photo PM3913-1: chainflex M, a range of reliable low-cost cables covering all cable types, for 1 million double strokes in energy chains.

(Source: igus GmbH)

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stations. Low-cost range for tool machines: Reliable quality at a favourable price All cable families in the chainflex M range - whether these are motor, servo or measuring system cables – cost 20-30% less than the ranges on offer so far.

Decades of research and market experience allow the energy chain company to develop and manufacture high-quality yet low-priced cables especially for requirements in machine tool designs. This development includes the optimisation of materials and adaptation of the twisting and shielding methods particularly where mechanical engineering systems are designed for one million parts or cycles and work under normal environmental conditions. For example, it is not always necessary to use products, that have undergone costintensive approval procedures and meet several kinds of industry standards. In addition, improved manufacturing processes and technological finesse helps to unite the igus “savfe” characteristics of cost efficiency and quality.

Close to customers - worldwide With the new cable category chainflex M, the energy chain specialist, igus is supporting machine engineers in very competitive regions with suitable components. A widely branched local logistics and sales network ensures that these components reach customers quickly.

About igus®: The igus GmbH is a world`s leading manufacturer in the field of energy

Photo PM3913-2: igus can make this reliability promise for chainflex M because their cables and systems are subject to permanent simulated reality tests. These tests are done within the company’s own 1,750 m² testing laboratory. Two billion test cycles are run every year at 180 test stations.

(Source: igus GmbH) chain systems and polymer plain bearings. The family-run company is based in Cologne, represented in 29 countries and contracts 2,200 employees worldwide. In 2012 igus generated a turnover of 399 million Euro. igus operates the largest test laboratories and factories in its industry to offer customers innovative and tailor-made products and solutions within the shortest time.

The terms “igus, chainflex, readycable, easychain, e-chain, echainsystems, energy chain, energy chain system, flizz, readychain, triflex, twisterchain, invis, drylin, iglidur, igubal, xiros, xirodur, plastics for longer life, manus, vector” are legally protected trademarks in the Federal Republic of Germany and, where applicable, in some foreign countries.

For more information Web: www.igus.de

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Scientific Automation drives the convergence of control technology with comprehensive measurement technology Two industrial worlds have merged Traditionally, the worlds of PLC, motion control and control technology on one hand, with measurement technology and “lab applications” on the other, have diverged when it comes to data entry and processing in an industrial environment. Yet divergence always means having to use additional interfaces, which leads to restrictions on efficiency and operating convenience. But why have this separation in the first place? For some time now, PC-based control from Beckhoff has offered sufficient performance reserves to manage both tasks seamlessly and scalably – from the computer to the high-speed fieldbus EtherCAT and to the wide range of I/O terminals for measurement in particular.

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EtherCAT distributed clocks Accurate synchronization is especially important when distributed processes require simultaneous actions. This is achieved most efficiently through the accurate alignment of distributed clocks because they offer a high degree of tolerance against potential fault-related delays in the communication system. With EtherCAT, the data exchange is based fully on a pure hardware machine.

Because the communication uses a logical (and thanks to full-duplex Fast Ethernet, also physical) ring structure, the “master clock” can calculate the run-time delay with respect to the individual “slave clocks” simply and accurately – this also applies vice versa. The distributed clocks are readjusted based on this value and a highprecision, network-wide time basis is provided with a jitter well below one microsecond.

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he reason for the traditional separation of the two data processing worlds is precisely why PC-based control is of such an enormous benefit today: Until just a few years ago, the computing power of control systems was far too limited for handling automation and measurement technology. Thanks to Moore’s Law and its predicted rapid advancement of PC technology, highperformance automation and sophisticated measurement data processing, as well as functions such as condition monitoring and energy monitoring, can now be united. Taking the step from conventional PLC technology to PC-based control must be accompanied by a corresponding change in thinking – in other words, integration of measurement technology aspects – during development and design.

Measurement technology from standard to high-end functionality This shift in thinking is extremely sim-

Scientific Automation from Beckhoff unites control and measurement technology, thanks to high-performance measurement terminals.

ple thanks to a unique approach from Beckhoff. Measurement technology is no longer restricted to a “black box” that is difficult to integrate. Rather, it can be implemented directly in a familiar and easily upgraded engineering environment that utilizes standard I/O components. The main advantage is in the underlying system structure: The measured data is captured in a simple, cost-effective and optimally scalable manner directly at the machine using measuring terminals and is then transmitted for processing to high-performance Industrial PCs via extremely fast EtherCAT communication. All of the software modules, for example PLC, measurement technology, and visualization, are combined on a single platform – for the purpose of consistently integrating the two worlds of control and measurement technology.

High-end measurement applications and standard measurement technology tasks are capably covered thanks to a comprehensive range of measurement I/O terminals.

The numerous analog input terminals with standard resolution will suffice for many applications: For example, the KL30xx Bus Terminals as well as EL30xx EtherCAT Terminals with 12bit resolution record analog signal voltages in a wide signal range from -2 to +2 V, -10 to +10 V, 0 to 2 V, 0 to 10 V, 0 to 500 mV, 0 to 20 mA and 4 to 20 mA. Standard EL31xx analog input terminals with 16-bit resolution are already suitable for high-precision control processes. In addition, they also support time-critical applications thanks to the extremely fast A/D conversion time –

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TECH TRENDS

The EL3314-0010 thermocouple input terminal enables high-precision temperature measurement to be integrated in the controller while the EL33560010 analog input terminal allows direct connection of a resistance bridge or load cell. approx. 40 to 100 µs depending on the type – and provide support for EtherCAT distributed clocks.

High-end technology is further supported by terminals with 18 and 24bit resolution and the corresponding measurement accuracy for standard current and voltage signals. In addition, highly accurate models are available for connecting thermocouples and resistance thermometers as well as versions for especially complex signals, such as performance measurement or condition monitoring based on IEPE acceleration sensors. The EtherCAT Terminals enable the development of technically demanding solutions through the support of XFC technology (eXtreme Fast Control) from Beckhoff and with it, advanced functions like oversampling.

XFC delivers high-speed data acquisition for measured values XFC technology is based on an optimized control and communication architecture comprising an Industrial PC, I/O terminals with extended realtime characteristics, EtherCAT, and TwinCAT automation software. I/O response times of under 100 µs can be achieved with this finely tuned system.

XFC in particular uses functionalities such as distributed clocks, time stamping and oversampling.

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AUTOMATION

The distributed clocks in EtherCAT represent a core XFC technology and are a fundamental component of EtherCAT communications. This is because, in addition to minimum response times, the crucial factors for the control process are deterministic actual value acquisition (i.e. an exact temporal calculation must be possible), & a corresponding deterministic set value output. A deterministic behavior must therefore be supported by the I/O components, but not in the communication or calculation unit. All EtherCAT devices therefore have their own local clocks, which are automatically & continuously synchronized with all other clocks. Different communication runtimes are compensated, so that the maximum deviation between all clocks is generally less than 100 nanoseconds and the system time is synchronized with extreme precision.

Time-stamped data types actually contain a time stamp in addition to their user data. This time stamp – together with the synchronized distributed clocks – enables the provision of temporal information with significantly higher precision for the process data.

EtherCAT terminals with time stamp latch the exact system time at which edge changes occur. Digital values can likewise be output at predefined times.

Oversampling data types enable multiple samplings of process data within a single communication cycle and the subsequent collective transfer of all data. The oversampling factor describes the number of samples made within a communication cycle. High sampling rates can be achieved easily, even with moderate communication cycle times. Analog EtherCAT input terminals with oversampling thereby enable signal conversion up to 100 kHz and time resolution up to 10 µs; in case of digital input terminals, these values reach 1 MHz and 1 µs.

Analog input terminals with XFC functionality The 1-channel EL3356 analog input

terminals enable direct connection of resistance bridges, such as strain gauges, for example. The 24-bit XFC variant is especially suitable thanks to support of distributed clocks as well as automatic self-calibration (which can be deactivated), dynamic filters, and a sampling rate of up to 100 µs for fast and precise logging of torque or vibration sensors. The additional benefits of oversampling are leveraged, for example, by the 2-channel EL3702 analog input terminals for signals in the ±10 V range and by the EL3742 for 0 to 20 mA. The temporal signal resolution can be increased in both cases by an oversampling factor of up to 100 compared with the bus cycle time.

The EL3773 EtherCAT Terminal is a power monitoring device designed for status monitoring of 3-phase AC voltage systems and likewise supports XFC technology. For each phase, voltages up to 288 Veff/410 V DC & currents up to 1 Aeff/1.5 A DC are sampled as instantaneous values with a resolution of 16 bits. The six channels are measured simultaneously based on the EtherCAT oversampling principle with a temporal resolution of up to 100 µs & passed on to the control system. The control system has sufficient computing power for true RMS or performance calculations, and also for complex customer-specific algorithms based on the measured voltages and currents.

The 2-channel EL3632 analog input terminal also supports over-

The EL3773 terminal is a power monitoring terminal for status monitoring of 3-phase AC voltage systems with a high resolution of up to 100 µs.

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FerroClad Convetional Welding Electrodes

(As per AWS & ASME codes)

FerroClad boasts of ..

Corporate Ofď&#x20AC; ce

TECH TRENDS

AUTOMATION

TwinCAT Scope is an easily configurable software oscilloscope offering modern graphical signal representation incl. additional functions for measuring processes, e.g. a clear overview of oversampling values captured

by EtherCAT measurement terminals. sampling. It is suitable for condition monitoring applications in which fluctuations are to be detected by means of acceleration sensors or microphones.

Piezo sensors with IEPE interface (Integrated Electronics Piezo Electric) can be connected directly without the need for a pre-amplifier. The measuring signals sampled at a rate of up to 50 kHz are analyzed on the PC via the TwinCAT Library or alternatively by means of custom software. The terminal can be adapted to individual requirements through configurable filters and supply currents. Through interfacing via EtherCAT and support for the distributed clocks function, the measurement results – and any detected defects – can be precisely allocated to an axis position.

High-precision measured values for sophisticated measurement technology Higher resolution analog input terminals are suitable for recording signals with extremely high precision.

Examples include the 2-channel EL3602 input channels with 24-bit resolution for ±10, ±5, ±2.5 and ±1.25 V or the EL3612 input channels for 0 to 20 mA as well as the 2-channel EL3692 resistance measurement terminal for a measurement range between 10 mΩ and 10 MΩ.The EL3681 EtherCAT Terminal is a digital multimeter terminal with 18-bit signal resolution.

Currents of up to 10 A can be measured as well as voltages up to 300 V AC/DC.

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The measurement ranges are switched automatically, as is usual in advanced digital multimeters; the measurement type and range can also be adjusted with EtherCAT if required. Excellent interference immunity is achieved through the design of the EL3681 which features full electrical isolation of the electronic measuring system and dualslope conversion.

The EL3201-0010 (1-channel) and EL3202-0010 (2-channel) PT100 input terminals for direct connection of resistance sensors enable highprecision temperature measurement.

They are extremely precise with a resolution of 0.01 °C per digit and are suitable for a temperature range of -200 to +320 °C. The calibration result is confirmed in the case of the -0020 terminal versions by means of a calibration certificate. The 4-channel EL3314-0010 input terminal picks up the signals from four thermocouples and can also detect any broken wires. The high 24bit resolution enables a scaling of 0.1 to 0.001 °C per digit and 10 nV per digit.

The internal high-precision temperature measurement at the cold junction therefore allows precise temperature measurement in calibrated operation also when using thermocouples.

Full use of multi-core technology results in lower engineering costs In particular, it is the new TwinCAT 3 software generation, featuring integration in Microsoft Visual Studio, which best fulfills the requirements of Scien-

tific Automation – the convergence of automation and measurement technology. The real-time environment is designed in such a way that practically any number of PLCs, safety PLCs and C++ tasks can be performed on the same or different CPU cores. The new TwinCAT 3 Condition Monitoring Library exploits these opportunities in particular: Raw data can be sampled with a fast task and processed with a somewhat slower task. This means that measured data will be continuously recorded and can be analyzed independently in a second task with numerous algorithms. The individual functional modules of the Condition Monitoring Library store their results in a global transfer tray, i.e. a type of storage table.

From here the results can be copied to variables or processed using different algorithms so that an individual measurement and analysis chain can be compiled.

No specific Beckhoff modules or other modifications to the original model are required to create Matlab®/ Simulink® modules. The Matlab and Simulink coders generate C++ code, which is then compiled in a TwinCAT 3 module. Repeated use of the modules is possible through instantiation. The block circuit diagram from Simulink can be displayed directly in TwinCAT and used, for example, to set break points.

TwinCAT Scope enables the graphical representation of all relevant signals from Scientific Automation software.

Its viewer component can be used for visualizing signals in charts, while the server component logs the data on the corresponding target device. Scope also allows measured values to be read in the microsecond range to the exact cycle and enables visualization of oversampling values captured by EtherCAT measurement terminals.

For more information www.beckhoff.com/Measurement www.beckhoff.com/ScientificAutomation

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Sleek touchscreen displays | Rugged operator panels | Flexible plug-in modules Available in 8 different models | Remote monitoring and control | Converts over 250 protocols

Graphite

The next level of HMI is now here.

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With cast-aluminum construction, Red Lion’s new Graphite™ series combines flexible plug-in modules with protocol conversion, data logging and webbased monitoring to meet all of your industrial automation needs. From factories to extreme remote locations, Graphite enables customers worldwide to connect, monitor and control processes across a broad range of industries.

Graphite 12” wide touchscreen

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Red Lion, the trusted name in automation, now offers Ethernet and M2M networking.

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Plug-In Modules

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Graphite 15” touchscreen

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| December 2013

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TECH TRENDS

AUTOMATION

Omron Industrial Automation welcomes Mr. Sameer Gandhi as the Managing Director

O Mr. Sameer Gandhi, MD, OMRON Industrial Automation, India

mron Industrial Automation, a global manufacturer of automation products and a leading provider of application expertise, today announced the appointment of Mr. Sameer Gandhi as its Managing Director (MD) for India. As the new MD, Mr. Gandhi will be responsible for Omron Industrial Automation’s strategic growth and expansion in India, bringing global best practices and technologies to critical Indian industries.

Mr. Gandhi brings an experience of over 23 years across multiple disciplines and vertical industries. He joins OMRON from ABB, India where he served as Vice-President Strategic Account Management, focusing on strengthening relationships with key customers in India across various ABB business verticals. Prior to this, he has held various diverse responsibilities including sales, operations and P&L serving several industry verticals including Minerals and Cement, Pulp & Paper and Robotics.

Commenting on the appoint-

ment, Mr. Kunihiko Kohara Managing Director - HQ (Asia Pacific),said “We’re glad to have Sameer on the management team here in India as the market here is very promising. A strong leadership will help to have an accelerated growth with best productivity & quality, and here Sameer’s technical expertise combined with a deep understanding of the market and customers is the perfect mix.”

Mr. Sameer Gandhi, MD, OMRON Industrial Automation, India said, “Omron is well known for its products and application strength in the industrial automation segment globally. I would like to replicate the same in India and grow the business as I see a lot of market potential and we’ve a very strong team OMRON too.”

As Omron Industrial Automation continues to gather momentum in India, its focus on solutions will drive growth for the company going forward. The company is bullish on the Indian growth story, as seen through their continuous investments in human capital.

About Omron Industrial Automation Headquartered in Kyoto, Japan, OMRON Corporation is a multi-billion-dollar, diversified company with business units producing industrial automation products, electronic components, healthcare equipment, ticketing systems, etc. Omron Industrial Automation is a global leader providing complete automation solutions for industrial applications.

Omron Automation - India caters to over 8 industrial applications encompassing the wide requirements of packaging, automotive, material handling, solar, food & beverages, textile and panel handling applications. In recent years the company has been concentrating on the solution business which provides “One Stop” solutions, improving the overall efficiency on diverse production sites. Focusing on the themes of quality, safety and the environment, they support manufacturing innovation worldwide with their unique sensing & controlling technologies.

Omron is rapidly expanding its operations with focus on major cities namely Mumbai, Gurgaon, Bangalore, Pune and Chennai, making its presence felt across the vastness of India by appointing resident engineers to address the ever challenging requirements of the clients. A major factor in Omron’s progress globally & locally has been the strong commitment towards its customers keeping ‘Quality First’.

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IXXAT Econ 100 Highly customizable master solution for EtherCAT, CANopen and Powerlink

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he IXXAT Econ 100 is a universal ARM-based platform with a Linux operating system that comes as a standard version already with four Ethernet, two CAN and two USB ports.?Whether “out-of-the-box” or adapted to specific customer requirements, the IXXAT Econ 100 is the right choice for various applications in terms of performance, flexibility and price. For the implementation of EtherCAT and CANopen master applications or Powerlink Managing Nodes, special application development kits are available for the IXXAT Econ 100. These kits include a comprehensive board support package and, pre-installed on an SD card, the corresponding master software package and the Linux operating system.

For the enclosed sample applications, also a suitable IO module is included in the scope of delivery, as well as a detailed documentation, enabling the fast and easy start of the development.

The EtherCAT Master functionality is provided using the proven protocol software from acontis for EtherCAT Master Class A and B devices. A specially optimized link layer allows the IXXAT Econ 100 to operate with cycle times of less than 1 ms.

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The CANopen master implementation is based on the CANopen master/slave software from IXXAT, which enables the Econ 100 to act as a multi-channel CANopen controller. Powerlink has been implemented based on the IXXAT POWERLINK-master/slave software. Due to the integrated hub logic the managing node implementation also supports the typical Powerlink line topology.

Redundancy features, such as redundant master or line redundancy, enable the IXXAT Econ 100 to operate as highly-available Powerlink communication solution.

By combining the various master software packages, powerful controllers for heterogeneous systems with CANopen, EtherCAT or Powerlink can be easily implemented.

Typical operation areas of the IXXAT Econ 100 are customer-specific control applications and gateway solutions in which the IXXAT Econ 100 is acting as master in one network and as slave within a superior network.

The remarkably high degree of flexibility by using the IXXAT Econ 100 is achieved by the unique combination of extension interfaces, FPGA, software and services. In addition to the interfaces of the base version,

custom interfaces or enhancements (e.g. digital and analog IOs, DVI output) can be added quickly and easily via expansion slots and the integrated FPGA. This makes the IXXAT Econ 100 the perfect device for customized solutions.

During the development of the IXXAT Econ 100, special attention was paid to the requirements of the various fields of application. Thus, the unit has, despite of its fanless design, an extended temperature range from -40 ° C to + 70 ° C. The used CPU is a dual core Cortex A9.

The internal RAM memory has a standard size of 256 MB and can be extended up to 1 GB. The operating system and programs are stored in flash memory on an SD card.

Besides the version within the robust metal housing, IXXAT offers the IXXAT Econ 100 also a board-level product for spacesaving integration into already existing customer applications. On request, IXXAT can also deliver OEM versions including hardware and software adaptations - fast and economically priced

For more information Web: www.ixxat.com

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Kepware updates communications platform to strengthen support of industry standards and improve interoperability KEPServerEX version 5.13 features on-demand communications and achieves ODVA compliance with significant open standard driver updates

K

epware Technologies, a software development company focused on communications for automation, released KEPServerEX® version 5.13. The updated communications platform expands Kepware’s support of industry standards, and enables improved interoperability and communications across key industries.

KEPServerEX version 5.13 features client- or user-driven on-demand communications with new Device Demand Poll functionality.

This added flexibility enables users to meet the client-driven polling requirements of their application.

Also included in this release, the Allen-Bradley ControlLogix Unsolicited Driver for KEPServerEX is now compliant with Open DeviceNetwork Association (ODVA) standards, ensuring interoperability with other Ethernet/IP-based products.

“Interoperability issues are paramount with multi-vendor products, which is why our commitment to supporting industry standards is a top priority as we continue to advance our products,” said Tony Paine, President and CEO of Kepware Technologies.

“With version 5.13, we improved the performance of our AllenBradley ControlLogix Unsolicited Driver and achieved ODVA certification.”

The enhancements made to KEPServerEX’s EFM Suite considerably advance its communication capabilities for the upstream

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and midstream Oil & Gas Industry.

The EFM Exporter now supports exporting collected archive data directly to any SQL database for custom applications and analysis.

Furthermore, the Fisher ROC and ROC Plus Serial drivers now support User Programs in Emerson’s Fisher ROC and FloBoss™ devices, which enables automatic tag generation and data access to User Defined Points.

“As regulations tighten and Oil & Gas networks span increasingly greater distances, the industry requires new and innovative approaches for collecting and communicating data,” said Steve Sponseller, Product Manager of Oil & Gas Solutions at Kepware.

“The value of data to the Oil & Gas Industry is growing exponentially.

With version 5.13, we paid special attention to helping the industry leverage this information to make highly-informed business decisions.”

For more information Kepware Technologies E-mail: sales@kepware.com.

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Alcoa and Honeywell join forces to integrate global refineries “Working with Honeywell under the QUASAR program has enabled Alcoa to consistently exceed all our benefit expectations. What took the combined team five to six years to accomplish would have taken us more than 20 internally. The people are a major factor in the success of this program.” Dennis Mason, Process Systems Manager, Global Refining, Alcoa Inc.

Benefits To achieve significant enhancements in alumina production and raw material efficiencies across its refining business, Alcoa turned to Honeywell to provide standardized process control infrastructure and control solutions across multiple refineries in six countries.

The partnership resulted in a strategic program known as Quality Automation Solutions in Alumina Refining (QUASAR). By improving Alcoa’s plant efficiency, reducing raw materials consumption and lowering environmental emissions, QUASAR provides Alcoa with a sustainable, competitive advantage.

Key features of the QUASAR program include: ● Improved process performance by leveraging automation technology and combining best practices from each refinery ● Improved plant support through centralized monitoring of the system so Alcoa can analyze and rectify the process control system performance of each refinery from a single center, thus leveraging scarce expert resources ● Reduced downtime with integrated support and mainte-

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nance practices through a cosourced support center ● Rapid deployment at each location by a dedicated implementation team that minimized costs, improved quality and minimized plant interruption ● No disruptions to continuous refinery production during implementation due to strong project management, excellent engineering practices and intensive communication with stakeholders ● Financial funding of the program via a lease, rather than increase capital expenditure, to facilitate approval of the program

Background Alcoa is the world’s leading producer and manager of primary aluminum, fabricated aluminum and alumina facilities, and is active in all major aspects of the industry.

Alcoa serves the aerospace, automotive, packaging, building and construction, commercial transportation and industrial markets, bringing design, engineering, production and other capabilities of Alcoa’s businesses to customers.

Alcoa also markets consumer brands including Reynolds Wrap® foils and plastic wraps, Al-

coa® wheels and Baco® household wraps. Its other businesses include closures, fastening systems, precision castings and electrical distribution systems for cars and trucks.

The company has 129,000 employees in 44 countries.

Challenge Controlling production in an alumina refinery is a complex task requiring the processing of large volumes of bauxite, caustic soda, lime and other raw materials by large plants to digest the alumina minerals from the bauxite, separate the remaining waste material, recrystallize and then calcine the hydrate to produce the alumina product.

As a world leader in alumina production, Alcoa wanted to take this production process one step further by installing a common process control system and advanced process control applications across its global refineries. This would be supported around the clock by remote monitoring from Phoenix and two support centers in Houston and Perth.

“In order to accomplish this never-before attempted feat, we needed to partner with someone that had the process control

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product and solutions expertise but also understood the cross-cultural challenges of seven different sites, multiple countries and cultures, and four different languages,” said Dennis Mason, Process Systems Manager, Global Refining, Alcoa Inc.

Solution Alcoa and Honeywell partnered to deliver business results at refineries around the world.

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| DECEMBER 2013 | ENGINEERING REVIEW

Alcoa not only found a partner in Honeywell but also a company that would take ownership and help develop the QUASAR program. Six years later, the common platform has been successfully established and the shared benefits realized.

“Working with Honeywell under the QUASAR program, the benefits we expected to see were improved alumina production rates, reductions in our raw materials consumption and therefore costs, and increased technology transfer between our refineries,” continued Mason. “We’ve consistently exceeded expectations in those areas.”

QUASAR’s results are in part attributable to sound engineering practices. No production losses, no loss time injuries, no budget overruns and an aggregate customer satisfaction score of 4+ out of 5 meant that this program team met the stringent standards of both Alcoa and Honeywell.

One of the challenges faced

by QUASAR was ensuring Alcoa’s IT security policies could be maintained in relation to data access from the process control network and for access for the global support teams. The program results needed to be at the highest level of network security possible considering the interoperability of the resource teams from Alcoa and Honeywell. In 2003, Honeywell

and Alcoa jointly developed a sophisticated network management model that satisfied the needs of Alcoa’s security and audit requirements, and data integration needs.

It included: ● Virtual private networking to protect the network from the outside world ● Firewalls between the commercial network and the process control network to prevent intrusion to and from the commercial domain ● Trust settings on the process control network to ensure correct authentication for Alcoa and Honeywell users ● Access protocols so that Honeywell can remotely monitor equipment on the process control network and direct site staff to implement changes The value to Alcoa has been significant. While improvements in alumina production, raw materials usage and environmental emissions have an immediate impact on the bottom line, the ability to integrate reliable process information with the business has enabled the company to take a major step towards establishing global best practice benchmarks in process control.

For more information Web: www.honeywell.com/ps

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TECH TRENDS

AUTOMATION

Paving the way through London’s soft core Conveyor drives for rapid transit tunnel construction in central London sistency that makes the transport of excavated material especially challenging. H+E Logistik and NORD DRIVESYSTEMS, two German industry specialists, are supplying suitable conveying technology including geared motors.

Illustration 1: German technology for new train lines in London: the tunnel boring machines supplied by Herrenknecht.

T

he metropolis London is currently adding a new East-West rapid transit connection with a length of more than 100 km to its much-frequented public transport network.

For this major project, 21 km of new tunnels are being bored in the city center alone. The soil here mainly consists of soft clay with a sticky con-

Illustration 2 : The project also uses German conveying technology: every hour, several thousand tons of excavated material must be transported away

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Named after the mathematician Ada Lovelace and the city map pioneer Phyllis Pearsall, Ada and Phyllis are tunnel boring machines (TBMs) from German manufacturer Herrenknecht, each measuring approximately 100 m in length and weighing about 1,000 tons. Working for the rapid transit project “London Crossrail”, they have been pushing forward their 7 m wide “Cutterhead” blades below the City since 2012. After tackling the distance of six and a half kilometers between Royal Oak and Farringdon Station, they are planned to resurface in 2015. Besides Ada and Phyllis, more TBMs are currently boring similar tunnels in various other track sections for the East-West connection through London which will measure a total of 118 km. The first Crossrail sections will be put into operation in 2018. With an investment volume of more than 17 billion EUR, “London Crossrail” is currently Europe’s largest infrastructure project.

Demanding transportation task The TBMs excavate up to 1,300 tons of “London clay” per hour in the two 6.2 m diameter tunnels that are being bored in parallel below the city center. The handling of this soft material does require solutions that are tailored to its consistency.

In this case, the challenge lies in reliably transporting the excavated

material away from the building site, which includes routing it over machine, tunnel, and hall conveyors before loading it onto trains.

State-of-the-art tunneling includes the addition of tensides to the excavated material directly at the boring machines in order to facilitate handling. However, if the special London clay formation and these additives came into contact with standard conveyors, complications would soon arise: the mass would promptly and persistently stick to parts of the conveyor belts. Tunnel conveyors for the “London Crossrail” project were therefore custom-tailored by the Herrenknecht subsidiary H+E Logistik. In addition to special plastic coatings and other measures, a wiper system developed especially for the onsite requirements serves to prevent problems caused by conveyed material sticking to exposed system components.

Firstly: reliable, secondly: versatile Specifying and procuring reliable conveying drive technology proved similarly important. H+E Logistik approached its proven partner, NORD DRIVESYSTEMS from Bargteheide near Hamburg: “We have been cooperating with NORD for approximately ten years now, and have tackled hundreds of projects together”, says Dirk Uphues, the H+E project manager in charge of the London operation.

“The reliability of geared motors on our conveyors has always been a decisive factor. NORD fulfills this key requirement, no matter which

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TECH TRENDS

drive type they deliver for us.” For the London tunnel conveyors, NORD supplies helical bevel geared motors with a double-sided, smooth output shaft. An expansion coupling transfers the torque to the belt conveyor. “Of course we would like to minimize the drive variety, and the double-sided shaft allows for the versatility that we need: our systems typically complete

Illustration 3: NORD DRIVESYSTEMS supplied the drives for the conveyor belts

Illustration 4: The TBMs easily penetrate the clay soil found in London, although this poses a special challenge for the conveying technology

Illustration 5: Geared motors from NORD DRIVESYSTEMS ensure high availability and versatility

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AUTOMATION

not only a single tunneling project, but are often bought back on completion for other tasks. With a variable drive configuration, they can more easily be used in different locations”, says Uphues.

Seamlessly and without delay All NORD gearbox housings are manufactured using a single piece construction with no joints or seams. This applies even to very powerful industrial gear units up to 242 kNm which are required for extreme conveyor inclines and moving very large amounts of conveyed material. The one-piece UNICASE housings of NORD’s industrial gear units feature integrated bearing seats.

Thus, there are no sealing surfaces between the drive side and the gearbox housing that are susceptible to damage through torque and radial forces. With its offset bearing shaft arrangement, the UNICASE design also ensures very compact dimensions but allows for the use of larger bearings for higher loads and extended working life. Industrial gear units can be installed as left or right side conveyor drives. Most types are globally available with fast delivery times. Even though tunneling projects can take many years, customers like H+E Logistik appreciate suppliers who can ensure short-term availability.

Besides tunneling, the London Crossrail project also includes the remodeling of existing stations and the construction of new ones.

Some time ago, additional manual excavation work that could not be planned in advance near Bond Street Station was scheduled on short notice. So as not to affect other project deadlines, H+E was tasked with providing suitable short conveyors within eight weeks.

“The required drive technology from NORD arrived five days after ordering”, says Birgit Barian from the H+E purchasing department.

“Particularly when a project is nearing completion, you can easily find yourself in a situation with tight delivery deadlines and considerable time pressure.

Even if you have kept all of your own deadlines, many third party problems and sometimes unforeseen circumstances come into play. Without partners like NORD, that are available virtually on demand, you might easily find yourself in difficulty.”

Company background NORD DRIVESYSTEMS develops, produces and sells drive technologies with around 2,800 employees, and is one of the international leaders in the industry. In addition to standard drives, NORD supplies application-specific concepts and solutions, even for special applications, for example with energy-saving drives or explosionprotected systems. Gross sales amounted to approx. EUR 450 mn in the 2012 business year. The company founded in 1965 now has over 35 subsidiaries worldwide.

The closely meshed sales and service network ensures optimum availability for short delivery times and customer-oriented services.

NORD produces a wide variety of drive units for torques from 10 to 200,000 Nm, electric motors with powers from 0.12 kW to 200 kW as well as the necessary power electronics in the form of frequency inverters and servo controllers.

Inverter solutions are available for classical installations in the switch cabinet and for decentralised and fully integrated drive units.

For more information Web:www.nord.com

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TECH TRENDS

AUTOMATION

40% more space in your switch cabinet; remote I/O modules impress with their unique compact design Pepperl+Fuchs completes its wide range of I/O modules with the half-size, eight-channel digital input modules and offers the most compact remote I/O solution for process automation. The slim modules save valuable space in switch cabinets, thereby reduce the cost per channel.

P

epperl+Fuchs complements its product range of extra slim modules with the newly developed eight-channel digital input modules. Pepperl+Fuchs has essentially made these new modules possible by creating a new electrical design.

The new housings of the digital highdensity input modules are half as wide as those of the previous version, but this is partly due to the compact plug construction. The two plug-in connectors found on the front of the housing each have eight contacts.

In addition, the redesigned housing features status LEDs for each of the eight available channels, enabling quick diagnostics and accelerating both commissioning and maintenance.

space for more modules. The analog counter parts were introduced some time ago and are the result of innovative electrical design. At just 16 millimeters wide, the high-density modules fit in existing backplanes and are easy to configure.

About Pepperl+Fuchs Pepperl+Fuchs is a leading developer and manufacturer of electronic sensors and components for the global automation market.

For more than 60 years, our continuous innovation, high quality products, and steady growth have guaranteed us continued success.

One Company – Two Divisions

The new modules require Pepperl+Fuchs – PROTECTING around 40% less installation space YOUR PROCESS in a complete remote I/O system The Process Automation Division including com unit coupler and is a market leader in intrinsically power supply, depending on the safe explosion prosignal mix. This retection. We offer duced installation comprehensive, space increases flexapplication-oriibility when planning ented system soautomation solutions lutions, including using Pepperl+Fuchs customer-specific remote I/O systems. control cabinet The innovative, slim solutions for the modules can be inprocess industry. stalled in spaces where A large portfolio larger switch cabinets of components is cannot fit. The highavailable from our density modules are Fig. 1: Digital input various product half the size and their module lines: isolated barslim profile creates

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riers, fieldbus infrastructure solutions, remote I/O systems, HART interface solutions, level measurement devices, purge and pressurization systems, industrial monitors and HMI solutions, power supplies, separator alarm systems for oil and petrol separators, signaling equipment, lighting as well as emergency shutdown equipment and accessories.

Pepperl+Fuchs – SENSING YOUR NEEDS With the invention of the inductive proximity sensor in 1958, the company set an important milestone in the development of automation technology. Under the motto “Sensing your needs”, customers benefit from tailormade sensor solutions for factory automation.

The main target markets of the factory automatio n are machine and plant construction, the automotive industry, storage and material handling, printing and paper industry, packaging technology, process equipment, door, gate and elevator construction, mobile equipment, renewable energies.

The division offers a wide product range of industrial sensors whether it’s inductive, photoelectric or ultrasonic sensors, rotary encoders, identification systems, barcodes, code readers for data-matrix-codes and vision sensors.

Pepperl+Fuchs (India) Pvt.Ltd, Web: www.pepperl-fuchs.com

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AUTOMATION

Why to Choose SAP Business One ERP for your Business?

1. Complete small-business essentials in a single system The SAP® Business One application seamlessly integrates the entire business across financials, sales, customer relationships, and operations in one system, eliminating duplicate entries and errors.

2. Functionality that helps you keep your customers close Small businesses like yours can rely on SAP Business One to quickly track and access all customer contacts, records, and history to respond to customer needs faster and better than the competition.

3. Access to instant information for immediate action SAP Business One keeps all business information in one place for instant access and drill down, enabling you to respond quickly to changing business needs.

4. Application designed s pecifically for small businesses Designed from the ground up, SAP Business One is an affordable, awardingwinning product that is quick to install, easy to use, and simple to maintain.

5. Decades of proven experience With SAP Business One, SAP brings decades of proven experience in serving leading companies worldwide to small businesses like yours to help you achieve better results.

6. Ability to grow with your business As your business grows, SAP Business One can be flexibly configured to match your

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| DECEMBER 2013 | ENGINEERING REVIEW

evolving business needs today and tomorrow.

7. Wide range of industry-specific packages SAP Business One is tailored to your type of business by combining core small-business fundamentals and additional functionality specific to your industry.

8. Local support by experienced resellers SAP Business One is delivered and supported by certified local resellers that are knowledgeable about your business and responsive to your needs.

9. Backing from the people at SAP SAP Business One is backed by SAP, the world’s leading business software provider.

10. Software trusted by thousands of small businesses around the world SAP Business One is widely used and trusted by over 15,000 small businesses like yours around the world.

Like many decision makers in small businesses, you want to focus on growing your business but instead find yourself dealing with a flood of daily operational details, ad hoc requests for information, and nonstop competitive moves.

Meeting these challenges is difficult and time-consuming. When key pieces of information reside in different systems or locations, response times can lag and create customer dissatisfaction. And disjointed sales, accounting, and operational processes inevitably result in bottlenecks and reduced

productivity. Multiple systems also mean additional work – such as duplicate data entries – which in turn causes errors and delays.

Meanwhile, your competition is making it hard for you to find and keep customers.

To maintain a competitive edge, you need a clear view of all aspects of your business. You must streamline processes and find better ways to access the information that will result in the best business decisions. If you can effectively track and then access all customerrelated information, for example, you can service your customers more personally and intelligently at every point of contact – locking in their loyalty and ensuring repeat business. And if you can accurately monitor and manage revenue and expenses, you are positioned to optimize cash and liquidity, which increases your financial strength and gives you the flexibility to respond quickly when business opportunities arise.

The SAP® Business One application can help your organization see clearly, think clearly, and act clearly so that you can close the gap between strategy and execution and become a bestrun business.

For more information E-mail:info@softcoresolutions.com Powered by

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MACHINE TOOLS INDUSTRY SECTION Bright Annealing

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Blank Heating

Brazing Forging

Curing

Hardening

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Pipe End Heating

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As a multi-technology, global organization, the Inductotherm Group serves the thermal processing industry by manufacturing a diverse range of products and services, all of which feature the characteristics of high quality, leading edge technology and top-flight engineering.

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FACE TO FACE

Dowel Engineering : Cognitive tradition of excellence Q. History of the company?

The founder of the company Mr. Pravinbhai Dudakiya closely is associated with the well-known AVPTI – Rajkot. In 1971 he has decided to start his own fabrication unit namely M/s. Day-light Industries, and completed many big project like IOC, oil mill, installation of foundries, theaters etc. In 1981, he has established his new unit in manufacturing activity i.e. M/s. DOWEL ENGINEERING WORKS. The motto of the company is to supply quality hydraulic press and provide efficient after sales services. He is self made person and very hard working personality. Under his guidance the company has developed many Special Purpose Machines. His strong determination is come out in his one line sentence it. ‘ WE HAVE TO MAKE THE HYDRAULIC PRESS OF CUSTOMER’S EXPECTION’. He always strongly insists to use quality raw material. His ethics and enriched knowledge has given right path to the industry, and supply many machines in reputed industries. He has participated in many national and international level exhibitions, like IMTEX, Enterprise, Engimech, etc. in India. He had visited Germany exhibition, and the adopting latest technology. He has made hydraulic press of international quality and standard.

In the next generation Mr. Tejas Dudakiya is now looking after day-to-day business activity. He is a Mechanical Engineer. He is very young and dynamic personality. He had proved his self during his engineering education; his project has received very prestigious, in all India Inter College Project Competition, at Chennai. In 2007, he has established his new plant “DOWEL MACHINERY PVT. LTD.” which located at Veraval (Shapar) (15 km. from Rajkot). Now he is totally concentrating on production activity and sales market. He

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has regularly visited International exhibition like EMO, Euroblech, TIMTOS, SIMTOS etc. He is strongly insisting to achieve international standard in manufacturing hydraulic press. So far concern to our mission I always like to state few lines of poet Robert Froest “The woods are lovely dark & deep, but I have promise to keep, and miles to go before I sleep and miles to go before I sleep.”

He had proved his self in business line & social work. At Present he is a Director in M/s. Machine Tools Manufacturers Association – Rajkot since last 7 years.

‘DMPL’ established with the motto of manufacturer and supply, next generation hydraulic presses and steel fabricated machinery. The company is equipped with most modern manufacturing facilities, highly qualified team of engineers, having latest mother machinery.

‘DMPL’ having extensive marketing network supported by effective after sales service, which has kept us close to be ideals in tune with its markets & customers.

The promoter of the company belongs to the ‘DOWEL’ group, who is leading and in this industry since last 30 years and having more than 3200 end users, which include many national and international reputed companies. Our production range is too wide, as well as also expert to make “Application Selling Presses”.

On basis of requirement and demand of current stream, customers ask special purpose machinery, which give them high productivity as well as accurate quality. We have decided to manufacture heavy duty and high capacity machinery having latest modern technology. On platform of wide experience in the industry, The ‘DMPL’ established in 2007 & become a one of the rapid growing company.

The company had supplied many special designed as well as S.P.M. as

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FACE TO FACE

per customer specific requirement.

It’s our great pleasure to see many reputed company’s name in our esteem users list. ‘DMPL’ prefers “Make On Order” basis or principal.

Whatever the customer requires or company requires they will surely manufacturing those presses and if possible they may try to develop more and more presses and not restrict themselves to like their competitors.

