Green Sand Process - Economical, Flexible & Manageable Technologies

GREEN SAND PROCESS Economical, Flexible & Manageable Technologies 1. Generic View – Foundry Industry by Amit 2. Your Competent Partner – Rhino Machines by Amit 3. Green Sand Process – Overview by Manish 4. Sand Preparation & Conditioning – MaxCool (RMC) by Manish 5. High Pressure Moulding Machine – FM by Manish 6. Save money, money will save you – RTC by Amit 7. Comprehensive solution – EcoFlex by Manish & Amit 8. Summary Note – R C Kothari 9. Q&A and Thank you by Rhino Team

R a j k o t Rajkot is also the 22nd‐fastest‐growing city in the world.

Cricket is the most famous sport in the city. Rajkot has produced cricketers such as K S Ranjitsinhji, Karsan Ghavri, Cheteshwar Pujara And SIR Ravindra Jadeja.

Rajkot produce castings up to 70% of local diesel engine industry of India. There are about 500 foundry units in Rajkot.

The majority of foundry units in Rajkot produce grey iron castings for the domestic market.

A very small percentage (about 2%) of the foundry units export castings such as electric motor castings, automobile castings etc.

Rajkot is famous for providing education to Mahatma Gandhi (Gandhiji), at the Alfred High School.

Or

–ve Growth

Generic view of present business scenario: Days are getting tougher and tougher for foundries …..applicable to all of us….

Schedules are not coming, customers are not lifting ordered castings and tremendous pressure to reduce prices from customers ends to unhealthy competition by fellow foundries Many foundries from 70% of workload have slipped to only 40-50% of the workload. And no ray of hope is seen in near future.

We share our views how to survive in this difficult time, off course other than - reduce price and get competition’s share to remain at break-even.

Or

–ve Growth

USA Post World War I in 1918 Two of the most important new technologies were automobiles and radio.

Plus One more , that was the motion picture.

Technology made it possible for millions of people to improve their lives. It also caused great changes in American society.

USA Post World War II in 1945 The invention of air conditioning, the development of "Sun Belt" cities such as Houston, Atlanta, Miami, and Phoenix in the southern and southwestern states.

Shopping centers multiplied, rising from eight at the end of World War II to 3,840 in 1960. Many industries soon followed, leaving cities for less crowded sites.

Or

–ve Growth

USA Post World War 3 USA Post Cold War – often dated from 1945-1991 The Cold War was so named as it never had any direct military action.

Huge investment by Federal Govt. & Private Investors in R&D i.e. The Production of Knowledge boomed.

Cold War = Virtual War / No Physical War Let treat this –ve growth as virtual war!

How to win war?

Sustainable Technology through Innovation & Policy Initiative

Understanding the Challenges

CREATE AND EMBRACE SYSTEMS TO SUPPORT YOU

• If your systems and procedures are still not in place build them NOW! • If they exist, manage them dynamically to work for you!

Dream Decides Destiny!

So let’s Dare 2 Dream.

When it rains all birds occupy shelter but eagle is the only bird who avoids rain by flying above the cloud.

Problem is common to all but attitude makes the difference.

Dream to Deliverables!

Look for modular & manageable solutions Look for vendor who work with you for your comprehensive solution as your competent partner

Foundry, let’s focus on ROI Foundry Projects – Concentrate for competitive solutions Look for projects conceptualization, planning, detailed engineering & installation supervision Get support for Foundry Equipment manufacturing & installation, process support Procure Technical Solutions – Design process machines & handling equipment Select right vendor, who works as competent partner for you

What’s advantage?

Green Sand Process an Overview Sand Conditioning & Preparation System

Moulding System

Return Sand Management

Sand Conditioning & Preparation Flowable

Refactory

Plastic

Prepared Sand Green Strength

Dry Strength Permeable

The MaxCool Technology

Typical MaxCool Deliverables INPUT SAND

OUTPUT SAND 54

55

54

48

44 33 32 31 31 30 28 27 25 25

8‐9

Cycle Time 62

38 31

35

39

41

42

43 44 33

9‐10 10‐11 11‐12 12‐13 13‐14 14‐15 15‐16 16‐17 17‐18 18‐19 Day Avg

Typical Savings Derived v/s Fixed Rotor Mixers

Bentonite

• • • •

New Sand

• Reduction by upto 25% • For 1% sand reduction on 20 TPH, Savings upto Rs 15 Lakhs/annum

Rejection

• Controlled Temperature and Moisture Reduces Rejection by 0.5 to 3% • Sand Sticking Reduced, Surface Finish Increased, lesser finishing related rejections

Power

Upto 25% Reduction Active Clay Reduced Moisture Level Reduced Permeability Increased

• 25‐30% Lower with VFD Control for Optimised Power • Installed Power 25% Lower than Similar Machines

Moulding Systems FOUNDRY USER NEEDS

LOWER PRODUCTION COSTS REDUCED DEPENDENCE ON SKILLED PERSONNEL

• Lower Capital Investment • Lower Energy Consumption

CONSISTENT QUALITY • Dimensions

• Higher production with lesser manpower

• Surface Finish

• Lower Maintenance & Operational Costs

• Casting Defects

• Lesser Space Requirements

• Weight Variation

• Reduced Machining Allowance • Reduced Fettling Requirements

Moulding System ‐ The Options Jolt Squeeze

High Pressure Moulding Stand Alone

Unsafe

Inconsistent

Rigid & Dense Mould

Better casting surface finish

Noisy

More Manpower

Dimensional stability

Noise"less" "l " operation, no p sound pollution

Human Dependant

More Energy

Air "less" process ‐ no compressed air

Single Point Sand Filling

More Space

More Equipment

Higher Productivity

Strong Foundation

Higher Hi h Ownership Cost

Single semi‐skilled Operator

The Present

Upgrade the Present and d h d Look to the Future

Commercial Evaluation of Moulding Processes JOLT SQUEEZE Estimated Ownership Cost per annum : Rs 105 Lakhs • Capital & Finance • Rejection • Higher Weight/Fettling • Moulding Persons • Energy Cost • Match Plates (30 Sets)

