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ENTWINED FORTUNES, UNPARALLEL GROWTH ining sector has been making headlines lately…and it is not even making the other sectors go green with envy, because green, among others, is incidentally one of the reasons why this sector is getting negative publicity from all quarters. Suddenly the focus of media, ministry and the nation is on the mine and mineral sector. Understandably so, the stakes are high for both, the industry as well as the environment, not to mention the natives. Lately, the minute you blurt out the word mine, all eyes and ears are on you. You are supposed to choose your camp; it is a choice between tight-lipped white collared group or slogan shouting activists. With lot of hardline approach floating around, we are locked in a no-win battle. We cannot ignore the demands for unrestricted and abundant flow of minerals, which is critical for India’s growth… cannot even be less concerned about preserving the nature and the natives. Both are critical for India’s holistic and sustainable growth. It is a complex situation and there are wheels within wheels. The message from the government to the corporates and investors is loud and clear, the latest rejections of project approvals is not a part of ‘corporates Vs tribals policy’, but it is an action against illegal mining practices. Though the controversies surrounding the mines and mineral sector is not a simple one, there is no denying the fact that all the stakeholders whose fortunes and future is at stake – be it the miners, the natives, the environment conservationists or the rest of the ecosystem – has to work together to light the path of future mining practices, which should be all-enriching. With this as a backgrounder, the October issue of SEARCH is dedicated to the initiation of a new era of mining and mineral sector, which is cleaner, greener and all-enriching. We have also talked about the synergised growth of mines and material handling industry, with special emphasis on technology and automation. What is also unique is the fact that we are not forecasting trends and market opportunities in this sector sitting far away from where the action is…we travelled to gather the first-hand information, an experience that was enlightening, and expert opinions that is going to shape the fortunes of this sector and our country. As a part of this drive, we visited the mining frontrunners, National Aluminium Company (NALCO) and Central Coalfields (CCL). We also managed to get expert views of Mr AK Singh, CMD, Central Mine Planning & Design Institute, and Mr RK Saha, CMD, Central Coalfields… do read the in-depth facility visit report and exclusive interview. With sustainable mining under spotlight, we also did reportage on how mining equipment industry is fuelling growth with an insightful interview of Mr GK Pillai, CMD, Heavy Engineering Corporation. It is a must-read to know the plethora of opportunities that still remain untapped and the roadmap to tap these hidden growth treasures. It is also time that the industry looks inwards and finds solutions to make India the top mines and minerals producing country, but while we do that, let us not forget to don our green hats.

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Archana Tiwari-Nayudu archana.nayudu@infomedia18.in

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Printed by Mohan Gajria and published & edited by Lakshmi Narasimhan on behalf of Infomedia 18 Limited and printed at Infomedia 18 Ltd, Plot no.3, Sector 7, off Sion-Panvel Road, Nerul, Navi Mumbai 400 706, and published at Infomedia 18 Ltd, ‘A’ Wing, Ruby House, J. K. Sawant Marg, Dadar (W), Mumbai - 400 028. SEARCH - The Industrial Sourcebook is registered with the Registrar of Newspapers of India under No. 67827/98. Views and opinions expressed in this publication are not necessarily those of Infomedia 18 Limited. Infomedia 18 Limited reserves the right to use the information published herein in any manner whatsoever. While every effort has been made to ensure accuracy of the information published in this edition, neither Infomedia 18 Ltd nor any of its employees accept any responsibility for any errors or omission. Further, Infomedia 18 Ltd does not take any responsibility for loss or damage incurred or suffered by any subscriber of this magazine as a result of his/her accepting any invitation/offer published in this edition. No part of this publication may be reproduced in any form without the written permission of the publisher. All rights reserved.

O C T O B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK

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CONTENTS EXTREME MINING

NATIONAL ALUMINIUM COMPANY

| Pg 72

Taking The Path Less Trodden 27

EDITORIAL

Making the impossible possible and overcoming all the challenges requires strong will, determination and a sustainable futurist outlook. Creating history in the bauxite mining in a region with absolutely no basic facilities and connectivity with the outside world, National Aluminium Company (NALCO) has proved this to be true. Standing tall, tackling these extremities for decades is NALCO’s Panchpatmali mine at Damanjodi, Orissa, which has changed the way bauxite mining is being done in India. Because of its high-tech, eco-friendly and socially-oriented business approach, it has earned a high stature and set a precedent for other companies to follow.

Entwined Fortunes, Unparallel Growth

SPOTLIGHT 40

NATIONAL NEWS Latest In The Indian Manufacturing

80

NALCO Damanjodi Refinery Refining With Excellence

VIEW FROM THE TOP

NEWS ANALYSIS 46

Indian Diesel Genset Market Energising Prospects

50

Business@Orissa High On The Investment Radar

54

WORLD NEWS

Pg 60

Snapshot Of Latest Global Happenings In Manufacturing Domain

TECHNOLOGY TRENDS 148

Technology Update Cutting Edge Solutions

APPLICATION ZONE 154

Machine Vision Systems Market On The Crossroads

‘If India has to grow at 9-10 per cent, then mining has to contribute in an unprecedented manner’ AK SINGH, CMD, Central Mine Planning & Design Institute (CMPDI)

Pg 66

EQUIPMENT BUYING GUIDE 156

Overhead Cranes Sourcing The Best Fit Solution

DESIGN INNOVATIONS 161

164

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Innovators’ Outlook ‘Design Success Can Be Achieved By Identifying Features That The Customer Values’ Axel Schmidt, Partner & Head, Roland Berger’s Global Operations Strategy Competence Centre

‘Higher economic productivity can make mining products affordable’

Factory And Plant Equipment Simulating A New World Of Design

GK PILLAI, CMD, Heavy Engineering Corporation (HEC)

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CONTENTS SPECIALS IN THIS ISSUE INDUSTRY UPDATE Mining

INSIGHTS & OUTLOOK Material Handling

84

Sustainable Mining Paving The Green Path

107

90

Spotlight Central Coalfields - Living The Legacy

Mining & Construction Equipment Excavating Strong Potential

114

Material Handling Equipment Lifting Up The Competitiveness Quotient

98

‘CCL Has Accorded The Highest Priority To Environment Management For Sustainable Mining’ RK Saha, CMD, Central Coalfields

120

Mining Equipment Growing On Strong Fundamentals

132

Smart Engineering Materials Unravelling A New World Of Opportunities

126

Innovative Solution For Open Cast Mines Reliability And Ease Of Maintenance By Design

138

Ceramics Creating A New Wave In Energy Technology

143

New Materials Adding Substance To The ‘Material’ World

VIEW POINT 168

Profit Mantra Charting The Blueprint To Success

PRODUCT UPDATE 198

Mining Latest Products In Mining

202

Material Handling Latest Products In Material Handling

210

Engineering Materials Latest Products In Engineering Materials

218

New Launches Latest Products In The Offing

222

General Products Rolling Out The Best-in-class

SMART STRATEGIES 174

World-Class Manufacturing Unlocking The Potential To Be The Best

CASE STUDY 182

Statoil Pumping Up Production Levels Through ‘Smart’ Technologies

FACTORY FUNDAMENTALS 186

Proactive Maintenance Surpassing Conventional Techniques

SME ADVANTAGE 192

Data Analysis Driving Business Performance Through Visibility

247

254 262

180 190

PRODUCT INDEX ADVERTISEMENT INQUIRY FORM Get In Touch With Supplier Of Products You Wish To Buy

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ADVERTISERS’ LIST Advertisers’ List In Chronological Order

PREVIEW HiTech Manufacturing Show Envisioning The Future Of Manufacturing ENGINEERING EXPO Projecting ‘A Promising Pune’

PRODUCT UPDATE

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International Products Showcasing Product In A Global Arena

Alphabetical Listing Of Products Presented In The Issue

CURTAIN RAISER India Energy 2010 & India Nuclear Energy 2010 Aiming For ‘Power’ful Future

PRODUCT INQUIRY FORM For Product Inquiries Showcased In This Issue, Fill In The Form And Send It Back To Us

269 197

ENGINEERING MATERIALS

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Details on pg. 177, 190, 195


NATIONAL NEWS

Auto component industry to see 4-fold growth by 2020 he Indian car manufacturing industry is slated to witness an exponential growth in the next decade and according to projections indicated by the Automotive Component Manufacturers’ Association (ACMA), the Indian auto component industry is expected to grow by over four-fold to $113 billion by 2020. The total passenger car production in the country will jump four times to reach 9 million cars in the next ten years, ACMA said in its forecast report. Although a major chunk of this will come from the fast growing domestic market, exports are likely to form

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FDI Equity Inflows (Month-wise) During The Financial Year 2010-11: Financial Year 2010-11 (April-March )

Amount of FDI inflows* (In Rs. Crore)

(In US$ mn)

April 2010

9,854

May 2010

10,135

2,213

June 2010

6,429

1,380

26,418

5,807

34,211

7,016

2010-11 (Up to June 10) # 2009-10 (Up to June 09) % age growth over last year

2,214

(-) 22.78 % (-) 17.22 %

# Figures are provisional, subject to reconciliation with RBI, Mumbai.

Sectors Attracting Highest FDI Equity Inflows: (Financial Year-wise): Amount Rupees in crores (US$ in million)

Sector

Services Sector Computer Software & Hardware Telecommunications Housing & Real Estate Construction Activities Power Automobile Industry * Metallurgical Industries Petroleum & Natural Gas Chemicals

2010-11 % age to total (April -June Inflows 2010) (In terms of US$) 3,149 21% 1,427 9% 4,182 1,595 1,008 2,004 302 2,602 951 404

8% 8% 7% 4% 4% 3% 2% 2%

Note: Cumulative Sector- wise FDI equity inflows (from April 2000 to June 2010) - Annex-‘B’. * Earlier data has been revised, due to some figures interchange with the respective sectors.

Share Of Top Investing Countries FDI Equity Inflows: (Financial Year-wise): Amount Rupees in crores (US$ in million)

Country Mauritius Singapore U.S.A. U.K. Netherlands Japan Cyprus Germany U.A.E. France Total FDI Inflows *

2010-11 % age to total (April-June Inflows 10) (in terms of US $) 8,520 42% 4,245 10% 1,162 7% 707 5% 1,565 4% 1,966 4% 486 4% 189 2% 530 1% 312 1% 26,418 -

Note: (i) *Includes inflows under NRI Schemes of RBI, stock swapped and advances pending for issue of shares. (ii) Cumulative country-wise FDI equity inflows (from April 2000 to June 2010) – Annex-‘A’. (iii) %age worked out in US$ terms & FDI inflows received through FIPB/SIA+ RBI’s Automatic Route+ acquisition of existing shares only. Source: Department of Industrial Policy & Promotion, Ministry of Commerce and Industry, Govt. of India

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around 35 per cent of the total market by 2020. Indian component industry is

and three-wheelers are expected to double to 2.2 crore units by 2015 and reach

As per the estimates of ACMA, the local component industry would create an additional employment for over 10 lakh people in the next decade. To meet the increased requirement of skilled hands, the government has decided to set up a dedicated skill development body for the auto industry to train 25 million people in the next decade. expected to clock total revenue of $25 billion in the current fiscal. Given high growth projections, the local component industry is looking to invest $35 billion over the next decade. Production of two-wheelers

three crore units by 2020 driven by current low penetration levels, expanding rural sales and growth in exports. Commercial vehicles production is forecast to cross the 22 lakh-units mark in the same period.

Developers of power project in SEZs get duty relief ujarat is set to save close to Rs 400 crore a year with the Centre revising its earlier notification of levying custom duty from the power plants that are supplying power from special economic zone (SEZ) into domestic tariff area. The charges for the power project developers have come down to just 10 paisa per unit instead of the earlier 16 per cent duty, which was almost 50 paisa per unit for tariff of Rs 3 per unit. The most beneficial

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companies in Gujarat would be Adani Group company, Adani Power and its customer, state utility Gujarat Urja Vikas Nigam (GUVNL). Adani Power operates 990 MW of generation capacity at Mundra SEZ and sells its electricity to GUVNL. According to an energy expert, players like Adani Power that are catering to domestic tariff areas from SEZ will get major boost on account of revised notification. Adani Power will have to pay only 10 paisa per unit for its current

generation of 20 million units of electricity instead of the earlier duty of 50 paisa. As per the revised rate for 1,000 MW power project, duty would be Rs 100 per 1,000 units in case of imported coal fired generation and Rs 110 per 1,000 units in case of gas-based generation. Similarly, projects below 1,000 MW of capacity will have to pay only Rs 40 per 1,000 units in case of imported coal fired station and Rs 60 per 1000 units in case of gas based project.

Industrial production rises by 13.8 per cent in July 2010 ndia’s industrial production witnessed an increase of 13.8 per cent in July 2010, surpassing analysts’ forecasts. The official Index of Industrial Production (IIP) grew by 13.8 per cent as compared to 7.2 per cent in July 2009. The rise was powered by a 63 per cent jump in output of

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capital goods and 22.1 per cent in that of consumer durables. Among the major constituents of the IIP, the index for manufacturing has registered an annual growth of 15 per cent for July 2010 as compared to 7.4 per cent in the corresponding month in 2009, while mining grew at 9.7 per cent for July 2010 in comparison

to 8.7 per cent in July 2009 and electricity logged a growth of 3.7 per cent in July 2010. Till July 2010 in the current fiscal, the economy witnessed a cumulative industrial growth of 11.4 per cent, with the figures working out to be 12.2 per cent for manufacturing, 10 per cent for mining and 5.2 per cent for electricity.


NATIONAL NEWS

EVENTS

PUNE Maharashtra November 19-22, 2010 Auto Cluster Exhibition Ctr, Chinchwad

AHMEDABAD Gujarat December 10-13, 2010 Gujarat University Exhibition Hall

INDORE Madhya Pradesh January 7-10, 2011 Maharaja Shivajirao School Grd, Chimanbaug

CHENNAI Tamil Nadu March 11-13, 2011 Chennai Trade Centre

India’s premier industrial trade fair on products and technologies from machine tools, hydraulics & pneumatics, process machinery & eqpt, automation instrumentation, packaging & auxiliaries, IT products, electrical & electronics, material handling, safety eqpt.

Concurrent Shows

MUMBAI Maharashtra February 17-19, 2011 Bombay Exhibition Centre

One of the largest advanced design and manufacturing events in India featuring machine tools, hydraulics & pneumatics, process machinery & equipment, packaging & auxiliaries, it products, electrical & electronics with a special focus on automation & instrumentation, material handling For further details contact: Tel: 022 3003 4649/4651 Fax: 022 30034499 Email: engexpo@infomedia18.in Web: www.engg-expo.com

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Grundfos launches ‘Incredible Indian Pump Yatra’

In India

rundfos India has recently launched ‘The Incredible Indian Pump Yatra’ - a fully equipped business lounge on wheels, equipped with a series of interactive displays of a wide range of industrial pumps. The journey that started from Ahmedabad on September 10, 2010 will cover various cities of Gujarat enabling visitors to gain hands-on experience of Grundfos products & solutions. Commenting on the initiative, Ranganath NK, MD, Grundfos Pumps India, elaborates,

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“Grundfos India has been directly associated with the Indian industrial market for over 10 years. Our intensive research in the market has revealed that in many engineering industries, there exists a great potential for energy savings, even in the small and medium range pumps. To address this gap, Grundfos has a wide range of energy efficient pumps.” Highlighting on energy efficient technologies, Ranganath adds, “For decades, Indian industrial end-users were used to conventional low cost

but inefficient pumps. Further, the pump recommendations and selections were made more on historic assumptions. Grundfos has the distinction of introducing pump and pump technologies that are very efficient and reliable and did not exist in India. These pumps and systems not only conserve energy but also save space. Moreover, the cost of installation/maintenance and the overall life cycle cost are far lower than the pumps that were in the market. The payback in most cases was a year or lesser.”

Godrej and IMER Group tie up for powered access equipment odrej Material Handling has joined hands with IMER International for their Iteco range of powered access equipment in India. Godrej will offer powered scissor lift from Iteco’s full product range. Iteco’s range of powered access equipment is known for its innovative design and features which no other manufacturer offers. For instance, Iteco’s scissor platforms are drivable at full platform height. The platform

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capacity remains maximum even on deck extension. Iteco powered access equipment is known for its design and rigidity. The powered access equipment market has been g r o w i n g consistently in the last few years in India. Godrej and IMER have decided to cater to this growing demand by

offering the Indian customer a wide range of powered access equipment. Godrej and Iteco both have a long-term vision towards this business in India. Initially, Godrej will be marketing and servicing the Iteco products, followed by rapid steps to manufacture popular models of the range in near future.

Govt plans policy to attract funds for building manufacturing hubs he Union Commerce & Industry Ministry is in the process of formulating a draft policy to attract investments for setting up mega manufacturing hubs in the country. Anand Sharma Union Commerce & Industry Minister said, “The Ministry is in the final stages of formulating the policy,

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which is most likely to be placed before the interministerial group by the end of October this year. This policy will facilitate timely approval and clearances of investments needed for large manufacturing hubs.” The Minister stressed that engineering and manufacturing need to go hand-in-hand to have a meaningful impact on

the economy. “India has tremendous potential in manufacturing though our share in global exports is just 1 per cent,” he remarked. However, Sharma said that before these investments are made, efforts should be directed towards skill training and up-gradation of the workforce, given that millions are going to join the labour pool in the near future.


NATIONAL NEWS

EVENTS

In India

PROMACH 2010 Focus: Tools and Tooling Equipment When: October 1-4, 2010 Where: Bangalore International Exhibition Centre, Bangalore Tel: 080-80-65833234 Email: dayanand@bies.co.in INDIA ENERGY 2010 Focus: Technologies in renewable energy When: October 7-9, 2010 Where: Bombay Exhibition Centre, Mumbai Tel + 91 22 6612 2644 Fax: + 91 22 6612 2626-27 Email: abhijit.mukherjee@ubm.com Website: http://www.ubmindia.com WIRE & CABLE INDIA 2010 Focus: Wire & cable industry When: November 18-20, 2010 Where: Bombay Exhibition Centre, Mumbai Tel: 011 2697 1745 E-mail: DughL@md-india.com IPVS - INDUSTRIAL PUMPS, VALVES AND SYSTEMS Focus: Industrial pumps, valves and systems When: December 9-11, 2010 Where: Chennai Trade Centre, Hall 3, Tamil Nadu Tel: + 044 - 22316033, 044 - 22315551 Fax: + 91 22 24102805 Email: info@ipvs.in / ho.exb1@orbitzexhibitions.com HANNOVER MILANO FAIRS INDIA Focus: Concurrent trade shows on material handling & logistics; motion, drives & automation; building automation; energy & surface technology When: December 15-18, 2010 Where: Bombay Exhibition Centre, Mumbai Tel: +91 22 40050681/82 Fax: +91 22 40050683 Email: info@hmf-india.com EA WATER EXPO Focus: Water and Wastewater Management When: January 06-08, 2011 Where: Bombay Exhibition Centre (BEC), Mumbai Tel: +(91)-(11)-29531288 Fax: +(91)-(11)-29531291

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CII supports solar power projects financing in India the meet was that banks funding oday, with the Financing of Solar Power renewable energy projects will requirement of Projects in India’ in Mumbai. A major point put forth at require long-term resources, large finances in for which they should s o l a r be allowed to float taxproject development, free solar bonds. S project financing seems Sridhar, CMD, Central to be one of the major Bank of India, said barriers to this market. We have completed first phase with power “Bankers are concerned, To address this issue, purchase agreements signed for 100 MW. but not averse to Confederation of Indian Apart from this, expressions of interest financing these projects. Industry (CII) and for another 700 MW are with us. Banks should be allowed Indian Renewable to float tax-free solar Energy Development bonds, of about 10-15 Agency (IREDA) DR FAROOQ ABDULLAH, years duration. This will recently organised an Minister for New & Renewable Energy, enable them to raise exclusive interactive Government of India long-term resources. session on ‘Enabling

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MEDC hosts MSME Global Conference SMEs (Micro, Small In view of the magnitude of Management College had and Medium this imperative sector, the recently organised a two day Enterprise) business conference are widely ‘MSMEs – Gearing up to regarded as the growth Global Competitiveness’ engine of the Indian in Mumbai. The event We are planning to have 30 per cent extra focussed economy. on the The sector land reservations of plots for MSMEs in importance of MSMEs in constitutes 95 per cent MIDC. The state government will also India’s economic growth of the overall industrial have a new industrial policy, next year, and delved in depth into units and contributes various challenges faced which will have a special section for the & ways to overcome 40 per cent of the MSME sector. industrial output along them. with 40 per cent of the Rajendra Darda, exports in India. With Minister for Industries, RAJENDRA DARDA, their expansion and Maharashtra, announced Industries Minister, Maharashtra exposure to the launch of the new international markets, industrial policy for the the sector has been evolving its Maharashtra Economic MSME sector during his entrepreneurial skills over the Development Council (MEDC) inaugural speech at the years. & Indian Education Society’ IES conference.

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CII to host seminar on transmission & distribution merging dynamics of the Indian power market make it pertinent for the industry players to realign their strategies and operating models to the changing sectoral trends. Buoyed by incentives & support from the government as well as advancements in the

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technology, the Indian T&D sector is all set to play a critical role in defining the future of the industry and in ensuring sustainability of the Indian energy sector. To tap this market, CII with SEARCH as its media partner are organising a seminar on ‘Challenges in Transmission and

Distribution’ on October 1 in New Delhi. This seminar will bring together the industry, policy makers, and service providers all under one roof to derive and arrive at consensus on vital issues and plan to leverage on emerging opportunities and face upcoming challenges boldly.


INDIAN DIESEL GENSET MARKET

ENERGISING PROSPECTS With the increasing demand-supply gap in power generation, diesel genset segment has bounced back riding on growing need for uninterrupted power for telecom and manufacturing sectors. Making smart moves, this segment is tapping emerging opportunities to enhance business prospects for the long run.

KTP RADHIKA JINOY

he growth in manufacturing and construction activities has intensified the need for continuous supply of power in India. Several studies reveal that at present there is a demand-supply gap of about 17 per cent when it comes to power generation in the country. This has opened up huge market opportunities for players in the power and allied sectors. And one instance of this is the creation of a highly competitive market space for the generator set manufacturing companies. The boost in diesel genset sales in the country is attributed to growth spurt in industrial sectors and peak power deficit being faced in India. Amol Kotwal, Deputy Director – Energy & Power Systems, South Asia & Middle East, Frost & Sullivan, avers, “The diesel genset market is estimated to be around 1.5 lakh units in FY 2009-10. The genset market witnessed a growth rate of 15 per cent in revenue terms, chiefly driven by demand from retail and telecom sector, during the period.”

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DEMAND TRENDS Diesel genset market can be broadly divided into three segments. Namely, small diesel generators (15-75 kVA), medium diesel generators (75.1-375 kVA), and large diesel generators (375.1-2000 kVA). Acute power shortages coupled with high growth in manufacturing, infrastructure, telecommunication, information technology (IT), and IT-enabled services, retail segment, etc., has triggered market growth for all the diesel genset segments. In the recent past, telecom sector was the key growth driver for the small diesel generator set market. Even though, the 15-75 kVA diesel generator set market witnessed a slight slowdown in the last few years on account of saturation in certain telecom circles, industry experts predict that with the advent of 3G services in 2010, the small diesel generator market will revive and witness a high growth rate. According to industry estimates, the DG set market in India (15-2000 kVA range) was estimated at `60,253 million with 1,47,040 units in the financial year 2006-07. That is now projected to grow

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to `12,2230 million with sales of 2,05,450 units. D Srinivasa Reddy, Managing Partner, Reddy Generators, says, “During recession, the diesel generator market was witnessing a low market growth. However, in 2010 the genset market has started to pick up and currently, it is having a high growth rate mainly due to the boost in telecom sector. Following this, real-estate, manufacturing, construction, retail and consumer market are driving the growth of this segment.”

TAPPING THE MARKET Observing the current trend and demand rise, Indian diesel genset manufacturing companies are adopting innovative practices to tap this potential market. Major players like Mahindra & Mahindra, Kirloskar, Cummins, etc have introduced new brands for specified users. For example, foreseeing the huge potential, Mahindra & Mahindra has launched Powerol brand for the Indian market. Company report says that this new brand has helped to grow their business to `1,010 crore in 2009 from its earlier revenue of `51 crore in 2005. For


INDIAN DIESEL GENSET MARKET

the retail and consumer market, Cummins India announced its entry by introducing small power generator sets of 7.5 kVA and 10 kVA in the beginning of this year. Sources reveal that the company plans to set up a separate retail channel for marketing these small generators through 300-400 retailers in the next 18 months. Kotwal says, “Indian diesel genset manufacturers have already geared up to take advantage of the current growing demand. However, adequate engine manufacturing and sourcing is required to address the market demands. In addition, the emphasis on sales and services network is important.” Manufacturing companies are also developing new technologies and designs to augment growth. The emission norms in India are being continuously updated to match international standards. New technologies and designs will help the companies reduce emission and improve efficiency. “Previously, Indian diesel generators were causing high pollution and their carbon footprint was high. However, today, due to advancements in technology and design, emissions have reduced to a great extent,” says Reddy. Adding to this,

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Kotwal says, “Stricter emission norm is expected in 2013. However, all major genset OEMs already have or are in process of enhancing the engine technology to meet emission norms. Hence, as per major genset manufacturers, change in emission norms is not expected to affect them. However, new norms may affect the unorganised engine manufacturers.”

THE FLIP SIDE Even though market is growing, the Indian diesel genset industry is still facing major challenges, which need to be addressed on priority. Import of low-cost diesel generators and the competition from unorganised players are some key constraints that have slowed growth of late. Reddy says, “Lowcost imports, especially from China, are impacting the domestic manufacturers & suppliers. This is also hurting the profit margin.” Another threat is the hike in diesel price. Industry experts predict that the global price hike of crude oil will result in the rise of diesel prices significantly, thereby causing huge losses to the end-users. This necessitates shutdown of diesel-based generation that will negatively impact the demand for new diesel generators in the

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future. Supporting the point, Kotwal points out, “Shortage of diesel engine manufacturing capacity in India and lack of availability of skilled manpower, who are shifting to other lucrative professions, are posing as major challenges to the Indian diesel genset industry.”

BRIGHT FUTURE Looking forward, the degree of competition in small and medium genset market is expected to increase significantly. Kotwal asserts, “In the near future, the genset industry in India is set on a robust growth path, fuelled by power supply deficit and investments in industrial and commercial activities, where reliable back-up power is a necessity. The market is expected to witness a CAGR of 8.4 per cent for the period 2010-14.” Noticing the demand trend, several new participants, both domestic and international suppliers are planning to venture into the diesel genset market. However, the players in this space have to focus on product positioning, service strategies and better customer service in order to win the competition and enhance their business prospects in the long run.


BUSINESS@ORISSA

HIGH ON THE INVESTMENT RADAR

With investments worth over Rs 74,757 crore in 31 projects in FY10, Orissa has emerged as the undisputed leader in total investment intentions, a total turnaround to its previous image of not being a very investor-friendly state. With mining and power companies making a beeline for Orissa, more investments are slated to come into this state in the years to come. SUMEDHA MAHOREY his year, Orissa grabbed the highest number of investments in the country. Emerging as a preferred business destination, the state has outrun Maharashtra and Gujarat in major sectors like mining and power. With this development, the above-mentioned states and those in Western India seem to have lost their status of the most preferred destination for investment in India. According to a Reserve Bank of India (RBI) study on corporate investment, which considered 796 projects in FY10, involving bank/FI fundings, Orissa attracted the highest investments of Rs 74,757 crore in 31 projects, accounting for 13.4 per cent of total investment intentions during the year. Maharashtra ranked a distant second with investments worth Rs 49,480 crore in 124 projects. Gujarat, which used to be a top investment destination earlier, managed to attract only Rs 16,572 crore in 72 projects

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during FY10 compared to Rs 59,887 crore in 77 projects in the previous year. The other top investment destinations were Andhra Pradesh and Chhattisgarh. According to an economist, “Much of these investments are in mining projects that are coming up in Orissa, with the state opening up this sector and addressing a number of hurdles faced by it. Most of them are high value projects. This could result in investments picking up in projects that are already cleared.”

REASONS BEHIND THE DEVELOPMENT Orissa, a state which was not known to be very investor-friendly till date, managed to grab maximum amount of investments, thanks to the largely capital-intensive mining projects coming up in the region. However, many believe that these investments are three-fold. Nilesh B, MD, Orange Financials, elaborates, “Orissa is attracting major investments in power, mining and

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steel. Of these, the major chunk is focussed on mining as the state has abundant natural resources in the form of iron ore, aluminium, platinum, precious metal and base metals. Companies like Mittal Group, POSCO and Vedanta have already entered this space, but are facing multiple problems due to regulatory issues.” Highlighting the issues that companies entering this region are facing, PK Mohapatra, Executive Director, Mines & Refinery, NALCO, avers, “All the major aluminium companies like Utkal Alumina, Hindalco, Vedanta are already in Orissa, but so far these companies could not initiate the mining process because of local resistance and other issues. Companies need to give due consideration to the people’s needs and sentiments, and consider it as a part of the investment. Unless these companies do something for the people, the issues would not get resolved.” According to the RBI report, the


BUSINESS@ORISSA

location of high value projects tends to change the spatial pattern from year to year. The location, in turn, depends on a host of other factors like the nature of the project, market size, growth prospects, availability of skilled labour, suppliers, adequate infrastructure, etc. Another notable feature on the pattern of project investments is that the geographical distribution of the projects was seen to be broad-based in FY10. There are growing investment prospects in Chhattisgarh, Orissa, Tamil Nadu, Arunachal Pradesh and Rajasthan as reflected in the increasing share of project expenditure intentions in these states in relation to last year.

POWER GENERATION During the last decade, the power generation in Orissa had been adversely affected by widespread criticism. Taking note of this, the state government has started pursuing the companies that have signed MoUs to complete their power plant as per the deadline. Soon after this decision, many private players had evinced keen interest to set up power plants, mostly coal-based as the state has huge coal deposits. Elaborating on this, Narendra Nainani, Chairman & MD – Bullet Advice for Indian Stocks, points out, “Natural resources in Orissa are in plenty, but they have not been explored by the government as yet. With aggressive companies making the entry, 8-10 per cent growth in investment can be witnessed in mining in this region. Also, with the surge in power companies in the state, mining production is bound to increase.” Around 26 power companies from the private sector have signed agreements with the state government to set up thermal power plant with an installed capacity of 32,000 MW. Besides, the state has agreed to host three of the five new ultra mega power projects of 4,000 MW each. Apart from this, after confining itself to mining since the last two decades, the stateowned Orissa Mining Corporation is now diversifying into power and coal mining sector by setting up 2,000 MW thermal power plant near Rengali in a joint venture with Orissa Hydro Power Corporation, with an investment of Rs 8,000 crore.

INCREASING COMPETITION With multiple projects coming up in the mining and power sector, more investments are projected to come up in this state. This would lead to intense competition and open up more opportunities for Orissa. Commenting on the future market scenario, Nilesh avers, “With these developments, competitive growth is evident. Competition in any industry is both, investment- and consumptiondriven, thereby creating a win-win situation for all.”

FUTURE INVESTMENT DESTINATION The government initiatives in opening up the state for further investments have created a conducive environment for companies looking forward to enter mining and power sector in the future. Opining on the same, Nainani says, “Investments in both mining and power will rapidly go up in the future. Amidst this, the government needs to create a green channel for companies, which are planning to invest in the state. It also needs to fasten the resolution of the increasing number of applications, which are coming in from the mining and power sectors. Wastage of time should be decreased as much as possible.”

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WORLD NEWS

EVENTS

Intertool Moscow Focus: Tools & Tooling Equipment When: October 5-8, 2010 Where: Crocus Expo International Exhibition Center, Moscow, Russia Tel: + (1)-(203)-8404800 Fax: + (1)-(203)-8404801 BIMU Focus: Tools & Tooling Equipment When: October 5-9, 2010 Where: Fiera Milano, Milan, Italy Fax: + (39)-(2)-26255214 EMCW Expo 2010 Focus: Electrical manufacturing and coil winding When: October 18-20, 2010 Where: Gaylord Texan Convention Centre Grapevine, Texas Tel: 619-435-3629 Fax: 619-517-3707 MM Live Focus: Manufacturing & Repair When: October 19-20, 2010 Where: Ricoh Arena, Coventry, United Kingdom Tel: + (44)-(1829)-770037 Fax: + (44)-(1829)-770047 2010 Advanced Manufacturing & Technology Show Focus: Manufacturing and Machinery When: October 20-21, 2010 Where: Dayton Airport Expo Center, 2900 McCauley Dr Vandalia, OH 45377 US Tel: 937-512-3862 Fax: 937-512-3224 Tooltec Expo Focus: Tools & Tooling Equipment When: November 4-6, 2010 Where: Prague Exhibition Grounds, Prague, Czech Republic Tel: + (420)-(220)-103111 Fax: + (420)-(233)-379450

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China emerges as fifth largest global investor

Abroad

hina, the world’s second largest economy has now become the fifth biggest global investor even though Foreign Direct Investment (FDI) into the country is set to cross $100 billion this year. “Bucking international trends in both outbound and inward investments, China stepped up its outbound direct investment (ODI) to $56.5 billion, jumping from 12th position in 2008 to 5th in 2009. Also, FDI in the country this year was set to surpass $100 billion compared to $90 billion last year,” said Shen Danyang, Vice-Director of the Ministry. During the first half of the year, China’s ODI to the US and the European Union went up by almost 360 per cent and

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In 2009, global ODI volume reached $1.1 trillion, and China contributed about 5.1 per cent of the total. This is just a beginning. Although the figure is already quite amazing, the volume is not large enough considering China’s economic growth and local companies’ expanding demand for international opportunities. SHEN DANYANG, Vice-Director of the Ministry, China

107.2 per cent, respectively, on a year-on-year basis. Its investment in ASEAN and Russia also grew by 125.7 per cent and 58.5 per cent. Jinny Yan, Economist, Standard Chartered Bank, Shanghai, predicts that the EU would continue to be a hotspot for China’s outbound investment

in the coming months, thanks to the ongoing European debt woes. “The growth in both outbound investment from and inbound investment to China reflects the nation’s rising economic power and attractiveness as an investment destination,” adds Shen.

US trade deficit pins down in July s exports reached their highest level in two years, the US trade deficit dropped more than expected in July, official data showed. The Department of Commerce declared that the trade deficit dropped to $42.8 billion in July,

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a 14 per cent decline from the previous month’s revised figure of $49.8 billion-its highest level in almost 20 months. The total exports in July increased by 1.8 per cent to $153.3 billion from June to its highest level since August 2008. A major reason for this was the strong sales of

aircraft, industrial machinery, computers and telecommunications equipment. On the other hand, imports fell 2.1 per cent from the previous month to $196.1 billion in July. The July deficit beat most analysts’ expectations of $47.3 billion.

French industrial output grows in July rench industrial output beat forecasts and experienced a good growth of almost 0.9 per cent in July compared to the level in June. This growth was powered by a sharp rebound in the auto sector, the national statistics institute INSEE reported. This growth in July came after there was a decline of 1.7 per cent in June compared to the previous month.

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The overall manufactured production, which excludes the mining and construction sectors, registered a rise of 1.4 per cent in July compared to the fall of 1.2 per cent experienced in June. The July performance is clearly much better than expected, said analyst Laurence Boone, Barclays Capital, noting that her bank had foreseen a gain of around 0.2 per cent. However, at research group Xerfi, economist

Alexander Law cautioned that there is no clear trend that has emerged. “Given the weak state of industry order books, the end of the year could be rather complicated.” he explained. Although following the drop of 6.5 per cent in June, and with the July output in the auto sector surging 6.5 per cent in July, “The volatility that has characterised this industry for several years is far from over,” said Law.


WORLD NEWS

EVENTS

Abroad

American Manufacturing Strategies Summit Focus: Manufacturing and Machinery When: November 11-12, 2010 Where: Hilton Chicago - Indian Lakes, Chicago, IL Tel: 1 416 214 1144 Fax: 1 416 214 3403 SHEET METALEX Focus: Manufacturing and Machinery When: November 24-27, 2010 Where: Bangkok International Trade & Exhibition Centre (BITEC), Bangkok, Thailand Tel: + (66)-(2)-6867299 Fax: + (66)-(2)-6867288 Machine Tool Indonesia Focus: Tools & Tooling Equipment When: December 1-4, 2010 Where: Jakarta International Expo (JIExpo), Jakarta, Indonesia Tel: + (44)-(20)-78402100 Fax: + (44)-(20)-78402111 Tire Technology Expo 2011 Focus: Tire design and manufacturing When: February 15-17, 2011 Where: Cologne, Germany Tel: +44 (0) 1306 743744 Fax: +44 (0) 1306 742525 Hannover Messe 2011 Focus: Industrial automation, Motion, drive & automation, energy, power plant technology, etc. When: April 4-8, 2011 Where: Hannover, Germany Tel: +49 511 89-31146 Fax: +49 511 89-31149 E-mail: info@messe.de

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Manufacturing grows in India and China, drops in Europe expanding fast, the ugust saw a growth there is a slowdown in the manufacturing growth in in the manufacturing trade cycle which first affects Germany slowed in August. sector in China and the economies which are Also, business in France Russia owing to reliant on it,” averred Silvio accelerated but Italy and Spain the constant rising domestic Peruzzo, RBS. In addition, led experienced a drop in their demand. Purchasing managers by weakest expansion in new manufacturing indexes. “We indexes (PMIs), which measure orders for more than a year, are at a delicate juncture of the changes in business activity growth in Britain’s manufacturing global business cycle. Globally across thousands of private sector was slower than sector companies, showed expected. On the other diverging fortunes among hand, markets in China and Euro zone manufacturers India picked up at a good which expanded at their pace. A pair of China’s slowest pace since February. We are at a delicate juncture of the manufacturing surveys The Markit Eurozone global business cycle. Globally there showed activity picked up Manufacturing PMI for is a slowdown in the trade cycle last month, recovering from August dropped to 55.1 which first affects the economies a government-engineered from 56.7 in July, marking its slowdown designed to calm which are reliant on it. 11th month above the 50 an overheating economy. mark. Also, Indian factories Though recent data expanded rapidly in August, SILVIO PERUZZO, showed that Germany, although slightly slower than Economist, Royal Bank of Scotland Europe’s biggest economy is in July.

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EuroBLECH 2010 to be held in Germany this October heet Metal is a vital production requirement for various products, be it consumer goods or even heavy machinery. In an endeavour to tap this growing demand, the 21st International Sheet Metal Working Technology Exhibition ‘EuroBLECH 2010’, will open its doors in Hanover, Germany on October 26-30, 2010. The trade exhibition, this year, will

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focus on innovative technologies of sheet metal working for the future. Enhanced fabrication processes for adapting to changing demand; intelligent systems for energy-saving and environmentally sustainable production; new materials and the latest trends in R&D will be on display. “The current situation, a period of economic regeneration, demands a great deal of innovative capacity from every company. After a difficult

time, it is important to now set the course by sourcing the right equipment. For industry experts from all over the world, EuroBLECH 2010, with its theme ‘Time for Innovation’, is therefore, the first choice to gain a comprehensive overview of trends and innovative technology, and to find suitable machinery and tailor-made solutions”, explains Nicola Hamann, Exhibition Director EuroBLECH.

Daimler to build Mercedes truck in Brazil ecently, Daimler, a leader in heavy truck manufacturing, announced that it will build a popular Mercedes-Benz model in Brazil to meet the fast growing demand in Latin America. The Actros truck, designed for long-distance transport is likely to be produced in Juis de Fora,

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southern Brazil. “The move will enable Mercedes-Benz to respond more quickly and flexibly to the growing demand for trucks in Latin America, particularly in the rapidly expanding heavy-duty segment,” say officials. With sales of 21,700 vehicles from a global total of 56,300, Brazil emerged as the truck unit’s biggest market in

the first half of 2010. Mercedes was surprised by strong growth in Brazil, even though it had announced an extension of its biggest truck factory outside Europe, in Sao Bernardo do Campo, southern Brazil in March this year. Building its trucks close to foreign markets will allow Daimler to significantly reduce costs.


CMD, CMPDI

IF INDIA HAS TO GROW AT 9-10 PER CENT, THEN MINING HAS TO CONTRIBUTE IN AN UNPRECEDENTED MANNER “Considering the vast and untapped resources in the coal sector, I believe that India has a huge mining potential,” avers AK Singh, CMD, Central Mine Planning & Design Institute (CMPDI), during an exclusive interaction with Sandeep Pai. Providing insights on the various aspects of coal mining and its future growth prospects in India, Singh shares his expertise on mine planning and development. Excerpts…

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REREQUISITES FOR EXPLORATION AND SETTING UP OF A MINE

Exploration and setting up of mines are two different concepts involving different processes. The exploration precedes the setting up of a mine. Once the exploration is successful and viable deposits are found, only then the mining process starts. In the case of public sector units, for starting the exploration process, a company has to take prospecting license and notify under section 4 of the Coal Bearing Areas (A&D) Act. Moreover, if the forest land is involved, then permission has to be obtained from the Ministry of Environment and Forest (MOEF), under the Forest Conservation Act. Even the private companies have to go for prospecting licenses. Once that is sought, the company requires licenses from the respective state departments under MMRD Act. The procedure for forest land is the same as that for public sector units. Nevertheless, as per the current norms, companies need to also ensure that they do not have more than 15-20 bore hole per 10 sq km. After the completion of exploration process, the companies have to obtain acquirable land and then the mining can start. Companies like Coal India have been given the right to mine under section 11 of

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the CBA Act. The land has to be acquired under LA Act with respect to non-forest land and through the help of state governments. Local conditions and demands are considered by state governments for paying compensation. In order to kickstart the mining process, after the acquisition, clearance of environmental management plan is also required. Furthermore, permission under Forest Conservation Act, DGMS and controller of mines is also obligatory. All these formalities are necessary for setting up of mines. For setting up of explosive magazines, companies need permission from chief controller of explosives.

MINERAL EXPLORATION AND GEOLOGY Currently, there are several new technologies available for the exploration process, which have brought down the cost and time factors. Most of these technologies are based on geophysical methods. However, in India, we are applying these technologies only for broad mapping of an area. Once the coal bearing areas are found, perspective exploration is done in two parts – regional exploration and detailed exploration. Regional exploration is done by a central committee called Geological Promotion Council. The Council comprises representatives from Geological Survey of India (GSI), Ministry of Mines, Ministry of


CMD, CMPDI

Coal, Mineral Exploration Corporation (MECL), CMPDI and the respective state governments. It decides the availability of coal in a particular area and prepares an annual programme based on it. The Ministry of Mines & Ministry of Coal provides the funding for exploration. For the regional exploration, samples are collected from every 1-2 km spacing to obtain a broad idea, and once some evidence of minerals is found, then detailed exploration is done. In case of Coal India, detailed exploration is done by CMPDI. However, some captive coal blocks allottees are also doing it themselves. Detailed exploration is required for examining the reserve, strata, geological structure and quality, etc. It is done intensively by mechanical wireline coring drilling. We, at CMPDI, have also started using hydrostatic drills. Nonetheless, the quality of coal is determined by coal core samples generated during drilling.

GEOPHYSICAL METHODS TO SUPPLEMENT CORING DRILLING Under geophysical methods to supplement the coring drilling, CMPDI is using the following methods depending on the specific geological complexities in a particular area: Multi parametric geophysical logging High resolution shallow seismic Resistivity surveys Magnetic surveys Keeping the future programme of exploration in view, CMPDI has initiated efforts to introduce some advanced geophysical methods to enhance coal exploration further, like 3D seismic survey and acoustic imaging system.

R&D IN COAL MINING

terrains, unapproachable areas especially during the monsoon season. Moreover, mining changes the land use pattern of any area. Thus, we have to be more conscious about environment preservation and bringing the land back to its original state. Furthermore, CMPDI is faced with the challenge of retaining its expertise. Previously, the pay scales were low and private mine operators comparatively offered attractive remuneration, so there was a sort of exodus from CMPDI. Although the attrition rate has decreased after the revision of pay scale, it still exists.

MONITORING LAND USE PATTERN OF OPENCAST PROJECTS Through remote sensing and satellite information, CMPDI has been monitoring all the major opencast projects of Coal India. Every year, we conduct surveys about the land use information regarding the opencast mines and reclamation and plantations done there. Strikingly, we have found that the vegetation cover has actually increased postmining. Thus, by way of analysing the reclamation aspects, we ensure that the land use environmental issues are taken care of.

ENVIRONMENTAL AND REHABILITATION FACTORS We have to conduct base line survey before setting up of any mine. This includes land use pattern, air quality, water quality, noise, reabilitation & resettlement (R&R), demographic survey, etc, which are presented in the Environmental Management Plan (EMP). Coal India has a R&R policy, which stipulates compensation package to the Project Affected Persons (PAPs). Along with compensation, it provides employment as well. For instance, Coal India provides one job for each 2 acre of land acquired. It is given in the form of a package. There are R&R schemes notified by the state governments also. So, the best compensation package is given by Coal India for acquiring land for its projects.

So far in coal sector, only a limited effort has been made over R&D. However, recently the emphasis on R&D activities has increased significantly. This is majorly done under the S&T grant, provided by the Ministry Of Coal. EXPLORATION OF ALTERNATIVE ENERGY Standing Scientific Research Committee (SSRC), headed by Exploration services offered by CMPDI are till date limited to coal and Secretary to the Government of India, Ministry of Coal, oversees the coal-based energy sources. Apart from the conventional coal mining, research work. Under SSRC, there is a technical sub-committee alternative coal-based sources are being sought for exploration to headed by CMD, CMPDI, which is responsible for analysing the meet the increasing energy demand in the country. Methane trapped proposals submitted by scientists / engineers from CSIR labs or in coal beds is an important additional clean energy resource, akin to technical institutes like ISM (Dhanbad), CIMFR, IIT(Kharagpur), natural gas. IT(BHU), etc. After the screening by the technical sub-committee, it With technological advancements, coal bed methane (CBM) is put up to the SSRC for final approval. along with its subsets coal mine methane (CMM), abandoned mine It should be noted that S&T grant is an ongoing system and newer methane (AMM) (for recovery of methane during and after mining) projects are being taken up time and again. Recently, we have and ventilation air methane approved a few projects on identification of trapped miners Coal bed methane is an unconventional form of natural (VAM) (for recovery of methane from ventilation air of mine) in underground mines and gas. Within next 15-20 years, CBM will contribute have proved to be alternative development of a mobile goafedge support system. Apart from significantly to India’s energy requirement. About 33 resources of energy. In this S&T grant, even Coal India has blocks have been awarded for production of CBM, and regard, we have successfully implemented one got its own R&D programmes. It work has started in a few of them. demonstration project under performs research work on UNDP in one of the mines in different aspects of mining and Bharat Coking Coal (BCCL). Apart from this, development of the has come out with exceptional results. Till date, we have completed technology for underground coal gasification (UCG) is another non312 research projects including 287 S&T projects and 25 R&D conventional, coal-based energy that is being focussed upon. For projects. UCG, 9 blocks that include 7 outside CIL and 2 in CIL have already CHALLENGES FOR CMPDI been identified by us. Thus, we are exploring every possible way of Our greatest challenges involve working in remote and difficult energy generation.

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CMD, CMPDI

CBM AND ITS FUTURE IN INDIA CBM is an unconventional form of natural gas. Within next 15-20 years, CBM will contribute significantly to India’s energy requirement. About 33 blocks have been awarded for production of CBM, and work has started in a few of them. For example, Great Eastern Energy in Raniganj is laying a pipeline to start the supply of CBM gas to IISCO plants at Burnpur. Essar is developing a CBM block to supply gas to consumers in Durgapur and nearby areas. Similarly ONGC-CIL block in Parvatpur is being developed and it may supply gas to Bokaro expansion steel project. They have already started compressing and selling it in cylinders. Ultimately their plan is to lay a pipeline and supply it to various industries. Going by the development activities shaping up in this domain, it can be said that various projects related to CBM have been initiated in the country.

LAND RECLAMATION AND BEST USE OF RESIDUES Under Environmental Protection Act, a company has to leave the mining site in a safe condition. Thus, mining companies have to prepare a Mine Closure Plan. A Progressive Mine Closure Plan alongwith tentative detailed Mine Closure plan has to be submitted at the beginning of the mining process and every year some amount has to be deposited, which will be released during the closure of the mine. Moreover, some activities have to be done concurrently during the operation of the mines such as the back filling of the area once the mining has been done in that area. A detailed Mine Closure Plan has to be submitted five years before the final closure of the mine for approval by MoEF. The company has to ensure that the land used is filled properly and revegetated. If refilling is not possible, then it has to be turned into a water body.

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They have to make sure that the water body not only recharges the ground water but also be usable for fishing and other allied activities. Coming to the residue part, for coal washeries where rejects are dumped or mineral processing plant where wastes are dumped, companies have to take special care of these dumps. They need to ascertain that leaching or the heavy metals present in the residue do not contaminate either the ground or surface water. Worldwide, there are numerous examples regarding the best use of land. In Spain, for instance, the old dump areas have been reclaimed beautifully and have been given to other industries to set up their base. By doing so, the skill of the local population is also utilised.

GROWTH PROSPECTS OF MINING IN INDIA Considering the vast and untapped resources in the coal sector, I believe that India has a huge mining potential. Nevertheless, the contribution of mining to the overall GDP has been less, and if India has to grow at 9-10 per cent, then mining has to contribute in an unprecedented manner. While scope of growth is huge, land acquisition has to be done in an effective manner taking the local people into confidence. This can be done by having a liberal compensation and land acquisition policy in place.

EXTREME MINING: NALCO

Taking The Path Less Trodden on pg.

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CMD, HEC

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OLE OF EQUIPMENT IN INDUSTRIAL GROWTH

Industries like steel, mining, automobile, etc, provide business to capital equipment manufacturers, who in turn provide competitive edge to these industries. Manufacturing sector and other industries are interdependent. Each of them has to undertake some improvement and innovation in a continuous manner; otherwise there is a risk of getting eliminated.For instance, if an auto manufacturer plans to improve its welding quality which they think will sharpen their competitive edge, the equipment manufacturing companies have to shape a device that can satisfy this need. Again, if an equipment manufacturing company works on a furnace design for steel plant that can cut one per cent fuel cost for the steel plant operator, it will give the manufacturing company an edge over other companies working in the same segment. Thus, we can safely say that both manufacturing and core industrial sectors work in close co-ordination.

CONTRIBUTION OF EQUIPMENT IN MINING Equipment in mining sector plays a vital role in increasing the mining output and at the same time increasing economic productivity. Due to an ever-increasing demand for new products as a result of increasing population, the demand pressure is ultimately passed onto the mining sector. For instance, when there is more demand for power, the pressure is on coal mining; when there is demand for new car or machinery, better infrastructure etc, the pressure is on steel sector, ultimately resulting into higher demand for mining of iron ore, coal and alloying material.There has been tremendous demand on quantum of mining product. The needs could be met only through mechanisation of the mining process and improvement in mining technology coupled with better management to result in higher economic productivity. Higher economic productivity can

HIGHER ECONOMIC PRODUCTIVITY CAN MAKE MINING PRODUCTS AFFORDABLE “Innovativeness in design, considering the local conditions, will result in a win-win situation for both equipment manufacturers and the industry,� opines GK Pillai, CMD, Heavy Engineering Corporation (HEC). In an exclusive interview with Sandeep Pai, he highlights the crucial role played by equipment in mining and its interdependency with other industry verticals.

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make mining products affordable and make our vision projects viable. So, both quantum and productivity are important; and use of advanced technology, mechanisation and automation is the way forward to achieve both. In India, almost 75-80 per cent of mining activity revolves around coal and lignite, so in the Indian context if I am making reference to coal, it gives a relevant representation of the total mining sector.


