OEM Update July 2014

OEM UPDATE MAHENG/2009/33944

Vol 6 Issue 2 • Pages 56 • Mumbai

July 1, 2014 • `100 • www.oemupdate.com

For Efficient Manufacturing

INSIDE Flow Control Technology Warehousing Bearings Process

LASER higher efficiency, lesser efforts

An I-Tech Media Publication

CONTENTS Cover Story LASER: higher efficiency, lesser efforts ������������������������������������������� 14

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Quick Update Grundfos India to switch from IE1 to IE2 motors as standard ����8 Telangana gets first major investment ����������������������������������������8 25% MSMEs in North India on verge of closure: ASSOCHAM 10 Henkel launches Loctite Safecoat with excellent adhesion ������12 Siemens conducts technology round table conference ������������12

Machine Tools Global market for laser cutting machines to reach $4.9 bn by 2020: Study ������������������������������������������������������������14

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Automation: ensuring success through maximum return ���������18 igus launches versatile construction kit for robotics �����������������20 Omron showcases advanced solutions at PackPlus ����������������21 Curbing cyber threats within manufacturing sector ������������������22

Instruments & Controls Smith Flow Control’s technology makes valve interlock adjustment effortless ��������������������������������������������������26 Honeywell presents efficient, economical SmartLine ���������������31 HanOnBoard to simplify decentralised distribution boxes �������� 33

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Warehousing Automotive warehouse:an essential gear ��������������������������������34 Technical Enterprises presents economical ‘handy’ lifts �����������36 On-line monitoring solution for pharma warehouses ����������������37

Components SKF’s Ahmedabad factory: the source of perfect bearings ������38 Turbo presents bearings for radial and combined loads ����������41 Delphi-TVS relies on Kennametal Extrude Hone for

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surface finishing �����������������������������������������������������������������������42 NTN’s Ultage series: assures value for money ������������������������42 Chlorine-free neat cutting oils to play vital role �������������������������43 ZAplus recognised as ‘most innovative fan of 2014’ ����������������44

Process Replacing diffusers with energy efficient aerator yield greater efficiency ��������������������������������������������������������������45 Submersible motor pump for handling wastewater ������������������45 New generation fluorescent lights for hazardous areas �����������46

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Ingersoll Rand launches 3CII-i centrifugal air compressor �������46 New Projects ����������������������������������������������������������������������������52 Tenders �������������������������������������������������������������������������������������53

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July 2014 n OEM Update n 6

Even sky is not the limit India proves it again! After the successful launch of the Polar Satellite Launch Vehicle (PSLV) - C23 rocket, the country has elevated itself into the elite group of space giants. So far, India has successfully launched 67 satellites to become one of six countries leading the field.

More significantly, the successful launch of C23 has become a global event as it carried five foreign satellites of France, Germany, Canada and Singapore.

In recent years, India has scored significant successes in space exploration. In 2008, Chandrayaan lunar mission discovered sources of water on the Moon whereas successful launch of Mangalyaan Mars orbiter in November last year grabbed global attention.

The recent success is being projected as a “global endorsement of India’s space capability”. Not only that, India is also maintaining the tag of ‘cost-efficient’ even in the field of space science. Commenting after the successful launch of C23, the Prime Minister of India Narendra Modi claimed its Mars mission will cost less than the Oscar-winning science-fiction thriller ‘Gravity’.

The successive achievements of Indian scientists in the field of space cannot be seen as isolated ones. It reaffirms India’s sustainable commitment toward indigenisation.

Gradually the Indian industries across the spectrum and educational institutions have come out of their infancy. Now it is one of the most preferred destinations in terms of manufacturing investment and available talent pools.

India is also doing significantly well in the areas of nanotechnology. According to an Assocham-TechSci Research joint study, from 2015 onwards, global nanotechnology industry would require about two million professionals and India is expected to contribute about five lakh professionals in the coming years.

These are just couple of examples in the writing of India’s growth story. If everything goes well, India will soon be in a commanding position to rule the world of manufacturing with indigenisation! Is it too much to ask from a country of 1.27 billion populations?

Please do send me your comments at editor@oemupdate.com

Quick Update

Grundfos India to switch from IE1 to IE2 motors as standard G

rundfos Pumps India Pvt. Ltd. (Grundfos India) announced that the company will be switching from IE1 to IE2 motors as standard from 1st August. To begin with, it will be implemented in the CR range of pumps and will be gradually extended to other products as well.

“In alignment with the global trend of shifting towards energy efficient motors which was introduced in Europe in 2011, and in China this year, Grundfos is the first pump company in India to move to these energy efficiency IE2 motors,” the company statement said.

Pumps currently consume 10 per cent of global electricity. Without precisely the right motor, even the best pump will consistently waste energy. “With Grundfos high efficiency pump and motor technology, it reduces the average pump’s energy consumption by up to 60 per cent,” the company claims.

IE2 motors are highly energy efficient. Using IE2 motors will help reduce the lifecycle cost of the pump and also save the operational costs. Some of the benefits of using these energy efficient motors include:

• Operate at better efficiency when they are lightly loaded because of their better design • Dissipate less heat compared to standard efficiency motors due to higher efficiency • Use of energy efficient fans keeps the motor at lower temperatures • Increases life of insulation and windings besides increase in overall life of motor • Total energy cost: its life cycle cost is much lower when compared to conventional motors • Better tolerance to thermal and electric stresses • Ability to operate at higher ambient temperatures • Ability to withstand abnormal operating conditions such as low voltage, high voltage or phase imbalance.

Ranganath N. K., Managing Director, Grundfos India, said, “The move to switch to IE2 showcases our commitment to helping our customers reduce their energy consumption and costs. There is an increased awareness about the use of energy efficient products and we are confident that this will be well received by our customers.” n

Grundfos CR pump with IE2 motor installed

Telangana gets first major investment T

elangana, the country’s youngest state, secured its maiden industrial investment on Monday from a Tata group company Tata Advanced Systems Ltd. (TASL).

The company will manufacture the fuselage and wings of Dornier 228 aircraft produced

by Switzerland-based RUAG Aviation AG. This partnership is TASL’s fourth such in the aerospace sector.

In a short span of five years since 2009, TASL has become a significant player in the global aerospace market, already establishing 100 per cent export-dedicated joint ventures with Sikorsky and Lockheed Martin.

The ground-breaking ceremony for the manufacturing facility here was held in July 2014 n OEM Update n 8

the presence of K. Chandrashekar Rao, Chief Minister of Telangana, S Ramadorai, Chairman of TASL, and Martin Bühlmann, Vice President - Supply Chain Management of RUAG Aviation.

Commenting on the relationship, Mr Bühlmann said, “With TASL, we have found the right partner for the future of the RUAG Dornier 228 Programme. Tata’s strong track record in similar programmes and their ambition to become one of the world’s leading manufacturing companies in the aviation sector make us confident that this partnership will be successful and offer long-term benefits to both Tata and RUAG Aviation.”

Speaking on the occasion, Mr Ramadorai said,

“The Tata-RUAG partnership is a glowing example of cooperation between India and Europe. That RUAG has entrusted us to deliver its showcase product, the Dornier 228, at world-class standards of precision and quality, demonstrates our success in developing a highly skilled and motivated workforce with established credentials to undertake high-technology work for global customers.”

This project is the fourth aero structures unit to be set up by TASL in Hyderabad. The joint venture with Sikorsky has already delivered over 70 Sikorsky S-92 cabins, successfully indigenising the production of the entire cabin. The joint venture with Lockheed Martin manufactures the empennage and centre wing box for the C-130 J Aircraft. n

Quick Update

25% MSMEs in North India on verge of closure: ASSOCHAM D

ue to unprecedented power crisis in northern India, over 25 per cent micro, small and medium enterprises have come to the verge of closure due to their inability to use diesel-based power generation, according to information received by apex industry body ASSOCHAM. “The worst affected states are Punjab, UP, Haryana, Rajasthan and Delhi, thereby threatening the livelihoods of thousands of workers,” said D.S. Rawat, Secretary General of ASSOCHAM while stating his observations.

In its survey released last week, ASSOCHAM had stated that the industrial production is likely to fall by 40 per cent due to frequent power outages in the aforesaid regions that are also coping with severe heat wave.

Due to extreme power deficit, industrial production in states of Uttar Pradesh, Andhra Pradesh, J&K, Haryana, Punjab, Rajasthan, Karnataka, Tamil Nadu, Maharashtra would have to be curtailed to the extent of 30-35 per cent particularly in manufacturing units as these have no alternative means to produce power, according to ASSOCHAM. The feedback received by ASSOCHAM is based on the latest power situation in leading states that have concentration of industrial presence at substantial level discloses that in states such as Uttar Pradesh Madhya Pradesh, Maharashtra, and J&K energy deficits which was around 20-25 per cent in April-May would go beyond 30-35 per cent in June –July, further noted ASSOCHAM. Uttar Pradesh and Andhra Pradesh are two states in which power cuts exceed 10-12 hours a day and face the worst energy crisis which will further deepen in the absence of corrective measures and therefore industrial locations in these two states would have to curtail their industrial production to the extent of 45 per cent, said Mr Rawat.

Uttar Pradesh, which is one of the industrialised states in the country is facing one of the worst crises with energy deficit July 2014 n OEM Update n 10

touching about 11.2 per cent, facing energy deficit of over 924 Million Units (MU). The state of Uttar Pradesh as per feedback given to ASSOCHAM by its constituents is resorting to an average load shedding of 1012 hours a day.

The state of Uttar Pradesh, which has a power requirement of over 8,282 MU, has availability of little over 7,358 MU with deficit ranging over 11.2 per cent. The situation is no better in Andhra Pradesh where the power deficit is approximately 12.1 per cent.

The availability in the state is only 7,976 MU against the requirement of 9,070 MU. The Southern part of the country is likely to suffer energy shortage to the extent of 2,111 MU particularly in Andhra, Karnataka and Tamil Nadu.

Jammu & Kashmir suffered a power shortage of 20.3 per cent in April which will go around 25 per cent and the gap between power availability and supplies would be around 1000 MU. Maharashtra has a potential to generate 5,000 MW of electricity through wind energy and another 1500 MW by way of bagasse cogeneration. With the use of nonconventional resources of energy, these

regions can become a power surplus state in few years.

Demand side management and also transfer of surplus power from the captive units to the state grids were few other suggestions cited to fight power shortages in short run.

According to the chamber power theft, leakages and transmission and commercial losses were the main reason for power deficit in these states. Use of non-conventional sources of energy especially for domestic usage and street lightning, is another shortterm solution recommended by opinion leaders.

Mr Rawat further said that since a few new capacities are emerging in power sector and T&D losses remain untamed to the extent of 50-55 per cent in most of leading states, the power situation is unlikely to be better in next few months even though mercury levels will fall significantly.

ASSOCHAM Secretary General also added that lack of fresh investment and modernisation coupled with huge transmission losses are responsible for the grave power situation in the country which will continue. n

20 - 23 Aug 2015 Pragati Maidan, New Delhi India

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Quick Update

Henkel launches Loctite Safecoat with excellent adhesion I

ndia has a vibrant agricultural sector where water for irrigation is extracted using submersible pumps. However, most of the anticorrosion solutions offer a very short life span to the equipment or are costly and timeconsuming to apply.

In practice, a submersible pump is a pump which has a hermetically sealed motor closecoupled to pump body. The whole assembly is submerged in the fluid to be pumped.

Submersible pumps are divided into two major parts i.e. motor side and pump side.

The motor side has two major components which are the stator and rotor which is made up of Silicone steel / CRNO (cold rolled non oriented) stampings. The motor is filled with water or at times with water and glycol mixture which acts as a coolant. The filling is done prior to installing the pump for operation in the field. Thus the rotor is always in contact with the water or water and glycol mixture.

Considering the above things, Henkel has innovated its new product Loctite Safecoat.