Q. Overview of the plant (Production capacity, size, product, market area)?

‘DMPL’ is equipped with most modern manufacturing facilities having all mother machinery like, Lathes, Drills, Shaping, Hydraulic Press, honing, grinding, CNC lathe, all precision measuring instruments, CNC Profile Cutting Machine & hand tools. ‘DMPL’ has highly qualified team of engineers with extensive marketing network supported by effective after sales service. We apply the most modern techniques in the designing field. The CAD/CAM is widely used and the personnel are highly qualified. The company has own developed & upgraded CAD/ CAM facilities to enhance machine’s design.

The company has one office & service center in hard of city in 380-sq./m area. The main plant of the company is located at Veraval (Shapar), which 15 km. far from Rajkot. The main Plant had 2000 sq./m land area. The company has well-furnished offices as well as CAD/ CAM designing center as well as R & D Center. The company is registering with factory act under 1948 & 1963 & labor acts.

PRODUCT RANGE ‘DMPL’ is manufacturing Hydraulic Presses from 5 ton to 500 tonnes & range are as under: ● Hand & Power operated Hydraulic Press ● Hand Cum Power Operated Hydraulic Press

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● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●

‘C’ frame Hydraulic Press Fix & Close frame Hydraulic Press Submersible Hydraulic Press Double or More Cylinder Hydraulic Press Mobile Cylinder Hydraulic Press Mobile Body & Cylinder Hydraulic Press Horizontal Hydraulic Press Paper / Plastic / Agriculture etc.

Waste Scrape Baling Press Metal Scrape Baling Press Bag Baling Press 2-Pillar or 4-Pillar Hydraulic Press Hydraulic Deep Drawing Press with Die Cushion & Blank Holder type Coin Press Cutting / Bending / Punching Press PLC / NC / CNC operated Hydraulic Press Iron Worker Other SPMs & Application Selling Press

Market Area “DMPL” has very huge market in India as well as abroad. We mostly export Presses to African Countries, Gulf Countries, Nepal, Sri Lanka, Bangladesh, Bahrain etc. We have regular supply in all Corporate Companies, Govt. Sector, Defence, Large, Medium & Small scale ind. also.

Q. Post-recession what have been the major changes in your product portfolio to meet the changing needs of the market?

Actually since last 3 years we are focus on Application Selling Press which help us most to avoid recession.

However, we do some necessary changes in our marketing network & improve it & also improve our export market.

Q. Tell us something about your products as it has well-accepted in almost all engineering sectors.

The presses are engaged with the works of auto service station, workContinue on page no.66

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PORT FOLIO

Walpha Engineering : The honor for technology excellence

W

ALPHA ENGINEERING, established in 1975, is the brainchild of Mr. Amardeep Patheja, a well experienced technocrat and a qualified mechanical engineer. The Company was established with an aim to develop and manufacture Electromagnetic & Mechanical Clutches and Clutch Plates for Machine Tool application.

A small seed planted in 1975 for developing and manufacturing of Electromagnetic & Mechanical Clutches and Brakes for the first time in India, has grown into a well established and highly successful industry. Backed by a highly qualified and efficient team of technocrats, Walpha is the first Indian Company to have successfully developed about 600 different types of Clutches, over 3000 types of Clutch Plates and 50 types of Current Supply Brushes. Walpha Engineering is well known for successfully import substituting multi-disc electromagnetic clutches and brakes.

The company manufactures clutches equivalent to those manufactured by Siemens Germany (EK1 to EK60 Series), Moninghoff, Ortlinghaus, Binder Magnet, Heid, Stromag, Warner and various other makes. Walpha is also a leading manufacturer of Single Disc (Dry) Clutches & Brakes, Failsafe Brakes, Mechanical Clutches, Clutch Brake Combinations, Clutch Plates, Telescopic

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Brushes & Friction Material since over 35 years.

Today with it’s expertise and experience spanning over 3 decades, Walpha is in a position to develop and manufacture any type of clutch/ brake and clutch plates used by the machine tool industry. The very fact that Walpha is the original equipment supplier for several machine tool manufacturers like Hindustan Machine Tools (HMT) speaks volumes of its quality assurance and reliability. Other than this Walpha supplies Clutches to almost all the industries - Manufacturing, Packaging, Textile, Mining, Pharmaceutical, Automobile, PowerTransmission etc. The

Company is also supplying its products to Defence and Railways and has a strong presence in theInternational Markets.

Walpha’s efforts towards import substitution and innovation were well recognized by the Government of India and the Company was awarded the National Award for Import Substitution on 26th January, 1979. The promoter, Mr. Amardeep Patheja who is the Company’s guiding force, has been honoured with several awards and recognitions for his personal contribution to the Indian Machine Tools Industry, for excellence in Import

Substitution, for his entrepreneurship and marketing skills, the quality of his products and his contribution to the society.

“Walpha” recognized as a trusted and recommended brand name is in a position to develop and manufacture any type of Industrial clutches to the entire satisfaction of our customer. Even a small batch quantity is accepted by the company.

The company is well equipped to export the Industrial Clutches, Brakes, Clutch Plates and also have an open mind to join hands with like minded competent companies to expand their existing business. The main motto of the Company after all is, “Customer Satisfaction & only Customer Satisfaction”.

For more information: Walpha Engineering R-235, M.I.D.C., T.T.C. Area Pipeline Road, Rabale, P.O. Ghansoli, Navi Mumbai 400 701. India Tel.: 022-6457 2442/3/4/5 Fax.: 022-2769 2761 Cell. 97691 09989 Email: sales@walphaengineering. com / mktg@walphaengineering.com Web: www.walphaengineering.com

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PORT FOLIO

Orbital Systems in its new avatar : A global solutions provider for precision assembly automation

W Mr. Paramjit Singh Seehra, CEO & MD, Orbital Systems (Bombay) Pvt. Ltd

hy does one start a new SSI unit? Because there’s a fire in him to do something unique and wants to tread a path which others haven’t taken. He has a dream to make his idea work and build an enterprise around it. This is precisely what happened to young Paramjit Singh Seehra way back in 1985 when he left a cushy job in Larsen & Toubro in the Switchgear Process Development Division.

Having done B.Tech in Mechanical Engineering from IIT BHU, he realized his limitation in service, the foremost being that one is not able to take calculated risks. This is what prompted Mr. Seehra to teamup with a couple of like -minded engineers and plunge into business.

Humble beginnings

This was the beginning of Orbital Systems (Bombay) Pvt. Ltd, whose CEO and Managing Director Mr. Seehra happens to be today. His first product was a Riveting Machine which even today is a major breadwinner for the company. Then came the cam indexing tables, screw running systems, clinching machines, safety light curtains and a pallet line for linear automation.

The common thread binding all these products is assembly automation.

As a matter of fact, today the niche of Orbital Systems is precision assembly automation comprising feeding and handling systems. What was started as an import substitute for saving precious foreign exchange for the Indian industry has now turned out to be a foreign exchange earner for the country. That’s where Mr.Seehra scores over.

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The growth phase Even three years ago his turnover was lurking around Rs.10 crores.This has now jumped to Rs.35 crores. And his target is to achieve Rs.50 crores by 2015. A major chunk of this would come from exports – that too to Europe and China! Networking is the key to success. China is a big market for assembly automation products. But then they are averse to buying products from India. They prefer to source such systems from Europe. Mr. Seehra was instrumental in forming a consortium comprising five international players – three from Europe (Sacel, Lazzero Technologies and Thor Europe ) one from China(Hangzhou Warm Automation Equipment Co. Ltd) and of course Orbital from India. The consortium called ACT(stands for Assembly, Calibration & Testing )is today a total solutions provider for factory automation offering competencies in assembly, palletizers, robotics,leak testing and camera systems addressed to manufacturing sector. ACT takes the benefit of sharing its members’ longterm based knowhow and portfolio to maximize the offer to the market, achieving design and manufacturing synergies and using most efficient locations to optimize end-user costs.

Orbital is the design and manufacturing hub for assembly automation modules which go to Europe and from there to all over the world including China!

Bridging the gap

“Our engineering and manufacturing costs are substantially low as compared to the costs in Europe. If at all there is a gap, it is in technology. Our partners Continue on page no.60

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PORT FOLIO

Continued from page no.58 in Europe bridge that gap . We do the design and manufacturing .The marketing and service are taken care by them.” states Mr. Seehra.

Orbital set-up

Orbital has two manufacturing facilities, one in Mumbai and the other in Nashik. It has acquired another facility ,16 kilometers from Thane for setting up yet another production unit as per its expansion plan. This new unit has a locational advantage due to its proximity to Mumbai. It will be operational very soon.

Orbital already has regional offices in strategic locations viz.Pune, Bangalore and New Delhi. It has representatives in Hyderabad, Chennai, Coimbatore and Ahmedabad to provide service support to its customers.

The company is currently busy executing a prestigious order from an automotive supplier in Europe ( end user Fiat) developing and supplying an automation system with a palletizing line for a typical valve assembly for electronic suspension system fitted on shock absorbers of a four-wheeler . This precision assembly has very fine washers with some having a thickness of as low as 0.15 mm. These washers are stacked, dispensed automatically, measured for thickness (tolerance limit is 20 microns) pick and placed and crimped into an assembly. The assembly comprising of 20 parts is completed in a cycle time of 5 seconds!

Annual requirement is 1.2 million assemblies. Orbital is working hard to complete the order and ship it within the stipulated time frame of 16 weeks. “Today we make products of international quality and give at a price which no one can match” . Another milestone is that Orbital is in talks with Asmo Japan, a subsidiary of Denso to build machines to their design for assembly of micro motors. Asmo has 23 plants worldwide making micro

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Orbital’s Palletizing Line for valve assembly for electronic suspension system motors for cars. Auto components manufacturers are looking at India as a potential manufacturing hub. “Our international linkages are going to place us in an advantageous position when the market opens up and looks out for niche players like us,” reveals Mr. Seehra.

Orbital systems riveting machines are already in use in advanced countries like Germany, US Japan and Brazil ,a classic example of business acumen and making synergy to work.

Leveraging synergy

Orbital has a strong, dynamic engineering team – each one trained and honed for nothing less than 10-15 years to fit into our mould, states Mr. Seehra. This is a major strength of the company. It already has the technology back-up enabled by the ACT. It is also financially sound. “Every machine we sell is our ambassador. It does the talking for us, underlining our quality and capability That is the reason why almost 60 per cent of our standard product orders on hand are repeat orders.’ One who is very particular about business ethics, Mr. Seehra says,

“We are pitted against the giants in the global industrial arena. If we are able to compete with them and keep our neck out, it is simply because of our quality and reliability espoused by the system we have developed and the standards we have maintained, and the company we are keeping.”

“If one has to be successful in business, one must dream big and work relentlessly towards achieving that goal .One should have a strategic planning (both long-term and short term) and remain focused“. Mr. Seehra opines that small units have inherent strengths and capabilities. Their weaker link is the marketing savvy and resources. One can overcome this by forming a small group with activities not competing, but complementing to each other.

This group can offer products and solutions to the international market.

This way there is a synergy which is indomitable and we can compete with any multi-national. It will be a winwin situation for every member and a small step to help our country take giant leaps in the international trade P.K.Balasubramanian E-mail: editor@engrreview.com

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PORT FOLIO

Solitaire Machine Tools Ltd. : Performance driven grinding solutions

Mr. Ashok J. Sheth - Chairman Solitaire Machine Tools Limited.

S

olitaire Machine Tools Limited, a leading manufacturer of Precision Centerless Grinders, was incorporated in the year 1987 and was publicly listed on the Bombay Stock Exchange (BSE) in the year 1993.

SMTL operates from its registered office in Mumbai. It has two manufacturing units in Vadodara, Gujarat (India). Over the years, Solitaire has developed a niche market for itself for catering to the demand of Centerless Grinders. SMT produced its first Centerless Grinder in 1988. In the years since, the plant has produced over 700 Centerless grinders. Managerial expertise and industry experience have helped the company to show profits every year since its inception.

Solitaire focuses on designing and manufacturing Centerless grinding machines of superior quality, high accuracy and top performance. The company is recognized for timely delivery, installation services, training and after-sales technical support.

Mission

Solitaire Machine Tools Ltd. is aimed at providing highly productive, user friendly and cost effective solution to Centerless grinding and offer world class innovation and service.

Manufacturing Facilities

SMTL has two manufacturing facilities in Vadodara, which are fully equipped with a wide range of manufacturing machines required for the production of machine tools. Some of the major ones include, Waldrich Coburg CNC Slideway Grinding Machine, Cincinnati 8 Axis CNC Horizontal Machining Center, Cincinnati and Dorries www.engrreview.com

Scharmann 4 Axes CNC Horizontal Machining Centers, BFW, Beaver & Batliboi CNC Vertical Machining Centers, Schaudt Cylindrical Grinder and a number of Horizontal Boring Mills. The plants are divided into several key areas: The Heavy machining area, Precision Grinding area, Scrapping and Assembly, Paint Room, Quality Control, Stores, Administrative Offices, and Engineering.

Products & Services Range of Grinders

Solitaire Machine Tools Ltd. has been working as an exclusive Licensee of CINCINNATI MILACRON, USA to manufacture Precision Centerless Grinders in two primary sizes with wheel widths of 200 mm (8″) and 250 mm (10″). These grinders are equivalent of Cincinnati #2 OM and OM-V Centerless grinders. SMT also manufactures small Centerless Grinders with 100 mm (4″) wheel width and large Centerless Grinders with 500 mm (20″) wheel width.

The grinders are offered standard with conventional hydraulic and pneumatic controls. More advanced CNC versions utilizing Siemens Controls and supporting from 1 to 6 axes of control are also being offered. Optionally, SMT also designs customized loading / unloading systems for complete automation of the grinding process.

SMT has entered in Licensing arrangement with BOCCA & MALANDRONE SUNEBO S.p.A of ITALY in 2007. The Bocca line of grinders is offered to Indian customers directly

by SMTL and worldwide through Bocca, Italy. SMT has developed Bocca line of CNC Centerless Grinders with ENGINEERING REVIEW | DECEMBER 2013 |

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Currently, the demand world over is being met by manufacturers in USA, Switzerland, Germany and Japan. SMT has in-house developed full 6 to 7 axis CNC Centerless Grinder. The prototype is now under development and would be launched in coming months. The grinder would be fully automated and equipped with latest technology available around the world.

2. Double Disk Grinder

Production Line wheel width from 200 mm to 500 mm.

These grinders are custom designed to produce high precision component in high volume. They are generally equipped with automation, gauging and various customized solutions

Rebuilding Services

SMTL offers Rebuilding and CNC Retrofitting services to customers for any model of Cincinnati Centerless Grinders as well as various other makes and models of European centerless grinders and sub-assemblies of grinders. The rebuilding/retrofitting of centerless grinders is equivalent of giving another lease of productive life despite its age.

New Developments

1. Micro Centerless Grinder With miniaturization of components in Electronic, Medical, Aerospace and Automotive field, SMT has seen the need to develop a Micro Centerless Grinder to grind components in diameter range of 0.1 mm to 10 mm.

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SMT has ventured in to development and manufacture of Double Disk Grinder with Technical Know-how from Laboratorio Eccellenza Italiana from Italy. The Horizontal Spindle grinder is available for Through Feed, Rotary Feed and Slide Feed grinding.

With large diameter wheel size and full CNC functions, it is designed for high productivity with close tolerances. The components from 1 mm to 120 mm width can be ground. Grinders offered completely tooled up to meet userâ&#x20AC;&#x2122;s requirement.

Customers

Solitaire caters requirements of wide array of customers from large Auto Ancillary MNCs to small Precision Job Shops. The major customers include Varroc Group, Rane Group, Sona Koyo Group, M & M, Automotive Axle, Tenneco, Eaton, Emerson and many others.

Export Performance and Future Thrust

SMT has always put thrust on exports and meeting competitors from developed countries head on to export machines to USA, Italy, Turkey, Australia, UK etc. The future thrust would be to expand business in South America and Europe.

For more information E-mail: editor@engrreview.com

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PORT FOLIO

ISGEC’s 200T Mechanical Press - An engineering marvel supplemented by a stiff guiding system to take care of duty conditions. High rigidity and precision results in quality stamped parts, lower component rejection and improved Die life.

These types of presses provide a cost-effective stamping solution to electronics, telecommunication, lamination and automotive industry.

Compliance with European directives and EN692 enabling CE marking helps users in adopting the equipment in their existing stringent safety environment.

The composition of the Press with the Coil Line is as follows:

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ersistent efforts by ISGEC Heavy Engineering Ltd. are resulting in winning the trust of quality and safety conscious European stampers. . ”We now have references in Germany, France, Spain, Czech Republic, Hungary and Romania for a variety of presses,” says Mr. Vivek Nigam, Senior Vice President, ISGEC, speaking about the company’s thrust in exports.

Recently, ISGEC developed and successfully commissioned 200T High Speed Mechanical Presses for a prestigious customer for their plants in Mexico and China. Highly delighted with the performance of the supplied presses, the company has received repeat orders for three(3) more 200T High Speed Presses.

Each 200T Mechanical Press is equipped with a Coil Line feeding aluminium strip, 2 mm thick and 300 mm wide. The Press is capable of running at 200 spm with a stroke length of 80 mm. The Press is equipped with a dynamic balancing system,

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● 200T Mechanical Press has a bed size of 1800 mm x 1200 mm; stroke length of 80 mm and speed of 45200 spm. ● Coil Line with coil weight of 1500 kgs comprises dual mandrel Decoiler; Compact Straightener-cum-Feeder; Lubrication unit, Finished part belt conveyor and Scrap conveyor.

All in all the Press is an engineering marvel. This Line is a testimony to ISGEC’s capability to cater to the requirements of such sophisticated Presses in the European market.indeed carrying the ‘Made in India’ label.

For more information Mr. Vivek Nigam Sr. Vice President ISGEC Heavy Engineering Ltd Yamunanagar -135 001, Haryana, India Phone: 0091-1732-307321 Email: nigam@isgec.com

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FACE TO FACE

Continued from page no.55 shop, pressing of ball bearing, remove & mounting of bushes & bearings, straightening, pressing, baling, drawing, embossing, broaching, bending, breaking, joining of steel, in plastic, rubber & plywood industries, in electric motors, submersible pump etc. industries, gold / silver coin monogram embossing, mosaic tiles, bakelite parts, textile part industries, bellows, cable trays, in fiber glass reinforced plastic industries, food industries, shipping industries etc.

availability of spares across the globe, timely delivery, user friendly, best product quality as well as performance & also operator’s safety features are help us to foothold in Indian as well as abroad market.

Q. What are the quality approach adopted by your company to enhance efficiency?

“DMPL” is ISO 9000:2008 certified company & at present implement Japanese 5 S cultural as it on final stage.

Q. Brief us something about the R&D effort of the company.

‘DMPL’ is equipped with most modern R & D Department. ‘DMPL’ has highly qualified team for R & D with extensive experience & knowledge. We apply the most modern techniques in the R & D. The CAD/CAM is widely used in R & D. The company has own developed & upgraded R & D center.

Q. How do you manage the logistics on domestics and international basics?

We are mainly using road transport for domestic market & sometimes using railway. For International market we are using road + See logistic as well as sometimes air logistic.

Q. What are the best practices adopted by you on the shop floor?

Q. What initiatives have been taken by you to be environmentefficient?

Over more than 32 years experience in the Hydraulic Filed, we have very huge experience. We do machining in CNC & VMC. Since last 2 years, we follow Taiwan’s Outsourcing Vendor culture for better accuracy in very short time.

Q. What are your strategies to gain foothold in Indian market and where does the Veraval (Shapar) plant feature in this?

Our best after sales service, easy

much due to our main focus on “Application Selling Press”. However our plus points are after sales service, easy availability of spares, timely delivery, user friendly, best product quality as well as performance & also operator’s safety features & wide experience & well known brand name.

Q. Kindly highlight 3 key manufacturing practices that have been critical for the success of the company in India.?

1) Horizontal Press specially design for Submersible industries to weld their pump in pressing condition with rotating as well as welding attachment.

2) Automatic Triple Compression Metal Scrape Baling Press.

3) High Speed Presses for Brass Industries.

We are so much caring about environment. We have not much pollution. The company is registering with factory act under 1948 & 1963 & follow all points to care environment.

Q. What are your expansion plans?

We are going to our new plant on same place where at present we located in 1600 sq. / meter. We are going to develop fully automatic Transmission Line Machineries, as well as High Speed Hydraulic Press and Robotic Deep Drawing Press as well as automatic Iron Worker & other sheet metal machineries.

Q. How do you stay ahead of the competition?

Actually, we not face competition so

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MACHINE TOOLS

HAAS: HE230-CS

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n one side of a narrow, dusty road in an anonymous industrial zone near Brescia, Lombardy, at the foot of the Alps, is a hangarsized building housing 16-Haas CNC machine tools. On the other side of the road, adjoined to another, smaller factory building, is a family home which acts as the mother-ship for four brothers, their wives, children and two dogs, and the retired grandparents who started Il Gruppo Gilberti S.p.A, more than 30-years ago.

Brescia is well known for its connections to motor sport; the famous Mille Miglia (1000 mile) road-race is held annually, starting from the centre of the historic city. Nearby, world-renowned engineering company Brembo S.p.A designs and makes braking systems for the world’s most powerful cars and motor cycles.

For enthusiasts of two and four wheeled fun whose budgets won’t quite allow them to race 1000 miles in a classic sports car, or invest in the latest, Bremboshod Ferrari, there’s a locally made

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alternative that promises just as much entertainment, but on a Lilliputian scale.

“OK, so this is our minimoto,” says Marco, 39, youngest of the four Gilberti brothers. “We build the whole thing entirely ourselves using our Haas CNC machine tools, except the motor, which we buy.

“The initial project to design and create a mini-moto was born 3-years ago. We started with just a line of spare parts – such as hubs, rims, etc. Now we have an online store where we sell them to customers all over the world.”

As well as parts for the automotive sector and general industry, the Gilberti business makes and supplies components for the GoKart racing community.

“Business took a sharp downturn in 2009,” remembers Marco. “Go-Kart racing was particularly hard hit. A little while later, we began developing the GR1RR mini-moto, which is currently our show bike. We make almost everything on it using our Haas SL-20 lathes and two Haas VF-2 machines. We don’t make parts in large quantities, but we do make a very wide variety. We use the Haas lathes to make the front forks, for example. We use the mills to make the brake calipers, from solid billets, the pistons, screws, all the frame supports, and the steering yoke.”

There is no shortage of similar mini bikes and quads available to buy both online and also off.

Needless to say, many of them come from countries where price Continue on page no.70

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Continued from page no.68 is the most important component, and longevity and safety come low down on the list of priorities.

“We have some examples of Chinese-made mini-motos,” says Marco. “To make something with a much better quality but that is still affordable, we needed to find CNC machine tools which were reliable, accurate and not too expensive.

We chose Haas machines because they have all of these characteristics. We bought the first one around 10-years ago and we liked it straight away. It was easy to

programme, robust and fast. So, as we built our business, we decided to stay with Haas. In fact, we don’t have any other make of machine and we’re pretty happy with that arrangement.

“We have a very good relationship with the sales company – they are attentive, including on the phone, and if we have a problem or a question, they are here immediately. The truth is, we’ve never had any significant problems!”

On the track, with the right rider on-aboard, a 49cc mini-moto like the GR1RR, weighing just 25kg, will easily reach 120km/h. It may not be very far to fall if something goes wrong, but at those sorts of speeds, the tarmac is plenty hard enough. “There are many cheap alternatives around, but there’s a good market for well-designed and well-made mini-motos like ours,” says Marco. “People can see immediately that the parts are beautifully engineered and finished. As well as the sheer fun of riding a Gilberti mini-moto, anyone with a love of fine machining will get a lot of pleasure from just owning one.”

End

For more information Web: www.HaasCNC.com

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Critical oil and gas production components rely on metrology systems

F

or companies operating in the oil and gas equipmentmanufacturing sector, recordkeeping and traceability are vital. As part of its company-wide quality protocol, FMC Technologies in Dunfermline, Scotland invests continually in a preventive maintenance programme that employs Renishaw machine tool probes and calibration products to check and verify the dimensional accuracy of its CNC machine tools. The resulting data are stored for quick and easy retrieval using Renishaw’s CNC Reporter software.

Craig Simpson, Maintenance Technician at FMC Technologies

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FMC Technologies is a Houston, Texas-based developer and manufacturer of oil and gas Production Control Systems (PCSs).

A PCS consists of topside (surface) controls, power equipment, the Subsea Control Module (SCM), various sensors, and subsea electrical and hydraulic distribution equipment. The whole system is configurable according to conditions and requirements, and provides engineers on-board an oil or gas production platform with precise control of the well.

FMC Technologies has operations around the world, close to the major oil and gas industry epicenters. Its UK manufacturing operation occupies several buildings on and around the Pitreavie Business Park, Dunfermline, a short drive from Edinburgh, across the Forth Road Bridge.

Craig Simpson and Mike West are FMC Technologies maintenance technicians, with respon-

sibility for the service and support of 20 CNC machine tools of various types, makes and ages. Also in their charge is one of the company’s more recent investments: a £2.5 million, purpose-designed and built, SCM machining cell, consisting of two Okuma Space Centre MA-600HB CNC horizontal boring machines, loaded and managed by a Fastems automation system.

An SCM contains electronics, instrumentation, and hydraulics for safe and efficient operation of valves and chokes on the well-top ‘subsea tree’.

“There are four, main, machined parts in an SCM,” says Craig Simpson, “one high, and one low pressure adaptor plate; the manifold block itself, and a base plate. There are also a large number of small valves and electronic circuit boards that go into the whole assembly.”

Wells can be as far as 120 km from the production platform, in water up to 10,000 feet deep.

Producing oil and gas safely and reliably under such conditions requires companies to make enormous investments. When an SCM is installed on the seabed, it has to be reliable and safe for the production life of the well, which can be decades. Hydraulically controlled valves must be free from defects and contamination.

If a critical part malfunctions, the potential cost can easily run to tens-, or even hundreds-ofmillions of dollars.

The Fastems automated cell is used to machine the stainless steel hydraulic manifold block, which

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TECH TRENDS

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Craig Simpson using the XL-80 laser calibration system to check machine accuracy. is a critical control element in an SCM assembly. The 267 kg block is approximately 400 mm x 400 mm x 400 mm and is a complex of 350drilled holes.

The company will make more than 200 manifold blocks in 2014, when the cell is fully operational and capable of working ‘lightsout’. Should a tool break during the machining cycle, a Renishaw NC4 laser-based tool setting system will detect the tool absence and notify the Fastems system, which will reject the pallet and replace it with another.

Guiding principles FMC Technologies is guided by what it calls the 5-absolutes of quality, the second of which emphasizes the importance of prevention, ‘not appraisal’ as the

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‘cause’ of quality.

“Quality control in the new cell is extremely thorough,” adds Mr. Simpson. “The finished part is 100% inspected and has to be precise and flawless before it can be shipped to assembly.”

For example, since each SCM manifold block takes up to 35-hours to machine, FMC Technologies engineers need to know that the Okuma machines in the Fastems cell are performing exactly as they should be.

Scrapping a semi-finished or finished part due to an inaccuracy in the machine geometry would be very expensive.

“Traceability is everything,” says Mr. Simpson. “We have to be seen to be keeping precise records of our machining processes.

We have to know if and when a machine is out of alignment, for any reason, so we can put it right.

Then, when the problem is fixed, we have to be 100% sure that the machine is accurate, again.”

To ensure that its 20 machines are accurate, the FMC Technologies’ maintenance department services them all, up to three times annually. All machines are checked with a Renishaw QC20-W wireless ballbar. The Okuma machines are serviced twice a year, at which point machine geometries are checked and rectified. Once a year the company also checks them with a Renishaw XL-80 laser measurement system and linearity is corrected. Every second year, at their annual service, all machines are leveled, aligned and checked with the XL-80 system.

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Data from both the Renishaw ballbar and also the Renishaw XL80 are collected and collated using Renishaw’s CNC Reporter software package.

“During the routine service we check each machine in the factory using the Renishaw ballbar,” says Mr. Simpson. “We keep those records so, should a finished or shipped part show a fault or a problem, we can prove whether the machine was accurate and aligned at the time the part was manufactured. In the event of an accuracy ‘issue’, we can also re-run the Renishaw ballbar, and compare the results with the records, to see how the dimensional accuracy of the machine has been affected.

“We use the Renishaw laser primarily to check linear dimensions,” he adds. “We have Renishaw RMP60 touch probes on most of our machines, including the Okumas, so we need to know the linear movements are exactly right.”

FMC Technologies’ service contract with Renishaw includes 11 RMP60 touch probes with radio signal transmission, which are replaced annually or in the event one is damaged.

FMC Technologies initially invested in the CNC Reporter software primarily for keeping production records. But, the company’s maintenance department has also found it invaluable and has recently invested in several, additional licenses.

“The Renishaw package is very useful for comparing data, and it’s not very expensive,” says Mike West. “So, we’ve bought another six seats, solely for maintenance operations.”

“Having CNC Reporter means in the event of an accuracy

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MACHINE TOOLS

issue, we don’t have to drag out the granite-square, parallel bars, etc.,” adds Mr. Simpson. “We don’t even have to remove the job from table.

It saves a lot of time.”

To help speed-up machine checking and calibration in the SCM cell, FMC Technologies has designed and built a custom calibration block, which it mounts on the Okuma machines during scheduled maintenance or when the machine is being checked.

“We’re currently introducing a new pallet size in the SCM cell, and some of the re-programming is being done manually, rather than off-line, using the Siemens NX CAE system. There’s increased potential for minor collisions. For example, we recently had a small knock. First, we ran the Renishaw ballbar to check the 3-axes were square. We also checked the Y-axis using a test bar and we compared the results to the data in CNC Reporter. We found that the zero position had been affected, so we re-taught the machine new zero positions using the test block.”

Craig Simpson and Mike West both agree that the Renishaw XL-80 laser measurement system, the QC20-W

FMC Technologies uses Renishaw’s QC20-W wireless ballbar to check the accuracy of its CNC machine tools.

wireless ballbar and CNC Reporter software are very easy and intuitive to use. “We had one week of training with a Renishaw engineer,” says Mr. West. “If ever we have a problem or a question, we call the head office in Gloucestershire and we usually get an answer the first time. At the very least, someone calls us back that day.”

FMC Technologies’ fifth ‘absolute of quality’ states that the goal of quality control is not customer satisfaction, but is in fact, customer success. The company claims that its Production Control Systems – including its SCMs are used on more than 1,000 subsea wells around the world, with an uptime rate of 99 – 100%!

Nevertheless, Craig Simpson says the maintenance programme in FMC Technologies in Dunfermline is evolving continually: “When I first started at the company, six years ago, our preventive maintenance was far less structured and much more time consuming. Now, we are very well organised and using the Renishaw equipment means we know much more about our machines and our processes.

We’re always looking for ways to do things better. Our performance standard is zero defects, which is the third absolute in our quality philosophy. Nothing leaves this machine shop unless it is exactly right, but we couldn’t do it without Renishaw.”

For more information Web: www.renishaw.com

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HAIMER Power mill range HAIMER Power Mill solid carbide endmills are the latest tools developed by HAIMER GmbH, the European market leader for toolhoding.

They are made from high end fine grain carbide and are equipped with the HAIMER pull out protection system, Safe-Lock™, which has become a standard for HSC and HPC machining in the last years.

T

he HAIMER developed endmill geometries are based on an unequal flute and helix design for chatter free high end machining. All tools are coated with latest PVD technology and have an extremely smooth surface for the best possible chip evacuation. The new HAIMER Power Mill range, with cutting diameters available from 2 to 20mm, will be made available with 3, 4 and 5 cutting edges having multiple lengths of cut.

To offer maximum flexibility in order to address the customers application requirements, different cutting edge solutions (sharp, chamfer and radius) will be offered. Also a roughing geometry with a cord profile will be part of the portfolio.

A typical HAIMER specialty is the high precision of the tools.

All end mills are fine balanced and have a run-out of 5 μm. All shanks are based on the h5 tolerance.

With the launch of the new Power Mill range HAIMER has expanded

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the Safe-Lock™ offering. Resulting from the wide spread and multiple customer requests for different application areas, Safe-Lock™ will be available starting from shank diameter 6mm.

Andreas HAIMER summarizes: “As the inventor of Safe-Lock™, HAIMER steps up and offers this shank solution as a standard for all HAIMER Power Mill tools starting from shank diameter 6mm and intentionally gives up on plain round and Weldon shanks.”

Due to the inherently balanced design, the Safe-Lock™ shanks can be clamped in standard shrink fit and collet chucks without any problems. In comparison, it now doesn`t make sense to clamp μm precision high performance geometries with weldon shanks and push them extremely out of center while introducing extreme unbalance. HAIMER target is to have high availability and replace the Weldon system in the next 10 years. Whereas Safe-Lock™ not only supports roughing applications, but becomes a new universal solution that continues to find more and more use during HSC applications with high helix endmills.

For more information Web: www.haimer.de

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TECH TRENDS

MACHINE TOOLS

Turn & mill complete machining with the largest Y-travel of 300 mm in its class

T

he CTX beta 2000 TC from DMG / MORI is the new addition to the successful CTX TC series. “Priced at € 349,900 the CTX beta 2000 TC offers our customers the perfect entry into the turn-mill complete machining of components with diameters up to 550 mm and turning lengths of 2m,” is how the Managing Director of GILDEMEISTER Drehmaschinen GmbH, Harry Junger, introduces the new machine.

Its core element is the B-axis with a turning-milling spindle that is mounted on a highly stabile travelling column with wide distances of up to 750 mm between the guideways. This concept is made possible by the large Y-travel of ±150 mm that is unique in this class. The large Y-travel also enables eccentric machining, for example, the milling of large plane surfaces and gear milling with a hobbing process. Maximum stability and accuracy is achieved through the combination with the direct measuring systems in all axes of the travelling column.

The B-axis is equipped with a DirectDrive, which enables highly dynamic machining with a swivel range of ±120 ° with rapid traverses of 100 rpm. For sophisticated milling operations up to 5-axis simultaneous machining, the B-axis has a HSK-A63 (optional Capto C6) turning-milling spindle with 12,000 rpm and 100 Nm. Optionally an 18,000 rpm spindle with

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23 kW and 105 Nm is available.

Harry Junger, Managing Director of GILDEMEISTER Drehmaschinen states the following with regard to different expansion options: “Our high-tech modular concept provides customers with the option to customise the machine individually to their range of parts. This includes amongst others different tool magazines with a capacity of up to 100 pockets. Furthermore, the optionally available counter spindle enables 6-sided complete machining even for complex workpieces.”

The tool magazine of the CTX beta 2000 TC provides a capacity of 24 pockets as standard. Two optional chain magazines with 48 or 100 pockets provide more flexibility. A special magazine with 3 pockets for oversized tools up to Ø80 × 700 mm is also available.

Complete machining with main and counter spindle up to 770 Nm The standard version of the machine includes a main spindle with integrated spindle motor (ISM76) with 380 Nm and 34 kW, as well as NC-controlled tailstock.

For 6-sided complete machining, the machine can be equipped with a counter spindle instead of the tailstock. Here, either the ISM76 is available, or an ISM102 with 770 Nm and 38 Nm, which can also be used on the main spindle if required. To ensure the highest

degree of temperature stability, the main as well as the counter spindle is liquid-cooled.

Large work area – optimum accessibility – for processing workpieces up to 2 m in length The large work area of the new CTX beta 2000 TC enables a turning length of no less than 2,050 mm, which is 750 mm larger compared to the CTX beta 1250 TC. Furthermore, workpieces with 550 mm turning diameter can also be machined, 50 mm more than for its smaller sister.

In combination with the above mentioned powerful and high-torque spindle motor ISM102, chucks up to 400 mm diameter can be used on the machine. For machining long workpieces, usage of steady rests is recommended, which are available up to a workpiece diameter of 350 mm.

The steady-rest slide is NCcontrolled and can be extended with an optional quick change system with double cone tension, which achieves 50 % shorter set-up times at 3 µm repeat accuracy.

While the CTX beta 2000 TC already impresses with its large working area, its advantages with regard to ergonomics, accessibility and space requirement are also remarkable. With only 530 mm distance from the machine front to the spindle centre, the machine ENGINEERING REVIEW | DECEMBERR 2013 |

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is ideal for ergonomic loading and only requires a footprint of no more than 17.7 m².

All in one – 6-sided complete machining with turn & mill The possible applications of the new CTX beta 2000 TC are manifold, but all have one feature in common – real 6-sided complete machining.

The combination of main and counter spindle enables machining of all six sides. Combined with the B-axis, borings, milling operations or free-form surfaces can be machined from any angle.

Exemplary areas of application are machine parts like for example sprocket wheels or turret discs. Also, fluid and hydraulic components, for example pump or valve housings or fitting parts. Harry Junger explains: “We keep being intrigued about the components our customers produce with the turn & mill machines of the CTX TC series. Many workpieces do not show much evidence about having been machined on a lathe. Most of all when 5-axis simultaneous machining of free-form surfaces comes into play.”

Energy efficiency measures as standard To take account of the growing energy prices, the new CTX beta 2000 TC is equipped with a number of energy-saving features.

The machine has the proven features like low-friction bearings, regenerative AC drives or pressure accumulators in the hydraulic system. Furthermore, switch-off of the sealing air when the work area door is open and a frequency-controlled hydraulic pump ensure 9 % less energy consumption. The cooling aggregate with active cooling control even reduces energy consumption by 15 %.

Operate 4.5 and exclusive technology cycles for up to 60 % time savings.

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The CTX beta 2000 TC is equipped with Operate 4.5 on SIEMENS 840D solutionline. Operate 4.5 is the new system platform by DMG MORI SEIKI for all machines with SIEMENS control – from entry to high-end class. Operate 4.5 comprises the entire automation technology of a machine tool, from the drives to the CNC control. Furthermore, Operate 4.5 provides users with a standard user interface for all technologies. This holds clear advantages, particularly for turn & mill complete machining. All in all, Operate 4.5 impresses as integrated power package for maximum machining productivity.

Combined with ShopTurn 3 G (standard) for workshop-oriented programming, the programming takes place most easily directly on the machine. Complete flexibility between DIN and workshop-oriented programming is guaranteed by the DIN / ISO interface. A combination of ShopTurn cycles with DIN functions is also possible.

Possible applications of the CTX beta 2000 TC are rounded off by eleven exclusive technology cycles which are optionally available. By using them the technology cycle saves up to 60 % through simplest programming. Based on a simple and dialog-supported input of the required parameters, the machining functions for example for off-centre turning and milling machining or special threads are generated, without CAD/CAM system. In addition, a tool sorting cycle is available. It minimises idle times by sorting tools in the chain magazine according to their program fetch. “The success of our turn-mill machines is amongst others the result of simple and fast programming. In addition to the standard options of the ShopTurn 3 G control, our exclusive technology cycles realise an additional

time advantage of 60 percent. This increasingly makes the CTX TC series a profitable alternative for a growing number of users compared to sequential machining on different machines,” Harry Junger believes.

Highlights of the CTX beta 2000 TC ● Turn-mill centre for turning lengths up to 2,050 mm ● 6-sided complete machining by the main and counter spindle* up to 5,000 rpm or 770 Nm ● At 300 mm the largest Y-travel in its class ● Only 17.7 m² footprint ● Steady rests* up to 350 mm in diameter, chucks* up to 400 mm ● High level of energy efficiency and precision ● Powerful turning-milling spindle up to 18,000 rpm with NCcontrolled DirectDrive B-axis ● Direct travel measuring systems in the X, Y and Z-axis ● 24-tool disk magazine, 48 or 100-tool chain magazine* plus an additional magazine for three oversized tools* ● Spacious, transparent and easily accessible work area (530 mm infeed) ● Size 55 roller guides and 50-mm ball-thread drives ● Operate 4.5 on SIEMENS 840D solutionline ● Exclusive technology cycles for up to 60 % time savings ● * optional 1. CTX beta 2000 TC -Turn & mill complete machining with the largest Y-travel of 300 mm in its class 2. Large working area for the usage of chucks up to ø 400 mm and steady rests* up to ø 350 mm.