CMD, HEC

POLICY INITIATIVES

helped in the phenomenal growth of mining output, which in turn In 1946, just before independence, India was producing around 30 has supported the economic growth. MT of coal, almost entire quantity of which came from underground TECHNOLOGY TRENDS mining.During the first Five-Year Plan period, it was felt that Technological advancements can be discussed in two parts, first the mechanisation is essential to boost coal production by way of open cast (above-ground mining) technology, and second systematic and scientific development of the coal industry. This led to underground mining technology. Owing to the hazardous nature of the setting up of the National Coal Development Corporation underground mining, safety considerations and regulatory measures (NCDC), a Government of India undertaking in 1956 with the are more stringent. This leads to longer time periods in the collieries owned by the Railways at its nucleus – the first major step development of a mine. towards planned development of the Indian coal industry. At the As a result, quantum jump in technology based on underground same time, the Singareni Collieries that was already in operation mining is difficult. Comparatively open cast mines have more flexibility since 1945 became a government company under the control of in equipment selection, deployment of equipment and workforce. Government of Andhra Pradesh in 1956. Even, control during operation is better due to visibility of action. So, Incidentally, in 1964, HEC started its operation and within 2 years mining of coal through open cast route was more preferred to meet rolled out the first ever 4.6 CuM Electric Rope Shovel for the increasing demand of coal, and today almost 88 per cent is Bhurkunda Colliery. This was one of the initial instances of produced through open cast mechanisation at Indian mines. The equipment has undergone Undoubtedly, India has the strongest technical base route. In case of open cast mining, many design improvements since among the developing nations with the manufacturing the present emphasis is on then and over 552 of the same have been supplied to coal and capacity. But it lacks design and technology capabilities. development of further advanced iron ore mining industries. The Most of the products manufactured are as per the equipment mainly for higher productivity and less deployment speciality of such equipment lies drawings developed by overseas organisations. of manpower. Target machineries in its rugged structure that gives have higher degree of automation long operating life and simple that can be hooked to mine management system using global design, making its maintainability easy, resulting in high availability, positioning technique for continuous monitoring and control of thereby making these machines dependable for the Indian mining operation. sector. Mines are planning to use 20/42 CuM excavator for their Nationalisation of coal mines in 1971-73 was the second policy operations. In some areas, this is likely to increase the production decision of the Government of India that encouraged the second substantially, with much reduced workforce. But application of such phase of mechanisation. huge machinery will depend on geological conditions and other DEPENDABILITY ON COAL supporting infrastructure. Two major industries that depend on coal are steel and power. Open cast mine again has certain limitations. There is a depth limit Coking coal is required particularly for steel, while other grades are in open cast mines beyond which mining with the conventional required by the power sector (and other industries like cement, shovel or dumper is not feasible on account of longer hauling distance. engineering etc). More than 70 per cent of power is coal-based and In India, the near surface reserves are fast-depleting. As a result, the to meet the requirements, much higher capacity mines were planned plan is to focus on underground mining. particularly in the mining areas of Northern Coalfields (NCL), South For increasing productivity, mechanisation was introduced in Eastern Coalfields (SECL). These new generation mines needed underground mining during 80s with long wall mining technique. But higher capacity equipment. HEC pitched in and came out with higher mechanisation remained limited to a few and major parts of the size excavators (10 CuM) and dragline with 20 and 24 CuM bucket underground mines that are semi-mechanised, limited to loading and capacity as a solution to meet these demands. These types of transportation of coal from face after blasting. Technology level and equipment had a great supportive role in boosting mining product. mechanisation of underground mining did not get proper attention in Along with main excavating equipment, there was a need for higher the era of over-emphasising open cast mining. size hauling machines like dump trucks, dozing and their grades. Currently, however, due to difficulty in land acquisition for open Companies like HM, BEML contributed significantly towards this end. cast mining and environmental reasons, the interest in underground Many of these companies subsequently manufactured excavating mining is increasing. A survey suggests that around 49.07 billion equipment also. tonne coal reserves are spread over 213 coal blocks in India. Of this, around 22 billion tonne of extractable coal under CIL are at a depth COAL PRODUCTION: STATISTICS of 450-500 m, which will need increased level of mechanisation to The production of coal maintained an impressive growth as a result extract by underground mining. of these developments – 72.95 MT (1970-71); 114.01 MT MINING TECHNOLOGIES (1980-81); 213.86 MT (1990 91); 313.7 MT (2000-01); Currently, the two main technologies available are long wall process 382.62 MT (2004-05). At present, the production stands at 500 MT. and continuous mining. Long wall process is more popular in China In 1990s, mining companies took one major step towards mine and Russia and has limited application in Indian coal seam due to management and optimisation. This resulted in the adoption of geological disturbances. Therefore, more inclination is towards information technology in mine planning, equipment selection continuous mining technique, which uses package of and operation monitoring. All these developments have

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Bosch Rexroth (India) Ltd


CMD, HEC

equipment and system like: Continuous coal cutter with roof bolting Coal conveying by shuttle car, which are commonly operated electrically (diesel operated are also under implementation) From shuttle car discharge to feeder breaker for crushing In developed countries, various information technologies for continuous monitoring of mining operation and synchronisation of sub-systems are used. In the wake of these technological developments, HEC is trying to tie up with companies that manufacture higher capacity excavators and explore the possibility to enter into underground mining equipment market.

SURGE IN ADOPTION OF AUTOMATED EQUIPMENT Different types of automated equipment are also being introduced in phases in Indian mining, but the full benefit will be derived when interphasing with other operating modules will be completed. Individual equipment use sophisticated PLC-driven system that prevents accidental mal-operation. Further, it ensures machine condition monitoring and alarm system, etc.

Priority factors to rate a machine Applicability/capacity along with secondary features Operating factors Machine availability Maintainability and availability of spares Prompt service support Life of service Price COAL HANDLING PLANTS, WASHERIES AND DIRECT REDUCTION PLANTS Handling of coal in huge quantity received from various mines, processing the same and routing to use points is equally a challenging task. While mine reserves get exhausted and the mine faces keeps on shifting, the decision about location, capacity technology level of CHP/ washery is important from long-term economic point of view. HEC has developed expertise in designing and execution of CHP from concept to commissioning. Over the years, it executed CHPs at Jayant, Bina, Nigahi for Northern Coalfields. In addition, a number of CHPs and bulk material handling plants has been executed by HEC for steel plants and power plants. Indian coal has high ash content and low calorific value. Washery is an important area for value-addition to the product mined. A washery set up near the mine helps in avoiding transportation of unsuable products (ash), while reducing the threat of polluting the environment by the ash content during transportation. In India, washing of coal was not given priority for a long time. Thankfully, the mindset has now changed and Coal India has decided to add 20 washery projects of around 111 million tonne per year aggregate capacity, with an estimated investment of Rs 2,500 crore. This will be further increased to cover almost the entire coal production by CIL. Even, the new mode of tendering by CIL is highly productive and environment-friendly.

Furthermore, the direct reduction of iron ore (DRI) process, for iron making is considered as a popular means of intermediate product, sponge iron, in the beginning of this decade. During those times, HEC supplied tyre casting and other components for sponge iron projects. Moreover, in late the 70s, SAIL R&D and HEC had set up a pilot sponge iron plant adjacent to foundry forge plant of HEC to study feasibility of technology.

SELF-RELIANCE Undoubtedly, India has the strongest technical base among the developing nations with the manufacturing capacity. But it lacks design and technology capabilities. Most of the products manufactured are as per the drawings developed by overseas organisations.

ROLE OF DESIGN AND ENGINEERING Unfortunately, most Indian companies have not yet achieved design and engineering capability. Earlier, design and technology were being transferred to Indian companies through technical collaboration, which involved manufacturing drawings along with technology for one or few models of particular equipment. With this, manufacturing of identical equipment was possible, but changing of design based on Indian conditions or customers requirements was not possible. As a result when the equipment design becomes obsolete, there is need for fresh technical collaboration to get the drawings.

R&D ACTIVITIES SHAPING UP IN THIS SEGMENT Shortcomings in design and engineering for Indian companies are based on two reasons: Indian companies primarily focus on domestic market – low output level Customers’ acceptability The multinational companies having a wider market and larger sale of same/similar products facilitate them to invest more in R&D and its outcome is used in commercial products for gaining an edge over competitors. But Indian companies, most of whom focus on domestic market, have low business volumes resulting in low investment in R&D. This scenario appreciably does not add to product design working successfully. So, even if in-house product designs are prepared, they are not readily marketable. The real capability of manufacturing sector cannot be realised until customer collaboration is taken into account and there is a policy framework to encourage Indian designed products.

LEVERAGING OPPORTUNITIES The rate at which the core sectors are growing will have to be supported by the manufacturing sector in terms of quality supply and service. The product features and quality have to be further improved, if we want a global industrial culture. Innovativeness in design considering the local conditions will result in win-win situation for both equipment manufacturers and industry. It not only entails mechanisation and automation, but also the safety, hazard handling and environmental considerations to be inbuilt in the product feature. Equipment manufacturers and plant operators also have to ensure comfortable and good working environment in the shop-floor that will ensure a longstanding healthy industrial culture in India.

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NATIONAL ALUMINIUM COMPANY

TAKING THE

PATH LESS TRODDEN

Making the impossible possible and overcoming all the challenges requires strong will, determination and a sustainable futurist outlook. Creating history in the bauxite mining in a region with absolutely no basic facilities and connectivity with the outside world, National Aluminium Company (NALCO) has proved this to be true. Standing tall, tackling these extremities for decades is NALCO’s Panchpatmali mine at Damanjodi, Orissa, which has changed the way bauxite mining is being done in India. Because of its high-tech, eco-friendly and socially-oriented business approach, it has earned a high stature and set a precedent for other companies to follow.

SANDEEP PAI AND SUMEDHA MAHOREY astern Ghats, a beautiful stretch of mountains spanning over a thousand kilometre from Visakhapatnam in Andhra Pradesh to Kalahandi in Orissa, is renowned as the bauxite belt of the country. Four thousand feet high, extending roughly parallel to the coast, this belt is also home to one of the most successful mining endeavours in Indian history.

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THE BAUXITE STORY Around 40 years ago, it was estimated that more than 2 billion tonne of bauxite was present in this hilly region. Today, with over 4.8 million tonne of this estimate being extracted annually, this figure just constitutes a speck in the ocean of abundant resources that still lies untouched in this vast expanse. Back then in the 70s, the bauxite deposit from this belt was not considered economically-viable because of its low alumina and high silica contents. Another

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reason was the reluctance to mine in a region that was located in one of the most backward districts of Orissa, with no railroad connectivity and deep forest cover as the roadblock . With next to negligible logistical support, it had become a humungous task even for the Railways to set up infrastructure in this region. This region was impenetrable for any mining company, as it almost had no connectivity with the outside world. Apart from logistics, lack of adequate power


NATIONAL ALUMINIUM COMPANY

NALCO, elaborates, “During those years, there was no road even to Damanjodi. Thus, for bringing in equipment and materials to start the exploration process, we had to make alternative kuccha road. For years, we had operated relying on that road before the pucca road came into being. Another challenge confronting the company was to keep the workforce motivated under such harsh circumstances. “Those were the toughest times that the employees had faced. There was no proper shelter, water or food available to them. We started from scratch and now have reached a stage where we have our township with adequate facilities,” adds Mohapatra.

THE SURVIVAL INSTINCT

N W

E S

Top view of Panchpatmali hill

Surviving through that phase, Panchpatmali open cast mine now stands as Asia’s largest bauxite mine located at Koraput district in the southern part of Orissa. Moreover, with an annual capacity of 4.8 MT and under expansion to 6.8 MT shortly, it is the only deposit from the two billion tonne east coast bauxite reserves, which has been mined so far. Over the years, it has bagged certifications to ISO 9001, ISO 14001, OHSAS 18001 and SA 8000 standards. Along with the mine, NALCO currently has Asia’s largest integrated aluminium complex, encompassing bauxite mining, alumina

Latest technologies deployed A semi-mobile in-pit crusher is under development in the far North block. A surface miner to eliminate drilling and blasting.

required to run a mine and the subsequent refinery was another major constraint. Besides the basic infrastructural bottlenecks, there were issues related to availability of human resource. The villagers inhabiting these hills were tribals in true sense. With meagre living resources, reluctance to change and the highest illiteracy rate, communicating with these tribes and convincing them was a Herculean task. Under such extreme conditions, companies were not too keen to invest, as they were unsure about the returns. In fact, many believed that mining was next to impossible in these regions. However,

National Aluminium Company (NALCO), a public sector enterprise incorporated in 1981, went against the preset notions and demonstrated to the world as to how sustainable and profitable mining can be achieved even under such extremities. While the company had to overcome a lot of challenges for carrying out mining activities efficiently, with sheer determination and perseverance to achieve the so-called ‘impossible task’, NALCO sailed through the storms successfully. Providing an in-depth account on the challenges faced by the company in its earlier days, PK Mohapatra, Executive Director–Mines & Refinery,

refining, aluminium smelting and casting, power generation, rail and port operations.

TRACING THE SUCCESSFUL JOURNEY A visit to Damanjodi reveals the legacy of more than 25 years of sustainable mining, maintaining perfect peace and harmony with its environment and surroundings. From the foothills of Panchpatmali mine, a camera zoom shows a green tabletop mountain with a white coloured rope bisecting it. A further zoom clears the view… it’s not a ropeway but a uniformly covered man-made conveyor. S Sameer

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NATIONAL ALUMINIUM COMPANY

14.6 km single flight long distance conveyor used for carrying bauxite ore

Majhi, Junior Manager, NALCO, explains, “This is a 14.6 km single flight long distance conveyor. We use this conveyor stretch to transport bauxite ore from Panchpatmali mine to NALCO’s 1.575 MT capacity alumina refinery located at the foothill.” During the journey to Panchpatmali mine, one travels close to the conveyor belt. The plantations are ubiquitous and conspicuous all along. After a while, as the mercury level drops and fog sets in, Panchpatmali hill emerges as a beautiful hill station. Before the mining commenced, this hill was practically barren except for sparse and stunted growth of amla, bushy date palms, ban tulasi and giant grass. However, because of the massive plantation drives taken up by NALCO, the place is wrapped up by lush greenery. Surprisingly, the central portion of the hill has more plantation cover than even the (unmined) southern part. When asked, SK Patnaik, Sr Manager-Mining, NALCO, states with evident pride, “While we pursue mining, we also ensure land reclamation and afforestation simultaneously. Our way of working is different from other miners. There the mining is done first, and reclamation & rehabilitation is done towards the end of the mine life. But here, mining and reclamation are concurrent processes. We carry out extensive plantation not only inside the mine but also in the surrounding valleys. Because of this, today, the hill is witnessing the return of a green lustrous forest on its top.” In future, NALCO is planning to take up huge plantation drives. The vision of the

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company is best described by Patnaik. He asserts, “We have given this barren hill a forest cover. After the completion of mining, we would like to see this place becoming an attractive hill station in the future.” The mining area of the hill (or the tabletop) is divided into three parts – north, central and south. While, the company has mined the central portion for around 25 years, it has just started mining in the north. The southern part of the hill has not been mined as yet. The hill characteristically has Sl.No Vertical profile offormation 1 Top soil 2 Laterite 3 Top bauxite

Thickness in Mtr. 0-1 3-4 8-10

4

Sub bench

2-3

Medium hard

5

Bottom bauxite

3-4

Soft

many features of this mine. Company officials give credit to the initial mine planners and executors, who had followed a systematic and scientific approach while designing this mine and its mining methods. Several computer simulated ore body models were experimented in those days to design a suitable mining method, which would not only protect, but also help in enhancing the environment during mining. Over the years, what has evolved is sustainable mining with efficient

Rock Type

Broken by

Remarks

Soft Hard Medium hard Hard ferruginous

Wheel loaders Drilling & blasting Drilling & blasting Big boulders by rock breakers to prevent Secondary blasting Ripping instead of blasting, using ripper dozers Backhoe shovel instead of loosening by blasting.

Blast-free ---Blast-free Blast-free Blast-free

Rock breaking techniques implemented by NALCO

sharp escarpments mostly on the eastern side and steep gradient slopes on the western side. Moreover, in order to prevent flow of surface run off water from mining areas to the valleys, rolling of mining equipment from slopes, spreading of dust and noise to surrounding, a 15 m width of bauxite has been left on both sides of the hill and trees have been planted well in advance to act as a peripheral green barrier. This peripheral barrier is one among the

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environment-friendly operations. With latest equipment and technologies ensuring high profitability and environment conservation in all aspects, here is an intriguing process that the company follows for sustainable mining.

MINING PROCESS A typical bauxite mine is formed in-situ by weathering and lateritisation of parent rock, which is known as ‘khondalite’. The crosssection of the reserve would show the top


NATIONAL ALUMINIUM COMPANY

being covered with an average soil thickness of 0-1 m, followed by ferruginous lateritic overburden of about 4-5 m, and below that lies about 14-15 m thickness of bauxite formation. The partially lateritised khondalite (PLK) is seen below the bauxite layer. The deposits are highly heterogeneous with wide variations in grades and thicknesses. Analysing these conditions, NALCO has come out with a unique way of mining. Explaining the process, A Chakraborty, GM– Mines states, “Conventional mining method is not effective in this type of deposits, and hence, the trench method of mining was adopted. This method provides staggered working fronts, effective quality control system, maximum ore recovery from undulated floors, fast land reclamation concurrent with mining, etc.” In this trench mining method, the fertile top soil is removed by wheel loaders and then the hard laterite is drilled and blasted. When the blasted laterite is removed

A drilling machine in operation in the Panchpatmali mine

bauxite gets exposed. The top slice of bauxite i.e. about 8-10 m thickness is loosened by drilling & blasting and also by ripping where bauxite is soft. The bottom bauxite of 3-4 m thickness is removed using backhoe shovels, as this does not require either blasting or ripping. The mining machineries used by the company are mostly wheel-mounted, diesel-powered and hydraulically operated. Equipments include wheel loaders, backhoe

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Social polices and business should go hand-in-hand. Amalgamation of technological upgradation, which reduces the cost of production, enhances efficiency and productivity and a good environment policy with an attitude for social development, would lead to major achievements in the future. PK MOHAPATRA, Executive Director–Mines & Refinery, NALCO

shovels, dumpers, blast hole drills, ripper dozers, water sprinklers, motor graders etc. NALCO has increased its production capacity from 2.4 MT to 4.8 MT per annum and is under further expansion to 6.825 MT. Patnaik points out, “We increased the mine production by introducing higher capacity machines, an in-pit crusher in far off north block and drawing a flexible long distance conveyor from north to present crusher location in the central block such that equipment fleet size remains minimum but the average mine productivity goes very high. The speed of the only conveyor belt has been increased to carry higher tonnage in each hour. Had we continued with the same size of equipments, we would have required large size of equipment fleet leading to high traffic congestion and increased pollution load onto environment.” While the previously aimed target has been achieved, the company is now determined to make this mine blast-free. Currently, the blasts are limited to overburden and top bauxite only. Patnaik says, “We aim to make this mine ‘Totally blast-free’ by resorting to mechanical means of mining in place of blasting. Since surface miner is one of the best alternatives, we conducted several rock analysis studies with the help of IIT Kharagpur and the results were very encouraging. Accordingly, a Surface Miner ‘T1255’ of Vermeer (USA) make has been hired and put under trial operation to actually see its performance in our mine.” By deploying surface miner, NALCO

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has become the first bauxite mine in the country to try this technology. Elaborating on this, Mohapatra avers, “Surface miner is an advanced way of performing blast-free mining. It also curbs environmental hazards arising out of a blasting operation considered as the key factor for pollution.” Surface miner technology eliminates: Blast Hole Drilling machine, its operations & maintenance Explosives procurement and storage Security arrangements during transportation & storage of explosives Crushing of ore and operation & maintenance of crusher.

MOVING TOWARDS ROBUST MECHANISATION While the company is deploying technologically advanced equipment, it is also ensuring that these are being utilised to the fullest. A GPS-based truck dispatch system installed few years back takes care of these requirements. The system is placed on the trucks and on loading equipment as well. They are monitored by a centrally located control room. Illustrating the system, Vikash Mohanty, Engineer, Truck Dispatch System-Mining, highlights, “With this, we are able to e-log the equipment performance, productivity and establish communication with the operators.” The mine has a pit head primary crusher of double roll tooth crusher type which receives 1cubic metre size input and reduces it to-150mm size. The crushed ore is transported through a 14.6 km-long single flight cable belt conveyor to refinery at the foothill. Even the conveyor belt has unique features. Describing it in detail, Patnaik articulates, “It can move in curvilinear paths unlike other belts, which move only in vertical plane. Moreover, the whole conveyor belt is completely covered, leaving no scope for spillage or dust emission.” Adding to this, a PLC controlled auto sprinklers has been installed all along the main haul road to prevent dust generation during the movement of dumpers. Dry fog system has been installed inside the crusher and conveyor system to arrest dust before becoming air borne. Water requirement for the mine is pumped from two reservoirs made out of tapping streams at Jholaguda located at the foothill. The company has also installed five


NATIONAL ALUMINIUM COMPANY

rainwater harvesting structures, which fulfill additional water requirements. Another commendable initiative for environment protection is the Zero Discharge System(ZDS). Patnaik expounds, “We ensure that there is no discharge from the mine to the surrounding valleys. Effluents, mostly oil-mixed water from the workshops, waste water from canteen etc. are routed through a scientifically designed zero discharge system and reused for dust suppression measures. These waste water are regularly sampled and analysed.” Further, the striking feature of the Panchpatmali mining is that it does not affect the ground water resource. Patnaik clarifies, “It has been more than 25 years, but we have never found that groundwater has been affected by any means. The different hydro-geological studies conducted in the past have established that mining does not affect groundwater table present below 150 m from the surface. Most of the springs originate from the hill below this level and they never dry during the year.” The steps undertaken by the company have worked phenomenally towards its commitment for sustainable mining. Taking the legacy forward, the company has also

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made special provisions to ensure the safety of its workforce. Mohapatra avers, “All dumpers are fitted with rear view cameras and have AC cabins; all machines coming from behind can be seen and monitored. Moreover, we have a separate health monitoring system for the employees, wherein doctors examine them periodically for occupational hazards, if any. Till date no employee has suffered occupational hazards on account of dust, silica or other substances.”

UNMATCHED APPROACH Starting at a time, when bauxite mining along the east coast was seen with a lot of scepticism, NALCO today, has reached a remarkable stature that has become a case study for many in mining. Its eco-friendly, well-planned and social approach to one of the toughest processes in the industrial history has helped the company achieve more value than plain profit. Today, standing at the pole position in bauxite mining in the country, NALCO’s business policy is highly people-oriented. Highlighting the fact, Mohapatra remarks, “Industries have exploited the environment to an extent that they need to pay a price

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for it today. Companies cannot think of the past and claim to work on similar lines even today. They need to devote some percentage of their success to their surroundings. It is not possible that only they earn the benefits and in the bargain the society at large suffers. At least 4-5 per cent of its profit should be reserved for the society.” Adding further, he says, “Social polices and business should go hand-inhand. Amalgamation of technological upgradation, which reduces the cost of production, enhances efficiency and productivity and a good environment policy with an attitude for social development, would lead to major achievements in the future. Thus, our focus remains in this direction and the government is supporting us in this endeavour.” Going by the unique practices the company has adopted to ensure safe and secure mining as well as its surroundings, it would be worth claiming that India has achieved sustainable mining to a certain extent. NALCO, with its mission to develop a people-friendly mine, has become a trendsetter of best practices for those who plan to venture into this so-called unexplored territory.


NALCO DAMANJODI REFINERY

REFINING WITH EXCELLENCE

Showcasing operational excellence, deploying best-in-class practices and state-of-the-art technologies, with due importance to environmental protection, NALCO’s Refinery at Damanjodi, Orissa stands out as one of the best refineries for alumina production in India with unmatched quality. Here’s how the company has been able to set inspirational benchmarks in becoming the country’s leading alumina producer… SANDEEP PAI arrying the legacy of Panchpatmali mine forward in every sense is NALCO’s Alumina complex located at the foothill of Damanjodi, Orissa. With a production capacity of 21,00,000 tonne per annum, the unit is able to generate high quality alumina out of the low content bauxite ore found in this region. To accomplish this, the company has adopted unique measures to extract alumina from the bauxite ore mined from Panchpatmali. NALCO’s Damanjodi refinery is equipped with state-of-the-art processes and technologies. Apart from this, robust mechanisation has helped the company in producing alumina at a faster rate. Here’s a snapshot of the systematic process followed by NALCO to refine bauxite ore into alumina.

C

PROCESSING UNIT The bauxite coming from Panchpatmali mine is stored in open yard stack piles and reclaimed at specific rate by bucket wheel reclaimers. The raw material is then crushed by hammer crushers to 30 mm size and stored in storage tanks called silo. As alumina processing involves solid bauxite and liquid sodium hydroxide reaction, fine size of solid is necessary to have better reaction and higher yield. To achieve this, bauxite stored in the silo is extracted at a measured rate and fed into ball mills, which grinds the material to 63 micron size.

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Each of the four ball mills has a grinding capacity of 200 tonne per hour and is loaded with about 100 tonne of hyper steel spherical balls. At this stage, silica is present in the bauxite ore in the form of reactive silica (kaolinite), which needs to be removed. For this, the ground bauxite in caustic soda solution, also known as ‘mill slurry’ is pumped to a subsequent process called predesilication. This process converts harmful reactive silica to nonreactive sodium aluminium silicate by heating the mill slurry with steam to react kaolinite with sodium hydroxide, which in the end forms sodium silicate. After that, the slurry is passed to the tanks where sodium silicate is converted into sodium aluminium silicate or sodalite. The slurry is then mixed with concentrated caustic soda solution and pumped to cyclones for classification. The particles having size bigger than 63 micron are recycled back to the ball mills for further grinding. Subsequently, the fine particles slurry proceeds to the digestion process. Digestion Here, fine bauxite slurry in caustic soda is heated in tanks to achieve 105°C. Sodium hydroxide reacts with alumina tri-hydrate to form sodium meta-aluminate. The non-reactive components such as iron oxide, bohemite and silicon dioxide remain in suspended form in the slurry. For about 2.3 hours, the slurry remains in digestion tanks and


NALCO DAMANJODI REFINERY

is then pumped to separating cyclones for removal of coarse particles called ‘sand’. Sand separation Digested slurry having about 100gm/litre solid is fed tangentially into small conical tanks called cyclones. Due to tangential feeding, the particles experience centrifugal force and are thrown towards periphery and collide on the wall of the cyclone. With this, heavier particles fall under gravity and get separated from bottom. The slurry having very small particles come out from top of the cyclone and are moved forward to a dilution tank. The separated sand is washed with water to extract soda from it. The washed liquor is then fed into a dilution tank. Here, the slurry which contains solid is separated in subsequent stages and washed with water for recovery of soda. The washed liquor thus derived from there is partly mixed in dilution tank to get the desired soda concentration of 167gm/litre. After this, the diluted slurry is pumped to post desilication tanks. Post desilication process The remaining amount of reactive silica, which had earlier remained inactive in the pre desilication process, now reacts in the digestion stage and forms sodium silicate. This sodium silicate has to be converted to non-reactive sodalite in precipitation. For this, diluted slurry is heated in post desilication tanks to 105°C and retained for about 8 hours. The slurry is then slowly agitated in post desilication tanks to facilitate sodalite formation. At the end of this process, the outlet is pumped to settler for solid waste separation.

The bauxite ore is being stored in open yard stack piles and reclaimed at specific rates.

Settler These are 6m high, 40 m diameter tanks in which desilicated slurry is fed. Here, the mud settles down at the centre. A slow speed rake mechanism then drives the settled mud from centre to periphery. The settler overflows containing about 400 mg/ lt of solid and 165gm/lt soda is then collected in an overflow tank. The underflow of settler containing 500 gm/lt of settled mud is washed in six stages with water to recover maximum amount of soda. Part of that wash liquor is mixed with the settler overflow liquor to attain 148 gm/lt of soda concentration i.e. favourable condition for alumina precipitation. The liquor thus, achieved is pumped to security filter feed tanks for third and last stage of solid impurity removal. Security filtration Since 400 mg/litre of solid impurity in the liquor will make the alumina impure in precipitation up to unacceptable limit, further separation of solid is being done by means of filtration. For this purpose, settler

overflow liquor is filtered in security filter or Kelly filter to bring down the solid from 400 mg/lt to below 30 mg/lt. Here quick lime solution is used as filter to aid in filtration. The liquor from here onwards is called ‘aluminate liquor’ and is ready for alumina production by precipitation. Precipitation Aluminate liquor is cooled down to about 65°C in plate heat exchangers to achieve better precipitation. As per quality demand of precipitated products, small hydrate particles are mixed with aluminate liquor so that alumina hydrate precipitation takes place on those particles and their size increases. At the end of precipitation process, the particles are classified as per size and coarse particles are taken out as final product hydrated alumina. The fine particles are mixed with fresh aluminate liquor to allow precipitation on the surface to make them grow further. In this manner, coarse products are taken out and fines are recycled to precipitator after mixing with aluminate liquor. After classification of the precipitated products, slurry containing coarse particles is filtered in product filter to remove the mother liquor called ‘spent liquor’. The spent liquor received from both product and seed filters is then heated up in plate heat exchangers, while cooling aluminate liquor, and dispatched to evaporation area. The seed hydrate is not only mixed in aluminate liquor for agitation but also for increasing the rate of precipitation as auto precipitation rate of aluminate liquor is very low.

A closer view of the NALCO’s alumina refinery at Damonjodi

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NALCO DAMANJODI REFINERY

pumped to red mud pond at a solid concentration of 28-30 per cent. But with the introduction of the new system, the slurry concentration has been increased to 55 per cent, thereby increasing the pond life. In the present system, the deposit takes place conically instead of flat thereby reducing dusting issues. While generated solid waste is disposed off efficiently, the extracted alumina is either sent to Angul for smelting and further processing or Visakhapatnam Port to be exported directly. The company has a tieup with the Indian Railways, which runs its dedicated freight service. Apart from alumina transportation, it also helps in the logistics of coal used to feed the SPP unit. Ash generated from the steam plant is slurried to the ash pond.

Low concentration of soda in aluminate liquor, low precipitation temperature, high surface area of seed hydrate, high amount of seed hydrate are favouring factors for better precipitation. The unit has 16 precipitators of 4200 cubic metre. They are cooled in between to decrease the temperature to get more yields. After this, the spent liquor is pumped to evaporation area and product hydrate to calcinations area. Evaporation This unit has six evaporator batteries, each having six effects. Any one of the first five effects can be bypassed for maintenance purpose. In this process, steam is used for heating the spent liquor and boiled to get vapour, so that the liquor gets concentrated. The steam is generated by back pressure turbine in the steam and power plant (SPP). Talcher Coalfield, under Mahanadi Coalfields provides coal for SPP. Required evaporation: 800 tonne/hour of water Steam used: 260 tonne/hour The steam condensate from these multiple effect evaporators is sent back to steam plant. Generated vapour is condensed in different effect and the condensate is used in different area as sodic condensate. Calcination The hydrated alumina received from precipitation is washed in drum filters to reduce impregnated soda. In order to remove bound or chemically combined moisture from the hydrate, it is subjected to a temperature of 1000°C in the furnace.

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SOLID WASTE MANAGEMENT

PERSISTENT THRUST ON QUALITY

While NALCO generates 5500 tonne of NALCO refinery at Damanjodi has created alumina per day, the company also a distinct identity for itself in alumina effectively utilises major solid wastes – fly production in the country. A visit to ash and red mud – generated during the process. There are red Best practises adopted mud and fly ash ponds, where these wastes are sent in the form of slurry Highly advanced atmospheric pressure with water. Fly ash is a residue digestion process generated as a result of burning of Pre-desilication and inter-stage cooling coal in boilers for generation of for higher productivity steam and power. Once the water is reclaimed from the ash pond, it is Energy efficient fluidised bed calciners reused for ash slurrying. Moreover, Advanced red mud disposal system ash is used for cement making, concrete brick making, filling of low Effective utilisation of ash generated. lying area and even for agricultural purposes. For red mud handling, the environment NALCO’s Alumina refinery clearly and safety department has introduced emphasises this notion. Moreover, a Thickened Tailend Disposal & Thickened detailed understanding of the refining Red Mud Tailend Disposal (TTD & TRMTD) process involved in the refinery package. As per NALCO’s earlier system, demonstrates the emphasis that company red mud generated from alumina plant was places on quality control and effective utilisation of all the generated solid wastes. While the refinery is the exact reflection of the kind of precision maintained at the mine, it is itself an iconic brand to reckon with.

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INSIGHTS & OUTLOOK : Mining & Construction Equipment

Excavating strong potential High quality alumina produced after the rigorous refining process

on pg.

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SUSTAINABLE MINING

SUSTAINABLE MINING: Paving The Green Path.............................................................................84 SPOTLIGHT: CENTRAL COALFIELDS - Living The Legacy ............................................................90 INTERVIEW

RK SAHA, CMD, CENTRAL COALFIELDS: ‘CCL Has Accorded The Highest Priority To Environment Management For Sustainable Mining’ ..........................................................................98

MINING & CONSTRUCTION EQUIPMENT: Excavating Strong Potential ...................................108 MATERIAL HANDLING EQUIPMENT: Lifting Up The Competitiveness Quotient ......................114 MINING EQUIPMENT: Growing On Strong Fundamentals ...........................................................120 INNOVATIVE SOLUTION FOR OPEN CAST MINES: Reliability And Ease Of Maintenance By Design..............................................................................................................126

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SUSTAINABLE MINING

ndia is a mineral rich country and boasts of about 4 fuel, 10 metallic, 46 non-metallic, 3 atomic and 23 minor minerals spread across the country. India has the world’s fourth-largest coal reserves, the fifth-largest iron ore reserves, and a significant proportion of reserves of bauxite and several other minerals. Given the large infrastructure deficit the country faces, these resources play an important role in the economic and social development. Indian mining and mineral sector has recorded a strong growth of 8.29 per cent during 2009-10 over the previous year. The growth recorded this year is significant

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over the historical growth, which was modest at about 4 per cent over the last five years. The sector today is valued at $28.8 billion in production, of which coal and iron ore contributes more than 50 per cent. The pace of growth is expected to accelerate, keeping in view the fact that the country has sizeable potential for mineral wealth and demand from manufacturing sector continues to expand. While mining operations impact the local ecosystems, the business operations are in turn dependent on the ecosystem for sustained and continued operations and are in turn impacted by degradation of these natural resources. These effects could result from physical scarcity of the natural resources or other reputational, regulatory

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or litigation risks arising as a result of ecosystem degradation due to business operations.

GROWTH STORY The gross budgetary support for Indian mineral industry (coal and metallic minerals including steel) has been increasing each year and has recorded an annual compounded growth rate of around 25 per cent. This indicates the expanding nature of mining industry and the Indian economy in general. The significant growth in mining has been registered due to increasing consumption pattern resulting in the development of various industries. Currently, the total coal production stands at about 550 million tonne against


SUSTAINABLE MINING

PAVING

The GREEN PATH Mining operations have a huge impact on the ecosystem, and hence, sustainable environmental management throughout all the life stages of mining and mineral operations is a critical component of sustainable mining. While the minerals industry plays a significant role in the economic development of India, there are also tradeoffs to be made with respect to the impact of these activities on the environment and the local communities. This scenario calls for a sustainable development framework by the government to preserve & protect the natives & the nature. socio-economic challenges. Some of these are discussed below, which call for developing a sustainable development framework by the Government of India to pass the benefits of growth to all and give appropriate recognition to local interests.

through employment creation. Mining companies need to incorporate these issues (along with other issues identified for their specific operations based on the geography in which they operate) as part of their business strategy for long-term sustained growth of their business.

SUSTAINABILITY CHALLENGES

demand of more than 600 million tonne. By the end of Twelfth Five-Year Plan, the coal production is projected to be more than 1 billion tonne. Similarly, iron ore production has been growing in the country. The production of coal and iron ore is concentrated in the eastern regions of India, i.e. Jharkhand, Orissa, West Bengal and Chhattisgarh. These four states account for more than 78 per cent of the total coal production of the country. Though rich in mineral resources and the largest producers of minerals, these four states score low in per capita income and living standards. This indicates the disparity between the growing mining sector and poor state of local economy. The benefits of growth have not accrued to the locals and pose serious

SOCIO-ECONOMIC CONCERNS

The mining sector is accountable to their stakeholders for financial performance as well as with respect to social and environmental issues that are increasingly becoming critical to the successful operation of mining operations. The need has further increased in India due to lack of local, community and environmental development in the mineral rich areas in the past. The ‘license to operate’ is based on the responsiveness of mining companies to various stakeholder expectations including issues related to health and safety of the workers involved in mining operations, environmental impact of the operations and socio-economic development of the region Budget Trend

FY 05

FY 06

Though mineral industry in India has been growing at moderate to high pace, the benefits of the same have not been passed to the local community. This has resulted in the growing perception that the industry is taking over the mineral resources and land from the locals leading to the loss of livelihood but not compensating appropriately. This growing discomfort between the locals and industry has resulted in strong opposition of land acquisition for major mining and mineral beneficiation projects, especially in the eastern regions of the country.

FY 07

FY 08

FY 09

FY 10

FY 11

Proposed outlay (INR Crores)

6244

4828

6412

10699

15403

19292

23806

Revised outlay (INR Crores)

5631

4255

6374

10988

12933

18002

NA

Planned Outlay (%)

63%

87%

90%

94%

95%

95%

96%

Budget trends witnessed in mining sector

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SUSTAINABLE MINING

Another concern that needs to be addressed is the exploitation of the mineral resources in a manner, which fulfill the demand of present but at the same time conserve the resources for the future generation. Presently, the total proved coal resources are pegged at about 109 billion

Viability of mining business operations

India are also those with high forest density. The mining activities have had an adverse impact on the surrounding forests and environment. Several mining projects have been deferred due to delay in getting environmental clearance. Besides, some of the mining projects have been closed due

• Good financial performance for access to capital • Social licence to operate • Safe, healthy and committed workforce

Control, use and management of land

• Address competing land uses to avoid problems and disagreement around issues such as compensation, resettlement, land claims of indigenous people and protected areas

Contribution to socio-economic development

• Potential to contribute to poverty alleviation and broader economic development at the national level • Requires development of framework for the creation and management of mineral wealth

Contribution to local communities

• Impact on communities due to local employment generation, mine closure and distribution of benefits within the communities

Environmental impact of mines

• Management of large quantities of waste, cost of acid drainage, improving impact assessment & environmental management systems, and effective planning for mine closure

Life cycle approach for use of mining products

• Incorporating resource optimisation, efficiency and waste minimisation practices throughout the value chain of mining operations • Enhancing the recovery of mineral resources.

Figure 1: Sustainable development challenges

tonne. With the present production rate, the proved resources will sustain for about 180 years but since production is expected to grow to more than 1 billion tonne per annum in the Twelfth Plan, the proved reserves will be exhausted in about 100 years. This is assuming complete recovery of the reserves, which is unlikely to be the case. With the present technologies, coal recovery in open cast mines is only about 80 per cent and less than 40 per cent in case of underground mines. Better technology is required to increase the recovery of coal. On the regulatory front, the present regulations call for leaving a barrier pillar of 15 metre between two coal mines. Significant amount of coal resources are lost under these boundary pillars. Larger size mines should be promoted to increase the recovery rate. The other significant issue is the lack of R&D activities in the field of mining in India. More emphasis needs to be given to mining R&D to increase the recovery from the underground mines. Most of the mineral bearing areas in

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to environmental concerns. Thus, extraction of minerals is required to maintain the pace of growth but at the same time, it is necessary to address the environmental concerns. Given this context, it becomes necessary to develop a strategy for sustainable development of mining and mineral sector. At the same time, it is also important to communicate the strategies adopted and steps taken towards sustainable development to the stakeholders. The approach has to be both comprehensive – taking into account the whole minerals system – and forward-looking, setting out long-term as well as short-term objectives.

GLOBAL SUSTAINABLE DEVELOPMENT EFFORTS Major work towards ‘sustainable mining’ has been happening in the recent years in the form of important collaborative processes, international conferences, extensive compilations and monographs, and the beginning of individual company plans. Among these, the Mines, Minerals

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and Sustainable Development (MMSD) Project of International Institute of Environment Development (IIED) and World Business Council for Sustainable Development (WBCSD) is prominent. The project was initiated by nine major mining companies and conducted over a period of less than four years. The final report provides a complete and balanced overview of what is required for mining to become sustainable.The MMSD report states that sustainable development of mineral industry will require a robust framework for sustainable development based on an agreed set of broad principles. It will have to be based on the local factors for each of the regions by understanding the key challenges and constraints facing the sector at different levels and in different regions. It also describes actions needed to meet or overcome these, along with the respective roles and responsibilities of each stakeholder. Further, the framework is expected to suggest process for responding to these challenges addressing the concerns of each stakeholder and take care of everyone’s interest to the extent possible, besides setting priorities and tackling the problem areas. It should also have an integrated set of institutions and policy instruments to ensure minimum standards of compliance as well as responsible voluntary actions; and verifiable measures to evaluate progress and suggest improvements. In addition, it aims to work on following ten principles towards achieving sustainable development: Implement and maintain ethical business practices and sound systems of corporate governance Integrate sustainable development considerations within the corporate decision-making process Uphold fundamental human rights and respect cultures, customs and values in dealings with employees and others who are affected by mining activities Implement risk management strategies based on valid data and sound science Seek continual improvement of health and safety performance Seek continual improvement of environmental performance Contribute to conservation of biodiversity and integrated approaches to land use planning Facilitate and encourage responsible


SUSTAINABLE MINING

product design, use & reuse, recycling and disposal of products Contribute to the social, economic and institutional development of the communities where they operate Implement effective and transparent engagement, communication and independently verified reporting arrangements with stakeholders. These principles form the backbone of global developments in the arena of sustainable mining.

SUSTAINABLE DEVELOPMENT JOURNEY

In December 2009, the Ministry of Mines, Government of India, commenced the work on the preparation of Sustainable Development Framework for the Indian Mining sector. The SDF is expected to facilitate the scientific development and exploration of mineral resources and ensure the protection of the environment and prevention & control of pollution from prospecting and mining-related operations. The draft SDF is expected to cover the following aspects among others, with regard to all non-coal, non-fuel minerals (both major and minor minerals): Factors influencing sustainable and scientific mining (and indicators thereof) Broad criteria beyond which mining may not be deemed sufficiently sustainable and scientifically manageable Systemic measures needed to be taken or built to increase sustainability of mining operations considering its entire lifecycle inter-alia: a. Ensuring minimal adverse impact on quality of life of the local communities b. Protecting interests of affected persons including host population c. Creating new opportunities for socio-economic development d. Mineral conservation (both in terms of mining technologies/practices and mineral beneficiation) e. Reducing waste generation and related waste management practices f. Minimising and mitigating adverse environmental impacts particularly on surface as well as ground water (both in terms of its quality and availability as resource), air, ambient noise and land

contours of sustainable mining management system Regulatory and other mechanisms to ensure that the systemic measures are in place and are implemented Consultative mechanisms with stakeholder groups right from premining stages (including exploration) through the lifecycle and up to postclosure stages to ensure their involvement and participation in identifying and addressing the sustainability issues; developing the broad contours of the approaches to the sustainable management of all the activities including formulation of the measureable indicators and monitoring mechanisms for the purpose A system of public disclosure of miningrelated activities and environmental parameters including indicators and mechanisms to facilitate formal and informal sustainability audits Measures to ensure industry acceptance and adoption of the SDF including indicators for benchmarking the nature and extent of SDF adoption Roll out mechanism for adoption of the SDF at the grassroots level including the training, publicity, conducting workshops, handholding, and time-frames for the roll-out.

In the year 2005, the high-level committee for the National Mineral Policy recommended introduction of best practices in implementation of environment management and also to track the global trends in sustainable development. This committee held that some of the challenges facing the Indian mining sector towards sustainable development would be to identify the appropriate use of land within a land planning framework through a democratic decision-making process on the basis of integrated assessment of ecological, environmental, economical and social impact. Further, it was spelt out that mining should contribute to economic, social and cultural well-being of indigenous host population and local communities by PATH FORWARD creating stakeholder interest in mining Several complex decisions that need to be operations for the project-affected persons. made on the path towards sustainable The committee recommended development will involve compromises or development of a SDF-based International trade-offs: between different objectives and Council on Mining & Metals (ICMM)/ dimensions, between different groups of International Union for the Conservation of stakeholders, and between different Nature and Natural Resources (IUCN) generations. There may be conflicts model, specially tailored to the Indian between global and local context. The said SDF, it was priorities. Long-term needs will envisaged, would be composed Several complex decisions that need to be made have to be balanced against of principles, reporting initiatives on the path towards sustainable development will short-term imperatives. The and good practice guidelines for the three sectors of Indian involve compromises or trade-offs: between different various constituencies, acting in mining – SMEs, captive and objectives and dimensions, between different groups of concert, will need to evaluate the acceptability of, for example, large stand-alone sectors. stakeholders, and between different generations. sustaining minor environmental The recommendations of damage in exchange for major this committee were accepted social and economic gains, or of sacrificing g. Ensuring minimal ecological by the Government of India, and the revised economic and social goals for a significant disturbance, in terms of bio-diversity, National Mineral Policy 2008 addressed the environmental benefit. flora, fauna and habitat issues of recognising the impact of mining h. Promoting restoration and on other natural resources and also on the Deeksha Vats, Associate Director- Sustainability reclamation activities, so as to make land use planning. The policy also recognised and Pukhraj Sethiya, Senior Consultant-Mining, optimal use of mined out land for the the significance of rehabilitation and PricewaterhouseCoopers with inputs from Krishna benefit of the local communities. resettlement of local host population and H Prasad, Manager and Shubhra Jain, Assistant Systems to devise measurable indicators enunciates that apart from compensation as Manager- PwC of sustainable development and draft an important aspect of the SDF.

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C

CENTRAL COALFIELDS

LIVING THE

LEGACY

These days, the word mining is juxtaposed with land erosion and environment disaster. Hence, the efforts of mining companies towards creating a sustainable environment are considered as mere eyewash at the back of a strong business plan. Contrary to these notions, Central Coalfields, a subsidiary of Coal India, is providing a new dimension to coal mining in India. The best in-class sustainable development practices along with advanced equipment and commitment to environment protection can be seen in every aspect of mining and processing in its largest coal producing Piparwar mine. SANDEEP PAI

otted with huge plantations on both sides, the road from Ranchi to Piparwar, a backward district in India’s mineral rich state (Jharkhand), is a beautiful trek. After a few strides ahead, the forest cover thickens and one can witness huge trucks carrying coal. Pointing in the direction leading to the mine, the localites state, “This is a common sight, and going further ahead, the frequency of trucks on the road would only increase, as it is en-route to the India’s largest coal reserve.” While the mesmerising surroundings kindled the growing anticipation of seeing these famous coal-mines, the mere thought of coal reserves brought to the fore the

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alarming pollution rate juxtaposing harsh working conditions of the people. However, this perception proved to be just another illusion, even before reaching the Piparwar mine, one of the largest mines located in the region.The place has as much forest cover as what was seen on the way. Besides, it has a commendable dust-free environment, which is a rarity when it comes to coal mines. Since its inception, Piparwar mine that is located in North Karanpura Coalfields in the Chatra district has witnessed two decades of mining. Despite such a long mining history, it is a shining example of the kind of sustainable mining that the government and corporates are aiming to achieve. Piparwar mine is a trendsetter in exemplifying how

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planned quantity and quality of coal can be produced efficiently and economically, with due respect to safety, conservation and environment aspects.

THE GLORIOUS PAST Commissioned in 1989, Piparwar open cast mine, under Central Coalfields (CCL) – a public sector enterprise – was developed by White Industries, an Australian company. Between the latitudes of 230 42’ 38” and 0 23 44’ 45”N to longitudes of 850 01’ 43” and 850 03’ 15”E, the mine is part of the integrated unit comprising Coal Handling Plant and Coal Preparatory Plant (CHP/ CPP). It is connected by road from Ranchi, Hazaribagh and Chatra district. One of the


GO significant features of this mine is that despite having a production capacity of 6.5 MT annually as per the project outlay, it is able to generate more than 9 MT annually. Another striking fact is that the mine has the highest output per man per shift, which amounts to around 36 tonne. The CCL officials describe Piparwar mine as the company’s backbone. Charan Singh, Project Officer, Piparwar, says, “The mine is responsible for one-fifth of the total coal produced by the company. This has been possible because the mine is equipped with the latest mining technologies.” With a mineable reserve of 197.49 MT( at the time of inception), all together, the mine has six coal seams (layers) starting from the deepest to the uppermost – Lower

CENTRAL COALFIELDS

Dakra, Upper Dakra, Bukbuka, Bukbuka Top, Bisrampur and Karkatta respectively. By following the direction opposite to the flow of coal on the 4.3 km conveyer belt leading up to CHP/CPP unit, Lower Dakra seam can be reached, which is also the deepest face (80 metre below the sea level) of the mine.

INPIT CRUSHER AND CONVEYOR SYSTEM For mining the thick Lower Dakra seam, CCL has deployed Mobile Inpit Crusher and Conveying technology, the only unit of its kind engaged in coal production in India. With a crushing capacity of 2,800 tonne per hour, the technology is imperative for this seam primarily because of its thickness (22

metre), which is otherwise difficult to break. On account of the crushing technology, the number of blasts required is less compared to those required otherwise. Baliram Singh, Tripartite Safety Committee Member, Piparwar Area, avers, “The layer is so thick that we cannot avoid blasting. However, the number of blasts is almost negligible and this plays a pivotal role in addressing environmental concerns. Moreover, it is the safest form of coal extraction for thick coal seam layers.” The significance of this seam is that it accounts for nearly 2/3rd of the total coal that is being extracted from this mine. Inpit crusher operates very close to the face of the coal and extracts it in one bench

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CENTRAL COALFIELDS

Inpit crusher in operation in Piparwar OCP

making the process simple. It is mobile and moves in four directions – normal, transverse (900), angular (150), circular (3600). The coal is extracted using shovel and is placed in the first unit of Inpit crusher known as hoper having a capacity of 100 cubic metre. Water is sprinkled constantly into the hopper to avoid dust generation. “We use water here, which attaches itself with coal and does not allow dust particles to cause air pollution,” Baliram Singh adds. Thereafter, large size heavy coal blocks are transported through the steel-chainconveyor-belt and put into the crushing unit known as double-role crusher. In this, two large size wheels run simultaneously and reduce the size of the coal to -300 mm, i.e. coal size=<300 mm. The crushed coal is placed into moveable wagon belts. Wagon belts are nothing but conveyer belt systems used for covering the distance between Inpit crusher and 4.3 km long conveyor, which goes to CHP/CPP. Inpit crusher runs on a PLC controller, which monitors the entire process. The screen placed in the control room reveals problems, if any and the exact location where the problem has been encountered. Because of the use of Inpit crusher, the manpower required is not more than 7 persons per shift. By deploying the conveyer system to carry coal, CCL has ensured that there is reduction in pollution because of the less movement of dumpers. In

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addition, accidents caused due to the heavy movement of dumpers are avoided this way.

SURFACE MINER TECHNOLOGY While Lower Dakra is thick, the mine has seams having size of 1-3 metre as well. These upper seams are being mined using surface miner technology and pay loadertruck combination. Currently, in the Bukbuka and Bukbuka top seams where the coal size is less, mining is done through ecofriendly surface miner. The advantage of this

equipment is that it is blast-free and ensures total recovery of coal. It is generally used to crush coal whose thickness is less. Showing the front face of the one-metre highBukbuka seam, Baliram Singh explains, “As the coal layers are thin in these seams, blasting would result in wastage, as it might get burnt. To avoid this, we use surface miner to do selective mining.” The equipment stands at the top of the coal seam and scratches the surface. About 76 pointed spokes at the lower end of the machine are responsible for breaking the coal into smaller sizes. Moreover, water is being sprinkled along with the scratching process to ensure that dust is not being generated. With an input of 160 litre of diesel, 800 tonne of crushed coal can be extracted per hour using this technology. Nevertheless, crushed coal is being transported directly to the customers without processing because some customers want it that way. “Some customers demand unprocessed coal, so we send them directly,” says Baliram Singh.

ENVIRONMENT PROTECTION Apart from Inpit crusher and surface miner technologies, the company adopts best practices in every operation, ensuring environmental sustainability at its best. It is evident from the fact that the mine has 100 per cent back filling technique for overburden handling. Elaborating the process, Charan Singh explains, “As we are extracting new areas within the mine, we ensure that we conserve their top soil and the stones separately. Thereafter, when the mining in that area is done, we fill them back and start the plantation process.” Such has been the plantation drive that the recent satellite survey showed that the plantation cover has increased by more than 12.5 per cent as compared to when the mine was started.

SAFETY AND SECURITY

Surface miner scuffing the top of Bukbuka coal seam

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Apart from environment protection, the company follows stringent measures with regard to safety of its workforce. Elaborating on this, Charan Singh, explains, “As coal is sensitive to heat, sometimes excess heat lead to automatic fires. To ensure safety of our workers and bare minimum loss of coal,


CENTRAL COALFIELDS

Beneficiation of coal is done in this CHP/CPP unit

we have set up a department that deals with the fire-fighting operations.” On normal days, the workforce is equipped with all the prescribed safety gears and equipment. “We provide all kinds of equipment to the workers, be it helmets or gloves. Also, we keep dividers between the roads in the mines, and have also framed several rules for the dumper’s movement to avoid accidents,” he adds. Nevertheless, it is not just the exploration process alone, even in the beneficiation or recycling process, the company has adopted state-of-the-art technologies to drive operational excellence and attain sustainability.

CHP/CPP- COAL BENEFICIATION PLANT The beneficiation of coal is done in the CHP/CPP unit, which is the first ever noncoking coal beneficiation project in any public sector enterprise. The unit was started in 1997 and has a capacity of processing 6.5 MT annually. Last year, however, it challenged its own production capacities and processed a massive 7.2 MT of coal. The company provides best quality coal to its customers, which is evident from the fact that around 12-13 per cent of coal is rejected from the unit. A visit to the washery makes one feel that the sustainability mantra of the mine has been carried forward. Let us take a look at its processes and best practices followed to conserve water, air and soil: Input from the conveyer is fed into the first crusher wherein 300 mm coal sizes are converted into 100 mm and is placed in stacker 1. It is then sent to the surge bin

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where the crushed coal is stored before feeding into the washery. The washery has two modules, each with a processing capacity of 775 tonne per hour. In the first stage, screening of –100 mm coal at 13 mm on both the modules produces two size fractions i.e. 100 to 13 mm and –13 mm. While the -13 mm fractions are sent directly to the stacker 2, the heavier coal is sent for preparation and washing. The preparation of 100 to 13 mm raw coal is done in batac jigs (capacity 646 tph each) to produce de-shaled coal and rejects. Here, de-watering of deshaled coal from each jig on both the double deck dewatering of 267 tph capacity each takes place. The units are designed in such a way that it settles down the higher ash content carrying coal (34 per cent or more) and rest is emitted out. The ones that pass out from there are known as ‘pure coal’ and are carried to the stacker 2. MM Dongre, Section Engineer, CHP/CPP unit, states that the process is simple but highly productive. “We have seen that accepted coal has an ash content of 40-45 per cent at the time when it was inputted in the washery. However, after beneficiation, its ash content is reduced to much less than 34 per cent,” he reveals. “The entire unit is controlled by a software known as Supervision Control and Data Acquisition Software (SCADA), which instantly determines any error in the entire system. Trained personnel operate master computer in the control room. Depending on the nature of the problem, they direct engineers from electrical and mechanical departments to rectify it,” he adds.