It is an easy to use product which helps in in-house production set as compared to processes like chrome plating etc which needs to be outsourced. It offers excellent adhesion to submersible pumps rotor stamping substrate. In addition, it gives a dry film thickness of 80-100 microns which is the expected range for submersible pump rotors.

Some other important features of Loctite Safecoat are:

• Superior performance 2 part epoxy product specifically developed for the submersible pump rotor coating application • Heat cure product which leads to reduction in curing time • Product is applied by spraying with standard pilot S 59 gun which helps to attain consistent coating thickness • No need to add thinner into the mixed product since the viscosity of the product aids in easy sprayability • Salt spray test of 1,000 hours passed by the product n

Pump Side

Motor Side

There have been customer concerns as the rotor is susceptible to corrosion since the rotor is always in contact with water or water and glycol mixture and runs at about 2800 rpm. The corrosion affects the efficiency of the pump.

Powder coated rotor

Siemens conducts technology round table conference S

iemens with its extensive experience in engineering and commissioning critical infrastructure and industrial projects, coupled with strong domain knowledge of data centres has evolved as preferred partner for data centres. With regard to the same, Siemens recently conducted select media round table conference. The major topics discussed included innovative technologies, global and regional growth trends and their impact on the strategic priorities of the data centre markets.

In light of the large economic potential as well as enormous energy demand of data centres, July 2014 n OEM Update n 12

effective facility management of data centres is of primary strategic concern.

On the occasion, Philip Krause, Head of Datacenter Centre of Competence, AsiaPacific, Siemens discussed about technologies that enable 24x7 operational excellence for data centre.

Varoon Raghavan, AVP Growth Ventures, Tata Communications Limited, expressed his views on an end user perspective on designing, building, and maintaining efficient data centres.

Stephen Worn, CTO and CEO, North America Datacenter Dynamics, talked about a global perspective on the data centre market and its growth potential, with focus on India.

According to Nasscom, India’s data centre market was pegged at approx $2.2 billion in 2012 and is estimated to grow by more than 8 per cent over the next 3-4 years. The data centre is considered as the most energyintensive and data-sensitive type of facilities in the world and the demand for more data centres is growing unceasingly. n

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Machine Tools

Global market for laser cutting machines to reach $4.9 bn by 2020: Study Driven by robust demand from key end-use industries such as consumer electronics, aerospace and defence, medical devices, and automotive, the global market for laser cutting machines is expected to reach $4.9 billion by 2020

L

aser beam is being widely used for precision micromachining from cutting lacy implants to thick steel. In the machine tools industry, laser cutting machines represent important manufacturing tools that are critical to the production of a range of manufactured parts and finished goods. These machines are primarily used in production processes to shape, cut, bore, weld, grind, drill, tap and form metal components.

Laser cutting machines score over conventional cutting machines in terms of precision, flexibility and accuracy. Rapid economic development, industrialisation, expansion in manufacturing bases, and massive investments in machinery were largely responsible for the market’s strong evolution over the years.

With growth strongly linked to the health of end-use industries, the world economic recession weakened sales of laser cutting machines during the years 2008 and 2009 before posting a recovery in the year 2010.

The recovery was largely aided by the resurgence of growth fundamentals in enduse sectors such as aerospace and automobile manufacturing, medical devices, renewable energy, semiconductors and consumer electronics. Current growth is driven by

July 2014 n OEM Update n 14

steady gains in global GDP performance, and improving industrial and manufacturing activity as indicated by the relatively stable global manufacturing Purchasing Managers Index (PMI).

According to new report published by Global Industry Analysts, Inc, “The global market for laser cutting machines is forecasted to reach $ 4.9 billion by 2020, driven by robust demand from key end-use industries such as consumer electronics, aerospace and defence, medical devices, and automotive, among others.

Growth drivers Future growth will be spearheaded by the consumer electronics sector supported by spiralling demand for smartphones and tablet PCs. Laser cutting machines are increasingly used for the production of integrated circuits, displays and printed circuit boards. The strong automotive industry in developing countries is also expected to aid market growth. Novel application of laser cutting machines in the aerospace and defence sector represents another important growth driver. The sector largely depends upon precision laser cutting for manufacturing highly advanced parts and components with complex geometric designs.

Growth in commercial aviation, rising global

air traffic which is set to explode further in the coming years, strong military budgets against a backdrop of rising terrorism, and the need for efficient homeland protection bodes well for high-end laser machines used in the aerospace and defence sector.

Growing focus on plant automation in most end-use markets in a bid to enhance productivity, reduce downtime, and conserve energy, is poised to benefit demand for robotic laser cutting machines. A key technology innovation expected to benefit the market in the near term is the development of ultrashort or ultrafast pulsed lasers, which are gaining rapid traction in material processing applications due to their ability to process majority of material types with high precision.

As stated by the new market research report on Laser Cutting Machines, Asia-Pacific represents the largest market worldwide.

The region also represents the fastest growing market with a CAGR of 11.1 per cent over the analysis period. Strengthening GDP, increasing industrialisation, expanding manufacturing base, along with rapidly growing electronics, semiconductor and automotive end-use industries represent key growth drivers in the region. n

Cover Story

LASER: higher efficiency, lesser efforts I

n today’s world, laser technology is growing in diverse industrial applications. Though the automotive sector has predominantly implemented the laser technology as a new alternative to traditional manufacturing processes, today laser technique is enjoying its presence in various applications, from automation to optics, and from telecommunication to security.

Laser cutting is a technology that uses a laser to cut the materials, and is typically used for industrial manufacturing applications. India is growing global automation hub primarily on account of labour and easy availability of technology.. Here we discuss about the latest innovations in laser cutting machine tools and overall laser use in machine industry.

away. A high pressure jet of gas also blows away any debris, resulting in a highly finished surface cut.

Two types of laser cutting machines mainly in use are CO2 and Nd:YAG. CO2 laser cutting machines were one of the first gas lasers and are the most common variety of laser cutting machine. They offer an excellent power input-output ratio, as efficient as 20 per cent.

Nd:YAG lasers are solid state and use a crystal as a lasing medium. They cut steel and other alloys in the metal working industry.

Latest trends in laser cutting

As laser technology is continuously developing, it is interesting to see what are the latest technological advancements and innovations being offered by the current players in industry. Let’s have a look at the same.

Laser cutting machines allow metal fabricators to create high-quality parts that require very little, if any, finishing work. As the high-powered laser is cutting, excess material either melts, burns or vapourises

“We have come up with latest CNC structure with power automation (German) controller,” says Jayesh Patel, Marketing Director, A Innovative International Ltd. “Also

July 2014 n OEM Update n 16

Lesser in efforts Accuracy in applications Simple in handling Efficient in operation Reliable in outcome we are having solution of slab technology for CO2 source for which maintenance is also very less and is safe in operation. We provide latest fibre technology with different suitable structures which ultimately gives reliability and flexibilities to customers.”

“Quality of cutting and efficiency of operation are the two key aspects that are in much focus at our R&D centre. The operating cost and consumables for our fibre laser cutting machines are almost half that of the conventional CO2 technology. Our fibre laser cutting systems ensure lowest maintenance cost as well,” assures Maulik Patel, Executive Director, Sahajanand Laser Technology Limited (SLTL).

Maulik Patel also informs about what SLTL has done in this regard to offer its other features which include: • Butter cut: The glossy and smooth finish on steel of thickness varying from 5 to 12 mm; achieving the finish at this thickness level at a high speed is what considered as

Cover Story Laser cutting vs. mechanical cutting

Jayesh Patel, Marketing Director, A Innovative International Ltd.

Laser cutting offers benefits like no need of tooling, no mechanical stress on cutting edge, and making variety of cutting profiles possible in a single setup.

a key advancement in technology.

• Striation free edges at thicker metals.

The angular distortion caused in the conventional non-contact type cutting system has been corrected and the finish has been improved with various evolutions. The dynamic edge control mechanisms have been developed to control the pressure of assist gases, cutting speed and laser power in order to deliver perfect geometry and to achieve least angular distortion.

• 1G to 5G acceleration has been able to achieve with modifications in design and redefining material technology, for point to point positioning it has been saving time and electricity to a large extent.

Laser cutting machines are distinct from traditional mechanical cutters. Since the laser never makes physical contact with the metal, there is little to no wear on the equipment, and there is less opportunity for the material to become contaminated. Laser cutting machines also cut metal with higher precision than that of mechanical means.

According to Jayesh Patel, laser cutting offers benefits like no need of tooling, no mechanical stress on cutting edge, and making variety of cutting profiles possible in a single setup. It is also possible to cut non-metals with the help of laser. Moreover, laser cutting gives higher material scrap value too and is suitable for wide range of applications.

Explaining how laser cutting is advantageous, Maulik Patel says, “Unlike the conventional cutting processes namely punching and turret press, lasers have two indigenous benefits i.e. non-contact type cutting and profile cutting.

Profile cutting with fibre lasers has equal preference in lot manufacturing these days.

Thanks to the very high speed of cutting, precision and best-in-class quality of finish achieved through fibre laser technology.”

In mechanical cutting, there is usually a wide heat affected zone that can cause material warping from time to time. However, as in case of laser cutting machines, the heat affected zone is kept small, possibility of warped material gets significantly reduced.

Although laser cutting offers numerous advantages, it also consumes a very high level of energy, making it more difficult for a conventional machine shop to incorporate into its metal fabrication system.

Reflecting surfaces: a concern

Maulik Patel, Executive Director, Sahajanand Laser Technology Ltd.(SLTL)

The operating cost and consumables for our fibre laser cutting machines are almost half that of the conventional CO2 technology.

While exceptional for cutting steel and other hard metals, laser cutting machines typically do not function well on highly reflective metals, like copper and aluminium. Since these metals easily reflect the laser’s light and also absorb its heat, highly-powered beams are required to cut them. Also when piercing, laser cutting machines create slightly tapered holes due to the hole entry being slightly larger in diameter than the exit.

slightly different optics design with laser’s wavelength to work on reflective metals. Else to adjust the focal lens in the cutting head in a way that it does not get hampered with the laser reflected from reflective materials.

In some cases, the cutting head is tilted in a minute angle to avoid the back-bashing of laser.”

“Generally for reflective materials fibre laser is recommended. However, in case of CO2 laser, ATFR mirror could be installed (back reflection unit) to prevent damage of laser source due to reflection of laser beam,” suggests Jayesh Patel.

Since laser cutting melts the material in the beam’s path, metal can harden in the puncture, especially in heat treated material.

While this may be beneficial for some applications, this issue can be detrimental to those requiring further work, like threading.

Application areas and future scope Nowadays laser cutting machines are finding their applications on large scale in various fields like sheet metal fabrication, architectural and hardware segments, enclosures, pharma machineries, agro equipments.

Fibre laser cutting system has its applications at wide range of industrial segments. Fibre laser cutting of course is one of the apt solutions for precision engineering. With the growing industries focusing on precision and accuracy, there is a booming market with wide open gate for fibre laser cutting systems.

“It’s not only the economic performance of the system that stood best. It’s the quality of cut, repeatability and accuracy achieved through fibre laser system made its penetration into other applications as well,” adds Maulik Patel.

“Other than sheet metal industry, structural fabrication and heavy engineering, tube, angle and bevel cutting applications also have felt the need of fibre lasers.”

Fibre laser with power options less than 1kW is now emerging as a replacement for turret punch. The low power fibre laser is now finding its place in the turret punching industry due to its capabilities in profile cutting, and investment.

Conclusion “Catering to defence and aerospace industries, now the fibre lasers are capable of cutting reflective metals and even metals with special coatings,” says Maulik Patel. “This is possible in two ways. One is to increase the power of fibre laser cutting system and have

In all, as laser technology will always keep exploring itself in many segments, we can say that it is clearly offering a bright future not only to machine tool industry but overall world of ever-increasing and ever-changing technology. n 17 n OEM Update n July 2014

Speak Out

Automation: ensuring success through maximum return “In the manufacturing world, business success depends on your ability to employ your assets in a way that delivers maximum return for which automation is indispensable in today’s manufacturing environment,” says Himanshu Shaparia, Vice President-Sales, Jyoti CNC Automation.