3. Powerful turning-milling spindle up to 18,000 rpm and 105 Nm torque.

For more information Web: www.dmgmori.com

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TECH TRENDS

MACHINE TOOLS

Root Cause Analysis(RCA) of Machine Failures

By Hemant M. Gore

R

oot cause analysis(RCA) is a class of problem solving methods aimed at identifying the root causes of problems or event s. The practice of RCA is predicated on the belief that problems are best solved by attempting to corrector eliminate root causes, as opposed to merely addressing the immediately obvious symptoms. By directing corrective measures at root causes, it is hoped that the likelihood of problem recurrence will be minimized. However it is recognized that complete prevention of recurrence by a single intervention is not always possible. Thus RCA is oft en considered to be an iterative process, and is frequently viewed as a tool of continuous improvement.

RCA is initially a reactive method of problem detection and solving. This means an analysis is done after an event has occurred.

By gaining expertise in RCA, it becomes a proactive method. This means RCA is able to forecast the possibility of an event even before it could occur.

Root cause is not a single sharply defined methodology.

There are many different tools, processes and philosophies of RCA in existence. However, the most of these can be classed into five very broadly defined “schools” that are named here by their basic fields of origin: safety-based, productionbased, process-based, failurebased, and systems-based. ● Safety-based RCA descends from the fields of accident analysis and occupational safety and health.

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● Production –based RCA has its origins in the field of quality control for industrial manufacturing. ● Process-based RCA is basically a follow-on to production-based RCA, but with a scope that has been expanded to include business processes. ● Failure-based RCA is rooted in the practice of failure analysis as employed in engineering and maintenance. ● Systems-based RCA has emerged as an amalgamation of the preceding schools, along with ideas taken from fields such as change management, risk management, and systems analysis.

Despite the seeming disparity in purpose and definition among the various schools of root cause analysis, there are some general principles that could be considered as universal. Similarly, it is possible to define a general process for performing RCA.

Contents: (a) General principles of root cause analysis (b) General process for performing and documenting an RCA-based corrective action (c) Root cause analysis techniques (d)Basic elements of root cause

General principles of root cause

analysis ● Aiming performance improvement measures at root causes is more effective than merely treating the symptoms of a problem. ● To be effective, RCA must be performed systematically with conclusions and causes backed up by documented evidence. ● There is usually more than one potential root cause for any given problem. ● To be effective, the analysis must establish all known causal relationships between the root cause(s) and the defined problem. ● Root cause analysis transforms an old culture that reacts to problems to a new culture that solves problems before they escalate, creating a variability reduction and risk avoidance mindset.

General process for performing and documenting an RCA-based Corrective Action Notice that RCA (in steps 3, 4 and 5) forms the most critical part of successful corrective action at the root of the problem. That is to say, it is effective solutions we seek, not root causes. Root causes are secondary to the goal of prevention, and are only revealed after we decide which solutions to implement. ● Define the problem ● Gather data/evidence ● Ask why and identify the causal relationships associated with

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the defined problem ● Identify which causes if removed, or changed can prevent recurrence ● Identify effective solutions that prevent recurrence, are within your control, meet your goals and objectives, and do not cause other problems. ● Implement the recommendations ● Observe the recommended solutions to ensure effectiveness ● Variability Reduction methodology for problem solving and problem avoidance.

MACHINE TOOLS

system is complex, there is no obvious link between the observed undesirable things, and a deep understanding of the root cause(s) is desired.

IT Failure mode and effects analysis also known as FMEA. ● Fault-free analysis ● Five Whys

Root cause analysis techniques Barrier analysis – a technique often used particularly in process industries. It is based on tracing energy flows, to identify how and why the barriers did not prevent the energy flows from causing harm.

Ishikawa diagram, also known as the fishbone diagram or cause and effect diagram. The Ishikawa diagram is the preferred method for project managers for conducting RCA, mainly due to its simplicity, and the complexity of the rest of the methods.

Kepner-Tregoe Problem Analysis – a root cause analysis process developed in 1958, which provides a fact-based approach to systematically rule out possible causes and identify the true cause.

Bayesian inference Causal factor tree analysis – an investigation technique often used for problems or accidents. It is based on comparing a situation that does not exhibit the problem to one that does, in order to identify the changes or differences that might explain why the problem occurred.

Current Reality Tree – A method developed by Eliahu M. Goldratt in his Theory of Constraints that guides an investigator to identify and relate All root causes using a causeeffect tree whose elements are bound by rules of logic (Categories of Legitimate Reservation). The CRT begins with a brief list of the undesirable things we see around us, and then guides us towards one or more root causes. This method is particularly powerful when the

Pareto analysis RPR Problem Diagnosis – An ITILaligned method for diagnosing problems.

Common cause analysis (CCA) and common modes analysis (CMA) are are evolving engineering techniques form complex technical systems to determine if common root causes in hardware, software or highly integrated systems interaction may contribute to human error or improper operation of a system. Systems are analysed for root causes And causal factors to determine probability of failure modes, fault modes, or common mode software faults due to escaped requirements. Also ensuring complete te4sting and verification are methods used for ensuring complex systems asre designed with no common causes rthat cause severe

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hazards. Common cause analyses are sometimes required as part of the safety engineering tasks for theme parks, commercial/military aircraft, spacecraft, complex control systems, large electrical utility grids, nuclear power plants, automated industrial controls, medical devices, or other safety-critical systems with complex functions.

Basic elements of root cause Materials ● Defective raw material ● Wrong type for job ● Lack of raw material Machine/Equipment ● Incorrect tool selection ● Poor maintenance or design ● Poor equipment or tool

Environment Orderly work place Job design or layout of work Surfaces poorly maintained Physical demands of the task Forces of nature Management ● No or poor management involvement ● Inattention to task ● Task hazards not guided properly ● Other horseplay, inattention…) ● Stress demands ● Lack of process Methods ● No or poor procedures ● Practices are not the same as written procedures ● Poor communication.

Management System ● Training or education lacking ● Poor employee involvement ● Poor recognition of hazard ● Previously identified hazards were not eliminated. ● ● ● ● ●

For more information E-mail: editor@engrreview.com

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TECH TRENDS

MACHINE TOOLS

Two chip breakers, one circlip expansion for TaeguTec’s QuadRush

T

aeguTec is introducing two new chip breakers and expanding its “J” chip breaker to include the handling of circlip grooving applications for its very popular QuadRush product line.

Due to its unique four cutting edges that allows for excellent performance and repeatability in grooving, parting and turning applications, QuadRush has taken the metal removing market by storm. The expansion of the “TQJ” chip breaker for the QuadRush series gives TaeguTec a strong presence for grooving products that use circlips. The “TQJ” line offers good chip control, tolerance and surface finish and conforms to the DIN 471 standards of external circlips.

The two other chip breakers added to the QuadRush line, “TQC” and “TQS,” have been developed for grooving and parting operations on

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a wide range of cutting conditions.

The “TQC” type’s improved chip breaking properties is for industrial users that require increased productivity in high cutting conditions due to its highfeed rate and is designed to machine hard materials; tough applications; is perfect for general applications on steel, alloy steel and stainless steel, and is designed for good chip evacuation in medium to high-feed rate cutting conditions (0.05-0.25 mm/rev).

On a general carbon steel workpiece, QuadRush’s TQC chip breaker increased tool life by a whopping 433 percent against a leading competitor’s offering.

In another case study, TaeguTec was able to increase tool life by 60 percent against another competitor’s similar tool while machining a part made from alloy steel.

On the other hand, TaeguTec’s “TQS” chip breaker is made for industrial users in the metal removing field who are looking for tools that can outperform others when grooving and parting products made from soft materials.

QuadRush’s “TQS” insert type is

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available in widths up to 5.2 mm and can be applied to standard and special items, and is available for any special profile needed by customers.

As it is available in several width types and cutting shapes, it has the capacity to reduce the machining cycle time compared to existing tools and its straight cutting edges with high positive rake angle enables reduced cutting resistance.

The “TQS’s” improved surface quality, tool life and higher cutting speeds were highlighted during a case study against a similar product from another company. During the test and following the same cutting conditions, the “TQS,” with its cermet grade, increased tool life by an amazing 300 percent while machining a part made from low carbon steel.

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MACHINE TOOLS

Both the “TQS” and TQC” can produce the flat bottoms of workpieces and both are perfect solutions on a wide range of shallow grooving applications.

For more information Web: www.taegutec.com

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TECH TRENDS

MACHINE TOOLS

Major surfacing processes & their applications in machine tool industry

by P.T. Bindagi, Chairman, Spraymet Surface Technologies Pvt. Ltd

What is Thermal Spray?

Thermal spray is a process in which material is heated to a molten state and sprayed over the surface of another material to create a coating.

Features of thermal spray

Plasma Spray Process A high temperature plasma stream is created by non-transferred plasma arc within the torch.

Many gases may be ionized this way, argon or nitrogen with small additions of hydrogen and helium are popular choices.

Cermaic Coated Plungers

● A Wide Materials Choice ● Metals, Alloy blends, carbides, ceramics.. ● Uniform Coating Thickness 0.02 to a few mm ● Selective coating capability by masking ● In situ coating capability - paper /power ● Coatings with high performance: 60Rb-72Rc ● No metallurgical change in Base material In an ionized gas, free electrons have been stripped from the atoms and recombination releases very significant thermal energy.

The plasma stream can reach temperatures of 10,000-50,000 degrees Fahrenheit.

Ceramic Coating On Bearing Sealing Area Of Spindle

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For more information E-mail: editor@engrreview.com

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MACHINE TOOLS

Kennametal and Sumitomo Electric sign agreement to supply Kennametal’s Breakthrough KM4X spindle connection

K

ennametal and Sumitomo Electric have signed a licensing agreement under which Sumitomo Electric will provide and support Kennametal’s new and advanced KM4X spindle connection solution to Sumitomo Electric customers globally. Sumitomo Electric, a leading global supplier of electric wire, optical fibers and cutting tool products, sees significant benefit for its manufacturing customers. By combining high

clamping force and optimized interference levels, KM4X™ by Kennametal provides a robust connection, extremely high stiffness, and bending load capacity for greatly improved performance in machining high-strength alloys and other materials.

The KM4X spindle connection is the most rigid system in the world today. This design enables manufacturing companies to maximize their capital investments. KM4X enables higher metal removal rates, which facilitates higher machine tool utilization and reduced cost per part, while increasing the manufacturer’s available capacity,” says John R. Tucker, Vice President and President of the Industrial Business Segment for Kennametal Inc. “Having an innovative technology partner like Sumitomo Electric supply the KM4X

connection will create a powerful production advantage for manufacturing companies around the world.” The spindle connection, the interface between the machine tool’s spindle and toolholder, has to provide the torque and bending load capacity compatible with machine-tool specifications. Cutting forces, particularly in roughing or machining high-strength materials, generate bending moments that will exceed the interface’s limits prior to reaching torque limits.

By combining high clamping force and optimized interference levels, KM4X provides a robust connection, extremely high stiffness, and bending load capacity for greatly improved performance in machining high-strength alloys and other materials. This means extremely high metal removal rates and more completed parts per day.

Advanced Materials Require Advanced Manufacturing The continuing development of high-strength, lightweight materials such as titanium alloys, Inconel, and new aluminium alloys are eagerly sought by manufacturers in many industries, including aerospace and defence, energy, and transportation. These new materials present significant machining challenges in themselves.

Add the competitive pressures in

these global industries, and finding advanced manufacturing solutions becomes a top priority.

Machine-tool builders have responded with milling and turning centers that feature improved stiffness and damping on spindles and sizable machine structures and motors, all to provide the significant horsepower, torque and thrust forces required while minimizing undesirable vibrations that deteriorate part quality and tool life. “In most cases, the toolspindle connection determines how much material can be removed on a given operation,” says Doug Ewald, director, global product management, tooling systems at Kennametal. “This is because this interface must withstand high loads and yet maintain its rigidity. With the ongoing advances in cutting tools and machining centers, a spindle connection that makes the best utilization of available power possible is an important consideration to investigate early in production planning.”

“This is a full-system partnership between companies,” says John Jacko, vice president and chief marketing officer at Kennametal.

“With the KM4X spindle connection and Sumitomo Electric’s innovative technology, there is no reason why companies should hold back investigating high-torque, high-speed machining capabilities for both existing and new equipment. This means achieving the maximum potential of your machine tools.”

Web: www.kennametal.com

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PORT FOLIO

MONORAIL - Overhead Conveyor System : The answer to increasing productivity & tea quality

Mr. Rajeev Kapoor - Director (Marketing & Export)

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M

onorails or the Overhead Conveyor Systems are now functioning as silent partners in a factory’s operation in all Manufacturing and Storage units across the Globe.

It’s like a heart – continuously operating the lifeline without tiring.

The toughness of systems endures all ups and downs during its 20 years of life.

The system caters from small to very large requirements i.e. from as small as 200 ft to as large as 3000 ft + “so it serves all like the Heart”.

The most astonishing feature is its extremely low running cost in terms of electric consumption. The system runs on merely 1.5 HP / 2 HP Motor Drives.

An extremely low amount of lubrication and care ensures smooth running of system – year after year and also longer healthy life.

Normally as production increases Machines need to be replaced entailing considerable capital cost as old machine is of no use anymore.

But these conveyors do not need any replacement as they can be kept upgraded with newer components.

For the Modular Overhead Conveyor Systems one just keeps adding on in the same systems with enormous flexibility of making desired changes in route layout.

You name any industry or Warehouse and you will find these unique Conveyors working as your Silent Partner.

Real estate being the most expensive part of any industry and turning as a scarce resource – these

conveyors are the simplest and most economical answer to your needs of increasing production and storage in the same site.

With an excellent Marketing Network with highly dedicated “Customer Support Services Teams” the valued customers enjoy the relationship as a family member of the company.

As we believe in two simple rules: 1. Look after the best interest of employees.

2. Take the best care of our valued customer.

AND SO WE WILL ALWAYS REMAIN THE FIRST CHOICE ACROSS THE GLOBE.

For more inforamtion Email: info@holtzmansystems.com rajeevkapoor.holtzman@gmail.com

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Tough & Tireless Conveyors, which never retire.

U S E D E X T E N S I V E LY I N FA C TO R I E S I N A S S A M , CACHAR, TRIPURA, NORTH BENGAL, TAMILNADU, KARNATAKA, KERALA, MADHYA PRADESH, ORISSA, BIHAR, UTTAR PRADESH, MAHARASHTRA, BANGLADESH, NEPAL, SRI LANKA, MOZAMBIQUE, KENYA, RWANDA, TANZANIA, VIETNEM, MALAWI & UGANDA. Brewery

Automobiles

Tannery Polymer

Dairy

Corporate Office : South Plaza (Ballygunge A. C. Market),4th Floor, 46/31/1 Gariahat Road, Kolkata-700 029, India Phones : (91-33) 2464-6191/92, 2466-6478, 2461-7263/8135 Fax : (91-33) 2466-9889 Mobile : 08902495617/18 E-mail : rajeevkapoor.holtzman@gmail.com / info@holtzmansystems.com Web Site : www.holtzmansystems.com

Handling Products,Spreading Smiles, Worldwide, Since 1990

TECH TRENDS

MATERIAL HANDLING

Konecranes : Lifting into future Modern WMI Konecranes factory in Jejuri is testament to the smart and, efficient lifting equipment it manufactures’ & has the unique distinction of being Biggest of all the Konecranes Production facilities.

ADMIN BUILDING

PARENTAGE WMI Konecranes India is wholly owned subsidiary of Konecranes Plc based in Finland, which is one of the world’s leading suppliers of industrial cranes, crane components, harbour cranes and port automation technology. Services, in particular maintenance, Modernization & Techinal services, are another key element of the group’s business activities. Konecranes group has rich history of more than 80 years in this industry. In financial year 2012, the group, with 11,600plus employees, generated revenue well over 2 billion euros. Konecranes is present in 626 locations worldwide, with maintenance contract covering 4, 30,000 equipment of different makes.

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T

he highly competitive environment of Manufacturing Industry linked to present market scenario, demands from companies more agility, better performance and the constant search for cost reduction.

Materials handling equipments are among many factors that contribute to improve a company’s performance. Effective material handling systems create savings that helps directly to improve the bottom line.

In material handling systems, industrial cranes play a vital role in all industries, specially manufacturing. Indeed, it could be said Industrial cranes powers today’s efficient distribution in manufacturing facilities. Industrial cranes market in India is growing at steady rate. The key driver of the industrial cranes industry currently is primarily the infrastructure industry.

The infrastructure industry is closely followed by steel and then the automobile industry. Despite its significance, this vitally important equipment market is fragmented & only handful of organized players being active.

It is in this light that we decided to visit the new manufacturing facility of one of the few organized players, WMI Konecranes India Limited.

WMI Konecranes India Limited is a wholly-owned subsidiary of Konecranes Plc, Finland, which has presence across 50 countries with 21 production sites worldwide. The Indian operation offers a complete

range of products and services available under the Konecranes umbrella. Its business is broadly divided under three divisions: Cranes, Components and Services.

Focusing on establishing foothold in Indian subcontinent, Konecranes started its operation in 2007. With such advanced technologies & vast global experience Konecranes easily found acceptance in Indian Market. By 2008 Konecranes India had a factory in Sanaswadi & head office at the heart of Pune city. After watching enormous growth opportunities in Indian subcontinent, Konecranes acquired full stake in WMI Cranes, a Pioneer in Indian Crane Industry. To cater to the growing demands Konecranes consolidated all its manufacturing facility at Jejuri, Pune in 2013. Within a short span of 6 years, Konecranes sold more than 1000 cranes which itself is a testament of substantial growth, considering stiff competition it faces in Indian market from much older counterparts.

Foreseeing the demand of Industrial Cranes, Konecranes invested more than 100 crores, establishing this humongous manufacturing facility which will boost in a big way the goal of Konecranes, entrenching itself as the leaders of this Industry in the sub continent.

Konecranes Plants at Jejuri are state-of-the-art world class manufacturing facilities, which can manufacture more than 1000 cranes.

Spread across huge area of 1.85 acres www.engrreview.com

SMART CRANES COST LESS IN THE LONG RUN

At Konecranes, we believe that what we do is the part of your process. We have learnt this by working closely to our customers globally. Our smart features like sway control, load positioning, load synchronization, make the cranes more smart to work with and safe. Our remote data monitoring service helps to analyze actual crane usage data and to plan maintenance schedule effectively to reduce downtime.

Our smart technology and efficient service helps to manage complete crane operations during the lifecycle of crane, right from installation, operations, maintenance, modernization and so on. What you invest in Smart cranes actually cost you less in the long run.

PRODUCT RANGE: Electric Chain Hoist, Industrial Cranes, Process Cranes, Shipyard Cranes, Container Handling Cranes, Lift Trucks & Reach Stackers, Crane Maintenance and Modernization Services.

WMI Konecranes India Limited 19, Level 2, Muttha Towers, Don Bosco Road, Yerwada, Pune - 411006, India Tel: +91 20 400 47470, Fax: +91 20 400 47475.

Email: india.sales@konecranes.com, www.konecranes.in

TECH TRENDS

MATERIAL HANDLING

VITALS: COMPANY: WMI Konecranes India Limited

Jejuri Plant 1 Component Facility

Jejuri Plant 1 Component New Facility

Jejuri Plant 1 Component Facility

Jejuri Plant 1 Component New Facility which has 2 manufacturing facilities, administrative building, stores, advanced simulation training centre.

Factory is having most advanced & automated equipments which do work with precision & limits chances of human error.

In terms of production, quality and performance norms have become the single stringent parameter that determines efficiency & durability.

Keeping quality in their mind & heart Konecranes has a dedicated Facility for manufacturing components.

Quality is maintained with stringent quality tests done at each and every step of production.

One of the unique things carried out in this facility is, FAT- Factory Acceptance Testing, in which Cranes are tested before they are dispatched to Customers.

Saeesh Nevrekar, Country Manager & Managing director rightly stated â&#x20AC;&#x153;Establishing this world class manufacturing facility demonstrates our commitment to sell high quality products in the Indian as well as export markets. This facility is undoubtedly the biggest crane factory

COMPANY HEAD: Saeesh Nevrekar, Country Manager & MD HEAD OFFICE LOCATION: 2nd floor, Muttha towers, Yerwada FACTORY LOCATION: Jejuri, Pune CAPACITY: More Than thousand Cranes per year FACTORY AREA: 1.85 acres BRANCHES OFFICES: Bangalore, Chennai, Hyderabad, Vadodara, Mumbai, Kolkata, Delhi

in India and will help us strengthen our position as the market leader in the crane business in India.â&#x20AC;?

For more information Web: www.konecranes.in

MANUFACTURING FACILITY HIGHLIGHTS Products manufactured: Cranes and components Manufacturing capacity: 1,000 cranes per annum Market Catered: Both Domestic & Export Investment till Date: More than 100 crores Raw material used: Mild steel Staff strength: 550

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Tested: Tested: 2727 million million times times twisted twisted ...from ...from stock stock

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chainflex chainflex robot fibre robot optic fibre cable opticCFROBOT5.501 cable CFROBOT5.501 +++ Glass +++fibre Glass cable fibresurvives cable survives more than more 27than million 27 cycles million at cycles ±180°/m at ±180°/m torsion torsion +++ +++ chainflex chainflex lasts +++ lasts Proved +++ Proved in test no. in test 3105no. +++ 3105 online +++calculable online calculable +++ Test +++ information Test information and details: and details: igus.in/chainflexTest3105 igus.in/chainflexTest3105 ®

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chainflex chainflex bus cable busCFBUS.044 cable CFBUS.044 +++ Has +++ withstood Has withstood more than more 76than million 76 million strokesstrokes in the running in the running endurance endurance test +++ test chainflex +++ chainflex lasts +++ lasts Proved +++ Proved in test no. in test 3089 no.+++ 3089 online +++ calculable online calculable +++ Test +++ information Test information and details: and details: igus.in/chainflexTest3089 igus.in/chainflexTest3089 ®

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chainflex chainflex thermalthermal compensation compensation cable CFTHERMO.K.001+++ cable CFTHERMO.K.001+++ Lasts more Lasts than more 97than million 97 strokes million strokes at a 48 mm at a 48 radius mm+++ radius chainflex +++ chainflex lasts +++ lasts Proved +++ Proved in test no. in test 4009 no.+++ 4009 online +++ calculable online calculable +++ Test +++ information Test information and details: and details: igus.in/chainflexTest4009 igus.in/chainflexTest4009 ®

igus (India) igus Pvt. (India) Ltd. Pvt.36/1, Ltd.Sy. 36/1, No.Sy. 17/3 No.Euro 17/3 School Euro School Road Road Dodda Dodda Nekkundi Nekkundi Industrial Industrial Area - 2nd AreaStage - 2nd Stage Mahadevapura, Mahadevapura, Bangalore Bangalore - 560048, - 560048, Karnataka, Karnataka, India India Phone Phone +91-80-45127800 +91-80-45127800 Fax +91-80-45127802 Fax +91-80-45127802 info@igus.in info@igus.in ®

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TECH TRENDS

MATERIAL HANDLING

Material Handling & Construction Equipment : Indian & Global Industry Trends

W

e are going to take a broad look at the driveline technology employed solely in heavy material handling machinery, because that is one topic that seems untouched so far. This article will first attempt to define the entire spectrum, what is material handling, what is heavy material handling, what are the power transmission or ‘driveline’ elements that provide ruggedness coupled with high precision, reliability and long lifespan.

The focus will be first on the global scene and then we shall drill down to the Indian scenario also, highlighting lacunae where the indigenous manufactures can hope to move in for the kill, since construction business, an integral part of the infrastructural projects -and beyond any doubts that is not only a sunrise industry, but also a very consistently fruitful enterprise overall.

Material Handling : Material handling equipment covers all types of equipment that is concerned with the ● Movement, ● Storage, ● Control and ● Protection of materials, goods and products.

This definition also encompasses all aspects throughout the process of manufacturing, distribution, consumption and disposal.

Material handling equipment is the mechanical equipment involved in the complete system. Material

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handling equipment is generally separated into four main categories: storage and handling equipment, engineered systems, industrial trucks, and bulk material handling.

Bulk material handling equipment :

Bulk material handling equipment is used to move and store bulk materials such as ore, liquids, and cereals. This equipment is often seen on farms, mines, shipyards and refineries. After the advent of the large infrastructural projects even in smaller cities, e.g. shopping malls and multiplexes, even the construction equipment has been employing not only bulk material handling equipment but also heavy mobile cranes, stationary cranes, hoists, and truck-mounted cranes, concrete mixing equipment and much more. This trend has proliferated throughout the major and medium sized cities everywhere.

Material Handling Equipment :

Material handling vehicles with internal combustion engines are real “all-rounders”. In outdoor applications, for example, they must not only be able to quickly transport extremely heavy loads over long distances, but they must also be able to precisely manoeuvre their load and set it down in the tightest of spaces.

MHE ( Material Handling Equipment) covers a very large range of equipment. Handling and storing materials involve diverse operations such as hoisting tons of steel with a crane; driving a truck loaded with

concrete blocks; carrying bags or materials manually; and stacking palletized bricks or other materials such as drums, barrels, kegs, and lumber.

The efficient handling and storing of materials are vital to industry. In addition to raw materials, these operations provide a continuous flow of parts and assemblies through the workplace and ensure that materials are available when needed.

Unfortunately, the improper handling and storing of materials often result in costly injuries.

MHE for the most part tend to work on diesel engines and hence the power transmission automatically becomes a very vital area in design, assembly, use and maintenance of such equipment. Lets examine some interesting aspects :

Power Transmission :

The widely varying functions make the highest demands on the driveline, in particular on the transmission: It must be designed for strong engines with a high input torque and smooth gear shifts that take place under full load, without interruption to the tractive effort. Important for the manufacturer and the end user is also the fact that the transmissions must however not take up much space.

Manufacturers who want to keep their products small and manoeuvrable are restricted with installation space.

Power packs for material handling

Continue on page no.96

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ENGINEERING REVIEW |

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Continued from page no.94 The products from some world leaders usually have a series of power packs that extend over a wide range of input torques: from 800 Nm to 2,750 Nm respectively 750 Nm for the fully automatic transmission, and thus match many different vehicles.

The shifting can be fully automatic and without interrupting the tractive force or with power-shift. Most such models usually are designed for the most versatile applications in material handling with combustion engines. By optimum matching of transmission hardware and electronic control, smooth and reliable operation is guaranteed under all types of weather or climate conditions.

Such power packs assure soft shift transitions in operation – a decisive criterion in practical applications.

User-friendly with electronic assistance, most new models feature the electronic inching facility. This offers a “creep function” which makes it easier to position loads with highest levels of accuracy.

This is a great feature for stacking, or removal without causing problems.

What are the benefits of such sophisticated transmissions ?

Main product advantages

● Electronical inching possibility available (no mechanical linkages) ● No tractive effort interruption by using proportional valves ● Logistic advantages, less different parts ● High sophisticated shift quality (soft and smooth shifting), ● Low noise level (high contact

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MATERIAL HANDLING

helical gears) ● Various torque converters for different engines available ● Stiff and short rotating shafts – less deflexion ● Special design for material handling application (ratios, centre drop, installation dimensions) ● Electronic diagnostic

system

with

self

● Easy maintenance and repair (set right bearings, no shimming) ● Short and long drop gear boxes - a choice is available.

Air Bearings :

Air Bearings (also known as Air Casters, Air Cushions or Air Skates) are pneumatic elements that can be positioned under heavy loads for friction free movement in any direction. Air bearings work using the air film technology, which means that a thin air film is created between the floor surface and the air bearing, virtually eliminating friction and allowing heavy loads to be moved with very little force.

Air Bearings (also known as Air Casters, Air Cushions or Air Skates) are pneumatic elements that can be positioned under heavy loads for friction free movement in any direction. Air bearings work using the air film technology, which means that a thin air film is created between the floor surface and the air bearing, virtually eliminating friction and allowing heavy loads to be moved with very little force.

To demonstrate the power of air bearing technology consider an air bearing the same size as the steering wheel in a car. With just 3

bar air pressure this air bearing can alone float up to 2 tonnes and would have no problem moving the total weight of a normal sized car.

Advantages of air bearings

● Heavy loads can be positioned safely and accurately in any direction

● Possibility to move heavy objects between halls where cranes cannot reach ● No fixed installations in the building are required

● There is no floor wear due to the low friction ● Air bearings make little noise

Examples of applications What Are Air Bearings :

More usually known by many other names, air bearings fall under the category of fluid or hydrodynamic bearings. Fluid bearings are bearings which support the bearing’s loads solely on a thin layer of liquid or gas.

Air bearings are designed to lift loads away from the floor surface and float them off to their destination on a thin film of air. Each individual air bearing is housed in a load module which contains an air flow control valve to regulate the operation of that air bearing.

Basically, air bearings use a thin film of pressurized air to support a load, the same way the puck on an air hockey table “floats” on air. This type of bearing is called a “fluid film” bearing. Fluid film bearings have no solid-to-solid contact under typical running conditions; instead, Continue on page no.98

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TECH TRENDS

Continued from page no.96 a film of lubricating fluid (in our case pressurized air) forms a layer between the solid machine elements and serves to transfer forces from one to the other. To compare this with ball bearings, in ball bearings the balls are in constant contact with and form a solid bridge between the machine elements. When compressed air is introduced into the air bearing, the bearing initially inflates to form a seal between the bearing and the floor surface. As the air bearing is further pressurized it is forced to expel compressed air from the exhaust holes in the air bearing diaphragm. The force of this expelled air against the floor surface causes the air bearing and load module to lift off the floor on a thin film of air.

The load should now be in flotation mode and ready for action.

Why Use Air? :

While most people are familiar with oil fluid film bearings - for example the crankshaft journal bearings in car engines - most people have not been exposed to air bearings.

Remembering our high school physics class, there are two basic types of fluids - liquids and gasses. In terms of fluid film bearings, the difference between these two is essentially the viscosity - liquids have much higher viscosity than gasses. When applied to a fluid film bearing, this difference has a number of implications.

Why we use air (instead of oil):

● Air is clean, contaminant free ● Zero friction - no heat generation at high speeds ● Small bearing gap means high accuracy components, high accuracy

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motion ● Air nitrogen of any other gas can be used

First, lower viscosity means that for the same working pressure gas bearings have lower load capacity (liquid fluid film bearings typically support five times the load of gas bearings for the same pad area).

Second, because of the extremely low viscosity of gasses, gas film bearings operate with essentially zero static and running friction where liquid fluid film bearings have much higher friction and pumping losses within the bearings, which can cause heat generation. And third, gas bearings require very tight bearing gaps for proper operation (10 µm for gas compared to up to 100 µm for liquid bearing) which translates into extremely high accuracy requirements on the components.

What this means for air bearings is that although they have a lower load capacity, gas bearings have essentially zero friction at all speeds and because the tight bearing clearances demand high accuracy components this results in extremely high accuracy motion. Another benefit is the cleanliness of using air as a lubricating fluid as opposed to oil, water, or another fluid. Since compressed air is very common in industrial environments it is probably the most often used gas, however other gasses such as nitrogen can be used where they are available (such as in clean room environments).

They can be broadly classified into two types: fluid dynamic bearings and hydrostatic bearings.

Hydrostatic bearings are externally pressurized fluid bearings, where the fluid is usually oil, water or air, and the pressurization is done by a

pump. Hydrodynamic bearings rely on the high speed of the journal (the part of the shaft resting on the fluid) to pressurize the fluid in a wedge between the faces. Fluid bearings are frequently used in high load, high speed or high precision applications where ordinary ball bearings would have short life or cause high noise and vibration. They are also used increasingly to reduce cost. For example, hard disk drive motor fluid bearings are both quieter and cheaper than the ball bearings they replace. Fluid bearings use a thin layer of liquid or gas fluid between the bearing faces, typically sealed around or under the rotating shaft.

There are two principal ways of getting the fluid into the bearing: In fluid static, hydrostatic and many gas or air bearings, the fluid is pumped in through an orifice or through a porous material. In fluid-dynamic bearings, the bearing rotation sucks the fluid on to the inner surface of the bearing, forming a lubricating wedge under or around the shaft.

Hydrostatic bearings rely on an external pump. The power required by that pump contributes to system energy loss, just as bearing friction otherwise would. Better seals can reduce leak rates and pumping power, but may increase friction.

Hydrodynamic bearings rely on bearing motion to suck fluid into the bearing, and may have high friction and short life at speeds lower than design, or during starts and stops.

An external pump or secondary bearing may be used for startup and shutdown to prevent damage to the hydrodynamic bearing. A secondary bearing may have high friction and short operating life, but good overall service life if bearing starts and stops are infrequent. www.engrreview.com

FACE TO FACE

Techno Products : Drives to gear up excellence

Mr. Murli Srinivasan - Director- Techno Products Development Pvt. Ltd.

Q. Please brief us about companyâ&#x20AC;&#x2122;s infrastructure & achievements?

The Brief Details Of The Company Infrastructure Are As Under: 1) Sales &Marketing Department: Consists of General manager-Sales, Business managers, Area sales manager, -across Tamilnadu, , Sales Co-Ordinator who supports Sales team,

2) Design, Planning and Consultation Department: Consists of professional Mechanical, Electrical Engineers, certified in CAD, preparing engineering drawing of Different dimensions and Specification various Power transmission equipments. Plans engineering design Layouts, implementations and consultations for the different applications of Transmission equipments required by the customers.

3) Service Department: Consist of technically qualified experi-

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ence mechanical, Electrical Engineers supported by Service Coordinator to follow up all service related calls.

Qualified, experienced, Subject matter expert engineers for attending to all service related complaints, installation and commissioning of the products.

On site visit to provide support for reengineering solution.

Also service department consist of an Exclusive qualified experienced Engineer for Harmonic survey And Energy audit

4) Store /Logistic Department: Consists of Manager Stores who supports Stock management. He is supported by two executive for Inventory management, GRN, inward/outward, Billing, Dispatch management.

Operation manager supports from enquiry to dispatch supported by team leader Purchase, team leader SO/ Delivery note, Executive for Invoicing.

Executive for Logistic and store housekeeping supported by Technicians and workers for the execution of all store related work Continue on page no.102

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FACE TO FACE

Continued from page no.100 5) Spare Parts & Maintenance Department: Consists of Electrical and Mechanical engineers. The department of aftersale services by providing spare parts, partial and comprehensive maintenance to customers by giving the necessary information and advice as per the recommendations of manufacturing companies.

4) Financial Department: Involving the Director-Commercial and CFO with a manager accounts, manager Finance/Credit Control, followed by the Accounting Executive, in a financial department.

6) Human Resources Department: Consists of Directors –HR supported

by HR management consultant and their Executive in the Office for all HR related activities.

Our achievements. ● Established in the year 1999 to provide products & services to all industries ,Techno Products Development Pvt Ltd, India’s’ largest most preferred, trusted, valuable lifetime partner as Technical Distributor of

multi branded Transmission equipment. ● Techno Products Development Pvt Ltd emerging as “Leader in End To End Transmission solution.

Organization is “Drives to Gear Up excellence “in the is emerging scenario and changing transmission technology trend. ● Techno Products has been

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successfully associated with pioneers in the industry like Siemens,ICBauer, Rossi, Danfoss, Nord Drive systems, MGM-VARVEL, Lenze, Hindustan Motor Mfg,Crompton Greaves, Marathon,TGT & Esco Gear Couplings. ● The company is ably led by Mr.Madan Dodeja with the support of Mr. Murali Srinivasan, a Mechanical Engineer by qualification, with over 22 years experience in the transmission solution re-engineering technology. ● Exponential growth in business volume from 20 laks business in 1997 to 18 crores in 2012-13. ● Being the largest, trusted, most preferred technical distributor for many reputed brands in power transmission products.

developed system and process and all the activities are performs in SAP system supported by sales force for sales team. ● Variety of service complete solution providers in Power Transmission products through our well trained Electro Mechanical Engineers based on the customer need and focus. ● Having warehouse capacity to hold adequate stocks of all material handling equipments products & power transmission equipments to meet the supply demand across country all the time. ● Power Transmission Products & services : like Motors, Gear Boxes, VFD, Coupling, Pumps & others 25 leading brands in all major industries

Q. What are the market opportunities for your products in India?

How do you plan to position these products?

Q. What are the latest initiatives executed by your company in material handling space? Which are your focus areas? ● On sepetember-2013 Joined hands with one of the leading PAN India Channel partner M/s. VASHI ELECTRICALS and became 500 crore joint venture enterprise. ● Driven by passion we had

The Indian gearboxes and geared motors market is poised to grow at a compound annual growth rate of (CAGR) of 17.3 per cent over 2010-11 to 2017-18.

The XI five-year plan (INR 20,271,000.0 million) and its impact on the growth of heavy industries is expected to spur the growth of Indian gearboxes and geared motors market in India.

Growing demand for electrical efficiency and increasing investment in modernization of infrastructure will drive the global VFD (variable Continue on page no.104

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FACE TO FACE

Continued from page no.102 frequency drives)/VSD (variable speed drives)/ASD (adjustable speed drives)/ inverters market to $18,854 million by 2017, with a CAGR of 8.7% from 2012 to 2017.

Asia-Pacific, with its thriving economies and rapidly expanding manufacturing bases, is expected to experience highest revenue growth during the next five years. Rising energy prices, stringent efficiency regulations, and increased awareness about advantages of the drives are the factors increasing the demand for VFD.

General Stages in Planning 1. Definition of goals, in 4 perspectiveFinancial Perspective, Customer perspective, Internal Process perspective, Learning & Development PerspectiveBalanced Scorecard Approach.

2. Identification of constraints, Analyzing evaluating the current practices, emulating the suitable business planning, department wise and generate strategic plan.

Development of alternative plans.

3. Preparation of the financial, goal, calculating the budget department wise, and workout the initiative, measurement plan of implementation of functional strategies.

4. Selection of the best suitable employee mapping competency skill matrix, built with KRA-Core responsibilities, Individual Contribution Area 5. Plan periodic review, evaluate and take action plan for execution with PDCA cycle.(PLAN, Develop, Check and Action).

TECHNO Strategic Plan: ● Variety of service complete solution providers in Power Transmission products through our well trained Electro Mechanical Engineers based on the customer need and focus. ● All our Major principle who

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● ●

●

●

●

●

supplies transmission equipments established their manufacturing plants in India, thus minimizing operation cost, improving supply.

Branches across TN will help to do statutory compliance on time.

Technology Training, Functional training, Soft skill training to enhance skill, competencies of sales and service team, simultaneously improving to connect to customer need.

Territory demarcation, new territories expansion, deployment filed sales and service team to explore the market potentials.

Implementation of Filed work system and periodic review and evaluation mechanism to increase performance.

Team of sales and service team demarcated territory wise to provide what required.

Having warehouse capacity to hold adequate stocks to meet the supply demand across country all the time.

●

●

●

●

●

●

TECHNO Strategic Plan: There are three distinct factors accountable for Business Strategic Planning.

1. Organization’s Vision; 2. Customer’s Need Fulfillment; 3. Organization’s people growth.

●

●

Q. What is your marketing strategy for India?

TECHNO PRODUCTS DEVELOPMENT PVT LTD, marketing strategy for India One stop Re-Engineering Solution by Designing, Developing, Cost Effective Energy saving, Operational efficient Transmission solution, with quality Power Transmission Products & service in motor, Gear Boxes, VFD, Coupling, Pumps & others 12 leading brands in all major industries, since 1997 ● Providing customized Engineering solution ● Moving into new market segment

●

and adding up newer products catering to the market need.

A new all India market coverage by email campaign, products web seminars, products demo in industrial expo, Organizing engineering awareness program at SIDCO/SIPCOT,CII and other affiliated Industrial units, Sponsoring Industrial meet by taking part in their marketing programs.

Marketing activities like Product campaign, DEMO mass contact program, Industrial seminar, Customized on site solution by technical expert engineers.

To tap the new market growth potentials and growth of different industries.

Well trained Service Engineers to offer 24x7 technical services, attended in the shortest possible time, to support to our customers.