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MAINTAINING ECOLOGICAL BALANCE The rejected coal is carried through a conveyor and dumped in the yard. To prevent any hazard, the rejects are either sold using e-auction or are used for the purpose of back-filling the mines. Moreover, the water used in the washery is accessed from nearby abandoned mines. The water is constantly recycled and reused in the washery. This is done by allowing the slurry (of water and waste particles) to settle down in the slurry pond. Various flocculants are used that facilitate faster settling down of the contaminated particles. When the particles settle down, water is sent for reuse in the washery. “In summer, when the water gets evaporated, the coal dust is collected and used for reclamation of land in the mines,” says Dongre. Thus, by deploying such a system, CCL has ensured bare minimum loss of water and effective utilisation of waste particles. Apart from focussing on minimal water loss, the company gives paramount importance to air pollution control as well. Dust control on entire road transport from washery premises to ‘bachra siding’ by mobile water sprinklers can be seen. Moreover, just before the trucks leave for dispatch, water is sprinkled for air pollution control. It is not just the passage alone, even the transfer points are sprinkled to suppress dust generation.

COUNTERING THE HURDLES In the case of Piparwar mines, CCL has set standards for mining companies to follow.


CENTRAL COALFIELDS

Processed coal stored as huge stacks before being dispatched

LEARNINGS TO IMBIBE Exhibiting operational excellence in one of its largest mines, CCL is certainly mining a sustainable future with a vision to bring forth the need of environment protection. Visiting the Piparwar mines reflects the same. It managed to do so just by deploying best-in-class practices and latest technologies, bearing in mind the importance of environment protection. Nevertheless, they have managed to produce more than expected quality of coal, which is extraordinary by all standards. Moreover, the company has recognised hurdles coming its way and is determined to overcome them in the near future. With this, it has set a trend-setting expedition for other companies to follow.

However, the only hurdle that it faces is pertaining to logistics. Dongre admits, “Logistics is a problem as the coal is dispatched using trucks to the nearest railway consignment which is 8 km away. Though we take care of the pollution by using sprinklers, we have to bear the cost of the fuel.” To overcome this problem, CCL is working in tandem with Indian Railways to

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bring the railway tracks near the CHP/CPP unit. “Land acquisition has almost been done and soon you will see a highly reduced number of trucks in this region,” affirms Dongre. With the reduced cost of logistics, CCL will be able to provide coal at a cheaper rate to its customers. Currently, coal from the Piparwar mine feeds units of NTPC at Dadri, Badarpur, Bhatinda and Unchahar.

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VIEW FROM THE TOP: CMD, HEC

‘Higher economic productivity can make mining products affordable’ on pg.

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CMD, CENTRAL COALFIELDS

“With the growing power demand in the country, coal production needs to be increased to meet consumer needs,” avers RK Saha, CMD, Central Coalfields, during an exclusive interaction with Sandeep Pai. Excerpts…

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OLE OF COAL IN POWER GENERATION FOR FUTURE Coal is the prime source of power generation in India. Almost 2/3rd of generation in India constitutes thermal power with coal as the main fuel. The situation is not likely to change much in the

near future. Power plants are the main customers of coal suppliers. With the growing power demand in the country, coal production needs to be increased to meet consumer needs. The demand for coal from the power sector is estimated approximately at 60 MT/year by the end of the Eleventh Five-year Plan. It is likely to reach 80 MT per annum (approximately) by the end of Twelfth Plan. During the same period, production will continue to increase, until it reaches almost a plateau level of around 125 MT by the end of Fourteenth Fiveyear Plan.

TECHNOLOGIES IMPLEMENTED Almost all opencast mines of CCL are fully mechanised. In large opencast mines, the entire mining operation including charring the drill holes is mechanised. Shovel-dumper combination is used for loading and transportation with Australian collaboration. In some of the

CCL HAS ACCORDED THE HIGHEST PRIORITY TO ENVIRONMENT MANAGEMENT FOR SUSTAINABLE MINING outsourcing patches, surface miner has been deployed, which completely eliminates drilling and blasting. UG mines are labour-intensive. There are, however, some mines where coal loading has been mechanised using side discharge loaders (SDLs) and long haul dumpers (LHDs). Attempts are being made to systematically replace manual labour with mechanisation. Some mines have been selected for the introduction of mass-production technology for instance, continuous miners. It is expected that production using this technology would be commencing from Twelfth Plan.

and reclamation of degraded land to improve the environment. The land being degraded by mining is being reclaimed concurrently or phase-wise through planned and sequential reclamation. The environment management plan is being prepared for the mines and scientific methods are being followed for reclamation and pollution control. Continuous monitoring with respect to ambient air quality, water and noise is carried out at units and clean water/treated effluents are discharged.

LAND RECLAMATION ENVIRONMENT-FRIENDLY MEASURES ADOPTED CCL has accorded the highest priority to ecology development and environment management for sustainable mining. The company has made major breakthroughs by planned afforestation programmes

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Large mines are being monitored for land reclamation by remotesensing techniques through CMPDI on an annual basis. Mines like Piparwar and Ashoka are being monitored since the last four years and it can be seen from the analysis that the reclamation/afforestation has increased from 198 Ha to 225 Ha – an increase of about 14 per


CMD, CENTRAL COALFIELDS

cent in two years. The success in land reclamation of these spoiled mines and afforestation has been significant. The mined areas or the de-coaled areas are refilled with overburden at places where no mining is required in future. The OB fills and dumps are not conducive to growth of plants, since these sites do not contain adequate plant nutrients. The dumped soil is improved in stages through modern techniques to regain its fertility, and the horticultural operations are carried out by adding nutrients like organic, inorganic and biofertilisers. Bio-reclamation of degraded mined areas of more than 4,300 Ha (since 1991) of different types of land including OB dumps, subsided areas are carried out on a large scale.

ADDRESSING SAFETY CONCERNS The steps that the company has undertaken to ensure safety of its workers and enhance productivity include ensuring availability of safety materials, conducting scientific studies, organising safety awareness programmes, sectionalisation of underground workings, establishment of mine rescue stations/rooms in the coalfields, and enhancing preparedness for dealing with emergencies and eventualities. Other measures comprise observing safety drives periodically on different safety matters, imparting training to workers in group vocational training centres as well as external institutions.

CHALLENGES FACED The major challenges that engineers and workers face are related to law and order i.e. frequent bandhs by Naxal groups, threatening/ extortion, etc. Given below are some of the problems faced by coal mines and measures taken by CCL to deal with it:

Interference by political parties/outside agencies/villagers: We have set up a grievance/dispute committee that addresses the problem areas amicably. Moreover, the management undertakes various courses of training/re-training to enhance skills of workers. Government policies: Due to various policies, delays occur in land acquisition. To overcome this, continuous follow-up and meeting with government officials are being done. Changing market condition: We constantly take steps to meet the expectations of customers by maintaining the quality of coal being supplied. Adverse geomining conditions: We strictly follow the guidelines related to mining operation stipulated in various Rules/Regulations/ Acts.

CCL’S CONTRIBUTION TO STATE’S OVERALL DEVELOPMENT CCL contributes in a number of ways for overall development of the state. Under corporate social responsibility (CSR), Rs 1 per tonne of coal produced has been earmarked for the purpose of improving the living conditions of the society around the periphery of CCL mines. A number of schools are run, bore wells drilled, mobile dispensaries operated, etc, by CCL around mining areas for the benefit of the society. During this financial year, 5 per cent of the retained earnings of pervious years subject to a minimum of Rs 5 tonne (whichever is higher) have been earmarked for CSR activities. At the time of emergency/unforeseen circumstances, CCL has always been eager to render support to the state, both in terms of cash as well as rendering services.

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MINING & CONSTRUCTION EQUIPMENT

EXCAVATING

STRONG POTENTIAL

The mining, irrigation and other infrastructural segments together account for around 45 per cent of the Indian mining and construction equipment (MCE) industry volumes. With mining activity being a key demand driver, and focus on infrastructure development by the government, MCE industry is all set to explore the untapped growth potential in the future. he Indian mining and construction equipment (MCE) industry has been maintaining a healthy growth rate over the past few months. Indian MCE volumes started picking up in November 2009, which had suffered a decline earlier due to the tight liquidity conditions on account of the economic slump, and weak sentiments across user-industries that resulted in a 15-30 per cent drop in demand across product segments. While government-funded infrastructure projects largely remained on track even during the downturn, a number of privatelyfunded projects suffered due to insufficient credit and a sharp deterioration in the investment environment. Moreover, the progress in segments like mining and roads, which are relatively more mechanised, and thereby use more of MCE, supported growth of MCE industry during the past few quarters.

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BUILDING DEMAND The MCE industry is cyclical, with the longterm demand strongly correlated to the health of the underlying economy and infrastructure investments. It is particularly affected by macro-economic factors like

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investments in infrastructure, housing demand, real estate prices, employment rates and commodity prices. As the purchase of construction equipment industry is largely debt-funded (about 85 per cent of the MCE industry purchase is financed), timely availability of credit at favourable terms and interest rates also remains a strong industry driver. Given below are some of the key trends observed in the MCE industry:

FALLING COMMODITY PRICES CURTAIL DEMAND FOR MINING EQUIPMENT For a period of over a year-and-a-half, starting 2007, commodity prices reigned high owing to strong global demand. With the fall in global liquidity and demand from Q3 2008-09, commodity prices corrected. While the fall in commodity prices, especially for steel, was beneficial for the cost structure of the industry, it also suppressed demand from the metal mining segment, which scaled down activity as prices fell. The Indian mining industry comprises three key products: coal (around 50 per cent of the volumes mined in the country), iron ore (around 22 per cent) and limestone (20 per cent). The government and public sector undertakings (PSUs) account for more than 90 per cent of the coal mining activity, around 25 per cent of the iron ore mining and negligible limestone mining in India. With ample coal reserves and the ongoing power deficit, coal mining by PSUs has continued to grow at a steady pace, thus providing regular demand for mining equipment. On the other hand, iron ore production in the country is influenced by global prices for ore (as over 50 per cent of Indiaâ&#x20AC;&#x2122;s iron ore production is exported) and government policies. With falling commodity prices and liquidity crunch faced by private companies, there has been a decline in the demand for equipment from the Indian metal mining segment. In the longer term, commodity (metals) prices will continue to play a key role in demand for mining equipment like heavy tonnage dumpers, dozers and excavators.

NEW MNC ENTRANTS SETTING UP BASE IN INDIA With MCE industry volumes of around 40,000-45,000 units per annum and an estimated turnover of $2.6-3.1 billion, the Indian market is relatively small as compared

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to the global market that is estimated at over $75 billion. Nevertheless, many international original equipment manufacturers (OEMs) have indicated plans of setting up manufacturing facilities in India owing to its good growth prospects and slack demand in the traditional developed markets. With the incremental capacities and new entrants, the industry is expected to become more competitive and fragmented. However, growing mechanisation and large infrastructural projects proposed in the country indicate the potential to absorb these new capacities. The entry of global MCE manufacturers has also facilitated product upgrades in the growing Indian market.

and availability of spares/after-sales support. Some Chinese manufacturers have started addressing these concerns through tie-ups with local established OEMs. While the current approach of domestic buyers towards Chinese equipment remains cautious on concerns related to quality and availability of long-term after-sales service, the future trends could be largely determined by the success of local tie-ups in addressing these concerns. Further, the resale value of the Chinese equipment currently remains low, restricting availability of finance. However, the Indian OEMs will continue to face competitive pressures to lower costs, thus requiring higher localisation; improving value through

The IIP for April-February 2010 posted a growth of 10.1 per cent as against 3 per cent in the corresponding period during the previous year. Infrastructure spending by the government towards schemes like Pradhan Mantri Gram Sadak Yojna and preparation for the 2010 Common Wealth Games has served as a strong demand driver for the MCE industry, especially for the northern part of the country. The southern part of the country, which was hit by a fall in iron ore and granite mining activity, also showed some signs of revival. However, the demand from the real estate segment (which impacts concreting equipment) continues to be relatively weak, particularly in the commercial area. Nevertheless, the longer-term prospects for the industry remain healthy, with strong demand expected from the housing segment. THREAT OF IMPORTS FROM LOW-COST COUNTRIES LIKE CHINA China has a huge domestic market for MCE. The Chinese loader market alone stands at over 1,25,000 as against 1,800-2,000 wheeled loaders sold in India per annum. With such economies of scale, the Chinese equipment has the competitive advantage of being significantly cheaper than the Indian equipment. A number of Chinese companies has established their presence in India through a combination of manufacturing facilities, sales offices or marketing tie-ups with Indian companies for selling their products in India. It is estimated that the Chinese MCE companies currently hold over 12 per cent in the wheeled loader segment, around 13 per cent of the dozer segment and enjoy a strong presence in concrete mixers, with the potential to expand their presence in the Indian markets. The challenges for the Chinese products in India stem largely from warranty support

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greater customisation to meet local needs besides strong service and spares support to beat competition. Imports into India also originate from other countries too, either because of nonavailability of such products in India (higher tonnage cranes and mining equipment for instance) or owing to a cost advantage (on used equipment). This trend is more pronounced in material handling equipment; where over 10-15 per cent of the equipment in the country is currently imported. Developing nations like India are key destinations for used cranes from countries like Australia.

LIMITED INVESTMENTS IN R&D BY MCE ANUFACTURERS MCE companies with MNC parentage typically have depended on parental support for product development and have made minimal investments on R&D - largely limited to homologation of the global products for Indian conditions. Further, the need for technology investments specific to


MINING & CONSTRUCTION EQUIPMENT

the Indian market is relatively low, as the large geographically concentrated vehicle capital and deterioration in capital structure. requirements for emission/noise control in population helps generate economies from However, with a relatively moderate level Indian off-highway vehicles continues to be the service network. As the population of of leveraging, many industry participants basic as compared to the developed on-road equipment increases, service and had sufficient cushion to support these markets. The Indian MCE industry is spares income is likely to become a stable, borrowings. With a sharp decline in currently BSII-compliant, with the next high margin and counter cyclical source of volumes, most of the MCE players now transition expected in April 2011. revenue. have surplus capacities, and hence have cut Developed nations like Japan and even back on fresh capacity-additions. However, USED AND RENTAL emerging markets like China have already some players with new product introduction EQUIPMENT MARKETS ARE moved to cutting-edge technology of plans may continue to invest, albeit at a STILL IN THEIR NASCENT hybrids and electric vehicles (EV) to increase slower pace. STAGES productivity and comply with stringent The MCE industry has bounced back While there is good potential for used emission/noise control norms. With the strongly during H2 2009-10, supported by equipment in India, the market size of which increasing presence of international easing of liquidity conditions; correction of is estimated at about three times the primary companies/products in India, Indian market pipeline inventory and revival in infrastructure market, India does not have an established participants have started to invest in R&D to investments led by government spending. common platform for trading in used match the international quality standards. However, the overall performance of the equipment. Deeper understanding of the market and industry in 2009-10 is expected to be Again, the current rental penetration in the requirement for application/topography relatively modest owing to the weak first India at around 7-8 per cent remains low as specific products has further raised the need half. compared to the global standards of 50-80 for increased R&D by participants in the DEMAND FOR SERVICE AND per cent. An average of 30 per cent of the Indian market. SPARES TO INCREASE IN equipment sold in Europe and over 60 per Industry enjoyed high profitability during IMPORTANCE cent in the UK is to rental operators. A up-cycles. However, profitability and capital Globally, income from spares and services robust rental market enables reduction in structure deteriorated in H2 2008-09. Most accounts for over 15 per cent of revenues investments in projects by outsourcing the of the large established players in the Indian for major MCE companies, supporting equipment requirement (including spares MCE industry enjoy healthy operating profitability and smoothening revenue and services) and improving capacity margins. A number of players operate as volatility. This also enables the manufacturers utilisation of equipment. The key equipment assembly facilities with high proportion of to sell their goods initially at a competitive in the rental fleet in India currently include imported components procured as boughtprice while making up in the service backhoe loaders, pick-and-carry (PNC) outs/ completely knocked down (CKD). contracts - a lifecycle approach to profitability. cranes, excavators, motor graders and Managing raw material costs through However, at current levels, the contribution vibratory compactors. effective sourcing, especially for imported While a number of organised equipment to revenues in the domestic market from content coupled with benefits from banks have entered the fray with large spares and services contracts remains low, economies of scale had resulted in growing fleets (of over 100 equipment), the market largely due to a relatively small equipment profitability for the industry during the fivecontinues to be serviced mainly by small population and availability of non-OEM year period from 2003-04 to 2007-08. fleet owners with less than 10 equipment spares. However, the profitability declined in recent The life of an equipment is around each. However, there are various periods â&#x20AC;&#x201C; especially during H2 2008-09 seven years although the actual on-road structural/operational concerns that need and H1 2009-10 â&#x20AC;&#x201C; contributed by a sharp fleet in India is sometimes over 20 years to be resolved for the Indian equipment contraction in demand, thus resulting in old. Ground-engaging tools (GET) like rental markets to evolve. Concerns include under absorption of fixed costs. undercarriages, buckets and teeth, lack of synchronisation of interstate tax Inventory pile-up was another cause of policies (on movement of concern for the players during equipment between states) H2 2008-09, especially for Low-cost countries like India and China stand to gain and logistics of the equipment. those with significant import content. A number of companies from the potential for export of components, equipment Further, the dominance of anticipated robust off-take in H2 and engineering/designing services - an area where unorganised market participants that operate on cash 2008-09 and placed orders for China has already made significant inroads. transactions (on rentals, thereby components and CKDs from avoiding taxes and enjoying an their global parents/suppliers. especially in the case of mining equipment, unfair advantage to the larger rental With a longer lead-time on imports, the have to be replaced faster based on surface operators) prevents the evolution of a sudden contraction in Q3 2008-09 resulted and usage while engines, transmissions and more organised system. in stock pile-up. With the large infrastructure investment axles have to be overhauled after 4-5 years Additionally, a number of OEMs were proposed over the next few years, demand of use. Hence, there is a strong potential forced to extend support to their weaker for rental equipment is expected to see a for annual maintenance contracts (AMCs) channel partners (through interest large growth over the medium term. and spares business. subventions and longer credit periods), However, it needs to be noted that a Globally, a number of OEMs are actively resulting in a significant increase in working

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MINING & CONSTRUCTION EQUIPMENT

involved in the equipment rental business, an area that has not caught on in India as yet.

commodities globally. Large proposed investments over the next several years in infrastructure (ports, airports, roads) have the potential to sustain the growing demand LOW LEVELS OF for CE. The Eleventh Plan Commission INDIGENISATION EXPOSE (2007-12) envisages the need for an MNC COMPANIES TO HIGH infrastructure investment of over $155 FOREX VOLATILITY billion for development of roads, bridges, The Indian MCE industry has only few large railways, ports and airports and over $2 local players. Most of the international billion in mining. According to the Economic majors in the industry are Survey of 2009-10, the Ministry already present in India, either of Road Transport & Highways While there is good potential for used equipment in India, has set a target of completion of through subsidiaries or joint the market size of which is estimated at about three times 20 km of National highways per ventures. The level of indigenisation in the domestic the primary market, India does not have an established day, translating to over 35,000 MCE industry, however, km during the period from common platform for trading in used equipment. continues to be low (at around 2008-09 to 2013-14. The 40-50 per cent depending on NHAI has formulated closely the company and the product) with the monitored work plans for awarding 12,000 mining activity and a virtual standstill in import of technology and component CKDs km of projects each during 2009-10 and equipment financing in the aftermath of the (especially for power train and hydraulics) 2010-11. The Special Accelerated Road economic meltdown towards the end of by the Indian entity from its technology Development Programme in the NorthQ2 2008-09. In 2008-09, the global MCE parent. The key import driver is a lack of eastern Region (SARDP-NE) envisages two/ industry is estimated to have fallen by over domestic suppliers that assure good product four-laning of about 5,184 km of National 20 per cent, mainly on account of a 38 per quality. A lack of economies of scale has also Highways and two-laning/improvement of cent fall in global demand for construction been a contributing factor in the past, about 4,756 km of state roads. Since equipment while the demand for mining although this is likely to undergo a change in inception in December 2005 and until equipment improved in few geographies. the future. High import content adds to the December 2009, 515 projects across 31 The fall in demand was led by sharp declines cost due to the longer lead-time and higher states at a cost of Rs 580 billion have been in the key markets of Europe, Japan and inventory levels for components, and sanctioned for urban infrastructure North America. exposes the industry to high forex volatility. development under the Jawaharlal Nehru Barring certain markets like China, the In 2008-09 and the first half of the current Urban Renewal Mission (JNNURM). These global CE industry continued to fall in the fiscal (2009-10), rising cost pressures, are, but a few of the large infrastructure first nine months of 2009-10 as well, especially on account of the hardening Yen, initiatives that are currently under way in although the magnitude of global decline affected a number of players with Japanese the country. slowed down to around 4 per cent in Q3 parentage. The long-term demand drivers for the 2009-10. The mining industry, on the other construction equipment industry are hand, has shown stronger signs of recovery GLOBAL SCENARIO relatively low levels of mechanisation and in Q3 2009-10, as commodity prices Globally, the growth in the industry has penetration of equipment in the construction started inching upwards. In addition to been led by emerging economies; the industry; proposed heavy investment in China, where there has been a full-scale economic crisis in the recent past, however, infrastructure and increasing population and recovery of demand supported by fiscal put a brake. The US is the largest mining urbanisation. The demand for mining stimulus and advancement in large-scale and construction equipment market in the equipment is expected to grow in line with infrastructure development, markets like world followed by China (around 0.3 the demand for metals and energy. Australia, Brazil, India, Indonesia and million units) and Europe (around 0.2 Low-cost countries like India and China Thailand have shown signs of a more million units). The global MCE industry has also stand to gain from the potential for gradual recovery. Among the developed been on an upswing since 2003-04 and has export of components, equipment and countries, the Japanese market witnessed grown by over 15 per cent annually until engineering/designing services - an area full usage of rental equipment in Q3 2009Q3 2008-09. The growth was mainly where China has already made significant 10. However, a lack of consumer confidence driven by the fast-growing BRIC nations of inroads. Some of the areas that need to be in the prospects resulted in weak demand China and India. The size of the MCE addressed during this growth phase include for new equipment. Normally, full usage of market in emerging economies has also introduction of customised products for the rental equipment is a precursor for fresh expanded significantly and now accounts for Indian markets; setting up of a viable and demand. 50 per cent of the global market as against efficient aftermarket network; an equipment POSITIVE OUTLOOK just 35 per cent in 2004. The Indian market rental & used-equipment market and Over the past few months, the industry has grew by over 30 per cent annually during training of manpower to operate the been on an upturn supported by increased this period but on a significantly lower base equipment. financing availability; step-up in infrastructural than in other major countries. The key Courtesy: ICRA Rating Services investments and pick-up in demand for growth drivers were strong economic

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development, government and private investments in infrastructure, large government projects like road building, high commodity prices (supporting mining activity), the booming real estate industry and growing levels of mechanisation. The global MCE industry experienced a contraction in Q3 2008-09 as a result of reduced construction activity, especially in the real estate segment; slowdown in

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MATERIAL HANDLING EQUIPMENT

LIFTING UP

THE COMPETITIVENESS QUOTIENT Though the Indian material handling industry is witnessing a growth spurt, even today, it lacks the desired sophistication, a prerequisite for new age equipment. With an aim to improve its manufacturing competitiveness, and keeping the required safety precautions in mind while designing and developing equipment, the Indian material handling industry is poised to grow, not only in the domestic market, but also globally. SUDHIR MUDDANA aterial handling equipment (MHE) includes all the mechanical machinery that are deployed throughout the manufacturing, distribution, consumption and disposal processes. MHE increase throughput, control costs and maximise productivity. With MHE playing such an important role in all industrial segments, it is vital to ensure that these are maintained well. Moreover, while using the equipment, the required safety precautions need to be kept in mind. All these efforts will enable a safe and smooth material handling process.

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MHE MARKET IN INDIA Today, India has the capacity to manufacture almost all types of MHE. However, one of the major barriers impeding the growth of MHE market is the poor level of sophistication of the equipment. For

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example, an automobile company, even today, may prefer to import a high-end system for their vehicle rather than using a locally manufactured one. One of the major reasons for this is that the segment is still dominated by the unorganised players, which account for almost 80 per cent of the products. However, with the fast-paced economic growth of the country, and with the constant inflow of foreign investments, the MHE industry is poised to scale new heights. Elaborating on the current market scenario of MHE industry, Rajesh Sharma, VP & Head - Marketing, Escorts Construction Equipment (ECEL), explains “Investment on infrastructure projects such as urban utility, rural infrastructure, modernisation of airports, mass rapid transit system (MRTS), growing power sector, etc, have fuelled the demand for material handling equipment industry and we are looking at huge growth

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potential. With Indian economy poised for a sustainable, nine per cent plus growth per annum and government’s five-year plan (11th Plan & proposed 12th Plan) documents envisaging various policy initiatives for sustainable growth, we can look at huge growth in this segment in the long term.” He further adds, “The short-term demand scenario also looks good, as the budgetary allocations for developing infrastructure in current fiscal of 2010-11 have seen a huge set-up. This would lead to a significant increase in demand for material handling equipment.” According to Tushar Mehendale, MD, ElectroMech, the size of the Indian MHE industry is estimated to the tune of `5,000 crore and is likely to grow at 20 per cent year-on-year over the next five years, in keeping with overall economic growth. The two growth drivers for this segment include domestic production and foreign trade.


MATERIAL HANDLING EQUIPMENT

Since MHE is closely associated expected to be 8 per cent in 2010Impact of appropriate & efficient material with the country’s imports and 11. Therefore, with all these exports, its importance to the advantages, the Indian MHE industry handling equipment in India logistics industry cannot be may see a rise in sales of about 3 to Reduces the production cycle undermined. The report titled 4 per cent globally. Creates smoothness in all process like machining, ‘World Material Handling cutting, bending, welding, turning and painting SURMOUNTING Products’ states that the global CHALLENGES demand for material handling Reduces the costing of final product Despite the positive prospects, products will grow 5 per cent Avoids accidents in the unit there are still several challenges that annually through 2012. The Reduces man power the equipment manufacturers face. demand for material handling Improves the quality of the product. Unless these are not overcome, it equipment will continue to grow will be difficult to have a smooth and in the areas of manufacturing, Inputs by Vijay Devta, Sr Sales Executive, Safex Electromech seamless MHE industry in India. logistics, warehousing, general Some of the problems faced are as engineering related to power Mehendale states, “Any manufacturing unit, follows: plants, metro or irrigation projects, and There is low demand and low-scale of be it in any industrial vertical, requires government sectors like the railways, operations. Due to this, MHE equipment to handle materials in the factory. ordnance factories, armed forces, etc. manufacturers find it difficult to sell critical Different verticals need different solutions GROWTH DRIVERS components that are produced in to cater to their MHE needs. Chemical Apart from the improved level of smaller quantities at competitive prices. industry, pharmaceutical, construction, There is a strong need for talented and sophistication, and the increasing foreign electronics, energy, food & beverage, highly skilled people in the MHE industry. investments in the industry, there are other metalworking, metalcasting, plastics, Due to better offers from allied factors that will contribute to the growth of aerospace manufacturing, automotive industries, all the valuable human the MHE industry. When asked about the industries – all are dependent on MHE resources make the shift. major factors that will take this industry to industry.” There is a need to enforce stringent greater heights, Mehendale avers, “India Talking specifically about the cranes labour laws for those carrying loads has few advantages such as robust domestic segment, Sharma observes, “The complete manually. growth rates, strong internal fundamentals manufacturing set-up is highly dependent While highlighting about the challenges and a healthy banking system that will on the MHE industry. However, for us faced by the material handling equipment ensure continuous growth of MHE. In more pertinent would be to talk about manufacturers, Mehendale notes, “The addition, the resumption of a steady inflow cranes, which includes approximately 8,500 major problems faced by the segment today of investments from foreign multinationals, cranes and stands at `1,000 crore. In the are related to the low level of demand and increase in domestic spending on mobile crane segment, where we have volume as compared to major markets infrastructure construction and power huge presence, we enjoy a marketshare of outside India. Due to this, Indian projects will also make India an extremely more than 60 per cent.” manufacturers face a cost disadvantage due attractive destination for companies that are GOING GLOBAL to economies of scale as compared to facing shrinking sales in other economies. The global MHE market is projected to foreign manufacturers from China and other Consequently, India is emerging as one of increase more than five per cent per year till countries. Further, the availability of the best global investment options. And as 2012. In such a case, rapidly developing components from ancillaries and other long as industrial investments continue to areas such as China and India will witness a suppliers is at a much lower level in the be made, the demand for capital goods rise in the global demand due to their Indian market as compared to other such as material handling systems will healthy economic conditions. Talking about countries.” Elaborating further, he adds, grow.” India, the Indian MHE industry is competitive “India also has a lot of administrative and The widespread use of MHE has led to as compared to developed countries like infrastructural bottlenecks related to cost of the shrinking of project timelines and scaling the US, Japan and Germany. Here, though power; delays in transportation and import up of projects. This augurs well for the there is lack of sophistication, a major and export clearances; administrative country’s economy, as timely completion of reason for its competitiveness is that the problems; high taxation limits; high interest projects – airports, ports, highways, power, industry offers value for money to customers rates, etc. Some initiatives from the steel, etc, propel the economy to the next by providing cheaper equipment, while level of development, believes Sharma. being reliable. NEWS ANALYSIS: DEPENDENT INDUSTRIES Another factor that plays an important Business@Orissa The importance of the MHE industry can role in the growth of the Indian MHE High on the investment be gauged by the number of industrial industry globally is that, even today, radar segments dependent on it. Any industry economies such as the US, Europe and that involves repetitive handling of materials Japan, have not recovered fully from the or bulk material handling is dependent on slowdown, whereas India witnessed a GDP on pg. material handling equipment industry. growth of 6.7 per cent in 2009-10 that is

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TIPS & TRICKS Parameters for efficient material handling equipment Safety: Safety is of paramount importance, as the value of human life can never be underestimated. Flexibility: An ideal material handling system should be as flexible as possible to allow for changes in the production flows that are so common with changes happening in the industry due to shorter product lifecycle. Credibility: The vendor for the material handling equipment should have a solid credibility and name in the market. A renowned company cannot afford to take ‘short-cuts’ that will destroy its reputation, and hence, the products will always be up to the mark. Technology: The choice of correct technology for the desired job is very important. Usage of exotic technology for a simple job does not serve any purpose just as usage of a simple technology for a difficult task. Hence, correct evaluation needs to be made on proper selection of product and its specifications. Support: After-sales support is extremely critical to ensure that the equipment is in top notch running condition. The vendor must be in a position to support the equipment till its full lifespan. Inputs by Tushar Mehendale, MD, ElectroMech

government in these areas will certainly benefit industry. Moreover, the MHE manufacturers should ensure safety, quality & technical innovation in their solutions offered.” According to Sharma, three major challenges currently faced by MHE manufacturers include: Unrestricted import of used equipment The unbridled imports of used equipment has not only impacted the local manufacturer in terms of the new equipment sales, but has also made India a dumping ground for used equipment, which many-a-times compromises on safety & other environmental regulations. The government needs to regulate such imports by imposing stringent rules pertaining to age and condition of equipment. Skill gaps and shortage of trained manpower Skill gaps & shortage of trained manpower has become a major area of concern. For instance, in the mobile crane segment, there is no policy framework on specifying neither the skill requirement nor a mechanism to develop skilled operator. The need of the hour is to have a national policy framework, which specifies the skill & eligibility criteria for crane operations, and integrates this with a structure to conduct vocational training programmes at schools

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and technical institutes. Recently, ECEL have tied up with the Government of Delhi and MITCON, an NGO in Delhi, to provide training to graduates from ITI and polytechnic institutes in operation and maintenance of cranes. Weaker implementation of patent laws Coming to the third challenge, weaker implementation of the patent laws, in India it is difficult to protect one’s design as laws are full of loopholes and the process of enforcing them is long-drawn and cumbersome. As a result, imitation and blatant duplication has become order of the day.

TECHNOLOGICALLY APPROPRIATE & EFFICIENT EQUIPMENT According to Sharma, the selection of appropriate & efficient material handling equipment is the most important factor determining the economies of operation. The correct selection would not only bring down the overall cost of operations, but also enhance the safety and comfort of the operators, resulting in less fatigue and consequently more productivity. “Over the years, we have seen the need for more robust equipment with high demand on uptime and capabilities. The equipment manufacturing industry has met these

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expectations with technologically advanced products, marking a shift towards more versatile and capable equipment. We, for example, have launched TRX series of cranes, which are higher capacity cranes with higher reaches and are versatile with greater mobility,” he notes. While Emphasising on how appropriate & efficient material handling equipment can help the Indian industries, Mehendale opines, “As the production processes get more evolved, and with increased exposure of the Indian industrialists to modern manufacturing techniques and global best practices, there is a definite shift towards adoption of newer technologies for industries as well. For example, the industrial cranes segment in India was traditionally dominated by the old 1960s type Russian crane design. However, companies are at the forefront in convincing people to dump the old technology and move towards more modern and contemporary crane technology that is prevalent in Western Europe.” He adds, “With the fast-changing business landscape, clients today demand a MHE model that yields a quicker ROI than ever. Even companies that are replacing or upgrading their existing range of material handling equipment are inclined towards technology that is efficient, faster, safer and cost-effective. This in turn adds to increased industrial productivity with minimum engagement of resources.” On the shifting trends of the MHE markets towards automation, Mehendale points out, “The general trend in the MHE industry is towards increasing automation, enhancing productivity and maximising safety. Technologies have progressed rapidly in the past decade. We see superior control methodologies in terms of accuracy, repeatability and efficiency in the market today. Advanced mechanisms and use of electrical sensors, invertors help ensure safety while using such equipment.” According to Vijay Devta, Sr Sales Executive, Safex Electromech, some of new edge technological innovations in India for material handling equipment are: Hydraulic conveyors Hydraulic working platforms and material lift Passenger cum material lift in construction industries In process industries roller conveyor.

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technologies, another factor that will help improving the MHE industry is the adoption of adequate safety measures that need to be taken while manufacturing the equipment. This will not only avoid losses, but will also increase the overall productivity. “Optimum utilisation and good maintenance practices coupled with adequate knowledge on working of the equipment increase the life of the equipment and ensure safety of the operations,” said Sharma. According to Mehendale, the adherence to safety norms while manufacturing products is a challenge that the Indian market has not been able to live up to. The absence of a regulatory body for standard safety norms is a concern. Strict discipline is required in designing and manufacturing of hoisting equipment to ensure that there is not even a remote possibility of accidents happening. The ability to safely and securely lift load against gravity without any casualties poses a challenge. Devta believes that the process of using material handling equipment can be safe by using the following: Hand gloves Helmet Goggles Ear phones Safety belts. Design aspects Design plays a vital role in equipment manufacturing. Considering the case of warehouse operations, material handling has a major effect on the efficiency and speed of the operation, which eventually results in the increase or decrease of time during order completion cycles. Therefore, investments made in MHE are important and always based on long-term requirements, considering product volumes and varieties. While designing an effective and efficient material handling system, a few guidelines to be followed include: The system has a continuous flow of material, i.e. zero idle time The use of standard equipment as it ensures low investment and flexibility, especially in the case of future changes in material handling requirements Incorporating gravity flow in material flow system Ensuring a minimum ratio of the dead weight to the payload of material handling equipment. Selecting best fit equipment Another aspect to be kept in mind is the importance of selecting the right equipment that suits the needs. The selection of a particular system depends on the following factors. Speed in handling Product characteristics (weight, size, shape) Volumes to be handled Productivity Nature of the product (hazardous, perishable, crushable).

SURGING AHEAD With the advancements in technology, growing awareness on safety of equipment, large number of foreign investments, etc, the MHE industry is bound to grow. “Apart from advances in automation and controls, a lot of development is also being made in ensuring that the products are environment-friendly without sacrificing costcompetitiveness. An example is the distinct shift taking place in several industries in eliminating hydraulics and moving towards purely electrical drives. Thus, the MHE industry will soon be seeing a lot of exciting new developments in the near future and as always will help its customers maximise their ROIs,” concludes Mehendale.

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MINING EQUIPMENT

GROWING ON

STRONG FUNDAMENTALS As mining becomes intense, the role of mechanised and highly productive, safe, efficient and cost-effective machinery and equipment becomes paramount. However, it is also critical that India should be well-equipped to meet this surging demand for mining equipment and technologies. PURNA PARMAR AND SHIVANI MODY

he mining sector has been witnessing a growth rate of 3-4 per cent annually over the past several years. Moreover, the new mining policy of the Government of India is expected to give a further boost to the sector and increase its share in the GDP. One of the factors that contributed to this growth is the use of technologically advanced equipment. Subsequently, the growth in the mining sector translated into an exponential growth for the Indian mining equipment industry. Currently, the market size of the industry in India is estimated approximately at Rs 3,700 crore. MM Shahane, EVP & COO – Engineering Products Business Group, Voltas, avers, “The size of the mining and construction equipment industry in India today is roughly to the tune of Rs 13,000 crore. However, if one considers only the mining equipment segment, which basically consists of large heavy earth moving machinery like rope shovels, huge excavators, mining loaders, dump trucks, draglines, underground equipment, then the size of the industry would be around Rs 3,700 crore. This would also include spare parts and service-related business.”

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MINING SECTOR India is a mineral rich country, with coal dominating the field. Majority of the country’s mines are located in Karnataka, Andhra Pradesh, Orissa, Bihar, Gujarat, Madhya Pradesh and Rajasthan. In the year 2008-09, the production from these mines was worth Rs 1,13,700 crore amounting to approximately 2.8 per cent of the country’s

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MINING EQUIPMENT

D11T CD dozing at dusk

Courtesy: Caterpillar

GDP. The mining sector is extremely labourintensive, and therefore, generates large number of employment opportunities, with over two million people working in the sector. Coal mining, which covers around 80 per cent of the mining activity, is slated to grow at a fast pace as power demand is expected to rise enormously. The government is planning to double power production that in turn will increase the demand for coal and give a boost to coal mining. Moreover, as surface coal mining is nearing saturation, mining companies are exploring the underground mining option for which sophisticated and highly technical equipment are required. Besides, with a growing economy, there is always a demand for all types of metals and minerals. Hence, as the mining sector becomes dynamic, the role of mining equipment also becomes decisive.

develop the country’s mining sector, mining equipment manufacturing companies offer products at par with international standards. “Several technological advancements have been happening in the area of mining equipment over the years. These include developments in hydraulic technology, use of environment-friendly technology like lower emission engines, electric-driven machines, etc. Further, there has been an increasing use of sophisticated electronics, control systems and computers for monitoring the mining equipment, which has extended up to even remote monitoring usage global positioning systems (GPS) and satellites,” says VS Satyan, Branch Manager, Dozco. The technology developments have made the maintenance of mining equipment much simpler. It is also possible to track the performance of various machines by logging onto the data through computer systems. “The trends in the mining equipment industry revolve around developing many new types of machinery and technology that aim at reducing the mining cost. There have also been many upcoming trends in underground mining equipment where new techniques like long wall and high wall are being employed more often now,” observes Shahane. The deployment of automation in the mining sector is relatively a recent trend. Implementing automation techniques in mining is far more complex considering the extreme applications.

AUTOMATION SOLUTIONS Adoption of fully integrated and automated

systems have made mining operations efficient and have addressed the issue of rising costs and safety of workers at remote sites. Moreover, it has helped minimise fatal incidents on mine sites. The ‘smart’ mine of today include machines that navigate underground and collect as well as transmit complex sample analysis data. Technologies for automated aerial mapping as well as explosives are important developments for the industry, alongside sophisticated new processing technologies to access mineral sands, resources and uranium deposits. To carry out remote operations, many companies have set up centres in their facilities. The centres use remote-controlled ‘intelligent’ trains, drills and trucks to carry out the daily tasks. Teams are trained to manage mine operations remotely in sites, which are located thousands of kilometre away. Annette Slyman, Commercial Manager, Caterpillar Global Mining Technology, states, “We have progressed in the mining machine automation, accelerating from the automation of specific functions of operatorcontrolled machines through semiautonomous machine operation and ultimately to totally autonomous machines. For example, the largest Cat track-type tractor (bulldozer), the D11T, enables AutoCarry, which provides automatic blade control during the carry segment of the dozing cycle. AutoCarry is intended to enhance productivity in high production earthmoving situations with carry distances of more than 30 metre. By monitoring ground speed with the belly-mounted radar gun, AutoCarry controls blade load through

INDIAN MINING EQUIPMENT INDUSTRY The overall performance of the mining equipment segment has been strong in the last three years. During 2009-10 and the current financial year, there have been substantial orders for mining equipment from various mining segments like coal, iron ore, zinc and other minerals. This has been primarily driven by the growth of the mining sector wherein many companies are undertaking large projects for mining of various minerals.

TECHNOLOGICAL TRENDS With the Indian Government keen to

MINEGEM equipped LHD

Courtesy: Caterpillar

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the electro-hydraulic controls to maintain optimal speed – without any input from the operator.” A key area of automation in mining is robotics. Automation and robotics have an increasing impact on the safety, predictability, and precision of mining. It provides increased computing power; new algorithms for signal processing, perception and control; new sensing technology including GPS, radar and laser systems, which adds to the efficiency of the operations. Professor Hugh Durrant-Whyte, Director, Rio Tinto Centre for Mine Automation, says, “The ability to accurately locate, control and co-ordinate robotic machines also delivers better predictability. When equipped with sensors, these systems are able to provide real-time estimates of material geometry and geology;

Delay in project commencement, poor logistics support, lack of skilled machine operators and service mechanics are some of the challenges faced by the equipment manufacturing industry. However, the growth potential in the mining sector overshadows these challenges. S SRINIVASAN, Head - Business Planning & Development, Construction Equipment, Business Sector, Larsen & Toubro

the operation of such machines can be controlled in a near optimal manner. Using this information to plan and schedule the actions of many robotic mining machines, working in tandem, will result in increased utilisation, precision and overall efficiency.” Delving in depth on the benefits of automation, Slyman says, “Depending on the level of automation, the benefits include enhanced safety, increased productivity and sustainability, improved machine utilisation and many others. For example, removing the human operator from the underground mining environment improves safety immensely.” Slyman further adds, “Productivity increases when the machine is operated optimally, without human variability. Improved utilisation comes from fewer machine problems introduced

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through operator errors, and in the case of remote operation of underground machines, the operator does not have to travel underground to rectify the problem. Shift changes are seamless. Sustainability mainly is enhanced through better fuel utilisation during automated functions.” Some of the specific innovations in the field of automation for the mining sector include automated surface haul trucks, automated underground load-haul-dump (LHD) vehicles, and autonomous drills. In some cases, only components of automation have been developed, such as automatic swing control for drag-lines, heading control for coal shearers, or proximity warning and safety systems for trucks. Such developments reflect the relatively conservative nature of the industry in developing and adopting robotics. Experience shows that it is difficult to derive the full benefit when only part of a system is automated. The mining sector has benefited greatly from improvements in computing and communications technology over the last few years, with mobile communications playing an increasingly important role in automation systems. A key focus for mining is tighter integration between increasingly clever equipment and back-end systems such as enterprise resource planning (ERP). For new mining companies, such as those in China and India this will provide a competitive edge. These countries have an advantage as the facilities are being built using the latest automation and control equipment. Slyman says, “It appears that significant advances in perception, communications and distributed intelligent control systems, along with integration efforts with existing enterprise, fleet management, equipment maintenance and planning systems will bring advanced technologies, such as autonomous machine operation, into the realm of everyday operations over this decade and the next.” New techniques are under trials in underground coal mining with elements of tracking the seam and keeping machines inside the seam. The mining sector is now moving into the third generation of automation, known as autonomous systems, as distinct from automated or automatic components of the mining process. Solutions are now emerging that will allow companies to deploy intuitive, remote-controlled machines into remote

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and/or dangerous areas and enable them to perform chemical analysis as well as independently assess and react to geological conditions in real-time. Automated aircraft are also increasingly being considered to perform aerial mapping of mine operations. Underground loaders are being fitted with technology to allow mapping of tunnels in real-time, while ore-digging equipment is increasingly being fitted with sensors as a means to quickly assess mineral concentrations.

WIRELESS SYSTEMS Nowadays, companies are using processbased production management system using electronic machine monitoring and PDA technology. Several firms have reported increase in productivity through the adoption of such technologies. The systems garner the desired inputs through accurate, meaningful and on-time process measurement enabled by electronic machine monitoring and real-time shift reporting by shift supervisors through the use of PDAs. In addition, deploying realtime monitoring systems can be useful for immediate resolution of mine site issues. Wireless technology has been effective in underground operations for sensing, control and visualisation systems for effective teleoperations.

TIME TO SPEED UP With the need to speed up high capacity mining and increasing automation, the requirement for large equipment is also expected to shoot up. The mining sector is now looking at highly sophisticated, efficient, customised and safe equipment, and therefore, it is imperative for the mining equipment companies to introduce technologically innovative machinery and increase R&D investments. Since there is a huge pressure on mining companies to speed up production and also maintain quality of the minerals, the demand for highly sophisticated equipment is sure to go up. The end-users opt for operationally efficient, safe and cost-effective machinery, and hence the industry needs to look at ways to fulfil the emerging demands. The Indian mining companies largely cater to the domestic market. However, with the opening up of this market to the international players, the competition has intensified and the stakes have gone up tremendously. The local companies need to start benchmarking product efficiencies


MINING EQUIPMENT

and quality with global norms. Shahane notes, “The Indian companies that manufacture large mining equipment do not have the latest technologies related to electronics and control systems as seen in some of the imported mining equipment. The imported machines are integrated with automation and control systems. While Indian companies can upgrade their equipment, it takes time for development of the same. However, there are strong R&D opportunities for Indian companies, which would allow them to compete with the international manufacturers.” Unlike agriculture and smaller construction equipment like tractors and backhoe loaders, the mining equipment volumes do not support multiple manufacturing locations. “There are few global players who support the global demand through competitively-scaled manufacturing locations. Indian companies are competent to source the best mining equipment through strategic partnerships with such world majors. L&T through its partnership with Komatsu has the capability to provide the whole range of mega-mining equipment. L&T has already supplied 240 tonne electric dump trucks to India,” says S Srinivasan, Head - Business Planning & Development, Construction Equipment, Business Sector, Larsen & Toubro. While elaborating on the trends shaping up in the mining equipment industry, Srinivasan points out, “Today, larger size mining machines are being planned. Equipment is purchased with long-term maintenance contracts where the supplier is responsible for equipment maintenance including supply of spare parts. Moreover, high equipment uptime and higher asset utilisation is encouraged. With the advent of global mining companies, the demand for mining equipment has also increased, further growing the industry base of mining equipment manufacturers.” According to Srinivasan, there is a significant increase in private participation in the Indian mining sector. The private sector is bringing in world-class mining technologies to India. Subsequently, large-size hydraulic excavators, ultra-class electric dump trucks and other mega-mining equipment are expected to be deployed in Indian mines. The machine utilisations are also expected to increase significantly. The use of modern technologies like geographic information system (GIS), GPS, Mine Planning Software, among others have helped the Indian

The size of the mining and construction equipment industry in India today is roughly to the tune of Rs 13,000 crore. However, if one considers only the mining equipment segment, which basically consists of large heavy earth moving machinery like rope shovels, huge excavators, mining loaders, dump trucks, draglines, underground equipment, then the size of the industry would be around Rs 3,700 crore. This would also include spare parts and service-related business. MM SHAHANE, EVP & COO – Engineering Products Business Group, Voltas

mining industry to a great extent.

ROADBLOCKS While the mining sector is slated to grow in the coming years, the mining equipment manufacturing industry is confronted with many challenges. For instance, environmental restrictions for open cast mining, stricter emission norms, higher competition from MNCs, and constraints in availability of financing are some of them. It is also possible that many mining projects may get detained due to delays in approval for forest and environmental clearances. “The manufacturers face challenges in terms of high input cost, high taxation rates, administrative delays in customs, bottlenecks in transportation due to administrative issues like road permits, etc. This increases the cost of operations in India,” opines Shahane. Meanwhile, Srinivasan highlights, “Delay in project commencement, poor logistics support, lack of skilled machine operators and service mechanics are some of the challenges faced by the equipment manufacturing industry. However, the growth potential in the mining sector overshadows these challenges.”

FUTURE BEHOLDS The mining sector aims at achieving Rs 4,16,500 crore by 2015 and this augurs well for the mining equipment companies. On an average, 50 to 60 per cent of mining

equipment business in India comes from coal sector; approximately 20 per cent comes from cement (lime stone) sector, 10 per cent from iron ore and 10 per cent from other minerals like zinc, copper and bauxite. The coal and iron ore mining is expected to be intensified, as the government strives to meet the set target of ‘Power For All’ in the next couple of years. The mining equipment market is largely driven by the coal-mining sector, which is witnessing increased coal production for thermal power plants. The current power generation in India is estimated at 1,63,669 Mega Watt (MW) as on July 31, 2010. Of this, 53 per cent is from coal-based thermal power plants. The government plans to add 78,000 MW during the Eleventh Plan period. Around 54,355 MW of energy is coal-based. Even if government realises 65 per cent of the planned output, an estimate considered by independent agencies, it is much better than 50 per cent achieved in the last three Five-year Plans. The planned addition to generation capacity during the Twelfth Plan is expected to be around 1,00,000 MW. According to Srinivasan, India will continue to depend on coal-based thermal power plants to meet its energy demand. This growth in power generation will require large-scale deployment of mining equipment, and thus, we expect the market for mining equipment to grow by at least 20 per cent over the next five years. The growth prospects for the industry are strong. These are due to large investments of over Rs 10,000 crore in various mining segments. In coal mining, Coal India and its subsidiaries are undertaking many new coal projects, while there are many coal blocks allotted to private sector companies, which are also expected to start operations in the next few years. These include Reliance (SASAN), ESSAR, Tata Steel, Hindalco, Tata Power, etc. In iron ore, there are many steel projects planned, which will require higher production of iron ore and many companies like SAIL, Tata Steel, Jindal, JSW Steel, Bhushan Steel and other smaller mining companies are expected to invest in developing new iron ore mines in the near future. In addition, the construction of infrastructure is expected to witness a boom since the government is trying to achieve an economic growth of 8 to 9 per cent in the next decade. All these indicate a bright future for mining and allied equipment industry.

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INNOVATIVE SOLUTION FOR OPEN CAST MINES

RELIABILITY and EASE of MAINTENANCE by DESIGN With surge in mining activities in the recent years and heightened focus on environment management, it is mandatory for miners today to deploy the best-in-class equipment and state-of-the-art technologies, which aim at reducing pollution to its minimum. One such promising development in this field is the deployment of electrical and automation systems, which have significantly helped Neyveli Lignite Corporation in lifting up its productivity and efficiency. eyveli Lignite Corporation (NLC) is India’s largest lignite mining company and one of the country’s leading power-generation companies. NLC operates three open-pit mines in Neyveli, Tamil Nadu, that produce around 24 MT of highgrade lignite per year. Mine I, the company’s original mine, is operated over an area of nearly 27 km2 and offers a reserve of about 365 MT. Mine II, first opened in 1984 and expanded in the early 1990s, features a reserve of nearly 400 MT. Most of this production is used in NLC’s thermal powergeneration plants, which have a combined capacity of 2,490 MW. Neyveli Lignite has been long searching

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for a technology and automation partner to meet its future needs amid the fast changing dynamics of this industry. Amongst the successful for more than two decades, Siemens, which has been catering to the Indian mining sector by providing electrical turnkey solutions for various applications, proved to be the preferred partner for NLC. Siemens offerings include a range of electrical solutions and automation systems for the operation of conveyors and special mining machines such as spreaders, bucketwheel excavators, stackers and reclaimers.

DATA TRANSFER VIA WLAN Siemens, in September 2008, commissioned a complete electrical and automation system for a line of six conveyors and four special

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mining machines, including two bucketwheel excavators (BWE), one crawlermounted tripper car and one spreader at Mine II. The system was designed for nine conveyors, which were subsequently put into operation step by step. It was the first time in India that conveyors were equipped with variable frequency drives. These conveyors can be speed controlled from a centralised location depending on the load condition. The result is low operating costs, high availability and very low wear. Individual speed controls at the head guarantees optimised operating conditions of the conveyors, especially under heavy load conditions or when the drive drums are wet. The entire flow of material in the open-pit mine can be tracked


INNOVATIVE SOLUTION FOR OPEN CAST MINES

and controlled by Simatic S7-400 route controllers. A WincCC server provides relevant production data online. Since the conveyors need to be shifted from time to time, communication via cables was impractical. To overcome this problem, Siemens Scalance industrial WLAN equipment has been used to connect the conveyors and machines to the centrally located gateway PLC. Even when the conveyors are shifted, the WLAN equipment ensures instant and reliable communication. With the implementation of the system, the operator at a central location can select one of the 20 probable routes and issue the start-and-stop commands for each of them. All operation and machine-status data are available at a centralised control station, thereby reducing troubleshooting time and enabling the generation of sophisticated reports that allow immediate access to historical and live production data.

VARIABLE FREQUENCY DRIVES

equipped with Simovert AC Masterdrives in 12-pulse configuration and controlled by a special software tool kit that has been developed for conveyor applications and runs on the FM458 technology module.