T

oday automated machining processes are finding their applications in many fields on large scale. Himanshu Shaparia talks about the same and also analyses the scope for Indian automation sector to establish itself in the said segment.

• Greater control and consistency of product quality and accuracy • Reduction in process time, resulting in higher production • More efficient use of materials, resulting in less scrap • Increased worker safety.

developing country like India, automation seems to be the keyword today. In fact, the Indian automation industry is currently witnessing yearly growth of 20-25 per cent.

Industrial automation is accelerating India’s pace in joining the list of global developed countries.

It is observed that the process comes up with its disadvantages as well. Some of which are: • Lack of skilled manpower availability for running an automated process • Worker displacement stress, whose job has been taken over due to automaton • The high cost of capital expenditure required to invest in automation • Rigidity/vulnerability: An automated system may have a limited level of intelligence as programmed, and therefore cannot operate outside its immediate scope of knowledge/program • Requires a higher level of maintenance standards.

According to a study conducted by Frost & Sullivan, as a fast growing economy Indian manufacturing industries in particular would be influenced in future by trends in automation technologies wherein industries need to build expertise in end user requirements in order to face competition and sustain growth.

Therefore, the vendor should understand the end user’s need of service and sales support, his perception of mega trends, his outlook towards and need for hybrid products and his opinion on standardisation of automation products.

Different types of automation solutions Automation solutions entail a number of electronic and mechanical devices, out of which the most common types of automation are: • Feedback control, which is usually continuous and involves taking measurements using a sensor and making calculated adjustments to keep the measured variable within a set range • Sequence control, in which a programmed sequence of discrete operations is performed, often based on system logic.

Automated machining process can be performed through overhead gantry systems, robots, FMS (flexible manufacturing system), etc which can be integrated with various CNC machines such as turning centre, vertical machining centres, horizontal machining centres, 5-axis machines, etc. for all complex metal cutting operations.

Conclusion

In the manufacturing world, business success depends on your ability to employ your assets in a way that delivers maximum return for which automation is indispensible in today’s manufacturing environment.

To sum up all the above mentioned trends, it is obvious that Indian automation industry has a bright and promising future unfolding within it. India’s aspiration to compete with global leaders is not far from realisation as the country embraces the latest technology in industrial automation.

As technology is developed to meet manufacturer’s demands, customers continue to push the limits of machining speed and precision, leading to a continuous cycle of innovation in the field of automation. In a fast

The automation technologies can yield substantial opportunities to provide a growing social and economic environment in which people can enjoy a higher standard of living and a better way of life. n

Scope for Indian market

Pros and cons However, like any other process, automated machining process also has its own pros and cons. Its positive side includes: • Improved processes resulting in increased productivity and repeatability July 2014 n OEM Update n 18

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P-7 & 8 Industrial Estate, City Jodhpur, Rajasthan - 342003, Tel: +91-291-2433737, Fax:+91-291-2615203, Mobile:+91-9414195707 , Email: marketing@plasticpalletindia.com, Website: www.plasticpalletindia.com

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Machine Tools

igus launches versatile construction kit for robotics Ranging from online tools to complete e-chainsystems - igus presents its comprehensive solutions at Automatica

from igus, these can be configured quickly and easily. igus is showcasing its products for the robotics industry at Automatica in Munich.

These include the triflex TRCF energy chain designed specifically for multi-axis systems.

This three-dimensional chain consists of a completely enclosed system.

The unique feature of this robot chain is that it can be quickly opened and filled at the same time, with the flip-open mechanism enabling chainlinks to be opened quickly and easily with a screw driver. This approach allows even large filling diameters to be inserted in record time, therefore triflex TRCF is suited for applications with dirt and chip exposure. trfilex TRCF 85 is now available as a new version with a nominal diameter of 85 mm and - as is customary for 3D robot chains from igus - with defined minimum bending radii and torsion stop dogs. This guides and protects hoses and cables reliably in the interior. A rugged stop dog system also ensures high strength. trilex TRCF can be shortened and extended as needed. Accessories, such as mounting brackets and protectors are also available.

Compact triflex RSE retract system

igus supplies various products for the robotics industry, which customers can ideally configure and assemble based on the construction kit principle. (Source: igus GmbH)

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t this year’s Automatica, igus presents its innovations, which move robots reliably and extend their service lives. The products on show range from 3D energy chains to retract systems or specially developed cables for robot applications - igus presents products that give customers the ability to configure optimised, low-cost solutions for their applications. Using the appropriate tools July 2014 n OEM Update n 20

The compact triflex RSE retract system is yet another novelty shown at Automatica 2014. At a total weight of only 1.8 kgs, an overall length of 44 mm, and a maximum retract travel of 500 mm, the cost-effective module is ideally suited for smaller robots.

The system reliably guides the 3D energy chain, while also preventing the formation of loops.

Complete cable product range for 3D applications The CFROBOT cables from igus put the finishing touches on the construction kit principle for the robotic industry. The

cable product range for difficult robotic applications ranges from hybrid and control cables to bus, data, and fibre-optic cables, creating a comprehensive assortment optimised for use in 3D energy chains with respect to the cable design. For cores, braided elements and shields are constantly exposed to significantly changing stresses in torsion applications. For this purpose, highly wear-resistant and halogen-free PUR or TPE jackets protect the torsion-optimised braiding elements against potential damage.

The specialised designs guarantee that even fibre-optic cables work reliably in torsion applications. This was proven in tests with 27 million torsion movements. Deliveries are available starting at one metre without minimum order quantity or cutting charges.

“QuickRobot” configuration

supports

quick

online

igus not only sells products optimised for the robotics industry, but also provides online tools, such as “QuickRobot”, which is used to configure the entire equipment for 79 robot types immediately. By indicating the robot manufacturer and the type series, the complete matching equipment for up to a maximum of six axis is displayed within seconds. Ranging from large welding robots to small handling robots , this tool is capable of designing a wide range of applications. n Contact: Harish Bhooshan Product Manager E-ChainSystems & ReadyChains igus (India) Pvt. Ltd. 36/1, Sy. No. 17/3, Euro School Road, Dodda Nekkundi Industrial Area - 2nd Stage Mahadevapura Post, Bangalore – 560048 Tele: +91-80-45127809 E-mail: harish@igus.in www.igus.in

Omron showcases advanced solutions at PackPlus Omron displayed its key strengths in the packaging automation segment like the pick and place scara robot, vision, safety and bottling solutions at the exhibition

LEVEL MOISTURE DENSITY FLOW

RF ADMITTANCE LEVEL SWITCH VIBRATING FORK LEVEL SWITCH ROTATING PADDLE LEVEL SWITCH FLOAT LEVEL SWITCH CAPACITANCES LEVEL TRANSMITTERS ULTRASONIC LEVEL TRANSMITTERS OMRON booth at PackPlus 2014

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eiterating its significant contribution towards packaging automation solutions, Omron Automation India is all set to ramp up its focus in the segment for FY 2014-15. This was shared

by Sameer Gandhi, MD, Omron Automation India during the showcase of the company’s integrated packaging solutions at the renowned exhibition - PackPlus 2014.

Being one of the largest packaging, processing and supply chain events in India, PackPlus 2014 is known to bring together the worldwide manufacturers and providers of machinery, materials and services for packaging industry from India and neighbouring countries. The exhibition was held at Pragati Maidan, New Delhi from June 11 to 14.

“Omron is well-known for its quality products and application strength in the industrial automation segment. Packaging solutions is one of our fortes worldwide as well as in India. Our SYSMAC platform gives value addition to the packaging industry by integrating logic, motion, vision and robotics together which enables customers to achieve higher machine speeds, greater accuracy, better quality and enhanced safety,” said Mr Gandhi.

The company’s strategy is to be the first choice as an Automation Partner for the packaging industry. This was well displayed at Omron booth at the exhibition which attracted many customers.

The SYSMAC platform was also displayed by giving hands-on experience to the visitors on the SYSMAC software. n

MICROWAVE LEVEL TRANSMITTERS ULTRASONIC FLOW METERS ELECTROMAGNETIC FLOW METER UPTO 600 MM TRANSIT TIME FLOW METER MICROWAVE MOISTURE MEASUREMENT NUCLEONIC DENSITY MEASUREMENT

An ISO 9001-2008 and C E Certified Co.

Shed No. 7, Nanekar Industries Building, Survey No. 79/2, Dangat Industrial Estate, Shivane, Pune - 411 023, India.

Tel.: 020 - 64703186 / 25290744, Email : jayceetech@vsnl.net, jayceetech@gmail.com, Web: www.jayceetech.com

Feature

Image : Verizon

Curbing cyber threats within manufacturing sector This article highlights the impact of cyber attack on manufacturing sector and the preventive measures

July 2014 n OEM Update n 22

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he manufacturing sector in India is growing at an unprecedented pace. According to global management consulting firm, McKinsey, India’s manufacturing industry could touch $ 1 trillion by 2025. But with growth, comes several risks as well. The manufacturing sector is increasingly becoming an easy target for cyber crimes. The impact of cyber attack on manufacturing operations is colossal and can lead to unexpected downtime, illegal use of systems, loss of proprietary information, financial loss and worse. Cyberespionage

is identified as a top security threat to the manufacturing Industry.

According to Verizon’s recently released 2014 Data Breach Investigations Report (DBIR), cyberespionage topped the list of online security threats to the manufacturing industry last year followed closely by distributed denial-of-service and web-application attacks.

In fact, 54 per cent of all manufacturing attacks examined were attributed to cyberespionage which the report defines as incidents that

were perpetrated by or linked to state-affiliated infiltration.

And though cyberespionage was the top culprit of attacks on manufacturers, the DBIR data also revealed that organised crime rings, competitors and current and former employees were complicit as well. Further, this year’s report illustrated how manufacturers were targeted for their intellectual property, technology and business processes.

So just how did state-affiliated actors infiltrate the network ecosystems of manufacturers? The majority of the attacks, 67 per cent, were carried out by phishing schemes in which deceptive e-mails are designed to trick an employee into giving up proprietary information. In addition, Strategic Website Compromises, in which websites of importance to a business are breached to distribute malware, inflicted their share of damage as well.

Given such pervasive threats, what can manufacturers do to safeguard their often complex operations against these types of attacks?

The DBIR breaks down tips in its cyberespionage category into basic blocking and tackling and more specific practices that can help protect against attacks of this nature which tend to be very sophisticated and well-financed. Let’s start with some basics: • Secure your software: Exploiting vulnerabilities in browser, operating system and other third-party software is an easy initial step that attackers use to infect systems. Keeping security patches up to date should be table stakes for preventing infiltration and will make these types of ‘gateways’ tougher to breach.

• Maintain anti-virus software: Though deploying and maintaining anti-virus software may sound ‘old school’, the DBIR experts stand by the importance of this practice for detecting application anomalies and other malware.

• Educate your employees: Train your employees to recognise suspicious activity and help keep security measures active.

• Segment your network: Segmenting networks helps to contain incidents and protect the rest of the ecosystem from being infiltrated.

• Keep good records: Maintain accurate logs by logging all system, network and application activity.

Moving onto more prescriptive measures that organisations can take if they are concerned with state-affiliated attacks, the DBIR recommends the following practices which can better isolate key network locations for an attack and give victim organisations the best defence opportunities: • Aggressively defend against Phishing attacks: Focus on a solution that can effectively combat e-mail phishing attacks by expanding beyond spam detection and block lists into ‘header analysis,’ ‘pattern matching’ based on past samples and ‘sandbox analysis’ of attachments and links included in the e-mails.

• Track ‘Command and Control’ (C-2) and data exfiltration activity: Monitor and filter outgoing traffic for suspicious connections and exfiltration of data to remove hosts. Also monitor your DNS connection which represents one of single best sources of data across an organisation.