Opening up service center in all industrial area, SIPCOT/SIDCO in collaborating with CII. Expanding our sales and marketing operation in all potential market like Coimbatore, Hosur, Erode, Salem, Tiruppur, Madurai, Trichy in the year 2013-14.

PAN india operation from september-13 due to joint venture operation with one of the leading Channel partner VASHI ELECTRICALS PVT LTD Starting operation and sales promotion in Kerala, Karnataka, Andhrapradesh by end of the year 2014.

Opening up manufacturing unit for all accessories, Panel development above 10hp in Tamilnadu in the year 2014-15.

Our methodology is centered on the following 7 steps: ● Step 1: Understand business functionality of the system. ● Step 2: Understand pain areas, in transmission equipment with other systems Continue on page no.106

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FACE TO FACE

Continued from page no.104 ● Step 3: Identify appropriate system reengineering pattern, by an technical expert. ● Step 4: Agree with business and technology teams on benefits of reengineering & timeline. ● Step 5: Procure order and perform reengineering. ● Step 6: Implement the new reengineered solution. ● Step 7: Feedback to measure actual benefits of reengineering against perceived benefits

Q. What is the role of R&D activity? What are the measures that are being taken from the product manufacturing to distribution?

elements which apply to the technical activities of the organization, such as policy and procedures for instrument calibration and performance checks; use of celebrants’ and reference materials, and; use of statistical procedures.

3. Organizational quality elements.

These are quality management structure with a defined role within the organization; a quality system; documented procedures for key activities; a recruitment and training policy for all staff;

Measurement methods ● Prescribe

guidelines

which

are

management are an integral part of its management function. The organization proudly takes this as core responsibility. In addition, we believe that in adopting a quality management system, we are striving to improve our efficiency, work environment, service to customers, and ultimately our profitability.

We will measure or performance by the following objectives: 1. Training Development: To ensure that all that work force, are educated in the detail of our quality standards, and to ensure that quality becomes a part of our business culture at all levels.

2. Commitment: We wish to ensure that all our staff are fully committed to the principals and customers’ objectives laid out in our quality program.

3. Product & Service:

● The first major role of R&D is the development of fundamental knowledge or “enabling technologies” ● The second important function of R&D is to provide support to manufacturing, customers, and business management. ● The third major function of R&D is to develop and implement new technology.

Measurements: 1. Analytical task quality elements represents the activities carried out for particular projects or individual analytical tasks. It includes the planning, control and reporting practices recommended at the start of, during, and at completion of R&D work.

2. Technical quality elements forms a subset and comprises specific QA

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intended to cover analytical testing or measurements. ● Define process of manufacturing and evaluate the deviations. ● Establish the quality audit steps in r3efining the processes and ensure the quality, to increase productivity and minimize the wastage. ● Methods to analyze problem and provide appropriate timely solution.

Q. Brief us about the quality policy for your business?

Techno Products Development Pvt Ltd-Quality Policy Our USP is “Transmission Solutions Re-Engineered” and “Drives to gear Up Excellence” Techno Products development Pvt LTD recognizes that the disciplines of quality, health and safety of employee, and work environmental

Provide industry leading quality in both product and service to our customers, at fair and competitive prices.

4. Continued Improvement: To ensure that we are continually monitoring our performance in quality and service, and implementing programs to improve our business.

5. Work Environment: Make sure that we have a safe, healthy, and comfortable work environment for our field and office staffs.

6. Supply Chain: Ensure that our customers are satisfied with timely & speedy delivery to meet and exceed a defined level of quality standards thereby ensuring that our quality standards are support by our suppliers, vendors and customers.

Q. Could you brief us on Indian & Global perspective of material Continue on page no.108

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FACE TO FACE

Continued from page no.106 handling industry?

Material Handling Equipment Market in India 2011-2015 India Perspective: Material Handling Equipment market in India to grow at a CAGR of 15.62 percent over the period 2011-2015.

One of the key factors contributing to this market growth is the increased industrialization across the states in India.

World Material Handling Products to 2016 - Industry Market Research, Market Share, Market Size, Sales, Demand Forecast, Market Leaders, Company Profiles, Industry Trends. The global MHE industry is estimated to be Rs 4.68 lakh crore by 2010. The growth is being led by developing countries such as India, China, Turkey Mexico and Russia.

While the US, Germany and Russia are worldâ&#x20AC;&#x2122;s largest producers of MHE, Germany and Japan are exporters of MHE. Global demand for material handling products is forecast to climb 4.0 percent annually through 2016 to $123.6 billion. Opportunities will be best for sales of advanced equipment such as automated conveyors and automated guided vehicles. Among national markets, India and China will see the fastest gains.

This study analyzes the $101.4 million global material handling product industry. It presents historical demand data for the years 2001, 2006 and 2011, and forecasts for 2016 and 2021 by product (e.g., industrial trucks and lifts; conveying equipment; hoists, cranes and monorails; automated storage/retrieval systems; AGVs), market (e.g., durable goods manufacturing, nondurable goods manufacturing), world region and for 24 major countries.

The worldwide markets for Material Handling Equipment in US$ Million by the following Product Segments: Conveying Equipment, Industrial Trucks & Lifts, Hoists, Cranes, & Monorails, and Automated Material Handling Equipment. The report provides separate comprehensive analyt-

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ics for the US, Canada, Japan, Europe, Asia Pacific, Middle East, and Latin America. Annual estimates and forecasts are provided for the period 2010 through 2018.

A six-year historic analysis is also provided for these markets. The report profiles 771 companies including many key and niche players such as Beumer Maschinenfabrik GmbH, BEUMER Corporation, Cargotec Oy, Clark Material Handling Company, Columbus McKinnon Corporation, Daifuku Co., Ltd., Jervis B. Webb Company, Dematic GmbH & Co. KG, DĂźrr AG, Eisenmann AG, Flexlink AB, HK Systems, Inc., Hytrol Conveyor Co., Inc., Ingersoll-Rand Plc, Interroll Group, Jungheinrich AG, Kardex Remstar International Gruppe, Kion Group, Konecranes Plc, Liebherr Group, Lockheed Martin Corporation, Manitou Group, Manitowoc Company Inc., NACCO Materials Handling Group, Paccar Inc., Sandvik Materials Handling, Shanghai Zhenhua Heavy Industries Co., Ltd., SSI Schaefer GMBH, TCM Corp., Terex Corporation, Toyota Industries Corporation, Vanderlande Industries Nederland B.V., Viastore Systems GmbH, WITRON Logistik + Informatik GmbH, and Xuzhou Heavy Machinery.

Q. In your opinion how can the Indian material handling industry become globally competitive ?

Indian material handling industry: Parading the growth path Common trend in the material handling industry today is to build material handling equipment that is smaller yet smarter. Apart from this, material-handling equipment is being incorporated with immense electronic intelligence in the form of touch screen interfaces, distributed control functions that obviate the need for bulky control panels, upgraded software, and many more features.

Once considered a total in-house

operation, material handling is now being done by third party logistic (3PL) providers,cross-company collaborations have increased with integrated supply chains and concurrent movement of goods and information. Economic trends and the performance of the construction, power, and manufacturing sectors are major factors affecting the dynamics of the material handling systems market.

The developing economies of India and China, in particular, hold enormous potential for the market owing to the high economic growth rates and the burgeoning industrial products and consumer goods sectors. Growth in the thermal power sector will spike demand in the market for coal handling equipment.

Dominant Market Chennai is emerging as a key market for material handling equipment (MHE) with a spurt in the number of warehouses and container freight stations (CFS) in and around the city.

There are over 100 large warehouses and a few more are to come up in the next few months, according to sources in the industry.

There are around 15 CFS in and around the city and a few more are expected to come up with Chennai port emerging as a major container handling port. This will, in turn, boost the demand for MHE like fork lifts, pallet trucks, stackers, order picker and reach trucks. The Indian MHE market has been pegged at over Rs 5,000 crore with Larsen & Toubro and Godrej as major players.

There is no data on Chennai alone. The Indian MHE industry is expected to grow steadily. The improvement in the Indian economy will result in accelerated demand for goods movement and create opportunities for suppliers of goods-handling products and services of all types. The need for MHE is directly related to the amount of cargo and freight traffic. India will see Continue on page no.110

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FACE TO FACE

Continued from page no.108

Godrej & Boyce Mfg. Co. ;Mcnally Bharat Energy Co. ;Mukand Ltd. Escorts Ltd. Ahluwalia Contracts [India] Ltd. ; Saico Engineers & Fabricators Ltd. Elecon Engineering Co. ElectroMech ; ACE ; OMEGA ; Voltas ; TIL ; TELCON

estimated to be around € 300 million.

The table below explains the different material handling equipment and their market share. The material handling equipment is dominated by cranes and forklifts. Pick and carry cranes is the largest segment with 27 % share of the material handling equipment market.

Slew cranes, crawler cranes and tower cranes together account for another 24 percent. Forklifts have 12 percent share.

Q. What are the key technological trends that are driving material handling industry?

Material Handling Equipment Market Share/Total Market Size ~ € 300 million

● Dual clutch transmissions (DCTs) significantly contributes to fuel consumption reduction. ● DCTs enable engine start-stop without any additional electric driven pump or pressure oil accumulator needed. ● Hybridization by connecting the motor to a certain path of the DCT with higher speeds instead of connecting to the lower engine crank shaft speed directly. ● Electronically-controlled AMTs [automated manual transmissions] or DCTs but the biggest gains come from optimizing the power train as a whole, engine and transmission together.” ● Designs, develops and calibrates automotive driveline control systems and in the management of complex driveline` integration programmes. ● Adding an AMT capability to an existing manual transmission can be fast and cost-effective and, by optimizing the gear shift points, can bring substantial real-world reductions in emissions and fuel consumption.

● ● ● ● ● ●

a major pull in the demand for these equipments,

Major Players in the Material Handling Equipment Sector:

Q. How do you perceive the future of the Indian material handling industry ?

Market Size and Segmentation - Indian material handling industry The present market size is

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Pick-n-Carry Cranes : 27% Forklifts: 12% Slew Cranes: 11% Crawler Cranes: 8% Tower Cranes: 5% Others: 37%

Source: IBEF

Q. What is your vision for your company in near future?

● Exposed to more global competition. ● The Uncertainty in invoicing, billing with different Tax system creates additional accounting procedure adding to tedious operations. ● Pay due attention to cost reduction, improvement in quality, delivery schedule and after sales services. ● Globalize our business by increasing the quality standard. ● Given opportunity to import machineries and raw materials on liberal terms.

Q. What are the best possible remedies you can advise in order to maintain the high profitability in the shrinking margins market of India? ● Reduce Inventory and prepare proper planning on stock management. ● Prefer to put in system to monitor market trend and accordingly procure material Just in time. ● Proper enquiry generation by understanding exact need of the customer and service them with required products and services at appropriate time. ● Procure materials back to back (against the order) and supply against Performa. ● Increase demand of the products and reduce inventory. ● Focus on the market need based products & fast moving products and service. ● Increase profitability to increase volume focusing on project orders. ● Reduce credit limit and define suitable credit policy depending on the value of the purchase and customer profile. ● Market segmenting, customer profiling, product segmenting to sell what is needed at right time.

Q. How far the factors like government norms, excise duty, taxation, exim policies are affecting your business?

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GEARS & MOTORS INDUSTRY SECTION

MGM-Pubblicità(210x297)_Layout 1 08/04/13 10.33 Pagina 1

HIGH QUALITY FOR YOUR MACHINERY

MGM brake motor main features

VARVEL production lines

• TEFC 3-ph asynchronous brake motor (0.09kW-130kW) • AC 3-ph brake (no rectifier) or DC brake on request • Oversized brake disc for higher brake torque, longer life and reduced maintenance • Fine and easy brake torque adjustment (as standard) • Very quick brake reaction time • Frequent START/STOP cycle applications • Manual brake release (as standard) • Hexagonal hole on non drive end of the shaft for manual rotation • Single speed or two speeds motors • All motors designed for inverter duty

• RS-RT worm gearboxes: 28 to 150 mm centres.

One stage worm, helical/worm and double worm.

• RD helical gearboxes: 50 to 2300 Nm. Two and three stages.

• RN parallel shaft gearboxes: 180 to 3300 Nm. Two and three stages.

• RO-RV bevel/helical gearboxes: 180 to 3300 Nm. Three stages.

• RG precision planetary gearboxes: 10 to 230 Nm. One and two stages.

• VR dry friction speed variators: IEC63 to IEC90 1 to 5 stepless speed range, 300 to 1500 rpm.

• VS planetary speed variators: IEC71 to IEC112 1 to 5 stepless speed range, 200 to 1000 rpm.

agency.com

A new generation of electric motors and gearboxes for power transmission quality from the alliance of two dynamic italian companies.

For those who want quality.

MGM-VARVEL Power Transmission Pvt Ltd Ware House No. G3 and G4 • Ground Floor • Indus Valley's Logistic Park • Unit 3 • Mel Ayanambakkam • Vellala Street Chennai - 600 095 • Tamil Nadu, INDIA • Phone: +91 44 64627008 • info@mgmvarvelindia.com • www.mgmvarvelindia.com REGIONAL OFFICE: KOHLI TOWERS • 4th Floor, Dapodi • Near Bharat Petrol Pump • Pune - 411012

ENGINEERING REVIEW |

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PORT FOLIO

Ameya Transmissions : Success through innovation

A

MEYA TRANSMISSIONS located in Pune, India, is a premier manufacturer of gear operators and a leader in the domestic and global markets.

We continuously offer the most innovative and dependable solutions in the energy sector, water industry, petrochemical industry and users from the most diverse industries worldwide.

We are a preferred global supplier to leading MNC’s and we serve as a single source to majority of our customers.

Our extensive product range includes : ● Quarter-turn worm gear operators for Valves ● Multi-turn Bevel Gear Operators for Valves ● Declutchable Manual Overrides for Pneumatically Actuated Valves

gearbox for Valves in 1994 ● Started first export of quarter-turn gearboxes in 1999 to Italy ● Manufactured first gearbox for circuit breakers in 2001 ● Currently we manufacture approx. 10,000 nos. of quarter turn gearboxes per month and 1,000 nos. of gearboxes for circuit breakers per month thereby making us the no.1 gearbox manufacturer in India by sales volume and value both for these products ● We have a good domestic presence all over India. ● Besides, we also directly export to countries like UK, USA, Germany, Spain, Italy, Austria, Turkey, China and Middle East ● We are an ISO 9001:2008(QMS), ISO 14001:2004(EMS) and ISO 18001:2007(OHSAS) certified company and adhere to stringent quality norms ● We have a state-of-the-art infrastructure comprising of an inhouse manufacturing unit and a design department at Pune, In-

dia. ● The design department is supported by CAD/CAM facility which ensures to develop innovative and customer specific designs for our range. ● The manufacturing unit is independently functioning at two different plants and has a total coverage area of 45,000 sq.ft ● We also have an in-house Gearbox testing set-up to carry out type testing (life cycle testing) ● Through our efforts in low cost manufacturing, we offer products at extremely competitive prices thereby increasing customer delight ● Take advantage of nearly 40 years of experience & allow Ameya Transmissions application engineers to provide you with quality unrivalled products.

● Two Stage Gear Boxes for Circuit Breakers.

Following are some of the facts and figures of our company. ● Started in 1993 as a gear components manufacturing unit ● Manufactured first quarter-turn

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Chennai

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Vizag

| December 2013

Jamshedpur

Kolkata

PORT FOLIO

Essential Power Transmission : The mark of excellence Having initiated a successful start, Essential Power Transmission Pvt. Ltd., (EPT) soon expanded its production facilities to include manufacturing of Helical Gear units, Geared Motors, Helical – Bevel Gear units, PIV drives and Special application Gear units.

Bharat C. Shah – Technical Director, Essential Power Transmission P. Ltd

1

947 marked the year of the first member company of Essential Group

–

M/s.

Excellent

Engineering Co., founded by the

dynamic entrepreneur Late ShriChandulal

Shah. The company was setup as an

import and trading company for several reputed

international

manufacturers

from technologically advanced countries.

The pioneering venture soon paved

the way for the establishment of the group’s first ‘Worm Gear manufacturing unit’ in 1958. This marked the beginning

of manufacturing and marketing of

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mechanical power transmission products Chemical, Waste Water Management, under “Esenpro” trademark.

Paper, Pumps & Compressors, Thermal & Having initiated a successful start, Nuclear Power and OEM’s. On the exports Essential Power Transmission Pvt. Ltd., front EPT crossed borders in providing (EPT) soon expanded its production consultancy, design and manufacturing facilities to include manufacturing of service to meet drive applications in Helical Gear units, Geared Motors, Helical countries all over the world, ascertaining – Bevel Gear units, PIV drives and Special all along, its commitment to service. application Gear units.

An ISO 9001:2008 certified company ensures that our manufacturing activities are complied with the Quality Management System. Along with a team of experienced engineers and technocrats, gears are designed as per DIN and AGMA standards. The gear ratings are as per AGMA Standard 2101 – D04.

State-of-the art technology has been the hallmark of EPT’s growth and success.

In fact, EPT plays an active role in both national and international up-gradation standards in Industrial gear units. Latest CNC Gear grinding and Machining facilities ensures high quality gear units. The complete computerization of design calculation and evaluation on latest CAD/ CAM software’s plays a significant part in obtaining optimum precision in gear design.

Our gear units are running successfully in various Kashyap C. Shah industrial sectors including – Chairman & Managing Director, Steel, Cement, Plastic, Essential Power Transmission P. Ltd www.engrreview.com

TECH TRENDS

GEAR & MOTOR

Selecting the best bevel gear A Bevel gearbox has advantages over say, a worm gear because of efficiency, which is considerably higher. Another vital advantage is that bevel gears offer the flexibility of 90 degree solution at ratio that is lower.

S

ome of the important factors to be noted in the selection process of a bevel gear are given here. It must be remembered that all the points need not apply in tandem but depending on the application, they must be looked out for:

● Power transmission requirements ● Design life ● Corrosive elements ● Noise and heat generation.

All of these factors determine the success of the gear in a particular application. Four bevel gears in a square make a differential gear, which can transmit power to two axles spinning at different speeds, such as in an automobile.

Why use Bevel Gear Box? A Bevel gearbox has advantages over say, a worm gear because of efficiency, which is considerably higher. Another vital advantage is that bevel gears offer the flexibility of 90 degree solution at ratio that is lower.

Other advantages include: ● Good performance under high speeds and loads. ● Works particularly well for rightangle drives.

Basic Limitation of a Bevel Gear • Bevel Gears have been observed to suffer from a basic limitation making it sometimes not a

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preferred choice for application.

This limitation is because of the fact that in Bevel Gears often there is no room or leverage provided for supporting it at both the ends while the shafts intersects. This creates the problem of one or both the gears displaying a tendency to overhang their supporting shafts.

This problem is referred to as the overhung load (OHL). It causes further problems like deflecting the shaft, misaligning of gears leading to poor tooth contact and consequently accelerating wear.

• The complicated tooth form of Bevel Gears is a limiting factor in precision.

Accuracy of the Bevel Gears According to the international standards there is generally four types of error. They are the following: Single Pitch Error This type of error is reported as the deviation found in the actual measured pitch value between any of the tooth placed adjacently and the circular pitch(theoretical) at mean cone distance.

Pitch Variation Error Error of the Pitch Variation type is referred to the absolute pitch variation taking place between any two of the tooth placed side by side at the mean cone distance.

Accumulated Pitch Error Accumulated Pitch Error is referred

to as the difference found between the pitch sum (theoretical) of a teeth interval and the total summation of measured pitches(actual) for the same teeth interval taken at the mean cone distance.

Runout Error of Teeth Runout Error of Teeth is defined as the tooth runout, maximum taking place in the radial direction. It is often measured by placing a ball or pin placed between any two teeth at central cone distance.

Manufacturing Bevel Gears There are different ways available now for the manufacturing of Bevel gears. But unlike the spur gears, Bevel gears can be made to have cones that are shaped differently, depending on the type of manufacturing process.

Highlights of the Manufacturing Process ● As shown in the image, these gear mates with a virtual generating gear. ● The cutting blades copies the teeth of a virtual generating gear. ● The virtual generating gear is rotated around its axis (called the cradle). Please see the image.

Application of Bevel Gears The bevel gear find suitable application in a variety of industries.

Prominent among them are the locomotives, printing press, power plants marine applications, cooling towers, steel plants etc

ENGINEERING REVIEW | DECEMBERR 2013 |

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TECH TRENDS

GEAR & MOTOR

Vacuum compatible maxon motors for extreme conditions maxon motor spent several months working alongside Instrument Design Technology (IDT) to customize a small, brushless motor to perform in the extreme vacuum conditions of the synchrotron. This article highlights the challenges in the design.

Fig. 1: The Diamond Light Source particle accelerator in Oxfordshire © 20113

T

he Diamond Light Source particle accelerator in Oxfordshire has been used for projects as diverse as analyzing the effects of strain on aircraft wings, studying the behavior of the HIV virus, and even reading ancient letters without opening them. The 45,000m2 synchrotron facility works by accelerating electrons to 3GeV, generating beams of synchrotron light, up to ten billion times brighter than the sun, in order to un-derstand molecular structures.

To prevent electrons being lost in collision with air molecules, the whole process is undertaken in a vacuum; around one billion times lower than atmospheric pressure.

Clearly, creating scientific instrumentation for such conditions requires great specialist knowledge, and Widnes-based Instrument De-

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sign Technology (IDT) supplies the world’s leading synchrotron facilities.

Diamond specified that the Double Crystal Monochromator for its new X-Ray Spectroscopy Beamline B18 should drive the crucial Bragg rotational axis with a DC motor rather than the usual stepper motor. IDT managing director Paul Murray explains: “The goal was to achieve higher rotation speeds, with a lower motor temperature and smoother drivetrain than the stepper motor we had used previously. Stepper mo-tors are inherently noisy, and often sources of vibration. Eliminating this issue would immediately improve results from the DCM - but the new motor would have to work flawlessly in a vacuum of 10-8 Torr.”

To help solve the problem IDT enlisted the help of Paul Williams, senior sales engineer at maxon motor UK. With experienced engineers handling the project at every stage, and a long history of customizing high-performance motors for applications as demanding as space and surgical robotics, maxon’s teams in Brit-ain and Switzerland were eager to rise to the challenge of creating a cutomized solution.

Williams says: “Because the vacuum in the synchrotron must not be compromised, each individual aspect of the motor and its construction had to be analyzed Continue on page no.120

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Machine Tools and Accessories l Hydraulics and Pneumatics Material Handling Equipments & Machinery l Foundry Equipments l Pumps & Fittings l Precision Tools, Cutting Tools, Dies & Moulds l Instrumentations Automation l Metallurgical Plant and Equipments l Industrial Electrical & Electronics l General Engineering l Machinery for Process Industry l IT Consulting & Service Providers l Fabrication Machinery & Equipments l Industrial Consumables l Factory Cleaning and Pollution Control Equipments l

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TECH TRENDS

GEAR & MOTOR

Continued from page no.118

for possible outgassing. The challenge for us was effectively to create a brushless motor with virtually no glues or plastics, an incredibly high temperature tolerance, and excellent performance.”

The starting point for the custom motor was maxon’s EC22 Heavy Duty. Although originally developed for subsea oil applications, the 22mm brushless motor’s laser-welded stainless steel construction and broad temperature range already addressed many of the needs of high vacuum applications - and being a brush-less DC motor meant it would immediately be more efficient, quiet and responsive than the previous step-per motor.

When customizing the EC22 HD for use in the synchrotron, maxon accounted for a number of factors. First among these was temperature management. Motors in a vacuum cannot dissipate heat through convection in the normal way, so can be prone to overheating. It is therefore important to choose a motor with high temperature tolerance, stay well within its rated performance in

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air, and, if possible, position other components in such a way as to spread heat by conduction. A high ratio gearbox was also vital. High vacuums of 10-7 Torr and greater can pull gaseous compounds from materials such as plastics and glues, compromising performance and contaminating the vacuum - a problem known as outgassing.

Each component in the motor was individually tested, and upgraded as necessary. For example, standard PVC cable coating was re-placed with a more inert, Kapton version. It was therefore important that the EC22 HD was already substantially made from stain-less steel, rather than plastics. Because of the potential for outgassing, the usual glues and epoxies could not be used, and the motor was put together using extensive micro laser welding.

From its work with space and aero-space projects, maxon knew how standard, light greases used on motor bearings are affected in low pressure conditions. It was therefore important to specify an extremely inert lubricant which was also thick enough to avoid giving

off vapor under high vacuum - and to account for the effect of this change on the motor’s operating characteristics and anticipated life cycle. To finally remove any remaining outgassing threat, motors for controlled vacuum conditions are baked at 120ºC for 24 hours. Already purpose-built for temperatures in excess of 200º C, the EC22 HD proved an ideal starting point.

The Double Crystal Monochromator, incorporating the special maxon DC motor, is now in active service in Diamond Light Source’s Beamline B18, playing its role in key experiments on a daily basis.

As an exam-ple, a group of Italian scientists used Beamline B18 to study dust in snowflakes that fell some 800,000 years ago - about the time of the first hominid life on Earth. Ice cores drilled from the Antarctic are made up of layers of frozen snow, dating back hundreds of thousands of years... and minute dust particles trapped as the snow fell hold key information about the earth’s climate, atmosphere and volcanic activity at the time.

Using X-Ray Absorption Spectroscopy, the scientists were able to study the mineral composition of the dust, determining its origin, and unlocking clues to the changes in global climate patterns over hundreds of millennia.

For more information, maxon precision motor India Pvt. Ltd. E-mail info.in@maxonmotor.com www.maxonmotor.in

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PUMP-VALVS INDUSTRY SECTION

PORT FOLIO

Lubi thrives on water pumps & motors.

S

ince 1965 Lubi Industries is a leading Indian manufacturer who produces more than 4500 products ranges of Water Pumps & Electric Motors. It is located at Ahmedabad, just 10 Km away from the International Airport and 400km from Sea Port. Lubi has a massive strength of 2000 steadfast employees, the company has a product manufacturing capacity of 700,000 pumps per annum consisting of Borewell Submersible Pumps, Centrifugal Pumps as well as Drainage & Sewage Pumps suitable for various applications viz. Irrigation, Water Circulation, Building Water Supply, Pressure Boosting, Fire Fighting,

Gardening, HVAC, Civil Water Supply, etc. Lubi is equipped with a state-of-the-art infrastructure with a vertically integrated ultra-modern manufacturing set-up. It is accredited with National certifications like ISO, ISI & BEE and International Certifications like CE & UL. Lubi is recognized as a Market Leader since last 5 decades in the pump Industry, manufacturing a comprehensive range of products which can be utilized in almost all imaginable segments viz. Agricultural, Domestic, Industrial & Building.

Global Expansion : While being a market leader in the pump industry in India, Lubi has a global presence in more than 80 countries over 7 continents. It has overseas branches in UAE & Spain.

It also has 20 branches & more than 1200 Distributor/Dealer network spread across length & breadth of India.

“Our main motto is to ensure customer satisfaction by meeting their exact requirement and providing unmatched after sales service with our manufacturing excellence. Our vision is to strengthen our position by inching closer to becoming a benchmark in the pumps industry”, declares the company.

For more information, contact: Lubi Industries LLP Near Kalyan Mills, Naroda Road, Ahmedabad-380025, Gujarat (India) Ph. +91-79-30610100, Fax. +91-79-30610300 Email – mktsales@lubipumps.com Web – www.lubipumps.com Toll Free Service Hot Line No: 1800 3000 3055

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FACE TO FACE

Corrosion causes incalculable damage to our economy, draining a whopping Rs.50,000 crores annually : Mr. J. J. Dias Corrosion is indeed a big menace in the industry. If left unchecked, it can eat away our scarce resources, says Mr.J.J. Dias, Chief Executive , Kirloskar Corrocoat Pvt. Ltd.. A JV between Kirloskar Brothers Ltd. and Corrocoat Ltd of UK, Kirloskar Corrocoat is doing a commendable work in the area of combating corrosion in the industry and saving our assets .It does this through a plethora of speciality high performance glass flake filled coatings- be it on pipelines, pressure vessels, structurals or pumps. This way, their degradation is arrested and utility is enhanced.The rejuvenation of pumps enhances pumping efficiency in various municipal corporations and important projects and helps in energy conservation, reveals Mr.J.J. Dias, in an interview with Mr. P.K. Balasubramanian. Excerpts:

Q. Corrosion is eating way our scarce resources and, if left unchecked, it can bring incalculable loss to our national exchequer.

Your comments?

Mr. J. J. Dias, Chief Executive Kirloskar Corrocoat Pvt. Ltd

The annual loss due to corrosion in India is about Rs. 50,000 Crore.

India has a large coastline of more than 7500 km with many industries located nearby to utilize sea water for various process inputs. Industrial assets like sea water intake pipelines, pumps, valves, tanks and storage vessels need protection against corrosion to save the metal loss in the continuous metal oxidising chain. Such corrosion if not avoided is irreversible and causes heavy loss of metal every year to our country.

Various initiatives being taken by our Government and industrial associations like CII, SSPC and NACE help to build awareness on corrosion and its preventive measures.

Q. What are the ways and means to combat corrosion and conserve resources?

There are many different materials, technologies and techniques available to combat corrosion and within these primary control methods of corrosion control are: ● ● ● ● ●

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Material selection Coatings Design Changes Change in Potential Environmental Changes

None of these methods can be called as ideal for combating against corrosion. Every method has its own limitations based on the various factors which are important in client’s perspective. High Performance Protective Coatings have been proven as the practical solution to prevent corrosion. Reliability of these coatings is important as replacement or repair will need shutdown which can cost huge revenue loss. High value processes like electricity generation or petroleum refinery are continuous and industries find it difficult to go for emergency shutdowns.

Q. What’s KCPL’s niche in corrosion control and what’s your contribution to the industry?

As KCPL, we are in the business to control the corrosion by use of speciality high performance glass flake filled coatings. With the help of our state of the art formulations designed to offer peak performance in the industry further backed with our trained and experienced manpower, we have emerged as the first choice solution provider in the industry.

We provide long term reliable corrosion control solutions and are one among the few manufacturers in the world to offer single source responsibility turnkey solutions.

Our major contributions to the Indian industry are:

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FACE TO FACE

● Trouble free performance of mission critical equipment’s wrt corrosion issues ● Reliability of solutions and their delivery that delights customers. ● Cost effective long term solutions.

Our Glass Flake coatings are being used in India since last 20 years and still performing at their peak. Our customers have reposed their faith in our capabilities by awarding us many repeat Orders for protecting their capital assets where other conventional systems have failed.

Q. What are the various coatings you use for protection of pipelines from corrosion?

We manufacture a vast variety of glass flake filled coating formulations based on epoxy, Iso-phthalic polyester, polyester, vinyl ester etc.

over its expected design life.

We have a vast range of product basket containing Epoxy, Polyester, Vinyl ester based coating enhanced with glass flake and in some case with silicon carbide and stainless steel flakes for abrasion resistance. Also we have copper flake, copper powder filled coating, especially developed to prevent biological growth in marine environment and sea water carrying pipelines. The coating systems are selected to provide most optimum performance to meet the project design life.

Q. What’s special about ‘Polyglass ‘ coatings? Where are they used?

Torturous path principle

Broad classification of our product range is as follows: Corroglass Series : For Pump, Valves Coating & Refurbishment purpose Polyglass Series : For Internal & External of Pipelines, Vessels Coating Plasmet Series : For External of Structures, Pipelines, Vessels Coating Fluiglide Serie : For Energy Conservation / Energy Efficient coating of Pumps Pipelines are exposed to different environments, handling different liquids and subject to chemical corrosion, erosion corrosion due to flow and velocity of liquid, and also corrosion due to biological growth.

Looking at these corrosive forces that exist in the pipeline, coating system needs to be designed which should be capable of withstanding against such forces and perform consistently

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Polyglass coating system requires no primer although a primer can be provided where logistics demand. It is easy to apply, cures quickly and can be applied in single or multiple coats to achieve the required coating thickness.

Polyglass coating is glass flake filled product. This can be either spray applied or brush applied.

The glass flakes arrange themselves in a manner within film thickness and form torturous path which result in increase in path length for corrosive ions to reach the substrate which attributes the property of low water vapour permeation rate.

Apart from very low water vapour permeation, the glass flakes used

are chemical resistant glass and its specific size / shape when blended in appropriate quantity with resin, having many advantages like, high Abrasion resistance, Resistance to undercutting, Low shrinkage during cure, High adhesion strength and Resistance to cathodic disbondment.

In most of the Refineries and Power plants, pipe line carrying sea water for cooling is the heart of the plant on which efficiency of the plant depends. These pipelines are very prone to corrosion and leading to leakages which are unwanted situation for any industry. Our Polyglass range of products is best choice for all power plants and refineries whose performance is proven and established from last 20 years. Polyglass range is also used in internal coating of storage vessels of acids and alkalis. Polyglass is versatile grade and used in many different application and suitable for corrosive fumes, gases, aggressive chemicals, effluent water and sea water.

Pipe diameters ranging from 3” I.D. to any higher diameter and straight lengths from 6 M to 24 M can be coated using our advanced pipe blasting and coating equipment’s.

The coating work is carried out customer site or at our plant as convenient to the customer.

1 mm coating thickness is designed to provide protection for more than 30 years against sea water corrosion. We have excellent track record around the world including more than 20 years in Indian operating conditions.

Q. What about ‘Corroglass’?

Corroglass coating is developed especially as refurbishment coating for pumps, valves, cooler / condenser water box. The Coating has good dimensional stability which can be engineered in required shape for

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FACE TO FACE

The largest horizontal split case pump coated with Polyglass VEF for a power plant handling seawater.. repair of any severely corroded part.

This coating is tough and strong so that we are able to machine it and maintain original dimensions of the corroded part. This coating provides corrosion protection as well as erosion resistance against liquid flowing with high flow and high velocity.

Q. Do you also use epoxy-based coatings? What are their applications?

Epoxy coatings are mostly known for their mechanical properties and with moderate to good chemical resistance. We have a range of epoxy coating system developed as maintenance coating, chemical resistance coating and Abrasion resistance coating.

Our Plasmet ZF which is epoxy based coating is used as maintenance coating. This coating can be applied on manual prepared surface, where blasting is not allowed or feasible.

And this is recoated with any type of coating for further protection based on client’s requirement. Plasmet ZE is developed as chemical resistance coating used in pipelines internals

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as well as on external for buried pipelines. This epoxy based coating is also used on concrete surface.

Plasmet HTE, specially developed epoxy coating incorporated with Stainless steel and silicon carbide flakes has high abrasion resistance and used in metal extraction industries, Coal mines, Steel industries and sugar industries, where conveyors, pumps, coal chutes, hoppers and material handling equipment’s for protection against abrasion.

We have Epoxy polymer concrete specially developed for strengthening the old concrete and also cast the new concrete structure.

This has dual benefit of high strength and corrosion resistance property and protects rebar corrosion.

Our epoxy products are based on glass flake technology designed to provide long service life.

Q. Where do you apply ‘Fluiglide’ linings? What are their benefits?

‘Fluiglide’ is our specially designed coating formulation for Pump internals and has recognition as the best long-term solution for corrosion protection plus Energy conservation

(i.e. to improve the efficiency over and above already achieved thereby giving substantial saving in energy costs). Fluiglide coating provides very smooth surface and reduces the micro eddies, which may form at boundary layer due to surface roughness that exist on metal surface.

Due to hydrophobic nature of coating, development of high surface tension and reduction in eddies lead to enhancing the laminar flow in the boundary layer ultimately reduces the friction factor which attributes to efficiency improvement. It has good gloss and excellent corrosion resistance.

By use of these coatings, the efficiency of the new Pumps can be improved from 1% to 3% or more depending on the type of Pump and specific speed. The ROI on these coatings due to energy savings is less than 6 months. The improvement in old and used pumps by application of Fluiglide coatings improves the efficiency by 4 -12%. These coatings can be used for Pumps handling drinking water, effluent service, river water etc. the coatings have potable water certification from Indian and UL health authorities.

Q. You are also into refurbishing of pumps for enhancing the pumping efficiency. Which is the coating used for this application and how does it work?

We offer state of the art Pump refurbishment solutions wherein we can bring back the old used Pump performance very close to its original designed one. In case of old used Pumps, the improvement in efficiency due to refurbishment plus coatings can be in the range of 4% to 12 % or more depending on the type of Pump and specific speed.

The payback period is between 3 and 12 months generally. A wide variety Continue on page no.128

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FACE TO FACE

Continued from page no.126 of KCPL manufactured coatings like Corroglass, Polyglass, laminating resins etc are used for repair and refurbishment by cold techniques.

These coating materials are used to fill up, build worn out areas, strengthen weak areas and machined to bring back the original dimensions.

Dynamic balancing of Impeller is also carried out. After refurbishment, all the design tolerances are restored resulting in higher efficiency of pumps than its present operating efficiencies. Pump efficiency is measured before and after coating in the presence of Customer to provide them the confidence. This can be arranged either at customer site in In situ condition or at our Kirloskarwadi factory.

Q. Who are your major customers?

We have been partnering all major power generation, refinery, steel manufacturing, water infrastructure and chemical process companies in corrosion protection of their assets.

To name a few, NTPC Ltd., Lanco, Reliance Energy, NLC Tamil Nadu Power, Essar group, Tata Power, NPCIL, RIL, ONGC, Municipal Corporations etc.

Q. What’s your catalytic contribution to energy conservation?

In India, we pioneered the concept of pump efficiency improvement through coatings which results in energy conservation. Many clients have obtained tremendous energy savings and thereby reduction in operating costs. In each of the last two years, we have saved energy to the tune of about 13000 MW through our efficiency improved coatings.

Our energy conservations solutions are at work in Delhi Metro, Municipal Corporations and other such various important projects.

Apart from this, we also practice energy conservation approach at our

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factory and have received substantial benefits from government through rebates in tariffs.

Q. Could you give some idea of your manufacturing and service capabilities?

We have state of art manufacturing facility at Kirloskarvadi where we manufacture glass flake filled coating and apply on client’s equipment.

This facility is certified for Quality ISO 9001: 2008, environmental ISO 14001:2004 and occupational health and safety standard ISO 18001:2007.

We maintain high standard of quality and safety.

We have a large infrastructure and manpower resources to execute jobs at customer’s sites all over the country. At any given point of time we are operating about 15 projects sites of various sizes. The site infrastructure is modular and can be increased or decreased to meet client’s production schedules.

Q. What’s the technology and application engineering support you get from Corrocoat, UK? Corrocoat Ltd., U.K are the world leaders and pioneers in Glass flake filled technology coatings for Anti-corrosion Products. Kirloskar Corrocoat Pvt. Ltd. in India is their joint venture with Kirloskar Brothers Ltd. This association has been successful because of technology support from Corrocoat Ltd., U.K. and proven track record in manufacturing and service capabilities of Kirloskar Corrocoat Private Ltd. Corrocoat Ltd. U.K. designs, develops and carryout extensive testing in their sate of the art R & D facility at Leeds. The product formulation has advanced corrosion engineering skills and solid technical expertise to meet the demands of specific environments and problems which gives advantage to be able to provide reliable protective coatings

in a variety of corrosive environments.

Corrocoat is actively involved through their support in our various projects in India. All of Corrocoat’s experiences, innovations in projects abroad, special equipment’s used by them etc. are shared with us for adoption in India.

Q. What are the factors that helped you in your meteoric growth in recent years?

Glassflake filled coating technology products for Long Term Corrosion Protection has been the rising demand from industries that look for saving their maintenance and replacement costs. Kirloskar Corrocoat has proven track record of providing solutions using Glassflake filled coating technology to combat corrosion for more than 20 years in Indian conditions. Also the successful completion of projects in customer’s timeline and meeting their expectation of compliance to quality standards in product application has given us an edge over competition.

Q. What’s your road map for the future?

We being the preferred solution provider for corrosion protection and pump efficiency improvement, have strong brand reputation in industry. This helps us in getting turnkey projects. We aim to leverage our strengths of project management to increase our market share in the upcoming infrastructure development by Government and Private companies in Energy and Water segment. We are also reinforcing the pump efficiency improvement business so that more customers can benefit.