DYNAMIC CONVEYOR SPEED The speed variation of the conveyor ensures the safety of people and equipment, optimum usage of energy and avoidance of oscillations. The software features belt-slip supervision for safe operation of the conveyors. The current conveyor load is continuously recorded and stored during breaks. This feature permits a sophisticated load-based pre-control function that optimally adapts the torque to the conveyor load after a shutdown. This guarantees equal load sharing at start-and-stop operations as well as during normal operation and helps avoid any oscillations even at varying speeds and changing loads. Due to the length of the conveyors, it takes more time to come to a complete stop from a full speed operation. In order to

The intricacies of the project can be best understood with the help of Figure 1, which graphically represents the layout of the conveyor line with four mining machines. The two bucket-wheel excavators (BWE 1 and BWE 2) carry out the excavation of overburden and dump the material on the first conveyor, which is then transported away by a series of further conveyors. Figure 1: ConďŹ guration of the BWEs, conveyors, CMT and the spreader The last conveyor is equipped with a crawler-mounted tripper car, which in turn dumps the use this massive inertia, the power is fed overburden onto the spreader. The BWEs back into the system. Thanks to this are equipped with industrial-grade laser innovation, mechanical brakes are only used scanners mounted on their discharge when speeds reach near to zero, which booms. These laser scanners detect the significantly reduces wear. amount of overburden being excavated in The maximum speed of each conveyor real time and continuously transfer this data is specified at 5.4 m/s and the maximum to the central control room over the length of a conveyor is 1,800 m including wireless communication system. The potential conveyor length extensions. To centralised PLC in the control room avoid sudden changes in the speed of the analyses this information and determines conveyors, speeds remain fixed within a the cumulative load on the conveyor line certain band of tonne-per-hour loading. fed by both BWEs. When the loaded capacity is up to 60 per Each conveyor, length ranging from cent of the maximum, the conveyor speed 800-1,800m, is capable of carrying 20,000 is 65 per cent of the maximum possible; tonne of overburden per hour at a between 60-75 per cent of maximum maximum speed of 5.4 m/s. To achieve the loaded capacity, the conveyor speed is 75 controlled power delivery to these highper cent; and between 75-90 per cent of capacity conveyors, each conveyor is maximum loaded capacity, the conveyor

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speed is 85 per cent. When empty, the conveyor line works at 55 per cent of the maximum speed possible to save energy. After restarting the conveyor system with a simultaneous startup of both BWEs, the speed is immediately increased to 96 per cent and it remains at that level for five minutes. This prevents the transfer chutes from being blocked by existing material on the conveyor line or by the discharge boom of the BWEs. After running the line at 96 per cent speed for 5 minutes, the gateway PLC selects the optimal conveyor speed based on the loading pattern. Speed-increase commands are given to all the conveyors simultaneously to avoid chute blocking. If only one of the BWEs is started up, then the command is issued to all conveyor PLCs to change the speed to 65 per cent of the maximum speed. In a situation in which both BWEs are running and one stops, the line speed is reduced to 65 per cent in a phased manner. This ensures that higher loads on the conveyor line are cleared before the speed reduction is initiated. In

the event that both BWEs are stopped, the conveyor line will become empty in due course. To minimise energy consumption in this phase, the conveyor line is operated at 55 per cent of the maximum speed. Similarly, the speed reduction is done in a phased manner. Multiple technologies like these which have been adopted recently in mining have truely exemplified the need for automation in this space. Latest technologies for operation of conveyors and special mining machines have not only enhanced the process functioning and productivity but also strengthened safety conditions for equipment and the people working on it. Atul Joshi, Chief Manager - Mining Group, Industry Solutions Division, Siemens


SMART ENGINEERING MATERIALS

SMART ENGINEERING MATERIALS: Unravelling A New World Of Opportunities .....................132 CERAMICS: Creating A New Wave In Energy Technology .............................................................138 NEW MATERIALS: Adding Substance To The ‘Material’ World ......................................................143

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SMART ENGINEERING MATERIALS

NEW WORLD

UNRAVELLING A OF OPPORTUNITIES

The last five decades have witnessed an unprecedented spurt in ‘designer’ materials that address specific problems in industries, research or military applications. Today, advanced materials outperform conventional ones with superior properties such as toughness, hardness, durability and elasticity. The development of advanced materials enables the design of new products, including medical implants and computers, and thereby opens up a new world of possibilities. dvanced materials are is evident from the fact that a product, severe working environment and last long. Materials are divided into groups based amazingly versatile. They which is used to make windscreen wipers on what they are made of. These groups can have entirely new run smoothly and quietly, is also the main include polymers, metal alloys, ceramics, physical properties component for stain-resistant carpet, semiconductors, composites and including the ability to upholstery as well as the non-stick surface biomaterials. In addition, the search for memorise shape, or sense on frying pans, for instance, teflon also lighter, stronger or cheaper materials led to changes in the environment and respond known as polytetrafluoroethylene (PTFE). It the development of glass fibre reiforced accordingly. The field of advanced materials has found myriad uses, the most conspicuous plastics (GFRP) for fibreglass, half a century research is broad in scope, with numerous being kitchen gadgets that need to endure a ago. This paved the way to the potential applications. Today, research is need-based, driven Nickel-based superalloys not only have high temperature exotic world of composites made by the market demands, and in oxidation resistance, but also the incredible property of from metals or polymers or ceramics – with added strength tune with the Olympian motto not melting, not even softening at 14000. That is only coming from powdered particles – altius, fortius, celtius that mean 2000 below their melting points. or fibres embedded in them. higher, stronger and faster. This

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SMART ENGINEERING MATERIALS

they come into contact with human blood, which is warmer than outside temperature. At present, smart materials are made by embedding sensors into existing materials. For example, a pressure- or wearsensor can be embedded into a car tyre. This will alert the driver when the tyre needs to be changed and how to drive to reduce tyre wear. New ceramics can sense strain in a building structure and provide early warnings on mechanical failure, while others react to changes in temperature or electric current.

Materials scientists have developed new high-strength steels for use in car bodies that are 24 per cent lighter and 34 per cent stronger than conventional materials. The magnetorheological fluids can be used in the suspension system of cars to cope with vibration. These liquids are free-flowing until they are placed near a magnetic field, and then instantly and reversibly become semi-solid.

Different types of composites are available now such as metal matrix composites (MMCs), polymer matrix composites (PMCs) and ceramic matrix composites (CMCs). Rigid foams are plastics that have been ‘blown’ with gas during solidification, and act like wood when machined or shaped. These are commonly used in lightweight but strong furniture or for construction of houses. Expanded metals or honeycomb structure type metals and alloys are often used in aerospace engineering to reduce weight drastically without sacrificing strength. While some advanced materials are already well-known, it will take a few more years for others to find applications in products. Given below are insights on some advanced materials and future technologies:

AN ARRAY OF ‘SMART’ MATERIALS

A shape memory alloy polymer sheet for aircraft

‘Smart materials’ respond to the minutest changes in their surroundings such as temperature, light, magnetic fields or electrical currents. Future research may result in the development of materials for building self-repairing houses; making antennae that bend towards a weak signal, liquids that solidify when heated, and cans that can be crushed and could regain their original shape under heat – the ‘shape memory alloys’ (SMAs). Originally invented in early 1960s, SMAs did not find too many applications. It just remained a laboratory curiosity. The first alloy with memory effect was ‘Nitinol’ –half nickel and half titanium, which was difficult to cast or form or weld. Today, the Japanese have patented more than 160 stainless steel grades that exhibit the SMA effect, so virtually every designer can now afford to use them. Medical instruments and implants received high level of acceptance in the market. German companies are offering a tubular maze of SMA, small in diameter, as a ‘stent’ to widen the arteries of heart patients. These small diameter mazes blow up by ten times to their original size when

Ideally, devices made from smart materials would not only provide the information to assess a situation, but also react to it. These devices could then lay down extra adhesive to reinforce a weakened structure or apply an anticorrosion agent in response to rust, without any human effort.

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SENSORS IN CLOTHES Smart materials in clothes will have the ability

to monitor health, stress levels or other physical needs and respond accordingly. The fibres may become more insulating, if one is cold, emit an alarm if one is about to get an heart attack or provide a read-out of vital health risks. Scientists are working on ways to incorporate ‘responsive polymers into fibres and to make them tough enough to cope with daily wear and tear.

TRANSPORT BUSINESS CARS, BIKES AND TRAINS No car, bike or train or plane today can be designed nor made without the use of advanced materials, and most importantly, the use of advanced surface engineering when metallic alloys look like they have exhausted their strength properties. For example, thermal barrier coatings of alumina or zirconia, which are advanced ceramics, are applied to the nickel-based superalloys that form the blades of gas turbines at the heart of a jet engine. Automotive vehicles The passenger car consists of several types of advanced materials, including plastics and advanced alloys. Ceramics are used in engines to reduce wear; oils with additives maintain lubrication; polymers are used in interiors; pipes are made of neoprene and other specialised materials, etc. If one examines the designs and the bill of materials for making Formula 1 cars, one would see hundreds of new advanced materials used judiciously, so that those cars work consistently and reliably. Materials scientists have developed new high-strength steels for use in car bodies that are 24 per cent lighter and 34 per cent stronger than conventional materials. The magnetorheological fluids can be used in the suspension system of cars to cope with vibration. These liquids are free-flowing

The Maltese researchers have developed a new route for the manufacturing of high value-added auxetic foams from ordinary, cheaply available, conventional foam. These auxetic foams exhibit the unusual property of getting thicker when stretched rather than thinner.

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SMART ENGINEERING MATERIALS

until they are placed near a magnetic field, right kind of strength or flexiblity. Medical Hydrophobicity or water-repellent and then instantly and reversibly become applications of advanced materials may be properties commonly used in thin mansemi-solid. In the future, bumper bars may relatively simple, such as uses in dentistry or made fibre fabrics for windcheaters, light be made of an auxetic material, which for making better contact lenses, or they jackets etc, was inspired by the lotus leaf on grows thicker when stretched may be as complicated as and thinner when compressed. The idea for nanosprings – minute ‘springs’ for use in producing a functional and lasting Titanium alloys are increasingly hip. tiny nano-machines – came from an elastic protein called replacing the advanced grades Materials scientists are resilin, which helps power insects’ flight and fleas’ jumping working towards implanting of steels, as they are much lighter and stronger – the main ability. Resilin has a rubber-like elasticity, changing man-made devices and materials deterrent in the use of titanium into the human body to shape under stress without breaking and recovering to overcome rejection of biological alloys is the difficulty in extraction its original form when the stress is removed. of titanium and welding/cutting implants by the immune system. or fabrication, as it tends to get Implants include: Artificial joints including hips, knees, oxidised at temperatures as low as 1500 – which water drops cannot stay. They just spine, shoulder, finger and toe joints applying protective coatings on large roll off. Today there are ‘atmospheric plasma Artificial heart valves surfaces would be costly and impractical. treatments’ that can turn a surface into Implanted lenses Bicycles and motorbikes hydrophobic or hydrophilic (water Cardiac stents to hold arteries and veins Every part of a bicycle takes advantage of absorbent). When plastic materials are around the heart open advanced materials including the spokes, printed, the inks do not get absorbed Urinary catheters tyres, seat and frame. Kevlar tyre tubes are causing smudges and blotches. A hydrophilic Dialysis tubing for kidney problems. becoming popular because they prevent or hygroscopic surface absorbs the ink fast. However, how well an implanted punctures from thorns, glass, and other Once printed, another plasma treatment material can do its job depends on how its sharp objects and can prevent ‘pinch’ flats makes it hydrophobic, so that in future no surface interacts with the cells of the body when a bicycle tyre thumps into a rock. fluids or substances could erase what is – its biocompatibility. Fouling is caused by The frame of a standard bike is made of printed. It is indeed a neat solution from the accumulation of proteins and cells on chromium steel, which is inexpensive and bio-mimetics. The idea for nanosprings – minute surfaces, which can lead to bacterial generally rust-resistant. Aluminium alloy is ‘springs’ for use in tiny nano-machines – infections and other life threatening becoming more common but, for the came from an elastic protein called resilin, complications. bicycle connoisseur, the ultimate frame which helps power insects’ flight and fleas’ Scientists are developing new coating material is titanium. It is highly corrosionjumping ability. Resilin has a rubber-like materials to resist fouling of implants. One resistant and light, but is more flexible and elasticity, changing shape under stress coating that shows great promise is a tworesilient than steel. without breaking and recovering to its part polymer that has a sticky side, based on BIO-MIMETICS/BIO-MIMICRY: original form when the stress is removed. an adhesive made by mussels to hold onto NATURE-INSPIRED NEW Scientists plan to use resilin for spinal disc rocks – and another side that repels cells MATERIALS implants, as a substitute for heart and blood and proteins. Materials scientists have always watched the valves or even to add extra bounce to THE MATERIALS AGE wonders of nature to get inspired by the running shoes. Other discoveries inspired by nature Human beings created the stone, bronze simplicity as well as complexity of nature, include pollution-free water-based paints, and iron ages. Many believe that we are when it comes to magical effects. The and Velcro fasteners that came from now in the materials age, and it is not hard strongest substance in the universe is the observing burrs attached to woollen to understand why. Advanced materials spider’s web, which can stretch up to 300 materials such as impact every aspect of human life, right times before it breaks; a flea can jump up to socks. from the clothes to furniture or any products 50 times its own height; an ant can carry up used in day to-day lives. The future for new to 200 times its own weight, etc. A million MEDICAL materials seems most exciting. wonders exist around us in nature. BioAPPLICATIONS mimicry covers a new generation of OF ADVANCED MAK Babi, Metallurgist & Plasma Technologist materials that aims at mimicking materials MATERIALS E-mail: maxbabi@gmail.com and structures in the natural world. Producing a material The fibrous structure of bamboo, which that can function is one of the strongest wooden materials, EQUIPMENT BUYING GUIDE: effectively inside the has inspired many composites. ‘Velcro’ is Overhead Cranes human body is quite a believed to be one of the best inventions Sourcing The challenge. They need since it has limitless use, with a clean & Best Fit Solution to be resistant to robust appearance and an impressive corrosion; compatible lifespan. It was inspired by the almost with the biological invisible ‘burr’ on wool fibres, which on pg. system; and have the seemed to have interlocking properties. Kevlar tyres for bikes

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CREATING A NEW WAVE IN

ENERGY TECHNOLOGY

As the alarm bell on energy constraints ring out for action, the whole world is shifting its focus towards sources of clean and environmentfriendly energy. Moreover, researchers are exploring various material options, especially ceramics, that can enhance the efficiency of power generation, be it from fossil fuels or alternative sources such as solar or nuclear. In this regard, there are several untapped opportunities in the area of ceramic materials for energy technology creating a new ray of hope for achieving energy efficiency. he growing need for production of huge amount of energy and mitigating the human impact on the environment go hand-inhand. Currently, the primary reservoirs of energy include fossil fuels like petroleum and coal. However, the use of fossil fuels adversely impacts the environment through the emission of green house gases such as carbon dioxide and nitrous oxide. This poses as a big challenge, which can be resolved by promoting all forms of clean energy technologies. Hence, it is clear that major advances in alternative energy technologies are required at the earliest.

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ALTERNATIVE ENERGY SOURCES Alternatives to fossil fuels constitute solar and nuclear energy. The problem with effective use of solar energy revolves around its appropriate distribution among the users.

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Many believe that hydrogen will serve as the means of distributing solar energy, especially for transportation and distributed power generation. The idea is to use solar power to dissociate water into hydrogen and oxygen gases. The hydrogen can then be distributed, much like fossil fuels are distributed at present. Other ways of distributing solar energy are through rechargeable batteries and solar thermal power. Another option lies in finding a clean, environment-friendly and responsible way for using the fossil fuels, which will be possible by enhancing the efficiency of fossil fuel energy harvesting. This implies that thermal power stations must consume less coal per megawatt hour of electricity produced. Widespread use of clean energy is hindered mainly by technological challenges. More often than not, the success of clean energy technology hinges on the materials used, more so on the development of better

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materials. While talking of materials, these fall into the categories of metallic, polymeric and ceramic. Of course, there are composite materials, which combine two or more of these basic material types. All these types play their roles in energy technology. Here the focus is on ceramic materials.

CERAMIC MATERIALS The fossil fuel deposits continue to be the major source of energy. Steam turbines are coated with wear-resistant materials, often ceramics. Ceramic coatings play an important role in enhancing the efficiency of power generation using coal, natural gas or petroleum-derived fuels. The purpose of ceramic coatings is to provide protection to metallic components against corrosion, oxidation, wear, erosion and excessive heat. As an example, stabilised zirconia coatings are deposited on the high-pressure turbines and combustor liners of gas turbines used for power generation as well as aircraft


FACFACT T

CERAMICS

and oxygen gases. Splitting of water can also be achieved by directly using sunlight in the presence of a catalyst. Right now, titanium dioxide-based ceramic photocatalysts are being developed for this purpose. The idea of hydrogen as the medium of distributing energy for transportation and power generation has fascinated many researchers for several decades. The product of oxidation of hydrogen is water, which is environment-friendly. The most important energy conversion device for power generation from hydrogen is the solid oxide fuel cell (SOFC). This device is almost entirely made from ceramics. Stabilised zirconia ceramics can conduct electricity through the diffusion of oxygen ions at temperatures above ~600°C. This property is exploited for building SOFCs. The chemical energy of the fuel-oxygen reaction is released directly as electricity. While hydrogen is the most common fuel, hydrocarbon fuels like methane and combustion by-product gases like producer gas can also be used as fuels in an SOFC. This is not possible in other types of fuel cells based on polymers and expensive platinum. Such fuel flexibility of SOFCs is perhaps its strongest advantage. Apart from stabilised zirconia, SOFCs make use of ceramics such as strontium doped lanthanum manganite (LSM) in cathodes, lanthanum chromite in interconnects and glass-ceramic sealants. The only metallic material required is nickel catalyst in the anode. Research efforts are in progress to develop better materials for SOFCs. Nuclear energy Nuclear energy is a major alternative to solar energy. Current nuclear power plants are of fission types, i.e. large atoms emit radiation and become smaller atoms. These power plants also have steam turbines and heat exchangers that are coated with ceramics. However, the biggest contribution of ceramics is in the form of radioactive waste immobilisers. Glass ceramics and crystalline ceramics with the ability to hold radioactive atoms within their structural cages are being developed, so that the waste can be prevented from entering the ecosystems for centuries to come. Only ceramic materials offer this possibility of managing radioactive waste. Another type of nuclear power plant uses a fusion reactor. Such reactors are still

A well-established application of ceramic coatings is that of porcelain enamels on steel components of heat exchangers. Specially developed compositions are coated using frits in the form of slurries. Enamelling is completed in furnaces at temperatures of ~425°C and above.

engines. These ‘thermal barrier coatings’ (TBC) represent one of the most critical applications of ceramic coatings. They allow the gas turbine to be maintained at high temperatures, which enhances efficiency. Moreover, the lifespan of metallic components is increased as TBCs keep them below their maximum permitted temperature. Air plasma spray or electron beam physical vapour deposition is used for depositing TBCs with thickness in the range of about 150 to 250 micrometre. Usually, a temperature difference of ~100°C is maintained across the TBC. Another application of ceramics in gas turbines is in the form of abradable coatings, which maintain a tight seal between the rotating turbine and its casing. This is not all. The efficiency of internal combustion engines, especially diesel engines can be augmented by using ceramics. For instance, a thick coating of a zirconia ceramic on the piston head can increase performance or lifespan. Similarly, ceramic turbochargers can operate at high temperatures and increase the power delivered by the diesel engine for the same amount of fuel consumed. Many automobile components are coated with wear-resistant ceramics such as nitrides to enhance wear resistance.

ROLE OF CERAMICS IN ALTERNATIVE ENERGY Ceramic materials hold huge potential in alternative energy technologies, be it solar or nuclear. Solar energy Focussing on solar energy harvesting, the main photovoltaic (PV) material continues to be silicon. Ceramic materials, particularly silicate glasses, are used as substrates on which the various layers of a photovoltaic cell or a solar cell are deposited. Also, transparent but electrically conducting ceramics such as oxides of indium, tin, zinc and their combinations act as contacts in the PV cell. As mentioned earlier, the electrical energy generated in a solar cell can be stored in rechargeable batteries, or it can be used for dissociating water into hydrogen

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in the experimental stage. In a fusion reactor, small atoms like deuterium and tritium, which are isotopes of hydrogen, are made to collide with each other to produce larger atoms like helium. The primary challenge in fusion reactors is to develop the materials that can face plasma and withstand bombardment of neutrons. Ceramic materials like SiC/SiC composites are candidate materials for confining plasma. In magnetically confined fusion reactors like Tokamaks, superconducting ceramics are used for generating strong magnetic fields.

BECOMING GLOBAL LEADERS IN ENERGY TECHNOLOGY In the Indian context, and in terms of manufacturing technologies, there are ample opportunities in energy conversion technologies. Surface engineering of power plant components is well-established in India. Various coating deposition techniques like plasma spraying, high velocity oxyfuel (HVOF), detonation gun, cold spray, and chemical vapour deposition can be carried out for depositing ceramic coatings for wear resistance, corrosion and oxidation resistance, and thermal insulation (TBCs). However, the raw materials for these deposition techniques are almost always imported. Indian manufacturing enterprises have the opportunity to not only carry out the deposition jobs, but also develop the raw materials and further improve the coating techniques. Alternative energy technologies have tremendous opportunities for getting ahead of the competition. In the area of solar cells, cost reduction is the greatest challenge in the Indian context, and indeed for the whole world. Innovative manufacturing techniques can achieve this goal. Ceramics processing technologies are put to the test when developing solid oxide fuel cells. Any advancement in this area will prove crucial for the profitability of this technology. There are several exciting opportunities in the area of ceramic materials for energy technology for Indian entrepreneurs. Academic institutions and government research laboratories are putting in a large amount of research efforts in this domain. Now the time has come for the entrepreneurs to grab these opportunities for becoming global leaders in energy technology. Dr Ashutosh S Gandhi, Department of Metallurgical & Materials Engineering, IIT, Madras Email: a.s.gandhi@iitm.ac.in


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With continuous evolution of new materials, the manufacturing and allied sectors are all set to make quantum leap forward. The polymer composites hold promising prospects in the world of science and can add substance to a variety of sectors from fuel-efficient aircraft to major pharmaceutical breakthroughs in cancer therapies. he ever-increasing demand for eco-friendly products has resulted in enormous consumption of natural resources, which are therefore soon depleting. Novel material systems play a key role in tackling these challenges and increasing the eco-efficiency in process chains and material life cycles. Besides, most of the innovations are based on the utilisation of new material developments. These advanced engineering materials pave the path for new systems solutions with high added values in various fields of applications.

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MATERIALS THAT MATTER The areas of application of engineering materials are many and varied: from automotive and aircraft engineering via resource-saving chemical process engineering to medical engineering and technology. Completely new system solutions, for instance, for energy-saving lightweight engineering designs in vehicle body, motor and turbine engineering; or emission-free drive trains in transport engineering; resource-saving separation processes for materials mixtures, or also for medical implants, can become a reality through materials developments like these.

Many companies and research institutes are constantly striving to develop new materials for the industries to upgrade their product lines, and at the same time, help them enhance productivity with the use of these materials. Some of the new materials developed include DiaCer, PureEdge, Duratron D7000 PI, Spectra fiber, silicon carbide, DuPont PV5300 Series and DuPont PV5200 Series, buckypapers, etc.

DIACER Scientists from four Fraunhofer institutes, together with partners from industry, produced a new composite material called

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NEW MATERIALS

QUICK TAKE Many companies and research institutes are constantly striving to develop new materials for the industries to upgrade their product lines, and at the same time, help them enhance productivity with the use of these materials. The new materials provide cost-effective solutions to the performance gaps currently facing machine designers and engineers. DiaCer. The composite material, diamondcoated ceramics – DiaCer – combines the best of both materials. Any area where components and tools are subjected to heavy strain such as in pumps or forming and shaping dies, DiaCer offers maximum wear-resistance coupled with low values of friction. The basis is a silicon-nitride or carbide ceramic, which researchers of the Fraunhofer Institute for Ceramic Technologies and Systems IKTS in Dresden modified for the diamond coating. Dr Lothar Schäfer, Project Co-ordinator, Fraunhofer Institute for Surface Engineering and Thin Films IST in Braunschweig, says, “Components and tools are initially placed in a vacuum reactor for the hot wire chemical vapour deposition (CVD) technology applied for the coating process. Next, the researchers add methane and hydrogen. Further, for enabling the diamond coating to grow, wires are spread at intervals of just a few centimetre across the objects that need to be coated. The wires are heated until they reach incandescence.” He also added, “This activates the gases; carbon is deposited on the surface in crystalline diamond form. By employing the process we follow, we can apply a diamond layer of up to a half square metre in size. There is nothing else like it in the world.”

DURATRON D7000 PI Quadrant is expanding design and performance possibilities for machined parts in high temperature applications with the launch of Duratron D7000 PI polyimides and modified PEEK Semitron MP370. The new materials provide cost-effective solutions to the performance gaps currently facing machine designers and engineers. Duratron D7000 PI and new bearing grade Duratron D7015G PI are high performance polyimide materials that bring the benefits of polymer materials to applications operating in the region of 315°C (600°F). While polyimide has been widely used in semiconductor and

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electronics manufacturing equipment for years, Quadrant’s new Duratron D7000 PI materials are available in a wider range of sheet sizes and tube configurations than other PIs. Sameer Bhogate, GM, Quadrant says, “As a result, new opportunities in parts design are made possible. It also provides access to these shapes via the strongest worldwide distribution network in the materials industry. This new material marks an important addition to Quadrant’s portfolio of ultra high temperature, polyimide materials. The new Duratron PI grades, available in a range of sizes, will help engineers to select the most suitable and highest performing products for specific applications and environments more precisely and economically.” Quadrant has also introduced a new addition to the Duratron line of advanced machinable plastics. Duratron PI machinable shapes are ideal starting points for designs that reduce weight, extend length of service before maintenance or replacement and reduce overall costs by increasing process uptime.

SPECTRA FIBER Spectra fiber, a polyethylene fibre, is produced using a patented gel-spinning process. A bright white polyethylene, it is pound-for-pound, fifteen times stronger than steel and more durable than polyester. It has a specific strength that is 40 per cent greater than aramid fibre. Polyethylene is a remarkably durable plastic, and scientists at Honeywell have captured the tremendous natural strength in the molecular backbone of this everyday plastic to create one of the

world’s strongest and lightest fibres. The gel-spinning process and subsequent drawing steps allow Spectra fiber to have a much higher melting temperature (150°C or 300°F) than standard polyethylene. With outstanding toughness and extraordinary visco-elastic properties, Spectra fiber can withstand high-load strain-rate velocities. Light enough to float, it also exhibits high resistance to chemicals, water and ultraviolet light. It has excellent vibration damping, flex fatigue and internal fiber-friction characteristics, and Spectra fiber’s low dielectric constant makes it virtually transparent to radar. Spectra fiber is used in numerous high-performance applications, including police and military ballistic-resistant vests, helmets and armored vehicles, as well as sailcloth, fishing lines, marine cordage, lifting slings, and cut-resistant gloves & apparels.

SILICON CARBIDE Sebastian Polster, a student from Fraunhofer Institute for Integrated Systems and Device Technology IISB, has developed a new upcoming semiconductor material silicon carbide. Silicon carbide (4H-SiC) is the ideal semiconductor material for power electronics. For instance, efficient power converters for electric vehicles or photovoltaic systems can be produced as well as electronics that work at high temperatures. Until now, however, very few electron devices made of silicon carbide are available in the market. The reason for this is that the quality of the crystals and epitaxial layers is not yet sufficient for the demanding applications because even the slightest material defects, in the form of dislocations, can lead to a malfunction of the component. Dislocations are deviations from the ideal crystal lattice structure, which may occur in different types.

DUPONT PV5300 SERIES AND DUPONT PV5200 SERIES

DuPont PV5300 Series and DuPont PV5200 Series deliver long-term protection for the most sensitive part of photovoltaic modules – the solar cells. They Duratron D7000 PI’s Key Benefits: contribute to ensure longer life and reduced cost per watt, helping system Good performance at elevated temperature – manufacturers deliver more reliable over 600˚F and cost-effective solar power. On a Good chemical resistance global basis, DuPont expects to nearly Easily machined from a broad range of shapes triple annual sales from its portfolio of photovoltaic materials to more than – rod, sheet, tubular forms $1 billion by 2012. “With these new High strength, tough and dimensionally stable. introductions, DuPont science is

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enabling the faster spread of solar power,” said William F Weber, VP & GM – DuPont Packaging & Industrial Polymers. “These new encapsulant materials contribute towards keeping the cost per watt low and reducing the total cost of ownership for solar power. We expect growth of more than 25 per cent per year for encapsulant materials such as these in the next five years, due to the anticipated strong growth in solar module installations globally.” DuPont PV5300 Series sheets are five times tougher and 100 times stiffer than materials typically used as encapsulants. Their structural properties make possible new module designs such as building-integrated photovoltaic (BIPV) tiles that can be installed on building roofs. Companies like SYSTEM Photonics S.p.A of Italy are adopting DuPont PV5300 for architecturally appealing built-in rooftop photovoltaic power generation. The company’s DuPont PV5200 Series sheet is designed to meet the needs of thin-film solar power generation, a fast-growing segment of the industry. They are based on polyvinyl butyral polymer technology and offer high performance in physical processing. They enable faster, more efficient module production and longer service life.

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DICARBOXYLIC ACIDS USING POLYKETIDE SYNTHASES Jay Keasling and Leonard Katz of the Joint BioEnergy Institute (JBEI) have invented polyketide synthases (PKSs) that can be introduced into a host organism for the production of a variety of dicarboxylic acids often used as polymer intermediates. The invention promises to enable the manufacture of a wide range of polymers from sugars derived from renewable, cellulosic or other biomass instead of from petroleum intermediates. While PKSs have been widely used to produce pharmaceuticals and agricultural products, Keasling and Katz are the first to use this specific PKS system to produce a range of dicarboxylic acids. Because of the chemical and biological flexibility of the enzymes they are using, a large number of diverse diacids can be produced. The technology is compatible with multiple feedstocks and hosts, enabling the optimisation of yields for a particular diacid. Lawrence Berkeley National Laboratory (LBNL) is seeking collaborative research partners interested in funding development of this technology over a three-year period. The major application of this technology is

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to produce a wide variety of dicarboxylic acids for the manufacture of commercial polymers, e.g. polyesters, polyamides, polyurethanes. The major advantage is that it uses materials that are renewable, cellulosic or other biomass instead of petroleum. Polyketide synthases can be modified to produce a wide variety of diacid polymer precursors. It is compatible with a variety of host organisms and feedstocks, enabling yield/tolerance optimisation.

LOOKING INTO THE FUTURE With the constant emphasis on development of new engineering materials, one can only expect these new technologies to redefine humans lives – through advancements in medicine, computer science, energy, consumer products, architecture, etc. These materials and their uses are evolving faster on account of the efforts taken by researchers and thinkers. The innovation drive and the need for meeting the ever-growing demands of customers ultimately result in better products made with new and improved materials. Thus, sky is the limit for the future of engineering materials. Compiled by Geetha Jayaraman


CUTTING EDGE SOLUTIONS

HEATABLE FILMS: AN INNOVATIVE OPTION TO AVOID FOG ON GLASS nanocrystalline indium tin oxide (ITO)”, says n many countries, fogged or glass bending process. As a result, tin-oxide Szyszka. “This material doesn’t just have frozen windows can be a bane films only have limited industrial applications. outstanding optical and electrical properties; for drivers’ lives in winter. While “Our new film is extremely resilient” says it is also mechanically and chemically much heaters may be a solution in more stable than tin oxide.” The researchers many cases, a better option – especially are utilising high power impulse magnetron concering energy costs – would be to sputtering technology (HIPIMS). With ensure the problem does not arise in the magnetron sputtering, accelerated noble-gas first place. This means preventing ions shoot atoms from an ITO plate, much condensation on windows which would like what happens with billiard balls. These save a great deal of hassle – and car owners A transparent heatable film made out of indium tin oxide atoms are deposited on the required can save the time they once spent scraping surrounds the glass tube substrate in vacuum. “Yet instead of 10 off the ice. ampere, we use 1000 ampere with HIPIMS”, Researchers at the Fraunhofer Institute Dr Bernd Szyszka, Fraunhofer IST. explains Szyszka. “We ionise the sputtered for Surface Engineering and Thin Films (IST), “Temperatures up to 9000C are no problem, and even if you bend it aggressively material; therefore the film is built up by in Braunschweig, have finally solved the – the film remains intact.” The coating can higher energetic particles and shows superior problem. They will be developing a process therefore also be used in large industrial properties.” This provides a major advantage that can be used to manufacture transparent, plants where transparent protective heaters for the engineers as depending on the pulse conductive and heatable films. Moreover, are often required to monitor the process and power conditions during sputtering, the their surface films also provide another chain safely. engineers can adjust the texture and decisive advantage: the low emitting morphology of the film so that it properties of the outer film ensure the window cools down much To avoid fogging or frozen windows, researchers have subsequently takes on the desired properties during a subsequent more slowly, preventing developed a process that allows them to manufacture tempering process. “We can then condensation. The window not just transparent, but heatable films. These films bend the film and even coat threetherefore remains dry and icefree. Films that up to now have also prevent condensation, ensuring ice cannot build dimensional materials with the technology”, says the researcher. been produced with tin oxide are up on the windscreen overnight. The HIPIMS process can also be both mechanically and optically conducted at room temperature, still far from ideal. Cracks may What can the new film do, that tin oxide so that even temperature-sensitive plastics form as a result of excessive temperature cannot? “Our coating system is based on can be coated. loads – a problem encountered during the

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SMART METERS HELP TO SAVE MONEY ow can domestic electricity customers be motivated to use energy more efficiently, let alone make more efficient use of renewable sources? One possibility is to install electronic meters to measure the electricity consumed. In the RESIDENS project, scientists are examining how to get the best out of smart meters by simplifying their use. In the project RESIDENS - research project for more efficient energy usage by system orientated integration of end consumers - researchers are examining how electricity customers can be motivated to use energy from renewable sources more efficiently. The work is being conducted as a collaborative effort by researchers at Ilmenau University of Technology, the Fraunhofer Application Center for System Technology AST and the Fraunhofer Institute for Digital Media Technology IDMT in Ilmenau. But

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electricity customers can only use energy more efficiently if they know exactly how much power they are consuming at any time, and under what conditions they can save money by using green electricity. This is why the researchers are using electronic power meters, which measure how much electricity is consumed and transmit the recorded data at almost any predefined interval to the meter-reading company. Smart meters make it possible to analyse the data in numerous different ways, explains AST engineer Peter Bretschneider. For instance, you can display a reading of the instantaneous power consumption or the cost of a kilowatt-hour of electricity. And you can trace how much energy you have used over a certain period. The smart meter enables actual consumption to be determined on a monthly basis. The meter also displays the currently applicable tariff, enabling customers to select the appropriate

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time to do their laundry, by waiting until offpeak rates apply before starting the washing machine. To simplify the use of the new digital meters for electricity customers, the researchers are also working on applications for a Web portal, where consumers will be able to see at a glance how much they paid for electricity last year, how much energy they have consumed today, and how the cost compares with the previous day’s electricity consumption. An annual overview highlights the months in which the most electricity was consumed, and a daily overview pinpoints the hours of peak consumption. The portal will also inform consumers of the most cost-effective times to use green electricity and calculate their carbon footprint on the basis of their present pattern of consumption. This might prompt electricity customers to switch more often to energy from renewable sources.


CUTTING EDGE SOLUTIONS

RESEARCH EFFORTS ON TO DISCOVER HYDROGEN-COMPATIBLE METALS hough hydrogen can be considered as the fuel of the future, this lightest of the chemical elements poses as a danger to industrial machinery, especially the vehicle engineering as it can embrittle the metals used. This can cause components to suddenly malfunction and break. To overcome the issues faced due to the element, a new special laboratory is created to aid researchers’ search for hydrogencompatible metals. The use of hydrogen to power vehicles was seen in the US television series ’Knight Rider’. Here, KITT – the legendary talking supercar had a hydrogen

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Through the combination of special laboratory and simulation tools, we have found out which materials are suitable for hydrogen, and how manufacturing processes can be improved. DR WULF PFEIFFER, Head – Process & Materials Analysis Business Unit, IWM

turbo motor that helped it chase the bad guys, while running at over 300 miles an

hour. In the future, cars may be equipped with hydrogen propulsion not just in the movies, but in real life as well. In the transportation and energy sectors, hydrogen is seen as an eventual alternative to the raw materials of fossil-fuel power, such as coal, petroleum and natural gas. However, for metals like steel, aluminum and magnesium - which are commonly used in automotive and energy technology – hydrogen is not quite ideal. It can make these metals brittle, while decreasing their ductility. Therefore, the durability of the metals decrease and can lead to sudden failure of parts and components. Beside the fuel tank itself, even ordinary components like ball bearings could be affected. Costly repairs are the consequence. To prevent cracks and breakage in the future, the researchers at the Fraunhofer Institute for Mechanics of Materials IWM, in Freiburg, are studying hydrogen-induced embrittlement. Their objective is to find materials and manufacturing processes that are compatible with hydrogen. “With our new special laboratory, we are investigating how and at which speed hydrogen migrates through a metal. We are able to detect the points at which the element accumulates in the material, and where it doesn’t,” says Nicholas Winzer, Researcher, IWM. Researchers will be able to release and simultaneously measure the movable part of

the hydrogen by heat treatment, where samples are continuously heated up. In addition, the experts can measure the rate that hydrogen is transported through the metal while simultaneously applying stress to the material samples mechanically. They can determine how the hydrogen in the metal behaves when tension is increased. For this purpose, the scientists use special tensile test equipment that permit simultaneous mechanical loading and infiltration with hydrogen. Then they determine how resistant the material is. Explaining the special feature of the simultaneous tests, Winzer says, “In industry, components have to withstand the combined forces of temperature, mechanical stress and hydrogen. With the new special laboratory, we can provide the necessary analytical procedures.” Researchers use the results from the laboratory tests for computer simulation, with which they calculate the hydrogen embrittlement in the metals. Doing this, they enlist atomic and FEM simulation to investigate the interaction between hydrogen and metal both on an atomic and a macroscopic scale. “Through the combination of special laboratory and simulation tools, we have found out which materials are suitable for hydrogen, and how manufacturing processes can be improved,” says Dr Wulf Pfeiffer, Head – Process & Materials Analysis Business Unit, IWM.

FIBRE-REINFORCED PLASTICS FOR CAR WHEELS ests and calculations show that fibre-reinforced plastics are highly damage-tolerant and distinctly superior to aluminum in car wheels. A car breakdown, due to its wheels, can be expensive. Also, there are safety risks involved to the occupants. To create the fundamentals for the production of lightweight and yet safe & reliable components, Fraunhofer Institute for Structural Durability and System Reliability LBF, in Darmstadt launched the highstrength plastic structures project in cooperation with five other Fraunhofer institutes. “The aim was to provide the conditions and the tools for the operationally reliable design of extremely light safety parts made of sheet molding compound (SMC) material, which could be produced on an ongoing basis in medium to large volumes.

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SMC is a fibre-reinforced to large quantities. composite material which Describing the tests mainly consists of inorganic conducted at the LBF, constituents,” explains Büter said “On our test Prof Dr-Ing Andreas Büter, stands, we have simulated, Fraunhofer Institute for for example, how the Structural Durability and wheels and suspension of System Reliability LBF, in a car behave on a rough Darmstadt. “Up to now, road, in forward motion SMC has only been used and reversing, and how This wheel made of fibre-reinforced plastic is for secondary parts of the long the components can particularly light and exhibits high structural bodywork such as the endure these conditions,” durability. bonnet or doors,” states After three years of Büter. “The purpose of research work, scientists our project was to clarify whether SMC is can now present the results. On conclusion also suitable for safety-relevant primary of the project Büter highlighted an important parts.” SMC is superior to metal in several finding “If correctly processed, fibreways. It is not only lighter but also exhibits reinforced plastics are highly damagean excellent mass-to-strength ratio. In tolerant and distinctly superior to aluminum addition, it is cheap to produce in medium wheels.”

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MACHINE VISION SYSTEMS MARKET

ON THE CROSSROADS

The lack of awareness about the importance of machine vision systems coupled with limited automation in core manufacturing industries has resulted in a restricted demand for these systems in India. The fact that the machine vision systems market is on the crossroads and has not registered exuberant growth in the past half a decade evokes questions on its future and what lies ahead for it in India. It remains to be seen whether the market has met its Armageddon or is it the Genesis. he level of automation in the manufacturing industry in India is varied, with some industries having a high level of automation compared to others that still rely on manual processes. Deterrents to the penetration of automation include

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the low-technology awareness, lack of regulation, and abundance of low cost labour. The entry of multinational companies into India, especially original equipment manufacturers (OEMs) that set up manufacturing facilities in the country, created a market for automation equipment. It is the MNCs that were the early adopters

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of automation and proponents of quality inspection in manufacturing units. However, the machine vision systems or automated inspection systems market in India is relatively in its nascent stage and adoption of these systems is still to reach appreciable volumes. Some of the challenges that continue to constrict the


MACHINE VISION SYSTEMS MARKET

industry include: Relatively low quality awareness in manufacturing set-ups Misconception of machine vision systems being higher priced Lack of qualified system integrators Cheap labour costs acting against automation, and therefore, inspection systems Low awareness about machine vision systems. Despite these bottlenecks, there is a ray of hope for machine vision systems industry, which is witnessing a higher level of demand and acceptability, albeit slowly.

the country. Further, as most of the equipment used in electronics manufacturing are imported, it comes embedded with machine vision equipment, thereby lowering prospects of local sales. India’s electronics consumption that currently stands at $40 billion is expected to grow in excess of 20 per cent year on year. However, local production, on the other hand, meets just about 50 per cent of this consumption. Even if local production grows on par with consumption, it will not be sufficient to meet the demand. This has resulted in the government directing its focus on encouraging more of indigenous electronics manufacturing under the aegis of a dedicated task force. Efforts taken in this direction are expected to usher more of local manufacturing, which is expected to drive the demand for machine vision systems as well. The semiconductor industry has remained on the backburner despite the growing electronics market. India has attained its dominance in the design field, but fabrication continues to be a distant

be the next big application area for machine vision systems when these investments translate into production centres in the ensuing years.

EVOLVING TRENDS AND THE WAY AHEAD

Though in its nascent stage, the machine vision market in India has been constantly evolving. From technology evolution such as a shift from analog to digital to smart cameras to application evolution such as the shift from end-of-line inspection to component/assembly level inspection, there have been continuous developments in the machine vision industry. Cost that OPPORTUNITY CLUSTERS was hitherto considered a challenge has Over the past decade, machine vision also been overcome by these trends. Prices systems have started witnessing adoption in of cameras are on the decline and costs of industries such as food processing, component level systems are about $5,000, automotive and pharmaceuticals. The which is five times lower than an end-ofadvent of global automotive OEMs has line inspection system. strengthened the demand for such The potential in India for machine vision systems in the country. Even indigenous systems is reflected by the abundant automotive component manufacturers are opportunities for automation in various realising the advantages of deploying industries. This huge potential has attracted automated inspection, and the attention of global hence, are adopting these suppliers. India’s foothold on the global photo voltaic (PV) industry systems. The pharmaceutical While the market is industry in India, which caters expected to foresee demand is expanding exponentially. Investments for setting up of to a large generics market for high levels of customisation PV cell and module manufacturing units are on the rise. globally, has evolved to be a that are specific to different The PV industry is expected to be the next big application preferred destination for industries, a significant increase Contract Research and in the demand is also likely from area for machine vision systems when these investments Manufacturing Services OEM applications that procure translate into production centres in the ensuing years. (CRAMS). With most of the locally-made machines. The Indian pharma companies need for system integrators having to adhere to the prescribed US FDA who have the specific application expertise dream. The absence of indigenous fabs or norms, the regulatory restrictions is going to be on the rise as demand for even many assembly, test, mark and package encourage them to adopt highly efficient customised systems increases. (ATMP) units has not only enervated the processes, which include automated Given the growth in demand in the semiconductor industry locally, but it has inspection systems, as well. The food future, the success of the machine vision also been the dampener for markets like processing industry, too, relies heavily on industry depends on how well suppliers can machine vision systems. The proposed exports and has various regulations that it educate users on the right systems for their government plan to set up a fab coupled has to adhere to when exporting to process and how well system integrators with the increasing interest shown by countries like the US and Europe. These absorb the requirements of customers and private companies to set up ATMP facilities regulations have driven the adoption of implement the correct solutions. The in the country are expected to be energy machine vision systems. machine vision systems market in India, is boosters for the automated inspection thus, at the crossroads of growth and its market. FUTURE GROWTH ZONES success depends heavily on the value chain Besides these, other markets such as Globally, some of the largest adopters of stakeholders, who need to enhance food sorting, cotton contamination machine vision systems constitute the awareness and evolve business models for detection, medical applications and process electronics and semiconductors industries, machine vision systems in India. The burden industries such as steel are expected to be though they have not been significant lies on the suppliers to educate users on the demand drivers for inspection systems. demand creators in the Indian market. need and benefits of automated inspection India’s foothold on the global photo Electronics industry is yet to adopt to grow the market. voltaic (PV) industry is expanding automated vision equipment on a large exponentially. Investments for setting up of Deepa Doraiswamy, Industry Manager – A&E, scale, and this primarily stems from the PV cell and module manufacturing units are Frost & Sullivan – South Asia & Middle East fact that mostly assembly activity happens in on the rise. The PV industry is expected to

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OVERHEAD CRANES

SOURCING THE

BEST FIT SOLUTION

The marketplace, today, is flooded with multiple options. Therefore, a buying decision for an individual in the purchase department of any organisation can be cumbersome, especially if one has to deal with overhead cranes. Since the overhead crane segment is highly unorganised in India, customers are unable to make an informed decision. Here we attempt to assist prospective buyers of electric overhead travelling cranes in selecting the appropriate equipment most suitable for their applications. n overhead crane is a simple equipment, which reduces human effort in lifting and carrying load from one place to another. It typically consists of a hoist to lift the load, the girder or the beam, and a trolley to move along the girder. Often, manufacturing floors have limited workspace and overhead crane systems act as a perfect solution in these places. Support columns generally take up valuable floor space, which can be avoided by using overhead cranes. Instead of requiring support columns, these systems are supported by the existing building structure. The first step to decide whether an overhead crane is the right solution for a company is to consult a qualified architect or engineer. This is because a building structure should be able to support the crane system, and professionals are the

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right people to determine that. Selecting the right type of overhead crane is critical to streamlining workflow and maximising productivity. In order to make a profitable investment, it is imperative that all buyers should freely interact with the crane manufacturers and provide them relevant information, so that the crane can be engineered optimally and a wellengineered turnkey solution can be sought. Outlined below are twelve parameters that can help buyers choose a well-designed and cost-effective lifting solution.

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TYPE OF CRANE

Different types of cranes are deployed to lift various categories of loads. Some of them include: Single girder electrically operated/semielectric/hand-operated cranes Double girder electrically operated/semi electric/hand operated cranes

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Single or double girder cranes designed as gantry cranes or semi-gantry cranes Special cranes. The first two crane types are normally used for indoor applications, while the third type is normally used for outdoor applications. It must be understood that the lifting capacity and span do not play any role in selection of type, though it is believed that a single girder crane cannot be selected for capacities in excess of 10t.

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LOCATION

A crane could be located either outdoor or indoor or at times both. It is important for the buyer to specify this need appropriately. An outdoor duty crane has to be engineered considering wind forces, and therefore, specifying this aspect is important. It would help to optimally design the crane, if the buyer also specifies the geographical location (besides


OVERHEAD CRANES

simply specifying outdoor), so that the correct wind speeds are assumed while designing. Moreover, if the crane is operating in a coastal area, it might need epoxy painting instead of normal synthetic enamel paint. Specification might also be applicable for indoor duty cranes, especially those operating in acidic or alkaline atmosphere.

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SAFE WORKING LOAD

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CLASS OF DUTY

Safe working load is defined as the load that could be lifted under the crane hook. If the crane is intended to be used along with a magnet, ‘C’ hook, grab, ladle or any other appliance; the dead weight of such appliance should be specified, so that the safe working load of the crane would be determined appropriately. Never build-in factors of safety over and above what has been specified earlier, since this would result in over engineering of the crane leading to added costs.

Cranes are classified from M1 to M8 depending upon their usage pattern. Higher the class of duty, higher would be the cost. Crane mechanisms also differ based on the utilisation. It should be remembered that while the crane is available 24/7, no crane operates 24/7 at its rated load and speed. The class of duty essentially depends upon the application of the crane, usage frequency and pattern. Ideally, the buyer should provide a load spectrum. This would be too difficult, and hence, the class of duty should be arrived at, after explaining to the manufacturer of the crane its application in detail. Since the selection of the class of duty would not only determine the cost of the crane, but also affect all other points listed above, maximum attention should be paid to this aspect.

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SPEEDS

Selection of speeds is directly dependent on the crane’s usage and application. Increased speeds (where not required) would increase power rating of motors, increasing the cost of the crane as well as the owning and operating cost.

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CONTROL SYSTEM

A variety of control systems are possible such as pendant control from floor, fixed cabin control, movable cabin control, control through radio remote control, etc. Appropriate selection depends upon the application.

Selection parameters in a nutshell The type of crane required should be correctly determined The location must be specified, whether indoor or outdoor or both The safe working load selected should be appropriate The class of duty needs to be in conformity with the application The speeds must be apt for the application intended The control system should be in conformity with the application The hook and end approaches needs to be minimum to enable maximum utilisation of shop area The crane headroom has to be minimum, so as to reduce the shop height The hook headroom must be minimum, so as to increase the height of lift The wheel loads should be minimum, so that the gantry girder and column sizes are reduced to the minimum, saving building and foundation costs The down shop leads and LT rails have to be determined The owning and operating costs should be minimum.

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HOOK AND END APPROACHES

One cannot expect the hook to be in line with the column or reach up to the end of the shop in any crane. In other words, some loss of built-up area cannot be avoided. The appropriate approach would be to minimise this loss, so as to enable maximum utilisation of the built-up area. To ensure this, the mechanisms have to be designed optimally, and this would depend upon the class of duty selected. Since the class of duty is totally dependent upon the application, the buyer and the manufacturer should understand the application and usage pattern to the fullest.

8

CRANE HEADROOM

This is defined as the highest obstruction of the crane above the long travel rail top. Lower the dimension, lower could be the building height. A reduced building height would certainly reduce the building cost.

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HOOK HEADROOM

This is defined as the distance of the hook at its highest elevation, below the long travel rail top. This should be minimum to optimise the column height, so as to reduce the building cost. The sum of dimension six and seven would be constant for a given crane. Hence, if the

crane is to be installed in an existing shop, one could distribute this sum so as to optimise the usage of the shed.

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WHEEL LOADS

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DOWN SHOP LEADS AND LT RAILS

For a given crane, heavier the crane and the trolley, higher would be the wheel load. This has a direct impact on the gantry girder selection, column design and foundation. It is a misconception that a heavier crane is a stronger and safer crane. So long as the crane is engineered to satisfy all the clauses of the relevant IS specifications, the weight of the crane and trolley should not be the method of establishing the strength and safety of the crane. In fact, the buyer should opt for the lightest crane with the least wheel loads.

Down shop leads is the power supply system adopted to feed the crane with electrical power. There are several systems possible. The safest system is through shrouded busbars, since this provides maximum safety and does not affect end approaches at all. Bus bars have to be selected based on the connected load. If multiple cranes are proposed to be operated, the connected loads of all such cranes have to be considered while selecting the busbar rating. The buyer, therefore, has

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OVERHEAD CRANES

Any company that requires a cost-effective solution for material handling while saving precious workspace, should definitely consider overhead cranes. However, proper consultation and consideration should be done before making a purchase, as there are many options available. to provide this data. The same applies to LT rail selection too.

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OWNING AND OPERATING COSTS

A crane is invariably installed at an elevation of six or more metre above floor level. Hence, a crane involving minimum maintenance should be preferred. By providing leak proof gearboxes, lifelong lubricated bearings, appropriately selected wire rope and optimally selected electrics one can achieve this objective. Other factors that influence the cost of the crane are: Provision of full length platform on both girders Provision of hydraulic or spring buffers Provision of under bridge lighting Provision of closed, glazed and airconditioned cabin. It is important that the need for all the above-mentioned additional features is

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carefully evaluated. Once the specifications are finalised and frozen, vendor/s will have to be selected to obtain quotes. Here are a few important points to be considered when choosing the crane vendor: Experience including client list, number of years in business, number of cranes currently manufactured per year, technical tie-ups and collaboration, if any Existing design team and their experience Manufacturing facilities including handling capacity trained & experienced craftsmen and supervisors Sub-contractors and their technical capability In-house load testing facility, which should include test pit and calibrated test loads Surface treatment and painting facility, which should include shot blasting and dedicated paint booth Empowered and independent quality

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assurance team and their experience Welderâ&#x20AC;&#x2122;s testing and systematic periodic approval procedure and maintenance of records Stocks of critical items always maintained Dedicated erection and commissioning teams located at various locations Provision of annual maintenance contract (AMC) Dedicated after-sales and service team Availability of spares on a timely basis Adherence to safety and environmentfriendly manufacturing norms. Having selected the vendor/s with the above guidelines, the buyer can obtain technical and commercial quotes, evaluate and then place the order for the crane. Any company that requires a costeffective solution for material handling while saving precious workspace, should definitely consider overhead cranes. However, proper consultation and consideration should be done before making a purchase, as there are many options available. The chosen crane solution should truly be the best fit for oneâ&#x20AC;&#x2122;s business needs. S Raman, Head-Design, ElectroMech


INNOVATORS’ OUTLOOK

Western universities/research institutions in a number of technology areas. However, there are ways to resolve the problem areas. The measures that need to be taken include: Increasing the number of foreign investors, JVs, etc to gain good knowledge of international markets Improving the ease of doing business in India and removing all the bottlenecks encountered to attract foreign investors, JVs, etc. Investing in companies that have access to Western markets, knowing the customer expectations and requirements, besides acquiring relevant technologies Increasing trend scouting in Western countries Thinking out-of-the-box and defining stretch targets Aiming at market segments where customer demand is not sufficiently satisfied Combining Indian creativity with Western technologies Leveraging knowledge of welleducated, young Indian engineers, MBAs, etc and combining the knowledge pertaining to Western technologies/management practices/ markets with that of Indian technologies

DESIGN SUCCESS CAN BE ACHIEVED BY IDENTIFYING FEATURES THAT THE CUSTOMER VALUES “The perfect mix of superior technical properties and design newness will help create a winning design,” affirms Axel Schmidt, Partner & Head, Roland Berger’s Global Operations Strategy Competence Centre, during an interaction with Prerna Sharma. Excerpts…

E

VOLUTION OF INDUSTRIAL DESIGN IN INDIA

It must be the goal of every manufacturer to make the dream of ‘Designed in India’ on each and every product come true and work towards it. But this is not an easy task to achieve. The first priority should be to transfer the outstanding abilities in the field of software design to all other products. The best products are the ones that are able to conquer the world, and one instance of successful product in India is Tata Nano.