• Prevent lateral network movement: Though network segmentation and containment was previously mentioned

Proaktive Engineering Services We provide engineering Services of CNC Machines in the areas of maintenance, commissioning, retrofitting, Automation, Training (in maintenance and programming), refurbishing Spares (Electrical, Electronic, Hydraulic, Pneumatic and Mechanical), new and pre used machines.

Proaktive Engineering Services

F-2, Abhiman Gram, Near Chaitanya Nagari, Warje, Pune - 411058, Maharashtra, India Ph: +(91)-(20)-25234549 I Mob: +(91) - 9890946285.

Web : www.proaktiveengg.com I email:proaktivengg@rediffmail.com

Feature

Nine classification patterns covered the majority of security incidents.

In 2013, Verizon analysed over 63,000 security incidents and more than 1,300 confirmed breaches to provide new insight. This year’s report identifies nine patterns that covered 92 per cent of all the 100,000 security incidents Verizon has looked at from the past 10 years.

in the basics, the DBIR experts stress that doing this well can be challenging.

Defence practices such as two-factor authentication can help contain the widespread and often uncontested re-use of user accounts.

Lastly, and not unexpected, Manufacturing industries are also targeted for their intellectual property, technology, and business processes.

Intellectual property (IP) is one of the most valuable business assets you have. Lose it and you could lose that secret ingredient that sets you apart from your competitors.

Leveraging insider help — whether malicious or accidental, through phishing or some other form of social engineering — is common in IP data breaches. But if an attacker can’t get an insider to help, stealing their credentials will work just as well — malware and hacking techniques dominated the top spots in our list of most common attack vectors.

Regardless of how they gain unauthorised access, attackers will always want to expand and retain it. That’s where system utilities and backdoors come into play.

There’s no silver bullet that can guarantee protection against IP theft. The diversity, July 2014 n OEM Update n 24

complexity, and ingenuity of tactics preclude a one-size-fits-all solution. Given that, a few recommendations are listed below.

• Use pre-employment screening to help reduce the risks of internal problems later. And don’t give users more privileges than they need.

• Educate employees about social engineering. We often see users clicking on links they shouldn’t and opening attachments received from unidentified senders. Consider rewarding users to create the incentives necessary for vigilance.

• Implement time-of-use rules and “last logon” banners.

• Consider two-factor authentication, IP blacklisting, and restricting administrative connections (e.g., only from specific internal sources).

• Monitor and filter network egress traffic. By understanding and controlling outbound traffic you will greatly increase your chances of mitigating malicious activity.

• Enable application and network logs and monitor them. All too often, evidence of events leading to breaches was available but it was neither noticed nor acted upon.

• Identify what’s critical and what constitutes normal behaviour, and then put mechanisms in place to sound the alarm upon deviations from expected norms.

• Focus on the obvious things rather than the minutiae. A simple script that counts log file length and alerts administrators to exceptions can be pretty effective and save time, effort and money. n

Authored by__

Harsh Marwah, Country Manager, India, Verizon Enterprise Solutions

the-chain:

the-chain [ðə]-[tʃeɪn] Moving energy made easy for any motion.

Simply construct using e-chains , cables and components from igus .

For selection aids, service life calculations and configurations, visit www.igus.in/onlinetools ®

®

.in/the-chain24h

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

®

Instruments & Controls

Smith Flow Control’s technology makes valve interlock adjustment effortless Trapped-key interlocks offer enhanced safety and efficiency for the most difficult process management challenges. Mounted directly to valves, interlocks ensure a process only happens in the correct operational sequence

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rapped-key Interlocks for handwheeloperated valves are different from those for lever-operated valves, as the latter only have a finite movement (normally 90 degrees). Interlocks on handwheel-operated valves, however, usually require several full revolutions between the locked open and locked closed positions.

Because of this, handwheel-operated interlocks need to be able to ‘count’ the number of handwheel turns in order to release keys in the required open and/or closed positions. Similarly, with gate and globe valves, the closed position can vary through the effects of valve seat wear. After a period of use, the closed position on gate and globe valves may have altered. This can mean that when the valve is shut tight, the interlock (closed) key will not release as the valve has travelled past the original set key release position.

Smith Flow Control’s (SFC’s) GL Interlocks are ideal for this scenario as they can be adjusted in-situ in a matter of minutes simply July 2014 n OEM Update n 26

GLM Handwheel operated

by operating the valve back to the original key release position in two easy steps: • Using the special tamperproof tool (provided), the interlock cover is removed and the set screws adjusted • The valve is then operated again to its shut tight (closed) position and the screws are retightened (reset) in the new position.

This simple in-situ adjustment feature is unique to SFC’s GL interlock and provides a fast and efficient method of maintaining valve interlocks on site.

About Smith Flow Control Smith Flow Control Ltd is a UK-headquartered company specialising in mechanical valve control equipment.

The solutions include procedural control using mechanical valve Interlocks and activity management systems, EasiDrive portable valve actuators, FlexiDrive mechanical valve linkage systems for remote and/or simultaneous valve operation and TorkDrive, torque limiting device for the effective operation of valves. n

BUILDING BETTER SUPPLY CHAINS TOGETHER

MOVE GOODS ON PALLETS Move raw material on CHEP Pallets from supplier location to your manufacturing facility and nished goods from manufacturing location to warehouses and onward to the retailer, creating a seamless end-to-end supply chain. This eco-system collaboration creates value through efcient operations, reduces costs, helps better resource utilization and greens the entire supply chain. These cutting edge solutions are available on pay-as-you-use basis, freeing up valuable capital that can be deployed in the core business.

To know, how these award winning solutions can ADD VALUE to your supply chain Call Toll Free: 1 800 209 7273 or Email: salesindia@chep.com INDUSTRY AWARDS ELSC “Supply Chain Solution Provider of the Year” 2013 Manufacturing Today “Excellence in Supply Chain” 2013 ELSC “Supply Chain Innovation of the Year” 2013

Honeywell presents efficient, economical SmartLine

SmartLine

H

oneywell Process Solutions has recently launched its new range of SmartLine industrial temperature transmitters, which is designed to improve overall efficiency even in harsh and noisy process environments. “The SmartLine temperature transmitter is based on the same proven platform as our current SmartLine pressure transmitter.

SmartLine helps reduce project costs and startup time, improve product quality, avoid unplanned downtime, and shorten time to repair,� said Don Maness, VP and GM, Field Products, Honeywell Process Solutions.

Honeywell claims that SmartLine temperature transmitters lower plant lifecycle costs by making it easier to maintain field devices.

This is done with their unique efficiency enhancing features like an advanced graphic display capable of showing process data in graphical formats and communicating messages from the control room. In addition, all SmartLine transmitters utilise modular components which simplify field repairs and reduce the parts inventory required to make those repairs. These parts can be easily upgraded and even exchanged between the two different product lines.

Moreover, they ensure plant reliability and safety also. For example, the SmartLine temperature transmitter incorporates dual-compartment housing for maximum robustness. In addition, it features intuitive diagnostics for both the transmitter and sensor. This diagnostic information is also uniquely available on the transmitter display providing a real-time view of the sensor health to support proactive maintenance.

Unlike most other transmitters, SmartLine transmitters cannot be damaged by reversed loop wiring polarity and will function correctly if reverse connected. To reduce lifecycle costs, the transmitter features a built-in dual-input and digital output option to minimise the number of instruments needed for both monitoring and switching needs. SmartLine also reduces complexity along the entire lifecycle, from avoiding initial purchasing costs to reducing maintenance and inventory expenses by eliminating spare parts requirements and simplifying module replacements and upgrades. n

Instruments & Controls

HanOnBoard to simplify decentralised distribution boxes To the manual wiring of Han connectors in the box, HARTING Technology offers a compact, light-weight alternative named HanOnBoard

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elaying data, signals and power are essential prerequisites of industrial production. Decentralised distribution boxes equipped with Han connectors perform this task. HARTING Technology Group now offers an alternative to the manual wiring of Han connectors in the box.

The standard solution for distribution boxes is contacting individual connectors via manual wiring. However, manual wiring is associated with significant drawbacks. The substantial wiring effort needed in production and the high susceptibility to harsh outdoor conditions such as shock and vibration are considerable. Troubleshooting the system is not efficient, while there is also the risk of secondary faults in service.

The solution offered by HARTING Technology is called HanOnBoard.

In this solution approach, Han connectors are connected with a PCB (Printed Circuit Board) using an adapter. Data, signals and power are then quickly and reliably distributed via the adapter.

HanOnBoard entirely dispenses with time-consuming and potentially fault-prone wiring and is based on an industrially manufactured combination composed of the tried and tested Han components, HARTING PCB adapters and the HARTING PCB instead.

The aim of HARTING‘s development effort was a solution that permitted the continued use of proven Han products while making it possible to avoid the disadvantages of manual wiring. The company assures about HanOnBoard that it is compact, light-weight and also reduces susceptibility to shock and vibration to a minimum. Tedious troubleshooting is replaced by modern, quick module replacement and secondary service faults are avoided as well. In addition, special technical processes ensure that sufficient flexibility remains for onsite adjustments also when PCBs are used.

Conventional wiring in a box HanOnBoard solution: robust, simple to manufacture and service

space-saving,

All HanOnBoard components come from HARTING. Since the design of the overall solution also takes place at HARTING, only a single contact partner is needed, which significantly reduces the time required to produce a solution.

Contact: Abhishek Bimal, Assistant Marketing Communications Manager, HARTING India Pvt. Ltd. 7th floor (West), Central Square II, TVK industrial estate Guindy, Chennai - 600032 Tel: +91 44 43560415 Email: abhishek.bimal@HARTING.com Web: www.HARTING.in

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HanOnBoard solution: space-saving, robust, simple to manufacture and service

Conventional wiring in a box

F-6, Rahul Complex, Opp. Tata Motors, Miraj Road, Sangli, (MS), Ph. 0233-2305580, Cell 9373699888 E-mail : uksyst@yahoo.com Visit : www.ubcalindia.com Dealer Enquires are Solicited

Facility

Automotive warehouse: an essential gear An automotive warehouse needs to be a versatile in many ways as compared to regular warehouses.

This article tells the story of special provisions they have to offer and why they are so desirable for specific purposes

I

t is known that a warehouse is a place to store goods until they are required for their use or sale. These stored goods can include any raw materials, packing materials, spare parts, components, or finished goods. Warehouses are built to protect the products from sunlight, rain, snow, wind, dust, moisture and pests.

Simply, a warehouse as understood generally is a very large area that provides space for optimum storage of different kinds of material. However, there are different types of warehouses and automotive warehouse, July 2014 n OEM Update n 34

being one of them, seems to be different from others and multitasking amongst all.

It’s different Automotive warehouse find itself certainly different from regular one. Regular warehouses generally have 2 or 3 different types of products, but automotive parts warehouses can have unlimited different types of products.

“Automotive warehouses are required to hold a wide range of components, while storing everything safely, efficiently and easily reachable,” points out Jitender Virmani,

Director, Ajooni Storage Systems.

However, at the same time there are some key issues for such warehouses as well.

Such as available space is rarely sufficient to satisfy demand, or bulky items consume storage capacity but needed to be stocked.

Commenting on the same Mr Virmani describes some more of them: • Manual operations need good accessibility to fast and slow moving parts • High number of product lines to cover current and old models causing wide stock variation

Facility example, if a factory is producing 50 cars per day, the warehouse will send materials only for 50 cars and keep the balance in the warehouse. The warehouse therefore becomes an extended store for the factory but outside the factory premises.

Mr Saravanan, Vice President, Sri City Pvt. Ltd.

Quality inspection can be done at the warehouse and problems identified well before they are used in production.

However, it is observed that in the case of imported items, components could be stored in a bonded warehouse and no duty is payable for such goods. As and when the goods move to the factory, duty is payable.