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PORT FOLIO

Peristaltic Hose Pump replaced many American, Japanese & Italian Pumps To keep pace with current and future requirements and to meet the demand of economical and maintenance free pumping in the construction industry, Rakesh Engineer would like to showcase the new generation peristaltic hose pump and other superior technical attributes at coming exhibitions. Our focus is to streamline our business operation to have proper focus on cement transfer plants wherein we shall be opening a bigger factory area from Vasai to Palghar.

We have also entered into collaboration with major EPS based Concrete manufacturing companies in India.

Apprises Mr. Rakesh Engineer, B.E. Mech and Mr Ronak Engineer ,Master of Science: Product Development Engineering Systems from the University of Southern California, Los Angeles, MONIBA IN AN INTERVIEW WITH ME.

F

rom time to time moniba has been adding new produsts to its range and upgrading its offerings. the latest being upgrading of the existing series of peristaltic hose pumps and piston diaphragm pumps. What are the important technical attributes of these attributes of these additions and how have the market responses been so far?

We, at Moniba, understand the needs of customer and deliver cost effective and value added solutions to all end users. Our hose pump series have attained unprecedented growth, thanks to its productivity, mobility and labour savings feature.

The demands from varied application sectors and semi-urban geographies has propelled the hose pump to be positioned as an integral part of the

mobile eps/light weight concrete machines for small to medium concreting requirements.

Piston Diaphragm Pump (Germany) Applications : Abrasive and highly viscous slurries with high concentration of solids transfer with very low cost and breakdown. Please see below a list of companies which have benefitted by using Moniba pump for there media transfer

Name of the Company & Application 1. Mahaphant South East Asian Pvt. Ltd. Eps Based Concrete 2. Ashtech India Pvt Ltd Foam Concrete/clc/light Weight

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Cement 3. Godrej And Boyce Ltd Foam Concrete/clc/light Weight Cement 4. Everest Industries Ltd Eps Based Concrete 5. Delta Technologies Foam Concrete/clc/light Weight Cement 6. Eman International Foam Concrete/clc/light Weight Cement 7. Jr. Building Blocks Foam Concrete/clc/light Weight Cement 8. Ishvarya Bricks Foam Concrete/clc/light Weight Cement 9. Samriddhi Buildcon Foam Concrete/clc/light Weight Cement 10. U Brothers Buildcon Foam Concrete/clc/light Weight Cement 11. Larsen & Toubro Ltd Concrete/grouting 12. Gujarat Fluorochemicals Ltd Ptfe Solution For more information E-mail: moniba83@gmail.com Web: www.moniba.net

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ENGINEERING REVIEW |

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TECH TRENDS

PUMPS VALVES

Corrosion, Conservation and Ecology â&#x20AC;&#x153;In a broad perspective corrosion can be defined as tendency of metals and alloys to go back to their original natural state. All the metals are found in the nature in compound form which could be oxides, sulphates, chlorides, phosphates and so on. That is why we observe that the metals and alloys used allover transform themselves into their oxides, sulphate, chlorides phosphates etc. and that is what Corrosion is.

Erosion is the mechanical counter part of corrosion. It is the physical loss of metals or alloys due to friction, abrasion, lack of lubrication, etc during the process. Erosion can be reasonably controlled by proper selection of materials of construction to suit the adverse process parameters and by avoiding or minimizing metal to metal contact .

By S.B. Kunte, Chief HR Manager, Training Institute, RCF Ltd, Mumbai

Typical materials of construction commonly used for some corrosive fluids 1. Nitric Acid

Weak Nitric Acid SS Conc. Nitric Acid 304L,SS310 2RE10 Aluminium

2. Sulfuric Acid

Weak Sulfuric Acid Strong Sulfuric Acid Carbon Steel Carbon Steel with Fibre reinforced Bisphenol Or Vinyl ester lining

3. Phosphoric Acid

30 % concentration Rubber lined Carbon steel, CPVC

4. Urea

SS 316L, 2RE69, Ti

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T

he types of corrosion in chemical industries are very complex in nature because of the different types of chemicals handled in the process. The overflows and leakages of the chemicals from process equipments, the passing valves and leaky flanges make the structural steel and concrete very prone to corrosion attack. Due to this, it can be easily said that corrosion and pollution go hand in hand.

Corrosion damage to the process equipments, pipelines, tanks and vessels can cause leakages and accidental failures resulting in financial losses and irreversible damage to the environment, to the ecology. This is where a plant engineer can make an attempt to control the damage due to corrosion in process plants, stores and godowns. The loss to our

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TECH TRENDS

PUMPS VALVES

Nation due to corrosion damage alone is estimated to be more than Rs. 100,000/ - crores.

The major process corrosion problems in today’s industry can be taken care of by the design Engineers by selecting proper materials of construction for various process equipments and structures.

Most of the equipments today have a definite calculated life due to availability of superior metals and alloys. The modern technology and improved materials of construction have extended the life span of process equipments considerably. Use of extra low carbon high Nickel and Chromium micro alloyed stainless steels, Titanium, Zirconium, Glass, Teflon , synthetic rubbers, polymers etc. have virtually solved many process related corrosion problems.

However all corrosion problems in chemical plants cannot be controlled totally and corrosion in industries and elsewhere continues to take its toll in some form or the other.

Corrosion damage is not faced only by steels and concrete but all alloys and even the precious metals are getting deteriorated in service.

attack causing deep pits or cavities.

Stainless steel and aluminum suffer commonly from pitting corrosion.

of the simultaneous action of corrosion and cyclic stress is called corrosion fatigue.

Intergranular Corrosion:

A few commonly faced types of corrosion are described below:

This is the combined effect of static stress and corrosion which leads into multiple cracks in the materials.

The prime factors involved in this phenomenon are stress, environment, time and internal structure of the materials. For each metal or alloy there is a specific environment for stress corrosion cracking to take place. The corrosive fluids attack materials superficially if stresses are absent. The time required for failure may vary from few days to few years. The damaging effect

Besides these peculiar types of corrosion the most commonly experienced corrosion is “General atmospheric corrosion” of structural steel used every where.

In a developing country like ours the attempt made to economize the project cost by way of not choosing the correct materials of construction or by not providing adequate protection to structural steel have failed miserably in many cases. Such undesired economy has always resulted in premature failure of process equipments.

Inadequate protection of structural steel ends up in heavy corrosion damage demanding an early replacement. This external corrosion of steel is contributing more in destruction of steel than the process corrosion.

In extreme cases external corrosion of process equipments is controlled by using the same lining that is used inside the process vessel e.g. use of rubber lining or FRP lining from outside of vessels. Use of SS or FRP gratings is another example of arresting corrosion in extreme conditions.

Because of a very casual approach, negligence and unawareness of the concerned engineers towards protection of steel and concrete we are destroying steel and concrete worth billions of rupees.

We are exhausting our precious natural and national recourses because replacement has become easier than maintenance.

Painting if executed sensibly is considered to be the easiest and cheapest method of protecting steel and concrete from corrosion.

The idea of painting is to create an

Oxidation: It is the loss of metals due to reaction with oxygen in the atmosphere either at ambient temperature or at elevated temperatures.

Pitting corrosion: Metals which are protected by thin passive oxide film are prone to suffer highly localized corrosion

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selective corrosion of grain boundaries without much damage to grains causes intergranular corrosion. This results into loss of ductility and strength. Austenitic stainless steels and some copper – aluminum alloys suffer from this type of corrosion if the heat treatment is not proper.

Galvanic Corrosion: If two dissimilar metals are electrically in contact with each other in presence of an electrolyte then galvanic corrosion takes place.

The metal with higher corrosion potential becomes anodic and gets corroded. The materials of constuction should not be largely separated in galvanic series to control the galvanic corrosion.

The area of contact of more basic metal should not be very low as compared to the noble metal to reduce the galvanic corrosion.

Stress corrosion:

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impervious barrier between the surface to be protected and the corrosive environment. This barrier should have an optimum thickness so that adequate protection is provided economically. If the barrier is very thin and porous then the efforts in carrying out painting of the plant areas go waste along with the cost of paints, leading to aggravated under film corrosion.

It is not always advisable to use a tailor made painting scheme in a corrosive environment. A plant engineer should try different paints by exposing actual samples and hanging coupons in his corrosive plant environment. The area of such exposed samples should not be less than two sq. ft. The coupons used for evaluating paint samples should not be smaller than six sq. inches. The performance of such samples should be observed at least for one year before finalizing a suitable painting scheme for the corrosive environment of the plant.

The industrial premises can be classified as less corrosive, moderately corrosive and severely corrosive areas. This will largely depend on the process fluids handled, the wind direction, the climate and the age of the plant.

All this demands involvement and supervision of the plant engineer.

A paint technologist alone cannot make a painting scheme in the industry perform well as expected.

The concerned plant engineers must show more involvement and sense of responsibility towards maintenance painting than what is shown presently.

Many times maintenance painting is not given due importance in the plant activities or during project implementation. The plant engineers are seen depending

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largely on the painting contractors.

All the painting contractors are not having adequate knowledge about industrial painting and industrial paints. Such contractors employ a group of labors and try to do maintenance painting with the expensive paints under a very poor and unskilled supervision unsupported by the plant engineers. This is what results in inadequate corrosion protection.

Surface preparation plays an important role in the performance of any painting scheme. Since shot blasting is usually not possible in running plants, one has to rely on mechanical cleaning by wire brush, scrapers emery papers etc.

Air jet or water jet should be used wherever possible. The loosely adhering rust, scales, paint films etc should be removed. The edges and corners should be cleaned with more care because these are the sites where corrosion initiates.

Chemical cleaning should be done under expert supervision only. Before applying paint the surface should be wiped with cloth every time. After applying paint and providing the recommended drying time, a touch up job should be carried out before applying the next coat. A strict supervision is required on proper mixing of paint and on addition of thinner in recommended quantities.

Normally synthetic enamels are used in less corrosive areas and chlorinated rubber, epoxies, polyurethanes etc. are used in more corrosive areas.

Surface preparation, skilled application and expert supervision are the keys to good performance of any paint system. The use of higher grades of paints in a less corrosive area may not be of great use unless surface preparation is done by

shot/grit blasting.

The use of synthetic enamels and chlorinated rubber paints could fulfill about 60 to 80 percent requirements of maintenance painting in the industries.

The higher grade paints could be more effective on new structures where painting could be done after shot blasting.

Like super alloys there are super paints which can be applied on wet surface without any primer and without any shot blasting. The higher cost of these paints and their application by unskilled painters has put limitations on their use.

Knowing more about paints is interesting and very useful as the specifications laid down for paints and painting are very limited. A limited knowledge about primer as red oxide and finish paint as enamel by the user department is not enough today. The plant engineers should learn more about composition and properties of paints. One should be conversant with terms like solid volume ratio, pigment content, binder content, viscosity, shelf life, pot life, dry film thickness, wet film thickness etc.

The difference between domestic painting and industrial painting needs to be clearly understood.

Like all other professions painting also needs to be treated as a skilled operation by expert painters, supervisors and contractors.

A paint system could consist of anything between two to five coats. A two coat system could be with self priming paints and a five coat system could be with two coats of primer, one coat of MIO ( Micaceous iron oxide) and two coats of finish paint. Both the two coat and five coat systems are peculiar cases and not very Continue on page no.136

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Continued from page no.134

The entire process is adding to carbon foot prints in the life cycle of earth and disturbing the ecological balance. This may not be tragic but the way we are using everything is definitely a matter of concern. For understanding the severity just look at the careless and extravagant use of staples, pins and U clips.

These might be weighing in grams or milligrams but globally the consumption per day could be in tonnes. Where one staple is required two or even more staples are used and sometimes they are used when not required. Efforts to conserve must begin from a stapler pin.

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commonly used. By and large a three coat system comprising of one primer and two finish coats is s easy to execute and hence widely used. A DFT ( Dry film thickness) of about 110 microns can be normally achieved in a 3 coat system and it could be enough to protect the steel, provided painting is carried out under strict supervision and is inspected periodically.

The interval between two painting cycles may not be fixed as a schedule but it should depend on the performance of the paints used. A delay in painting even after the paint is damaged badly could lead to severe corrosion of the steel under the paint film. As soon as the paint shows damage in the form of blistering, chalking, peeling off etc. a touch up job should be carried out and if the damage is severe then repainting should be planned. One litre of paint manufactured for protection adds to the carbon foot prints and its application is going to generate some non biodegradable waste after the purpose is served. Both are of ecological concern.

With all these efforts to protect the steel and concrete one may not be able to stop a structure from falling but one can extract maximum life from it. And that is conservation. Like charity conservation also begins at home.

We are running out of all resources at a dangerous rate due to the global population explosion and due to our own extravagancy. We are likely to run out of fresh Nickel before the end of this century with present rate of consumption.

This could be true for many other resources.

Extracting pure metals from natural ores is very costly in terms of money as well as energy. Making

desired alloys from them is more costly and the bill goes further high for making the required objects from metals and alloys. The entire process is adding to carbon foot prints in the life cycle of earth and disturbing the ecological balance.

This may not be tragic but the way we are using everything is definitely a matter of concern. For understanding the severity just look at the careless and extravagant use of staples, pins and U clips.

These might be weighing in grams or milligrams but globally the consumption per day could be in tonnes. Where one staple is required two or even more staples are used and sometimes they are used when not required. Efforts to conserve must begin from a stapler pin. The used objects are scrapped either due to damage or for replacement with a better object.

The scrap could be either melting scrap or soiled scrap. Melting scrap could be reworked to make new objects costing more energy and more carbon foot prints. The soiled scrap is gone forever back to earth.

The staples, pins and such small objects are to be treated as soiled scrap the day they are born. The mother nature has very generously stored all the resources at select locations for our use. Soiling any resource means taking it out from the reservoir and spreading it in PPT level all over, not to be seen again by our future generations.

The real celebration of the Earth day or Environment week will be an attempt to save that gram of steel from getting soiled or to convert that nut fallen on the ground from soiled scrap into melting scrap.

For more information

By S.B. Kunte, Chief HR Manager, Training Institute, RCF Ltd, Mumbai.

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INDUSTRIAL SAFETY & SECURITY SECTION

ecure

FACE TO FACE

A made in India brand revolution Mr. Sanjeev Sehgal, Managing Director Sparsh

Q Sparsh has gained remarkable positioning in the security industry; please share some of its milestones & achievements?

Established in 2002, Sparsh is pioneer and leader in manufacturing CCTV video surveillance products in India with product presence in more than 10 countries, presence in more than 100 cities in India, channel strength of more than 1500 and manufacturing more than a million security equipments every quarter.

Sparsh has revolutionized the Indian security market by being India’s first company to manufacture CCTV cameras in India in 2007 and in just span of six years, Sparsh, today is the pioneer and leader in the security industry having global footprints. Our focus on indigenous designing and manufacturing of technologically advanced electronic security devices has put India on the global map for designing & manufacturing high quality and technologically advanced CCTV video surveillance products. In short “Sparsh strives to have Global Footprint for ‘Made in India’ Products”.

Sparsh has won admiration and trust of its partners, customer and industry as large and has a proven track record of a lot of firsts, technical advancement, corporate maturity, and achievements and has won many awards, some which are as follows:

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• Best Security Solution Provider (NCN 2012) • Technology Evangelist of the year (VAR India 2012) • “Top 100 Most Trusted Companies in India” (VAR India 2012 & 2013) • “Leaders of Tomorrow” in Electrical and Electronics category.

(ET Now-IndiaMART 2010) • “Best Security System Company”

by South Asia’s most popular electronics magazine (Electronics For You (EFY) 2009, 2010 & 2011) • Award for Entrepreneurial Excellence in Manufacturing (ElcinaDun & Bradstreet 2009) • “Entrepreneurial Company of the Year 2007- CCTV” Frost & Sullivan award.

Q Could you brief us about overall business activities of Sparsh (tieups, associations, reach, network)?

Sparsh has been at the forefront for introducing new CCTV technology in the Indian market. As a result of our focus on innovation, quality & customer service, many multinationals have chosen to work closely with us including but not limited to Sony Electronics, Texas Instruments and Aptina. Sparsh has a PAN India network with more than 1500 resellers compromising of C&F, franchisees, distributors, dealers,

channel partners, system integrators and enterprise SI’s. We have presence in more than 100 cities in India and we target to increase our partners to 3000 having presence in more than 150 cities in next fiscal.

We aspire to be a true Indian company with global outlook having worldwide presence, and therefore we have increased focus on global partners. We have our participation in major international security trade shows like Security China in Beijing, INTERSEC in Dubai & SECUTECH in Taiwan wherein we want to spot the potential distributors, dealers or an OEM for our range of CCTV Surveillance products. We already have separated our international sales department and have special focus on emerging markets including South Asia, Middle East & Africa.

Q Can you elaborate more about the product portfolio & its applications?

Our product portfolio includes: • CCTV Camera • Digital Video Recorder • IP Camera • Analog Speed Dome • IP Speed Dome • Video Management Software • CCTV Accessories CCTV today has application in all fields of life. Our products are used in all security applications including • Government and public buildings • Transportation – airport, railways and bus stations • Education–schools & universities • Retail – shops and malls • Banks • Hotels • Residential buildings

Q Which are the some of your pioneering products and services you introduced in the market recently or is there any plan to launch the new products?

We pioneered the analogue video surveillance category in 2011 and now we are pioneering the category www.engrreview.com

FACE TO FACE

of IP video surveillance which would be our new growth driver. We have engineered and added lot of products in the IP range. Last year we launched our ZSecure IP camera series and have already received overwhelming response for it. We have already bagged good projects and both our analogue and IP products have passed stringent performance and quality tests from NABL approved government lab in India, once again re-sounding our focus of quality and technology at par international standards.

Our new ZSecure Video Management Software comes in three different versions Lite, Professional and Enterprise with features and scalability suiting every requirement. It supports features like virtually unlimited camera integration, video analytics, distributed client server architecture, open platform supporting multi brands, multi server support, server failover mechanism, etc.

We are launching Mega Pixel IP cameras and would soon be launching Standalone NVR series which would be very helpful in addressing the installation complexity for IP camera, still retaining all benefits of IP but installation friendly like analogue cameras. This would be more like plug and play for IP camera quite similar to how plug and play happens for analogue camera along with DVR. We are also aiming for newer heights in the analogue product domain as well. Our new WD1 DVR series based on Texas Instruments’ new DaVinci™ DM8107 platform has received overwhelming response from partners & customers.

This is the next generation DVR series with features like NAS storage support, FTP storage, alarms for crucial events, complete health check up of the DVR, 3G & Wi-Fi enabled, etc. Moreover the next generation compression technology helps the customers save crucial storage requirements thus saving cost. We are already working on supporting all our future product lines with next generation H.265 compression technology, which would further help customers

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to get an increased ROI on their investments. We have also upgraded our HQIS series from 600 TVL to 700 TVL and would be showcasing 800 TVL and 1000 TVL analogue camera series in IISE, New Delhi.

With several traditional free and unreliable DDNS services and reliable one’s converting to fee based services, Sparsh has bridged this gap by launching reliable and secure Sparsh Express DDNS services – Free DDNS services for all Sparsh partners and customers. This service would not only help bridge the gap of a free DDNS service but also provide a platform for customers and partners to manage their Sparsh devices on a single window and at click of a mouse button.

We have also integrated our customer care centre with Integrated Voice and Recording System (IVRS) for hassle free support to all our partners and bring customer service to a completely new level. Our dedicated professional team of customer care executives now provides support for all Sparsh products at a single central number. We do not follow the herd mentality of easy low cost imports from China but do them better with our inherent strength in product design, software development and manufacturing. We want to make our customers “Feel Secure” when they buy Sparsh products rather than being unsure about Chinese quality.

Q How do you account R&D activity in your company?

Getting the expertise from world’s top companies; Sony Electronics and Aptina in the analogue domain, we are today manufacturing world class products in the analogue range. In IP range, getting expertise from the leading company; Texas Instruments, Sparsh has developed and launched the next generation IP cameras and also became the first India-based company to launch 4, 8 and 16 channels designed and developed DVR series based on TI’s DaVinci™ DM8107.

We would be launching our Mega Pixel IP cameras in IISE, New Delhi

from 26th to 29th Septmeber,2013 which are developed with technical expertise from Aptina, one of the leading and popular company in the Mega Pixel space. We have associated with the best and leading companies in each space to support us with the latest and best in class technologies.

This in combination with our R&D team and software expertise, what India is known world over for, enables us to design and develop work class products.

Q What has been the growth story of Sparsh?

Sparsh has grown at more than 50% CAGR from last five years and would continue to grow by expanding its product portfolio and global footprint.

This year we focus at growing more than 50% and consolidate our brand position in different regions in India.

We also focus to streamline our channel and expand our reach to more than 150 cities with more than 3000 channel partners. We by our studies hold approximately 8% of the CCTV market share by volume and want to increase our market to more than 10% this year. This year our DVR market share grew by 75% and we aim to have more than 15% of market share in DVRs and 5% in IP cameras by this year end.

Q Brief us about future plans of Sparsh?

Our future expansion will be both in Analogue and IP video surveillance category, with IP category getting more focus. We have already launched products in this category and aim to complete the IP portfolio by end of this fiscal including megapixel IP

Sparsh Core Team Members

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2014 and is also an Event Associate for IBEX 2014.

Q How do SPGI will facilitate the industry to promote standards & right products to end users?

Sparsh Team at Corporate Office cameras and network video recorders.

We would also be adding 800TVL and 1000 TVL of analogue products to address the increasing demand for high resolution cameras. We are already a leader in the analogue category and our target is to be the leading brand in the IP category as well in next two years.

This year we are also focussing on government vertical with Sparsh already registered as an approved DGS&D brand for supply of CCTV cameras and solution to all central and state government bodies. We also aim to expand our global reach and target to achieve 10% of our sales revenue through exports in next two to three years. We have already started exports to more than ten countries including Nepal, Bhutan, Sri Lanka, Bangladesh, UAE, Oman, Kuwait, Vietnam, and few countries in Europe.

The main objective of SPGI is driven by the sole motive of structuring the industry and unitedly making a representation in various segments for the growth and benefit of Indian Security professionals and organizations and in turn making the end customer benefit from an organized and structured industry. SPGI has initiated the matter of Standardization of Security Products with BIS (Bureau of Indian Standards), who have already initiated the process of formulating Indian Standards for all Electronic Products. BIS has made these standards mandatory for 15 Electronics/ IT Products from July’2013.

SPGI is in talks with various State Governments so that the taxes are reduced on Security Products and Services. This will not only reduce the burden on Customer’s pocket but shall also ensure healthier competition between good security system providers.

Our vision includes India to be put on the world map as a competition to other security equipment manufacturing countries specially China. We

are talking to various associates and government bodies to get a preferred status to the Security Industry so that it can grow faster and catch up with the other manufacturing countries.

Q How do you foresee “India” as a potential market, what are the prospects?

The growing incidences of terrorist attacks (26/11 attack) and other criminal activities have significantly changed the security perception of the Indian customers and various government agencies, which are now looking for better and advanced security products & solutions. The changing socio-economic conditions have made video surveillance a must have for both government and private organizations.

The need for security in almost every walk of life is driving the demand for CCTV cameras thus providing attractive business opportunity for multi-nationals, local firms and traders. Based on various estimates, global CCTV market is still growing at double digit rates and Indian market is growing at few times that rate. Asia accounts for over 1/3rd of the global market with India and China driving bulk of the growth. Indian CCTV market has grown at 25-35% CAGR in last few years and we expect growth rates to continue for next 3-5 years.

Q You being the Founding Chairman of SPGI, what are your plans to promote this association?

Q What are the issues you need to address that are related to your industry?

SPGI is a group of Key Security Professionals who have come together for the sole and selfless purpose of betterment of the Indian Security Industry.

We believe that we need not need to promote the group as we believe that like-minded people will keep on joining without any promotion.

In a short span of time, SPGI has become an invincible force and is successfully working in multiple fields which will prove beneficial to the Indian Security Industry. SPGI has been appointed as a Co-organizer of IISE 2013, associate for Intersec Dubai

Despite such a growing market, Indian CCTV market is still much unorganized with many traders flooding the market with inferior imported products. Customers need to be educated so that they can buy the right product for their security needs and get best return on their investment. In addition, government needs to set standards for security devices that can be sold and provide guidelines for import and export of electronic security products. In addition, government needs to create policies to promote local manufacturing of security products.

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Sparsh Corporate Office in Noida

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PORT FOLIO

SHOWA BEST GLOVE appoints Marvel Gloves Industries - as authorized distributor for the region of India

Mr. Shuji Kondo - Director & GM of International Division Showa Glove Co., with Mr. Farooq Abdullah of Marvel Gloves Industries

E

stablished in 1954, Showa Glove Co., a manufacturer of a wide variety of gloves from home-use to industrial â&#x20AC;&#x201C; use gloves, vigorously promotes high-quality gloves that provide grip & dexterity, including Top Fit gloves and Palm Fit gloves, targeting semiconductor and electric and electronic equipment plants both in Japan and abroad.

The company has an annual total production capacity of 180 million pairs of gloves.

SHOWA maintains a manufacturing plant and research and development centres in Himeji, Hyogo Prefecture in Japan, in addition to its head office. It also has production plants in Perlis, Malaysia and Binh Duong, Vietnam. It has sales bases

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in Seattle in the United States and in Paris, France and has been strengthening its sales activities in the Asian market.

SHOWA offers high-performance solutions to the complex problems of hand protection in the workplace. The constant growth of our brand on the international market is a testament to the increasing popularity of SHOWA range of gloves.

Mr. Shuji Kondo, Director and GM of International Division Showa Glove co. says â&#x20AC;&#x153;From its inception, the basics of SHOWA company have been to produce high-quality products based on our original idea and with ethos of accident reduction through the promotion of Glove wearing, SHOWA will continue to offer high quality Gloves and Solutions for Hand Protection Mr. Farooq Abdullah of Marvel Gloves Industries is confident that Indian workers & Industries will use high quality gloves for hand protection and will not compromise by using low quality safety gloves and will insist for right safety gloves for hand protection and also to avoid workplace accidents Considering tremendous growth of Industries in India and demand of high quality safety gloves in Indian Industries in all sectors, Showa Best Glove decided to enter in Indian market and has appointed Marvel Gloves Industries Mumbai-India as their Authorized Distributor for SHOWA BEST Gloves for India.

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FACE TO FACE

Cognitive heritage of technology excellence Gunnebo India, a subsidiary of the Swedish-based Gunnebo Security Group, has emerged as a dominant player in the security business in India.

The parent company incorporated in 1764, is today a global security group with 5,800 employees in 33 countries and an annual turnover of EUR 580 million. Gunnebo’s portfolio today encompasses the entire gamut of security & safety systems and solutions, having brought the top-of -the-line international brands under its umbrella through acquisitions. Mr. P.K. Balasubramanian converses with Mr. Sandeep Deshpande, Managing Director& Country Manager – Gunnebo IndiaPrivate Limited to get a ringside view of the company’s products & services spectrum which is all-pervading, reliable and the best- in -class to help the customer maximize his ROI and ultimately get the much needed peace of mind. Excerpts:

Mr. Sandeep Deshpande, Managing Director, Gunnebo India Pvt. Ltd.

Q. Gunnebo is a name to reckon with in the security solutions industry worldwide. What’s your standing today and how could you achieve this position?

We are a leading global supplier within safety & security products, systems & solutions, striving round the clock and all 365 days of the year to make the world safer – literally.

We are not just a niche leader. Our solutions are unique, cutting across even competitive brands which are maintained and serviced by us. Being a system integrator, we at Gunnebo India partner with all OEMs

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for implementing different turnkey projects.

Besides our own broad portfolio of solutions, products and services we also partner up with world renowned brands in every category.

We do so in order to provide the best solution for our customer’s needs, today and tomorrow. For our fast organic growth, we believe in leveraging upon existing brands of repute. This is how the brands trusted the world overlike Fichet-Bauche, Chubbsafes, Steelage and Minimax are under our umbrella. Minimax, for instance, is around since 1932.

Q. You have been operational worldwide. Could you throw some light on your gamut of activities and affiliations?

As for Gunnebo India, whose operations started within Steelage in 1932, many of our 32 sister companies around the globe has a long heritage. Being part of a global group among others means to take advantage of concepts and solutions already developed and implemented with customers in other parts of the world and bring them to India.

For some parts of our portfolio we are self-sufficient through our www.engrreview.com

FACE TO FACE are in Halol, Gujarat. We have a workforce of 800 people. Here we manufacture all Physical security products plus our exhaustive range of Fire Extinguishers. We also have our full-fledged R&D set up here.

Globally, we have additional 11 manufacturing facilities and an R&D-team of close to 100 people.

Gunnebo’s modern manufacturing facility in Halol, Gujarat, also housing its R & D center well-equipped manufacturing facility at Halol in Gujarat. The plant also houses our centralized R & D whose onus is to innovate existing products, develop new products demanded by emerging applications and markets, and help in the industrialization process. For other ranges, we use our global supply chain, being a mix of own production in 11 global factories and partnerships.

When we talk about our global operations and spread, we have our presence in 33 countries.

Our presence is prominent in Asia Pacific, Europe, Africa, Australia and North America. We are the global leading supplier of entrance control solutions for pedestrians, and in the US market, we are the second largest supplier of physical security equipment to the banking and governmental sector.

products representing virtually every domain. Our portfolio includes cash handling solutions, safes and vaults, entrance security, electronic security, fire protection systems, system integration and security services

Q. What ‘s your product range and what are their applications?

As I said earlier, we have a basketfulof

Q. What’s your manufacturing set-up?

In India, our manufacturing facilities

Q. What’s your market penetration - sector-wise?

We are there in all the domains, be it security solutions for banks, retail, CIT, airports, mass transit, offices and large institutions. Our portfolio includes cash handling solutions, safes and vaults, entrance security, electronic security, fire protection systems and security services

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Q. Frankly, there is no dearth of products in your class. That being the case, what is your differentiated offer to the discerning customer?

We differentiate from many of our competitors through our deep knowledge of the security business, together with our broad in-house portfolio of products, solutions and services. Unlike most competitors, security is all we do – this is our core focus and competence!

To answer your question, our ‘Life cycle approach to service’ is something unparalleled. We are in constant touch with the customer who is using our products. When there are upgrades in technology/ products, we share the benefits with the customers and help them go in for retrofitting so as to make the system contemporary. We also offer remote monitoring services to check intrusion and surveillance of customer premises.

Q. Reliability is of paramount importance in safety products. How do you infuse quality and reliability in your range of manufacture?

We infuse quality and reliability in our design stage itself. Subsequently, the products are all manufactured to conform to our own stringent QC regimen. Our fire extinguishers, for instance, are designed to conform to the latest IS:15683-2006 which is in line with the latest internationally accepted standards in force in all developed countries. We have a fire test facility at Halol where these extinguishers are subjected to fire test as per this standard. The products coming out of our crucibles are of impeccable quality and rugged enough to fight the hazard of fire.

Q. What are the strategies you adopt to market these products at home and abroad?

While our HO is in Thane, we have a network of regional offices and branch offices strategically located to stay closer to the markets and the customers. Our regional offices are in Kolkata, Bangalore, Chennai and Noida, while the branches are in Chandigarh, Jaipur, Ahmedabad and Hyderabad. To secure full coverage of the Indian marketplace, we also have over a hundred channel partners with thorough product knowledge to sell and provide after-sales support.

Also we have a dedicated team to handle key accounts.

Our strategy is to serve our customer better, gain his satisfaction and be his dependable partner in progress.

Q. Could you give some insight into your operating philosophy and corporate governance?

Being part of a global group, we

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Entrance control – The Gunnebo way naturally have global, corporate governance procedures, starting with the code of conduct and our core values, and additional policies and guidelines within the field.

For India, the main plank of our operating philosophy is high ethical standards in our diverse businesses. Our HR Head also acts as the Corporate Ethical Officer. All our communication channels are open to educate our own people on our beliefs and values.

Q. Do you foresee India as a potential and burgeoning market?

India is undoubtedly a burgeoning market and it is one of the top three growth markets in the world. Our global CEO often visits India and discusses global trends with key customers. We attach so much importance to India and its potential.

Q. What ‘s the status of the global security solutions industry?

In general, the security market is known to grow at 3-5 per cent more than average GDP. With this being said, there are of course wide differences around the Globe. In Asia –India in particular, we have seen an amazing growth within the sector over the past years, and our business is still growing with double

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percentages year-on-year.

For Gunnebo, we can also see the same trends in many other Asian markets like Malaysia, China and Korea. Our sister companies in Americas also see a strong growth pace, right now especially in Brazil and Mexico. In Europe, the market situation in general is a bit different with many developed economies currently experiencing a financial slowdown. However security investment is something that normally is quite flat also in a recession. Especially for a company like Gunnebo with a well-developed service offering.

Q. What are the measures you take to maintain your leadership position?

Our success builds on long-term relationships with our customers.

Together with them, we are striving to innovate all the time, to find solutions that will help our customer develop as well. We want to remain customer focused, giving more value and retaining the customer. We want to continue to be their selected partner in progress in the security domain.

Q. What are the technology trends that drive the security business?

If you visit a security fair today, the average exhibitor is in electronic security, especially CCTV and surveillance. For Gunnebo, the focus is more on how to integrate different applications into one solution, making life easy for our customers.

There is also a trend where also more traditional security equipment like safes and vaults become intelligent and are connected online through locking systems and other security related equipment.

We anticipate a big technological leap in physical electronic security and cashrelated products. Convergence is possible on common platforms. So we must take cognizance of these developments and come out with solutions. If we have to make a dent

in the market, we have to have a 360 degree approach.

Q. What are the extraneous factors that affect this business and what are the challenges ahead for a front runner like you?

The upheavals in the political and economic scenes will make an impact. Right now there is a slowdown in infrastructure. It is a matter of concern. The perception of the customer with respect to security also matters quite a lot.

Many customers today want to ‘play safe ‘rather than ‘be safe’. This is a dilemma to be addressed. Customer awareness and education are to be stepped up.

Q. What are your inherent strengths?

Long and strong customer relations, strong brands, innovative products, purely focused on security, life cycle approach to security solutions, customer focus and a dedicated workforce yearning and trained for excellence make up our inherent strengths.

Q. What’s your roadmap for Gunnebo?

We want to grow faster than the market, doubling our turnover every three years. We want to maintain our leadership position and we want the industry to recognize us as the ‘thought leader’

Q. How do you look at the future?

The safety and security business in India is still at the nascent stage.

We have a long way to go, giving clear-cut directions. The business is growing and will continue to grow at a rate of 12-15% for the next 5-10 years. Innovation and technology will change the landscape. Our estimation is that the market size in India is in the vicinity of a billion US dollar.

Gunnebo India will continue to grow at 30-35% in the coming years.

Overall, the future is quite bright both for the industry and for us. www.engrreview.com

TECH UPDATE

The business case for health and safety

By Maria Maniati, Research Officer at the British Safety Council

G

iven that health and safety interventions require money, time, knowledge and workforce support, when the time comes to invest, employers sometimes find themselves asking the question ‘why bother?’ It’s a reasonable question, but it’s one that needs to be confronted. Many employers who manage health and safety in a sensible and proportionate way do not see it as a burden. For them, health and safety is an integral part of managing business risk; is about people, about taking care of one’s business; it is about enabling the workforce to play their roles while ensuring workplaces are kept healthy and safe.

For many organisations, it is about the reputation of the business and how it is perceived by key stakeholders and the public. A well managed health and safety system has a positive impact on productivity; it should be seen as an enabler, not as a brake on business success. Research conducted by insurance company Aviva in 2011 found that nearly two thirds of workers said they would work harder for an employer who invested in their health. The same study showed that 42% of the employers surveyed considered that a good work/life balance helps increase morale and productivity and 63% believed that a healthy workforce is more productive than an unhealthy one. Apart from the effect on productivity, company image is a vital asset which can be directly affected by the business’s health and safety performance. Failures can have

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devastating impact on a company’s image, including media grilling, negative public opinion, criminal sanctions, unwanted attention, reduced sales and a fall in profits.

Furthermore, a company’s willingness to innovate is always risky and it is interwoven with health and safety issues. Therefore, it is unlikely that an organisation unable to control risks in the workplace will be either innovative or successful.

The benefits of health and safety interventions do not stop here. Numerous companies have reported savings after implementing a new initiative or modifying a faulty procedure. In 2009 AstraZeneca, the global pharmaceutical company, reported savings after the implementation of a wellness programme that included health promotion activities and an ergonomically designed working environment. The company saved £500,000 to £700,000 through improved productivity and £80,000 on health insurance costs; occupational accidents and illness fell by 61%. At the end of the 1990s, the British Polythene Industries (BPI), one of the largest manufacturers of polythene film products worldwide, decided to engage in an ‘Osteopaths for Industry’ programme, in order to reduce the days lost due to musculoskeletal disorders (MSDs). The main component of the programme was a new system, the Musculoskeletal Injury Management System, through which the company gained access to a national network of osteopaths, chiropractors and physiotherapists. In the first year of the initiative BPI reported savings of £192,000. Taking into account that the annual cost of the programme was approximately £16,000, BPI concluded that for every £1 spent, the organisation benefitted with savings of £12. In 2006 British Gas, one of the UK’s leading domestic energy suppliers and employer of 30,000 people, focused on managing its road risks to cut down driving injuries and make financial savings. New gadgets were incorporated in every vehicle, including

speed limiters and incident analysis equipment. The company also introduced electronic driver licence checks and a brand new Driver Risk Management System (DRMS). The DRMS resembled an ‘evaluation system’, which allocated points according to the number of incidents the driver had been involved in.

The higher a driver was rated in terms of the risk, the more hours of intensive driver development training they had to attend. British Gas estimated that the number of incidents fell by 30%, and the company saved over £2m in vehicle repairs to its own fleet alone. Picking up the ‘why bother?’ question again, we can see there is a great deal of evidence saying exactly why we should bother. Any hesitation or denial about sound and appropriate investment in health and safety is nonsensical given the existing evidence. The data concerning the business case for sound and proportionate investment in health and safety is clear. Rare are cases where an organisation did not benefit one way or another from the introduction of a wellness programme or a risk assessment; few companies regret spending money on health and safety initiatives. The goal is to help business understand the potential costs of poorly managed health and safety and the benefits that properly focused and resourced initiatives can produce. Effective health and safety will follow when there is a widespread recognition of the benefits that can be achieved through sensible and proportionate risk management. With powerful voices determined to discredit health and safety, there is a long way to go in raising its profile. However, with the existing evidence and a clear vision about the importance of health and safety for the future, this can be the start of how health and safety is seen.

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FACE TO FACE

Prolite Autoglo The Guiding Light The importance of Emergency Lighting Systems is not realised till an emergency arises or a mishap strikes. It’s a crucial resource in rescue operations and in safeguarding people’s lives. The National Building Code makes it mandatory to install Emergency Lighting System in high-rise and all commercial buildings. In India, till recently it was considered an unnecessary investment but given the increasing awareness, companies and individuals have started incorporating it in their premises. Mr. Harsha Joshi, C.E.O. of Prolite Autoglo Limited, gives more information about the future of Emergency Lighting Systems in India, his plans and vision. are opening their shop in India and a good number of international brands coming in, the emergency lighting system has made inroad into the Indian market. Even domestic market is realising the importance of emergency lighting system.

Mr. Harsha Joshi, C.E.O Prolite Autoglo Limited

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How has India’s emergency lighting system evolved during the last one decade?

Emergency lighting system has always been an integral part of residential, commercial and industrial lives. It’s followed all across the world and has played crucial role in safeguarding human lives and property, to the centre stage and resulted in changing people’s outlook towards safety norms.

In India, there have been changes in the perception towards emrgency lighting system. As more and more multinational companies | December 2013 | ENGINEERING REVIEW

What potential do emergency lighting system have in India?

In India, the potential is huge, especially when India’s economy is growing and new industrial and commercial buildings are being set up in large numbers. According to National Building Code, installation of Emergency Lighting System is mandatory. There is already a law about it and the government needs to make sure it’s implemented in letter and spirit.