BARRIERS TO INNOVATION & WAYS TO OVERCOME THEM The companies aspiring to achieve design success are faced with a multitude of barriers. These include: Regional and cultural distance from world markets/Western customers, i.e. knowledge of customer requirements Technology gap/lack of access to hightech technology in a number of areas Lack of presence in Western markets (small marketshares, etc), e.g. with sales & service network/partners R&D infrastructure/universities, research institutions, etc, not yet on par with

and cultural strengths/ customer requirements/market specifics and so on.

INNOVATIVE CAPABILITIES OF INDIAN SMEs SMEs in India have huge potential to create innovative products and move towards global markets. The latest trends in design that can drive the growth of Indian SMEs are simple products for meeting growing demands of Indian and other emerging markets, for instance goods catering to the rapidly growing middle income population. Regionally adapted or best-suited products

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INNOVATORS’ OUTLOOK

for market segments, which are currently offered by international competitors without adaptation to specific market requirements, should be among the areas of focus. Design that is based on specific customer usage and different from world market standards in terms of performance, convenience, economic value, environmental, health and safety standards in India and other emerging markets needs to be developed. The product concepts must be based on adapted product characteristics, simple product architecture, modularisation with low number of variants and use of ‘industry kits’, high level of functional integration, installed cost-driven approach (manufacturing, assembly, logistics, etc.). In addition, product development should be based on low degree of vertical integration, use of lowcost engineering resources, strong front loading, lean engineering approach and there should be no duplication of work between OEMs and suppliers.

INGREDIENTS TO CREATE A SUCCESSFUL DESIGN Talking about industrial design, the perfect mix of superior technical properties (e.g. performance attributes) and design newness

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will help create a winning design. Other factors include differentiating product offerings from that of competitors, creating a new market niche and matching products with customer expectations, i.e. fulfilling the functional objectives of the customer in a better manner. Design success can be achieved by identifying features that the customer values and is willing to pay for. All these factors can provide a distinct advantage to companies.

INDUSTRIAL DESIGN IN INDIA Design in India is gaining pace slowly and steadily. The factor that would make India design hub of the world is globalisation of R&D. According to a recent study, depending on the nature or the industry, companies globalise based on key parameters such as technology access (e.g. pharmaceuticals industry) or market access (e.g. consumer goods, automotive suppliers, engineered products). Thus, for industries where technology is crucial, India needs to adopt state-of-the-art machineries. For industries where market access is crucial, India needs to convince global companies of the attractiveness of the Indian market

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and the need to design or customise its products locally at a competitive cost. This will be possible by creating awareness about the competitive advantage in India compared to other emerging/potential global R&D locations such as China, Eastern Europe, Brazil among others.

ADVENT OF MATERIALS IN DESIGN New materials enable the development of different forms and designs as well as functionalities. One example, I would like to refer, is the lightweight aspect pursued in the vehicle construction industry through the use of aluminium and plastic materials. Flexible designs would not have been possible with traditional materials.

DESIGN PHILOSOPHY TO SUCCESS Our design philosophy to success revolves around differentiating our products from that of competitors by way of superior technical properties (e.g. performance attributes) and design newness. Of course, this has to match with customers’ expectations and offer them what they need.


FACTORY AND PLANT EQUIPMENT

SIMULATING A NEW WORLD OF

DESIGN

From small job shops to giant super factories & processing plants to facilities throughout the supply chain use production equipment to turn raw materials into products. However, to survive in the global economy of the third millennium, manufacturers need to be inventive in terms of factory equipment and raw materials, as well as processes they develop. Using simulation-driven design tools can bring value and innovation to a wide range of product development applications.

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when production is halted. Energy efficiency is mandatory in lowering operating costs in the face of rising electricity utility prices. Noise emissions must be low to meet strict regulatory standards. Vibrations must be minimised to avoid fatigue failures and unwanted resonances in precision machines. In addition, equipment must be costsensitive; new models must be launched quickly to meet fierce global competition. Companies in the factory and plant equipment market regard engineering simulation as an indispensable tool in meeting these challenges. The simulation technology, in particular, is used by many of these firms in their product development cycle. A range of leading-edge solutions provides a breadth and depth of analysis capabilities including meshing of complex parts and assemblies, computational fluid dynamics (CFD), optimisation, structural and thermal tools, and a wide range of multiphysics solutions.

FACFACT T

imulation-driven design plays a major role in developing industrial machines for manufacturing and process facilities around the world. To keep up with the increasing demand for manufactured products, companies rely on factory equipment that include machine tools, injection-moulding equipment, robots, material handling equipment, stamping machines and other industrial machines. In the competitive drive to produce more with less, the increased speed and efficiency of todayâ&#x20AC;&#x2122;s technology-based equipment is credited as a major element in industrial productivity gains. According to the National Association of Manufacturers, the US productivity grew 4.8 per cent last year amounting to a 24 per cent increase during the past four years. So, in order to remain competitive, companies around the world invest heavily in the latest state-ofthe-art production equipment. On the flip side, industrial equipment buyers have a long list of demanding requirements. Machines must operate for decades under harsh conditions and often for multiple shifts, seven days a week. Downtime is unacceptable, since daily revenue losses can run into millions of dollars

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Worldwide, simulation technology plays a key role in making industrial equipment more productive in terms of machine capacity as well as operational speed.

BOOSTING MACHINE SPEED AND CAPACITY Worldwide, simulation technology plays a key role in making industrial equipment more productive in terms of machine capacity as well as operational speed. A technological research centre, for example, performed a coupled thermostructural analysis with simulation mechanical software in developing a new design for a steel-making ladle â&#x20AC;&#x201D; resulting in a 15 per cent more capacity for handling liquid metal. Likewise, metalworking equipment manufacturers use mechanical simulation in static, dynamic and thermal simulations of the metalworking equipment it develops, which includes transfer lines, machining centres, flexible manufacturing systems, and milling & broaching machines. Typical simulations include deformation of parts, modal analysis and frequency response of the machines together with tools and workpieces, structural temperature distribution and topology optimisation. Simulation also helps in the development of robots that are widely used in different industries.

ROBOT DEPLOYMENT According

to

the

Robotic

Industries


FAC T FACT

FACTORY AND PLANT EQUIPMENT

the rigidity and vibration behaviour of the system met customer demands of rapid testing movements, high dynamic precision and accurate synchronisation among multiple robots working together. Simulation is a powerful tool for better understanding the behaviour of complex industrial machines. With this insight, engineers can then more effectively optimise designs and develop innovative concepts.

swirling flow through the mill’s intricate geometry and the nature of media distribution, secondary flows and wear characteristics of parts. In this way, simulation has improved the understanding of mill behaviour for scaling up the design and enhancing mill operation. Adoption of simulation methods offer several benefits in terms of increasing efficiency, enhancing quality and enabling breakthrough innovations.

COMPLEX EQUIPMENT BEHAVIOUR

The structural analysis software is a core tool for the state-of-the-art development facilities of moulding industries that are into designing and manufacturing the most comprehensive range of injection-moulding equipment – machines, moulds, hot runners and robots – for the plastics industry. In developing these large injection-moulding machines, engineers face demanding design challenges. Machine weight must be minimised to keep manufacturing and transportation costs low. Operating speeds should be fast enough for required throughput of manufactured plastic parts. Reliability and precision needs to be maintained to provide satisfactory service with minimal downtime. Efficiency is a requirement to keep energy consumption low, and thus, minimise operating costs. Engineers met these challenges with simulation workbench and other relevant tools. The integrated solutions provided efficient contact representation for complex non-linear assembly analysis, additional preanalysis in construction and the benefit of common simulation methods in various types of analyses. Engineers report that analysis that formerly took a week can now be completed in just half a day. This level of increased analysis efficiency enables development teams to achieve better machine quality and greater innovation in products.

According to the World Machine Tool Output and Consumption Survey, Japan ranks number one in terms of world output of machine tools and second in usage of equipment. Meanwhile, figures from financial services firm JP Morgan specify that the rate of manufacturing expansion in the European sector is reaching a six-year high.

Association, nearly one million robots populate global manufacturing, with almost half of it working in Japan. Robots perform a wide range of production tasks including material handling, workpiece and tool positioning, arc & spot welding, packaging, and process applications such as inspection, testing, spraying and dispensing. Simulation is critical in developing these versatile machines for optimal speed, precision, lifting capacity and cost. A German-based company recently used simulation workbench tools to develop a six-axis robotic system for ultrasonic testing of helicopter parts up to six metres in length. The company reports that the ability to analyse the design throughout the development process Grinding mill enabled them to verify that

Some of leaders in engineering consulting firms use advanced analysis tools such as CFD for design evaluation, optimisation and problem-solving in which heat transfer, fluid flow, combustion and mass transfer are critical issues. Researchers use simulation CFX software in analysing a multiphase grinding mill that vigorously stirs incoming material together with solid grinding media using a series of high-speed rotating disks. The CFD analysis showed the complex multiphase

CASE IN POINT Adding Revenue By Shortening The Development Cycle Computer simulation enabled a leading engineering firm in the US to reduce the time needed to develop a new aggregate drying burner designed for use in asphalt plants from the normal 6 to 12 months to only 32 days. The burner is intended to remove moisture from rock, so that it will bind properly to cement in forming asphalt. Getting dryers to market as quickly as possible necessitated development of the burner in an extraordinarily short time. The design team used CFD technology, recently added to the simulation software solutions, to readily evaluate numerous virtual prototypes and quickly iterate to an optimised design. The primary concern was related to determining the best way of injecting fuel to obtain an optimal gas mixture. CFD saved considerable time by determining the flow and chemical concentrations early in design, providing far more information than would have been ever possible with physical experiments. In only two weeks, a working prototype was built; within a month, the design was optimised to meet stringent emission regulations. In this way, simulation drastically reduced time-to-market, thus providing up to a year of additional revenues while substantially bringing down engineering costs.

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BETTER QUALITY AND GREATER INNOVATION

Pierre Thieffry, Lead Product Manager, ANSYS Inc

SPOTLIGHT: NALCO Damanjodi Refinery

Refining With Excellence on pg.

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PROFIT MANTRA

Profitable growth is everyoneâ&#x20AC;&#x2122;s business. However, being caught up in the rat race to be the best, companies, globally, miss out on a few important, but simple things that could propel growth. Some of these crucial factors include vision, mission statement, core values, among others. By adopting such strategies, companies can chart out the roadmap to success. orldwide, the aim of all businesses is centered on growth and profitability. As with any initiative, growth is a comprehensive goal that requires several components to be implemented. In order to map out an appropriate strategy, it is critical to identify and understand the purpose for which a company was founded and whether it is structured to attain continuous profitable growth. In

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addition, it is pivotal to assess whether a company was established to offer a specific product/service or to meet an identified need in a niche market. The answers to these questions will enable to identify and understand an organisationâ&#x20AC;&#x2122;s targeted objectives. It can be observed that some companies that were established in the 1800s are still thriving today on the merit of efficient & solid planning. In addition, some of them, which were created to launch a new

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technology or service, were successfully acquired by another company and continued to build the brand. These success stories were achieved because of strong leaders, who were able to craft and implement a blueprint for success. First and foremost, what a company needs is a vision â&#x20AC;&#x201C; an idea (or concept) of where it would stand at maturity. The vision needs to be such that it can be communicated easily and understandably, makes a difference to marketplace and will


PROFIT MANTRA

guide an organisation through the good and bad times.

that describe how a firm operates. These should represent a comprehensive list, covering all aspects of business including product/service offerings, customer relationships, commitment to employees and company’s philosophy. Core values are

and share information on virtually anything at anytime. It is critical that a company is focussed on building and maintaining a VISION & MISSION strong reputation. The cornerstone of a The purpose of a vision is to provide a strong reputation is an unwavering roadmap for the company’s growth. No commitment to delivering quality products one would like to venture on a and services every time. There trip without having an idea of the The cornerstone of a strong reputation is an unwavering can be a fine line between destination. It is the same concept investing too much in building a commitment to delivering quality products and services quality product or service that with regard to businesses too, if every time. one doesn’t have a completion will be obsolete in a few years target (or goal) it would be and keeping costs under difficult to gauge how, when and where to like the reflectors along the highway. Those control, so that the organisation can make grow one’s business, chalk out the best reflectors are there to warn people regarding profit. The key is to find that balance expansion plan, etc. Without the answers where the ditch or embankment begins, between building a quality product and to these vital questions, one could get lucky ideally giving them time to move away from delivering a quality service that everyone in and realise the company’s targeted growth, danger and get back on the road. Core the organisation is proud of and willing to but it would be achieved at a high cost, with values have the same function in that they support. several detours or derailments. are there to guide an organisation’s growth INNOVATION The key to keep the growth on track is profitably and ethically. One of the key factors impacting a to have a visionary vision. A vision is TWO-TIERED STRATEGIC company’s growth is the ability to innovate something that will project a company’s PLAN quickly. However, care needs to be taken future 100 to 150 years from the time of its If a company aims at becoming ‘the biggest, that innovations are not done just for the establishment. If it is designed to project the best, number one in marketplace, the sake of being perceived as an innovative growth during the next five years, it cannot most recognised, and/or the most company. be termed as a visionary vision. If the vision profitable’, then its leaders should identify True innovation delivers value and a revolves around being number one, the four or five yearly corporate goals. Once measurable improvement in product/ most recognised and the fastest growing or these goals are identified, then the strategy service offerings and upgrades. To be an the most profitable company – it doesn’t can be created that will help achieve the innovative organisation, it is essential to qualify as a visionary vision. A vision should describe what product/ objectives. reach out and communicate with one’s service a company offers that would have a The corporate strategy should be a twocustomers, vendors and suppliers. It is vital measurable impact on the world. One might tiered plan, focussed on both the shortto find out if any new benefit or feature is think that his/her company’s product/service term (1-3 years) and the long-term (3-5 or desired in the marketplace, and strive to offerings are best managed locally or 10 years) plan. The plan needs to identify bring that product/service to reality. There regionally, but in this day of globalisation and the market segments the firm is involved in have been a myriad of companies that technology, even localised products/services and provide options (flexibility) for ‘thought too far out-of-the-box’ with their have (or will have) an impact on everyone. adjustments to the ever-changing economy. innovation and were unable to establish a Hence, it is important to make sure that the It acts as a roadmap to achieve the competitive presence for their products/ vision is a guiding light for the organisation to company’s vision, but there can be delays services. Continuous two-way move ahead successfully, enabling it to and/or changes in plans, so one should be communication with customers is critical for measure the value of the products/services prepared to deal with them. a successful innovation strategy. it provides to make the world a better place. QUALITY FOCUS ATTAINING CONSISTENT After vision comes the need for mission. GROWTH In this age of technology, anyone can find MISSION STATEMENT A strong, committed and focussed A company’s mission might best be drafted leadership willing to build a company that Steps to ensure profitable into one succinct mission statement and provides products/services offering the right growth should highlight ‘what a company does’. value and meeting customer expectations The mission statement simply tells everyone will drive the profits of a company. The Visionary vision involved with the organisation what the inclusion of vision, mission, core values, Descriptive mission statement company does and why it exists. The attention to quality, innovation among purpose is to keep everyone focussed on others into the priority list of an organisation Set of achievable core values the goals. Along with a vision and a succinct will ascertain that it will stay on the growth Two-tiered strategic plan mission statement, it is imperative that track. Commitment to quality every organisation has a set of core values.

CORE VALUES These values usually comprise 4-6 statements

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Ability to innovate successfully.

Janet Boulter, Business Advisor, Center Consulting Group E-mail: jboulter@centerconsultgroup.com


WORLD-CLASS MANUFACTURING

The ultimate goal of companies, be it large or small, is to become a world-class organisation and be able to compete in todayâ&#x20AC;&#x2122;s global markets. This is possible by adopting a few strategies such as reducing lead times, meeting customer expectations, cutting operation costs, to name a few. Being world-class is all about being as good as any competitor in the world, and just a little better, quicker, smarter, or more responsive than the rest.

UNL CKING THE POTENTIAL TO BE THE he keys to becoming a world-class manufacturer are not a secret. They are simply a distillation of the experiences of leading companies and how they have managed to excel in their chosen markets. Any company can take advantage of the wisdom and the practices developed in more than 100 years of manufacturing since the industrial revolution. But many simply do not have the insight or the will to recognise what must be done to accomplish it. It is a poor workman who blames his tools for shoddy work, but it is also true that professionals understand the value of good tools and insist on having and using the best whenever possible. When selecting a production machine, be it a machining centre, insertion machine, automated

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assembly line or robot, one would certainly look for something that can handle the given tasks and is flexible enough to adapt to additional products and uses that may arise in the future. This practice is even more important with a business solution because of the change in the way information is being handled and used for various purposes. And, it is essential to remember that information management is a fundamental support for each and every key to world-class performance. Some of the strategies to achieve manufacturing excellence are presented below.

REDUCE LEAD-TIMES Shorter lead-times are always beneficial. In many markets, the ability to deliver sooner will give a company an edge from its competitors. Quick delivery can justify a

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premium price and will certainly enhance customer satisfaction. In all cases, shorter lead-times increase flexibility and agility, reduce the need for inventory buffers and diminish obsolescence risk. Lead-times are cumulative and bi-directional â&#x20AC;&#x201C; that is, order handling, planning, procurement, inspection, manufacturing, picking, packing, and delivery all contribute to the lead-time. In addition, the time taken to get signals down the supply chain to initiate each activity adds to the overall time taken to get the job done. Inflexible business rules and policies can result in undesired effects. Purchasing rules focussed on unit cost lead to large quantity buys that result in high inventory and long lead-times. Ironically, this type of buying can also lead to shortages, since longer leadtimes mean that a manufacturer will be making and buying to a less accurate forecast.


WORLD-CLASS MANUFACTURING

The best combination of price and lead-time and customer relationship management received as much attention as it deserves; often comes from a stable buyer-supplier (CRM) have focussed more on top-line inventory cost, transportation, management collaborative relationship based on longbenefits – growing revenue – the bottom costs, electronic communications, and term contracts with deliveries according to a line is still greatly dependent on controlling storage account for a significant part of the forecast that is shared with the supplier and costs. Companies with a lower operational cost of doing business. Fortunately, updated frequently. The same is true on the cost structure enjoy an obvious advantage improving customer service can also customer side. Instead of focussing on in profitability, and the ability to adjust pricing generate cost benefits at the same time. securing large, one-time, single orders that to meet competitive pressures, if necessary, IMPROVE BUSINESS clog up the supply chain, companies must to maintain or gain marketshare. PERFORMANCE VISIBILITY focus on creating long-term contracts with Costs are really just a part of the Today’s fast-moving, ever-changing customers and sharing forecast information scoreboard. When a company implements manufacturing environment demands faster with them to reduce lead-times. world-class operational processes, it The same issues concerning large lot responsiveness to changes in the market, improves multiple measurements sizes also apply to internally produced parts product innovation and supply chain events. simultaneously, including cost, lead-times, and products. Large lots, driven by a focus In this environment, ignorance is one of the inventory and customer service. This on lowest unit cost, raise inventory and greatest threats to a manufacturing approach is superior to a pure cost reduction lengthen lead-times while reducing flexibility company’s health and success. Executives focus without associated business process and responsiveness, as well as increasing and senior managers must understand how change, which can negatively impact other eventual cost through premium the enterprise is meeting expediting. Instead of using large strategic objectives. Middle-level The ultimate goal of any business is pleasing the managers need visibility into fixed lots, companies must customers. The most successful companies don’t just how they are performing against dynamically adjust the lot size based on market demand, meet customer expectations, they exceed them and beat tactical objectives. Responsible product mix and capacity. the competition by setting the bar at a level that makes individuals must be notified Ongoing continuous immediately when supply chain it difficult, if not impossible, for others to surpass. improvement efforts focussed on issues threaten the completion reducing set-up times can help of objectives, so actions can be companies reduce lot sizes, which provides operational measurements. Localised cost taken to ensure customer delivery and flexibility in responding to market demand. reduction efforts can often increase costs in quality requirements. Appropriate measurements contribute other areas. Moving production overseas to A well-implemented and effective to high performance on the plant floor. Onan area with lower labour rates, for business solution delivers overall visibility time shipment and inventory turns are good example, will increase costs for into the health of the company and its examples of high-level measures that tie to procurement, transportation, inventory and operations, besides providing detailed company objectives. Focussing on isolated reduced flexibility, among others. information for performance measurement, measurements like equipment utilisation on The relative cost of source/make/deliver, process management, and problem non-constraining resources encourages and therefore, the opportunities for cost identification and remediation. ‘busy work’ that creates excess inventory reduction, will vary with the specific industry An enterprise business solution will and longer lead-times. and the kind of products the manufacturer literally capture thousands of pieces of Shop floor measurements must makes. Most manufactured products today information each day, as activities are encourage overall performance – shipping have relatively little direct labour content, reported throughout the enterprise. All of orders on time at minimal total cost and generally less than 20 per cent and often this detailed data is of little use without minimal total cycle times. Performing manual less than 10 per cent, whereas the material placing it in context and seeing each activity transactions often slows down the supply content of most products is more than onein relationship to all the other activities and chain and adds to lead-time. Reporting half the cost-of-goods sold (COGS). The the overall plan. To turn data into meaningful transactions at each operation or creating a rest is ‘overhead.’ Since most direct labour information is an up-and-down process. paper purchase order before suppliers work costs tend to be fixed, effective deployment Bits of data, taken together and summarised, on a component are just two examples. In of these resources can reduce unplanned form higher-level contextual information addition, manual transaction reporting often manufacturing overtime, premium and from such summaries, the observer introduces errors and impacts work expediting and outsourcing, as well as must be able to drill down to details to productivity. Companies must eliminate dramatically reduce cycle times. Since understand exactly what is happening and non-value added transactions and automate material cost is the dominant cost, significant how to drive those activities towards the transactions to speed up the supply chain. opportunities for reduction lie in analysing goals and objectives. For example, supplier purchase orders can current spending and devising effective Management information and analysis is be electronically sent or completely sourcing strategies for materials. Overhead only as good as the data it is based on. eliminated using supplier relationship reduction is always a fertile area for bringing Therefore, data must be collected as quickly management (SRM) solutions. down costs by using automation to as possible and with the least amount of streamline the procurement, manufacturing human intervention, which tends to CUT OPERATION COSTS and customer management processes. introduce delays and errors. It is equally Although recent developments in planning Additionally, fulfillment costs have not important to collect data from supply chain

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WORLD-CLASS MANUFACTURING

partners through automation as much as possible. Electronic data interchange (EDI) is the most commonly used method today, but it is rapidly being replaced by XMLbased e-commerce communications and Web-based portal technologies. All systems should be integrated, so that information can pass freely between them without manual re-entry. Many manufacturers are left with ‘islands of automation’ after implementation of specialised information systems in isolated portions of the business over the years. While each contains valuable information, absence of integration prevents the effective use of that information for overall management and co-ordination of effort towards company objectives.

products quickly to market has become more crucial than ever. Customers are quick to compare and switch vendors. The Internet empowers buyers by providing fingertip access to many more suppliers around the globe; they can even customise products over the Internet without having to ask an engineer to quote their specific requirements. These capabilities impact behaviours and expectations, and success in today’s markets can only be achieved through innovation, agility and aggressive marketing.

products, high quality, the right price and superior customer service.

STREAMLINE OUTSOURCING PROCESSES

Outsourcing of manufacturing operations is a common practice today because it offers flexibility – the ability to change products or processes rapidly – and can often save money by exploiting economies of scale or other favourable cost factors offered by the contractor. There are two approaches to outsourcing: a single process step or group of steps may be performed by an outside EXCEED CUSTOMER resource (heat treating, for example, or EXPECTATIONS electroplating) or the entire manufacturing The ultimate goal of any business is pleasing process might be contracted to a third party. the customers. The most successful In either case, the manufacturer relieves companies don’t just meet customer demand on its own plants and can SPEED TIME-TO-MARKET expectations, they exceed them and beat concentrate on its core competencies – Developing and introducing new products the competition by setting the bar at a level which might not include volume and services is vital to most manufacturing that makes it difficult, if not impossible, for manufacturing – while its partner(s) provide companies. Good ideas are not enough; others to surpass. Successful manufacturers the resources for producing products. Depending on the current resources and well-managed processes for bringing new manage the entire customer relationship – circumstances, outsourcing a part of the products to market can lead to significant from prospect to post-sales service and manufacturing process could save a company competitive advantages. Those activities, support – involving the entire organisation from having to expand its however, represent a significant risk that can either lead to missed Today’s fast-moving, ever-changing manufacturing manufacturing space (perhaps opportunities or huge financial environment demands faster responsiveness to even adding a new plant), searching for and hiring losses. In addition to new changes in the market, product innovation and supply experienced resources, training product development, the same chain events. the new recruits and paying processes and resources are various expenses involved in applied to product in a customer focus. Whether or not they ramping up a new production line or improvements, corrections and variations have direct contact with customers, process. Capital assets can become a liability throughout the product lifecycle. Based on contributors must keep the customers’ in a fast-changing marketplace. As customer market research, products are often subject needs in mind as they plan and carry out demands and technologies change the to frequent engineering changes due to day-to-day operations. nature and make-up of products, it can be customer requests, technological Manufacturers must truly understand the an advantage to not get tied to a relatively advancements, regulatory concerns or customers’ goals and objectives. Products inflexible physical plant. The fastest and competitive pressures. and services must strive to support the easiest way to achieve manufacturing Changes and improvements are easiest customers’ vision. Communication is excellence is through partnerships with to make – which are least costly and important; neglect is the number one reason companies that have attained superior disruptive – earlier in the process. It is a that customers terminate a relationship. The capabilities in particular phases of the process good business practice to collaborate with key is to give customers access to all – like production. By partnering with worldall operational areas of the business while appropriate information required to manage class contract manufacturers, one can reap the products and processes are still being customer relationship – the Web is an ally in the benefits almost immediately – welldesigned. Co-operation should be focussed achieving this objective. managed processes, high quality, on-time on the following areas: making sure that the As most companies have painfully learnt deliveries – and increase performance and new product meets market needs in recent years, customers often change expectations. At the same time, a firm can (marketing and sales), it is priced to sell and their mind. To be fair, market conditions are focus on its own resources and capabilities generate a profit (marketing and accounting), such that product cycles and demand – product innovation, design, marketing, it can be manufactured efficiently patterns are constantly changing. Agility is distribution, sales or manufacturing. (production, production engineering, extremely important. A solid, collaborative quality, purchasing and key suppliers), and MANAGE THE GLOBAL partnership with customers will provide the that the product can be maintained and ENTERPRISE most reliable advanced information, and serviced (service) with ease. The world in which we do business is therefore, the earliest warning on upcoming With increasing customer expectations shrinking, and virtually every enterprise is changes. A company should strive to be the and competition from new players around now involved in some form of international preferred supplier by offering competitive the world, bringing better and less expensive

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WORLD-CLASS MANUFACTURING

trade, whether marketing and selling to customers in other countries, or simply using parts or materials that are produced elsewhere. The Internet is, to a large extent, responsible for opening markets to products and services almost without limitations of time and distance. The ‘glass-is-half-full’ crowd will view these developments as the onset of unlimited opportunity, while the half-empty-glass crowd will see significant threats in virtually unlimited competition from literally any place on earth. Like it or not, every executive must recognise this new reality and factor in global business into plans, processes and strategies. He/she must design products to appeal to international markets; search for suppliers in other geographies; understand local regulations and expectations, import/export processes and requirements. Moreover, it is necessary to address language challenges in labelling, documentation and marketing, besides establishing new sales channels or co-ordinate manufacturing operations across geographies and time zones. The Internet is a key tool for joining the global business community and conducting business around the globe. Globalisation and Web commerce have changed traditional business behaviours and practices. If manufacturers don’t expand into new geographic markets, their marketshare is likely to shrink as new competitors will enter their territory and target their loyal customers. Companies must adapt their products and services to new potential customers. They must leverage the Internet to quickly establish a virtual presence. They must use collaborative technology in order to respond to customer’s requirements better and faster. Manufacturers often grow and enter new markets by acquiring or merging with other companies. This usually means, however, that different facilities within the newly merged enterprise are using several applications on different hardware platforms, applying different part numbers for the same items and using different operating procedures. The challenge is to bring as much uniformity to the varied facilities as practical without destroying the uniqueness and competitive edge that the individual units had before the merger. The new divisions need to communicate, exchange many kinds of data (product information, customers, suppliers, employees, etc), co-ordinate and synchronise logistics operations, provide visibility to materials and components requirements, optimise fixed assets utilisation across multiple facilities, consolidate financials and much more. A natural consequence of having operations scattered through multiple locations, whether around the world or in a specific region, is the need to gain visibility across all sites. Visibility can lead to more negotiating power for purchased parts, more efficient centralised credit and collections and accounts payable, and opportunities for improved customer service by gaining access to worldwide inventories and production capabilities.

MARKET WINNING PERFORMANCE The keys to world-class manufacturing dictate a requirement to deploy technological capabilities to improve manufacturing operations and processes. World-class manufacturers can choose their battles and compete on their own terms. They are in control of their own destiny and are seldom, if ever, blindsided by something they haven’t anticipated or cannot handle. Courtesy: Infor Global Solutions Technology GmbH

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HITECH MANUFACTURING SHOW

ENVISIONING THE

FUTURE

OF MANUFACTURING Mumbai | 17-19 Feb, 2011

Indian manufacturing sector has shown its calibre in toughest of times and performed consistently. But, merely depending on these achievements won’t suffice and if India has to live the dream of becoming a future factory for the global marketplace, then its manufacturing growth ought to be innovation-led and technology-driven. HiTech Manufacturing Show to be held in Mumbai on 17-19 February, 2011 at NSE, Goregaon, Mumbai is one such platform that will be the flag bearer for the futuristic manufacturing processes & practices. Here’s presenting you a window to gaze through the future of manufacturing technology…

SHIBANI GHARAT veryone wants a glimpse of the future, to know what it withholds, to witness growth, prosperity and ultimately accomplishing the goals. Same theory holds true for the manufacturing sector. The blooming manufacturing environment in India today desires as well as deserves a promising future.

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INDIAN MANUFACTURING COMING OF AGE India is fast emerging as a global manufacturing hub with huge amount of investments spanning across industry verticals. India is no longer merely ‘a sweat shop’ or ‘cheap labour market’ but is fast positioning itself as innovation and technology driven manufacturing hub. Indian companies are fast developing increasingly sophisticated manufacturing technology to match global standards. But, in order to achieve a world-class stature, the industry needs to inculcate selfsustainable habits with minimal pollution levels, maximum recycling, optimised energy supplies and efficient infrastructure along with being responsible towards society. There is a need for a collaborative effort in this direction from various industry verticals in order to accomplish a common goal. For the first time in India, there is an event that promises to deliver future solutions for the complete manufacturing & engineering industry. With HiTech Manufacturing Show (HMS) as a backdrop for the entire value chain, the show also has HiTech Material Handling and HiTech Automation as concurrent shows to

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compliment the growth process and future of the industry. It intends to bring the entire manufacturing and engineering industry under one roof to provide a conducive environment for sharing ideas, smart strategies and pooling strengths for a better manufacturing future. HiTech Manufacturing Show, a Network 18 event, is a dedicated platform for initiatives like sustainability, design innovation, green manufacturing and automation that will be driver growth in the years to come.

SUSTAINABLE MANUFACTURING Sustainable manufacturing is a practice that spreads out across a company’s processes into the social and natural environments that it operates in and affects, with an overt objective of reducing or eliminating any negative impact, while pursuing the desired level of technological and economic performance. Inculcating sustainable practices in the manufacturing process will not just help the individual company but also the industry as a whole. At HMS, the industry will converge to embark on sustainability in day-to-day manufacturing.

AUTOMATION DRIVEN PRODUCTIVITY Need for automation in manufacturing process is increasing by the day. “Automation will play a crucial role in helping manufacturing companies achieve economies of scale, global competitiveness, and meet stringent quality/safety standards,” says R Narayanan, Head - Discrete Automation and Motion Division, ABB India. Today, industrial automation is considered to be a step

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beyond mechanisation. A concurrent show on automation at HiTech will do justice to this aspect of manufacturing that will have a lion’s share in manufacturing in the future.

DESIGNING A GROWTH MAP A cutting edge design can effortlessly give companies an edge over their competitors. It is a strategic activity in many organisations as innovative products contribute significantly to the sales revenue. Keeping this in mind, the event will have a specialised ‘Design Zone’ where a visitor can design his product with the help of design software on display.

GREEN MANUFACTURING: LEADING THE WAY FORWARD The most important goal of green manufacturing remains the same – designing, manufacturing and delivering products that minimise negative effects on the environment through their production, use, and disposal. At the show, a committed platform ‘Green Zone’ will help the industry come together and discuss their green initiatives by way of seminar and interactive sessions. These factors will not only aid individual organisations but the entire manufacturing industry and help pave way for a luminous manufacturing outlook. “Integrating futuristic processes across the manufacturing value chain will give Indian manufacturers an edge over their global competitors,” says Frank Khoshnoud, Sr VP & Head - Manufacturing, Retail & Distribution (MRD), Patni. With HiTech Manufacturing Show, India is finally set to give shape to its futuristic aspirations of smart manufacturing with an intention of achieving a leadership position globally.


STATOIL

PUMPING UP

PRODUCTION LEVELS Through

‘SMART’ TECHNOLOGIES

Modest recovery rates have been seen as a fact of life in mature oil and gas fields. But, Statoil – a leading player in the oil & gas segment in Norway – saw Norway’s economic reliance on petroleum production as an incentive to ‘rewrite the rules’ on production efficiency. It teamed with an industry consortium to combine advanced sensing technology with integrated operations to optimise the management of its oil & gas fields that will eventually yield huge revenues for the Norwegian economy. orway has a top ranking in the list of countries with the highest gross national income per capita, a key indicator of a nation’s standard of living. Underpinning Norway’s high standard of living are vast oil & gas reserves lying under its continental shelf, beneath the frigid waters of the North Sea. Norway’s oil resources are so abundant that the country ranks behind only Saudi Arabia in oil exports. With 25 per cent of its economic activity associated with the oil & gas industry, the fortunes of Norway’s economy have become closely entwined with the health of this industry. However, the oil & gas producers are faced with many challenges in their efforts to increase recovery rates and extract more out of the remaining 50 per cent that is left in the oil & gas bearing reservoirs of the North Sea.

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PROBLEM Statoil sought to offset the natural trend towards declining production levels and aimed at streamlining as well as improving operations. Compared with a worldwide average recovery rate of 35 per cent, it aimed at increasing its rate to 55 per cent for sub-sea platforms and 65 per cent for fixed platforms by incorporating new technologies into production processes. SOLUTION Statoil teamed with key industry players to create a new process framework that links advanced real-time sensing capabilities in the field to powerful, collaborative and analytical resources accessible across the enterprise. Together with other initiatives, the solution will contribute to Statoil’s efforts to increase the recovery rate of its existing oil & gas fields, thereby adding to its oil revenues.


STATOIL

In April 2006, the Norwegian Oil Industry Association (OLF) published a report stating that if the oil & gas companies on the Norwegian continental shelf were to quickly integrate their operations by advanced use of information and communication technology, they could increase their revenues by $41.5 billion. If they fail to do so, they would risk losing $10 billion in potential revenue within the next three years, the report said. These rather dramatic figures have caused the entire industry to consider new measures to integrate operations and reverse the decline in North Sea production rates and extend the lifespan of its existing oil & gas fields. As one of the largest producers accounting for 60 per cent of Norwegian oil & gas production, Statoil has been a key catalyst for this change.

TAKING CONTROL To address the challenges stated in the report, Statoil initiated the TAIL-Integrated Operations (TAIL IO) project with key industry partners IBM, ABB, SKF and Aker Kværner to identify methods, technologies and work processes for integrating its operations. As the name implies, TAIL IO aimed at improving operations in fields approaching the end of their lifetime. The widespread use of advanced information and communication technology was only part of the equation to reach the estimated potential. The implementation of new work processes based on real-time access to data, in addition to organisational changes of moving functions and personnel from costly offshore oil rigs to onshore locations, was equally important. Statoil and the consortium members have been contributing equally to the project in terms of resources and inputs. The company approached ABB, Aker Kværner and SKF for leveraging their extensive engineering and energy expertise, and IBM for its ability to apply innovative insights and open standard technology to drive efficiency improvements. A key part of IBM’s mission in this consortium was to bridge the gaps between different parts of Statoil’s operation, so that data and employee knowledge can be leveraged across all processes. For Statoil, having to operate with independent ‘islands’ of corporate knowledge has been more than just a metaphor, since its offshore platforms have

long operated independently of one another. This means that even though a group of platforms may be gathering subsurface data on the same underlying oil or gas field, they nonetheless have been unable to combine their information into a more comprehensive view of the field. To bridge this gap, IBM offered its WebSphere integration software with manufacturing domain adapters and an integration industrial-semantic model based on a linkage of key oil & gas standards to create a flexible information integration and interoperability framework. When implemented, this will allow Statoil to aggregate its collective knowledge across rigs and fields, thus creating a foundation for more informed decisions, optimised processes, and ultimately, higher production efficiency. Within this framework, IBM WebSphere Enterprise Service Bus is a standards-based integration broker within a service-oriented architecture environment – a crucial factor to enable the flow of information through the company’s IT

where and how much to pump. By combining information from all its production facilities, the company can gain a much more comprehensive view of the state of its oil fields, vastly improving its ability to optimise extraction activities. When the ability to visualise subsurface conditions in three dimensions was first introduced, it represented a major innovation in oil production. As embodied in the IBM solution, Statoil’s vision of smart field management pushes that notion even further by adding a fourth dimension – time. Getting data feeds from its sensors in realtime will provide the company with the means to make decisions for production optimisation on the spot, without having to wait for weeks or months to gather and synthesise information. This can make a crucial difference in maximising a field’s production yield. The solution’s framework for integrating information and business processes is also the key enabler of Statoil’s preventative maintenance strategy, which is designed to

Business Benefits Of TAIL IO Project Expected 5 per cent increase in oil & gas production through planned and improved maintenance processes Expected 30 per cent reduction in costs through the use of predictive maintenance practices Extension of oil field life and increase in production yield through ‘smart’ field management, enabled by real-time wireless sensing of subsurface oil field installations Lower costs and improved production efficiency through the consolidation of well monitoring and management into onshore facilities Increased interdisciplinary collaboration through improved information sharing. systems, regardless of its format, and make it accessible wherever it is needed the most.

DECISION-MAKING IN FOUR DIMENSIONS IBM provided Statoil with the key elements required to implement ‘smart’ field management practices. Using data from wireless sensors, which monitor subsurface conditions (such as pressure and temperature at different points in the field, as well as the movement of gas or oil deposits within the field), the solution can provide Statoil’s engineers with the information they need to know when,

identify potential maintenance issues before they become critical and cause shutdowns. Wireless sensing and telemetry technology combined with IBM Information Server software helps the company derive more value from the complex, heterogeneous information spread across its systems. The solution enables to gather information on asset conditions, such as the thickness of a pipe, from all its platforms and facilities. Algorithms developed by IBM Research will process this data to determine when proactive or ‘condition-based’ maintenance should be performed. For Statoil’s production engineers, IBM Research developed similar well-algorithms

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STATOIL

Furnishing with the key elements IBM provided Statoil with the key elements required to implement ‘smart’ field management practices. Using data from wireless sensors, which monitor subsurface conditions (such as the pressure and temperature at different points in the field, as well as the movement of gas or oil deposits within the field), the solution can provide Statoil’s engineers with the information they need to know when, where and how much to pump. By combining information from all its production facilities, the company can gain a much more comprehensive view of the state of its oil fields, vastly improving its ability to optimise extraction activities. that analyse the subsurface data gathered by sensors to provide the decision support needed to optimise field production.

COLLABORATING OFFSHORE AND ONSHORE While the IO initiative is in many ways all about bringing information and processes together, it is also about bringing them onshore. The combination of the harsh platform life, the steady aging of its workforce and the increasing challenge of keeping up the work continuity, threatened Statoil with a staffing crunch and, perhaps more importantly, the loss of valuable human capital as experienced workers retired. By leveraging the process integration enabled by IO as well as advanced wireless sensing and communications technology like RFID, the consortium is helping Statoil in migrating key processes from its platforms to its onshore facilities. By making its processes less location-dependent, Statoil will gain a whole new level of efficiency and flexibility in the way it deploys its personnel. In addition, by stemming the outflow of experienced workers, this new service paradigm will enable the company to preserve its valuable assets – its employees’ knowledge. Statoil expects the TAIL IO project to identify ways to increase its overall production by 5 per cent – an enormous margin in the realm of offshore oil & gas drilling. What is more, by enabling the proactive maintenance of its facilities, the company expects to reduce its operating and maintenance costs by 30 per cent. By moving from a scheduled maintenance process campaign to a proactive and preventative maintenance model, it aims at achieving a drastic reduction in shutdowns and their consequences such as expediting costs and long delays. This model will also help Statoil to optimise turnarounds and shutdowns across all assets. Adolfo Henriquez, Head, Statoil’s Integrated Operations, believes that IBM’s insights will play a critical role in the success of the IO project. “Few companies have the combination of technological expertise, leading-edge research and industry knowledge that IBM has displayed in its engagement,” says Henriquez. “Our efforts to bring more integration and collaboration to our production processes are critical to the future of the offshore industry. IBM has shown a strong commitment towards helping us achieve this goal,” he adds. Courtesy: IBM Corporation

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PROACTIVE MAINTENANCE

SURPASSING CONVENTIONAL TECHNIQUES Over a quarter of the total cost of finished goods can be attributed to maintenance problems, such as mechanical assembly failures. The key to prevent such failures and reduce the maintenance cost is through implementing proactive maintenance practices. Proactive maintenance is now recognised as the most important means of achieving savings unsurpassed by conventional maintenance techniques or reactive processes. aintenance-related issues typically contribute to more than 25 per cent of the total cost of finished goods in the manufacturing sector. Industry experts believe that just a two per cent reduction in this cost can equate to a 7.5 per cent gain in sales. Recent studies have shown that the majority of unplanned downtime is caused by mechanical assembly failure. Further, equipment analysis shows that fastener loosening, polytetrafluoroethylene (PTFE) tape fouling control valves, fitting leakage and spun bearings are some of the problem areas resulting in the need for equipment repair. In order to highlight these challenges and promote a shift from reactive maintenance methods, techniques and procedures to proactive methods, Loctite Maintenance Reliability Workshops were recently conducted. The workshops aimed at a series of practices that provide maintenance personnel with ways to increase the reliability of mechanical assemblies, minimise maintenance costs, and offer proactive solutions to prevent unplanned downtime. Moreover, various

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Proactive maintenance training programs are key to minimising downtime.

case studies were presented on the occasion to enlighten the participants about the significance of proactive maintenance in their shopfloor.

REDUCING DOWNTIME: A CASE-IN POINT A leading lumber and plywood manufacturer managed to save on manufacturing cost by adopting the proactive maintenance technique. Like in many cases, one of the major causes of unscheduled downtime was on account of mechanical failures such as fastener loosening. This manufacturer was experiencing ‘tap root’ (mechanical assemblies) that cause failures with their limit switch arms. Limit switches translate motion into switch actuation. The maintenance department found that the screws were loosening in the arms, which made them fall out or become misaligned. A maintenance person was assigned the task of tightening all the screws. This job took about 5-10 minutes per occurrence with two occurrences per shift. Each time the task was completed, the equipment was ‘tagged out’, tightened and brought back on line. In one year, it was found that over 91 hours had been spent on labour

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and downtime. The company implemented a proactive maintenance process as a response to the labour and downtime problem. In just two months, the maintenance personnel identified 29 ‘tap root’ (mechanical assemblies) that caused failures. If left uncorrected, these failures would have cost the company over $53,000. The maintenance personnel chose the appropriate thread-locker to rectify the limit switch situation. The thread-locker unitised the screws within the assembly and prevented them from getting loose. Since implementing this technique, the manufacturer could prevent 91 hours of downtime and labour costs in one year, which translated into a saving of over $57,000 on maintenance costs.

SOLVING AIR LEAKS Air leaks are among the biggest contributors to needless costs in any facility. A leak is more than a minor inconvenience and a costly drain on overall operating costs. A single leak in a plant’s air-line can siphon off as much as $8,286 every year. For instance, say a leak point resulted in a loss of 35.73 cubic metre per minute (cmm) of air at a


PROACTIVE MAINTENANCE

QUICK TAKE Proactive maintenance deploys various techniques to extend operating lives of machines. Root cause failure analysis, which determines the mechanisms and causes of machine failures, constitutes the major part of a proactive. The fundamental causes of such faults can thus be rectified, and the failure mechanisms can be gradually engineered out of each machinery installation.

line pressure of 100 psi. Figures similar to this compelled an automotive component manufacturer consider proactive maintenance for ways to decrease costs associated with air leakage. Through proactive maintenance process, state-of-the-art ultrasonic equipment was used to identify air leaks, including fittings, valves, flanges and hoses were tagged with a number, their location, severity and cost. The maintenance team was trained to remedy the fittings and avoid problem reoccurrence, which saved the company over $37,000 in air

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DEALING WITH CHALLENGES leaks per year. PROACTIVELY Apart from air leaks, oil leaks also pose Proactive maintenance has many advantages several challenges to manufacturers. A oneover the traditional reactive processes. It drop oil leak every 10 seconds results in enables to take 153 litre of fluid per year corrective actions aimed that must be recycled or at the sources of failure. disposed of. And if this It is designed to extend number is multiplied by the life of mechanical several leaks in the facility, machinery instead of it does not take long to making repairs when realise that hundreds of often nothing is broken; thousands of litre of oil is accommodating failure lost every year. Disposal as routine and normal; costs can range from Oil leak prevention with threadlocker and pre-empting crisis $500 to $1,000 per 208failure maintenance. litre drum. In addition, safety hazards exist when oil leaks onto the Rupesh Navthale, Senior Executive - Marketing, shop floor. Here is an instance wherein a Henkel Adhesives Technologies India paper mill resolved the problem of oil leak E-mail: Rupesh.Navthale@in.henkel.com through proactive maintenance.

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Projecting ‘A Promising

SHIBANI GHARAT

Pune is emerging as a preferred manufacturing hub owing to massive investments and lucrative projects that the region has attracted during the past one year. These projects have had a major impact on the local industry and have also played a pivotal role in changing the dynamics of the region. Assisting the trade & industry and keeping the growth spiral alive in Pune are trade shows like Engineering Expo that help the entire industry to converge effectively under one roof.

hat does General Motors, Mercedes Benz, Bajaj Auto, Volkswagen, Tata Motors, Apollo Tyres, Alpha Laval, Force Motors, Piaggio Vehicles, Bharat Forge, Mahindra & Mahindra, Kirloskar Oil Engines, ThyssenKrupp, TCS, Wipro, Patni, Honeywell, Whirlpool, Matsushita, LG have in common? Besides being colossal in their respective industry verticals, they all have a manufacturing facility in Pune. Pune, once known as the ‘Oxford of the East,’ is growing strength by strength to become the ‘Detroit of the East.’ From educational institutions to foreign institutional as well as direct investments, the city has a new face and identity today. Presently, almost every foreign company wants to be a part of Pune’s flourishing manufacturing belt.

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PUNE, AN INVESTMENT HUB The city has been a favourite destination for several MNCs since time immemorial. It has a vast pool of engineering and management talent. Its propinquity to Mumbai, favourable climate and a cosmopolitan culture have contributed to the growth of this city. Moreover, the opportunities that Pune offers in infrastructure and its allied sectors are tremendous. Besides, the distribution of SME clusters in Pune follows a logical pattern of proximity to industries. During the last few years, this region has

seen a plethora of gigantic investments. In the local populace. They set up their the last year alone, three massive new plants manufacturing units in various industry owned by General Motors, Volkswagen and clusters like automobile, auto components, Mahindra & Mahindra were inaugurated engineering and machining, electronics, here. The new projects include Fiat-Tata joint venture at Ranjangaon with Vibrant competition has helped in a proposed investment of increasing competitiveness, spur `4,000 crore, GM’s `1,400 crore investment with a innovation and boost efficiency. further `900 crore expansion, Volkswagen’s Mangesh Agarwal, GM, CFFI India project of `3,800 crore, Mercedes’ `250 crore investment and Mahindra & Mahindra planning a huge `5,00,00 crore plastic and rubber components, etc, located investment by 2012. Bajaj Auto proposes in satellite towns of Ranjangaon, Pimpri`300 crore investment in two- & threeChinchwad and Talegaon. wheelers and a further `1,000 crore SMEs GAINING MOMENTUM investment in a car plant. In January, Pune SME clusters are the ones that have automotive component manufacturer ZF benefited the maximum from these India inaugurated a manufacturing facility in investments. Apart from economic gains, Pune. In April 2010, China-based SANY these big manufacturers have helped the Group, a leading global major in construction industry by bringing in latest technologies, machinery industry, inaugurated its first technical knowledge and efficient manufacturing facility at Chakan, near Pune. management system to the region. These companies usually zero in on “There is a dramatic impact on Pune component manufacturers for technology upgradation in the region over localisation of their products to suit the the past few years. Companies like Indian conditions. From engines to raw Volkswagen apply the latest manufacturing materials, hydraulic parts, auto components, technology in their units. They demand material handling and storage equipment, products that are compatible with their everything is local. This has helped the technology. This has resulted in an increasing industry at Pune massively with generation demand among the local companies to of significant employment opportunities for


Pune | 19-22 Nov, 2010 Engineering Expo, organised by Infomedia 18, is one of the engineering industry’s biggest events in the country. The 2009-10 edition of Engineering Expo saw business transactions worth over Rs 150 crore. Launched in Ahmedabad in the year 2002, the event today boasts of a fabulous visitor turnout. The Expo is a preferred destination for SMEs and manufacturing & engineering companies to transact, network, tie up, and exchange ideas for the growth of the industry. The Engineering Expo 2010-11 is scheduled to take place in four cities, starting off at Pune in November 2010 and proceeding to Ahmedabad, Indore and Chennai in subsequent months.

match the quality and technology standards of these big organisations. They have started accepting automation in a big way,” says Milan Supanekar, Director, Welding Technologies India. SMEs have some inherent advantages as compared to large enterprises in terms of greater flexibility in operations for responding efficiently to changing customer needs. Vibrant competition among the local companies to attract the attention of big companies is now being seen in this region. “This competition has helped in increasing competitiveness, spur innovation and boost efficiency,” says Mangesh Agarwal, GM CFFI India, Durr Ecoclean. He believes that there is a notable change in the quality of the products, especially after the big manufacturers have turned their attention to Pune.

SURVIVING IN A COMPETITIVE SET-UP The SMEs in Pune operate in a dynamic

There is a dramatic impact on technology upgradation in the region over the past few years. Companies like Volkswagen apply the latest manufacturing technology in their units. They demand products that are compatible with their technology. This has resulted in an increasing demand among the local companies to match the quality and technology standards of these big organisations. Milan Supanekar, Director, Welding Technologies India business environment where growth has become a necessary objective for the survival and viability of the enterprises. The challenge for any company in a competitive set-up is to remain competitive and consistently deliver value to customers. “It is also necessary for a manufacturer to deliver proper post-sales services and back-up support,” opines Supanekar. One of the strategies these companies can implement to remain competitive and deliver customer value despite their smallscale of operations is by way of promoting their products and services. Jagdish Gajjar, Manager – Operations, J K Automation, explains, “Spreading awareness about your products and services will surely help your organisation in getting that extra edge over your competitors. Word of mouth publicity is not enough.” There are several channels for promoting one’s organisation and products. Creating product presentations and catalogues, advertising in B2B publications are some of the tried and tested methods to spread product awareness. “We offer in-house seminars with references and case studies; we also get our prospective clients to come and visit our plants,” says Agarwal. But there is a common point of agreement that the most efficient way of spreading awareness about products and services is by participating in exhibitions. Exhibitions and trade shows have been used as an effective marketing medium to find new customers, improve business relationships with existing customers, introduce new products and services, and deliver many other meaningful and tangible business outcomes.