Therefore cash for duty payments can be deferred based on actual need of such goods.

captured on a computer. Identification and retrieval is fast and efficient.

“Automotive warehouses need not be in the factory premises and can be far away provided there is a transport system to ship goods regularly to the factory,” comments Mr Saravanan. “Moreover, perennial inventory system is possible in automotive warehouses. Quality inspection can be done at the warehouse and problems identified well before they are used in production.

Further, production runs smoothly since only when all materials are available, materials are issued for the day.”

Special provisions

• Stock needs to be stored carefully to avoid damaging packing and remain in a saleable condition • Ability to handle regular incoming parts deliveries without significantly reducing available storage space • Maintaining control over stocking profiles to ensure obsolete stock is minimised.

For any automotive warehouse, to function itself well and in healthier manner, obviously the storage area must be fully optimised and tailored to suit operation and layout of the building. Keeping this in mind, Ajooni Storage Systems offer the suitable solutions.

“Our shelving range has a number of possibilities which can be tailored to meet even the most unusual storage requirements. Equipped with our specially designed automotive accessories, we are able to meet the daily challenges faced in automotive warehouses,” says Mr Virmani.

No chance of mix-ups or wrong materials being used because the warehouse issues only those materials that are required and others are kept back at the warehouse.

Bonded warehouses can phase out duty payments and reduce pressure on cash flow.

A third party warehouse can operate for 2 to 3 different companies at the same time and reduce costs by economies of scale.

Non moving and slow moving goods can easily be identified and tracked. Then after, some effective action could be taken to use this material or dispose it off.

Mr Saravanan, Vice President, Sri City Private Limited, explains the working of automotive warehouses with an example highlighting on the way that differs these warehouses from regular ones. Mr Saravanan says, “Automotive warehouses could receive supplies from multiple suppliers. The warehouse then picks up materials as per the list from the factory and then consolidates and ships as one lot to the factory.” For

The option to combine shelving with a mezzanine floor or offer a multi-tier solution can maximise the height of storage area. For larger scale automotive situations, Ajooni Pallet racking might be more appropriate.

“Small parts or odd shaped and bulky items like exhaust pipes are also the challenges Ajooni Storage Systems solve for the automotive industry on a regular basis,” adds Mr Virmani.

Mr Virmani also considers automotive warehouse very beneficial in many aspects due to the number of advantages it offers. He says, “Automated warehousing applied to part or entire distribution centre operation can provide a wide variety of benefits including space savings, lower building costs, improved productivity, more efficient material flow, less people, safer operations, reductions in inventory, increased reliability, reduced running costs, better ROI and lowest lifecycle cost.”

Usually the warehouses are fully computerised with tracking for storage and issue. This saves a lot of time and enhances efficiency also by offering faster operation.

Jitender Virmani, Director, Ajooni Storage Systems.

Automotive warehouses are required to hold a wide range of components, while storing everything safely, efficiently and easily reachable.

Mr Saravanan says, “At the time of issue the pick list is computer generated and the person has to go the mentioned rack and take the goods and dispatch. All goods are bar coded. Racks are up to 6-7 metres high for economic storage and easy retrieval.

Such warehouses use forklifts to transport goods.”

Automated warehousing provides the maximum thinkable usage of accessible floor space and building height. In many cases, this allows companies to increase storage capacity by up to 400 per cent compared to conventional forklift operations.

“Where space is limited, switching to an Ajooni automated warehousing solution can free up additional space for other activities,” comments Mr Virmani.

Bunch of benefits

Conclusion

Automated warehouses definitely offer some benefits which make them suitable as per requirement of storage. These warehouses store goods systematically and all transactions for receipt or issue are

In all, automotive warehouses are proving to be a good option on account of their fast and efficient operation. Also offering an increased productivity and reliability make them more desirable for automotive industry. n 35 n OEM Update n July 2014

Facility

Technical Enterprises presents economical ‘handy’ lifts T

echnical Enterprises, through its handy lifts, offers a more economical alternative to the scissor tables, particularly for lighter loads and other useful products as well.

One person can handle the job by this type of lifting platform under hydraulic cushion.

Electric push buttons are provided on the control panel for raising and lowering the table. Further, two limit switches are provided for limiting the raised height as well as the lowered height.

and long life. Parts are interchangeable and available of the shelf.

Jet aerial maintenance platform

Pallet trucks

This is an aerial maintenance platform suitable for attending the maintenance works of lighting, overhead cranes, window cleaning etc. at high levels in workshops, warehouses or anywhere on good pucca floors.

The company manufactures hydraulic handlift pallet trucks in standard capacities of 1.1, 2, 2.5 and 3.2 tonnes and standard fork length of 900 mm, 1,050 mm and 1,220 mm. The minimum pallet gap varies from 65 to 100 mm. For special applications, pallet trucks can

This is available in two versions i.e. 8 metres and 10 metres lifts. It has got four outriggers for purposes of stability. Two load wheels and two steering wheels each with two ball bearings are provided. There are several

Standard Pallet Truck

Transformer Type Pallet

Paper Reel Pallet Truck

Mini Pallet Truck

Low Profile Pallet Truck

Big Wheels Pallet Truck

Special Long Fork Pallet Truck

10 Top Special Truck

High Lift Pallet Truck

Hydraulic wall mounted lift

Hydraulic wall mounted lift Wall mounted goods lifts (wall mounted stackers) manufactured by Technical Enterprises, under its brand name ‘handy’ can be used to transfer the materials from basement to first floor, second floor, or even up to third floor height, especially for lighter loads up to 1,500 Kgs. In these lifts, two parallel vertical channel masts are provided with foundation plate which can be grouted in the wall which must be strong enough to sustain the vertical and horizontal load. Push buttons are provided on the control panel for up/down motion.

These are available in single phase or there phase electric supply.

Hydraulic highlift powered scissor lifting platform These are designed to reach up to a height of 9 metres and are used in places where very high equipment are installed or materials/items have to be shifted from ground floor to first or second floor. Their low capacity model is used for servicing of overhead cranes.

July 2014 n OEM Update n 36

be tailor-made to suit customers’ requirement of capacities up to 10 tonnes, fork lengths up to 1,650 mm, and pallet gap up to 250 mm and even more. The ram and plunger used in hydraulic unit are hard chrome plated and mirror finished. The cylinders are honed to high degree of finish. Lifting is done by swift and easy strokes of the steering handle and lowering by pressing a foot pedal.

This makes it an ideal machine for internal handling of raw materials, components and finished products from store to shop floor, from machine to machine, from one bay to another, ultimately to loading/unloading platform and vice-versa, completely a one man show on smooth level pucca floors. Hydraulic unit has few working parts, for easy maintenance

vertical scissors which open while moving up and close while going down. All the controls are in the hands of the operator. The wheels are wide faced for easy pulling and pushing on good pucca floors. The net weight is very low comparing to the work done at 8-10 metres height. n

Contact: Technical Enterprises S-5, Industrial estate Partapur, Delhi road, Meerut - 250 103 Phone: 91-121-2440330 Email: agromec@vsnl.com, handyindia@vsnl.net Web: www.agromecindia.com, www.handyindia.com, www.jetonnet.com

Facility

On-line monitoring solution for pharma warehouses A

Daily Data Reports via E-mail LAN

mbetronics Engineers Pvt. Ltd. (A.E.P.L), an ISO 2000 - 2008 company, is a manufacturer of all types of measurements and control of process parameters such as temperature, humidity, gas and factory automation systems suitable for pharmaceuticals, food, chemical, and textiles and glass industries. The company is offering these services for the past 19 years.

Pharmaceuticals can lose their effectiveness if not stored or handled appropriately.

Regulatory compliance obligations such as 21 CFR Part 11 compliance prepared by Food and Drugs Association (FDA) is mandatory for pharmaceutical industry.

Temperature & Humidity Sensors

Alarm alert via SMS

Data Recorder & Controller

Local Monitoring using 21 CFR Part & Complaint Software

Remote Monitoring via Internet

is connected to PC via Ethernet port, a 21 CFR part 11 compliance software is used in PC for local monitoring of data.

Based on this regulatory compliance A.E.P.L provides effective on-line monitoring solution for temperature and humidity monitoring in warehouses.

• • • • • • •

Gas detection systems Protocol converters GSM GPRS-based alarm modems Thermometers Sensors Indicator and controllers Software.

Products include: • Data loggers • Transmitters

Few temperature and humidity sensors are placed in warehouse are connected to data logger for logging of data. Data logger

GSM GPRS modem, connected to the system, sends daily reports to head office via e-mail. In event of an alarm this modem sends instant SMS and e-mail alerts to user.

User can monitor data remotely via PC or mobile phone using standard internet connection. n

Partner State

Pre Event Of

ENVIROTECH ASIA 2014 International Exhibition & Conference on Waste and Resource Efficiency, Water and Waste Water Treatment, Pollution Control Systems, Recycling, e-Waste, Renewable Energy

22-23-24 SEPTEMBER, 2014 Mahatma Mandir, Gandhinagar, Gujarat, India.

Organized By

Partner Country

Knowledge Partner

Member Of

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Factory Visit

SKF’s Ahmedabad factory: the source of perfect bearings After a tour of SKF’s bearing manufacturing facility in Ahmedabad, Subhajit Roy writes about his understanding on what goes into making a perfect bearing

I

ncepted in 1907, SKF has established itself as a global supplier of bearings, seals, mechatronics, lubrication systems and services. SKF entered the Indian market in 1923 and today provides automotive and industrial engineered solutions through its five technology-centric platforms: bearings and units, seals, mechatronics, lubrication solutions and services.

In India, having fully operational state-of-the-art manufacturing plants in Pune, Bangalore, and Haridwar; SKF is well-positioned to cater to the need of Indian market. However, in an aim to further strengthen its manufacturing footprint in domestic and Asian markets, SKF Technologies (India) Pvt. Ltd., a subsidiary of AB SKF (SKF Group), has set up a plant in Ahmedabad in 2010. The plant manufactures medium to large size bearings of various types for heavy industrial segments such as power generation, renewable energy, construction, mining and material handling.

Green with a purpose Spread over 33 acres of land on the Ahmedabad-Rajkot highway, the July 2014 n OEM Update n 38

Factory Visit Ahmedabad facility of SKF is the first bearing factory in India to be certified by LEED rating and the third SKF facility across the globe to attain a LEED certification.

Explaining the efficiency quotient of this facility Ajay Naik, Factory Manager, SKF Ahmedabad said, “The manufacturing facility is certified to ISO 14001 and OSHAS 18001. We are also expecting a certification for energy efficiency soon. The plant is designed to achieve atleast 23 per cent energy efficiency and 30 per cent reduction in water use.”

Maintaining global standard The manufacturing process of bearings is not as simple as we presumed especially in the case of large size bearings! SKF uses highly sophisticated processes in manufacturing. SKF treats its rings in a highly automated sophisticated furnace with patented process that defines the highest level of quality. After the heat treatment, a series of tests are carried to ensure high quality and post which, the rings go through the grinding operations. This is where super finishing is done in fully control environment and checked for 100 per cent in CMM for dimensions and once passed, the components are assembled by highly skilled and trained engineers. To support this process the plant follows controlled environment for manufacturing. The plant also has state-of-the-art sophisticated automated furnace, high precision grinding machines, CMM for checking. The plant is equipped with metallurgy and metrology lab with latest equipment. However, the optimisation of real-time monitoring makes the plant highly efficient.

Today, Ahmedabad facility of SKF involves almost all crucial functions of a manufacturing unit that helps in achieving optimum localisation level to churn out affordable products. Strengthened with technologically advanced machines, quality skilled employees, and in-house QA & QC team, the facility is gradually becoming a global resource hub for SKF.