How has Indian market been responding to innovations in the emergency lighting system?

Innovations are always welcomed if it serves the required purpose.

Emergency Lighting System is crucial because it’s a matter of people’s lives and need to be reinvented to serve definite purpose.

We are the market leader in the segment and have made sure that our clients get the latest technology.

We come out with new models every two years. We create market for our products as we know our clients interests best. www.engrreview.com

FACE TO FACE

When compared globally, where does India stand in terms of adopting new technologies in lighting system?

We are at par with the rest of the world. Our products meet all the international norms and follow the approved safety standards. The only exception to this is Europe, which is, if spoken qualitatively, two years ahead of India. European companies invest in R & D appropriately to remain ahead of the race. They are always more innovative. They thought of Centralised Emergency Lighting System much ahead of the rest of the world.

Do you think Indian companies invest adequately in R & D to upgrade their products?

We give special emphasis to R & D because Emergency Lighting System is all about technology. In order to excel one has to continuously look for better products. We invest approximately 6-7% of our budget into R & D. We believe in coming out with new innovative products rather than copying the existing products.

If you thing copying a technology helps then look at China which has been doing this for the last few decades. It can make products in volume but not qualify products. To come out with a new product, it has to be thought out much in advance and knowledge has to be acquired to do the same.

What measures have you been taking to comply with international standards in terms of quality?

We have adopted latest technology to test our products and we stick to international standards when it comes to quality. The testing of our products are the best. We have been following the NBC norms which www.engrreview.com

are qualitatively higher than any international standard. It’s better than the standards of the UAE. The government needs to make sure that the law is followed in its true spirit.

Today’s product- orented clients want to customise their products as per their needs. What facilities do you provide to meet their requirements?

We give a fairly good amount of leverage to customers to come out with their needs, but not at the cost of safety norms. A customer can demand a change in the design but only as long as it doesn’t effect the main features of our products. In fact we tell our customers that we are the best in the field and we know what’s good for you.

You are also in the field of consultancy services, which type of services do you provide?

We provide designing, lay out and installation of Emergency Lighting System. Our customers give us the drawing of their office and we come out with the planning and implementation of emergency lighting system.

Who are your role models in business?

I would say, Tata’s are my role models.

They have not only turned their business into successful models but have inspired a whole generation of entrepreneurs. They have ethical work culture with equal concern for people and environment. The Group has feelings, a human heart and they are into a lot of charity work.

Have a great escape.......

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TECH UPDATE

India relies on VdS certificates The ”Bureau of Indian Standards“ has become the next organi-zation to recommend VdS standards for optimum fire protection. // Approval from VdS, Europe´s number One institute for fire protection, guarantees the certified reliability of products. // Come see the exhibition of German top engineering for fire pro-tection at the Fire India, Hall 1-F11.

V

dS guidelines, which are wellknown for their particularly high level of practice orientation, are being used as safety standards in a multi-tude of countries all over the world. The latest nation to put its trust in VdS guidelines is India, which continues to be one of the world´s most rapidly expanding economies, boasting economic growth of 5% in 2012. In its “Code of Practice“for automatic fire detection and alarm sys-tems, for example, the ”Bureau of Indian Standards“recommends the use of systems that have been approved with a VdS certificate. ”The standards announced by the Indian authorities are a recognition of both the achievements of our testing teams in the German VdS la-boratories and the skills and abilities of our clients who develop such reliable life-saving technologies“, states Jörg Wilms-Vahrenhorst, Head of the Fire Protection Department at

the German institute VdS. ”We are delighted that India has now joined the multitude of countries all over the world in recognizing our VdS certificate as a seal of ap-proval for high-quality safety and security.”

“In our high-tech world, there is a bewildering variety of electronic as well as mechanical systems protecting us from fire and theft. Thou-sands of complex technologies are available on the mar-ket”,emphasisesWilms.

“With the VdS approval, the most important factor is guaranteed forproducers and for customers: The certified reliability of products.”

The VdS certification mark provides guidance and creates trust – and thus equal benefits for both suppliers and consumers. A certification from Europe´s number One institute for fire protection and security documents the high quality and reliability of products.

It provides manufacturers with

clear positioning, thus giving them a crucial com-petitive advantage in the market.

The WIK Enquete(the most com-prehensive security sector survey in Europe) has in 2013 and for many years in row confirmed that the most important factor for the experts responsible for decisions concerning investments in safety and security technology is the VdS certification mark.

VdSis now additionally supporting its clients on the subcontinent with a new trade fair concept. At the “Fire India”, the countrieslargest fire protection exhibition (taking place in Mumbai from 24th - 26th Octo-ber), a variety of VdS clients will showcase their innovations at a joint exhibition stand under the claim“Rely on Fire Protection Made in Germany”. You can visit this exhibition of German top engineering in Hall 1-F11.

Caption: VdS-approved fire protection systems have proven that they will reliably save lives (as shown here in an EMC test). In-dian authorities now also recommend the standards produced by Europe’s top organization for safety & security.

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www.ind-safety.com

TECH UPDATE

Leveraging proven technology for mass notification Introduction Mass Notification and emergency communication was first defined in 1997 by the United States Department of Defense (DoD) in an investigative document termed: “Khobar Towers Report”. The report was developed in response to the deadly terrorist bombing of an American Military housing complex in Saudi Arabia in 1996.

In summary, the report concluded that significant loss of life could have been reduced and even avoided entirely if there were an effective means of alarm and “mass notification” in place at the housing facility. A mass notification system provides information and instructions about emergency conditions in a building, area site, or other space.

The objective of an MNS is to protect life by indicating the existence of an emergency situation and instructing people on the actions they should take through concise, accurate, timely, and well-directed messages.

The commentary on the Indian National Building Code (Part 4), Fire and Life Safety requires buildings 15m in height and above and apartment buildings with a height of 30m and above to have a communication system available to all floors and facilities for receiving emergency messages.

This article is provided to highlight the strategic advantages of providing stable, reliable, and proven MNS solutions.

Getting Started When developing an MNS solution, the first step is to perform a risk analysis to determine the technology that is best suited for the facility.

Often, the security team provides a

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list of typical emergency and nonemergency incidents that they address throughout the life cycle of their campus.

NFPA Standard 1620 defines a risk analysis as follows: “to characterize the likelihood, vulnerability, and magnitude of incidents associated with natural, technological, and manmade disasters and other emergencies that address scenarios of concern, their probability, and their potential consequences.”

The goal is to anticipate and define the circumstances under which a mass notification system shall be utilized to protect lives. Once you have done that, the next step is to establish an appropriate response for any noted incident. Next we’ll explore the benefits of merging proven fire alarm and emergency voice solutions for the purpose of mass notification.

Fire Alarm Systems Integrated with Mass Notification Technology After the terrorist attacks in New York City, the industry focus shifted to providing real time emergency voice messages, rather than simply providing temporal emergency signals.

Fire alarm systems are required to provide both survivability and emergency operation performance.

They are afforded with emergency power and supervised circuits that report off-normal conditions on their system if they occur.

Therefore, utilizing fire alarm for mass notification provides a higher level of survivability than just connecting to a disparate telephone system. Telephone systems typically provide poor message intelligibility and little to no survivability during power outages. Fire alarm systems

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are regulated to provide both signal audibility as well as emergency message intelligibility during instances such as power failures. This means that when integrating security and IT messaging systems, fire alarm systems provide a higher level of performance.

Mass Notification / Fire Alarm Integration Advantages Since fire alarm systems must be supervised and wiring faults must be reported, the user confidence in the system performance is ensured.

This is especially important when utilizing a fire alarm system for mass notification incident broadcasting.

Fire alarm systems are combined with various peripherals such as sensors and speakers which are considered “safe” units. In a “safe unit”, regulatory testing is performed to ensure that unit construction will withstand the test of time and internal

wiring of the unit does not have to be supervised.

Fire alarm systems undergo the most comprehensive laboratory testing to ensure survivability. For instance, emergency backup battery charging circuitry is evaluated for its potential to provide 24 hours of battery backup for both lightly and fully loaded system configurations.

Incident sequencing software is guaranteed to perform in a consistent manner without fault and with predictable timing.The software written for fire alarm control units often follows standards adopted in other life-safety critical environments including avionics, health-care, and nuclear facilities.

For the reasons mentioned above, mainly the remarkable reliability of all hardware, supervision of all external wiring, well designed real-time embedded software routines, and system design and programming

flexibility, fire alarm systems have become the de-facto platforms for Mass Notification Solutions.

Mass Notification Market Potential According to recent market research, the global market for Mass Notification Systems is predicted to be $2.41 billion by the end of 2013 to an estimated $6.41 billion in 2018.

Summary The core objective of MNS is to save lives and reduce hardship by providing timely emergency messaging to all intended recipients. Manmade and natural disasters are unavoidable; the key to providing a successful solution is to understand the risks, plan in advance, and leverage proven life safety technology.

This article was co-authored by Jason Falbo and David Sylvester Jason Falbo, P.Eng, M.B.A., is the Vice-President, Engineering, at The Mircom Group of Companies.Jason has a background in Software Engineering and extensive experience in system interoperability, web-based technologies, and various standards for information/data exchange.Prior to joining Mircom, Jason was heavily involved in the XML-based HL7 standard for electronic health records interchange which will soon transform our hospital networks and provide advance care and accurate patient information to a global network of practitioners.

David Sylvester, Past CFAA-VP, 309A Electrical M.E. BCIN 29276, is the Director of Research and Industry Affairs for Mircom Group of Companies. In addition to his full time role at MGC, David provides instruction in the Fire Protection Engineering Program at Seneca’s College of Applied Arts & Technology.

David has over 23 years of Engineering Experience within Fire Protection and Life Safety Systems and with related services, as a designer, building systems manager and consultant. He is an accredited Master Electrician/Electronic Technician with experience in electrical/fire alarm instruction/training.

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TECH UPDATE

Cadbury (Kraft Foods)

“As CEM approved partners we are pleased to be in the position to offer Kraft Foods a fully integrated and highly proven security solution. The AC2000 Lite system is a feature rich yet affordable solution that allows us to be able to meet Cadbury’s requirements and budget.”

Kraft Foods is the world’s second largest food company with annual revenues of $49.2 billion.

They operate in more than 75 countries and employ 127,000 individuals worldwide.

Tarun Gupta, Director Neural Integrated Systems

Kraft Foods in India required a feature rich access control system to secure their facility. Based on the customer requirements, CEM Approved Resellers, Neural Integrated Systems chose AC2000 Lite for the Kraft Foods facility.

Introduction The AC2000 Lite security management system can secure up to 64 doors spread across multiple locations. Using sophisticated AC2000 Lite software features, Cadbury-Kraft Foods India can increase operational efficiency and protect against intruders or theft.

Solution Applications offered include AC2000 AED (Alarm & Event Display), AC2000 VIPPS (Visual Imaging Pass Production System) and the AC2000 Zone Monitor application which shows security what staff work in which areas/zones.

AC2000 VIPPS allows the user to produce permanent and temporary ID badges for staff and visitors to the Kraft offices and manufacturing facilities.

This will ensure all those on site have an access card with the correct privileges to gain admission to areas throughout the building. If someone forces a door at an access point, the AC2000 AED application can be used to view the alarm and respond to it immediately in real time. AC2000 Lite also provides access to AC2000 WEB, a suite of powerful and fully integrated browser based applications.

AC2000 WEB Visitors provides a powerful web based tool to control and monitor visitor access from any

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location. AC2000 WEB Visitors is a cost effective way for multiple users within a facility to manage visitors without having dedicated access control software installed. This powerful application allows the addition of new visitor details, scheduling of visits, a multitude of reports, the issuing of cards and the ability to remotely upload visitor images via the web prior to a scheduled visit and much more.

Utilising existing Ethernet connectivity without the need to set up additional cabling, the eDCM 300 is extremely easy to install.

With an internal database to hold offline transactions the eDCM 300 communicates directly with the AC2000 server, ensuring 24/7 card validation at all times. This ensures that the factory is always kept secure.

With the CEM AC2000 Lite security management system installed, the prestigious Kraft Facility has the highest of security measures in place.

CEM hardware To secure doors throughout the factory, Cadbury-Kraft Foods chose CEM eDCM 300 (Door Control Modules).

The eDCM 300 low cost, two-door intelligent controller is designed to interface third party readers with the CEM AC2000 system range.

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Returning water its true glory as the best known fire fighting agent to man!

Ceasefire’s Revolutionary Watermist Technology

W

ater has been fire’s oldest enemy. Water has been used to douse fires since the discovery of fire itself.

Water quells fire primarily by its tremendous cooling power.

Theoretical cooling ability of water is 2.6 MW per liter per second, thanks to its naturally flexible molecular structure and low kinetic energy. This cooling ability of water makes it very effective in fires on wood, paper and cloth etc, classified as Class A fires, which are often deep seated. Water when comes in contact with fire evaporates, absorbing large amount of heat and bringing the temperature down below combustible level. On the other hand, the escaping water vapor blocks the entry of oxygen in the fire zone thus further killing fire.

However, in modern times we face fire threats from far more types of fires than Class A alone. These are Class B fires that occur on highly combustible liquids such as petrol/ diesel, Class C fires on inflammable gases such as LPG / CNG; some industries are today prone to Class D fires on metals; Electrically started fires and Class F fires on super heated cooking oils. While some of water’s natural properties makes it an excellent fire extinguisher on Class A fires, some of its other natural characteristics like

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electrical conductivity and heavier weight than most oils renders water incapable of fighting fires on liquids, gases and electrical fires.

Even in a real life Class A fire situation, the cooling power of water can only be achieved with hundreds of liters of water as fire fighting effectiveness of water is directly proportional to the surface area of water that comes in contact with fire. Water’s immense firefighting power can be optimally utilized only by complete vaporization in a fire environment. Even with better dispensing mediums, nearly 80% of the water escapes the fire zone without evaporating.

Ceasefire’s revolutionary Watermist technology has made the unthinkable possible by modifying water’s natural properties to counter these problems. This new age Watermist dispensing technology from Ceasefire breaks down water into microscopic molecules to form mist that has a surface area many times higher. This enables complete vaporization of water. These droplets are then delivered to the fire with a kinetic force strong enough to overcome fire’s own convection currents.

The risk of electric conduction vanishes with micro droplet size of

the mist which evaporates as soon as it comes in contact with fire, also creating a blanketing effect to block oxygen. Ceasefire’s Watermist technology has the capability to quell all classes of fires, including electric fires, without causing collateral damage to property or equipment.

It accelerates fire incident response time and reduces the need to carry multiple types of fire extinguishers.

Currently, Ceasefire offers Watermist technology through portable extinguishers, hydrant systems & suppression systems.

The portable extinguisher range includes Ceasefire Greenmist, Ceasefire Hydro Pyro Quell System (CHPS) & Ceasefire Compressed Air Foam System.

Greenmist is a multipurpose fire extinguisher that can be used in place of powder based extinguishers.

Ceasefire Hydro Pyro Quell System (CHPS) on the other hand specializes in dousing Superheated oil fires/ Fat fires that occur in Kitchens. Lastly, the Compressed Air Foam system acts as a mini fire brigade, with an option of using water or foam in the form of mist.

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TECH UPDATE

The system uses low pressure technology that is reliable and safe to use. The mist stream generated from the specially designed nozzle, helps shield a firefighter from fire’s radiated heat and thermal shock, providing protection not seen from most fire extinguishers.

After the portable extinguisher range, comes the range of Watermist Hydrant Systems, where ceasefire offers two variants namely CF2000 & CF3000. The later is a completely independent system that has inbuilt propellant & extinguishing agent, while CF2000 is directly connected to a pressurized water pipeline at the location.

An individual equipped with these powerful hydrant systems can attack a fire immediately without having to worry about whether the agent is appropriate for the type of fire, whether it will cause collateral damage to equipment or harm people. This is important because response time is the main factor that determines the extent of a fire’s harm to life and property.

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While dousing a fire, mist quickly vaporizes in the fire zone and surrounding atmosphere and causes no harm to delicate equipment parts.

This avoid losses and get sites back to business faster.

Ceasefire also offers intelligent Indoor Fire Auto Quell Systems under Watermist technology. These sophisticated systems are designed to suppress all types of indoor fires. The systems are customized to suit the requirements of each location they are installed in terms of size, layout and nature of equipment present. Under this range Ceasefire offers Kitchen Suppression system, Generator Autoquell System, Transformer Autoquell System, Indoor Autoquell System & Twin fluid based Self Activating Watermist Instant Flooding Technology (SWIFT).

The Kitchen Suppression system works as an advanced automated version of CHPS that specializes in Kitchen fires. The Transformer & Generator Autoquell systems are used for the protection of named equipments against fire.

The atomization of water droplets makes extinguishing process efficient, without any risk of electrocution or short circuit. The Indoor Autoquell System can be used in place of normal sprinkler system, making fire fighting more effective.

The Twin fluid SWIFT System takes Watermist suppression range to a whole new level, as its ultra minute droplet size makes it fit to be used in computer & server rooms. Something that wasn’t possible a few years ago.

Ceasefire’s Watermist technology has indeed returned water its true old glory of being fire’s fiercest & strongest enemy.

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FIRE SAFETY IN INDIA - An overview Proper attention must be paid to minimize fire loss because ultimately the community at large has to bear all the losses.

R.R. Nair

1. INTRODUCTION

About Author Mr. R. R. Nair has more than 45 year’s experience in Occupational Safety, Health & Fire Protection.

He is author of 15 books & more than 65 articles in various topics on Safety, Health & Environment.

He has carried out more than 50 safety audits in various industries / occupancies including high rise buildings.

For more information contact: M.: 09224212544 / 09224807170 Res.: 022 2766 5975 E-mail: shib@vsnl.com

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A fire can happen at any time at any place irrespective of its occupancy status. You can expect a fire at any structure, may be at your home or at your workplace or in a hospital or in public places like theatres, malls, etc…

Fire in any occupancy has the potential to cause harm to its occupants and severe damage to property.

On an average, in India, every year, about 25,000 persons die due to fires and related causes. Female accounts for about 66% of those killed in fire accidents. It is estimated that about 42 females and 21 males die every day in India due to fire.

According to the statistics released by the National Crime Records Bureau, fire accounts for about 5.9% (23,281) of the total deaths reported due to natural and un-natural causes during the year 2012. Probably many of these deaths could have been prevented, had we taken enough fire protection measures.

No comprehensive data is available in India on the economic losses suffered on account of fires.

However, according to one estimate the major losses reported by the Indian Insurance Companies in the year 2007-2008 indicate, that about 45% of the claims are due to fire losses.

According to another estimate about Rs. 1000 crores are lost every year due to fire. Fire losses are reported both in industrial and non-industrial premises like hospitals, commercial complexes, educational institutions, assembly halls, hotels, residential buildings, etc… According to Fire Risk Survey

(FRS) 2013, carried out by Pinkerton & Federation of Indian Chambers and Industry, in India, fire accounted for 8.45% of the overall ranking of risks.

FRS also revealed that fires has been rated as the 5th highest risk in industry in 2013.

The above survey also revealed that in industry wise risk ranking, fire take 2nd place in hospitality, 4th place in IT/ITES, Manufacturing, Security Service Providers and 6th place in infrastructure. As far as the leading cause for the fire is concerned, according to the survey, the electric defaults are regarded as the major cause of fires. In Mumbai about 75% of fire-related incidents occur because of short circuit caused by loose wiring.

The survey also point out that during the period 2009-2012, Mumbai fire department had attended 13,185 incidents of fire out of which 9711 were caused due to defective electric circuit. The scenario for other major cities are also not different.

2. THE PROBLEM For mitigating a fire in any occupancy, whether it is a business house or in a factory or in a residential building, require a deep understanding about the problem.

A small fire in a residential building may be spread very fast and within a few minutes it can reach a stage beyond the control of its occupants and ultimately seek the help of fire brigade to carry out a major firefighting operation. During the last one decade there was a vibrant growth in the constructions activities

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TECH UPDATE

in India, especially in High Rise buildings. Thousands of High Rise buildings have already constructed in metros and major cities in India, and thousands are under construction.

Because of its peculiar nature, fire in residential buildings in particular, high rise buildings become more complex and the salvaging operations become more difficult and sometimes even resulting in many deaths and huge property losses.

In an era of highly competitive business environment any interruption due to fire can be catastrophic. A major fire can bring a business to halt.

Restoring the damage done by fire is only part of the cost of fire. A fire may have serious consequences for the production capacity of a business and in the extreme, the time taken to restore production may be such that the business is forced to close down altogether.

A fire can, not only interrupt the whole process of manufacture and production, bwut also the building and plant will be in ruins. Before they can be replaced and production restored, much work in clearing up the site will be necessary. It will also be necessary to determine what has been lost and damaged. Even if only a small part of the plant has been involved in the fire, staff from other work will need to be diverted to clear up the mess and to plan the rebuilding and restoration of production.

One must admit that fire creates total waste.

Such waste would not be tolerated by any efficient management, if it resulted from inefficient operation. The successful prevention of fire loss depends almost entirely on the management of the business. To control the loss through fire, the management must survey the total operation of the business to determine where the loss potential lies.

One must also admit that the

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fires are caused almost entirely by people, either through their actions, which may be accidental or deliberate and malicious or through their failure to make appropriate precautions such as, for example, the regular inspection, maintenance and repair of defective equipment.

Inadequately maintained machines can be fire prone. The overheating of bearing, due to insufficient lubrication or the presence of dust, and heat caused by friction are common causes of fire. Frequent inspection and regular maintenance will reduce risk and make the general tidiness of premises easier to achieve.

Remember that fires start when source of ignition comes into contact with combustible material. If you can control all sources of ignition and combustible material, you can greatly reduce the potential for fire.

You should also remember that waste and rubbish are friends of fire. Shop floors and offices can have substantial quantity of inflammatory materials such as oil soaked rags, loose packing materials, piles of papers, cartons, etc. All these materials, if ignited, will encourage fire to spread rapidly.

Volatile chemicals and explosives pose serious problems.

Although the paint, lacquer, flammable solvents and thinners are a less recognised hazard, negligence in handling them may result in fires. Handling small quantities of flammable liquids is a frequent causes of fires and injuries.

Heating and lighting systems that are inadequately maintained or safeguarded present risks. Many fires occur from electrical faults or misuse.

Smoking is a notorious fire risk. It should be prohibited in all areas where it is especially dangerous.

Major fires start in storage area and warehouses than production areas. Poorly stored goods, even though they are not flammable, may ENGINEERING REVIEW | December 2013 |

159

TECH UPDATE

help to spread fire and hinder fire

to reach the scene of the fire and start

employees / occupants. This stance

fighters gaining access to the seat of

effective firefighting operations.

has probably never been fully tested

the fire or reduce the effectiveness of

It

is

estimated

that

a

fire

legally.

However, many occupiers

sprinkler systems. Goods tidily stored

discovered within two or three minutes

take fire training seriously and train

with gangways may help to inhibit the

of its outbreak may be extinguished

a large number of their employees /

spread of fire.

with less than 1000 litres of water.

occupants.

However, if the water is not applied

3. PREVENTION STRATEGY

until 5 to 10 minutes later, which is

4. LEGISLATIONS

An effective fire prevention strategy is

probably the shortest time in which a

The

an essential feature of fire protection.

fire brigade may reach the scene of the

codes have a vital role in forcing the

However, it must be kept in mind

fire, the fire will have grown to such

occupiers to provide the required fire

that regardless of the efficiency of a

proportions that between 50 to 100

protection system, both active and

fire prevention strategy, some fires

times as much water may be needed

passive. The National Building Code

inevitably occur.

for extinguishing the fire.

of India, 2005, is the basic model

There

and

number

The successful use of any type

code in India on matters relating to

of fire equipment depends upon

building construction and fire safety.

equipment and suppression systems

the elements such as equipment,

Many of the code provisions has

like CO2, FM 200, and NOVEC, to suit

maintenance and training.

been incorporated by various State

different

types

large

standards

firefighting

of

exists

legislations,

of

specific requirements.

Automatic

It is vital that an occupier

fire sprinklers coupled with detection

ensures, its employees are trained

are the most effective fire protection

for and understand what is required

The Maharashtra Fire Prevention

system found in High Rise buildings

during an outbreak of fire. It must be

and Life Safety Measures Rules 2009,

which can, not only detect the fires,

remembered here that inappropriate

framed under the Maharashtra Fire

but also extinguish the fires in the

use of water to fight a fire has even

Prevention and Life Safety Measures

initial stage itself. Application of Water

caused much damage.

Act 2006, is an example to this, and

Mist in various situation is gaining

Governments and Local Bodies in their own building regulations.

It was observed that lack of

is aimed to improve the status of

Passive fire

knowledge in the area of fire and in-

fire safety measures in Maharashtra.

protection system is also becoming

adequate training in emergency drills,

Often a question has been raised by

more and more popular in India.

delay

momentum every day.

operations.

many that who will be responsible for

In spite of all technical advances,

Probably adequate fire safety train-

providing the required fire protection

water is the cheapest, most efficient

ing and periodic emergency drills can

and prevention system in a building

and environmentally friendly fire

make the emergency response more

or in an occupancy.

extinguishing medium. Water, which

effective.

has high latent heat of vaporization,

the

firefighting

The acts and rules enacted by the /

State of Maharashtra has well defined

is the most effective coolant and

occupants and fire drills are clearly

on these points. According to Section

protection agent.

No amount of

related but are not synonymous

3 of the Maharashtra Fire Prevention

appliances or equipment would be

and it is a common misconception

and Life Safety Measures Act, 2006,

of much use, if sufficient quantities

that conducting periodic fire drills

the developer, owner, occupier or

of water under required pressure

discharge

training

whatever name called shall comply

were not available for firefighting.

obligations. No doubt fire drills are

with all the fire and safety measures

To be effective, it must be applied in

very valuable exercise but taken in

adhering to the National Building

sufficient quantity and at such a rate

isolation, they are insufficient in

Code of India, 2005, and as amended

that it well prevent the accelerating

educating employees / occupants in

from time to time, failing which it shall

growth of the fire.

all the important matters.

be treated as a violation of the Act. It

It must be

remembered that if remedial measures

Training

an

the

employees

occupierâ&#x20AC;&#x2122;s

/

means that the onus of maintaining the

are not taken in the very early stages

occupants

matters

fire safety installations in a building or

of following the outbreak of a fire, the

continues to be a controversial issue

in an occupancy is the responsibility

amount of water required increases

with many occupiers adopting the

of the owner or occupier.

exponentially as the increase in the

attitude that it is not reasonably

In India, although there are

time taken for the fire fighting forces

practicable to provide training for all

many rules and regulations, codes

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| December 2013 | ENGINEERING REVIEW

Training in

of fire

employees safety

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TECH UPDATE

and standards related to fire safety, these are seldom followed. Laxity in following fire safety measures caused major fires in many buildings. Some of the fire authorities in India even felt that in the absence of heavy fines and penalties, occupiers or societies do not bother to conduct regular maintenance of the fire prevention systems installed in their buildings.

Probably this was one of the reasons behind in incorporating a provision about ‘Licensed Agency’ in the Maharashtra Rules. As per the section 3(3) of the Maharashtra Fire Prevention & Life Safety Measures Act, 2006 and Rule 4 (2) of Maharashtra Fire Prevention & Life Safety Measures Rule, 2009, a licensed agency is required to issue a Certificate regarding the work executed by them is in compliance in relation to Fire Prevention & Life Safety Measures in Form ‘A’ and Six monthly Certificate in Form ‘B’ in every January & July to the owner or the occupier for compliance of the Fire Prevention & Life Safety Measures duly installed by them in the buildings or premises are maintained in good repair and efficient condition at the time of issuing certificate.

5. FIRE SAFETY AUDIT Fire Safety Audit is found to be an effective tool for assessing fire Safety standards of an organization or an occupancy. In other words, it is aimed to assess the building for compliance with the National Building Code of India, relevant Indian Standards and the legislations enacted by State Governments and Local Bodies, on fire prevention, fire protection and life safety measures.

Though a comprehensive fire safety audit can address the inherent fire hazards associated with the day to day activities in an occupancy and recommend measures to reduce the potential fire hazards, there is no clear cut provisions in any of the safety

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legislations in India regarding the scope, objectives, methodology and periodicity of a fire safety audit.

However, NBC of India recommends for periodical fire safety inspection by the key personnel of the occupants of the building to ensure fire safety standards. In case of industrial building, the statutory authorities insist for fire safety audit by external agencies depending on the type of activity and the nature of the materials handled in the building.

Maharashtra Fire Prevention and Life Safety Measures Rules, 2009, made it mandatory for building owners and residents to conduct half-yearly fire safety audits and submit the report to the fire department.

It is a good measure and other states too can follow this. However, entrusting the responsibility of conducting the fire safety audit to the “licensed agencies”, has created some confusions, because the same agency has also been entrusted with the work of “installations” and “maintenance” of firefighting systems. Perhaps this arrangement has resulted in diluting the scope and methodology of the audit. It is also doubtful whether the so called “licensed agencies” have the required calibre / expertise in conducting an effective fire safety audit. So in effect, it seems that the fire safety audit has become a ritual.

6. CONCLUSION A fire can happen at any time at any place. It creates total waste. It has the potential to cause harm to its occupants and severe damage to property.

In India, fire accounts for about 5.9% of the total deaths reported due to natural and un-natural causes during the year 2012. The fires has been rated as the 5th largest risk in Indian industry. Electrical defaults are the major causes of fires in India.

Therefore proper attention must be

paid to minimize fire loss because ultimately the community at large has to bear all the losses.

The use of smoke detectors, fire alarms, automatic sprinklers, water mist systems, clean agent suppression system,

should

be

encouraged,

especially in high rise buildings.

Passive fire protection system should have major role in fire protection.

In India, although there are many rules and regulations, codes and standards related to fire safety, these are seldom followed. Laxity in following fire safety measures caused major fires in many buildings. Though fire safety audit is found to be an effective tool for assessing fire safety standards of an occupancy, there is no clear cut provisions in any of the safety legislations in India, regarding the scope, objective, methodology and periodicity of a fire safety audit.

Therefore, Fire Safety Audit should be made mandatory for all over India and the work should be entrusted to independent agencies, who have expertise in it. It is reasonable to have a fire safety audit in every year.

Above all the success of fire prevention and fire protection mainly depend upon the active co-operation from all personnel in an occupancy.

REFERENCES & RECOMMENDED READINGS 1) Accidental Deaths and Suicides in India 2012 – National Crime Records Bureau, New Delhi, 2013.

2) Hegde Patil, S.B. and Nair, R.R. – Management of Industrial Hazards (CEP Publications) Bangalore, All India Council for Technical Education, 1997.

3) India, The Factories Act 1948 with the Maharashtra Factories Rules 1963, Mumbai, Labour Law Agency, 2010.

4) India, Maharashtra Fire Prevention and Life Safety Measures Act, 2006.

5) India, Maharashtra Fire Prevention

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TECH UPDATE

and Life Safety Measures Rules, 2009.

6) Indian Risk Survey, 2013 -Pinkerton & Federation of Indian Chambers and Industry.

7) Madan Mohan and Nair, R.R. – Personal Protective EquipmentNon Respiratory (CEP Publications) Bangalore, All India Council for Technical Education, 1997.

8) Madan Mohan and Nair, R.R. – Safe Guarding of Machinery (CEP Publications) Bangalore, All India Council for Technical Education, 1999.

9) NFPA Fire Protection Handbook, 19th Edition – National Fire Protection Association, USA 10) Nair, R.R. – A Basic Guide to the Material Safety Data Sheet (Safety and Health Series No. 1), Safety and Health Information Bureau, 1989.

11) Nair, R.R. – Electrical Hazards, Industrial Safety Review, October 2012.

12) Nair, R.R. – Equipment for Fire Protection, Industrial Safety Review, November 2012.

13) Nair, R.R. – Evacuation System for High-Rise Buildings, Industrial Safety Review, July 2013.

14) Nair, R.R. – Exposure of chemicals and their effects on the body, Industrial Safety Review, May 2012 15) Nair, R.R. – Fire Alarms and Detectors, Industrial Safety Review, August 2013.

16) Nair, R.R. – Fire and Explosion Hazards, Industrial Safety Review, January 2013.

17) Nair, R.R. – Fire Hoses, Industrial Safety Review, March 2012.

18) Nair, R.R. – Fire Prevention and Protection, Industrial Safety Review, June 2012.

19) Nair, R.R. – Fire Safety Audit: The need of hour, Industrial Safety Review, July 2012.

20) Nair, R.R. – Glossary of Technical terms used in Material Safety Data Sheet (Safety and Health Series No. 2), Safety and Health Information Bureau, 1989.

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| December 2013 | ENGINEERING REVIEW

21) Nair, R.R. – Halons and Other Clean Agents for Fire Suppression, Industrial Safety Review, January 2012.

22) Nair, R.R. – Head Protection, Industrial Safety Review, December 2012.

23) Nair, R.R. – Noise Pollution: The critical overview, Industrial Safety Review, September 2012.

24) Nair, R.R. – Personal Protective Equipment, Industrial Safety Review, September 2013.

25) Nair, R.R. – Safe handling of compressed gases, Industrial Safety Review, March 2012.

26) Nair, R.R. – Safety in High Rise Buildings, Industrial Safety Review, November 2011.

27) Nair, R.R. – Water Mist Fire Suppression System, Industrial Safety Review, June 2013.

28) Nair, R.R. Workplace Accidents are Increasing – Science Today, Times of India September, 1982.

29) Nair, R.R. and Chakravorti – Safe Handling of Hazardous Chemicals (CEP Publications) Bangalore, All India Council for Technical Education, 2001.

30) Nair, R.R. and Joshi, D.K. – Safety and Loss Prevention in Process Industries (CEP Publications) Bangalore, All India Council for Technical Education, 2002.

31) Nair, R.R. and Joshi, D.K. – Safety Audit (CEP Publications) Bangalore, All India Council for Technical Education, 2001.

32) National Building Code of India, 2005- Bureau of Indian Standards, New Delhi, 2007 33) Ramesh Babu, J. – Learning from Losses, Cholamandalam MS Risk Services Ltd. 34) Safety and Fire Protection Handbook, 2nd Edition, – Edited by R. Veeraraghavan. Safe Technology, Mumbai, 2009 35) Veeraraghavan, R. and Nair, R.R. – Fire Technology (CEP Publications) Bangalore, All India Council for Technical Education, 2002.

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TECH UPDATE

Safety and Health in the Chemical Industry

By Vinay Pathak, Lab Head - 3M R&D Centre, Gurgaon

I

f we compare the size of chemical

industry, global chemical industry is about US$ 3 tn. Comparatively, India is a relatively small player as Indian industry is worth only around US$ 60 bn.

The petrochemicals, pharmaceuticals and the specialty chemical segment of the Indian chemical Industry have a considerable presence in the global chemical industry. India also has a major presence in agrochemicals.

Vinay Pathak, Lab Head, 3M R&D Centre, Gurgaon

The major challenge that the chemical industry faces today is the perception that it affects the

3MTM AircareTM Filtration Unit ACU-01 Wall Mounted

environment. The industry is viewed with a high degree of apprehension on the pollution and sustainability fronts.

Products

from

chemical

industry have dramatically altered the quality of life world over and have contributed significantly to our dayto-day requirements. However, the perception is changing slowly and this image will also change for the better in the near future.

In India, environmental rules and regulations are very stringent as compared to other developing countries and some of the developed countries. Furthermore, even though many

rules

notification

like and

identification,

development

of

landfill sites, were prescribed in the year 1989 under.

The

Hazardous

Waste

(Management and Handling) Rules, the state governments are still unable to identify, notify and develop the required sites even today. However, an amendment enacted in the year 2000, placed the responsibility on industry associations, as well as the government.

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One of the major problems related to the industrial growth and Pollution Prevention is the activism of several NGOs. Public opinion and various

public

interest

litigation

against pollution has lead to greater awareness amongst the industrialists, authorities and communities. Many of the measures to be adopted for solving environmental

problems

should

be based on the experience already gained by the developed countries.

Presently,

there

is

little

institutional impetus provided for the adoption of “cleaner technologies” and “waste minimization” techniques.

Process

technologies,

however,

have their own economic returns that mitigate the need for extensive regulatory interference.

In addition, industries that are leaders in the environmental front do not currently receive any specific advantages. No special consideration is

given

their

even

for

application

for

processing consents

/

authorizations. Consequently, there is

ENGINEERING REVIEW | December 2013 |

163

TECH UPDATE

no real driving force for

visibility has increased over the past

the industries to adopt

years. Legislation alone does not

cleaner

guarantee sustainable development.

and

technologies

of

Environmental

Management

System

standards ISO-14000.

The National State

3M

TM

Fahrenheit

TM

Comfort Goggle

The

implementation

situation

is

extremely

tricky in the country like India, where implementation is very difficult. Rules, however, can work as a driver towards conservation: for instance those that

Environment

are inbuilt in the permission system,

(SoE) Report of India

force industries to take environmental

2001 & the National

issues into consideration.

of

the

Environment Policy (NEP) 2006 both

This article discusses some of

have focus on some particular areas.

the major Health & Safety problems

The NEP 2006 focuses on policy issues

associated with this industry and its

such as

solutions offered by 3M from the PPEs

• conservation

of

critical

point of view.

environmental resources • intra-generational equity - securing livelihood for the poor • integration

Chemicals used, stored and handled in

environmental

the Chemical Industry are often treated

concerns in economic and social

in a way that exposes employees,

development

others and the environment to risks.

• efficiency

of

1. What is the problem?

in

environmental

• Cleaning agents or organic solvents

resource use • environmental governance • enhancement

For example:

of

such as white spirit alcohols, etc

resources

for

environmental conservation.

can be readily inhaled, swallowed or absorbed through the skin.

Excessive exposure to such agents

The SoE 2001 in turn has got the

can cause headaches, nausea, lack

focus on the current state of the

in

environment. The report identified

tiredness

concentration, and

intoxication,

damage

to

the

the five priority key issues for India: • land degradation • biodiversity • air pollution control with special reference to vehicular pollution in cities • management

of

fresh

water

resources • hazardous waste management.

Apart from the official focus areas, there are signals which are speaking for the change in the attitudes towards the environment.

As stated before, the environmental awareness is still very low. Awareness creating campaigns, however, have become rather popular and their

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| December 2013 | ENGINEERING REVIEW

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TECH UPDATE

safety data sheets (MSDS) and risk assessment results in the register) • Only

use

dangerous

goods

approved containers for decanted chemicals and label containers with the correct name and risk and safety phrases (eg do not use food or drink containers) • Put good housekeeping & regular 3MTM JupiterTM Powered Air Turbo

3MTM JupiterTM Powered Air Turbo with IS Kit

inspection practices in place, such as putting chemicals away when not in use, immediately clean up

central nervous system. Solvents can also de-fat the skin and cause dermatitis.

wastage and evaporative emissions

• A large number of cleaning agents, blanket wash, fountain solution, alcohols,

spills etc • Keep lids on solvents to reduce

etching

solutions

• Place solvent soaked rags in an isolated covered bin

etc

• Train employees using inks and

are highly flammable. Therefore,

solvents in the proper methods

there is a risk of fire or explosion

of

if flammable liquids are not stored

(including

information

and handled in an appropriate

as

personal

manner.

equipment (PPE) selection from

use,

handling

correct

and

storage such

protective

MSDS)

2. What are the risks?

• Provide and maintain suitable PPE

• There any many chemicals used in the industry. Many of these chemicals are classed as dangerous goods as well as them being hazardous substances. Dangerous goods are substances or articles

(eg respirators, gloves, goggles, apron etc) • Keep

minimal

quantities

of

chemicals on your site • Provide

spill

containment

(eg

bunding, spill pallets)

that have the capacity to pose an

• Ensure you have a spill kit and

immediate risk to life, property

procedures in place to manage

or

spills

the

environment

via

their

flammable, explosive or reactive nature.