AN IDEAL PLATFORM TO SHOWCASE BUSINESS Engineering Expo is a complete manufacturing & engineering trade fair to

display one’s products and services. It is one of the most preferred platforms to grow business, as selected by 1000+ companies that participated in the previous editions of the Expo. More than 55,000 industrial buyers benefit from Engineering Expo, every year. Over the years, it has become one of the most lucrative platform for business growth. “Engineering Expo has helped us in spreading awareness about the products that we offer,” points out Anand Rajadhayaksha, Manager-Advertising, Nilkamal. “Every year, we introduce new designs and sizes of material handling crates & bins to suit diverse applications in various industries like automobiles, pharmaceuticals, engineering, electricals & electronics, hospitality & catering, logistics, textiles, supermarkets, retail, food & beverages, agriculture & seafood, etc. Expo brings all the industry verticals together under one roof, making it easy for us to market our products effectively to various organisations,” he added. Seconding Rajadhayaksha’s point, Supanekar states, “Participating in the Expo has helped to create awareness about our five-year old company. Moreover, we were able to acquire bulk purchase orders in the past,” says Supanekar, whose company supplies almost 90 per cent of their materials to JCB. With the flourishing industrial environment, the opportunities for businesses are budding in Pune. Efforts in the right direction will help the domestic industry in Pune to amalgamate with the global market and be a driving force for the industrial growth of Maharashtra, and hence, India. Initiatives like Engineering Expo will prove to be principal platforms for this thriving industry to grow to limits beyond measure.


DATA ANALYSIS

DRIVING

BUSINESS PERFORMANCE

THROUGH

VISIBILITY The advantages of business analytics are many for both big and small firms. However, to derive the maximum benefit, small and medium enterprises need to reevaluate their approach or even design a new one to create knowledge that can drive business performance by enhancing visibility. SMEs can optimise operations on a daily basis, and make strategic decisions for pursuing business profitably by gaining visibility through proper use of data.

hen Albert Einstein said, ‘Information is not knowledge’, he could have been referring directly to the challenge that small and medium enterprises (SMEs) face while transforming data into insights that can drive improvements in strategy and operations. SMEs are better positioned than ever to collect and analyse data. The real imperative, however, is to develop visibility into how their businesses operate, enabling employees and executives to react quickly to market changes and shift strategies as new opportunities emerge. Certainly, any discussion of business analytics may at first seem irrelevant to SMEs, many of which operate without large databases or high-end information technology (IT) resources. Moreover, data management and analysis can be daunting even for firms that deploy the most sophisticated technology and management practices. Practically, though, SMEs are just as able as larger companies in deriving the

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benefits of business analytics. But it will probably require them to re-evaluate their approach – or design a new one – to create knowledge that can drive business performance. Indeed, SMEs require such visibility and insights to achieve sustainable growth and profitability. Strategically, they must be able to break down their business and identify relevant areas (e.g., customer segments, supply chain activities, revenue streams, partnerships) to find out at what stage of evolution they are in. Operationally, by looking at individual revenue sources, customers, products or services, delivery channels and supply chain links, they need to ascertain the activities that are most profitable and have the greatest potential. Moreover, they can combine these insights and spot warning signals from daily operations that have long-term strategic implications – for instance, a near-term concentration of receivables that would suggest when longer-term business diversification is advisable.

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TOOLS FOR ATTAINING VISIBILITY According to a recent survey by the Economist Intelligence Unit, SMEs recognise that unstructured data can be counterproductive. Fifty-one per cent of the survey respondents said that they have to spend valuable time searching for key information among unstructured sources. However, one-third of respondents said that they have ready access to the information they need to complete their tasks. SMEs need to formalise their approach to assemble, store and analyse data in a systematic and relevant manner so as to gain visibility into specific aspects of their business that are most relevant to meeting business goals and strategy (even though visibility may drive a shift in that strategy). For SMEs, technology is increasingly becoming affordable, thanks to the rising number of off-the-shelf and customisable business intelligence applications available to fit a variety of scales, budgets and capabilities. Pre-configured servers and software are available, with ‘plug-and-play’


DATA ANALYSIS

options that enable SMEs to adopt solutions that incorporate available data from a variety of sources, if necessary. SMEs lacking historical data can opt to set up their systems and populate them with data as it arrives. Subsequently, these data can be warehoused, integrated and analysed.

VISIBILITY CAN DRIVE PROFITABILITY The key, of course, is to utilise the analytics in a manner that can drive business results – by reaffirming or changing the way in which operations function on a daily basis and by driving longer-term strategic decisions. The tangible benefits of visibility depend on the SME, but the applications are considerable, irrespective of the type, scale, business focus or profile of the SME. Following are a number of potential benefits to be taken into account: Greater customer-centricity: By gathering information about products that sell best in specific locations, SMEs can make more customer-centric decisions about everything from marketing campaigns to staffing and inventory. When such data is linked with information-sharing systems, it can also help employees to add qualitative insights – for

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instance, sharing tips on the type of selling behaviours that have been shown to drive a customer to complete a given transaction. SMEs can also acquire quantitative insights into factors that drive customers to be loyal, or to any defect that prevent a customer from buying a product. Moreover, they can also find out which customer segments are profitable and those that destroy value. All this information provides the right ammunition for any SME trying to optimise its business focus and resources. A more responsive supply chain: Information gathering and sharing systems can also be established to provide visibility directly to supply chain partners. Such systems [part of a segment often known as collaborative planning, forecasting and replenishment (CPFR) tools] provide suppliers, for example, with real-time point-of-sale data, so they can track customer demand and immediately restock depleting inventories. Business-driven financial accounting: All SMEs produce basic ‘books’ or year-end accounts. However, they need to maintain accounts that provide thorough and timely visibility into profit-and-loss streams, cash flows, debtor and creditor positions among other statistics. This visibility can help them

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control cash flow more effectively, and optimise working capital and other resources, as well as help in containing costs. In fact, visibility may enable an SME to avoid or reduce external fund-raising. Although, if fund-raising is necessary, datadriven management accounts will also provide a clear picture of whether the SME is a good risk for financers (whether the SME is approaching a traditional bank, a micro-lender, peer-to-peer lender, or a vendor) or for potential strategic partners.

A STRATEGIC APPROACH SMEs are less likely than larger companies to have in-house systems that automatically gather, house and analyse data. But SMEs can still ‘mine’ their data to obtain visibility into their business. Admittedly, SMEs will need a strategic approach, and a workable IT solution, to produce the type of business intelligence that will actually drive enhanced performance. But once established, the resulting visibility can help SMEs optimise operations on a day-to-day basis, and make longer-term strategic decisions about the way to pursue their business profitably. Courtesy: Economist Intelligence Unit


INDIA ENERGY 2010 & INDIA NUCLEAR ENERGY 2010

AIMING FOR

‘POWER’FUL FUTURE 7-9 October, 2010 Bombay Exhibition Centre, Mumbai

With environment conservation taking the centre stage these days, Indian companies are now turning towards alternative and abundant sources of clean energy. As a mandate, energy conservation and efficient new technologies are the need of the hour for the power sector to grow. To tap this potential market, UBM India with SEARCH as its media partner, is organising its 2nd edition of India Energy 2010 & India Nuclear Energy 2010 from October 7-9, 2010, at the Bombay Exhibition Centre, Mumbai. A preview…

wing to factors such as France, Russia, the US, Finland, and providing a global platform for showcasing population growth and individual companies from other countries. cutting-edge technologies, raw material & rapid economic component supplying companies. The A UNIQUE PROPOSITION development, India’s format of the event has been designed to India Energy 2010 supported by the Ministry energy consumption has offer networking and business opportunities of Power, Government of India, and Ministry been increasing at one of and provide an interactive platform for of New and Renewable Energy, the fastest rates in the world. This can be equipment, technology suppliers and endGovernment of India, will be a holistic gauged from the fact that commercial users. The exhibition and the concurrent event covering the entire gamut of the primary energy consumption in India has summit will serve as an excellent networking energy sector. The event has participation grown by about 700 per cent in the last four platform for the exhibitors, visitors and from leading corporates and PSUs from the decades. Also, the per capita consumption delegates. The technical summit will be energy & power sector, making this a in India is around 400 KWH per annum. conducted by experts from India and premium networking event for the energy Therefore, due to the rising population, overseas in select areas of the nuclear sector in India. expanding economy and a quest for industry and they will also present case India Nuclear Energy 2010 is coimproved quality of life, energy usage in studies, which would be topical and relevant partnered and endorsed by the Department India is bound to grow at an exponential to nuclear professionals and the end-user of Atomic Energy, Government of India. In rate. industries. the backdrop of recent agreements Despite the overall increase in energy between India and various other countries demand, per capita energy consumption in EVENT HIGHLIGHTS and international bodies like IAEA and the India is still very low compared to other Hon’ble Union Minister of Power, NSG, this is the right event at the right time developing countries. Today, India has one Government of India, Sushil Kumar Shinde, for India. It provides an opportunity for of the strongest potentials for the effective will visit the exhibition and conference on domestic & international companies to avail use of renewable energy. It is the world’s October 8. Dr Srikumar Banerjee, of the huge untapped potential that the fifth-largest producer of wind power after Chairman, Atomic Energy Commission, is nuclear industry has in India. countries like Denmark, Germany, Spain the keynote speaker for the concurrent India Nuclear Energy is the only event of and the US. There is a significant potential in India Nuclear Energy Summit 2010. The its kind in India on nuclear sector. It offers India for generation of power from event has been able to attract participation advantages to the companies visiting and renewable energy sources, be it any from leading companies like Alstom, Areva, exhibiting their latest offerings. It provides a renewable source of energy, viz, hydro, Power Grid Corporation of India, BHEL, comprehensive platform for qualified buyers biomass or solar energy. Looking at the immense potential for NHPC, REC, Schneider Electric, Wartsila, and sellers from the global nuclear fraternity growth in the renewable energy market, Ingersoll Rand, GMR Group, JSW Energy, to find new customers and suppliers and UBM India is organising its 2nd edition of Rolls Royce, and many more. The event evaluate the Indian nuclear market. India Energy 2010 & India Nuclear Energy has also received excellent response from India Nuclear Energy Summit 2010 will 2010, a three-day international exhibition overseas with country pavilions from provide a global platform, which addresses on energy & power and key issues, identifies nuclear energy. This event opportunities and challenges, India Energy 2010 Highlights will be held from October captures learning and best 7-9 at the Bombay practices from global success It brings together the world’s diverse energy fraternity Exhibition Centre, Mumbai. stories and focusses on It offers the best networking and business opportunities India Nuclear Energy strategies for the sector, as it Designed to attract top-level management, production, Summit, a one day prepares to meet new utility, R&D and sourcing professionals Conference will take place challenges and moves towards on October 8, 2010. This competitive efficiency in the Great place to meet potential manufacturers and suppliers. annual exhibition aims at sector.

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MINING This section gives information about products, equipment and services available in the market. If you know what you want. . . refer to Product Index on Page 262 to find it quickly

MINING PRODUCTS adhika Industries (Diamond) manufactures and offers mining products, such as inner sleeve of beads & shanks, crimp locks, diamond wire springs, joint accessories, crimping machines, etc. Inner sleeves are widely used in various industries. These are available in different shapes and dimensions that suit industry’s requirements. Usually positioned every three diamond bead crimps are made in special annealed steel in order to squash without break protected by an electrolytical galvanization treatment. The springs for diamond wire assembly are made in special carbon steel grade-B smoothed and drying oiled. Joint accessories are available in various sizes and dimensions. These are made from quality materials that ensure strength and durability. Various quality control checks are performed to offer a range of superlative products. Manual heavy-duty crimping machines are offered for use in marble quarries to join inner wire rope.

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Radhika Industries (Diamond), Delhi 110 085. Tel: 011-6515 8610, Fax: 011-2518 1453, Mob: 09212327050 Email: radhikaindustries_d@yahoo.com Website: www.radhikaindustries.com

CLUSTER HAMMERS LR Industries offers Hippo cluster hammer that are manufactured to international specifications, from only the best quality alloy steel, machined to high-precision and supreme standards. These products are heat-treated in the most modern, fully process controlled, in-house facility. The tungsten carbide buttons, which are used, are obtained from leading and reputed indigenous and foreign manufactures. These cluster hammers are quality products that conform to international standards and strict quality control methods. KLR products are constantly improved with adaptation of the most recent manufacturing technologies. The product features ensure: longer product life; higher & consistent penetration rate; capacity & capability to perform hitch-free at higher pressure range; reduced number of parts, compact structure for lower rate of wear & tear; avoidance of back hammering, hammer blocking; and minimum maintenance costs.

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KLR Industries Ltd, Hyderabad 500 062. Tel: 040-2712 1828, Fax: 040-2712 0558 Email: klr4000@klruniversal.com, Website: www.klrindustries.com

MINING DTH HAMMERS i-Tech Pneumatics & Heat Treaters manufactures and offers mining DTH hammers that are designed to be aggressive so that maximum drilling penetration can be achieved. Wear sleeves have heavy wall thickness and are specially heat-treated to last

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internal and external wear. Pistons have been carefully designed to avoid stress contours and carry optimum weight to give more strokes. The use of superior materials and precision heat treatment allows the pistons to last long with minimum wear & tear. Inner cylinders are precision ground and honed to ensure consistent stroke alignment, which reduce internal hammer component wear and allows for unrestricted high volume air flow & enhanced hole cleaning capacity. Air distributors have been carefully studied and designed by the design department by using latest Pneumsoft Software. Front chucks are usually subjected to severe wear & tear as the pulverized cuttings cause extensive wear. Hi-Tech Pneumatics & Heat Treaters Pvt Ltd, Bengaluru 560 058. Tel: 080-2836 1397, Fax: 080-2836 3597, Mob: 09845193287 Email: hi_techpneum@vsnl.net, Website: www.hi-techcluster.com

MINING DRILLING RIGS RD Rigs India offers mining drilling rigs (model PRD-125 wagon drill) that are designed innovatively and manufactured under strict quality control. These are perfect lightweight and heavy-duty equipment ideal for carrying out all types of drilling operations by DTH method in mines, quarries and construction projects. They have capacity of 4” to 4½” dia hole up to 40-meter (130 feet) depth by DTH method. Salient features include: lightweight, yet rigid, value engineered construction ensuring easy portability & high drilling performance; design for rotation winch & self-propellant pneumatic piston-type air motors to provide maintenance-free efficient performance; effectively brake wheels with adjustable front two stabilisers; centralised control panel with auto feed arrangement; provision for anchoring of mast/locking arrangement between mast & boom that ensure perfect rigidity during drilling; and swivel of mast 25 degree either side & capable of drilling holes from 15-degrees in word from vertical up to horizontal position.

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PRD Rigs India, Tiruchengode 637 209. Tel: 04288-256435, Fax: 04288-251645, Mob: 09786665888 Email: myrig@prdrigs.com , Website: www.prdrigs.com

MINING & DRILLING EQUIPMENT uru Precision Tools offers an array of mining and drilling equipment that are offered with a capacity in steel. These drilling equipment are also offered with the option of automatic feed and manual feed spindle. The range of radial drilling machines is widely used in the automotive and heavy engineering industry.

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Guru Precision Tools Pvt Ltd, Bengaluru 560 021. Tel: 080-2312 4227, Fax: 080-2312 3402, Mob: 09845049816 Email: gurupro@vsnl.com, Website: www.guruproindia.com


MINING

CORE CUTTING MACHINES otorised core cutting machines offered by Associated Scientific & Engineering Works have spring-loaded slide handle for easy coring. These machines have convenient carrying handle on carriage. Standard features include: 6-inch bit capacity, weigh only 45 pounds, 15 A, 3.5 HP core bore motor, single-speed 800 RPM, very durable & reliable, and water hose connection.

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Associated Scientific & Engineering Works, New Delhi 110 055. Tel: 011-2352 1188, Fax: 011-2353 4863 Email: asew@bol.net.in, Website: www.asewindia.com

DRILL HAMMERS oodwill Enterprises offers a series of drill hammers that are specially manufactured for all types of formation, which gives higher penetration at lower air consumption. These are heavy-duty valveless hammers with fewer components, which provides hassle-free drilling even in depth points. It is an advance air engineering in which air blocks in the undercuts of barrel, which lifts the piston automatically and again due to blocking of air in the undercuts of piston it beats the drilling bit simultaneously. The drill hammers have reversible barrel, which ensures longer hammer life and higher penetration for a long time.

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Goodwill Enterprises, Dist Latur 413 512 . Tel: 02382-641110, Fax: 02382-240606, Mob: 09822455100 Email: goodwilllatur@gmail.com, Website: www.goodwilluniversal.com

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MINING

MINING CABLES orth Eastern Cables & Conductors offers superior quality mining cables for different industrial requirements. These mining cables are known for their accuracy in performance and are engineered to endure the most extreme demands of the toughest mining applications. With a reinforced, two-layer, lead-cured thermoset jacket, the mining cables ensure ultimate protection against worst hazards conditions of mining and reduce any chances of failure.

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North Eastern Cables & Conductors Pvt Ltd, Jaipur 302 016. Tel: 0141-2281654, Fax: 0141-2281540, Mob: 09414062461 Email: necab11@yahoo.com, Website: www.khetan-group.com

ROTARY DRILL RODS avdeep Industries (Regd) offers rotary drill rods. Diamond sections of 19/16” are used with 111/16” rotary coal drill bits as per BS specification 2593/1964 for dry drilling and fast penetration in friable material. Turbine sections of 19/16” drill rods up to 6” are used with 111/16” rotary stone drill bits as per BS specification 2593/1964 for wet drilling in abrasive rocks.

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Navdeep Industries (Regd), Sirhind 140 406. Tel: 01763-220067, Fax: 01763-222267, Mob: 09417322767 Email: navdeep_industries@yahoo.com Website: www.navdeepindustries.com

ROCK DRILLS & SPARES inghvi Traders manufactures and offers airflushed drills that are useful for a variety of surface drilling applications at stone quarries, granite-marble mines and construction jobs. Each rock drill spare part is precision engineered and heat-treated for tolerance level required for the best performance in the rock drill. Technical specifications include: hose connection 19 mm; rotation 240 RPM; impact rate at 2050 blows/ min; piston stroke 60 mm (2.4 inch); drill steel (hex) 22 mm x 108 mm (7/8 x 4¼ inch); air req at 6 bar (87 PSI) 3.4 m³/min (119 CFM); length 575 mm (22.5 inches); and weight 26 kg (56 lb).

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Singhvi Traders , Udaipur 313 001. Tel: 0294-2424029, Mob: 09829006761 Email: arihant_stone2008@yahoo.com; Website: www.singhvitraders.com

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MINING & LASHING CHAINS ega Link Chains (I) offers a wide range of mining and lashing chains, which is extensively used for mining and lashing purposes. These chains are made of superior quality raw material procured from reliable vendors. The use of proper material makes them abrasion corrosion & further makes them function under all

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extreme conditions. Mega Link Chains (I) Pvt Ltd, Dist Thane 421 506. Tel: 0251-2620238, Fax: 0251-2621774, Mob: 09833091410 Email: megalink@vsnl.com Website: www.megalinkchains.com


MINING

MINING GAUGES friso, Germany, manufactures measuring and control devices for pressure, temperature and level as well as measuring, control and monitoring devices for flue gases. Parts of this range are mining gauges. These are suitable for mining, cement applications or in any areas where there is a harsh environment, which will damage the gauges.

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Afriso India Pvt Ltd, Pune 411 005. Tel: 020-2551 4336, Fax: 020-2551 4336 Email: nilkanth.jatar@afriso.de, Website: www afriso.in

MINING CABLES entral Cables manufactures and offers mining cables that are armoured PVC and XLPE cables. These cables are suitable for use in mines with the following additional requirements for coalmines: copper as conductor and armour conductivity at least 75 per cent of main conductor conductivity. The cables are differentiated with (mining) embossed on the outer sheath.

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Central Cables Ltd, Nagpur 440 001. Tel: 07104-237564, Fax: 07104-236819 Mob: 09822698468 Email: care.centralcables@gmail.com Website: www.centralcables.co.in

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FORKLIFT TRUCKS

AIR TURBO VENTILATORS

alzgitter Hydraulics offers forklift trucks that are designed keeping the Indian conditions in mind, like rough terrain, weathering, etc. These trucks are ergonomically designed for operator comfort. Optional accessories are available upon customersâ&#x20AC;&#x2122; request. Features are designed to suit the Indian environment. Other features include: ease of maintenance in a rugged terrain; liquid level sensors; independent meter; spacious seat; absorption system; more space for maintenance; and offer 1-year warranty.

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Salzgitter Hydraulics Pvt Ltd, Hyderabad 500 037. Tel: 040-2308 8578, Fax: 040-2308 6532, Mob: 09440800223 Email: business@shplcylinders.com, Website: www.shplcylinders.com

FLOORING NAILERS aymo Fastener Company offers flooring nailers (model FNPT1838M) that weigh 1.8 kgs and have 18-gauge cleat nail type. The head dimension is 7.31 mm x 1.61 mm, wire gauge at 18 g and leg lengths from 32 mm to 38 mm. Features include: perfect tool for installation of solid hard wood tongue & groove joint; non-marring mallet (1.3 kg) accompanies the tool for operation; tool has easy jamfree operation & can accommodate up to 120 cleat nails; portable tool, which can be taken to sites as no electricity is required at all; large base to increase stability and minimise damage to pre-finished floors; quick loading magazine with spring-loaded pusher; tool recommended for solid wood having 8 mm to 15 mm thickness; tool shoots a cleat nail at 45-degree angle into wood; and cleat nails minimise wood splitting and still allows expansion & contraction of the wood material.

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Kaymo Fastener Company, Mumbai 400 011. Tel: 022-2495 2966, Fax: 022-2493 6823 Email: sales@kaymo.com, Website: www.kaymo.com

PIPE PARTING EQUIPMENT urrent methods of cutting pipe into suitable lengths are either of sawing or grinding with a cutoff wheel. Unipunch Toolings has developed an equipment, that press works parting of the tube/pipe, which is first scored and later parted with a blade. Suitable hydraulic actuation and electrical controls makes it ideal for quality cutoff. These equipments are suitable for volume of production. They accept interchangeable die holders for different sizes of tubes and pipes. Scrap due to parting is kept to the minimum.

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Unipunch Toolings Pvt Ltd, Chennai 600 058. Tel: 044-2625 2348/3436, Fax: 044-2625 2349 Email: unipunch@vsnl.com, Website: www.fabmachinesindia.com

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indop air turbo ventilators offered by Powertrac are developed from Korean technology and assure 24-hours, 365 days ventilation at zero operating cost to the industrial and domestic building. These ventilators are also used to exhaust pollutant particles, like smoke, dust, fumes poison gases, humidity, etc, from the building. Features include: top/bottom ring made of SS & blades made from aluminium; self-lubricated Teflon brush, UV-based glassfibre casing; no maintenance, rust-free, rain proof; fire-retardant, corrosionresistance; economic & environment-friendly; easy installation & adaptable to all kinds of people; available in different sizes & shapes; designed to withstand winds in excess speed; powdercoated on aluminium vanes; anti-block design to distribute water while heavy rain; micro-balanced to avoid vibration & run in low wind; and comprehensive 5-years guarantee. Powertrac, Vapi 396 195. Tel: 0260-2997004, Mob: 09909954612 Email: powertrackvapi@gmail.com, Website: www.powertracgroup.com

DOWEL SPRING PINS K Engineering Co manufactures and offers dowel spring pins as per DIN-1481 and IS:5988 specifications. These dowel spring pins are manufactured from high carbon spring steel (EN-42J) having HRC 44-51 and also from SS304, SS-316 materials. They can be used in place of rivets, nuts, bolts, washers, clevis pins, retaining rings, setscrews and other threaded components. The dowel spring pins are easy-toinsert due to their flexibility and can absorb shocks & vibrations. They can be removed and reutilised, as there is no interlocking. Non-standard pins are also offered to suit customersâ&#x20AC;&#x2122; specific requirements.

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R K Engineering Company, Mumbai 400 023. Tel: 022-2267 1141, Fax: 022-2265 5255 Email: rkeng@vsnl.net

FUNNEL MAGNETS aykrishna Magnetics manufactures and offers funnel magnets that are widely used in ceramic industries. These funnel magnets are supplied along with aluminum/stainless steel funnels. The magnetic rod incorporates modern anisotropic permanent magnets. Iron contamination in ceramic body & glaze is in the form of small particles and are removed when it passes through the uniform gap between the funnel & magnet. The funnel magnets are available in standard and special sizes.

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Jaykrishna Magnetics Pvt Ltd, Ahmedabad 382 415. Tel: 079-2287 0071, Fax: 079-2287 0070, Mob: 09824048706 Email: info@jkmagnetics.com, Website: www.jkmagnetics.com


MATERIAL HANDLING

HYDRAULIC DIE-LOADERS ertz Controls (India) manufactures and offers technically precise range of hydraulic dieloaders that are robust in construction and deliver enhanced performance. These die-loaders are used for loading and unloading dies, press tools of varying weight and size. The are manufactured in different models and load capacities varying from 300 kgs to 2000 kgs. The hydraulic die-loaders are offered with revolving and fixed wheels, hydraulic hand pumps or in powerpack operated versions. Height of the hydraulic die-loaders varies from 1000 mm to 3000 mm.

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Hertz Controls (India) Pvt Ltd, Ghaziabad 201 002. Tel: 0120-2780531, Fax: 0129-4782682, Mob: 09811225961 Email: info@hertzindia.in, Website: www.hertzfeeders.com

PALLET FLOW CONVEYORS onmat Systems offers pallet flow conveyors. Flow storage consists of two elements, ie, a static rack structure and dynamic flow rails. The flow rails are a track/roller system set at a decline along the length of the rack. Flow rails allow loads to move by gravity from the loading end to the unloading end. Each flow lane includes selfenergised speed controllers

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(brakes) to gently control the speed of movement within the flow lanes. As a load is removed, the loads behind it move forward to the unloading position. The flow system depth, height and width are limited only by the size of your facility and the capabilities of your material handling equipment. Flow storage solutions are used in situations where storage density and inventory rotation are priorities. The picking and replenishment aisles are separate. Gravity flow conveying system along with transfer trolleys can be provided. Conmat Systems Pvt Ltd, Vadodara 390 010. Tel: 0265-2647276, Fax: 0265-2630763, Mob: 09898870278 Email: info@conmatindia.com, Website: www.conmatindia.com

VACCINE CARRIERS memco offers vaccine carriers that are boxes with airtight lid, easy to handle, and strong to face all hurdles during transportation. These vaccine carriers are used to carry vaccines, maintaining temperature required during transportation. They contain ice packs, which provide constant low temperature for a longer duration. The airtight lid does not allow air to enter in. Thus, vaccines are safe against all tensions during transit, like virus, breakage, etc.

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Gmemco, Delhi 110 051. Tel: 011-2209 0997, Fax: 011-2209 4144, Mob: 09717098703 Email: info@vaccinecarrier.com, Website: www.vaccinecarrier.com

ABRASIVE BLASTING MACHINES rism Surface Coatings offers air-powered blasting machines manufactured by Clemco GmbH, Germany, that are used to clean, deburr, shot peen, remove coatings. Besides the most popular model SCWB-2452 of 200 litres capacity, the other fast moving models available are of 20, 60 and 100 litres capacity. The 4,500 litres capacity unit, which supports 4 blasters, is widely used for long duration of blasting in ship building industry and on site structures and large fabrications. The BNP 220 pressure blast cabinets deliver efficient, affordable media blasting to clean, peen, deburr, or finish parts. The larger enclosure (50” x 39” x 43” tall) accepts powered turntables. The BNP 220 suction blast cabinet comes with the unique pilot actuated air logic system to maximise airflow to the blast gun. A 4 double-wall, sound-insulated doors, with industrial quality lift off hinges, all-welded construction, with precisely formed bends, forms a rigid, long-lasting cabinet shell.

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Prism Surface Coatings Pvt Ltd, Bengaluru 562 158. Tel: 08810-417999, Fax: 08119-417900, Mob: 09844400285 Email: sales@prismsurface.com Website: www.prismsurface.com

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MATERIAL HANDLING

VARIABLE SPEED POLISHING MACHINES ower Master double-ended variable speed polishing machines manufactured by Prem Brothers are designed for working at different speeds to achieve different types of finish using the same or different buffs. Stepless speed variation (500 to 2900 RPM) is available by turning a knob fitted in front of the machine, operating through AC frequency drive panel. A wide range of machines is available (1 HP to 10 HP) to suit different job requirements.

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Prem Brothers, New Delhi 110 064. Tel: 011-2811 7456, Fax: 011-2811 7464 Email: powrmstr@vsnl.com, Website: www.powermaster-india.com

ELECTRIC WIRE ROPE HOISTS rident Precision International manufactures electric wire rope hoists (typeE & type-U) that are available in compact designs and are known for their smooth performance. These are compact designed monorail hoist with low headroom dimensions and two direct drive cross travel motors. The cross travel trolley is adjustable to suit various flange widths. These most cost-effective and frequently ordered hoists have a load range from 1 ton

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to 12.5 tonnes SWL. Salient features include: two-speed hoisting drive in 6/1 ratio with soft start/stop feature; two-speed cross travel drive in 4/1 ratio with built-in flywheel & soft start/stop feature; extremely low noise levels during operation; all motors are pole changing crane duty motors with class-F insulation; easy service electrical control system; and variable frequency drive available as an option on hoist as well as cross travel drives. Trident Precision International, Gurgaon Tel: 011-4142 5326, Fax: 011-2592 7181 Email: info@trident-precision.com, Website: www.trident-precision.com

CABLE GLANDS umitron Exports offers non-metallic nylon cable glands (CCPG11-G series) manufactured by Thomas & Betts Corporation, USA. These cable glands have a sturdy cable sealing mechanism that results in superior strain relief. The compact size ensures quick and easy installation in cramped spaces. Non-metallic construction provides excellent corrosion, chemical and impact resistance. The cable glands have long threads along with locknuts also available. Salient features include: halogen-free, flame-retardant UL 94V0, rated IP 68 5 BAR, suitable for NEMA 4 enclosures, UL listed, CSA listed for certain ranges of cable, working temperatures -30ºC (-86ºF) to +80ºC (176ºF), continuous +150ºC (276ºF) intermittent, and meet VDE ratings.

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Sumitron Exports Pvt Ltd, New Delhi 110 028. Tel: 011-4141 0631, Fax: 011-4141 0494, Mob: 09810344240 Email: sumitron@vsnl.com, Website: www.sumitron.com

ELECTRIC WIRE ROPE HOISTS enus Engineers offers electric wire rope hoists that conform to IS-3938-1983. These wire rope hoists are specified for medium, heavy-duty and rugged performance. Their unique modular construction becomes easy for repairing and maintenance purpose. Absolute reliability is one of the most important features for a wire rope hoist to ensure the highest possible reliability levels in day-to-day operation. The electric wire rope hoists are produced using the most advanced technology available and continue to bear witness to their reliability, safety and durability year after year, from motor to rope, gearbox, brake, and electrical & electronics systems. A part from quality, versatility is an outstanding feature of the electric wire rope hoists. These units cover an extremely wide load capacity range from 1 ton to 50 tonnes, and the comprehensive standard equipment means that even a standard electric wire rope hoist is a versatile unit right from the start.

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Venus Engineers, Delhi 110 041. Tel: 011-2548 3102, Fax: 011-2596 5079 Email: venus@venusengineers.com, Website: www.venusengineers.com

PLASMA CUTTING MACHINES echno Crafts offers the new flatbed plasma cutting machines (model HF 3015-160i) manufactured by Boschert GmbH & Co KG, Germany. These plasma cutting machines come with a stable, rigid portal design and are equipped with a sophisticated linear guide system as well as a double axle CNC control system.

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Dynamic drives ensure positioning speeds of up to 18 meters/minute, with a guaranteed positioning accuracy of Âą0.1 mm. The worktable is 3,000 mm x 1,500 mm (X/ Y traveling axes) with a compact overall machine length and width of 4,000 mm x 2,500 mm. Work feeders can be adjusted between 10 and 8,000 mm/min, and therefore can be optimally adapted to the material to be cut and the material thickness. The Kjellberg system HiFocus 160i, which has proven itself time and again in industrial use, is used as the plasma source. Standard equipment includes two plasma torch replacement inserts. Techno Crafts, Pune 411 004. Tel: 020-2542 5551, Fax: 020-2544 6496, Mob: 09422319755 Email: infoak@boschert.de, Website: www.boschert.de

EOT CRANES ingle girder and underlung EOT cranes offered by Eddycranes Engineers are designed in accordance with IS:807-1976 code of practice for design manufacture, erection and testing (structural position) of cranes and hoists and IS:3177-1999 code of practice for design of overhead travelling cranes. In the design of components adequate factor of safety as per relevant codes is allowed. Impact fatigue, wear and stress concentration factors is taken into account whenever applicable. Tested quality

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steel or equivalent is used in the manufacture of the main load bearing members of the crane structure. Hoist is complete with motor driven trolley/hand geared trolley for cross traverse motion. The long travel motion is achieved through long travel mechanism placed at the centre of the bridge or by means of two motor drive arrangements driving each wheel. The cranes are controlled from floor through pendant pushbutton station hanging from the hoist. They are tested at 25 per cent overload. Eddycranes Engineers Pvt Ltd, Mumbai 400 034. Tel: 022-2352 1798/2710, Fax: 022-2352 1886 Email: eddycranes@vsnl.com, Website: www.eddycranes.com

ELECTRIC WALKIE TRUCKS owalk electric walkie trucks offered by Jost’s Engineering Company are available in 1,000 kgs capacity. These walkie trucks are specially designed to reduce operator fatigue as the 1,000 kg load can be moved by merely pressing a switch. As the trucks are battery operated, noise and smoke pollution are totally eliminated. Ideal applications for the electric walkie trucks exist in factories, warehouses, pharmaceutical & chemical industries, textile mills, foundries, docks, ordnance factories, food grain godowns, banks, railway platforms and workshops.

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Jost’s Engineering Company Ltd, Mumbai 400 001. Tel: 022-2266 1150, Fax: 022-2266 18951 Email: jostsho@josts.in, Website: www.josts.com

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FILTERS ole-Parner India offers new filters for auto paints industry. Cole-Parmer India offers CP filters developed by Chisso Filter Co, Japan. These are true classifying filters, ideal for automotive paints that remove all unwanted contaminants while allowing the pigments and flakes to pass through, ie, they remove large undesirable particles that contaminate the paint while desired pigments, metallics and micas pass through it. Moreover, the filters are rigid that will not unload contaminant into the paint, thus maintaining the desired filter pore size regardless of the differential pressure and provide consistent particle removal efficiency. CP filters utilise state-of-the-art fibre technology combined with innovative process technology. It is supplied in polyolefin-based materials that is compatible with almost all the automotive paints. They exhibit excellent classification, rigid structure, depth filtration, are free of media migration and provide long service life. The product grades have nominal ratings from 1 μm through 350 μm and are clearly differentiated by fibre diameter.

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Cole-Parmer India, Mumbai 400 022. Tel: 022-6716 2222/2253, Fax: 022-6716 2211, Mob: 09967060106 Email: response@coleparmer.in Website: www.coleparmer.in


ENGINEERING MATERIALS

METALLIC CONVEYOR BELTS

and beams/joints (I-beam, H-beam & narrow parallel beams). Applications are in construction of buildings, bridges, transmission line towers (TLT), industrial sheds & structures, ships, etc.

N F Engineering manufactures and offers metallic conveyor belts that are achieve high standards of engineering and construction. One can choose from different types of standards. Belt weaves are often used for diverse belt applications across the entire span of industry. When additional strength is required and belt-tracking needs to be controlled, chaindriven belts are best. Flat wire belts are economical strongman of the conveyor belt family. Available in different belt specifications, the metallic conveyor belts are manufactured with various types of belt edges.

shore A to 75 shore D.

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Nand Composites Pvt Ltd, Pune 411 001. Tel: 022-2712 0382, Mob: 09822016337 Email: nand@vsnl.net , Website: www.nandcomposites.com

METAL FABRICATION SERVICES

POLYETHYLENE FOAM

rfa Impex offers metal fabrication services that have served the requirements of various organisations over the years (claims the company). The components are fabricated using only the highest grade raw materials, and are cut, shaped and assembled with accuracy and in accordance with all national and international standards. These components find their application across many engineering industries.

hri Ekvira Manufacturers & Coats offers polyethylene foam that is a strong closed cell foam, used for shock absorption, loose fill and vibration dampening. It is most commonly used in cushioning the products during packing. Polyethylene is a shatterproof, lightweight, flexible foam and is resistant to mould, rot, mildew and bacteria. This product finds application in industries including fishery, building & civil construction, sports insulation, and in the packing of electronic goods and fruits. Customisation is also offered as per customersâ&#x20AC;&#x2122; requirements.

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Arfa Impex Pvt Ltd, Chennai 600 058. Tel: 044-2624 5578, Mob: 09884454332 Email: arfaimpex@gmail.com

ENGINEERING PLASTIC RAW MATERIALS agpal Enterprises offers superior quality engineering plastic raw materials that find various applications in automobile industries and other purposes. These plastic raw materials are manufactured while keeping in mind various laid quality standards that provides strength to the products. These are further tested to check their quality and strength so that they result in the manufacturing of the most superior quality products for clients.

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Nagpal Enterprises, Delhi 110 039. Tel: 09811951977, Mob: 09810079099

MS STRUCTURAL STEELS ybrant Trading Company offers a wide range of MS structural steels that are supplied as per the Indian standards with specific shapes, correct chemical composition and tensile strength. These durable and highly functional MS structural steels are ideally used for industrial fabrications & steel construction work. Structural steel sections are mainly hot rolled products, with a cross section of special form like: angles (equal & unequal), channels,

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Vybrant Trading Company, Mumbai 400 001. Tel: 022-2265 0786, Fax: 022-2265 0786, Mob: 09869127864 Email: akapadia@vybrant.com, Website: www.vybranttrading.com

POLYURETHANE COMPONENTS and Composites offers polyurethane components that are manufactured by injection moulding process. These components are used for various engineering, wheels and casters applications. They come with hardness ranging from 60

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Shri Ekvira Manufacturers & Coats Pvt Ltd, Nashik 422 010. Tel: 0253-6521272, Fax: 0253-6601173, Mob: 09822548442 Email: ekviracoats@yahoo.com

ENGINEERING PLASTICS hilwara Polymers manufactures and offers ultra high molecular weight high-density polyethelene UHMW-PE new generation engineering plastics, which is prepared with the help of Ziegler catalysts. These UHMW-PE products are manufactured by compression mould method with heavy presses under the guidance of highly technically qualified personnel. Thus a highly homogeneous and nonwelded single block material in size 3350 mm long x 515 mm wide x 10 to 130 mm thick is offered. Any machine part, linear and any other components as per drawings are offered from full-fledged workshop having technicians. The UHMW-PE products have a molecular weight range in excess five million, which are approximately ten times higher, that of molecular weight HDPE. Applications are in dewatering element for paper industries, dewatering element for cement asbestos pipe & sheets, food industry, pharmaceutical industry, machine construction,

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electroplating, textile industry, coal industry & mining, electrical industry, refrigeration, etc. Bhilwara Polymers, Bhilwara 311 001. Tel: 01482-227693, Fax: 01482-239634, Mob: 09829047693 Email: info@bhilwarapolymers.com, Website: www.bhilwarapolymers.com

POLYMER PRODUCTS eriyar Polymers has topnotch infrastructure and meets every norms prescribed by the ISO:9000 system standard to maintain quality in the production of polymer products. From choosing raw materials to packaging finished products, every stage of production process is carried out under the strict surveillance of various departments headed by dedicated professionals of relevant spheres. To maintain the international standard on product quality and to deliver the best to the customers always, a number of quality checks are implemented by the Quality Assurance Cell on each and every piece of polymer product come out bearing the celebrated hallmark of Periyar Premium.

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Periyar Polymers, Dist Ernakulam 683 550. Tel: 0484-2461317 Email: info@periyarpremium.com, Website: www.periyarpremium.com

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ENGINEERING PLASTICS etalon engineering plastics from Quadrant EPP Surlon are available in various materials, such as Metalon 6SA, Metalon 6PLA, Metalon GSM, Metalon oilon gold, Metalon MC-901, etc. Metalon 6SA an extruded nylon grade offers optimal combination of mechanical strength, stiffness, toughness, mechanical damping properties and wear resistance. Metalon 6 PLA is most widely used cast nylon in industry, especially as bearing material. Metalon GSM is cast, partially cross-linked, nylon 6 material with additives, which gives excellent resistance, selflubrication and low friction characteristics. Metalon oilon gold is specially developed to extend the wear-resistance properties of unduplicated or dry lubricated materials. Metalon MC-901 is tough, heat stabilised cast nylon 6, which is easily distinguished from the other cast nylon products. Applications are in sheaves, wear pads, outrigger pads, gears, locomotive parts; and a host of other tough applications, where wear, noise & lubrication are problems.

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who use them to do more, to go farther, to be even better at what they do. Whether it is working in a plant, or handling sharp edge materials, at construction site or in a forest. Whether it’s reinforcing optical fibre, saving the precious life of nation guarding personnel, efficient way of conveying materials, or winning world hockey cup. Whether it’s protection from the hazards they face on the job every day, or the comfort and lightweight strength they rely on to help them achieve their personal best. E I DuPont India Pvt Ltd, Chennai 600 014. Tel: 044-2847 2800, Fax: 044-2847 3800, Mob: 09841002509 Email: alok.bhatia@ind.dupont.com, Website: www.in.dupont.com

ENGINEERING PLASTICS

ADVANCED FIBRE SYSTEMS

lassic Polymers offers ultra high molecular weight polyethylene (UHMW-PE) U Gd worldclass engineering plastics. These are lightweight, non-hygroscopic materials having good thermal and insulating properties. The materials have excellent wear, abrasion and corrosion-resistant properties. They are superb lining materials offering low friction, chemical resistance, high stress crack resistance, non-stick surface and are recommended for working temperatures up to 82°C. Typical product applications are in: sprockets, star wheels, liners, conveyor rollers, idlers, feed screws, wiper blades, bottling plant conveyor profiles. These materials are manufactured in the form of rounds from ½inch to 4-inch diameter in meter lengths and blocks ranging from 10 mm to 150 mm thickness, profiles and custom components.

uPont Kevlar is an advanced technology that helps transform the ordinary to the extraordinary. It combines high strength (5 times stronger than steel) with lightweight, and comfort with protection. Products made with Kevlar brand fibre help those

Classic Polymers & Resins, Mumbai 400 016. Tel: 022-2446 0090, Fax: 022-2445 4371 Email: classicpolymers@hotmail.com, Website: www.classicpolymers.com

Quadrant EPP Surlon India Ltd, New Delhi 110 092. Tel: 011-2216 4542, Fax: 011-2216 3541 Email: skumar@del2.vsnl.net.in, Website: www.quadrantplastics.com

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SOFT BLOW HAMMERS ndeavour Engineering offers soft blow hammers that are most advanced type of hammers fabricated with polyurethane heads, designed and engineered for silent and maintenance-free long lasting service. The pipe and body is firmly dowelled rather than welded, for more safety. Special property of PU used at the heads that attribute to its sturdiness and wear resistance when compared to conventional mallets available in the market, are high elasticity, irrespective of hardness, flexibility at wide range of temperature ranging from -40째C to +110째C, good resistance to all adverse weather conditions, even at high energy radiation, good resistance to oil, grease and many more chemicals and solvents as also to rotting, extreme high wear resistance and impact strength, available in two sizes 35 mm E and 50 mm E.

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Endeavour Engineering, Ahmedabad 380 022. Tel: 079-6512 3263, Fax: 079-2546 7633 Email: info@endeavourengineering.com Website: www.endeavourengineering.com

ENGINEERING PLASTICS umbhojkar Plastics offers engineering plastic products, like cable carrier assemblies, plastic flexible coolant pipes, plastic & bakelite knobs, bakelite handles & wheels, signal stickers, safety signs, barrier tapes, computer clips & cable carriers for

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round curve. The cable carrier assemblies are 100 per cent safe innovative cable trailing systems (claims the company). These avoid leakage of electric current and facilitate free and easy movement. Drag chains are available in various sizes useful for electric cable hoses. The signal/sign stickers are printed on PVC in the size of 185 mm x 250 mm. Pendent control station can accommodate cables ranging from 8 mm to 26 mm diameter. The selector switches are of standard companies. Oil hand pump is a chemicalresistant pump and can be used for oil, kerosene, acids, alkalies and water. Plastic filters are strainer buttons, valves useful for chemical industries, water softening plants and filtration. Kumbhojkar Plastics, Pune 411 030. Tel: 020-2445 0055/60, Fax: 020-2448 0544 Email: kpss@plamoulds.com, Website: www.plamoulds.com

CONVEYOR & PROCESS BELTS G Engineers manufactures and offers conveyor and process belts that are manufactured by using specially developed fabrics, with covers made of PVC, PU, PE, polyester or silicone rubber. The standard range comprises of more than 80 belt types and a large number of accessories. These products meet latest industry standards and requirements. Latest developments in industry are monitored closely. New and improved products are constantly added to the product range.

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A G Engineers, Ghaziabad 201 009. Tel: 0120-415 9660-62, Fax: 0120-415 1360/9662 Email: info@agengineers.net, Website: www.agengineers.net

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HELICAL GEARBOXES eva Industries offers high efficiency parallel helical gearboxes constructed for design excellence. These gearboxes are based on modular concept with centre distances, ratios, and dimensions corresponding to R10, R20 and R40 series. Hardened and profile ground gears for all stages running noiseless in vibration-free graded cast iron housings duly stress relieved and machined on precision machines with weight/power optimised due to use of casehardened steels of high strength. Computer-aided design based on Buckingham method resulting in compact and robust gearboxes with factory of safety > 1.5 both in wear and strength for gears and pinions. Integral pinion shafts supported between bearings to make these resist torsional and bending stress, taking advantage of recent advances in the gear technology. Reduction ratios follow R-20 series from 1.6 to 6.3 in single stage, 6.3 to 22.4 in two stages, 22.4 to 112 in three stages and 112 to 625 in four stages.

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Reva Industries Ltd, Faridabad 121 009. Tel: 0129-406 9967/68, Fax: 0129-406 9969 Email: reva@revacranes.com, Website: www.reva.com

FASTENERS undan Industries offers high tensile 8.8/10.9 class fasteners in austenitic stainless steel grade by cold forging process without heat treatment. A wide range of products like bolts, screws,

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studs, nuts, washers, etc, are manufactured. Hex bolts are made with in-built flange. Having integral making facility of bolt with washer, integral fastener aids in faster production at assembly line of automobile. The integral fasteners reduce labour cost, making production fast and also have technical advantages. The major production of fasteners is in stainless steel and remaining 10 per cent in carbon steel including non-ferrous. Grades are austenitic 304 & 316, martensitic, B8, B8M, etc. Size range includes: 1.6 mm to 42 mm dia; and 4.0 mm to 200 mm length. Standards followed are IS, ANSI, BS, DIN, JIS, ASTM, etc. Kundan Industries Ltd, Mumbai 400 066. Tel: 022-6152 1234, Fax: 022-6152 1359 Email: fasteners@kundan.com, Website: www.kundan.com

COMPOSITE ENGINEERING MATERIALS

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ermali Wallace offers composite engineering materials. These engineering materials find application in almost every industry. Some of the industries that are served include: electrical, defence, railways, automobile, foundries, forgings, textile machineries, telecommunications, chemical, petroleum, construction, automotive energy, etc.

Permali Wallace Pvt Ltd, Bhopal 462 011. Tel: 0755-2550085, Fax: 0755-2550504, Mob: 09826050516 Email: permali@sancharnet.in, Website: www.permaliwallace.com

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GEARBOXES lecon Engineering manufactures and offers gearboxes with pinion stand for the drive of wire rod mills. The set of these gearboxes consist of total 14 nos, 7 horizontal and 7 vertical, having higher ratio in the beginning and tapering into lower ratio at the tail end. The size varies from SCF 710/480 at the bigger end to K AF 315/285 at the small end. All the gear internals are out of case carburising steel duly carbusised and hardened and precisely ground with profile corrections on all pinions and longitudinal corrections depending on the load, so as to keep the noise level as low as up to 80 db. Forging ratios for the gear internals are specially monitored as well special care is taken in the sealing arrangement. All the bearings as well almost all gear meshing are spray lubricated, which get adequate supply of lubricating oil from the common force lubrication system.

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Elecon Engineering Company Ltd, Vallabh Vidyanagar 388 120. Tel: 02692-236513, Fax: 02692-236527 Email: infogear@elecon.com Website: www.elecon.com

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GAS & FIRE DETECTION CONTROL PANELS etection Instruments (India) offers Crowcon’s highly successful Vortex range of multi-channel gas and fire detection control panels that has been extended to include an ATEX certified extended flameproof version (the Vortex FP), which can be used in Zone-1 and Zone-2 hazardous areas. Capable of monitoring up to 12 gas detectors, the Vortex FP is also compatible with smoke/heat and flame detectors and up to three of its input channels can be used for fire detection. Each channel has one fault and three alarm levels, which can be combined to trigger up to 32 output relays, allowing connection to a range of external alarms and safety devices. Intrinsically safe safety barriers can also be incorporated for use with IS gas or fire detectors. Sealed to IP65, the Vortex FP features simple push button operation and visual status indicators for each channel, ensuring that the system can be checked at a glance.

cent). Measurement error is <0.5 per cent. The instruments operate on 220 V / 110 V ±10 per cent, 50 Hz/60 Hz ±5 per cent, power <15 W. Dimensions are 270 mm (W) x 215 mm (L) x 100 mm (H). Weight is 1.6 kgs approximately.

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Detection Instruments (India) Pvt Ltd, Navi Mumbai 400 710. Tel: 022-2761 7663, Fax: 022-2761 2103 Email: sales@detection-india.com, Website: www.detection-india.com

Kusam Electrical Industries Ltd, Mumbai 400 015. Tel: 022-2412 4540, Fax: 022-2414 9659, Mob: 09867000456 Email: response@kusamelectrical.com, Website: www.kusamelectrical.com

RETRO-REFLECTOMETERS angal Instrumentation has introduced compact, highly sensitive retro-reflectometers to test retro-reflective performance of retro-reflective sheeting/ retro-reflective material, etc. These retroreflectometers are designed to measure retro-reflection of sheeting material for quality control and engineering purpose in the material and testing laboratory. They can test one-inch measurement area with measuring range of 0-1999.9 and show the reading in 4½ LED digital display. The retro-reflectometers consist of optical head containing precision optics, light source, filter, sensor, etc, along with standards of different colour.

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MEMBRANE DRYERS esides filtration, compressed air drying contributes considerably to an increase in the process reliability. Humidity in compressed air systems causes corrosion and promotes the growth of microorganisms. In individual cases, condensate may even emerge at the point of withdrawal. Pneumatic controls may break down where humidity is introduced, wear & tear of tools is enhanced or disturbances occur in the production process. Thus, the industrial process is consistently at risk where users employ compressed air. Therefore, efficient drying of compressed air is of essential importance. This applies in particular for the drying directly at the compressed air consumer. There, drying orientates not only on the application itself but also on the ambient conditions, for eg, on trains & ships, in open manufacturing shops or outdoors. For these cases AVS offers the new generation of Drypoint M membrane dryers as a solution, by means of which almost any degree of drying may be achieved.

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Beko Compressed Air Technologies Pvt Ltd, Hyderabad 500 037. Tel: 040-2308 0275, Fax: 040-2308 0274, Mob: 09393002464 Email: rkreddy@bekoindia.com, Website: www.beko.de

FUNCTION GENERATORS usam-Meco has introduced new function generators (model KM-2002) that have 5-digit LED frequency display, 3-digit LED amplitude display synchronously. These are accurate testing instruments that have different output function wave: sine wave, square wave, rectangle wave, saw tooth wave and triangle wave. Sine wave distortion is <2 per cent, triangle wave linearity is >99 per cent and square wave rise edge times/fall edge times is <100 ns. The frequency, amplitude and duty cycle can be adjusted continuously. Frequency range is 0.2-2 MHz. Signal frequency stability is <0.1 per cent/minute. Amplitude is (2 Vp-p~20 Vpp) ±20 per cent. Attenuation is 20 dB/40 dB. Output signal impedance is 50 ohms. Duty cycle is 20~80 per cent (±10 per

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Mangal Instrumentation, New Delhi 110 065. Tel: 011-6584 5192, Fax: 011-2984 1033, Mob: 09811117940 Email: mangal_india@vsnl.com Website: www.mangalinstrumentation.com

PROGRAMMABLE POWER SUPPLIES B Electronics have developed programmable power supplies, which can be remote controlled using serial port. These SMPS units accept 0-10 V signal or 4-20 mA signal to control the output voltage or current as per requirements. The power supplies are designed using latest state-of-the-art current mode pulse width modulation controller. Output is protected for overload, overvoltage and short-circuit. Power factor correction is available as an option. Other products are DC-DC converters and SMPS based battery chargers for telecom and material handling application.

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K B Electronics, Mumbai 400 025. Tel: 022-6452 6057, Fax: 022-2436 4668 Email: sales@kbelectronics.co.in, Website: www.kbelectronics.co.in

GEAR FLOW METERS SE gear flow meters offered by BEDA Flow Systems are volume rate measuring sensors, based on mesh gear principle. These are designed for use with any liquid that can be pumped, and have known lubricant properties, for eg, petrol, paraffin, kerosene, diesel, skydrol (jet-fuel), mineral oils, hydraulic oils (including fire resistant fluids), inks, dyes, paints, greases, polyurethane, polyol & isocyanates, aroldite, glues, pastes & creams, resins, waxes, etc. Two precisely matched gear wheels are enclosed in a very accurately machined housing. Gear rotation is sensed by a non-contacting signal pick- up system. The space between the gear teeth (when fully enclosed on both sides by the housing) constitutes measuring

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chambers. Fluid flow causes the gears to rotate and the incoming flow is separated into discreet volumes with in these chambers. Applications are in automotive industries, hydraulics, dyes & paints, plastic technology, chemical industries, etc. BEDA Flow Systems Pvt Ltd, Noida 201 301. Tel: 0120-4329990, Fax: 0120-4080022, Mob: 09212289411 Email: info@bedaflow.com, Website: www.bedaflow.com

VIBRATORY BOWL FEEDERS lscint Automation has recently manufactured bowl feeders for feeding of steel tubes of various sizes. There were a total of 6 tubes. In case of some the diameter was more than the length while in some cases the diameter was less than the length (length being more). The orientation required was standing for one machine while for another it was rolling. A linear vibratory track was provided in case of the standing orientation while in case of rolling, gravity chute was provided. These bowl feeders are supplied along with stands, level controls as well as auto-switch off mechanisms wherein once the chute or the linear track is full, the vibrator is switched off. The vibratory bowl feeder (model 400) comes with a cast aluminum bowl. The bowls are coated with Elscinthane PU coatings and the tooling is manufactured in stainless steel.