Visual inspection of SRB at SKF Ahmedabad plant

Careful handling of finished large size bearings

Henrik Wickberg, Project Manager (SRB) at AB SKF, who was present during the trip, was quite astonished with the manufacturing set-up and process being followed at Ahmedabad facility. Sharing his experience, he said, “I was responsible for process development in Gothenburg factory and was working with manufacturing and implementing new processes. What we see here is the same processes we established at Gothenburg.” He was also quite impressed with available talent pool in India. SKF is also looking at increasing the production capacity

Fully air-conditioned and controlled manufacturing environment

Henrik Wickberg, Project Manager (SRB), AB SKF

I was responsible for process development in Gothenburg factory and was working with manufacturing and implementing new processes. What we see here is the same processes we established at Gothenburg.

State-of-the-art banite heat treatment facility

39 n OEM Update n July 2014

Factory Visit SKF SRB offering from SKF Ahmedabad Range: (Medium & Large) ID : 130 mm OD : 180 – 1500 mm Width : 40 – 375 mm Medium:180 mm ~ 420 mm OD Large: 420 mm OD <

of Ahmedabad facility to meet the increasing demand, he said.

Upgraded SRB – the perfect bearings Ever since the invention of the self-aligning ball bearing in 1907, SKF has been leading the development of self-aligning bearings.

SKF Explorer set a new standard for performance in 1999.

Now, the company has introduced a new range of upgraded Spherical Roller Bearings (SRBs): SKF Explorer SRB Upgrade, Sealed SRB and SE Housing. Developments in steel processing technology have enabled SKF to further improve the performance

of its SKF Explorer self-aligning roller bearings. Upgraded SKF Explorer spherical roller bearings, marked with “WR” on the package and the bearing outer ring, features a combination of high-quality steel and an improved heat treat process.

Sealed SKF Explorer spherical roller bearings can significantly increase bearing service life in contaminated environments.

These bearings are pre-lubricated with specially formulated bearing grease and sealed with highly effective contact seals. The seals protect the bearing and lubricant from contaminants that might otherwise cause premature bearing failure.

When compared to an open bearing, the higher level of cleanliness inside a sealed spherical roller bearing makes it possible to down-size the bearing arrangement without negatively affecting the service life or performance of the application.

SKF also launched SE Housing which enables efficient distribution of grease to the bearing for best possible bearing performance during operation. This design also enables heat dissipation via the supporting surface for reduced grease consumption to reduce environmental impact.

Presenting a case study Mr Wickberg said that the sealed bearings lasted twice as long and the grease consumption was reduced by more than 95 per cent. He also claimed that sealed bearings can often improve rating life 2-4 times compared to an open bearing.

Capacity expansion Built with a cumulative investment of around ` 300 crore, the plant is having an installed production capacity of ` 40 crore per annum.

As of now the production facility, office building, and service building occupy 26,700 sq.m. of area. SKF plans to utilise the remaining 20,400 sq.m. for future expansion. n

Process

Turbo presents bearings for radial and combined loads Turbo Bearings has always worked with the policy of orientation to customersâ&#x20AC;&#x2122; needs and end usersâ&#x20AC;&#x2122; expectations. It continues to adding value to customers, through quality products like TRBs and CRBs

I

n any rotating membrane of an automotive application, there is a need for a bearing, while in case of radial load of less amplitude and higher speed a ball bearing is used. But in most of the locations there is a need to use tapered roller bearing or a cylindrical roller bearing.

Tapered Roller Bearing (TRB) These bearings can carry radial or axial or combined loads of medium to heavy amplitudes. The bearing has a specialised feature of having angular configuration of all its components (Rings and Rollers) with perfectly matched angles of all the rolling surfaces. These angles converge at a common point. This feature makes its function very smooth.

These rolling surfaces also are designed with a specialised crowned surfaces, commonly known as logarithmic crowning, which enable smooth rolling action and enhanced life expectancy. These bearings are mostly used in the locations where combined loads are expected, such as wheel applications, gear boxes (with spiral, helical gear) applications etc.

Manufacturing unit

According to the company, its one of the major achievements has been to provide products giving good field performance with longevity of field life. To achieve this goal the company invested heavily in sophisticated or reputed quality appraisal equipment, such as, roundness and form/ finish testing machines of Taylor Hobson, UK make and precision universal length measuring machine of Trimos, Swiss make and metallurgical microscope with Image analyser from Olympus, Japan, etc.

These bearings can carry only radial loads of medium to heavy amplitudes. The bearing has a feature of having cylindrical configuration of all its components (rings and rollers) with higher smoothness on the rolling surfaces.

The company has three manufacturing units in Rajkot. Due to ever-increasing demand from its customers, Turbo has been expanding its capacity, particularly in TRBs and CRBs manufacturing lines. The latest have been an automatic ball bearing line and an automatic roller bearing line, consisting grinding machinery from world renowned TOYO- Japan and super finishing machinery from Thielenhaus, Germany.

For CRBs also, these rolling surfaces are designed with specialised crowned surfaces, which offer the same advantages as for TRBs. CRBs mostly find their use in the locations where radial loads are expected, such as gear boxes applications etc.

Turbo has also established facilities for the life-testing of the bearings for complete range of its products. It enjoys extensive customer base covering OEMs of automotive, transmission, tractors and general engineering segments. It has been

Cylindrical Roller Bearing (CRB)

Facilities for the life-testing of bearings

Facilities for the lifetesting of bearings

serving various domestic and overseas OEMs in the above fields and endeavours to expand its customer base to many other fields. n For more information visit www.turbobearings.com 41 n OEM Update n July 2014

Process

Delphi-TVS relies on Kennametal Extrude Hone for surface finishing M

anufacturers and quality professionals in industries such as automotive, aerospace, energy, medical, and others requiring high-precision components know that removing particles left at intersected holes and ensuring no micro contamination is a big challenge that cannot be overlooked.

Customised complex valves, gears, pinions, and thousands of components can be machined in seconds but can take minutes to get finished completely. This in turn results into production bottlenecks, increased costs, and longer time to market.

Delphi-TVS, a joint venture between Delphi Corp., USA and T V Sundaram Iyengar & Sons, India, is one of the largest automotive systems manufacturers in India. It found that its high component volumes approaching a million a year have made hand-deburring unaffordable and then high-precision nature of diesel fuel injectors made TEM solution a necessity. After much investigation, the company chose Kennametal Extrude Hone’s TEM (thermal energy method) solution.

“We manufacture diesel fuel injection parts – high-volume components. The main issue is burr removal on cross-sectional holes from previous machining operations,” says T N Umasankar, Head - Manufacturing Engineering Department, Delphi-TVS. Kennametal Extrude Hone is one of the leaders in the field when it comes to providing precision surface solutions for components.

Its proprietary technologies such as TEM are solving increasingly complex finishing challenges faced by manufacturers around the world.

New P400 TEM machine from Kennametal Extrude Hone

“There have been hundreds of installations and continued refinement of our TEM

equipment and process,” says Bruno Boutantin, Global Marketing Manager, Kennametal Extrude Hone. “TEM is a rapid, low-cost, high-production process that can process a million or more parts per year by a single machine.”

“The TEM process is particularly appropriate for high-volume applications where conventional deburring departments struggle to keep pace,” Mr Umasankar adds. “It instantaneously cleans up a large number of intersecting holes, threads and hard-to-reach areas in a flash, literally in 20 milliseconds.

Its ability to fire multiple components at the same time increases its capacity and costeffectiveness enormously. Any other process, including high-pressure water jet, will not provide this value.”

Combining vast experience gathered over more than five decades with worldwide application know-how, Kennametal offers proven solutions to many companies working in most demanding environments. In India, Kennametal Extrude Hone is an integral part of Kennametal India Ltd. situated in Bangalore, where its technical centre is wellequipped to support the customer needs. n

NTN’s Ultage series: assures value for money N

TN Bearing India Pvt. Ltd. is a subsidiary of NTN Corporation, Japan. It provides marketing and technical support to NTN customers in India, directly and through a well-organised network of authorised distributors. It offers range of bearings to the OEM industry from needle to spherical, taper and cylindrical roller bearings. The company has its manufacturing units in Haryana and Chennai which are currently making products for the automobile market.

The company believes in offering quality products and fast response to critical needs of customers. It has specialised products July 2014 n OEM Update n 42

such as NTN’s Ultage series for the earth moving equipment industry, sealed spherical roller bearings, large size and dust-cover type bearing units, triple lip sealed bearings for conveyor systems. The company always tries to meet the needs of its customers who expect more value for money.

NTN’s Ultage series spherical roller bearings are an example of this philosophy. NTN’s Ultage series bearings are engineered to work under extreme operating temperatures of 200 C and at the same time have the highest load carrying capacity in the industry, claims the company. They also support much

NTN’s Ultage series spherical roller bearing

higher speeds than the conventional type of spherical roller bearings. All this is available at the cost of a standard spherical roller bearing.

In comparison, the rest of the bearing industry offers high temperature bearings at a premium as compared to its standard range which can operate up to 100 C only. n

Process

Chlorine-free neat cutting oils to play vital role Chlorine-free neat cutting oils are developed to help meet productivity targets and to contribute to a safer environment

F

or many years, the metal removing industry has used neat metalworking oils that contain chlorine. Ongoing changes in machine tool design and global health and environmental-related concerns are limiting their use and leading to new opportunities for non-chlorinated products.

are typical Extreme Pressure (EP) additives used in neat metalworking oil formulations.

These different additives operate at different activation temperatures (Figure 1) to provide a robust lubricating film between the work piece and tool, reducing wear to help extend tool life, provide better surface finish, and improve productivity.

Machining trends to meet new technologies

Concerns with the use of Chlorinated EP Additives

Machine tool technology has changed rapidly in recent years. The use of new materials and changes in equipment design has led to faster machining speeds and higher cutting temperatures to help improve productivity. As the automotive industry attempts to reduce vehicle weight and improve fuel economy, there is a general shift away from ferrous alloys to lighter and more resistant materials such as alloys of aluminium and magnesium.

Chlorine in the form of short- and mediumchain chlorinated paraffins is a low cost, highly effective EP additive. However, regulations such as the Registration, Evaluation, Authorisation and Restriction of Chemicals (REACH) in Europe may limit their use.

Chlorinated paraffins as well as phosphorus compounds, sulfurised additives, polymeric esters and metallic overbased sulfonates

Other performance-related issues Chlorinated neat metalworking oils can

Figure1: Cumulative effects of additive chemistries

0.5

Pure Mineral Oil Co efficient of Friction, Âľ

Metalworking lubrication principles Considering all areas of lubrication, metalworking is one of the most difficult applications as forces of 50,000 psi and temperatures of 900 C can be generated at the work piece and tool interface. High concentrations of additive combinations are required in the metalworking fluid to provide the longer tool life, better surface finish and improved productivity required by engineering professionals.

Short chain chlorinated paraffins are considered carcinogenic and toxic to marine life under REACH and will not be authorised to be used in products that will affect health and the environment. Medium chain products have been identified in Europe to be toxic to marine life. Advocates of the use of chlorinated paraffins in the United States confirm that the most likely source of detrimental effect on the environment comes from the use and disposal of chlorinated metalworking products because of their low solubility in water and environment persistence.

Chlorine

0.4

Phosphorus

0.3 0.2

Sulfur

Fats/Esters

0.1 All Additives 0

0

200

400

600

800

1000

1200

Temperature,°C

43 n OEM Update n July 2014

Process

To meet present and future needs Chlorine-free formulations have existed in Europe for many years with proven Figure 2: Inactive neat metalworking products

Tapping Torque 6061 Aluminum Forming, HSS,13m/min 120 Relative Efficiency (%)

100 80 60 40 20 0

Chlorinated Product

Non-Active, Non-Chlorinated Product Lubrizol Corporation 2008

performance in demanding machining conditions and new equipment designs.

To replace chlorine effectively, a strong synergistic effect is required between the alternative additive chemistries that wet the metal surface, forming a film with strong EP properties. Only with few exceptions can chlorine-free neat oils not replace chlorine containing products.