Hazardous

substances

can cause harm to a person’s health if it gets into the body. The

• Train your employees in what to do when there is a spill and how to dispose of waste safely • Where

possible,

substitute

most common routes of exposure

dangerous

being through inhalation or skin

substances with less hazardous

absorption which can lead to immediate or long-term health effects.

and/or

hazardous

alternatives • Be aware that some so-called ‘natural solvents’ can be as toxic as normal solvents and they can

3. What can you do to manage the risks in your workplace?

have the added problem of auto

• Know exactly what chemicals are

to oxidative reaction

used in your workplace by creating a

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register

–

(include

material

ignition when placed on a rag due • Substitute solvent based inks with vegetable oil based inks

ENGINEERING REVIEW | December 2013 |

165

TECH UPDATE

• Substitute

solvents

It stands as a duty for the

with vegetable cleaning agents

employers concerning the provision

(vegetable

and

cleaning

agents

are

use

of

Personal

Protective

virtually free of volatile organic

Equipment (PPE) at work and to

solvents)

ensure

that

Personal

Protective

• Consider printing alcohol free.

Equipment is adequately supplied

Alternatives to isopropyl alcohol are

and used correctly at work wherever

available and can be used effectively

there are risks to safety and health

in some printing processes

that cannot be controlled in any other

• Use 3MTM 9913 Speciality Particulate Respirator

organic

aqueous

or

water

based

ways.

Personal Protective Equipment

varnishes • Keep work areas well ventilated.

should always be considered a last

ventilation

resort. When other precautions fail to

with appropriate capture hoods

reduce the risk of injury, PPE comes

on

releases

into picture. An employer’s duty is to

solvent vapours into the work

combat the risk at source if possible

environment

and the first priority being engineering

Use

local

exhaust

equipment

that

• Reduce contact with chemicals by

solutions such as provision of guards

using automatic processing (eg

on machinery which would help in

auto ink dispensers)

improving health and safety.

• Replace deletion fluid with deletion

On 1st January 1993, the main legislation

pens • Providing extractors to remove

that

governs

Personal

Protective Equipment called Personal

ozone from UV presses (UV curing

Protective

lamps convert oxygen in the air to

Regulations 1992 came into force. PPE

ozone)

as defined in the Regulations states

• Use water-cooled or cold-cure UV lamps to prevent ozone build up

Equipment

at

Work

“all equipment (including clothing affording

protection

against

the

• Store flammable liquids (dangerous

weather) which is intended to be worn

goods of class 3) away from

or held by a person at work which

ignition sources and combustible

protects him against one or more risks

materials (eg power points, paper

to his health and safety”.

and cardboard, timber tables and Therefore, PPE includes:-

shelving) • Keep in and around flammable

• Gloves

liquids storage cabinets free from other classes of dangerous goods

• Eye protection

• Do not store rags or rubbish in the storage cabinet. Do not store

• High visibility clothing

items on top of the storage cabinet.

Ensure the storage cabinet has a bund to contain spills • Provide

adequate

equipment

fire

throughout

fighting the

workplace • Have an emergency plan in place and practice what to do in an emergency.

166

| December 2013 | ENGINEERING REVIEW

• Safety Helmet • Safety footwear • Safety harnesses • Respirators All the equipments are of equal

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TECH UPDATE

importance for the protection of the

pressure leaks or Sp ray guns, Impact

employee at their job site.

or penetration, Excessive wear or en-

The nature of job decides the

tanglement of own clothing.

allocation of a PPE. Its use starts with the assessment of all different hazards

PPE Solutions are Boiler suits,

in the workplace. Further assessment

Conventional or disposable overalls,

should be done to ascertain which

High visibility clothing, Specialist pro-

types of PPE are suitable to protect

tective clothing, Chain mail aprons.

against the hazards linked to each

Hands and Arms:

job.

To add to this, an employer

Hazards - Chemicals, Abrasion, Tem-

must also see whether the supplied

perature extremes, Electric shock,

PPE is compatible with each other.

Cuts and punctures, Impact, Skin in-

For example, a particular type of

fection, Disease or contamination.

respirator may make it difficult to

PPE Solutions -Gloves, Mitts, Gaunt-

get eye protection or ear protection

lets, Wrist cuffs, Armlets.

to fit properly. More the pieces of PPE needed by an individual the

Feet and Legs:

more the potential problems. Usage

Hazards - Abrasion, Wet or cold

of PPE protects different parts of the

weather,

body from various hazards. Details as

Slipping, Cuts and punctures, Metal

mentioned below:

and chemical splash, Falling objects.

Electrostatic

build-up,

PPE Solutions - Gaiters, Safety Boots

Eyes:

and Shoes with protective toe caps

Hazards - Chemical or Metal splash,

and

Radiation, Projectiles, Debris, Gas and

Leggings, Spats.

penetration

resistant

soles,

Vapour.

Thus, an adequately equipped

PPE Solutions are Safety Glasses or

work place confirms the safety and

Goggles, Face Shields, Visors.

health of the employee. Together

Head:

with the installation of the PPE; its

Hazards - Impact from falling or

maintenance also plays a vital part.

The

flying objects or debris, Risk of head

PPE

should

be

well

bumping, Hair entanglement.

maintained and properly stored while

PPE Solutions are a range of Safety

not in use. It should be kept clean

Helmets and Bump Caps.

and in good repair. Manufacturerâ&#x20AC;&#x2122;s maintenance

schedule

should

Lungs/breathing:

be

regularly.

Simple

Hazards - Dust, Gas, Oxygen, Vapour,

maintenance

Deficient atmospheres.

the trained wearer but incase of

PPE

Solutions

are

Respirator

or

Disposable filtering face piece, Half or full face Respirators, Breathing apparatus, Air fed helmets.

followed

can

be

done

by

complicated repairs, it should always be carried out by a specialist.

Finally,

Personal

Protection

using Personal Protection Equipments (PPE) at work place is an indispensable

Body:

issue that helps both the employer

Hazards - Chemical or metal splash,

and the employee to stay and work in

Temperature extremes, Contaminat-

a healthy and safe environment.

ed dust, Adverse weather, Spray from

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ENGINEERING REVIEW | December 2013 |

167

TECH UPDATE

Providing the Eyes & Ears to Help Keep People Safe

Joshua Phillips, Director of Marketing, Verint Systems

T

o provide environments that are as safe as possible, security professionals need to see and hear what is happening all around them.

Building upon a core focus in this area and backed by proven technology, Verint recently launched an integrated audio and video intelligence solution that provides command, control and communications centers—as well as public safety answering points (PSAPs)—with a unified application interface to investigate incidents using key information from voice, video and other security systems.

There is indeed a need to enhance the safety and security of the country based on its large population and concentration of key industries.

Considering a vast population and concentration of key industries, there is always a risk for potential theft and crime. The idea for a safe city is to make more secure environment for citizens of India and to help proactively identify and neutralize such threats and help ensure 24x7 surveillance in the country. Early this year Verint announced its association with the Safe City Project initiated by the Surat City Police Department and Surat Traffic Education Trust to help enhance the safety and security of Surat City inhabitants. The initial phase of the Surat Safe City Project consisted of 100+ closed circuit

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| December 2013 | ENGINEERING REVIEW

television (CCTV) cameras covering all major traffic junctions along with critical entry and exit points in the city. In subsequent phases, the Surat City Police Department and Surat Traffic Education Trust plan to extend the coverage in the city, which has a population of approximately forty five lakh (or about 4,500,000), by integrating the project with the proposed state government surveillance and command center network in Gandhinagar. The city administration plans to increase the number of surveillance locations to 5,000 by the end of the project implementation.

The task of implementing a state-of-the-art command, control and communications center (C3) was successfully executed by Surat Traffic Education Trust in partnership with the Surat City Police Department. To support its focus, it invested in Verint’s Nextiva® Video Management Software™ and Nextiva Physical Security Information Management™solutions in September 2012, taking the technology live as part of the overall Surat Safe City Project rollout. According to the organizations, these capabilities serve as critical components of the city’s overall command center plan that’s focused on proactive approaches to help identify, analyze and take action on security and criminal threats.

Another interesting example is of the Detroit Metro Airport. In the last two months of 2001, there were 30 airport shutdowns in the United States alone. Breaches in security resulting in shutdowns cost the airline industry millions of dollars. Detroit Metro, like other airports in the US and around the world, suffered shutdowns from breaches long before the incidents of September, 2001. By integrating their surveillance system with alarm systems, Detroit Metro Airport has alleviated costly shutdowns and saved both time and money. Using Verint® Networked Video Solutions, airport security is notified immediately of any breach at a checkpoint and is able to immediately notify other checkpoints

to stop the processing of additional passengers. Beyond these automatic alerts, the system also enables cameras to go to predefined pan, tilt, and zoom (PTZ) positions down hallways, helping the control center to visually follow targets causing the breach. In addition, control center personnel have the capability to set and trigger alarms. Implementation of the Verint solution and integration with other third-party systems help airports like Detroit Metro reduce shutdowns, comply with government regulations, and respond rapidly to incidents.

Many of today’s organizations are high on demands and low on resources. Leveraging Verint’s integrated audio and video solution, they can strengthen their existing infrastructure and benefit from a complementary solution that streamlines their investigations while making them more productive. The solution enhances security, safety and operational intelligence by combining the Nextiva Video Management Software with the Audio Log Insight Center to improve the efficiency and effectiveness of critical investigations. Verint Communications and Cyber Intelligence Solutions offer law enforcement agencies and other police services a broad portfolio of solutions for rapidly detecting threats, conducting more productive investigations, collecting evidence, and preventing crime. The solutions efficiently collect, monitor, and analyze information from virtually any communications network or data source.

The solution also serves as a forensic tool that can provide public safety organizations and other critical infrastructure entities with a 360degree view of captured data for expediting investigations, debriefings and training. Its integrated interface and advanced analytics enable audio and video to be analyzed together by capitalizing on the robust functionality of two well-established Verint solutions.

The company’s solution help governments, agencies, and other organizations around the world improve performance and protect people, property, and assets.

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169

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TECH UPDATE

Indian Steel Industry : The pathway & Challenges

I

ndia has become the world’s fourth-largest producer of crude steel. The country is slated to become the second-largest steel producer by 2015 as large public and private sector players strengthen steel production capacity in view of the rising demand. The total market value of the steel sector in India stood at US$ 57.8 billion in 2011 and is expected to touch US$ 95.3 billion by 2016. Total crude and finished steel production grew at a compound annual growth rate (CAGR) of 6.6 per cent and 4.2 per cent over FY08-11 to reach 69.6 million tonnes (MT) and 66 MT respectively.

Steel consumption is expected to grow at an average rate of 6.8 per cent to reach 104 MT by 2017 driven by rising infrastructure development and growing demand for automotives. The infrastructure sector is India’s largest steel consumer, accounting for 63 per cent of total consumption in FY11.

Attracted by the growth potential of the Indian steel industry, several global steel players have been planning to enter the market. The Government of India (GOI) has allowed 100 per cent foreign direct investment (FDI) in the sector through automatic route in order to attract foreign investments.

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Market Size Latest figures by World Steel Association (WSA) has revealed that India’s steel production increased by 3 per cent to 59.62 million tonne (MT) in the first nine months of 2013, as against 57.90 MT in the corresponding period last year. Moreover, the data showed that India’s rate of production growth was the second-best following China among the major global producers. The country’s steel output grew to 6.54 MT in September 2013 from 6.24 MT during the same month in 2012.

Investments • JSW Steel has acquired Heidelberg Cement India’s 0.6 million tonne per annum (MTPA)-cement grinding facility in Raigad, Maharashtra for an undisclosed sum. The two companies have inked the Business Transfer Agreements recently.

• The deal marks Heidelberg’s philosophy of moving away from less profitable assets and focussing on more strategic and competent areas. JSW Steel had acquired the company through the erstwhile JSW Ispat Steel, which is now its merged associate firm.

• Leitwind Shriram Manufacturing has received a Rs 346 crore (US$ 56.18 million)-order for the supply and installation of machines from Neyveli Lignite Corporation for a 51 megawatt (MW) wind energy plant at Kaluneerkulam near Tirunelveli in Tamil Nadu. Leitwind, an IndiaEuropean joint venture (JV) between Shriram Group and Windfin BV (formerly Leitwind BV) which makes wind electric generators, has recently completed a project encompassing supply, erection and commissioning of a wind farm of a capacity of 43.2 MW in Tadipatri in Andhra Pradesh for Orient Green Power Company Limited. Leitwind has the onus to procure land, desig, manufacture, supply, install, test, commission the machines, and also take care of the operation and maintenance of farm. The order is to be executed over a period of 10 months.

• Meanwhile, Jindal Steel and Power Ltd (JSPL) has secured five exploration licences for iron ore mining in African countries including Namibia, Gabon, Sierra Leone, Mauritania and one in South Africa. Navin Jindal-led company has already

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043

An ISO 9001 : 2008 Certified Co.

TECH UPDATE

commenced assessing and checking the exact number of reserves in the region. It is also mulling over steel production and mining projects in Brazil, Indonesia and Mongolia. It has recently commissioned a steel melting shop and its allied unit of the 6 MTPA integrated steel plant at Angul in Odisha. JSPL has a steel capacity of about 5.5 MTPA in India and 2 MTPA in Oman, outside India. It intends to increase its total steel capacity to 11.5 MTPA by 2015-16. The iron ore will also be used for its steel plant in Oman. It mainly exports steel in West Asia, Africa, Southeast Asia, Taiwan and the Arabian Peninsula. The exports contribute 20-25 per cent of total steel products.

• Tata Steel is all geared – up to launch 30 new products in Europe in FY14. The company had launched 17 steel products in the European market in FY13. Also, Tata Steel has commissioned a 3 MT unit in Jamshedpur while it has spent Rs 10,000 crore so far for the first phase of another 3 MT plant in Kalinganagar, Odisha. The plant is scheduled to be commissioned in the second half of FY15.

to increase the demand of steel in rural areas and to enhance steel consumption in hinterlands. The effort aims at reducing the difference between the national annual consumption of 60 kg of steel per person and rural annual consumption of 10 kg per man. Setting up these factories will facilitate availability of various steel products in remote villages at reasonable prices. Also, these set-ups will open avenues for employment and rapid development of the region. In such regard, the Minister of Steel laid the foundation stone of a Steel Processing factory at Koyle Jungle, Gonda in September 2013 for production of 1,00,000 tonnes of TMT. This factory will be set up by RINL, a public sector undertaking (PSU) under the Ministry of Steel. A similar unit was founded at Dimroni, Jhansi in August. Many such other plants and factories have been commissioned in Indian villages in 2013. The point to be highlighted here is that all these units have been set up

by PSUs under the Ministry of Steel in collaboration with private companies.

The raw material for steel processing in these factories will be provided by the PSUs and the products will be sold in rural markets at cost-effective prices.

Government Initiatives Owing to its intense connections with core infrastructural segments of the economy, steel industry is of high priority and importance. Shri Beni Prasad Verma, the Union Minister of Steel, has recently stressed on establishing Steel Processing Units (SPUs) in order

Road Ahead WSA has released its estimates which state that Steel demand in India is projected to grow 3.4 per cent in 2013, higher than the 2.6 per cent growth rate recorded in 2012. Moreover, in 2014, the demand is poised to grow at even a higher rate of 5.6 per cent; thanks to sped-up efforts to implement structural reforms. The leading international steel body expects India’s total steel demand is to touch 7.4 MT in 2013 wherein the domestic expansion is pegged higher than the 3.1 per cent global growth.

Challenges : Globally, steel players have been operating in a challenging environment

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with rising input costs and persistent lower capacity utilization. This is driven by low demand growth in developed markets,accompanied by a structural shift in the global steel industry to developing countries like China and India. Over the last decade, Indian steel companies have consistently achieved higher earnings before interest depreciation taxes and amortization (EBIDTA) margins as compared to their global peers and have delivered steady growth despite external challenges.

Having established quality assets, Indian steel companies are now well poised to take advantage of expansion and growth opportunities in India. However, six long-term challenges are confronting the Indian steel industry’s growth aspirations • Volatile domestic iron ore supply is forcing Indian steel companies to pay higher prices or import this key raw material thereby exposing them to global iron ore price volatility.

• Flat products supply will exceed demand, leading to an overcapacity situation. This coupled with the muted demand growth will put significant pressure on margins.

• Customers are maturing and increasingly demanding valueadded products and services.

• Existing supply chains are stretched in order to cope with the wide range of customers and product specifications—original equipment manufacturers (OEM) at one end, to the rural retail markets at the other—which impact service levels.

• In the race to maintain market share,incumbents have taken on greenfield & brownfield expansion plans at a pace and scale unprecedented in the past. Skill gaps and other challenges have led to cost and time over-runs on these projects, putting further stress on the already stretched balance sheets.

• Investments in management processes, systems and people

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TECH UPDATE

capabilities have not kept pace with the nvestments in assets and the changing market place. This is increasingly becoming a bottleneck for growth.

Indian steel companies will face an increasingly competitive environment which will put pressure on market share and profitability. Accenture believes that in order to survive and thrive in this context, Indian steel companies will need to sharpen their capabilities in five areas:

Investing in raw material security Raw material security varies widely across the Indian steel companies and is probably the largest differentiator among the incumbents. As these companies look to secure their raw materials supplies, the capability to acquire, develop and operate overseas raw material assets has become a strategic imperative given the short term challenges in securing such assets in India. Even where the raw materials are not shipped to India, the overseas asset helps act as a natural hedge.

Capital project management Indian steel companies are taking on larger projects at an unprecedented pace as they invest to keep up with demand and enhance their market share. Commensurate investments in internal project execution capability have lagged the asset side investments, which makes project execution a complex task. Project execution is further compounded by challenges posed by external factors such as regulatory delays, limited talent pools, contractor and construction labor constraints and stringent environmental norms. All of this is reflected in the execution challenges faced by Indian steel companies. These companies need to focus on project management as a core capability integral to growth objectives.

They need to focus on selecting the right projects and optimize the

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scare resources available, ensure the projects identified are managed in a robust manner and the right enablers in terms of organization, processes and information technology are leveraged to deliver a successful outcome.

Becoming more customer centric As Indian steel companies expand, the overlap in their respective market and product footprint is increasing.

This coupled with a slowing demand growth means that these companies are increasingly competing with each other for the same set of customers.

In this scenario, increased customer centricity will differentiate the high performers.

Indian steel companies will need to deepen their understanding of buyer values and create innovative products and service offerings targeted at different customer segments. Capability to analyze customer buying patterns will enable the sales force to be more proactive in the sales cycle. Additionally, as customers become more demanding and product portfolio becomes more complex, Indian steel companies will need to embrace leading sales and distribution practices (e.g. tracking secondary & tertiary sales, solution selling) from consumer-focused industries such as fast-moving consumer good and pharmaceuticals, to differentiate from their peers. Finally, they will need to adopt new pricing strategies to capture a part of the economic value created for customers.

Building chains

differentiated

supply

Indian steel companies supply a wide range of products to diverse customers with very different buyer values, causing huge strain on the supply chain.

This increase in product portfolio complexity is a challenge to manage.

Even large global companies struggle to profitably manage complex portfolio. Hence, Indian steel companies will need to overcome this challenge and

reduce portfolio complexity. Further, the new capacities being built by Indian steel companies have the capacity to manufacture similar product.

Hence Indian steel companies will need to acquire capability to strengthen their sales and operations planning across multiple plants. In order to improve their customer service while controlling inventory, these companies will need to adapt their made-to-order (MTO) and made-tostock (MTS) production strategy by customer segments. Given the dynamic market, India steel companies will need to enhance flexibility by pushing differentiation as far down in the supply chain as possible (i.e., intermediate stocks and finishing to order). Finally, customizing channel management capabilities for customer segments will enable Indian steel companies to enhance customer service and potentially extract a premium.

Securing human capital Over the last decade Indian steel companies have more than doubled their crude steel capacity and integrated into mining by tapping skill pools from the incumbent integrated steel plants (ISPs). Indian steel companies are now faced with the problem of an aging workforce. This problem has forced a move toward more automation and, consequently, a highly skilled workforce. As the market grows, skills in critical areas of the steel value chain like mining, capital projects, supply chain and sales and marketing are in short supply and have become limiting factors for growth. Further, as Indian steel companies embark on aggressive growth plans, securing a leadership pipeline to fuel growth, programs to attract and retain talent and a sharp focus on skilling up current resource pools will become imperative. Proactive investment in capability building across these areas will differentiate the high performers from the laggards.

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PRODUCT SHOWCASE

PRODUCT INDEX Product Name

Company Name

Page no.

wAir Blow Gun - Size G1/4

Janatics India Pvt. Ltd.

182

Breath Alcohol Analyser : PD6000Pro

Subtronics (India) Pvt. Ltd.

192

Cable Glands – IP 54, IP 68, EMC, Double Compression 90 years + of German excellence in India

Geissel India Pvt. Ltd.

196

Cable Trays & accessories, Gratings, Handrails and Fabricated Steel Structures

Indiana Grating Pvt. Ltd.

195

Checker 4G 7 (Vision sensors)

Cognex Sensors India Pvt. Ltd.,

199

Combined bearings

Kavitsu TRANSMISSIONS Pvt Ltd.

198

Connectors & cable assembly, moulded type straight connectors

Katlax enterprises pvt ltd

188

Digital Insulation Resistance Tester

Udeyraj Electricals Pvt.Ltd.

194

ELMEX : KTT 6

Elmex controls pvt ltd.

196

EMC Cable Gland

Controlwell india pvt. Ltd.

182

Engineering Design Consultancy Services

The Brains-SPMs & Tooling Consultants

194

Forged Steel Components

Super Forge

193

Manganese Steel Casting

Meena Cast Pvt. Ltd.

179

Mhi forged components

Kishan forge pvt. Ltd

190

PORTABLE LCD Digital Microscope

India Tools & Instruments Co.

187

Precision components casting

Universal technocast

192

PTE5000 Pressure Sensor

CST Sensors India Pvt Ltd

184

Rapid roll-up doors

Gandhi Automations Pvt Ltd

197

Shot Classifier

ETA Engineering Services,

199

Spheroidal Graphite Iron Casting

Perfect auto cast

191

Stiller Diesel Platform Trucks

Mahindra Stiller Auto Trucks Ltd.

191

Surge protection device

Allied power solutions

180

Temperature and humidity transmitter

Kusam electrical industries ltd

185

The Ha-VIS preLink® Extender enables simple cable extension for up to 10Gbit/s network cabling

HARTING India Pvt Ltd

186

Tripple Level Spring Clamp Terminal Blocks ATL2.5, ATL2.5H & ATLG2.5

Connectwell industries pvt. Ltd.

184

Valves & pump parts

Twinkle Stars Engineers

180

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PRODUCT SHOWCASE

M

Dist.: Rajkot (Gujarat State) India TeleFax : +91-2827-252117/252118, Mobile No. +91-9824226454 E-mail: meenacast@gmail.com Web : www.meenacast.com

Manganese Steel Casting

eena Cast Pvt. Ltd. is manufacturer of MANGANESE STEEL CASTING by lost wax process in high Manganese Steel & Alloy Steel. Their plant is having ultra modern facilities of Medium frequency electric furnace, casting inspection laboratory, heat treatment, shot blast cleaning and production components range from 1.0kg up to 500kgs. single piece.

They are specialist in manganese steel components like Mill-ball, hammer, jaw plate, bucket teeth, big link pole, bare liner, grate plate, top grate, open grate, front wall and rack, sleeves and jaw crusher spares toggle plate, treadle bar, side plate, concave mantle, tips for VSI blow bar, cyr. liners.

Widely appreciated for optimum porosity, grain structure and wear resistance attributes, the Manganese Steel Casting is used in stone crushers, rail crossings, liners, grates, mineral pulverizing, earth moving, pipe lines, bends conveying abrasive media and construction equip-

ment, mining equipments, mineral processing, recycling industry, structural shredder parts, general machineries industry, dredging vessel, engineering ships industry, cement plants, rock crushing plants, coal gangue processing, brick & tiles industry etc. and these castings are also offered in customized specifications.

For more information Meena Cast Pvt. Ltd. In Street Opposite of Field Marshal High School, Rajkot-Gondal National Highway 8-B, Village: SHAPAR - 360 024, Taluka: Kotda Sangani,

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Engineering design consultancy services

rom 1993, The Brains, MUMBAIâ&#x20AC;&#x201C; is offering full services to Indian industries either SMEs or Big Business Industries for their need of engineering assistance i.e.

Machine Design, Design of SPMs & Conversion of GPMs, Toolings, Reverse Engineering, Material Handling, Automation, Product Development and R&D, Conversion of manual drawings to AutoCAD or any 3D softwares to make their Design Office compact & paperless.

The Brains offers a true engineering assistance with guaranteed secrecy for life time satisfaction maintaining clientâ&#x20AC;&#x2122;s trust without any breach. Design Office is a heart of every industry and needs utmost secrecy. The Brains have proved reputation with highest proud & moral with many clients throughout India.

The Brains proudly claims that they have no competitors because no one can assure you total services with secrecy & full satisfaction as desired by you; but, The Brains can. No other can offer such services at such a lowest overhead. Please, feel free to contact us; it is your own Design Office without any investment serving you for 24x7.

The Brains always advises Indian industries to make best use of the recession or slowdown period; because, in a peak period you will not have enough time to justify your R&D. Make your Design Office paperless & compact to maintain secrecy of your business and save on costly overheads during this period only. The Brains assures their service for any help; wherever you are, The Brains is not far from you.

Today, The Brains is a leading player in Engineering Design Consultancy field, Providing solutions for high productivity at low cost.

Air Cooled Cyliner Blocks Liners

M

EENA CAST PVT. LTD. is manufacturer of AIR COOLED CYLINDER BLOCKS LINERS by centrifugal & shell mould casting process. Their ultra modern plant is equipped by casting process, machining process and testing laboratory and having yearly production capacity of one lakh pieces of air cooled cylinder blocks liners made from standard and quality cast iron and other

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179

PRODUCT SHOWCASE

& non-ferrous metals, Alloy and Super Alloys of the finest quality. Company Plant is set up with the latest, sophisticated & ultra modern infrastructure & machines, Testing Equipments, Instruments & Facilities to maintain quality assurance to a high precision degree of accuracy required in process. It is their metal arrangement to cast virtually any metal/alloys such as Stainless Steel, Alloy Steel, Carbon Steels, Nickel Based Steels, Super Alloys, Hast Alloys, Aluminum Alloys, Copper based Alloys, Bronze Alloys and many other Ferrous & Non-Ferrous Metals as per customer need. They are specialist in manufacturing of Valves parts like Body, Bonnet, Disc, Plug, Seat Rings etc. and Pumps parts like Casings, Impellers, Bowls, Discharge & Suction Bells etc. They can develop and manufacture the Valves & Pumps parts according to drawing, specification,

allied materials. These products are manufactured for various engine requirements in domestic & international market which are in accordance with stringent quality standards. The production is carried out keeping into consideration the need to have strict tolerances for such products which ensures that the liners are optimally fitted within the engine block. The additional quality features of such air cooled cylinder liner are the material used, the structure defined for various engine purposes and the surface quality. Their products range contains Dry Sleeves (Fully-Finished and Semi-Finished), Wet Liners & Air-Cooled (Finned) Blocks of any size, model & series applicable with engines of compressors, marine and diesel engines, vehicles, generators and earth moving equipments.

For more information The Brains-SPMs & Tooling Consultants, C-309, Shree Vinayak CHS Ltd., Vaishali Nagar, Dahisar (East), Mumbai-400068 Tel : 09819 504 604 E-mail: thebrains3946@gmail.com

T

Valves & pump parts

winkle Stars Engineers is manufacturer of Valves & Pumps Parts by Investment Casting process in ferrous

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material detail, quantity detail and sample provided by the customers.

For more information Twinkle Stars Engineers “Arya Sadan”, Twinkle Stars, Dayanand Nagar Street No.3, Behind Vania Wadi Bagicha, Opp.: Sheth High School, 80 Feet Road, Rajkot – 360 002 (Gujarat) India Mobile No.: +91-9662525172 E-mail : twinklestarsengineers@gmail.com

SURGE PROTECTION DEVICE (SPD) from HAKEL (CZECH REPUBLIC, EUROPE) Protection against Lightning & Switching Surges Continue on page no.182

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PRODUCT SHOWCASE

Continued from page no.180

● ● ● ●

Fast Response Time Very low let through voltage Modular design - Pluggable version Inbuilt Visual Indication & Remote Monitoring Facility ● Application - AC/DC Drives, LT panels, MCC, PCC, CNC machines, PLC, etc

to the customers based upon the application requirement. Blowgunswith extended nozzle provides longer reach. Blow guns with extended angled nozzles are designed for use in difficult-to-reach locations.

Janatics Blow Guns are made of Engineering plastic and ergonomically designed, easy to handle, light weight, easy to hang, unbreakable and can be used in open environments. Designed for efficient cleaning with minimum air supply.

Blow Guns are normally used in applications like, a. Textile Mills, b. Food Processing, c. Foundries, d. SPM’s, e. Machine Tools and many more....

Note: Use of dust free air provides efficient performance and long life.

For more information Janatics India Pvt. Ltd. E-25, SIDCO Industrial Estate, Kurichi, Coimbatore - 641 021 INDIA. Tel : +91 422 2672800, Fax : +91 422 2672304, E-mail : janatics@md2.vsnl.net.in, Web : www.janatics.com

Other range of HAKEL SPD’s: ● Type 1 / Class B Encapsulated Lightning current arresters ● Type 2 / Class C Surge arresters ● Type 3 / Class D Surge arresters ● SPD’s for Solar projects, Signal, Telecom, Data, Oil/Gas pipelines, Equipotential Bonding, etc For more information ALLIED POWER SOLUTIONS C-301, Delhi Rajdhani Apts, 80, IP. Extn, Patparganj, Delhi - 110 092 Tel: +91 11 2223 6074 Mob: +91 9650044992, 99993 01007 Email: info@alliedpowersolutions.com

EMC Cable Gland

E

MC Cable Glands are used in applications which involve shielded cables for electromagnetic protection. These

Air Blow Gun - Size G1/4 Gun with different types of nozzles.

1. Blow Gun with Straight tube 2. Blow Gun with angled tube 3. Blow Gun with Long Straight tube 4. Blow Gun with Long angled tube Varieties of nozzles provides a perfect choice and solutions

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| DECEMBER 2013 | ENGINEERING REVIEW

Continue on page no.184

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PRODUCT SHOWCASE

Continued from page no.182 Glands help in maintaining electromagnetic integrity of the shielded cable by just tightening the gland. To get perfect shielding, the outer sheath of the cable is passed through the EMC gland. Tightening the gland enables a special spring inside the gland to come in contact with cable braiding. This not only helps in electromagnetic shielding but also gives an IP68 protection level along with strain relief to the cable. Cable glands with the long thread or reduced clamping are also available in our range.

cations are involved. The simplified three level connections tremendously increase wiring density in the circuit.

The top level of the ATL2.5H Terminal Block provide connection points for signal wires while the middle and bottom level are used for positive and negative potentials.

The ATLG2.5 is a triple level Terminal Block with an additional connection for earthing cables. This separate connection point is appropriately identified by the Green– Yellow imprint on its top.

Specification: Number of Levels

Technical Details: Material

Brass Nickel Plating

Plastic Inlet

Polyamide 6

EMC Spring

Copper Berrylium

Sealing Ring

Neoprene

O Ring

Perbunan (NBR)

Protection Class

IP 68

Temperature Range

-40 to + 100 Deg. Celsius

Threads available

Pg, Metric

Approvals

UL, VDE & Halogen Free

For more information CONTROLWELL INDIA PVT. LTD. C-203, Prithvi Park, Plot No. 4,5 & 6, Sector 30, Sanpada, Navi Mumbai 400 705. (INDIA) Tel.: +91 22 2775 6293 Fax: +91 22 2775 8767 email: sales@controlwell.com website: www.controlwell.com

Tripple Level Spring Clamp Terminal Blocks ATL2.5, ATL2.5H & ATLG2.5

ATL2.5 – 3 Feed through levels ATL2.5H – Top feed through and middle & Bottom half connection ATLG2.5 – 3 Feed through Levels + 1 Ground connection

Terminal Pitch

6mm

Connection Possibility

Stranded Wire – 0.2 – 2.5 Sq.mm Solid Wire – 0.2 – 4 Sq.mm

Approvals

UL, CE

Rated Voltage

500V

Rated Current

24 A

Applications: These Terminal Blocks are an ideal choice for motor, sensor, actuator and initiator connections.

For more information CONNECTWELL INDUSTRIES PVT. LTD. D-7, Phase 2, M.I.D.C., Dombivli - 421 204, India Tel.: +91 251 3980 600, 3980 800, Fax: +91 251 3980 700 Email: connect@connectwell.com Website : www.connectwell.com

PTE5000 Pressure Sensor Pressure Measurement ● Compact & Light-weight ● Superior Long-term stability & repeatability ● Outstanding shock & vibration performance

T

he ATL2.5 series Terminal Blocks are an ideal choice for control systems where sensor and actuator appli-

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| DECEMBER 2013 | ENGINEERING REVIEW

PTE5000 hermetically sealed modular pressure sensor: The PTE5000 with its small and compact design utilizes Kavlico’s thin film

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PRODUCT SHOWCASE

strain gauge sensing technology, incorporating a hermetically sealed design with no internal sealing required.

Specifically designed for industrial applications, the sensor is resistant to a broad range of liquid and gaseous media. It can be used at high operating temperature and has internal temperature compensation.

Our PTE5000 is the first product of an wider offer for this specific markets. One of the main sales arguments for the PTE5000 is the small design height compared to the products of our competitors. The PTE5000 represents the flattest Industrial Pressure Sensor Worldwide Industrial applications, with strict space limitations, are predestined for this Product and should be the objective of our sales force. The benefit of Kavlico’s thin film strain gauge sensing Technology is the directly welded measuring cell on the pressure port without any internal sealing. Only 304 stainless steel is in contact with the medium and guarantees a hermetically sealed connection. The PTE5000 is media resistant, allowing for a broad range of liquid and gaseous media compatibility.

For more information CST Sensors India Pvt Ltd 23, Trident Towers, 4th Floor, 100 Feet Road Ashoka Pillar Road, 2nd Block, Jayanagar, Bangalore 560 011 Tel: 080-41132204/05. Fax: 91-80-41132206.

Email: india@cstsensors.com

TEMPERATURE AND HUMIDITY TRANSMITTER MODEL – KM-THS-03/04/33/34

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odel-KM-THS-03/04/33/34 is a new Temperature & Humidity Transmitter introduced by “KUSAMMECO”, an ISO 9001-2008 certified company. This model is a compact and robust temperature & humidity signal transmitter.

This model is one of the most desired instruments for applications in monitoring for HVAC process/ air conditioning/ environmental ventilation control & environmental monitoring for building/ factory/

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clean room/ Lab & for storeroom/ crisper/ agriculture/ food industry. Other important applications are for use in hospital/ pharmaceutical industry/ textile industry. This model is at reasonable price with compact design. It is easy to install. It has High-Tech sensor with high accuracy and long-term stability. It has LCD display with back light, double line character & 3-wire loop connection of signal.

The input humidity range is 0-100% & a wide temperature range from -40ºC~60ºC & output range is 4-20mA. It is used in installation for indoor/ duct-mounting/ remote type with flange. It also has ZERO & SPAN adjustment for output. The power supply used for this instruments is 24VDC. It also has protection degree IP 65 (sensor : IP 20).

MULTIFUNCTION POWER QUALITY ANALYZER MODEL – KM 2100

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odel KM2100 is a new Power Quality Analyzer introduced by “KUSAM-MECO”, an ISO 9001-2008 certified company.

This Power Quality Analyzer has an Auto Power off & LCD Backlight display function.

It has safety features CAT III 1000V / CAT IV 600V & standards : IEC61000-4-30 (2008) S class, EN50160 (2007).

It can be easily operated to capture the power quality problem. It can be used in Single-phase 2W / Singlephase 3W / 3-phase 3W / 3-phase 4W system. It displays Run Chart, Bar Chart, Vector Graphic, Waveform, Event List, Readings & 8G Memory Card to Make the long-term measuring data storage. It support USB port to connect to PC and analyze the data / screen shots copied by Udisk & also supports LAN port to make the remote control available, transfer the measuring data. It measures Voltage range (0~1000Vrms), Current range (1~3000Arms), Frequency range (42.5~57.5Hz & 51~69Hz), Harmonics range (0~50). It can also measure Active power range (1.0~20MW), Apparent power range (1.0~20MW), Reactive power range (1.0~20MW), Power factor range (0~1),

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Energy (0kWh~200GWh), Inrush current measurement range (0.5~400Arms), DIPS & SWELLS range (0~200% for Vrms/Arms) with Programmable threshold in % of nominal voltage Event detection based upon ½ cycle rms voltages Captures Dips, Swells Interruptions and Rapid Voltage Changes. This model has Data Logger function, System monitor (Record time upto 7 days & Record Event number >10000). It has adapter input AC 220V (1 ± 10%), 50 Hz (1 ± 5%), ≤ 10VA. It is supplied with Voltage Test Lead 3 meters long x 5, Alligator Clips x 5, External DC Adaptor, Flexi CT Clamps 300A / 3000A X 4, Software CD & User Manual.

DIGITAL INSULATION TESTER (15kV, 2TΩ) MODEL – KM 7010 IN

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odel KM-7010 is a new Digital Insulation Resistance Tester introduced by “KUSAM-MECO”, an ISO 9001-2008 certified company. This Digital Insulation Resistance Tester can be used to measure High Insulation Resistance, with a test voltage of 500V to 15000V & the max Insulation Resistance range of 2TΩ. Short-circuit current is up to 5mA suitable for high power transformers in switch yards. It has EMC/ EMI approvals. It has an Auto-Hold function, Auto-ranging on all insulation ranges, Optical USB to RS-232 data transmission, Auto Power off & Backlight function, Internal memory for data storage. The display is 2 Lines×16 characters large intelligent LCD display & calendar display. 2 optical LEDs are built-in for data transfer with Bar graph indication for test voltage. It has indication of testing time & adjustment time 1 to 30 minutes. It has a high insulation resistance measuring capacity. The instrument has a AC measuring Voltage range of 0V to 700V & DC measuring 0V to 700V. It is useful for measuring Insulation resistance of transformers, motors, electrical installations etc. It can measure PI (Polarization Index) indication, DAR (Dielectric Absorption Ratio) indication.

For more information

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M/S KUSAM ELECTRICAL INDUSTRIES LTD G-17, Bharat Industrial Estate, T.J. Road, Sewree (W), Mumbai :- 400015. India.

Sales Direct :- 022-24156638, Tel :- 022-24124540, 24181649, 27750662 Fax :- 022-24149659, 27751612 Email :- kusam_meco@vsnl.net, sales@kusam-meco.co.in Website :- www.kusamelectrical.com

The Ha-VIS preLink® Extender enables simple cable extension for up to 10Gbit/s network cabling

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ARTING’s successfully introduced Ha-VIS preLink® technology is now complemented by another product, the Ha-VIS preLink® Extender.

This component of the innovative Ha-VIS preLink® cabling system enables the simple extension of transmission paths in data network cabling. In addition, it allows fire zones to be bridged and subscriber ports to be directly connected to the terminal block connector without the need for intermediate patching. It offers particular benefits for Broadcast TV Studio, Theatre, AV Multimedia or Theme Park installations.

Even unused cables can be reactivated and extended to the next required connection. The installer simply assembles the Ha-VIS preLink® termination module onto both ends of the cable to be extended. The terminated cable ends are then inserted into the Ha-VIS preLink® Extender. A flexible shield clamp transmits the cable shield potential. The Extender itself can be directly mounted on walls, in cable ducts or in a switch cabinet via two Ø 3.2 mm fixing holes. The small 15.6 x 13.2 x 65.7 mm (W x D x L) design permits installation even in cramped spaces.

The Ha-VIS preLink® Extender meets the transmission performance specifications for Category 6A pursuant to ISO/IEC 11801 Ed. 2.2 (2011-06). As a result, the structured cabling run can be used for applications up to 10 Gbit/s, up to the maximum link length.