: Rs 50 Lakhs : Rs 27 Lakhs : Rs 18 Lakhs : Rs 4 Lakhs : Rs 3 Lakhs : Rs 3 Lakhs

MULTIFLEX – High Pressure Moulding Estimated Ownership Cost per Annum: Rs 87.5 Lakhs • Capital & Finance • Rejection • Moulding Persons • Energy Cost • Match Plates (30 Sets)

: Rs 65 Lakhs : Rs 18 Lakhs : Rs 2 Lakhs : Rs 1 Lakh : Rs 1.5 Lakhs

Sand Management Tool the ROTOCONTROL Measures : Compactibility (RTC103.6) and GCS (RTC106)

Monitors : Water Additon & Additives

Generates : Savings in Rejection, Productivity

Save Money Money Will Save You Prepared Sand Manages :

Production by Mixer/Muller

Reports : Histogram, Consumptions, Production Data

ROTOCONTROL The Online Sand Plant Manager

100%

8 Hours x 3 Shift

Consumptions

Control

Production Monitor

Statistical Data

&

Analysis and Control

on Compactibility &

Compactibility

GCS

Graph

For

Users : Sharp Chucks, DCM Engineering, Pritika Autocast, Godawri Spherocast, Jainson Malleables, Amtek Auto, AB Tools, Uttam Foundries, Seaco, Kores India, Menon & Menon, RPS Vikas, Siddhi Ferrous, NeoSym Industries, Shanti Iron, Amar Udyog, Kalkaji Engg, Pefco Foundry, Howrah Ferrous, Singhbum Technocast, Mal Metalliks, Kirloskar Ferrous, Mahindra & Mahindra, Radhe Alloys, Supratech, Akshar Metalloys, JMP Inds, Boparai Metals,…………….>1000 units around the world.

Phased Implementation

Economical, Flexible and Scalable

EcoFlex

EcoFlex Phase 1 Phased Implementation

Economical, Flexible and Scalable

Screen & Magg Pulleyy Mixer

Cooling by Recirculation Knock Out

Mixer Knock Out

Start with Mini‐Ecoflex Mixing, Sand Storage, Cooling of Sand – Only Rs. 65 L

EcoFlex Phase 2 Phased Implementation

Economical, Flexible and Scalable

Screen & Magg Pulleyy

FM1

FM1 Knock Out

FM1 Boxes & Manual Handling

Moulding Machine Boxes and Manual Handling Added – Only Rs. 65 L

EcoFlex Phase 3 Phased Implementation

Belt Extended

Mixer Relocated

Knock Out

FM1 relocated

Screen & Magg Pulleyy

Economical, Flexible and Scalable

Moulding Machine Boxes and Manual Handling Added – Only Rs. 65 L

EcoFlex Phase 4 Phased Implementation

Economical, Flexible and Scalable Mixer RTC Added

FM1

Screen & Magg Pulleyy

Knock Out

FM1

Mould Line AUtomated

Boxes and Automation Completed.

Final Plant – Only Rs. 65 L

EcoFlex v/s Conventional ECOFLEX SOLUTION Space : 30 x 8 Mtr, 9 Mtr high 3 Belts, No Bucket Elevator, 45 cu.mtr Pit only Maintainable, Manageable, Clean

CONVENTIONAL SOLUTION Space : 30 x 8+12x16 Mtr, 14 Mtr high 6 Belts, 2 Bucket Elevators 100 cu.mtr Pit approx

EcoFlex v/s Conventional

Concluding Benchmarks for Green Sand Process Sand Preparation

Moulding Compact Plant ROIs of any Plant are Important, Mixing Efficiency – Additives Weight & Dimensional Area Occupied per MT of Consider Options Carefully and Consumed per MT of Casting Consistency Casting Produced Invest Today No of Elements – are they Sand Cooling & Conditioning Rejection Control optimum Which is Sustainable for the Future to Come Power Consumed for Preparation & Cooling

Human Dependance/Skill Required

Energy Consumed

Online Sand Management System

Energy Employed

Plant Environment Management & Plant Lighting

Manageability and Simplicity

Operator Safety – Physical & Environment

Plant Installation Time

Mantainability, Productivity

Concluding Note Shri R C Kothari Founder – Rhino Machines

time to think

Rajkot is also the 22nd�fastest�growing city in the world.

Cricket is the most famous sport in the city. Rajkot has produced cricketers such as K S Ranjitsinhji, Karsan Ghavri, Cheteshwar Pujara And SIR Ravindra Jadeja.

Rajkot produce castings up to 70% of local diesel engine industry of India. There are about 500 foundry units in Rajkot.

The majority of foundry units in Rajkot produce grey iron castings for the domestic market.

A very small percentage (about 2%) of the foundry units export castings such as electric motor castings, automobile castings etc.

Rajkot is famous for providing education to Mahatma Gandhi (Gandhiji), at the Alfred High School.

Q&A

Thank you . . . . .

Rajkot Members, IIF Rajkot Chapter And All Participants

Rhino Machines Pvt Ltd & RC Technologies Manish Kothari, Amit Shah, Renzo Cappelletto