Tests conducted with ferrous and non-ferrous materials in a Microtap Tapping Torque equipment can compare products with and without chlorinated paraffin (Figures 2 and 3).

It is not only the environmental aspects that new chlorine-free additive technology offers, but also, an improved operating environment.

Lighter colours and lower odour can help improve working conditions for the machine tool operator.

Chlorinated neat metalworking oils will continue to play a role at the present time in metalworking applications in niche applications, particularly the machining of very tough inert materials such as stainless steel.

The use of these newer technology products in current high speed machine shop designs

Figure 3: Active neat metalworking products evaluation

120

TappingTorque 1018Steel, Cutting, HSS, 10m/min

100 Relative Efficiency (%)

contribute to shorter activation times in high speed operations. Under these circumstances hydrogen chloride is produced and it can cause corrosion problems and a reduction of tool life. Corrosion can be accentuated by the presence of water in contact with the chlorine.

80 60 40 20 0

Active, Non-Chlorinated Product

Chlorinated Product

Lubrizol Corporation 2008

can help provide the increased productivity required by engineers and machinists while reducing the environmental and health concerns in metalworking operations. n Authored byUmesh Malik, Chief Engineer – Sub-Continent, ExxonMobil Lubricants Pvt. Ltd.

ZAplus recognised as ‘most innovative fan of 2014’ Z

Aplus fan system, offered by ZIEHLABEGG, has been recognised as the ‘most innovative fan of 2014’ by the China Refrigeration Organisation. The award is a part of the China Refrigeration Expo - a leading Asian trade fair for refrigeration, air conditioning, heating and ventilation systems. The ZAplus fan system, which has already won several other awards, is used in supermarkets, hotels and refrigeration.

Around 1,100 companies from more than 30 countries exhibited at the expo with many of them competing to receive the mark of quality from the China Refrigeration Organisation. “In the heating and ventilation equipment category, ZIEHL-ABEGG was the only fan manufacturer to succeed in winning over the panel of judges with one of its products. In the case of the ZAplus fan system, the members of the panel highlighted four main reasons for the award: the system’s July 2014 n OEM Update n 44

high level of efficiency, low noise, reliability and flexibility,” the company informed issuing a statement.

The ZAplus compact fan system has now been given the title “Innovation Product of the Year” in Shanghai. “We were the only fan manufacturer to receive an award,” comments CEO Peter Fenkl, who is delighted with the company’s success. “The China Refrigeration Organisation honoured us with the Innovation Award because the ZAplus complete system is very cleverly designed,” explains Jason Liu, Managing Director of ZIEHL-ABEGG in China. “The system integrates the fan, motor and control into a single, compact unit made from high-strength composite material. This optimises the air flow and spares the need for unnecessary packaging material.”

When it came to the blade design, the

ZAplus fan system

developers took inspiration from the wing of an owl – the quietest bird of prey: spikes on the rear edge of the fan blade and a kink on the top edge help to reduce noise generation.

“With this system, a saving of at least 25 per cent in electricity usage can easily be achieved,” the company avers. n

Process

Replacing diffusers with energy efficient aerator yield greater efficiency By replacing diffusers with energy efficient aerator for its ETP, Oneiro expects to save around ` 4 lakhs in energy cost

A

t Oneiro Chemicals Ltd., Vadodara, the flow is of 60 KL/day and COD is 8,000 ppm in their effluent. In their Effluent Treatment Plant (ETP), they have two aeration tanks of size 6M x 6M x 4.6M SWD + 0.6M FB. Previously in the aeration tanks, they were using Diffused Aeration System having the blower capacity of 15 HP in each tank. They have lot of maintenance problems like chocking of diffusers, uneven distribution of air, maintenance of blowers, blower making noise, etc. Therefore, they decided to replace this Diffusers with ENVIRON Energy Efficient Aerators.

On studying the characteristics of the effluent and tank size, ENVIRON recommended 7.5HP Aerator in each Tank. Oneiro decided to replace the Diffused Aeration System of Tank No. 1 and replaced the same.

At present they are using one Diffused Aeration System of 15 HP in Tank No. 2 and one 7.5 HP ENVIRON Energy Efficient Aerator in Tank No. 1. Now the results while comparing are:

â&#x20AC;˘

â&#x20AC;˘

In Tank No. 2 of 15 HP Diffused Aeration System the current drawn is 22Amps and the outlet COD is 2,500 ppm having the maintenance problems.

In Tank No. 1 of 7.5HP Environ Aerator, the current drawn is 7.3 Amps and the outlet COD is 2,100 ppm. Secondly, there is no maintenance cost.

Therefore, by replacing Oneiro would save energy of 7.5KW x 24 hrs x 365 days = 65,700 units per year. So considering the cost per unit at ` 6, Oneiro may make

a monetary saving of ` 3,94,200.00 in a year, getting the best result than Diffused Aeration System.

The Aerator is running since 6th June 2013 and now Oneiro has ordered for another 7.5HP ENVIRON Energy Efficient Aerator for replacing the 15 HP Diffused Aeration System of Tank No. 2. n For details contact: Environ Engineering Company, Vadodara (Mobile No. +91-9879788102, 9825008442)

Submersible motor pump for handling wastewater K

SB in India has launched Amarex N, a new cost-efficient low-weight pump set which is compact enough to be installed in narrow sumps and tanks. The pump is designed for handling all types of wastewater in municipal, industrial and commercial applications.

Amarex N is available in 7 models ranging from DN 50 to DN100 size, with maximum flow rate of 53 litres per second and a discharge head of up to 49 metres. Standard variant can withstand fluid temperature up to 55 C. The pump will primarily be used in pumped drainage systems, for example where wastewater needs to be drained from below the flood level or in systems with long

discharge pipes and insufficient natural slope for gravity drainage.

The pump is equipped with free flow impeller (type F) which can handle solids up to size 100 mm max. An option of cutter impeller (type S) is available in size 50 mm with the free passage of 6 mm to cut any fibrous material in the fluid. It benefits in selection of lower size pump which in turn saves initial investments and running costs.

The shaft is sealed off towards the motor by a shaft seal ring, and by a bi-rotational mechanical seal at the pump end, so the motor is protected against fluid ingress. A

reservoir between the two seals, which is filled with environmentally compatible oil, ensures proper cooling and lubrication of the mechanical seal even if the fluid contains gas.

Generously dimensioned ball bearings sealed for life support the stainless steel shaft. n 45 n OEM Update n July 2014

Brand Report

New generation fluorescent lights for hazardous areas R

. STAHLâ&#x20AC;&#x2122;s new line of light fittings for use in Ex zone 1/21 and 2/22 hazardous areas achieves better energy efficiency than comparable devices and provides approximately 10 per cent more luminous flux, the company claims.

New EXLUX 6001 luminaries also feature a design that is considerably more compact, stable, and torsion-resistant than their EXLUX 6000 predecessors. While more than one million of the long-proven EXLUX 6000 lights have been deployed worldwide over the last 20-odd years, the new generation now meets increasing user demand for a similarly economic, yet enhanced product with improved technical features reflecting the most current state-of-the-art.

Depending on their performance class, the 6001 luminaries are a quarter to a third lighter than their predecessor models. Users now also benefit from the extremely robust design of these slimmer, narrower units: unlike most lights, the new devices can be operated at extremely low ambient temperatures as low as (-) 30 C. In many cases, this amounts to a decisive extension of the application range that saves costs by making extra specifications unnecessary.

In order to facilitate a step-by-step exchange of existing EXLUX pendants, the installation of the new units remains fully compatible to the predecessor series. Moreover, swiftly removable replacement parts ensure quick

The explosion-protected EXLUX 6001 luminaries are more compact, lighter, more robust and more versatile than their predecessors and many competing products

and easy maintenance. Like before, the new lights are available with customer-specific modifications on request. In addition, R. STAHL provides especially cost-efficient standard models with a power consumption of 18 W, 36 W, or 58 W that are available at short notice. Featuring 4 mm² cage clamp terminals, 5-core through-wiring, and a full-phase safety shutdown, these models are adequately equipped for the majority of all typical applications. The new series fully complies with the requirements of all current industry standards. Notably, the new silicone-based foamed gasket has been optimised for maximum durability, as stipulated by IEC 60079. This sealing solution, which is resistant to various chemicals as well as UV radiation, the fittingâ&#x20AC;&#x2122;s hinge, and a newly designed central lock reliably ensure IP66/IP67 protection over many years.

6001 series lights are available as of now.

However, more products are due to follow in the new EXLUX generation: in the near

future, the program will be extended both by optional accessories, such as pole mount adapters, and by additional models such as emergency lights, lights with an address module, and models with T5 fluorescent lamps for use in zone 2/22. Moreover, LED lights from R. STAHL will also be available soon, though these will be based on a completely different housing and equipped with materials and features optimised for LED technology. n Contact: R. STAHL (P) Ltd. Plot No.5, Malrosapuram Main Road Sengundram Industrial Area, Malrosapuram Post Singaperumal Koil, Kanchipuram Dist.

Tamilnadu - 603204 Contact person: Ms. Ashwini Bondale Tel.: +91-44-30 600 600 Mobile: +91-99403 99463 E-mail: ashwini.bondale@rstahl.net www.rstahl.net

Ingersoll Rand launches 3CII-i centrifugal air compressor I

ngersoll Rand, one of the global leaders in creating and sustaining safe, comfortable and efficient environments and a pioneer in centrifugal technology, has announced the launch of 3CII integrated package or 3CII-i centrifugal air compressor with enhanced efficiency, ease of maintenance and everconsistent reliability. 3CII-i will cater to process industries looking for continuous airflow with reliable and efficient performance.

July 2014 n OEM Update n 46

3CII-i comes with advanced features and has been designed to provide new level of reliability, efficiency and productivity while reducing cost of ownership and operation.

It will cater to wide spectrum of customers from varied verticals including automobile, textile, iron and steel and other general industries.

With this design the cooling system has been

integrated and a plug and play concept has been introduced.

3CII-i offers some more advantages like aesthetic look with huge weight reduction as well as reduced footprint to provide ease of operation, no requirement of special foundation, and optimised turndown and advanced surge control for higher efficiency etc. n

Event

AMTEX: Gateway to the manufacturing world The stage is gearing up for Amtex 2014, the most hyped event as the largest show of machine tools, machineries and manufacturing technologies in the Asian continent. The exhibition could be the gateway to the world of opportunities

T

he 9th Amtex 2014 is the glittering event of the year where the convergence of exciting business opportunities, world-class technologies and enthusiastic participants from across the globe are transpiring on a single platform. It will be held from 25th to 28th July at Pragati Maidan, New Delhi.

AMTEX EVENT 2012

The exhibition is an attempt to create a rostrum for all the relevant sectors and technologies to interact with industry like aerospace, automobiles, defence, electrical and electronics, material handling etc. The opportunity for the exhibitors is enormous to present brand new technologies to enhance productivity.

Today India stands 13th in production and 6th in the consumption of machine tools in the world as per the latest survey. The country is all set and about to become a key player in the global machine tools industry and is likely to see substantial high-end machine tool manufacturing.

Cyril Pereira Managing Director, Triune Exhibitors Pvt. Ltd.

AMTEX 2008 and 2010 at New Delhi happened to be grand spectacle of the latest advances in machine tools and manufacturing solutions and provided a superlative stage for lively interaction between manufacturers, suppliers and users of the growing Indian market.

Currently Indian machine tool industry has around 1,000 units in the production of machine tools, accessories/attachments, subsystems and parts. Of these, around 20 in the large scale sector account for 70 per cent of the turnover and the rest are in the SME sector of the industry. Approximately, 75 per cent of the Indian machine tool producers are ISO certified. However, given the current gap between demand and supply, there is a clear need for adding capacities in this sector.

The industry is moving towards increasingly sophisticated CNC machines, driven by demand from key user segments.