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For more information HARTING India Pvt Ltd Abhishek Bimal Assistant Marketing Communications Manager 7th Floor (West Wing), Central Square II Unit No.B-19 Part, B 20&21, TVK Industrial Estate Guindy, Chennai - 600032 INDIA Tel : +91 44 43560415 Fax: +91 44 4356 0417 E-mail : abhishek.bimal@HARTING.com Web : www.HARTING.in

PORTABLE LCD Digital Microscope : Magnification : 1000x

Specification : ● ● ● ● ● ● ● ● ● ● ● ● ● ● ●

Image sensor: 5M high quality Image Sensor Magnifications: 10x-250x, up to 1000x Resolutions: 12M, 8M, 5M, 3M Lens: High quality microscopic lens Display: 3inches TFT panel, 4:3 ratio Light sources: 8 LED with adjustable brightness Power sources: Li-ion 3.7V / 800mAh battery Working time: 3.5-4hous; Charging time: 5 hours Frame rate: 30fps Adaptor: Input:100-240V, 50/60Hz; Output: 5V, 1A OSD languages: English Software languages: English Measurement: By software Size: 130x103x29mm Weight: 300g (with battery)

Special note : SOFTWARE for Measuring Distance, Area, Angles & radius . Suitable for Industrial Surface Inspection etc Supply : Portable Microscope, Stand, Adapter, USB/AV Cables, Software CD (inside Manual), Clean Fabric cloth in Box .

Handheld Digital Magnifier : (25X) Overview:

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he 3” Handheld LCD Digital Microscope is a fantastic microscope that provides a good way for you to have microscopic observation on the go. The 3” quality LCD panel brings vivid crystal image. Equipped with professional microscopic lens, it helps you to see tiny objects easily. With 250x optical and 4x digital zoom, the magnification can be up to 1000x. 800mAh rechargeable li-ion battery provides a 3.5-4 hours standalone working time.

The 8 bright LEDs, with brightness adjustable, is bright enough for perfect observation. More exciting is the professional measurement software can help to measure size as small as 0.001mm, which is extremely helpful to your scientific researches.

With this microscope, you can enjoy your researches anytime and anywhere.

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The 4.3 inches Handheld Portable LCD Digital Magnifier is an idea on the go digital magnifier for people with visual difficulty. It has 7 colour modes for different visual impair situation. The magnification can be up to 25x. Freeze function helps you to fix and keep the current screen image. After full charged, its rechargeable li-ion battery pro-

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vides a working time up to 4 hours. TV-out (to any monitor with TV-in) helps to get larger display.

In short, no matter for your personal use or get one as a gift for your parents, senior partners or friends, the easy-to-operate magnifier is the best LCD handheld digital magnifier you can find in the market.

● Stores up to 16GB of inspection results ● Attaches voice and written comments to the inspection record ● Illuminates the weld area for easier weld observation ● Exports results to spreadsheet for additional analysis like SPC

Detailed Specifications:

BENEFITS

● Magnification Range : 6x-25x ● Display: 4.3” diagonal; 16:9 aspect ratio ● Display mode: (7 modes) Full color, Positive, Negative, Blue on White, Black on Yellow, Blue on Yellow, Black on Green ● Freeze: Freeze and Defreeze ● Video-out: to any monitor with video-in ● Battery: Integrated lithium ion rechargeable battery 4 hours continual use, 6 hours charge time, Charger included ● Dimensions: 158 mm x 88 mm x 25 mm ● Weight: 285g, Carrying case included

● Any weld inspector will be proficient with the unit within minutes; ● Real time viewing for rapid evaluation of a joint or a weld ● The weld inspection record can be sent through Wi-Fi to anywhere in the world ● Fatigue critical features such as toe angle, undercut, and cracks can be quickly measured ● Over welding can be quantified so excessive welding time, consumable and energy usage can be reduced thus saving money ● Can inspect any weld the operator’s hand can reach

DIGITAL WELD GAUGE (New Generation) MULTI FUNCATION/USES FEATURES ● Very user friendly thanks to its integrated video and alignment functions: point, shoot and measure ● Compares the measurements against set tolerance limits ● Takes picture of the joint and/or weld for documentation ● Zoom allows observation and measure of porosity, cracks and spatter

RESULTS ● Quality assessment, Go/NoGo status,SPC data,Welder skill assessment ● Permanent record (photo, file, report & database) For more information India Tools & Instruments Co. BOMBAY - INDIA Tel: 23428862 / 9819345050 E-mail: ojus_itico@hotmail.com Web:www.indiatool.net

Connectors & cable assembly, moulded type straight connectors

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atlax Interface Products Group (IPG) manufactures various connectors, connectors with cables and such interface products which help in connecting various types of sensors to different types of cable trees or amplifier and controller units which make automation systems. Some of the common and standard products are available off the shelf and various others that need to be developed are also taken up to meet special needs.

The company offers M8 (M & F) Straight, M10 straight, M12 Female Straight various moulded type straight connector and cable assembly. Company has innovated and developed indigenously various moulded types of straight connectors and cable assemblies for sen-

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sors.

These connectors and cable assemblies have been accepted by United States & European market against international competition. Normally in Manufacturing Industries control equipments are mounted in a field but the central controls are located at remote location. The signal from field devices needs to be taken to controllers via cables. If there are environmental problems like fluctuating voltage, spikes, physical, abuse or accidental breakage, the devices fails more often than the connecting path consisting of cable and interconnections. Earlier the devices used to have their own cables and one had to change devices as well as cable. It means increased downtime and consequent production loss. With Connectors, one only needs to replace the device and quickly restart system.

Differential pressure transducer with LCD display, improved

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atlax Controller and Instrumentation Group (CIG) offers Differential Pressure Transducer with LCD display. Differential pressure transducer measures pressure differences between two points and give proportional analogue output (0 to 10V or 4-20 mA). This device can communicate on different communication protocol i.e.

MODBUS, RS232, and RS485 etc. Katlax differential pressure transducers are available with various measuring ranges starts from -0.5 mbar to 100 mbar. These devices are available without Display & with LCD Display.

Differential Pressure Transducer has Unsurpassed performance due to CMOS technology, offset and hysteresis free, it has excellent accuracy and reproducibility even below 10 Pa, fully calibrated and temperature compensated, not sensitive to the mounting orientation, sensor continuously monitors differential pressure between two ports, Integrated circuit converts differential pressure to electrical signal (0-10V Or 4-20mA), optional micro controller based circuit available for future up gradation to connect with SCADA on MODBUS protocol, condition-

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ing/ control circuit can be supplied in enclosure (IP-66)

Technical specification: Supply voltage: 24 VDC Pressure Range: -100 to 100 mbar # Over Pressure: 15 x Pressure Range Output: 0 to 10 VDC / 4 to 20 mA PC Compatibility: RS485 – MODBUS (Optional) Resolution: 0.1 mbar Linearity Error: 3% Display: Display Units: Termination: Housing material: ABS Plastic Nozzle Size: 3 mm Dia Mounting: Wall mount, Pair of clamp (132 mm apart) Protection Class: IP-65

Applications: ● ● ● ● ● ● ● ● ● ●

Variable air volume systems (VAV) Textile Air Engineering HVAC Pharmaceutical machinery Food/Packaging machinery Filter pressure drop Fan/ventilator control Duct air flow measurements Room/cabin pressure control Burner control

I/O (8) junction box with terminal block

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atlax Interface Products Group (IPG) offers 8 - I/O junction box with terminal block in Engineering Plas-

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put device/output device. This unit has a one power on as well as 4NO+ 4NC, 6NO+ 6NC,8NO + 8 NC Input/output on Indication. It can directly communicate with PLC which eliminates requirement of I/O module.

Technical Specification: tics. 8 I/O junction box with terminal block has an advantage of termination of wire at terminal block from different locations. It adds flexibility to user for routing of cable and trouble shooting. I/O Junction Box transfer status of 4 input devices as well as activate 4 output devices. The incoming or outgoing data transfer or receive through terminal block. It accepts M12 Socket connection of Sensor/ Input device/output device. It has an indication of Power ON as well as 8 NO+8 NC Input/ Output on. It works on 24VDC supply.

I/O junction box with wire termination greatly reduced no. of cores required to 11 from 12, 15 from 18 & 19 from 24 cores. It eliminates wiring of each individual sensor and greatly reduces downtime during initial setup or trouble shooting.

● ● ● ● ● ● ● ● ● ● ● ● ●

Max. Operating Voltage : 30 VDC Min. Operating Voltage : 10 VDC Current Consume/ Input Signal : Max. 12 mA Total rated Current / Junction Box : Max. 350 mA Number of Positions : 08 (4 NO + 4 NC) 12 (6 NO + 6 NC) 16 ( 8 NO + 8 NC) Number of Slots (CH) : 4,6,8 Protection : IP 55 Indication : LED*** Ambient Temperature : 0 to 70 °C Sensor / IO Connection system : M12 - Socket* Supply Connection System : 4 Core wire Connection For more information KATLAX ENTERPRISES PVT LTD (Interface Product Group) B-7, Pavana Industrial Premises, MIDC Bhosari, Pune – 411 026 (INDIA) Ph # 91- 20 – 2711 0224 Mobile # + 91 – 96897 83922 E -mail : sales@katlax.com

Applications: This modern device are useful for pharmaceutical industry, CNC machinery, textile machinery, plastic processing machinery, food processing industry (all automation applications) and more.

MHI FORGED COMPONENTS

I/O Junction Box – MODBUS

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atlax offers 4/6/8 - I/O Junction Box units transfers status of 4/6/8 Input devices as well as activate 4/6/8 output devices through RS 485 communication.

It uses MODBUS-RTU protocol. It accepts 24 VDC as a Supply Voltage. It has a very wide application in the field of machine to machine communication. It reduces requirement of wire. Junction box accepts M12 Socket connection of Sensor / In-

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K

ISHAN FORGE PVT. LTD. is ISO certified manufacturer of MHI FORGED COMPONENTS by close die forging capacity of 600 metric ton per month and job capacity 1kg. to 30 kgs. single piece in steel metals range.

They can take up forging job as well as development and manufacturing of all kinds of finished or semi-finished MHI FORGED COMPONENTS according to drawing, specification, material detail, quantity detail and sample piece provided by customer. Their forging plant is having infrastructure of forge shop, machining shop, heat treatment process and testing laboratory. MHI FORGED COMPONENTS having various applications in material handling equipments like cross blocks, clamps, and brackets, clamping knobs and heads, chain links, roller guides, hinges, mounting brackets, adjusting rods, cross blocks, supporting heads, idlers, rollers, pulley, feeders, hopper, chains, brackets, clamp, hinge, handle, cross block, rollers for conveyor systems, steel reinforced legs, adaptors for bipod/tripod, hoist Rings, handles, wheels,

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B-72, Sector-27A, Mathura Road, Faridabad 121 003.

Phone: 0129-2277564, Fax: 0129-4046252 Email: info@mahindarstiller.com

Spheroidal Graphite Iron Casting

P clamps, lugs, locking hubs, locating pins, clamps for pallet system, gears, crankshafts, camshaft, rockers for forklift trucks and fulcrum pin, sae flange, block for cartridge over center valve, swivel anchor top & bottom, top elbow for diesel level gauge, bottom elbow for diesel level gauge for earthmovers.

For more information KISHAN FORGE PVT. LTD. G. I. D. C. - Lodhika, Plot No. G - 1314, Kalawad Road, METODA- 360 021, Dist. : Rajkot (Gujarat) INDIA Cell: +91-9825800603 TeleFax No.: +91 - 2827 - 287062 E-Mail : kishanforgepvtltd@gmail.com URL: www.kishanforge.com

Stiller Diesel Platform Trucks

ERFECT AUTO CAST is ISO 9001:2000 certified manufacturer and supplier of quality Spheroidal Graphite Iron Casting (Nodular Cast Iron / Ductile Casting). Their Spheroidal Graphite Iron Casting plant was established during year of 2001. They can take up the development & manufacturing of any components by Spheroidal Graphite Iron Casting as per Drawing, Specification, Material detail and Sample provided by customer. They always take full care to maintain quality, accuracy and timely delivery. Their plant is set up with ultra modern infrastructure Melting shop, Moulding shop, Core shop, well equipped laboratory for conducting all type of physical, chemical, microstructure and sand test, finished goods inspection, fettling, grinding and inspection and machine shop etc. and relative all facilities to maintain quality assurance to a high degree of accuracy required in process of Spheroidal Graphite Iron Casting.

They have team of expert technical technocrat engineers, skilled workers and experienced trained administrative staff. They can take up the Spheroidal Graphite Iron Casting in capacity of weight range 0.5 Kg. to 500 kgs. per single piece and their production capacity is up to 3000 tons annum in materials as per ASTM, BS, DIN, EN, SAE, ISO, IS and other International Standards or according

T

he Stiller Diesel Platform Trucks are made in capacities of 2, 3, 4, & 5 Tonnes. The engine is of Greaves make. The trucks are three and four wheeled models, ideal for carr ying materials on platform which is fixed or elevating type. The truck has three forward and one reverse speeds through heavy duty gear box. The other features are: suspension on front and rear wheels.

Battery start of engine & engine cover, light and horn are optional. Oil immersed clutch and primary chain & sprockets are provided. The secondary and final chains are provided with chain adjusters. The driverâ&#x20AC;&#x2122;s seat is saddle type., sprung and cushioned. All controls are within easy reach of the operator. Tow hook for towing trailers is an optional extra.

For more information Mahindra Stiller Auto Trucks Ltd.

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to need of customers. Their product Spheroidal Graphite Iron Casting is having application in field of Automobiles, Internal Combustion Engines, Compressors, Machine Tools, Hydraulics, Textile, Pumps & Valves, Pipe Fittings, Earth Moving Equipments, Trailer Industries, Tractor Industries, Electrical Power Transmission & Switch Gear Industries, Heavy Equipments, Defense Sector, Aerospace, Construction Machinery. Material Handling Equipments, Farm Equipments, Rolling Mills, and Engineering Components.

For more information PERFECT AUTO CAST Shapar Main Road, Survey No.14, Village: SHAPAR Taluka: Kotda Sangani, Dist: Rajkot -360 024 (Gujarat) India Phone No.: +91-2827-253870 , Mobile No.: 9824225830 FAX No.: +91-2827-253880 E-mail: perfectautocast2012@gmail.com URL: www.perfectautocast.com

num and Job Handling Capacity from few grams to 100 Kg. Single Piece. They can take up the production of Precision Components Casting in capacity of weight range from 3 grams to 70 kgs. Per single piece component by Metal/Alloys such as Stainless Steel, Alloy Steel, Carbon Steel, Nickel based Steel, Super Alloys, Aluminum Alloys, Copper based Alloys, Bronze Alloys and many other Ferrous & Non-Ferrous metals. They are always alert to maintain quality, accuracy, on time delivery and reasonability in price. Their products Precision Components Casting is having applications in Industrial Valves, Pumps, Material handling equipments, Textile components, Machinery components and all type of Mechanical components.

For more information UNIVERSAL TECHNOCAST G-514, G.I.D.C. – Lodhika, Kishan Gate Road, METODA – 360 021 , Rajkot (Gujarat) India Phone No. +91-2827-287839 Fax: +91-2827-287838 Mobile No.+91 9227900098 E-mail: universaltechnocast2006@gmail.com Web Site : www.universaltechnocast.com

PRECISION COMPONENTS CASTING

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NIVERSAL TECHNOCAST is a leading manufacturer of PRECISION COMPONENTS CASTING by Investment Casting. They are also having quality certification ISO 9001:2000 TUV SUD. They can take up manufacturing of Precision Components Casting according to Drawing, Specification, Material & quantity detail and Sample provided by customer. For achieving excellency in their products, they have installed state-of-art plant equipments and machineries. Their laboratory department is also fully equipped by the latest measuring instruments, Physical Testing Instruments and Chemical Analysis by Spectrometer (German Make) & Wet Analysis Lab. Their Plant is having 2(two) Crusible of “Electrotherm” Brand having capacity of 250 kgs. & 150 Kgs. Their Production Capacity 600 Metric Tones/An-

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Breath Alcohol Analyser : PD6000Pro

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UBTRONICS (INDIA) PVT. LTD., an ISO certified manufacturing company offers its innovative breath analyser Model : PD6000NX Pro designed to check the presence of alcohol in breath.

PD6000NX Pro detects the presence of alcohol and alerts with an audio visual alarm in case critical levels are detected. This battery operated light weight instrument reads ranges from 0 to 120mg/100ml of blood and is shipped with Its own charger pack. The innovative design is registered with the Indian Patent Office as it does not require to come in physical contact with the subject under test.

The Multi colour indicator and single button operation

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makes it extremely easy to use even for an unskilled person to operate and crisp & accurate readings can be obtained with the help of on-board motherboard computer processing.

The light weight registered design extends the application of the analyser to versatile and exclusive applications like police, BPOâ&#x20AC;&#x2122;s, call centers, factories, night shifts, security, pharmacy and food industry, power generation plants etc.

The company is ISO 9001 certified with over 4500 clients and over 39 years of service and recipient of 31 coveted awards for its contribution to safety and offers complete solutions for detection requirements.

For more information M/s. SUBTRONICS (INDIA) PVT. LTD. 147, Kaliandas Udyog Bhavan, Near Century Bazar, Prabhadevi, Mumbai - 400 025. INDIA. Tel: +91 (022) 2422 4461 / 2430 3047 (Telefax) Email: service@subtronicsindia.com Web: www.subtronicsindia.com

FORGED STEEL COMPONENTS

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UPER FORGE is ISO 9001 BSCIC NABCB QM 030 certified and NSIC-CRISIL Rated Steel Forging Plant manufacturer of FORGED STEEL COMPONENTS. Their plant is having facilities and arrangement of Forge shop, Die shop, Machine shop, Heat treatment unit, Shot blasting unit, Testing Laboratory, Material store, Packing department and computerized management. They can take

up the development, manufacturing & supply of components by open die forging as per drawing, specification, quantity detail and sample provided by customers.

Their Forge plant is installed by Drop Hammers of 1000 Kgs., 750 Kgs. & 500 Kgs. And plant is having production capacity of 300 M.T. per month and job capacity from few grams to 7 Kgs. single piece by material range of 37C15, 40Cr4, 16MnCr5, 20MnCr5, A105, Brass, BS970, C30, CK45, Gunmetal, EN8D, EN9, EN31, EN32B, EN15, EN15B, MS, SAE1010, SAE1541, SS316, SS304 etc. They take full care to maintain the quality, accuracy and on timely delivery for forged components.

They can forge transmission shafts & gears, differential gears, drive shafts, clutch hubs, universal joints, yokes, crosses, tie rods, pinions, rocker arms, spindles, kingpins, idler arms, pitman arms, steering arms, linkages, connecting rods, small crankshafts etc. for Automobile industries and wing roots & spars, hinges, brackets, wheels, arresting hooks, sprockets, shanks, flanges, engine valves, elbows, reducers, saddles, tees, valve bodies, rod caps, rocker levers, pedestal caps, suspension clamps, hooks, Connectors, Brake jaws, Anchors, Slack adjusters, Straddle balls, Rotors, Knuckles, Handles, Push rods, Knobs, Housings, Pivots, Hinges, Fork crown etc. which are having applications in Engineering field like Valve, Pump & Engine industries, Architectural hardware industries, Aircraft & Aerospace industries, Medical devices industry, Electrical industries, Marine line industries, Agricultural implements industries, Railroad industry, Tractor industries, Steam, Gas & Hydraulic turbines industries, Windmill industry, Material Handling Equipments industries, Paper industry machineries, Mechanical power transmission equipments industry, Defense & ordinance hardware industry, Gymnastic equipments industry, Pharmaceutical & Food industries, Turbocharger industry, Air & Gas compressors industry, Textile machinery industry, Packing & Printing machines in dustry, Steam traps industry, Flow meters industry, Pollution monitoring industry etc.

For more information SUPER FORGE G.I.D.C.-Lodhika, Plot No.2756/57, Kranti Gate Road No.1, METODA â&#x20AC;&#x201C; 360 021 Dist.: Rajkot State: Gujarat India Phone No.: +91-2827-287215 FAX.:+91-2827-287115 Mobile No. +91-9825425199 E-mail: superforge2004@gmail.com URL: www.superforge.in

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ENGINEERING DESIGN CONSULTANCY SERVICES

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rom 1993, The Brains, MUMBAI– is offering full services to Indian industries either SMEs or Big Business Industries for their need of engineering assistance i.e.

Machine Design, Design of SPMs & Conversion of GPMs, Toolings, Reverse Engineering, Material Handling, Automation, Product Development and R&D, Conversion of manual drawings to AutoCAD or any 3D softwares to make their Design Office compact & paperless.

The Brains offers a true engineering assistance with guaranteed secrecy for life time satisfaction maintaining client’s trust without any breach. Design Office is a heart of every industry and needs utmost secrecy. The Brains have proved reputation with highest proud & moral with many clients throughout India.

The Brains proudly claims that they have no competitors because no one can assure you total services with secrecy & full satisfaction as desired by you; but, The Brains can. No other can offer such services at such a lowest overhead. Please, feel free to contact us; it is your own Design Office without any investment serving you for 24x7.

The Brains always advises Indian industries to make best use of the recession or slowdown period; because, in a peak period you will not have enough time to justify your R&D. Make your Design Office paperless & compact to maintain secrecy of your business and save on costly overheads during this period only. The Brains assures their service for any help; wherever you are, The Brains is not far from you.

The Brains is a leading player in Engineering Design Consultancy field, Providing solutions for high productivity at low cost.

For more information The Brains-SPMs & Tooling Consultants, C-309, Shree Vinayak CHS Ltd., Vaishali Nagar, Dahisar (East), MUMBAI-400068 Phones: 09819 504 604 Email : thebrains3946@gmail.com

Digital Insulation Resistance Tester

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he UDEY UDH-50-1T is a fully automatic – micro controller battery operated tester used to test insulation resistance, polarization index and dielectric absorp-

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tion ratio.It is light weight (2.5 kg), portable, user friendly and cost effective tester.

The huge range of applications range from testing for transformers, cables, HV generators, electrical circuits and many more.

The UDH -50-1T has a big LCD display with a built in rechargeable battery, data storage and recall facility. It is multi range voltage : 0.5-1-2.5-5 kV, up to 1 Tera ohms. The entire test is done automatically thus erasing scope of human error. Not only is this test set fast, efficient, accurate, reliable and dependable. It also incorporates the latest break through technology.

Transformer Insulating Oil Tester

The UDEY OTSA series oil testers are fully automatic micro controller based system, completely self – contained, compact and portable with test voltages of 0 to 60, 75, 80,90,100 kv. The tester is designed to test the dielectric strength of insulating oil in filed, floor shop or laboratory.

The tests can be done as per various international standards like IEC 156/ IS 6792/ASTM D 1816/ASTM D877 / UNE 21 which are pre programmed. A User definition

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mode makes it easy for the user to programme as per his settings. The entire test cycle is done automatically erasing human error. The operation is automatic as well as manual mode. The UDEY OTSA is user friendly, storage up to 100 test results, built in plain paper printer, day, date calendar, large LCD display for ease of reading, RS 232 interface and gives accurate performance regularly.

The tester weighs 34 kgs only.

Tan Delta Tester The UDEY CDF6000 is a fully automatic 12 kv capacitance and dissipation factor tester designed for insulation and quality assessment of high voltage power apparatus in the field, floor shop or laboratory. The entire test is done automatically in a matter of 30 seconds thus erasing scope of human error.

This CDF â&#x20AC;&#x201C; 6000 in a single unit construction with inbuilt standard capacitor of SF-6 type, HV transformer, built in printer, RS interface, can store upto 99 test results. Not only is this test set fast, efficient, accurate, reliable and dependable. It also incorporates the latest break through technology. The CDF-6000 does not require any balancing, is ready to test instantly. The single unit design makes it super easy to connect and save time of interconnections between the standard capacitor, HV transformer. The tester weighs 28 kgs only.

For more information Udeyraj Electricals Pvt.Ltd. 212-A, HIND SAURASHTRA INDL.EST., 85-86, M.V.ROAD, ANDHERI-E MUMBAI-400059 + 91 22 6691 6181/ 2, 2850 8017 Email: info@udeyraj.com Web: www.udeyraj.com

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Cable Trays & accessories, Gratings, Handrails and Fabricated Steel Structures

I

ndiana is a leading global manufacturer and exporter of Cable Trays & accessories, Gratings, Handrails and Fabricated Steel Structures (mainly Boiler structures for mega power projects). We are an ISO 9001, ISO 14001 and BS OHSAS 18001 certified company and 21 times export award winner of Engineering Export Promotion Council (EEPC).

We manufacture Ladder type, Perforated type and Wire Mesh (basket) Cable Trays & accessories in various materials like Mild Steel (galvanized as well as powder coated), Stainless Steel, Aluminium and FRP.We are in this business since last 40 years and our products are exported to various countries including USA, UK etc etc.

Since 2009 we have diversified into Fabricated Steel Structures and are mainly catering to all the leading Boiler manufacturers. We have installed all imported machineries to manufacture built-up beams. We have also installed Peddinghaus, USA â&#x20AC;&#x201C; CNC machinery for saw cutting, marking & drilling along with CNC plate processor with plasma cutting facility. The output from these machines are not only fast but also accurate. With in-house shotblasting facility, we can give faster delivery at competitive rate.

For more information Indiana Grating Pvt. Ltd. Indiana House, Makwana Road, Marol Naka , Andheri (E), Mumbai - 400059 Tel. : 91-22-2850 4743 / 28505857 Fax - 91-22-2850 5154 / 28505721 Email : sales@indianagraup.com website : www.indianagroup.com

ENGINEERING REVIEW | DECEMBER 2013 |

195

PRODUCT SHOWCASE

Cable Glands – IP 54, IP 68, EMC, Double Compression 90 years + of German excellence in India

Our 55 page catalogue has detailed specifications of all the products. It is available on special request and can also be found on our website. www.geissel.com For more information Geissel India Pvt. Ltd., 1102, Mutha Road, Pirangut, Taluka-Mulshi, Pune 412 115 Tel: +91 20 22922125 – Fax: +91 20 22922480 E-mail: info@geissel-india.com

G

eissel India is fully owned by the Geissel Group, Germany and is an ISO 9001: 2008 certified Company. The “Geissel” brand of cable glands is well known and accepted worldwide. The products are made from brass, polyamide and stainless steel S.S 303(1.4305) & S.S. 316 TI (1.4571) – according to RoHS standards – up to cable dia of 116 mm with all kinds of threads, i.e. Pg, metric and inch. The cable glands meet specifications of IP 54, IP 68 and EMC.

The latest introduction is DOUBLE COMPRESSION GLANDS–designed in Germany, but made in India.

They are certified by C I M F R, Dhanbad. The special features are: ● The only IP 68 solution for double compression glands. ● Available in BSC and Metric threads.Other threads like Pg, NPT or BSP on request. ● Three sizes of glands to suit cable dia from 12 – 34 mm- this wide clamping range per size allows the user to reduce stock and minimize different sizes of cable glands. ● One type of gland for Weather proof, Waterproof, Flameproof suitable for gas groups IIA & IIB, Zones 1 &2 ● Explosion proof suitable for gas group IIC, Ex – d, Zones 1 & 2. ● Patented and protected.

We also manufacture Conduit, Conduit glands, lock nuts, plugs, reductions, enlargements, adapters,&twisting sleeves. All these are available ex stock from our factory at Pune.

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| DECEMBER 2013 | ENGINEERING REVIEW

ELMEX : KTT 6

T

here are certain applications that require termination of small size conductors along with high current

terminal blocks for the same electrical circuit. However, this is not possible in high current Terminal Blocks for which the smallest connection possibility is also higher than the requirement (of small size conductor) under consideration.

As a solution for the application as mentioned above, elmex has developed “TAP Terminal” Type KTT 6 which is suitable for connection of conductor size as mentioned below.

Flexible – 0.5sqmm to 6sqmm Rigid – 0.5sqmm to 10sqmm KTT 6 can be conveniently connected to elmex high current terminals KUT 50 & KUT 95. KTT 6 is fully insulated and facilitates termination of small size conductors (as mentioned above) at same electric potential, in the same

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PRODUCT SHOWCASE

electrical circuit.

For more information ELMEX CONTROLS PVT LTD. 12-GIDC Estate, Makarpura Road, Vadodara 390010, India Ph: +91-265-2642021 (Ext 206) Fax: +91-265-2638646, Cell: +91-9327722477 E-mail: rpatel@elmex.net Alternate E-mail: hirenshah@elmex.net URL: www.elmex.net

G

Rapid roll-up doors

andhi Automations - India’s No.1 Entrance Automations & Loading Bay Equipment Company offers Rapid Roll-Up Doors that are ideal automatic doors used for fast access, goods and people transit areas or for internal and external areas of buildings. Fast sturdy, space saving and reliable, it is suitable for any industrial purpose.

The simplistic curtain design with its fast opening and closing speed ensures effective protection against cold, heat, dust and high resistance to wind pressures.

The wide range offered features a whole array of unparalleled technological features. ● Hot-galvanised steel available in the RAL versions with over-baked epoxy coating with smooth finish or fine satin-finish AISI 304 stainless steel, complete with galvanised curtain winding pipe and with vertical uprights fitted with special self-lubricating sliding guide installed on a shock-absorbing spring system. ● Provision for roll-up roller casing. ● Electronic safety device to reverse motion when door is closing if an obstacle is hit

● Heavy duty motor: 3 phase 400 V motor, complete with limit switch and electrically operated hand brake. ● IP65 rated electronic panel, complete with open-closestop membrane push-button panel with autotest function, in compliance with European Directives 98/37/ CE and 89/106/CE ● Provision for manual opening device with operation crank. ● PVC see-through window section ensuring better visibility and thus safety when going through the door. ● INVERTER system on request for different speed, accelerations and braking control.

For more information Gandhi Automations Pvt Ltd 2nd Floor, Chawda Commercial Centre

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ENGINEERING REVIEW | DECEMBER 2013 |

197

PRODUCT SHOWCASE

Link Road, Malad(W) Mumbai – 400064 Off : 022- 66720200/66720300 (200 lines) Fax : 022-66720201 E-mail :- sales@geapl.co.in Website: www.geapl.co.in

Combined bearings

K

AVITSU combined bearings are suitable for forklifts and are designed as per the technical requirements of the fork lift and mast manufacturers. Similarly these are also suitable for linear motion in other equipments. The design incorporated in KAVITSU combined bearings gives the best resolution of the external load into its components. The complete sharing of the radial and axial load is allowed with design of the bearing. It is a combination of main bearing and axial bearing which takes the radial and axial load well in proportion. With this, the linear motion is smooth and there is no sliding friction. This leads to low wear and tear of supports / channels and saves power as well. Vibration level is reduced, which in turn decreases the noise level.

This system allows the extended life for bearing and the profile, as it minimizes the specific pressure value between bearing and the beam. Assembly of bearing is very simple. A plate or a shaft can be directly welded on soft axle of bearing and the welded bearing can be inserted in the beam which is then ready for use. All rolling components are manufactured from alloy steel with proper heat treatment keeping hardness as per standard bearings (60 HRC). The bearing is a combination of inner race, outer race, centre pin, welding bolt and radial ring. The bearing is filled with lifelong lubricating grease and has a rubber sealing to avoid leakage and to protect it from dust and other foreign particle. Special greasing arrangement is done for applications where environmental conditions are extreme. The bearings are manufactured in LIGHT se-

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| DECEMBER 2013 | ENGINEERING REVIEW

ries and HEAVY series. Light series bearings comprise of outer diameters from 52 mms to 150 mm and are suitable for use in the channels or I sections accordingly.

For heavy duty applications heavy channels or I sections are used and the sizes involved are from 165 to 309 mm as outer diameters. The main application are in pallet stackers, pallet lifter, telescopic fork, lift masts, tool changer system for heavy moulds for plastic molding machine, tool changing systems for various dies, lifts systems, eccentric lifting tables, robot tracks, multi axis units, heavy load linear systems, pallet in feeding station, fast picks.

For more information Kavitsu TRANSMISSIONS Pvt Ltd. W-85, Additional MIDC, Satara – 415004.

E-mail: marketing@kavitsu.com, kaustubh@kavitsu.com

Shot Classifier For Classifying / Dust Removal ● ● ● ●

Steel Shots Glass Shots Casting Sand Sand Blasting Sand

ETA Vibro Screen are used for Classifying Mixed Shots or removing fused shots and dust/fines from used shots, in shot peening and shot blasting process. It can be used for similar purpose in sand blasting also.

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PRODUCT SHOWCASE

The machine can be placed on line for continuous operation or can be off line for intermittent working.

For more information ETA Engineering Services, Plot no.3/2, Ambica Estate, Kothari Char Rasta, Santej-382721 (Dist.Gandhinagar), Gujarat, India.

Tel: 02764-286288, +91-9909917170 Fax: 08764-286289 E-mail: enquiry@etamail.com Web: www.shot-classifier.com

Checker 4G 7 (Vision sensors)

T

he Checker 4G series of vision sensors offers unmatched performance and flexibility to solve even the most difficult applications. The Checker 4G series offers the same powerful and easy to use setup. Checker Vision Sensor is known for plus Ethernet networking for remote setup and monitoring, PLC communication through EtherNet/IP and PROFINET and the ability to save images of every inspection to an FTP server. ®

● EtherNet/IP industrial protocol with RSLogix5000™ Add-On-Profile ● PROFINET industrial protocol support ● Image storage to FTP server ● Remote setup and display through your PC ● Encoder-based part tracking for variable speed lines ● Up to four discrete outputs ● Up to 32 job changes for maximum flexibility ● Colored lens filters available

Applications of Vision Sensors: ● ● ● ● ● ●

Date code and MRP print presence/absence Detecting missing bottles Detecting missing caps and lot codes Verifying seal and cap presence absence Verifying label presence/absence Liquid Fill level Inspection For more information Cognex Sensors India Pvt. Ltd., Regus Level 6, Pentagon Towers P II, Magarphatta City, Hadapsar, Pune - 411 028. INDIA. Mobile: +91 98814 66003 Tel.: +91 20 4014 7840 • E-mail: vaggu.sunil@cognex.in Web: www.congnex.com

Key Features: ● Presence sensors verify that features are present ● Industry standard Ladder Logic editor allows for customization of results and eliminates PLC programming

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ENGINEERING REVIEW | DECEMBER 2013 |

199

ADVERTISERS INDEX COMPANY NAME

PG. NO.

A

COMPANY NAME

PG. NO.

G

A.C. AUTOMATION

31

GUNNEBO INDIA PVT. LTD.

ACMEE 2014

107

H

ACTION CONSTRUCTION EQUIPMENT LTD.

85

H. K. INTERNATIONAL

123

AMTEX 2014

75

HARTING (INDIA) PVT. LTD.

33

AUTOMATION INDIA WELDING TECHNOLOGY (P) LTD.

HIMTEX 2014

112

35 HOLTZMAN SYSTEMS LIMITED

89

HORIBA INDIA PVT. LTD.

23

B

143

COMPANY NAME

PG. NO.

NIMBLE MOTION - A DIVISION OF UCAM PVT LTD

71

NUGEN MACHINERIES LTD.

3

O ORBITAL SYSTEMS (BOMBAY) PVT. LTD.

59 & BOOK MARK

P PAARTH VALVES PVT. LTD.

129

PARAGDEEP METALS

175

PETHE INDUSTRIAL MARKETING COMPANY PVT. LTD.

69

BECKHOFF AUTOMATION PVT. LTD.

REVERSE GATEFOLD

I

BHAWAL STEEL AGENCY

175

IGUS (INDIA) PVT. LTD.

93

PIONEER CRANES & ELEVATORS (P) LTD.

87

BRY-AIR (ASIA) PVT. LTD.

7

INDIA TOOLS & INSTRUMENTS CO.

181 & 183

POWERCONNECT (INDIA)

14-15

INDUCTOTHERM GROUP

51

PRISM GAS DETECTION PVT. LTD.

65

PROCON TECHNOLOGIES PVT. LTD.

41

PROLITE AUTOGLO LIMITED

149

C C.P. FLUID SYSTEMS PVT. LTD.

7

INGERSOLL RAND (INDIA) LTD.

INSIDE FRONT COVER

CHHATARIYA RUBBER & CHEMICAL INDUSTRIES

147

INTEC 2014

119

COGNEX SENSORS INDIA PVT. LTD.

17

J JAY STEEL CORPORATION

D

171

123

K

DMG MORI INDIA

BACK PAGE

KNOWELL INTERNATIONAL PVT. LTD.

71

DOWEL ENGINEERING WORKS

67

27

DYNAMIC STEEL (INDIA)

173

KUEBLER AUTOMATION INDIA PVT. LTD.

INSIDE FRONT COVER

KUMBHOJKAR PLASTIC MOULDERS

105

DYNAMIC VALVES PVT. LTD.

E4 EVENTS

109

EA-WATER 2014

131

ELECTRO MAGNETIC INDUSTRIES

97, 99, 101 & 103

L

M

MICROSCAN

18

105

MIRANDA AUTOMATION PVT. LTD.

25

EXOTIC FABTECH PVT. LTD.

127

MONIBA ANAND ELECTRICALS PVT. LTD.

EXPRESS TOOLS CORPP.

71

ETA ENGINEERING SERVICES

FERROCLAD SOLUTIONS PVT. LTD.

123

39

52

SMALLEY STEEL RING COMPANY

1

SOFTCORE SOLUTIONS

135

SPRAYMET SURFACE TECHNOLOGIES PVT. LTD.

69 21

NETZSCH PUMPS & SYSTEMS INDIA ENGINEERING REVIEW |

TECHNO PRODUCTS DEVELOPMENT PVT. LTD.

INNER GATEFOLD

TEJ INDUSTRIES

7

TESTO INDIA PVT. LTD.

29

TINITA ENGINEERING PVT. LTD.

169

TOP GEAR TRANSMISSIONS

115

V VASHI ELECTRICALS PVT. LTD.

FRONT GATEFOLD

W

N

F

SIDDHAPURA MACHINE TOOLS

T

111

113

137

121

MGM-VARVEL POWER TRANSMISSION PVT LTD

ESSENTIAL POWER TRANSMISSION PVT. LTD.

SAMRIDDHI AUTOMATIONS PVT. LTD.

LUBI INDUSTRIES

141

53

175

SUPERTECH INSTRUMENTATION SERVICES (I) PVT. LTD.

MARVEL GLOVES INDUSTRIES

ERWIN JUNKER MASCHINENFABRIK GMBH

ROLEX FITTINGS INDIA PVT. LTD.

63

95

37 & 86

31 & 41

LAKSHMI RING TRAVELLERS (COIMBATORE) LTD.

MAHINDRA STILLER AUTO TRUCKS LTD.

ELECTRONICS DEVICES WORLDWIDE PVT. LTD.

RED LION CONTROLS INC.

S

DEL PD PUMPS & GEARS (P) LTD.

E

R

200

INSIDE BACK COVER | December 2013

WALPHA ENGINEERING

57

WMI KONECRANES INDIA LTD.

91

IN_Eng Review(Nov)_NLX_190x250_20Nov_Layout 1 11/20/13 2:58 PM Page 1

cooperation sustains innovation

NLX-Series

The new standard in CNC universal turning machines

For Service & Spareparts support call our new Toll Free No. 1800 103 6467

NLX Series Highlights _ Further enhancement to the popular NL Series, with

_ Energy efficient: Up to 30 % power savings over

over 10,000 machines sold _ Integrated cooling system in the machine bed for better thermal stability

_ A compact integrated automation solution – Work

_ BMT® technology with a direct drive motor in the turret for powerful milling

_ Various customisations available (example: directly driven tools, Y-axis, powerful counter spindle)

previous models piece storage / GX05 loading station and precision work piece measuring by Magnescale for optimal process integration* _ MAPPS IV control with a 10.4" TFT screen – optional with a CAM module from Esprit * Optional

All of the latest news available at: www.dmgmori.com

DMG MORI India: No. 3/1, 3rd Main Road, K I A D B Peenya 1st Stage Bangalore 560 058, India, Tel.: +91-80-40896500, Fax: +91-80-41131285, info@dmgmori.com, www.dmgmori.com If your phone is equipped with QR-code recognition software, you will be directed to our homepage.