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Elscint Automation, Pune 411 026. Tel: 020-2712 2059, Fax: 020-2712 2994 Email: sales@elscintautomation.com; Website: www.elscintautomation.com

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LOW DROPOUT REGULATORS exas Instruments Inc, USA has introduced the industryâ&#x20AC;&#x2122;s first -36 V low dropout regulators (LDOs). Model TPS7A30 is paired with the positive voltage, while model TPS7A49 provides designers with a total solution for powering precision analogue applications. These devices feature ultra-high power supply rejection ratio performance and as low as 16 uVrms of output noise. Model TPS7A30 generates 200 mA, while model TPS7A49 manages 150 mA. Power for precision analogue LDOs help meet that requirement with wide input voltages, lowest noise and maximum amount of transient headroom. The TPS7A30/TPS7A49 linear regulator family is stable with any output capacitance greater than 2.2 uF. The LDOs come in an adjustable version with an output voltage ranging from 1.22 V to 34 V. They are designed for noise-sensitive applications, such as test equipment; industrial, networking and telecom equipment; base stations; microwave and radio links; noise filtering for receive, transmit and power amplifiers; and medical applications.

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Texas Instruments India Pvt Ltd, Bengaluru 560 093. Tel: 080-4138 1665, Fax: 080-2504 8308 Email: tiasia@ti.com, Website: www.ti.com

TRANSMITTERS iemens has introduced a new family of WirelessHart products for wireless communication, including two new transmitters, the Sitrans P280 and the Sitrans TF280. The Sitrans P280 transmitter for pressure measurement and the Sitrans TF280 transmitter for temperature have a WirelessHart interface as well as a graphical display with backlight functions and are easy to operate via push buttons. An integrated battery supplies the transmitters with power for up to five years, with a display that shows the exact number of remaining days. Additionally, all other Siemens process instruments without WirelessHart interfaces can be integrated into WirelessHart communication with the new Sitrans AW200 adapter. The Sitrans AW200 adapter has an integrated battery, which can also power a connected process instrument. If an external power supply is used, up to four conventional process instruments can be connected to the WirelessHart adapter simultaneously.

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Siemens Ltd, Dist Thane 400 601. Tel: 022 2764 5791 Email: processintrumentation.in@siemens.com Website: www.siemens.com

SIGNAL ISOLATION TRANSDUCERS eco-G has introduced the highly reliable, low-cost, accurate DC signal isolation transducers that convert a DC signal like mV, mA, V, A into standard DC signals, like 4-20 mA, 0-10 V DC, etc, with optical isolation. The output is linearly proportional to the measured input signal. These transducers have 0.5 per cent accuracy class as standard. The signal isolation transducers are available in flame-retardant case and operate on 110 V AC, 230 V AC, 24 V DC, 48 V DC, 110 V DC, 220 V DC auxillary supplies. They are suitable for

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telemetering, dataloggers, PLCs, SCADA systems and control applications. Goliya Instruments Pvt Ltd, Mumbai 400 015. Tel: 022-2414 9657, Fax: 022-2413 0747 Email: goliya@mtnl.net.in, Website: www.goliyainstruments.com

DC POWER SUPPLIES ektronix, Inc has announced two additions to its line of bench instruments: the PWS4000 series programmable DC power supply and the PWS2000 series DC power supply. These power supplies smoothly integrate with other Tektronix bench instruments, such as oscilloscopes & digital multimeters, and deliver wide current & voltage ranges for maximum versatility across a variety of applications. The new power supplies are ideal for design engineers who require high performance, feature-rich power supplies at competitive price points. Series PWS2000 and series PWS4000 offer performance and ease-of-use advantages compared to similar offerings currently available in the market (claims the company). These new power supplies compliment the FCA3000/3100 and MCA3000 series timers/counters/analysers also introduced by Tektronix separately. With wide current and voltage ranges, plus up to 0.1 mA and 1 mV resolution, engineers using the PWS2000 or PWS4000 series can precisely generate the power needed for a variety of applications.

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Tektronix (India) Pvt Ltd, Bengaluru 560 025. Tel: 080-2227 5577, Fax: 080-2227 5588 Email: india.mktg@tek.com, Website: www.tektronix.com

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COOLANT FILTERS

AUTOMATION SOLUTIONS

& C Invotek manufactures and offers coolant filters with magnets that are designed for filtering metal working coolants and fluids. These coolant filters are available with/without magnets. The magnets hold heavy metal chips to avoid damage to the filter bags. Also offered are simplex filter housings, duplex filter housings, multi-baskets & bag units, dual capacity units, carbon adsorption units, all-polypropylene bags, beta bags, surface filter bags, cotton-wound cartridge elements, membrane cartridges, stainless steel filter elements, etc.

ightVision (India) offers automation solutions from Lasco for forming tasks, such as a fully automatic hammer forging unit, in which two forging robots replace the blacksmith. This had been regarded as infeasible for a long time because of the complex tasks the operator has to accomplish when forging in the closed die. Taking this into account Lasco developed special gripping tools adapted to the dynamic processes when holding the work pieces as well as software to enable the forging robots to fulfill their tasks precisely and reliably. The complex developments have been protected by a series of patent specifications. The experience of almost twenty users worldwide show that the advantages surpass the mere rationalisation effect by far. Exact reproducibility of all processes and their sequence create stable conditions, which bring about a clear increase in quality and a decrease in the reject rate.

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S & C Invotek, Bengaluru 560 070. Tel: 080-2672 1569, Fax: 080-2679 3748, Mob: 09844035677 Email: invotekfilters@rediffmail.com, Website: www.invotekfilters.com

WIRE DRAWING & FORGING OILS ahathol Drala 66 from Mahatha Petroleum is a thick viscous dark-coloured mineral oil incorporated with special additives to withstand high temperatures encountered in the deep drawing and die forging operations. These oils have excellent oxidation stability and die cooling effect. They also have extreme pressure additives and anti-wear additives for their effective performance. The wire drawing and forging oils are recommended for deep drawing and forging operations steel, ferrous, nickel metals, tubes and their alloys. They can be applied by spray. This enhances the die life and ensures sticky-free operations in reduction or final polish.

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Mahatha Petroleum Pvt Ltd, Chennai 600 117. Tel: 044-2247 1542, Fax: 044-2247 3800, Mob: 09444065754 Email: mahathapetroleum@dataone.in Website: www.mahathapetroleum.com

COMMUNICATION MODULES ilscher offers communication modules CA-type CANopenMaster that are a simple and economical solution for implementation of fieldbus interfaces. As a compact plug-in board it contains the entire CANopen including the potential-free driver interface. The data exchange with the Host systems is carried out via an easy to handle interface, which has a dual-port memory that is the same on all models. Here, the process variables are carried in a process image, whilst commands are transferred over a mailbox. The module accepts the data and carries out the data exchange via the CANopen network, independently without any load on the Host system. The configuration can be carried out with the aid of the SyCon System Configurator, eg, via the RS232C diagnostic interface. Some of the facts include: compact & economical CANopen interface; direct connection to the CANopen network; direct access to the process data in the Dual-Port-Memory; identical easy-to-use application interface to all COM modules; and interchangeable with COM modules of other fieldbuses.

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Hilscher India Pvt Ltd, New Delhi 110 001. Tel: 011-4051 5640/41, Fax: 011-4051 5642 Email: rsaraswat@hilscher.in Website: www.hilscher.com

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Rightvision (India) Pvt Ltd, Noida 201 303. Tel: 0120-4261026, Fax: 0120-4261026, Mob: 09810526627 Email: rightvision@rightvision.biz, Website: www.rightvision.biz

PRODUCTION LINE MONITORING SYSTEMS n a manufacturing industry, investment on the machinery is significant. Production operations by workers/machinery are carried out based on scientific management. At any cost production shouldnâ&#x20AC;&#x2122;t be affected by lack of timely supply of components or breakdown of machinery or nonavailability of required tools. Process Care Systems offers production line monitoring systems (PLMS) to communicate production parameters to a centralised system, to record those parameters and to use them for generating reports facilitating better management. In these systems machines are networked by connecting each machine to a PMI (data logger). The PC receives the data from the PMI and stores them. The PLM systems are complete solution for maintaining the quality of product and effective utilisation of machine time. They provide accurate and timely information on the real causes of downtime to enable increased output. The systems also free supervisory personnel to do more value added work and production target information displayed on every PMI unit keeps operator busy.

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Process Care Systems (India) Pvt Ltd, Bengaluru 560 058. Tel: 080-4352 1111, Fax: 080-4352 1140, Mob: 09731900027 Email: info@datacareindia.com, Website: www.datacareindia.com

INVESTMENT CASTINGS

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i-Tech Investment Casting manufactures and offers investment castings. They can handle castings in carbon steel, low alloy steel, stainless steel, duplex steel, aluminum alloys, copper alloys, etc. Cobalt and nickel alloys are manufactured from few grams to 60 kg per piece in weight up to a dimension of 650 mm. The company has captive


GENERAL PRODUCTS

tool room, captive CNC machine shop, captive heat treatment facilities and technical back-up capable of designing wax moulds and machining jigs/fixtures. The back-up services include in-house rapid prototyping facility and designing of parts using FEM analysis. The company is a one-stop shop for all value-added requirements on castings, like machining, zinc plating, polishing, surface coating, electro-polishing, painting as well as assembling of castings using other processes like bar turned parts and sheet metal parts. Hi-Tech Investment Casting Ltd, Dist. Bhavnagar 364 240. Tel: 02846-222427, Fax: 02846-222971 Mob: 09426598378 Email: info@hitecind.com, Website: www.hitecind.com

INVESTMENT CASTINGS mtech Investment Casting manufactures and offers investment castings. All kinds of in-house testing facilities, like ARL spectrometers (Fe, Co & Ni Base), universal testing machines, impact testing machines and hardness testers, etc, are provided. Pump casting metals, such as SS-304, SS-304L, SS-316, SS-316L, carbon steel, hastalloys, carbon alloys, etc, are manufactured. The product range includes: investment castings, aluminium investment castings, prototype investment castings, alloys investment casting, wax investment casting, etc.

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Amtech Investment Casting Pvt Ltd, Rajkot 360 002. Telefax: 0281-2782244, Mob: 09879817994 Email: sales@amtechcast.com, Website: www.amtechcast.com

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FORGED COMPONENTS ilver Forge manufactures and offers quality-forged products for manufacturers of auto components, diesel engines, compressors and other OEMs. They have complete in-house facilities for production, testing and supply of all types of forgings from prototype development to machined finished components. Raw materials are sourced from approved steel plants such as RINL, ISSAL, MUSCO, and TISCO, etc. All incoming raw materials are checked thoroughly in the chemical lab, by qualified metallurgists. Various types of forging components, like connecting rods, crankshafts, camshafts, gears, gear blanks, pinions, crown wheel, gear shifter forks, torque converter covers, universal joint components, bucket tooth, etc and many more intricate components with fully CNC Machined and finished parts are manufactured.

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Silver Forge Pvt Ltd, Metoda 360 021. Tel: 02827-28799, Fax: 02827-287996, Mob: 09426254299 Email: info@silverforgeindia.com, Website: www.silverforgeindia.com

STEEL FIREPROOF DOORS ehgal & Sehgal Industries offers steel fireproof doors. They manufacture a customised range of high tensile premium quality stainless steel doors that are extensively used in various industries for multifarious applications. Available in varied finishes, like etched, patterned, bead blasted, embossed, colored, etc, these stainless steel doors are anticorrosive and heat-resistant. Types of stainless steel doors manufactured are: bullet resistant doors, blast resistant doors and thermal protection doors. The range of products include: fireproof metal door frames, stainless steel doors, special purpose doors, pressed steel doors, fire resistant doors, etc.

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Sehgal & Sehgal Industries, New Delhi 110 064. Tel: 011-2811 4613, Fax: 011-2811 7907, Mob: 09891139441 Email: info@firedoorsehgal.com, Website: www.firedoorsehgal.com

MIG WELDING MACHINES lobal Medi Weld manufactures and offers CO2 /MIG welding machines. Gas metal arc welding (maw) is frequently referred to, as MIG welding. MIG welding is a commonly used high deposition rate welding process in which wire is continuously fed from a spool. MIG welding is therefore referred to as a semi-automatic welding process. Some of the benefits are: higher deposition than SMAW, less operator skill required, long welds can be made without starts/stops, minimal post welds cleaning is required, all position capability, etc. Features include: weld mild steel, aluminum & stainless steel wires and bronze alloys wires; suitable for solid wires as well as flux cored wires; easy connection system

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for torch plug-in to wire feeder; coarse/fine controls for proper selection of voltage; and sleek & most flexible torch. Global Medi Weld, Hooghly 712 235. Tel: 033-6453 9830, Fax: 033-6453 9830, Mob: 09230507639 Email: globalgroup.gmw@gmail.com, Website: www.globalmediweld.com

HANDHELD MOBILE COMPUTERS xim International Trade Consultants offers handheld mobile computers (model MC-3000) with brick configuration. These advanced mobile computers are small, lightweight & rugged, and are designed for applications & environments requiring high-quality data capture and high-performance real-time computing. They can be customised to the specific demands of individual jobs, allowing employees to complete their work faster and with better results. The well-balanced brick form factor is ideal for scanintensive environments, offering the best in comfort for workers throughout an entire shift. The handheld mobile computers excel at bar code scanning and wireless mobile computing within retail stores, warehouses, on loading docks, postal routes or any location demanding application performance and ruggedness.

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Exim International Trade Consultants, New Delhi 110 030. Tel: 011-2664 6430, Fax: 011-2664 6430, Mob: 09899867897 Email: sudhishagg@gmail.com, Website: www.eitc.in

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ETHERNET SWITCHES ax Networks offers the DX-526 series industrialgrade Ethernet switches which enable rapid network recovery. These Ethernet switches are targeted at automation, transportation, semiconductor and heavy industrial factories. They feature Dax’s new range of networking access and connectivity products, introduced to enhance the company’s networking infrastructure solutions portfolio. The Ethernet switches are designed to meet critical network environment standards with IP30 enclosure and have been tested under extensive industrial EMI and safety standards. They support Xring and a fast network recovery with a reaction time of under 10 milli seconds over 250 switches. Network recovery protection between X-ring groups is ensured by dual and couple ring technology. Dual homing is present as a backup to the X-ring groups when connecting to upper layer or core switches. The Ethernet switches’ relay-contact-to-alarm system immediately notifies users of power and/or port failures by instantly sending an email to pre-defined addresses.

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Dax Networks Ltd, Chennai 600 020. Tel: 044-4292 3558, Fax: 044-4292 3567 Email: thirupura@dax.com, Website: www.daxnetworks.com

ETX CPU MODULES dvantech offers its most cost-effective ETX CPU module (SOM-4463) with Intel Atom single/dual core processors. Supporting the latest Intel Atom N450/D510 single and dual core processors with ICH8M chipset, the SOM-4463 offers low power consumption and is the first Intel Atom based dual-core D510 solution (claims the company). In a basic form factor of 114 mm x 95 mm, SOM-4463 fits the embedded ETX 3.0 standard. It has two SATA interface and an upgraded Intel Gen 3.5 DX9 graphic engine supporting MPEG2 hardware decoding, and dual independent LVDS/ VGA display output. With its advanced display features and I/O extensions, the SOM-4463 presents developers with a superb cost/performance CPU module with all the benefits of low power consumption. Powered by the new Intel Atom D510/N450 processors and ICH8M chipset, SOM-4463’s economic performance will appeal to system integrators looking for the best value for money.

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Advantech India, Bengaluru 560 055. Tel: 080-2337 4567, Fax: 080-2337 5898 Email: info.in@advantech.com, Website: www.advantech.in

DC WELDING RECTIFIERS ricon Systems manufactures and offers DC welding rectifiers that are basically meant for converting alternating current to direct current. Generally, all applications require DC supply for operation, but since the main supplies are AC, hence, rectifiers find their use in this area, as they effectively derive DC current from AC supplies. Another usage of the power rectifiers comes when the need to convert DC current to DC current arises. The company’s rectifiers can also be used for efficiently detecting the amplitudemodulated signals.

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Fricon Systems, Faridabad 121 004. Tel: 0129-3256052, Fax: 0129-4154159, Mob: 09811906899 Email: friconsystems@gmail.com, Website: www.friconsystems.com

RETRACTABLE GATES ongmen gates offered by Gandhi Automation stand out among others because they blend perfectly with their surroundings. They not only complement the building installed with the gates, but are a piece of eye-catching architectural work with high functionality and aesthetic value. These gates are made from high strength alloy aluminium and mounted with sparkling silver, stainless steel plastic plates. They are equipped with anticrash intelligent infrared double detectors. Patented electronic soft starter and mechanical buffer device ensures smooth run. Patented wind-resistant device enable the electric gate to operate in strong winds. Horizontal 4-direction even pull straight-line technology with absolute trackless operation and reliable performance. Each hole of the retractable piece is mounted with a wear-resistant PA push to eliminate any irritating noise during operation. Composite self-locking wearresistant connection technology revolutionises the traditional perforated twist joint structure, making it stronger and more durable. Concealed wiring gives the gate a neater appearance.

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Gandhi Automations Pvt Ltd, Mumbai 400 064. Tel: 022-6672 0200, Fax: 022-6672 0201 Email: sales@geapl.co.in, Website: www.geapl.co.in

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ROUTERS ippon Electrical Industries offers contemporary routers (model TR-12R) that are available in 12 mm (1/2â&#x20AC;?) designed for woodworking jobs centered on grooving and chamfering of powerful 1300 W. These routers have specially designed motor and high RPM for smooth cutting. They also feature easily selectable threestage of cutting depths, with all ball bearing construction for long tool life and aluminium die-cast base for heavy-duty shopwork. The routers are meant for optimum use and have been exactly similar to other international brands with all the spare parts interchangeable.

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Nippon Electrical Industries, Ahmedabad 382 330. Tel: 079-2282 2750, Fax: 079-2280 0119 Email: marketing@nipponpowertools.com Website: www.nipponpowertools.com

MINI VACUUM BLASTERS lose-circuit mini vacuum blasters (model KUV-14P) manufactured by Kushal Udhyog perform blast cleaning operation with on-the-spot instant recovery of blasted media and dust. The operation is safe and dust-free with no risk of flying abrasives and dust in surrounding. The abrasive blasting and abrasive recovery in these systems is simultaneous. Spent abrasive is confined in small vicinity on the job itself and the same is pneumatically sucked and fed to abrasive storage for re-cycling. The mini vacuum blasters are lightweight machines weighing only 3.7 kgs; and can hold abrasives up to 1.7 kgs of metallic grit. These require 40 to 60 CFM at 90 PSI. Fine abrasives like aluminium oxide, plastic grit or agro-based abrasives is mostly used. Salient features are lightweight, nozzle can be positioned overhead/downhead or sideways, do not require setting time, no electric connection, need only compressed air, wide pattern, etc.

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Kushal Udhyog, Jodhpur 342 005. Tel: 0291-2720072, Fax: 0291-2724400, Mob: 09414301701 Email: kushaludg@sancharnet.in, Website: www.kushaludhyog.com

SURFACE GRINDING MACHINES innacle Engineering Enterprise offers horizontal surface grinding machines with manual table drive. These surface grinding machines are available in model GSM-4520 with table size 450 mm x 200 mm, model GSM-4525 with table size 450 mm x 250 mm and model GSM 6030 with table size 600 mm x 300 mm. They are designed with new concept having linear guideways for easy table movement with wire rope drive to avoid pitch marks usually observed in rack and pinion drive (charter) on the job ground. Also offered are surface grinding machines in full range, named as Sumo series, viz, GSH-50 Sumo,

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GSH-75 Sumo, GSH 5025, GSH 6030, GSH-100, GSH-8, GSH-8 Jumbo, GSH 15050, GSH 15060, etc. These are hydraulic as well as automatic 3-axes, automatic 5-axes and CNC version surface grinding machines. The Sumo series of machines have robust base structure and have internationally accepted fixed column design. Pinnacle Engineering Enterprise, Surendranagar 363 002. Tel: 02752-231167, Fax: 02752-231913 Email: mail@pinnaclegrinder.com, Website: www.pinnaclegrinder.com

LATHE MACHINES alaji geared head heavy-duty lathe and extra heavy-duty machines (VGH series) offered by Vinit Engineering Works are available with different height of centre ranging from 267 mm to 455 mm, length of bed ranging from 1675 mm to 6100 mm, admit between centres ranging from 525 mm to 5000 mm and main spindle hollow ranging from 50 mm to 104 mm. These lathe machines have 12 nos of speeds ranging from 30 to 1060 RPM. All gears are of 20 MN CR5 materials and hardened and ground. The main spindle nose is A 2-6 and A 2-8 designed. Also offered are electromagnetic pedal brakes and electrical switch shafts in the machine. The other range of geared head lathe machines includes light-duty VGL series and medium-duty VGM series.

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Vinit Engineering Works, Rajkot 360 004. Tel: 0281-2311734, Fax: 0281-2312091 Email: vinit@balajilathe.com, Website: www.balajilathe.com

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One State Many Opportunities!

Karnataka Business Growth

Invest in Future

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This November Investment Destination, a special edition with SEARCH, focusses on an undisputed investment destination Karnataka. Always at the forefront of Industrial Growth in India, Karnataka – with its inherent capabilities coupled with its enterprising citizens – offers vast business opportunities across sectors providing the ideal choice for investment opportunities. Content highlight. Present Economic Scenario l Future Growth Opportunities l Investment & Business Alliances l Role of Research-based Manufacturing l Government Initiatives l Cluster Development l Hits & Misses and much more…

For advertising opportunities: Call: 022 3003 4651 OR write to us at: b2b@infomedia18.in

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GENERAL PRODUCTS

MECHANICAL SHEARING MACHINES hailesh Machine Tools offers mechanical shearing machines that are available in two versions, ie, under-crank and over-crank, having capacities starting from 500 mm to over 3000 mm and thickness varying from 2 mm to 12 mm. These shearing machines incorporate several standard and optional features, like hold-down systems (mechanical), hydraulic manual or auto lubrication systems (mechanical back gauge), ball roller or ball transfers, extension squaring arm finger guard, etc. Special versions can also be offered to meet specific production requirements.

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for speeds up to 5000 RPM). Diverse models cover a bore range from 6 mm to 50 mm shaft diameter with option of a round/ square/hexagon bore and bore+ keyway. Male pin, quick release, single & double, hi-speed joints with a central cross are standard options in the large range. Stainless steel joints in single/double are also available. Rotar universal joints are used in different types of industries, namely printing, packaging, machine tools, equipment testing, automation equipment, material handling, nuclear plants, paper machines, etc. Tradelink Services, Chennai 600 058. Tel: 044-2623 1267, Fax: 044-2836 1741, Mob: 09282433591 Email: tradelink@vsnl.com, Website: www.tradelinkservices.in

WHEEL BEARING GREASES Shailesh Machine Tools Pvt Ltd, Rajkot 360 002. Tel: 0281-2461102, Fax: 0281-2461665 Email: info@shaileshmachines.com, Website: www.shaileshmachines.com

UNIVERSAL JOINTS radelink Services offers universal joints that have manufactured by Flli Aramini srl, Italy. These universal joints are all metal couplings between two shafts, allowing for radial and axial misalignment and simultaneously transmitting torque, even at variable speeds. The couplings have the ability to transmit power even at high working angles (up to 45-degrees) in a minimal amount of space. Models AL & A (for speeds up to 800 RPM) and Model V (fitted with needle bearings & used

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ahathol Grease WB-2 and WB-3 offered by Mahatha Petroleum are lithium-based greases having fibrous structure, excellent performance, shear stability, and are adhesive to metal surfaces. These greases maintain their structural stability even over long service periods and withstand excessive churning operations effectively. They also possess the required consistency for pumpability for application by grease guns. The wheel bearing greases are recommended for wheel bearings, universal joints, high temperature clutch release, generator and fan bearings, and all other automotive applications where these greases are not exposed to direct water or moisture.

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Mahatha Petroleum Pvt Ltd, Chennai 600 117. Tel: 044-2247 1542, Fax: 044-2247 3800, Mob: 09444065754 Email: mahathapetroleum@dataone.in Website: www.mahathapetroleum.com

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MITRE CUTTING BANDSAW MACHINES TL Industries offers fully-automatic motorised swiveling-type mitre cutting bandsaw machines that are used to cut angles in range of 30째-90째-30째. Model LMG mitre series is equipped with swiveling cutting head enabling to cut the job at various angles. Swiveling arrangement is available in manual as well as automatic mode. The machines are developed for meeting demands of fabrication industries, construction industries, transmission tower manufacturing and general cutting applications where jobs are required to be cut at various angles. Features include: cutting feed & rapid reverse of cutting arm; blade tensioning when hydraulic power is on & tension release no sooner the machine is off to minimise fatigue stresses; automatic clamping before cutting arm starts moving down for cutting; shuttle vice release & clamps as the cycle is set/synchronised with length indexing table; apart from fully automatic cycle, manual mode is provided to facilitate initial setting; and automatic machine stop when blade fails.

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ITL Industries Ltd, Indore 452 015. Tel: 0731-3044400, Fax: 0731-2721110 Email: itlindia@sancharnet.in, Website: www.itl.co.in

INDUSTRIAL PLUGS & SOCKETS onnectwell Industries manufactures and offers industrial plugs and sockets that provide a versatile and robust connection system for industrial field and factory connection applications. These are designed and manufactured as per IEC 60309-1 and IEC 60309-2 standards. The housings of the plugs and sockets are made of halogen-free, V0 grade polyamide 6 materials and hence are non-flammable with a very high impact resistance. Contacts are made from electroplated copper alloy offering high corrosion resistance and very low contact resistance. By virtue of their design these industrial plugs and sockets enable low insertion and extraction forces while maintaining excellent electrical contact. A wide range is available in 16, 32 and 63 A versions with a choice of IP44 or IP67 protection class and in 3-, 4- and 5-pin configurations to suit various applications. The industrial plugs & sockets are extremely safe and reliable for the field & factory connections.

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Connectwell Industries Pvt Ltd, Dist Thane 421 204. Tel: 0251-287 0766, Fax: 0251-287 0889 Email: sales@connectwell.com, Website: www.connectwell.com

CASTINGS winkle Stars Engineers manufactures and offers castings for pump impellers of various models, like open impeller grade CF-8M, CO2 and no-bake moulding, closed impeller vein of 7 mm grade WCB, CO2 moulding, closing impeller, passivated, 8 mm vein and closed impeller water quenched grade CF8M, CO2 and no-bake moulding, carbon steel impeller 6 mm gap, 65 mm opening, grade WCB, CO2, no-bake moulding, closed impeller passivated, low gap vein, small opening, CF-8M, CO2 and no-bake moulding. Each of the impellers is in various dimensions and weight. The impellers are vital components of the pumpsets. Castings are undertaken for pump impellers as per drawings, specifications, material details and samples provided by the customers, OEMs, assemblers, repairers, traders and exporters, etc.

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Twinkle Stars Engineers, Rajkot 360 002. Tel: 0281-237 9404; Email: tsengineers@rediffmail.com

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SHOP INFORMATION INDOOR DISPLAYS rocess Care Systems (India) offers shop information indoor displays that are made to work with a variety of power sources, for eg, 24 V DC, 12 V DC, 230 V AC/DC, 110 V AC/ DC, etc. All these displays in the range work on serial ports conforming to either RS232 (generally referred to as COM port) or RS485 interfaces. Proprietary protocol suitable to multi-drop several displays can be shared with the system integrators. Optional message designer, designing software running on PC is also available. All the displays can be of various dimensions with respect to pixel matrix or mechanical dimension of the pixel itself. All the other communication interface devices that may be required to network such displays are also available. There are at least 20 different serial communication interfaces designed in-house and are used by several customers for various other applications (claims the company).

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Process Care Systems (India) Pvt Ltd, Bengaluru 560 058. Tel: 080-4352 1111, Fax: 080-4352 1140, Mob: 09731900027 Email: info@datacareindia.com, Website: www.datacareindia.com

INVESTMENT CASTINGS hri Hari Cast Industries offers investment casting of components in ferrous and non-ferrous metals and alloys through lost wax process. These precision investment castings are supplied for use in automobile industries, aircrafts, artificial limbs, aerospace, boiler mountings & accessories, bottling industries,

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compressors parts, crimping tool industries, diesel & gas turbine equipment, dairy equipment, electrical, earth movers, electronic industries, fire-fighting equipment, food processing machinery, gauges, hydraulic pumps, instrumentation, machine tools equipment, power plants, industrial pumps, pneumatics equipment, pharmaceutical equipment, plumbing fixtures, process machinery, textile machinery, valves & fittings and in general engineering. They are also used in any industries where a component is difficult or uneconomical to be made by other conventional processes. The precision investment castings are supplied (by lost wax process) in ferrous and non-ferrous metals and alloys or any other alloys as per customersâ&#x20AC;&#x2122; requirements with all tests of materials. Shri Hari Cast Industries, Ahmedabad 380 008. Tel: 079-2545 1819, Fax: 079-2277 1112, Mob: 9825039727 Email: info@shriharicast.net, Website: www.shriharicast.net

PRECISION INVESTMENT CASTINGS i-Bond Strips manufactures and offers precision investment castings of ferrous and non-ferrous metals, alloys and super alloys of finest quality. These precision investment castings are manufactured by lost wax process, which is most modern, flexible and cost-effective metal forming technique of designing and manufacturing components for a wide range of manufacturing

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sector. The investment castings are manufactured in 10 MT per month, like tiny product as minimum as few grams up to 30 kgs, single piece as cast, linear up to 600 mm. It is the companyâ&#x20AC;&#x2122;s metal arrangement to cast virtually any metals or alloys. The precision investment castings have applications in pumps and industrial valves, automobile spares, material handling equipment, defence, aeronautical, oil engines, compressors, impellers, chemical plant machinery, textile machinery spares and other engineering line components. Hi-Bond Strips Pvt Ltd, Dist Rajkot 360 003. Tel: 02827-252152, Fax: 02872-2385120 Email: hibond@sancharnet.in, Website: www.hibond.com

PRECISION INVESTMENT CASTINGS i-Con Technocast manufactures precision investment castings by lost wax process. A negative replica of the part or component is prepared in the form of metallic die, for creation of wax pattern, which matches the configuration and finish of the final metal part. Multiple numbers of wax patterns are made, connected and assembled by gates to wax sprue to form a tree or cluster. Successive coats of ceramic slurry and refractory is sent, fused silica is applied on assembled clusterfree with intermediate drying time to form a self-supporting shell called mould. The specified molten metal alloyed in induction melting furnace is then poured in the pre-heated and hot-baked hollow shells (moulds) ensuring complete filling of the entire shell cavity. Upon cooling, the ceramic shells are removed by usual knocking out operations by mechanical vibration and chemical cleaning. Finished products of casting are carefully inspected for compliance with clientâ&#x20AC;&#x2122;s drawings and specifications.

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Hi-Con Technocast Pvt Ltd, Rajkot 360 021. Tel: 02827-287901/3, Fax: 02827-287902, Mob: 09824519346 Email: info@hicontechnocast.com, Website: www.hicontechnocast.com

SPHEROIDAL GRAPHITE IRON CASTINGS alson Alloy Cast manufactures and offers quality spheroidal graphite (SG) iron castings (nodular cast iron/ductile casting) and undertakes development & manufacturing of any components by SG iron casting as per drawings, specifications, required quantity details, material details and samples of customers. Moulds are moved by mould car on track lines for efficient movement. For melting, induction melting furnace of 250 kW is employed, with 2 nos of crucibles each having 300 kg capacity. Strict quality control at each stage of production is ensured at quality control laboratory by performing chemical analysis for determining various elements in casting, by studying microstructure and determining hardness and checking tensile strength/elongation of

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the casting. SG iron casting is taken-up in the capacity of weight range from 0.5 kg to 500 kgs per single piece. Kalson Alloy Cast Pvt Ltd, Rajkot 360 021. Tel: 02827-287574, Fax: 02827-287574 Email: kalsoncast@yahoo.com, Website: No website

INVESTMENT CASTINGS lltech Technocast manufactures and offers offer a wide range of stainless steel investment castings that are produced from quality raw materials. These castings are highly durable, corrosion-resistant, and possess high tensile strength. The products are used in different industries, which include chemical, food & beverage products, petrochemical, pulp & paper equipment, power generation, and waste treatment. Steel castings are available with in standard as well as customised configurations according to our client specifications.

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Mr Ashish Bhatt Director V.R.VALVES Pvt Ltd â&#x20AC;&#x153;SEARCH magazine is a delight in every sense, whether itâ&#x20AC;&#x2122;s response, inquiries or content. We have been associated with SEARCH magazine for the last 9 years. We promote our products through this magazine and receive many genuine inquiries in response. This has played significant role in our growth. We look forward to a long-term value laden relationship with Infomedia 18. It is undoubtedly the leading industrial magazine & we wish them all the very best in their endeavours for the years to come.â&#x20AC;?

Alltech Technocast Pvt Ltd, Dist Rajkot 360024. Tel: 02827-252240, Fax: 02827-252440, Mob: 09879476066 Email: info@alltechcastings.com, Website: www.alltechcastings.com

ENGINEERING COMPONENTS CASTINGS tandard Techno Cast manufactures and offers engineering components castings by ferrous or non-ferrous quality investment casting as per drawings, specifications and samples provided by customers. Engineering components are made by

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investment castings from a few grams to 70 kgs per single piece. There are also arrangements to cast virtually any metal-alloys, such as steel, alloy steel, carbon steel, nickel-based steel, super alloys, hastalloys, inconel, monel, ductile irons, aluminium alloys, copper-based alloys, bronze alloys and many other ferrous and non-ferrous metals. Also offered are investment castings for engineering components applicable to industrial pumps & valves, impellers, material handling equipment, aeronautical & aircraft, automobile, defence, dairy machinery & equipment, industrial clamps, hoists, chain & lifts, medical surgical orthopaedic & dental equipment, packaging & printing machinery, pneumatic tools & controls, steam traps, textile & pharmaceutical machinery, agricultural machineries, air compressors, engines, cranes, hardware, earthmoving equipment, electrical engineering, farm equipment, fire fighting equipment, flow meters, gas turbines, gears, gymnastic equipment, refrigeration plants and general engineering. Standard Techno Cast, Rajkot 360 001. Tel: 02827-287792, Fax: 02827-287709 Email: info@standardtechnocast.com Website: www.standardtechnocast.com

SPHEROIDAL GRAPHITE IRON CASTINGS erfect Auto Cast manufactures and supplies quality spheroidal graphite (SG) iron castings (nodular cast iron/ ductile castings). Manufacturing of any components by SG iron castings is undertaken as per drawings, specifications, material details and sample provided by customers. Quality, accuracy and timely delivery are maintained. Development of SG iron castings are taken up in the capacity of weight range of 0.5 kg to 500 kgs per single piece, while the production capacity is up to 3000 tons annum in materials as per ASTM, BS, DIN, EN, SAE, ISO, IS and other international standards or as per the need of customers. The spheroidal graphite iron castings have application in the field of automobiles, internal combustion engines, compressors, machine tools, hydraulics, pumps & valves, pipe fittings, electrical power transmission & switchgear industries, heavy equipments, material handling equipments, food process machineries, leather machineries, rolling mills, etc.

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Perfect Auto Cast, Dist Rajkot 360 002. Tel: 02827-253870, Fax: 02827-253880, Mob: 09824225830 Email: perfect_auto_cast@yahoo.com Website: www.perfectautocast.com

PISTON COMPRESSORS tatex Engineering offers portable piston compressors. These piston compressors are used in car & truck tyre inflation, testing instruments, clinical lab equipment, by dentists, and by artists (spray guns). Salient features include: single cylinder mini air compressor, high quality oil-less self-lubricated pistons & rings, compact in size & portable; die cast aluminum body with vibromount base fitted with auto start/stop for preset pressures; and as optional, 1 litre or 2 litres air tank can be supplied.

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Technical specifications are power of 1/5HP; voltage at 220-240 V / 50 Hz, 220 V / 60 Hz; maximum pressure 7 bar (100 PSI); air output 23 litres per minute; auto stop/start at 30 PSI & stop at 60 PSI (special pressure available); fittings are pressure gauge with special sensor regulator & air filter; connection 1/8 BSP; pressure tank (optional), net weight at 3.6 kgs; and dimensions of 245 mm x 135 mm x 170 mm. Statex Engineering (P) Ltd, Coimbatore 641 021. Tel: 0422-2673232, Fax: 0422-2672464, Mob: 09943022722 Email: statex@vsnl.com, Website: www.statexengg.com

VACUUM HEAT TREATMENT FACILITIES ssab Sripad Steels offers vacuum heat treatment facilities for plastic moulds, die-casting, extrusion & forging dies and tools for cold work applications. These are imported from Austria. The vacuum heat treatment facilities have a chamber size of 600 mm x 600 mm x 900 mm with a designed load of 600 kgs per charge. The maximum furnace temperature can go up to 1250°C, suitable to harden highspeed steels. There is a guaranteed temperature uniformity of ±5°C. A quenching pressure of 10 bar with two-speed fan and a convective fan is also provided. The furnace is run by advanced control system from Demig with Scada support system for process repeatability. The furnace is validated according to NADCA for PDC dies.

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Assab Sripad Steels Ltd, Chennai 600 028. Tel: 044-2495 2371, Fax: 044-2495 2273, Mob: 09600040849 Email: per@assabsripad.com, Website: www.assabsripadsteels.com

ELECTRONIC BALLASTS enson Engineering Company offers electronic ballasts that are very lightweight and have an elegant look. These ballasts save 50 per cent of electricity (claims the company). They have instant start and work at low voltage. Other features include: no flickering, easy installation, saves money, no need of starter & condenser, one year guarantee, etc.

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Venson Engineering Company, Bengaluru 560 010. Tel: 080-2335 8366, Fax: 080-2338 2591, Mob: 09448079756 Email: info@vensonlite.com, Website: www.vensonlite.com

AVIATION OBSTRUCTION LIGHTS B Industries offers neon and LED aviation lights, such as single aviation obstruction lights of neon spiral are available with builtin 75 VA step-up transformer, die-cast aluminum alloy housing, heat-resistant, clear thick glass and accessories; LED single aviation obstruction light comes in die-cast aluminum alloy housing with polycarbonate dome; and LED double aviation obstruction lights

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with die-cast aluminum alloy housing with polycarbonate dome. Salient features include: give omni-directional light; protection: weather-proof IP55; material of construction: cast aluminum (LM 6); transparent part: polycarbonate red glass dome; gasket of neoprene; light source: high power light emitting diodes, mounted on glass epoxy PCBs; operate directly on 230 V / 50 Hz AC, can withstand high voltage fluctuations; multiple light elements reduce chances of complete blackout due to any unlikely lamp failure; approximate life of around 100000 hours; and earthing terminals provided. J B Industries, New Delhi 110 015. Tel: 011-2510 4159, Fax: 011-2544 2097, Mob: 09871888634 Email: jbiulitelamps@hotmail.com, Website: www.jbindustries.in

AIRCRAFT PLASTIC MOULDING DIES atering to the needs of aerospace industries, Magna Tech CNC offers a wide range of aircraft plastic moulding dies. High-grade plastic is used for fabricating these dies. These dies are offered in various innovative designs, dimensions, sizes and finishes. The range can also be customised to suit the exact requirements of clients.

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Magna Tech CNC, Bengaluru 560 091. Tel: 080-2836 3518, Fax: 080-2836 3518, Mob: 09980097314 Website: www.magnatechcnc.com

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INTEGRATED PLANNING TOOLS ne of the novelties from X-Visual Technologies is the Visual Net-Planner, a planning tool for plant engineering and network planners. The new software solution for the planning and documentation of complex data networks and telecommunication distributors reportedly enables fast and efficient planning processes. In particular, the automated documentation is said to guarantee a high degree of planning security and company-wide quality assurance.

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X-Visual Technologies GmbH, Germany Tel: +49-30-63926125, Fax: +49-30-63926127 Email: wolfgang.welscher@x-visual.net, Website: www.x-visual.net

without burrs and to exact dimensions. The cutters are equipped with a hydropneumatic drive, which simply has to be connected to a 6-bar compressed air source to be put into operation. The movable length stop on the 1 metre long measuring bar can be set to the desired rail length to within less than a millimeter. Simply by pressing the compressed air key it is possible to cut any desired number of mounting rails without difficulty. It is also possible to make fixing holes, by adding stamping bits. The rail cutters are available for both round boles and slots, in varying dimensions.

GRINDING BELTS ermesit long-life grinding belts offered by Hermes Abrasives Group special hollow spheres covered with grain and produce typical Hermesit finish, called Hermesit bright effect. When grinding with Hermesit abrasives, the rough ness depth of the surface of the ground workpiece is the same throughout the entire lifetime of a belt. When grinding with conventional abrasives, an even surface quality can be achieved for only a relatively short time. The abrasive grain becomes blunt and the desired initial roughness depth drops considerably. As the hollow spheres coated in abrasive grain wear down, new grain is constantly being exposed. Some of the benefits include: consistent surface finish & roughness values on workpiece, throughout tool life; 3-5 times the tool life improves economy compared to conventional grinding belts: reduced grinding belt change times & reduced disposal costs for used grinding belts; and lower grinding temperatures.

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Hermes Abrasives Group, Germany Tel: +49-40-83300, Fax: +49-40-8330230 Email: hsd@hermes-schleifmittel.com Website: www.hermes-abrasives.com

Phoenix Contact GmbH & Co KG, Germany Tel: +49-5235-341512, Fax: +49-5235-341825 Email: info@phoenixcontact.com, Website: www.phoenixcontact.com

NON-CONTACT INFRARED PYROMETERS aytek offers CI non-contact infrared pyrometers that are compact and easy-to-install. Designed for easy integration into a standard 4-wire system, these infrared pyrometers can easily replace traditional contact probes with a J-type or Ktype thermocouple output. The onboard electronics of these pyrometers are protected by a rugged IP65 (NEMA-4) stainless steel housing, allowing the instruments to function in ambient temperatures to 70°C (160°F) without cooling. With water-cooling, the pyrometers can withstand ambient temperatures to 260°C (500°F). Some of the features include: cover temperature ranges from 0°C to 500°C (32°F to 932°F); easily replace traditional probes & thermocouples; accessories for cooling & air purging; and stainless steel electronics housing.

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Raytek GmbH, Germany Tel: +49-30-4780080, Fax: +49-30-4710251 Email: raytek@raytek.de, Website: www.raytek.de

CNC VERTICAL LATHES ou Ji Machine Industrial Company manufactures CNC vertical lathes (YN-200 series). The compact design of the YV series provides advantages, such as space saving and high rigidity for excellent accuracy. The versatile and flexible design greatly improves loading and unloading processes to ensure accurate work-piece location. 8-station turret and gang-type tool holders are available to meet specific production requirements. The vertical turning lathes are equipped with C-axis (VDI turret) for drilling and tapping operations in addition to turning operation.

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You Ji Machine Industrial Company Ltd, Taiwan Tel: +886-7-6983068, Fax: +886-7-6983071 Email: youji@ms15.hinet.net, Website: www.youji.com

AIR-OPERATED RAIL CUTTERS hoenix Contact GmbH Co manufactures air-operated rail cutters for standardised mounting rails. These PPS comfort compressed air-operated rail cutters are used for rapid cutting of the four regular mounting rail sizes NS-35/7.5, NS-35/15, NS15 and NS-32, as well as the NLS neutral bus, and cut virtually

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IMAGE SENSOR PROCESSING SOLUTIONS ltera Corporation and Apical Ltd have announced the world’s first high-definition wide dynamic range (WDR) CMOS image sensor processing solution for video-surveillance cameras. Altera and Apical’s complete solution ensures superb video-image quality regardless of varying lighting conditions, a major stumbling block for previous generations of surveillance cameras. Featuring Altera’s Cyclone III and Cyclone IV FPGAs, and Apical’s intellectual property (IP), this solution supports Aptina’s new MT9M033 high-definition WDR CMOS image sensor. Standard CMOS image sensors are limited by the vast range of brightness levels, from low light to direct sunlight, that can black out or wash out a video subject. WDR CMOS image sensors correct this problem, but present a design challenge. The large amounts of data (up to 20 bits per colour x 1.2 Mpixels at 60 frames per second) generated by these image sensors must be processed in the Image Sensor Pipeline (ISP), but are too much to be handled on-chip.

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Altera Corporation, USA Tel: +1-408-5446397, Fax: +1-408-5446403 Email: dcheng@altera.com, Website: www.altera.com


INTERNATIONAL PRODUCTS

MOTION CONTROLLERS E Intelligent Platforms has announced the availability of its latest update to its advanced motion controller (PACMotion firmware version 1.5). The PACMotion is designed to control up to 40 axes of synchronised motion all at the exact same servo update loop rate of 1ms independent of the number of motion axes. It is the motion controller of choice in a host of new areas, including packaging, material handling, and automated assembly. By enabling connectivity to a wider variety of off-the-shelf devices, users will find PACMotion available to serve many more applications, which can lead to lower system cost. Firmware version 1.5 features two axis analogue servo control allowing control of one or two third-party amplifiers using a 10 V DC analogue speed or torque command. A PACMotion module controls four axes, and each module can use two of those axes for third-party servos through this upgrade.

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GE Intelligent Platforms, USA Tel: +1-508-6987456 Email: elli.holman@ge.com, Website: www.ge-ip.com

OPERATIONAL AMPLIFIERS exas Instruments Inc has introduced high-linearity, lowdistortion, fully-differential operational amplifiers (op amp) that deliver 16-bit full-scale precision up to 200 MHz IF to maximise signal chain performance for wireless base stations, high-speed data acquisition, test & measurement, medical imaging & defense applications. The THS770006 op amp has an output third-order intercept (OIP3) of 48 dBm and the lowest distortion in its class,

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with a third-order inter-modulation distortion (IMD3) of -107 dBc at 100 MHz, at least 14 dB better than competitive amplifiers. Features include: best-in-class distortion & high linearity help designers meet the stringent sensitivity & bit-error rate (BER) requirements of emerging wireless standards; seamlessly drives TI high-speed analogue-to-digital converters (ADCs), including the new 16-bit, 130-MSPS ADS5493, with full-scale, 3-V peak-to-peak dynamic range for optimal design flexibility & signal-to-noise ratio (SNR) performance; and provide fast overdrive recovery of 7.5 ns (maximum) to help minimise the impact of lost or erroneous data from jammers and blockers. Texas Instruments, Inc, USA Tel: +1-972-6445580, Fax: +1-972-9276377 Email: support@ti.com, Website: www.ti.com

TIMERS/COUNTERS & ANALYSERS ektronix, Inc has announced the FCA3000 and FCA3100 series of timers/counters & analysers and the MCA3000 series of microwave counters & analysers. These instruments smoothly integrate with other Tektronix bench instruments, such as oscilloscopes & arbitrary/ function generators, and deliver industryleading frequency & time resolution coupled with lower cost of ownership. Instruments, such as the FCA and MCA series are used for measurement and analysis of frequency, time or phase signal parameters in design, production, and calibration labs or in field applications, such as radar equipment monitoring and test. Critical factors in this segment include high-performance for better accuracy, analysis tools to quickly find answers to design problems and support for fast data transfer rates. The new timers/counters & analysers compliment the PWS4000 and PWS2000 series power supplies also introduced by Tektronix separately. With industryleading performance, the new timers/counters & analysers allow design engineers to make over 13 different frequency, period, time, pulse, or phase measurements with high resolution.

T

Tektronix, Inc, USA Tel: +1-800-835 9433 Email: literature-request@tektronix.com, Website: www.tektronix.com

HYDROCARBON DEW-POINT ANALYSERS ichell Instruments offers Condumax II hydrocarbon dewpoint analysers for automatic, online measurement of hydrocarbon and water dew point in natural gas. Some of the salient features of these hydrocarbon dew-point analysers include: fully automatic online analysis; objective & highly repeatable; 0.5째C hydrocarbon dew-point accuracy; fundamental cooled mirror principle; patented detection technique; self-cleaning; no purge or cooling gas needed; optional water dew point analysis; and modbus RTU. Applications are in natural gas processing, protection of turboexpander plant, gas quality measurements at custody transfer, transmission pipeline monitoring, confirmation & control of fuel gas superheat to turbine power plant.

M

Michell Instruments, Inc. USA Tel: +1-978-4840005, Fax: +1-978-8437669 Email: us.info@michell.com, Website: www.michell.com/us

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MULTI-FUNCTION CONTROL PLATFORMS emikron Electronik manufactures and offers multi-function control platforms for IGBT modules and systems. The digital driver SKYPER-52, which has already proven to be a success in driving IGBT modules, is also being used in these systems. This driver boasts a wealth of functions with a minimum of components, making the digital driver even more flexible and robust than before. SKYPER-52 offers a high level of signal integrity, providing reliable immunity from interference signals. The digital driver communicates via CAN input/output, providing the optimum interface between controller and power module. As a result, this driver is particularly suitable for use in systems that integrate power semiconductor, cooling, capacitors, driver and controller hardware. The SKYPER digital driver transmits the commands of the controller for the power semiconductor with a high level of signal integrity, ie, clear logic levels.

S

Semikron Elektronik GmbH & Co KG, Germany Tel: +49-911-6559234, Fax: +49-911-6559262 Email: sales.skd@semikron.com, Website: www.semikron.com

GRAVITY SEPARATORS nviro-Tech Systems offers gravity separators (API 421) that are atmospheric horizontal vessels designed and built for free oil and solids removal. Oily water and solids enter the separators, via a pre-separator for flow equalisation and collection of bulk

E

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INTERNATIONAL PRODUCTS

oil, trash, and grit. The flow exits the separator forebay and is reduced to laminar flow as it passes through a distribution plate. The distributed flow then enters into each of the separator’s bays, via gateways, where free oil, solids, and sludge are separated using Stoke’s Law. Solids and sludge settle to a sludge storage hopper directly under the inlet chamber. As the oily water flows through the separator, oil and solids continue to separate. A flight skimmer mechanism pulls oil toward the skimmer and moves any solids that settle to the bottom of the vessel in the reverse direction, toward the sludge collection area. Enviro-Tech Systems, USA Tel: +1-985-8096480, Fax: +1-985-8096422 Email: sales@envirotechsystems.com Website: www.envirotechsystems.com

SERVO ROTARY TABLES rushless servo rotary tables manufactured by Haas Automation, are right for medium-size parts. In these servo rotary tables the 110 mm (4.33”) platter has three drilled and tapped hole patterns for flexible, secure workholding. The table turns with 65 ft-lb of torque, and has 80 ft-lb of brake torque (40 PSI) for accurate cuts. Compact design allows lots of room on the machine table for other tools and accessories.

B

Haas Automation, Inc, USA Tel: +1-805-2781800, Fax: +1-805-9886918 Email: sales@mtscnc.com, Website: www.haascnc.com

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WELDING HELMETS lfa welding helmets from Kemppi Oy are welding helmets intended for arc welding, carbon arc gouging, and plasma cutting. These welding helmets are used to protect the welder’s eyes, head, and neck from arc radiation, reflected radiation from the environment, and welding spatters. The helmets can also be used as protective gear during grinding and skimming while keeping the filter glass in the upright position.

A

Kemppi Oy, Lahti, Finland Tel: +358-3-89911, Fax: +358-3-899428 Email: export@kemppi.com, Website: www.kemppi.com

HOT-AIR COMPONENTS eister Process Technologies offers hot-air components that regulate process parameters, such as temperatures and application time of the hot air jet, precisely and comprehensibly. The smallest configuration is the Leister LE Mini air heater with a 400 W power rating, the largest works with 40 kW. These air heaters include heating element protection and an alarm output. They can be connected with a regulator or a PLC device, via a galvanically isolated 4–20 mA interface. The diversity of Leister standard nozzles allows customer-specific configurations. This makes it possible, for instance, to pass different parts across the same jet of hot air. All necessary components, such as nozzles, air heaters, temperature regulators and blowers, from a single source are offered.

L

Leister Process Technologies, Switzerland Tel: +41-41-6627474, Fax: +41-41-6602061 Email: leister@leister.com, Website: www.leister.com


INTERNATIONAL PRODUCTS

RECIPROCATORS praymation Inc manufactures and offers reciprocators that are electronically reversible electronically programmable reciprocators providing precise repeatable motion and painting. A simple operator interface offers immediate push-button control of speed, stroke length, and position. Model 360176 reciprocator is a member of the new S3 generation of reciprocators. It is a completely new design that continues the heavy-duty tradition of Spraymation painting machines. Salient features include: vertical column is only 10½” (267 mm) wide; base is 13” (330 mm) wide; stroke can be designed for strokes up to 15’ (4.5 m) using modular design; carriage travels on a square track using ball bearing wheels; carriage is driven by heavy-duty chain; adjustable counter weight is used on a separate track to balance the spray applicators; and designed for a payloads of 20 Lb (9 kgs) or 40 Lb (18 kgs).

the event of a leak. When the seal failure condition clears, the relay automatically resets. Installation is made simple with the standard 11-pin socket mount. The single channel leak detection relays are available in three different sensitivities: 470 ohm fixed, 470 to 10 k ohm adjustable, and 4.7 k to 100 k ohm adjustable.

S

Spraymation Inc, USA Tel: +1-954-4849700, Fax: +1-954-4849778 Email: sales@spraymation.com, Website: www.spraymation.com

LEAK DETECTION RELAYS wyer Instruments offers new series of SLD single channel leak detection relays. These relays are used to monitor the shaft seal of a submersible pump to detect a leak before pump failure. A leak is detected by sensing the status of a float or conductivity switch installed in the seal cavity. When this resistance drops below the set sensitivity, the output relay energizes and the LED indicator illuminates. The relays offer normally open and normally closed relay contacts to energize an alarm and de-energise the pump in

D

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Dwyer Instruments Inc, USA Tel: +1-219-8798000, Fax: +1-219-8729057 Email: info@dwyer-inst.com, Website: www.dwyer-inst.com

MINERAL INSULATED CABLES erOpal mineral insulated cables offered by Tashika Boeki Shokai KK, is a combination of high quality metallic sheath, ceramic powder insulation and thermocouple, heater or electric conductors. Single core or multi-core mineral insulated cables are available in standard sizes ranging from 0.15 mm to 12.5 mm OD. Choice of metal sheaths and insulation material can be made as per the application. Mineral insulated cables features long life and flexibility. They are processed in cleanroom conditions using controlled techniques during manufacturing and inspection to ensure quality conforming to international standards. The mineral insulated cables have a variety of applications in the field of temperature measurement, heating and data transmission.

A

Tashika Boeki Shokai KK, Japan Tel: +81-78-2419035, Fax: +81-78-2422105 Email: info@tashika.co.jp, Website: www.tashika.co.jp


INTERNATIONAL PRODUCTS

PORTABLE CABLE TESTERS T Italia manufactures and offers portable cable testers (model LanTest-8050) for complete verification of LAN cabling up to 2000 MHz (cat 5). Continuous diffusion of computer networks make it necessary to use instruments for testing and verification of LAN cabling, for control of both proper connection and cable positioning. The LanTest-8050 permits to effect all measurements easily and quickly. It permits to test and check LAN cabling according to category 5E both with RJ45 and coaxial cables. Tests can be affected according to the standards (EN50173, ISO/IEC11801, TIA cat5). With the TDR and TDCrossTalk modes, it is possible to trace the fault point quickly. Some of the functions include: control of cable wiring; measurement of cable resistance and impedance; measurement of cable length; attenuation measurement; return loss measurement; NEXT measurement (near end crosstalk); propagation delay measurement; ACR measurement; AutoTest function; TDR and TDRnext functions; identification of cable connectors through locators; and full duplex voice communication.

H

HT Italia srl, Italy Tel: +39-546-621002, Fax: +39-546-621144 Email: vendite@htitalia.it, Website: www.htitalia.com The information published in this section is as per the details furnished by the respective manufacturer/ distributor. In any case, it does not represent the views of

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PRODUCT INDEX

To know more about the products in this magazine, refer to our â&#x20AC;&#x2DC;Product Indexâ&#x20AC;&#x2122; or write to us at search@infomedia18.in or call us at +91-22-3003 4684 or fax us at +91-22-3003 4499 and we will send your enquiries to the advertisers directly to help you source better. Product

Pg No

2D-3D conversion 2-wire transmitters 3D modelling

53 12 53

Abrasive blast rooms 215 Abrasive blasting machines 65, 204, 215 AC motors 57 Access control systems 256 Acoustic enclosures 185 Adapter sleeves 106 Adaptors 212 Adhesives 97 Adjustable shock absorbers 58, 147 Adsorption dryers 184 Advanced fibre systems 212 Aerator gearboxes 118 Aerobridge installation & maintenance 207 Agitator seals 142 AGVs 226 Air compressors 67, 163, 194 Air purifiers 113 Air receivers 184 Air turbo ventilators 202 Air-cooled reciprocating compressors 67 Aircraft plastic moulding dies 253 Air-operated/airless shot blasting machines 61 Airport equipment & service providers 207 Airport passenger baggage trolleys 223 All material handling items 242 Alloy wheels 223 Alu-cera polymers 11, 17 Aluma coats 11, 17 Aluminium extrusions 145, 220 Aluminium oxide ceramic composites 11, 17 Appliance switches 31 Area sensors 63, 105 AS-interface systems 225 Assembly technology 69 Auto drains 260 Automated guided vehicles 226 Automatic rolling shutters 25 Automatic weighing systems 207 Automation & storage systems 51, 225 Automation solutions 222 Automation 12, 141, 280 Aviation obstruction lights 245 Baking ovens 61 Balancers 79 Ball & roller bearings 70 Ball bearings 221 Ball transfer units 223 Ball valves 235, 238 Balls 217 Basket strainers 235 Battery operated pallet trucks 95 Beam lights 139 Bearings 14, 70, 167, 169, 221 Belt-type magnetic concentrators 152 Bending machines 241 Bends 238 Best CAD 53

262

Product

Billet shearing machines Bin vibrators Bio toilets Blast room paint spray booths Blasting media Blowers Bollards Bow shackles Brake motors Brakes Brass castor wheels Breather valves Brine chillers Bronze wheels Building automation Butterfly valves

Pg No

16 206 257 61 215 158 25 242 43, 57, 124, 224 224 223 235 201 223 280 238

Cable carriers 14 Cable clamps 101 Cable connectors 14 Cable glands 206 Cable glands 47, 101, 213 Cable ID printers 237 Cable markers 101 Cable movers 216 Cable reeling drums 152 Cable ties 101 Cable trolleys 228 Cables & leads for fixed instaction 51 Cables for bus systems 51, 225 Cables glands 258 Cables handling & processing systems 51, 225 Cables scanps 51, 225 Cables 19, 43, 88, 257 CAD programs 53 CAD software 53 Cage hoists 245 Calibrators 12 CAM express 53 CAM followers 224 CAM 53 Capacitive & magnetic sensors 225 Carbide rods 137, 212 Carbide 212 Cargo lashing 242 Cargo systems & sort equipments 207 Cast/extruded 239 Castings 238 Castor wheels 223 Castors 223 CCTV surveillance 256 CED coating machines 280 Center drills 212 Centralised lubrication systems 78 Centrifugal blowers 67 Centrifugal compressor package 67 Centrifugal oil cleaners 257 Centrifugal oil water separators 257 Centrifugal pumps 41 Ceramic adhesive cements 11, 17 Ceramic electrical heater parts 11, 17

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Product

Pg No

C-frame power presses 16 Chain hoists 203, 245 Chain pulley blocks Front gatefold,124, 149 203, 216, 242, 245, Chain slings 242 Chain wheels 214 Chains 14 Chair castors 223 Channel magnets 253 Check valves 231, 235 Chemlok coating machines 280 Chucks 212 Circular motion vibratory screens 152 Circular vibratory screens 152 Circular/gyrator vibro machines 253 Cistern type manometers 235 Clamps 206 Cluster hammers 198 Clutch & brakes 22 Clutch brake combinations 224 Clutches 224 CNC cutting machines 280 CNC horizontal boring mill titan 189 CNC laser cutting machines 280 CNC machine solutions 160, 172 CNC machines 217, Back inside cover CNC oxyfuel cutting machines 280 CNC plasma cutting machines 280 CNC toolings 212 CNC turning centres Back inside cover CNC vertical lathe titan 189 CNC vertical machining centres 15, Back inside cover CNC/VMC machines 99 Coating machines 280 Coating plants 280 Coating systems 280 Cold saw blades 204 Cold storage dockhouses 25 Cold storage doors 25 Collet chucks 212 Collets 212 Communication modules 222 Composite engineering materials 216 Compressed air division 203, 223 Compressed air dryers 184 Compressed air systems 52 Compressors 45, 52, 67, 163 Concrete vibrators 152 Conductors 227, 257 Conduits & connector systems 31 Connectors accessories 51, 225 Connectors 8, 14, 25, 47, 213 Construction electric hoists (modular) 133 Contactless multi-axis joysticks 199 Container cranes 111 Contrast/colour scanners 123 Control & automation 19 Control cables 88 Control dampers 215 Control panel accessories 31


PRODUCT INDEX

Product

Pg No

Control systems 205 Controllers 12 Conventional pallet racking 231 Conveyor & process belts 214 Conveyor belts 162 Conveyor castor wheels 223 Conveyor chains 127 Conveyor trolleys 223 Conveyorised painting lines 187 Conveyors and automation systems 25 Conveyors 96, 102, 162 Coolant filters 222 Coolant rotary unions 58, 147 Cooling water treatment 279 Core cutting machines 199 Coromills 1 Corothread 1 Counters & power supplies 7 Counters rate products 12 Counters 105 Crab assemblies 119 Crab hoists 124 Crabs 149 Crane kits 119 Crane-duty gearboxes 118 Crane-duty motors 43, 124 Cranes Front gatefold, 20, 96, 117, 119 124, 130, 133, 146, 149 203, 211, 245 Crawler cranes 117 Crimp contact & tools 51, 225 Cross belt-inline magnetic separators 152 Cushion dock shelters 25 Custom-made cables 51, 225 Cutting machines 280 Cutting tools 137 Cylinders 256 Cylindrical grinders 217 Cylindrical sensors 123 Data cables 51, 225 DC motors 57 DC power packs 243 DC welding rectifiers 228 Dehumidifiers 201 Demagnetisers 49, 261 Desiccant dryers 67 Diaphragm valves 238 Digital almen gauge & almen strips 151 Digital mark sensors 63 Digital panel meters 105, 200, 208 Digital readouts 238 Digital soft starters 253 Digital temperature controllers 208 Dip spin coating machines 280 Disc brakes 227 Display units 105 Distribution boards 18 Dock levelers & dock shelters 25

Product

Door runners & tracks Door side sensors Dosing feeders Double column metal cutting band saw Double drum & triple drum magnetic separators Double girder EOT cranes Double sheet monitoring Dowel spring pins Down shop leads Drawer magnets Drill chuck arbours Drill chucks Drill hammers Drill mills Drilling machines Drivers & controllers Drives Drum trolleys Drum-type magnetic separators Dry vane pumps D-shackles Dust collectors DVRS Earthmoving equipment Electric controls Electric dock levellers Electric drives Electric drum lifters Electric forklift trucks Electric lifting platforms Electric scissor lift tables Electric stackers Electric walkie stackers Electric walkie trucks Electric winches Electric wire rope hoists

Pg No

223 105 152 235 261 119 123 202 244 253, 261 212 203, 223 199 212 79 105 23, 213 223, 231 152, 253 185 242 215 256

130 69 231 69 231 25 231 231 231 231 208 216 20, 119, 124, 133 203, 205, 206, 211, 214 Electrical & maintenance contractors 207 Electrical CAD/CAE software 211 Electrical connectivity 227 Electrical pallet trucks 231 Electrical products cable ties 47, 213 Electrical systems 19 Electro-lifting magnets 206 Electro-magnetic bin vibrators 152 Electro-magnetic disc brakes 227 Electro-magnetic feeders 206 Electro-magnetic ferro-filters 152 Electro-magnetic vibratory feeders 253 Electro-mechanical feeders 206 Electronic ballasts 245 Electronic barriers 256 Electronic connectors 208 Electronic drain valves 184 Electronic speed switches 253 Electronic timers 32, 34, 36, 38, 208 Electronics For You Expo-2011 232

Product

Pg No

Electronics products 47, 213 Electro-permanent lifters 49 Electro-permanent magnetic chucks 49 Element shrink discs 224 Elevators Front gatefold Emergency lighting systems 139 Emergency shock absorbers 58, 147 Encoders 7 End caps 238 End carriage assembly 119 End mills 212 Energy conservation 135 Energy efficient pumps Front inside cover Energy meters 208 Engineering class chains & sprockets 127 Engineering components castings 243 Engineering plastic plugs & sockets 32, 34, 36, 38 Engineering plastic raw materials 210 Engineering plastics 210, 212, 213, 239 EngineeringExpo exhibition 177, 195 Engines 194 Entrepreneur magazine 263 EOT cranes Front gatefold, 20, 96, 124 133, 203, 207, 211, 214, 216, EOT jib cranes 146 EOT/HOT cranes 149, 245 Ethernet switches 228 ETX CPU modules 228 Everything About Water Expo-2011 234 Excavators 194 Exhausters 158 Exhibitions 109, 177, 195, 232, 234 Extended trolleys 119 External grinding spindles 217 Eye bolts 242 Eye hooks 242 Fabricator & turnkey projects 207 Fabtec India-2011 109 Facility management 207 Factory automation 141, 280, Back gatefold Failsafe brakes 227 Fasteners 79, 215, 219 Feed units 256 Femap 53 Ferrous & non-ferrous castings 220 Fiber sensors 63 Fiberoptic amplifiers 123 Fiberoptic sensors 105 Filter cocks 238 Filters 184, 208 Filtration 279 Finishing machines 253 Fire shutters 25 Fixed mounting hoists 119 Fixtures 206 Flame arresters 235 Flameproof hoists & cranes 245 Flameproof hoists 149

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PRODUCT INDEX

Product

Pg No

Flameproof lights 139 Flameproof motors 57 Flameproof products 12 Flange motors 43 Flange mounting motors 57 Flanging machines 241 Flat cables for submersible pumps 51 Flat high-tension single-twin igniting electrodes 11, 17 Flexible cables & wires 51 Floor scrubbers & dryers 273 Flooring nailers 202 Flooring 257 Flow control valves 231 Flow indicators 238 Flow instruments 171 Flow rate indicators 12 Flow switches 235 Fluid 193 Fluidised bed coating machines 280 Flush bottom valves 235 Flux generators 152 Foot mounting motors 43 Foot valves 238 Force actuation 179 Force-feed lubricators 256 Forged components 220, 224 Forging presses 16 Forked photoelectric sensors 123 Forklift trucks 129, 202 Forklifts 102, 117, 130 Forks 130 Freewheel-oneway-clutches 224 Friction drop hammers 16 Friction screw presses 16 FRL spares valve spares 260 Front axles 130 Function generators 218 Funnel magnets 202, 253 Furniture castor wheels 223 Furniture castors 223 Gantry cranes 119, 124, 146, 216 Gap frame presses 239 Gas & fire detection control panels 218 Gas springs 58, 147 Gauge accessories 171 Gear boxes 149, 193, 214, 259 Gear couplings 214 Gear drives 165 Gear flow meters 218 Gear grinders 189 Gear motors 22, 193, 214, 259 Gear shapers 189 Gearboxes 217 Geared & flexible couplings 193 Geared boxes 75 Geared brake motors 224 Geared couplings 96 Geared motors 75, 124, 259 Gears 165, 193, 214 Glide coating machines 280 Globe valves 235 Goliath cranes Front gatefold, 124, 133, 149 Goods lifts 96, 146, 149, 245 Grab buckets 133

264

Product

Pg No

Product

Graphic panels Grill magnets Grinders Grinding machines Grinding media Grinding spindles Grinding Grip pliers Guard monitoring systems Gyratory screens

105 253 217 217 11, 17 217 79 206 256 206

Hydraulic hand pumps Hydraulic hoses Hydraulic manual pallet trucks Hydraulic pallet pumps Hydraulic pallet trucks Hydraulic power packs Hydraulic power units Hydraulic presses Hydraulic pumps & valves Hydraulic pumps Hydraulic punching machines Hydraulic rotary unions Hydraulic shearing machines Hydraulic shock absorbers Hydraulic steel working machines Hydraulic systems Hydraulic valves systems Hydraulics cylinders Hydraulics

Haconan-free cables 51 Halogen searchlights 139 Hammers 16 Hand magnets 253 Handheld mobile computers 227 Handheld vibratory motors 152 Hannover-2010 104 Hard chrome plated bars 241 Heat shrink tubings 47, 213 Heat shrinkable sleeves 233 Heat shrinkable tubes 233 Heating elements 238 Heavy-duty castor wheels 223 Heavy-duty castors 223 Heavy-duty industrial castors 223 Helical gearboxes 214, 215 Helical geared motors 20, 211 Helical gears 214 Helical inline geared motors/reducers 259 H-frame power presses 16 High intensity roller type magnetic separators 253 High-alumina wear resistant ceramic tiles 11, 17 High-carbon chrome 217 High-carbon steel balls 217 High-intensity induced roll magnetic separators 152 High-intensity rare earth magnetic separators 253 High-pressure blowers 22 High-pressure cleaners 273 High-speed doors 25 HOC dryers 67 Hoist drives 203 Hoists with trolley 119 Hoists Front gatefold, 96, 133 Holdbacks 224 Home automation systems 256 Hooper magnets 253, 261 Horizontal CNC machines Back inside cover Horizontal handle clamps 206 Horizontal machining centres Back inside cover Horizontal screens 206 Hose clamps 228 Hot oil rotary unions 58, 147 HP-speed blast wheels 61 HRC fuse bodies 11, 17 HRC fuse fittings 208 Hump magnets 152, 253, 261 Hydraulic bore grinders 217 Hydraulic cylinders 207, 243, 244, 256 Hydraulic cylindrical grinders 217 Hydraulic dampers 58, 147 Hydraulic die loaders 203 Hydraulic dock levellers 25 Hydraulic dock shelters 25 Hydraulic drum lifters 231 Hydraulic gear pumps 243

SEARCH - THE INDUSTRIAL SOURCEBOOK | O C T O B E R 2 0 1 0

Pg No

256 70 95 256 231 207 231, 243 231, 239 243 231, 243 241 58, 147 239 58, 147 241 243 256 231 69

IC counterbalanced forklifts 25 Identification systems 225 Imaging & vision systems 280 Impellers 238 Inclined tube manometers 235 Indexing machines 215 Indicators 12 Induction seals/wads 227 Inductive proximity switches 31 Inductive switches 123 Inductive 225 Industrial automation 141, 205 Industrial batteries 19 Industrial ceramics 11, 17 Industrial connectors 51, 225 Industrial control & sensing devices 7 Industrial cooling systems 201 Industrial cranes 111 Industrial electric power distribution systems 18 Industrial flooring 257 Industrial heating elements 238 Industrial motion control equipment 224 Industrial overhead doors 25 Industrial services 167 Industrial shock absorbers 58, 147 Industrial shoes 77 Inline drum-type magnetic separators 253 Inline shaft mounted helical geared motors/reducers 259 Instrumentation & controls 25 Instrumentation made cables 51, 225 Instrumentation 213 Insulated conductor systems 244 Insulated doors 25 Insulated power rails 244 Inter-and after-coolers 184 Interiors 207 Inter-locking doors 25 Internal grinding spindles 217 Inverter/variable frequency drives 7 Investment castings 222, 223, 239, 243 Investment destination - Karnataka 236 Isolators 87 Jacks Jib cranes

256 20, 119, 124, 149, 211


PRODUCT INDEX

Product

Pg No

Jigs Joining Joystick controllers

206 179 199

Keyless transmission elements

224

Laboratory testing rerods 152 Large bearings 70 Laser markers 63 Laser sensors 63 Lathe machines 235 Lathes 255 Lawn mowers 194 LED module pilot lights 208 LED signal tower lights 32, 34, 36, 38 LEDs 31 Level controllers for liquids 219 Level controllers 7 Level gauges 235 Level indicators for liquids 219 Level switches for liquids 219 Level switches for solids 219 Level transmitters for liquids 219 Lift & conveyor cables 51 Lift trucks services 111 Lifting hooks 130 Lifting machines 216 Lifting magnets 261 Lifting tackles 242 Lifts Front gatefold Light lifting 111 Light-duty castors 223 Lighting systems 139 Limit switches 31, 32, 34, 36, 38, 208 Linear motion vibratory screens 152 Linear motion 69 Load break switches 31 Loaders 117, 129 Loading bay equipment 25 Lock nuts 106 Lock washers 106 Long neck pipe ends 238 Loom switches 208 Loop powered indicators 12 Loop powered isolators 12 Lorry loaders 129 Low dropout regulators 220 Low lift pallet trucks 25 Lubrication 167 Machined components 220 Machines 241 Magna rolls 152 Magnetic chucks 49 Magnetic coolant separators 253 Magnetic equipment 206 Magnetic floor sweepers 152, 253 Magnetic grill & housing 206 Magnetic head pulleys 206 Magnetic lifters 49 Magnetic particle brakes 224 Magnetic pulleys 152, 261 Magnetic racks 261 Magnetic separators 49 Magnetic tools 49 Maintenance sprays 9 Manometers for measuring low pressures 235

266

Product

Pg No

Manual electric stackers Manual pallet trucks Manual stackers Master controllers Material handling equipment

231 25 231 228 20, 95, 102, 124 130, 162, 207, 211 MCBs 87 MCCBs 19 Measuring & monitoring relays 7 Measuring sensors 63, 123 Mechanical seals 142 Mechanical shearing machines 237 Mechanical vacuum boosters 158 Membrane dryers 218 Metal bins 231 Metal cutting tools 159 Metal fabrication services 210 Metal pallets 231 Metallic conveyors belts 210 Metering solutions & relays 19 Meters 19 Micro milling beads 11, 17 Micro-control switches 208 Micro-drives 10 Microswitches 32, 34, 36, 38, 208 MIG welding machines 224 Mill lining blocks 11, 17 Milling cutters 137 Milling grades 1 Mini sensors 123 Mini vacuum blasters 233 Miniature microswitches 208 Mining & drilling equipment 198 Mining & lashing chains 200 Mining cables 200, 201 Mining drilling rigs 198 Mining DTH hammers 198 Mining gauges 201 Mining products 198 Mobile control valves 207 Modernisations 111 Moisture separators 184 Monorail trolleys 149 Motion controls 7 Motor control centres 19 Motor protection circuit breakers 31 Motorised boom barriers 25 Motorised chain pulley blocks 149 Motorised vibratory feeders 253 Motors 43, 57, 224 Moulded cable assemblies 208 MS structural steels 210 Multi-functional tools 137 Multi-level car parking systems 207 Multiple joysticks and handle options 199 Multi-wire cable trolleys 228 MV switchgears 19 Needle roller bearings Needle valves Network axis controllers Non-maintained lights Non-return valves Nuts

70 235 238 139 238 106

Oil cleaning centrifuging machines

257

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Product

Oil seals Oil/coolant coolers On/off controllers Optical-touch switches Oscillating tools Ovens Overband magnetic separators Overhead doors

Pg No

242 201 12 63 79 187 206, 253 25

Packaging solutions 227 Packaging test equipment 227 Paint booths 187 Paint shop equipment 280 Paint shop machines 280 Paint sludge removal systems 187 Paint spray booths 215 Pallet flow conveyors 203 Pallet pumps 256 Pallet stackers 25 Pallets trucks 102 Panel air-conditioners 201 Paperless recorders 200 Passenger lifts 96 PBEGL geared motors 57 PD blowers 67 Pedestrian & rider-operated counter-balanced pallet trucks 95 Pedestrian low lift pallet trucks 25 Pedestrian pallet stackers 25 Peeing machines 151 Perimeter protection barriers 93 Permanent lifting magnets 206 Permanent magnetic chucks 261 Permanent magnetic drum pulleys 253 Permanent magnetic drum-type separators 261 Permanent magnetic lifters 152 Photoelectric sensors 7, 63, 105, 225 Photoluminescent signages 139 Pick & carry cranes 117 Pick & move cranes 129 PID controllers 12 PID temperature controllers 105 Pilot lamp holders 208 Pilot lights 31 Pipe bending equipment 202 Pipe bending machines 241 Piston compressors 244 Planners 255 Plano millers 255 Plasma cutting machines 206 Plate bending machines 241 Plate castor wheels 223 Plate lifting clamps 242 Plate magnets 152, 253, 261 Plat-trucks 223 PLCs 213, 217 Plugs & sockets 31 Pneumatic products 260 Pneumatic rotary unions 58, 147 Pneumatics 69, 70 Pole rings 238 Polyacetal 239 Polyester webbing 242 Polyethylene foam 210 Polymer products 211 Polypropylene 239


PRODUCT INDEX

Product

Pg No

Polyurethane components 210 Polyurethane 239 Portable blasters 215 Powder coating booths 187 Powder coating guns & equipment 187 Powder coating/speedy painting equipment 261 Power cables 88 Power controllers 105 Power magnets 261 Power pack units 256 Power packs 256 Power presses 239 Power quality management systems 19 Power supply for cranes/hoists 244 Power supply stem material handlings 244 Power transmission chains & sprockets 127 Power transmission products 22 Precision components 167 Precision fabrication works 206 Precision ground bars 241 Precision investment castings 241, 242 Precision rolling bearings 70 Precision switches 31 Prefill valves 231 Press brake machines 239 Press technology 179 Pressure blasters 215 Pressure boosting 279 Pressure gauges 12, 171 Pressure sensors 63, 105 Pre-treatment systems 280 Process controllers 200 Process cranes 111 Process water treatment 279 Product assemblies 220 Production line monitoring systems 222 Programmable logic controllers 7 Programmable power supplies 218 Programmable terminals 7 Prong magnets 152 Protective-conduit systems 51, 225 Proximity sensors 7, 32, 34, 36, 38, 63, 105 Proximity switches 253 PTFE/Teflon 239 Pull action clamps 206 Pull studs 212 Pulleys 214 Pulling lifting machines 242 Pulling machines 216 Pump seals 142 Pumps 13, 41, 185, 188, 209, Back cover Punching machines 241 Push buttons 25 Pushbutton switches 208 PVC flap/strip doors 25 Radio remote controls Rapid flexible doors Rapid roll-up doors Ratchet lashing Ratchet liver hoists RCCBs Reach trucks Reamers Rear cylinder hydraulic press brakes Recovery unit & consumables

220, 228 25 25 242 242 87 25 212 239 61

Product

Re-crystallised alumina tubes Rectangular lifting magnets Re-drawer & hopper magnets Reducers Refrigerated dryers Relay sockets Reliable flooring Relief valves Re-magnetic rods Remanufacture & repair services Repair services & retrofitting for CNC machines Resistance boxes Retractable gates Retro-reflectometers RFIDs Rigging solutions Right-angled helical bevel geared motors/reducers Right-angled helical worm geared motors/reducers Robotic cables Robotic shot peening machines Robust joystick controllers Rock drills & spares Roll lifters Roller-type magnetic separators Roots blowers Rope guides Rotary cam switches Rotary clean flow magnets Rotary drill rods Rotary drills Rotary encoders Rotary joints Rotary screens Rotary screw air compressors Rotating electrical connectors Rotating unions Round endless slings Routers RTD sensors Rubber products Sack trucks Safety laser scanners Safety light curtains Safety protection devices Safety relief valves Safety shock absorbers Safety shoes Sawing & cutting machines SCADA & DCS implementation Scanners Scissor lift tables Scissor lifts Scoops Scrap-circular lifting magnet Screw jacks Sealants Seals Sectional overhead doors Security seals Security systems Seminar-2010 Sensor controllers

Pg No

11, 17 152 152 238 67, 184 208 257 231, 235 152 167 205 228 231 218 7 181 259 259 51 61 199 200 231 253 185, 188 119 31 152 200 79 105, 225 58, 147 152 67 227 58, 147 242 233 12 242 223 63 7 31 235 58, 147 77 79 280 12 231 25 238 152 216 97 70, 167, 242 25 55 113, 256 246 105

Product

Sensors Serial converter modules Servo made bore grinders Shearing machines Sheet metal machines Sheet metal working machines Shipyard cranes Shoe brakes Shop information indoor displays Shot blasting hoses Shot blasting machines Shot blasting rooms Showels Shrouded DSL systems Side lock adaptors Sight flow indicators Signal isolation transducers Signal isolators Simplair anodised aluminum piping Single axis fingertip joysticks Single girder EOT cranes Sleeves Slew cranes Slings Slipon flanges Slip-ring crane-duty motors SMPS systems Sockets & switches Soft blow hammers Solar solutions Solder pastes Solderless terminals Solenoid valves Solid carbide drills Solid carbide mills Solid carbide reamers Solid carbide special drills Solid carbide special reamers Solid edge Sorting systems & automation Spades Special refrigeration equipment Special tools Specialised grooving & parting tools Special-purpose machines Spheroidal graphite iron castings Spindle nose tooling Spiral bevel gearboxes Spiral cables Spiral cum helical gearboxes Spray guns Spray painting equipment Spur gears Stacker pumps Stackers Stainless steel Star lifts Static control devices Steam engineering Steam rotary unions Steel balls Steel fireproof doors Steel mill duty & flameproof cranes Steel working machines Steels Stepping motors

Pg No

63, 225 105 217 239 241 79 111 227 239 215 151, 187 187 238 244 212 235 220 12 67 199 119 106 117 242 238 57 208 25 213 258 227 47, 213 260 159 159 159 159 159 53 207 238 201 212 137 255 242, 244 137 22 51, 225 193 203, 223 265 214 256 102 217 207 63 135 58, 147 217 224 133 241 167 105

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267


PRODUCT INDEX

Product

Pg No

Storage systems Straight line action clamps Suction blasters Summit Surface grinders Surface grinding machines Surface preparation Surface processing Surface treatment Suspension magnets Sweeping machines Switches Switchgear products Switching power supplies Switching relays System integrators

102 206 215 240 217 233 65 79 97 152, 206, 253 273 87 19 105 7 213

Tacho/speed/pulse (rate) meters 105 Tail lifts 25 Team centers 53 Technical ceramic 11, 17 Tees 238 Telescopic doors 25 Telescopic truck loading conveyors 162 Temp/humidity transducers 105 Temperature controllers 7, 200 Temperature instruments 171 Temperature-resistant cables 51 Tensioner nuts 224 Terminal blocks 208 Terminal strips 208 Thermocouples 12 Thread whirling tools 1 Throttle valves 231 Thruster brakes 228 Tie mounts 101 Timers 7, 12, 105 Timing belts 214 Timing pulleys drives 214 Timing pulleys 214 Toggle action clamps 206 Toggle presses 206 Tooling solutions 19 Tools 212 Torque motors 22 Totalisers 12 Toughened glass & round glass 235 Tower cranes 117, 129 Tower lights 105 Track rollers 224 Transfer trolleys 149 Transmitters 220 Trap magnets 253 Travel drives 203 Travelling machines 20, 211 Tri lobe roots blowers 158 Triple drum-type magnetic separators 152 Trolley castor wheels 223 Trolleys 223 Truck-dumper body vibrators 152 Tube magnets 152 Turbine gearboxes 118 Turn buckles 242 Turned components 220 Turning holders 137 Twin extruder gearboxes 118 Twin lobe roots blowers 158, 188

268

Product

Twist drills Two stage vacuum pumps Uf exiter vibratory screens UHMW-PE products Ultra sonic flowmeters Ultrasonic sensors Unbalanced vibratory motors Uni-force exiters Unigraphics nx Universal joints U-tube manometers

Pg No

212 188 152 239 200 123, 225 152 152 53 237 235

Vaccine carriers 204 Vacuum blasters 215 Vacuum booster pumps 185 Vacuum cleaners 113 Vacuum heat treatment facilities 245 Vacuum systems 185 Validation of packs 227 Valves 235, 238, 260 Variable speed polishing machines 205 Ventilators 221 Vertical handle clamps 206 Vertical order pickers 25 Vertical turning machines 255 Vertical turning-cum-boring machines 255 Vibrating equipment 206 Vibrating motors 22, 253 Vibrating screen machines 253 Vibratory bin activators 152 Vibratory bowl feeders 219 Vibratory bowls 253 Vibratory conveyors 152 Vibratory feeders 152 Vibratory fluidised bed dryers 152 Vibratory furnace chargers 152 Vibratory grizzly feeders 152 Vibratory knockout tables 152 Vibratory motors 206 Vibratory spiral elevators 152 Vibratory tables 152 Vices 203, 223 Vision sensors 7 Wall top security 93 Washers 106, 238 Waste-water treatment 279 Water analysers/combustible & toxic gas detectors 213 Water chillers 201 Water faucet & tap parts 11, 17 Water filtration 65 Water purifiers 113 Water ring vacuum pumps 188 Water rotary unions 58, 147 Water treatment 279 Water-cooled reciprocating compressors 67 Waterjet cutting machines 65 Wear parts 137 Wearing sleeves 130 Welding equipment 203, 223 Wet & dry vacuum cleaners 273 Wet drum-type magnetic separators 152 Wheel assemblies 214 Wheel barrows 223 Wheel bearing greases 237

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Product

Pg No

Winches Wire connectors Wire drawing & forging oils Wire rope clamps Wire rope drums Wire rope hoists Wire rope slings Wire ropes Wires Wiring accessories Wiring ducts Withdrawal sleeves Worm gear speed reducers Worm gears

96, 133, 146, 216 47, 213 222 242 214 149, 245 242 242 88, 257 101 258 106 22 193, 214

Y-type strainers

235, 238

Zirconia polycrystal ceramics

11, 17

INTERNATIONAL PRODUCTS

Air-operated rail cutters Apparel & footwear CAD drawings CNC vertical lathes Cranes Drives Elevators Gear reducers Gravity separators Grinding belts Hoists Hot-air components Hydraulic dock levellers Hydrocarbon dew-point analysers Image sensor processing solutions Industrial products Integrated planning tools IS interfaces remote Leak detection relays Mineral insulated cables Motion controllers Multi-colour LED scoreboard Multi-function control platforms Non-contact infrared pyrometers Operational amplifiers Operator interface series PID controllers PLCs Portable cable testers Programmable logic controllers Reciprocators Screw compressors Servo rotary tables Switches Timers/counters & analysers Transmitters Truck tailgate lifts Welding helmets

254 255 255 254 48 21 48 64 257 254 48 258 205 256 254 255 254 199 260 260 255 21 257 254 255 21 21 21 261 21 260 24 258 199 256 199 205 258


ADVERTISERS’ LIST

To know more about the advertisers in this magazine, refer to our ‘Advertisers’ List’ or write to us at search@infomedia18.in or call us at +91-22-3003 4640 or fax us at +91-22-3003 4499 and we will send your enquiries to the advertisers directly to help you source better Advertisers’ Name & Contact Details

Pg No

Acme Air Equipment Co Pvt Ltd T: +91-79-25831985 E: info@airequipments.com W: www.airequipments.com

158

Acropolis Engineering Ltd T: +91-22-26441180 E: acropolis@vsnl.net W: www.acropoliscranes.com

220

Action Construction Equipments Ltd T: +91-11-40549900 E: marketing@ace-cranes.com W: www.ace-cranes.com

129

Advanced Micro Services (P) Ltd. T: +91-80- 41624368 E: patil@amsindia.net W: www.amsindia.net

205

Advertisers’ Name & Contact Details

Bonfiglioli Transmissions (Pvt) Ltd

Pg No

Coatec India T: +91-172-5063436 E: info@coatecindia.com W: www.coatecindia.com

280

69

Confederation Of Indian Industry T: +91-22-24931790

246

E: sales@bonfiglioliin.com W: www.bonfiglioliindia.com

W: www.boschrexroth.co.in Buildcon Consultants Pvt Ltd

257

T: +91-141-4012629 E: sales@buildcon.in W: www.buildcon.in C&S Electric Ltd. E: ravi.gautam@cselectric.co.in W: www.cselectric.co.in

Allied Electronics Corporation T: +91-22-26616619 E: allied@vsnl.com W: www.aecconnectors.com

8

Amsak Cranes Private Limited T: +91-44-26273486 E: sales@amsakcranes.com W: www.amsakcranes.com

146

Atlas Copco (India) Ltd T: +91-20-30722222 E: marcom@in.atlascopco.com W: www.atlascopco.com

45

257

T: +91-11-22613408 E: cbs.director1@gmail.com

Connectwell Industries Pvt Ltd T: +91-251-2870636 E: connect@connectwell.com W: www.connectwell.com

26

Cosmos Impex (India) Pvt. Ltd. T: +91-265-3927000 E: sales@cosmos.in W: www.cosmos.in

160; 172

Crane Control Eqpts T: +91-11-26388401 E: ccedelhi@vsnl.com W: www.cranecontrolequipments.com

228

W: www.cbsenergy.com Cenlub Systems

78

T: +91-129-4113771 E: cenlub@ndb.vsnl.net.in W: www.cenlub.com Ceratizit India Pvt Ltd

137

T: +91-33-24947146 E: info@ceratizitindia.co.in W: www.ceratizit.com Chamunda Equipments

Autonics Automation India Pvt Ltd T: +91-22-27814305 E: sjlim@autonics.com W: www.autonics.com

105

Ballkings T: +91-161-2534501 E: ballkings@ballkings.com

217

206

T: +91-79-27522437 E: clamp@chamundaequip.com W: www.chamundaequip.com Chemical & Industrial Engineers

Bhagirath Heavy Transmission T: +91-11-32222661 E: bht_india1998@yahoo.co.in

87

T: +91-11-3088-7520-29

CBS Technologies Pvt Ltd

Pg No

23

T: +91-44-24781035

Bosch Rexroth (India) Limited

Advertisers’ Name & Contact Details

Cheng Day Machinery Works Co., Ltd 214

235

T: +91-22-28822740 48

T: +886-4-2688-1581 E: christy@chengday.com.tw W: www.chengday.com.tw

Bhardwaj Cranes & Elevators T: +91-161-2847081 E: bhardwajcompany@yahoo.com W: www.bhardwajcranes.com

96

Boge Compressed Air System T: +91-44-43009610 E: S.Sriram@boge.de W: www.boge.in

52

Classic Polymers & Resins

239

T: +91-22-24465251 E: sales@classicpolymers.co.in W: www.classicpolymers.com CM Hydro Systems Pvt Ltd T: +91-40-23222287 E: mktg@cmhydraulics.com W: www.cmhydraulics.com

231

CRI Pumps (Pvt) Ltd T: +91-422-3260011 E: corp@cripumps.com W: www.cripumps.com

13

Danfoss Indus Pvt Ltd T: +91-44-66501555 E: danfoss.chennai@danfoss.com W: www.danfoss.com

10

Darling Pumps Pvt Ltd T: +91-731-2720558 E: darlingin@satyam.net.in W: www.darlingpump.com

209

Delair India Pvt Ltd T: +91-124-4091111 E: delairmarketing@pahwa.com W: www.delair.com

201

Digital Marketing Systems Pvt Ltd T: +91-731-3046800 E: digicontrols@gmail.com W: www.digitalcontrols.org

213

Dongguan Dacheng Machinery Make Co., Ltd. T: +86-769-8321-7777 E: Davidquzhong@163.com W: www.cn-dc.com

205

Durga Bearings Pvt Ltd T: +91-44-26440414 E: durga@durgabrgs.com W: www.durgabrgs.com

169

Our consistent advertisers

274

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Advertisers’ Name & Contact Details

Pg No

EA Water Pvt Ltd

234

T: +91-11-43100519 E: enquiry@eawater.com W: www.eawater.com/expo East Coast Magnets (P) Ltd.

Engineering Expo T: +91-09819430607 E: shamal@infomedia18.in W: www.engg-expo.com

Pg No

177; 195

Advertisers’ Name & Contact Details

Pg No

G A Industries T: +91-79-25895577 E: gmac@gaindustries.net W: www.gaindustries.net

227

Entrepreneur T: +91-9819264108 E: sana.ally@infomedia18.in W: www.entrepreneurindia.in

263

G L Brothers T: +91-22-66047000 E: info@pilotindia.com W: www.pilotindia.com

223

Escorts Construction Equipment Ltd T: +91-129-2306582 E: marketing@escorts-ecel.com W: www.ecel.com

117

G W Precision Tools India Pvt Ltd T: +91-80-40431252 E: info@gwindia.in W: www.gwindia.in

159

Essen Deinki T: +91-172-4600600 E: info@essendeinki.com W: www.essendeinki.com

208

Gandhi Automations Pvt Ltd T: +91-22-66720200 E: sales@geapl.co.in W: www.geapl.co.in

Eureka Forbes Limited T: +91-80-30251500 E: fandb@eurekaforbes.com W: www.eurekaforbes.com

113

General Elek Mek Systems T: +91-120-2535064 E: khushdeep@airtelbroadband.in

162

185

193

Global Sleeve Solutions T: +91-09501040477 E: info@globalsleeves.com W: www.globalsleeves.com

106

Everest Blowers T: +91-11-45457777 E: info@everestblowers.com W: www.everestblowers.com

109

206

Grundfos Pumps India Pvt Ltd T: +91-44-24966800 E: salesindia@grundfos.com W: www.grundfos.in

284

Fabtec India 2011 T: +91-422-2221582 E: fabtecindia@codissia.com W: www.fabtecindia.codissia.com

79

152

H G Shah & Co T: +91-79-25621431 E: hgshah2000@rediffmail.com W: www.timingpulley.in

214

Fein Power Tools India Pvt. Ltd. T: +91-44-43578680 E: m.ameer@fein.in W: www.fein.in

93

Hafa Hoists Pvt Ltd T: +91-22-27694837 / 838 E: response@hafahoists.com W: www.hafahoists.com

119

Fenzgard India Pvt Ltd T: +91-422-2646178 E: info@fenzgard.com W: www.fenzgard.com

Hannover Fairs India Pvt Ltd T: +91-22-40050683 E: tushar.alekar@hmf-india.com W: www.mda-india.com

104

49

T: +91-40-23098262 E: info@sardamagnets.com W: www.sardamagnets.com East India Bearing Co. (P) Ltd.

Advertisers’ Name & Contact Details

70

T: +91-22-40939200 E: mumbai@eibc.in W: www.eibc.in Eddycranes Engineers Pvt Ltd

133

T: +91-22-23522710 E: eddycranes@vsnl.com W: www.eddycranes.com EFY Enterprises Pvt Ltd

232

T: +91-11-26810601 E: efyenq@efyindia.com W: www.efyexpo.com Elecon Engineering Company Limited T: +91-2692-236469 E: infogear@elecon.com W: www.elecon.com Electro Flux Equipments Pvt. Ltd. T: +91-44-26243317 E: marketing@electrofluxequipmentspvtltd.com W: www.electrofluxequipmentspvtltd.com Electro Magnetic Indus T: +91-265-3241361 E: sales@electromagneticindia.com W: www.electromagneticindia.com Electronica Hitech Engineering Pvt Ltd

99

T: +91-20-30435400 E: hitech@electronicahitech.com W: www.electronicahitech.com Elitech Machine Tools

217

T: +91-2752-228220 E: elitech@rediffmail.com W: www.teksolgrinders.com Emco Dynatorq Pvt Ltd

224

T: +91-22-25405490 E: mktg@emco-dynatorq.in W: www.emco-dynatorq.in Empire Cable Industries Pvt Ltd T: +91-11-23874632 E: empirecables@yahoo.co.in W: www.empirecables.com

Finechrome Shafts Pvt Ltd T: +91-22-29203647 E: finechromespl@yahoo.co.uk

241

Fontus Water Ltd T: +91-11-43100536 E: sales@fontuswater.com W: www.fontuswater.com

279

Havells India Ltd. T: +1800-11-0303;011-41660303 E: marketing@havells.com W: www.havells.com

Forbes Marshall Pvt Ltd T: +91-20-27145595 E: bgaikwad@forbesmarshall.com W: www.forbesmarshall.com

135

Heattrans Equipments Pvt.Ltd. T: +91-79-25840105 E: info@heattrans.com W: www.heattrans.com

25

43

220

88 Forging Machinery Manufacturing Co T: +91-161-5011755 E: info@nkhhammers.com W: www.nkhhammers.com

16

Henkel Adhesives Technologies India Ltd T: +91-80-25357771 E: marketing@loctite.co.in W: www.loctite.com

97

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ADVERTISERS’ LIST

Advertisers’ Name & Contact Details

Pg No

Hensel Electric India Pvt. Ltd.

18

T: +91-44-24541669 E: henselelectric@vsnl.com W: www.hensel-electric.de Hi-Fab Engineers Pvt Ltd

142

T: +91-22-28879351 E: info@hi-fab.com W: www.hi-fab.com Hitachi India Trading Pvt Ltd

163

T: +91-11-40605252 E: ice@hitachi.co.in

Advertisers’ Name & Contact Details

Pg No

Jindal Aluminium T: +91-80-23715555 E: jindal@jindalaluminium.com W: www.jindalalumium.com

145

Jrew Engineering Ltd T: +91-129-4132844 E: enquiry@jrew.in W: www.jrew.in

130

Jyoti Ceramic Industries Pvt Ltd T: +91-253-2350120/338 E: info@jyoticeramic.com W: www.jyoticeramic.com

226

T: +91-124-4715100 E: marketing@hitechroboticsystemz.com W: www.hitechroboticsystemz.com 194

T: +91-120-234 1050-59 E: ho.mktg@hssp.com W: www.hondasielpower.com/ 14

T: +91-80-39127800 E: info@igus.in W: www.igus.in Ingersoll Rand (India) Ltd

67

T: +91-79-22820123 E: airsolutionsindia@irco.com W: www.ingersollrand.co.in ITL Industries

E: ss-ccd@lth.ltindia.com W: www.larsentoubro.com

235

W: www.itl.co.in 32; 34; 36; 38

T: +91-44-26251279 E: dchandramohan@jaibalaji.firm.in W: www.jaibalaji.firm.in 231

T: +91-250-2481806 E: sales@jayequipment.com W: www.jayequipment.com Jayashree Electron Pvt Ltd

253

T: +91-20-27121295 E: sales@jayashree.co.in W: www.jayashree.co.in Jaykrishna Magnetics Pvt Ltd T: +91-79-22970452 E: info@jkmagnetics.com W: www.magneticequipments.com

77

E: warriors@libertyshoes.com W: www.libertyshoes.com 11; 17

Lokpal Industries

102

T: +91-120-3065372 E: lokpal@vsnl.com

Jyoti Cnc Automation T: +91-2827-287081 E: info@jyoti.co.in W: www.jyoti.co.in Jytra Engineering Services T: +91-40-66663747 / 9246553857 E: info@jytra.com W: www.jytra.com

281 Lubi Electronics

63

T: +91-79-39845300 E: info@lubielectronics.com 53

W: www.lubielectronics.com M+V Marketing - Leuze Electronic

123

T: +91-80-40854444 E: manish.sahay@leuze.in

Kanefusa India Pvt Ltd T: +91-124-4208440 E: info@kanefusa.co.in W: http://www.kanefusa.net

204

Kapasi Fastners / Inc T: +91-80-22279217 E: kapfast@vsnl.com

219

Klipco Pvt Ltd T: +91-22-28684221 E: klipco@mtnl.net.in W: www.klipcohoseclamps.com

228

W: www.leuze.in Maco Corporation India Pvt. Ltd

58; 147

T: +91-33-40224129 E: rdutta@macocorporation.com W: www.macocorporation.com.com Macro Tech Equipment Pvt Ltd

95

T: +91-33-24666261 E: info@macrotechcal.com W: www.macrotechcal.com Magtorq Private Limited

165

T: +4344-276897

E: info@itl.co.in

Jay Equipment & Systems Pvt Ltd

Liberty Shoes Ltd T: +1748-251120

T: +91-731-2722372

Jaibalaji Controlgears Pvt. Ltd.,

19

W: www.lokpal.com

Hitech Robotic Systemz

Igus India Pvt Ltd

Larsen & Toubro Ltd

Pg No

T: +91-22-67525656

W: www.hitachi.com.sg

Honda Siel Power Products Ltd

Advertisers’ Name & Contact Details

Knowell International Pvt Ltd T: +91-33-22304627 E: hktrading@vsnl.com W: www.knowell.co.in

221

E: rst@magtorq.org W: www.magtorq.org Manmachine (India) Private Limited

Konecranes India Pvt Ltd T: +91-20-40047470 E: india.sales@konecranes.com W: www.konecranes.com

111

Kryfs Power Components Ltd T: +91-22-67859999 E: sales@slingset.com W: www.slingset.com

181

Kushal Udyog Manufacturers & Engineers T: +91-291-2720072 E: kushaludg@sancharnet.in W: www.kushaludhyog.com

215

E: info@manmachineindia.com W: www.manmachine.in Mather And Platt Pumps Ltd

6

T: +91-20-27442100 E: sales@pun.matherplatt.co.in W: www.matherplatt.com Mecshot Blasting Equipments P Ltd

61

T: +91-291-2740609 E: pradeep@mecshot.com W: www.mecshot.com

253

Millenium Instruments Ltd Lapp India Pvt Ltd T: +91-80-7826000 E: sales@lappindia.com W: www.lappgroup.com

273

T: +91-120-2422727

51

171

T: +91-11-22456571 E: miepl@miepl.com W: www.miepl.com

Our consistent advertisers

276

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Advertisers’ Name & Contact Details

Pg No

Advertisers’ Name & Contact Details

Pg No

Advertisers’ Name & Contact Details

Pg No

Misumi India Pvt Ltd T: +91-20-66470000 E: sales@misumi.co.in W: www.misumi.co.in

282

Paras Enterprises T: +91-11-25820571 E: paras71@rediffmail.com W: www.parasenterprises.com

233

Prolite Autoglo Limited T: +91-22-26763090 E: sales@prolite.in W: www.prolite.in

139

Mitsubishi Electric Asia Pte. Ltd. T: +91-124-4630300 E: marketing@mspl.messung.com W: www.messung.com

141

Pathak Machines International T: +91-161-2510401 E: ritesh12@hotmail.com W: www.pathakeuromachines.com

241

Pull-Mac Mech & Structural Works T: +91-120-2788260 E: pullmac_cranes@sify.com W: www.pullmaccranes.com

211

225

Puriflair India Pvt. Ltd. T: +91-265-6567666 E: sales@puriflair.com W: www.puriflair.com

184

Nanfang Pumps India Pvt Ltd T: +91-22-25425540 E: sales@nanfangpumps.com W: www.nanfangpumps.com

41

Pepperl+Fuchs(India) Pvt Ltd. T: +91-80-28378030 E: info@in.pepperl-fuchs.com W: www.pepperl-fuchs.com

NI Systems India Pvt Ltd T: +91-80-41190000 E: ni.india@ni.com W: www.ni.com

29

Pidilite Industries Ltd T: +91-22-33087613 E: sunil.ugalmugale@pidilite.com W: www.pidilite.com

NIA Controls T: +91-22-26736864 E: niacontrols@rediffmail.com W: www.tscindia.com Ningbo Xinda Screw Compressor Co., Ltd T: +86-574-8833-6868 E: inquiry@xindaworld.com W: www.augustcompressor.com

215

24

Pilot Pneumatics Pvt Ltd T: +91-22-66047000 E: info@pilotindia.com W: www.pilotindia.com Pin Hong Technology Co., Ltd T: +886-2-2978-7348 E: pinhong.co@msa.hinet.net W: http://www.pht-gear.com.tw

Rajindra Machines (P) Ltd T: +91-1871-242763 E: rajindramachines@yahoo.com W: www.rajindra.net

12

255

64 Red Lion Controls T: +91-09879540503 W: www.redlion.net

21

Regulateurs Georgin T: +33-01-46126000 E: sales.in@georgin.com W: www.georgin.com

199

Power Build Ltd T: +91-2692-231070 E: infopbl@elecon.com W: www.pbl.co.in

259

Reid Supply Company W: www.reidsupply.com

255

20

Premier Engineering Technics Pvt Ltd T: +91-22-26852233 E: sales@premiertechnics.com W: www.premiertechnics.com

207

Reva Industries Ltd T: +91-129-4185400 E: reva@revacranes.com W: www.revacranes.com

224

Pioneer Cranes & Elevators Pvt Ltd T: +91-161-2491935 E: info@pioneer-cranes.com W: www.pioneer-cranes.com

Novoflex Mktg Pvt Ltd T: +91-33-22260733 E: novoflex@vsnl.net W: www.novoflexgroup.com

101

Nu-Teck Engineering Co. Pvt. Ltd. T: +91-20-27120644 E: info@nuteckindia.com W: www.nuteckindia.com

118

Oil Seals Mfg Co Pvt Ltd T: +91-22-22047943 E: omcoseal@rediffmail.com

242

7

203

Radix Electro Systems Pvt Ltd T: +91-22-42537784 E: sales@radix.co.in W: www.radix.com

2

NMT Group T: +91-79-22821527 E: nmtg@nmtgindia.com W: www.nmtgindia.com

Omron Automation Pvt. Ltd. T: +91-80-40726400 E: srirams@ap.omron.com W: www.omron-ap.com

9

Premium Transmission Ltd T: +91-20-27488886 W: www.premiumtransmission.com

75

Prism Surface Coatings (P) Ltd T: +91-08110-417999 E: sales@prismsurface.com W: www.prismsurface.com

187

Onyx Equipments (India) Pvt Ltd T: +91-20-65106213 E: info@onyxindia.com W: www.onyxindia.in

237

Procon Technologies Pvt Ltd T: +91-79-27492566 E: info@procon.co.in W: www.procon.co.in

200

P.P.I. Pumps Pvt Ltd. T: +91-79-25832273 E: sales@ppipumps.com W: www.ppipumps.com

188

Progressive Engineering T: +91-22-32944289 E: info@progressiveengineers.net W: www.progressiveengineers.net

227

Rexello Castors Pvt Ltd T: +91-22-4091777 E: rexello@vsnl.com W: www.rexellocastors.com

223

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211

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212

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216

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261

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Tox Pressotehnik India Pvt Ltd

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179

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245

1

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199

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219

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238

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240

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261

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47; 213 Trident Precision International E: trident.sales@tridenthydraulics.com

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151

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244

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207

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149

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189

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203

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244

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258

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242

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265

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65

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256

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57

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Theeta Electricals Pvt Ltd T: +91-124-4387400 E: sales@theeta.com W: www.theeta.com

238

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127

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167

124

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201

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256

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