Indian industry is now ready and all set to expand its reach to the global market and Amtex-2014 is going to provide the space for the purpose. Amtex 2012 had witnessed the representation of 14 countries such as exclusive pavilion from China, Taiwan and Korea, and participation from USA, Spain, Turkey, Japan, Slovenia, Italy, Israel, Singapore, etc.

Starting from the year 2001, AMTEX has constantly gained its position as one of the

July 2014 n OEM Update n 48

largest show of machine tools industry which has observed a growth of 300 per cent in this period. AMTEX with well over 1200 stalls is supposed to do a justice to a grand spectacle of the latest advances in industry. It is also expected to provide a superlative stage for interaction between manufacturers, suppliers and users of the growing Indian market and thus broaden up the horizon of machine tool industry. Thus AMTEX exhibition holds tremendous significance for all levels in manufacturing organisations.

Spreading over 149 acres of prime land in the heart of New Delhi with an attachment of 71,290 sq.mtrs of covered exhibition space in 18 air-conditioned halls is waiting for the footfalls from the far off countries to pursuing is expected to touch up to lakhs as said sources. Now its 10,000 sq.m showcased area is the most craved zone for the exhibitors, visitors for the month of July. The awaiting event is undulating with a grasp of hope to make substantial gain and the Asian giants are eagerly waiting to showcase the product into the recent trade development on the machine tool industry. n

OEM

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* * * * * *

Grabbing Cranes - 1 No. Goliath Cranes - 20 Tons. - 90 No. Jib Cranes - 2 Tons - 14 No. Winches - 3 Tons. - 300 Nos. Hoists - 10 Tons - 180 Nos. EOT Cranes - 1 0 Tons - 12 Nos.

D-6/15, Off Road No. 34, Wagle Industrial Estate, Thane - 400 604 MAHARASHTRA (INDIA), Tel.: (022) 3256 5975 â&#x20AC;˘ Telefax: (022) 2582 2003 / 01, Cell: 098215 43657 Website : www.c-zcranes.com, E-mail : info@c-zcranes.com, mpc1207@gmail.com

49 n OEM Update n July 2014

OEM

MART

Design, Supply, Installation of Material handling Equipments, Cargo and warehousing equipments

Installation, Operation and maintenance of Material Handling Equipments Baggage conveyor Systems - Arrival and Departure MHE for Logistics center Sortation Equipments Conveyors: Belts, Rollers, Pallets, Power Curves etc Ball Transfer Table

Weighing and dimensioning systems Automation and Control systems

Delite Systems Engineering (India) Pvt. Ltd #34, Guru Gobind Singh Industrial Premises, Goregaon (E), Mumbai - 400063 Tel: 022-26856404, 26858533. Fax: 022-26866000 Email: info@delite.in Website: www.delite.in

July 2014 n OEM Update n 50

COMMERCIAL PARTNERS Ace Micromatic Group ............................................................................. 5 BC Equipment Trading Company Pvt Ltd .............................................. 13 Boge India ............................................................................................... 9 Chep India Pvt Ltd............................................................................ 27, 30 C-Z Cranes & Handling Equipments ..................................................... 49 Delite Systems Engineering (I) Pvt Ltd .................................................. 50 Electro Steel Engineering Company ..................................................... 50 Environ Engineering Co. ....................................................................... 23 Ergen Plastic Industries ......................................................................... 19 Gebi Engineering ................................................................................... 49 igus India Pvt Ltd ................................................................................... 25 IMTMA ....................................................................................................11 Jayashree Electron Pvt Ltd ................................................................... 31 Jaycee Technologies Pvt Ltd.................................................................. 21 Omron Automation Pvt Ltd .................................................................. IFC Paramount Machine Tools ..................................................................... 49 Power Build Ltd.................................................................................... IBC Proaktive Engineering Services ............................................................ 23 RK CNC Solutions ���������������������������������������������������������������������������������51 Robinsons Cargo and Logistics ............................................................... 7 Sahajanand Laser Technology Ltd. �������������������������������������������������������15 Sameer Sales Corporation .................................................................... 49 TIDC India ............................................................................................... 3 U K Systems .......................................................................................... 45 Valvoline Cummins Ltd.......................................................................... BC

August 2014 Die & Mould CAD/CAM PVC Industrial Cranes

( 9821575178 & 022-32682214/15

New Projects

Thermal Power generation

Automotive components

Talavadi Cements plans a 35 MW captive power project at Village Bari, dist.

Satna, Madhya Pradesh. The power generated will be used for the cement project to come up in the same location.

Location: Satna, Madhya Pradesh Status: Planning Stage Contact: Talavadi Cements Limited, Plant address : Unit Satna Cement Works, P.O. Birla Vikas, Satna - 485005, Madhya Pradesh Tel: 91-7672-412000/ 412001.

Fax: 91-7672-257456 Email: admin@satnacement.com

Suprajit Engineering plans an automotive cables & components manufacturing project at Narsapur, dist. Kolar, Karnataka. The project will come up near Honda factory. Project is planned for completion in 6 months from zero date.

Location: Kolar, Karnataka Status: Planning Stage Contact: Suprajit Engineering Limited, Registered office: No.100, Bommasandra Industrial Area, Anekal Taluk, Bangalore Rural - 560099, Karnataka Tel: 91-80-27833828/ 27833829/ 43421100 Fax: 91-80-27833279 Email: info@suprajit.com Website: www.suprajit.com

Metallurgical Industries

Hydel Power generation

Tripura Ispat plans modernization cum expansion of its steel plant at Bodhjungnagar Industrial Growth Centre, dist. West Tripura, Tripura.

The scope of modernization will involve addition of new machinery & technology advancement.

Location: West Tripura Status: Planning Stage Contact: Tripura Ispat , Administrative Office: B.K.Road, Palace Compound, Near Indian Airlines City Office, Agartala, West Tripura - 799001, Tripura Email: tripura_ispat@yahoo.co.in Website: www.tripuraispat.com

Sneha Kinetic Power Projects implements the 96 MW Dikchu hydroelectric power project at Dikchu, dist. East Sikkim, Sikkim. The majority of the electro-mechanical components are on site and their installation is over 75 per cent complete.

Location: Dikchu, East Sikkim Status: Under Implementation Contact: Sneha Kinetic Power Projects Private Limited, Corporate office: 1366, Road No. 45, Jubilee Hills, Hyderabad - 500033, Andhra Pradesh Tel: 91-40-40301000 Fax: 91-40-23555503 Email: info@greenkogroup.com Website: www.greenkogroup.com,-www.snehakinetic.com

Cement

Non conventional energy

VP Cements plans an integrated cement project at Chinnakomerla, dist. YSR, Andhra Pradesh on 101.2 hectares. The estimated cost of the project is ` 12 billion.

Location: YSR, Andhra Pradesh Status: Planning Stage Contact: V P Cements Private Limited, Plant address : Survey No. 280, 322 -331, 346-361, 379-380, 395-463, 490-493 & 496-493, Tehsil Peddamudiam, Gundlakunta, YSR- 516431, Andhra Pradesh Email: veerareddy.rajoli@gmail.com

Shri Shivsagar Sugar & Agro Products plans an 18 MW bagasse-based co-gen power project at Village Udpudi, dist. Belgaum, Karnataka. The project is planned for completion in 12 months from zero date.

Location: Belgaum, Karnataka Status: Planning Stage Contact: Shri Shivsagar Sugar & Agro Products Limited, Plant address : Ramdurga Taluk, Udpudi, Belgaum - 591130, Karnataka Tel: 91-8335-273400/ 273402/ 273403 Fax: 91-8335-273401.

Email: shivsagarsugar@rediffmail.com/shivsagarsugar@gmail.com

Chemical

Petrochemicals

Vensun Laboratories implements a 200 TPA chemicals manufacturing project at MIDC, Chincholi, dist. Solapur, Maharashtra on 2 acres. The project is scheduled for completion in July 2014.

Location: Solapur, Maharashtra Status: Under Implementation Contact: Vensun Laboratories Private Limited, Plant address: Plot No. A-20/7, A-20/8, MIDC, Chincholi, Solapur - 413003, Maharashtra Tel: 91-217-2357499 Website: www.vensunlab.com

Sayona Colors plans an expansion of its dyes & colors manufacturing project at Navrangpura, dist. Ahmedabad, Gujarat. The project involves capacity expansion of products like synthetic organic dyes, food colors & cosmetic colors.

Location: Ahmedabad, Gujarat Status: Planning Stage Contact: Sayona Colors Private Limited, Plant Address : 201, University Plaza, Vijay Char Rasta, Navrangpura, Ahmedabad - 380009, Gujarat Tel: 91-79-66314147/ 66314148 Fax: 91-79-66314146 Email: info@sayona.in Website: www.sayonagroup.com

Ports

Textiles NES

Visakhapatnam Port Trust is developing EQ-10 berth at Visakhapatnam Port, dist. Visakhapatnam, Andhra Pradesh. AVR Infra, an SPV of IMC and ITD Cementation India, is the contractor.

Location: Visakhapatnam, Andhra Pradesh Status: Under Implementation Contact: Visakhapatnam Port Trust , Administrative Office: Port Area, Visakhapatnam - 530035, Andhra Pradesh Tel: 91-891-2564841/ 2873400 Fax: 91-891-2565023 Email: info@vizagport.com Website: www.vizagport.com

SVM Nonwovens is implementing a modernisation-cum-expansion of its textile products (related to automotive) manufacturing project at Bonthapally, dist. Medak, Andhra Pradesh.

Location: Medak, Andhra Pradesh Status: Under Implementation Contact: S V M Nonwovens Private Limited, Administrative Office: Building No. 6-2-9, Anushka Tower, Lakdi Ka Pool, Near Lotus Hospital, Hyderabad - 500004, Andhra Pradesh Tel: 91-40-23390345 Fax: 91-40-23325988

Note: Above information is the sole property of domexinfo.in and can not be published without prior permission.

July 2014 n OEM Update n 52

Tenders nOIL & GAS

Company Name: GAIL (India) Limited Tender Detail: Procurement, installation & commissioning of 6.6 KV vacuum circuit breaker for retrofitting in the existing 6.6 KV vacuum circuit breaker and SF6 circuit breaker at Gail, Lakwa by e-tendering.

Location: Lakwa Documentation Sale from: 10-June-2014 Documentation Sale to: 24-July-2014 EMD: ` 65,520/Closing Date: 24-July-2014 Address: LPG Recovery Plant, GAIL (India) Limited, P.O.-Lakwa, Sivasagar, Assam-785688.

Tel: 91-3772-257777, 91-3772-257778, 91-3772257780 Website: www.gail.nic.in Company Name: Government Of India, Ministry of Home Affairs Tender Detail: E-tender for Procurement of GC-MS (Gas Chromatograph Mass Spectrometer)regarding.

Location: New Delhi Documentation Sale from: 30-May-2014 Documentation Sale to: 31-July-2014 Documentation Fees: ` 2,000/EMD: ` 110,000/Closing Date: 31-July-2014 Address: Procurement Wing, Jaisalmer House, Mansingh Road, New Delhi-110011, Delhi Tel: 91-11-23387306 Fax: 91-11-23386764 Website: www.mha.nic.in

nDRUGS

Company Name: Government Of Karnataka Tender Detail: E-tender for procurement of drugs for non communicable disease control & prevention project.KDL/e-TND/NCD-Drugs/07/2014-15 Location: Bangalore Documentation Sale from: 9-June-2014 Documentation Sale to: 23-July-2014 Documentation Fees: ` 550/EMD: ` 300,000/Closing Date: 23-July-2014 Address: Office of the Additional Director, Karnataka State Drug Logistics and Warehousing Society (R), No.1 Dr. Siddaiah Puranik Road, KHB Colony, Magadi Road, Bangalore – 560 079, Karnataka Tel: 91-80-23283218 Fax: 91-80-23281477 Email: kdlws.edpsection@gmail.com Website: www.karnataka.gov.in

nRAILWAY

Company Name: Southern Railway Tender Detail: Works contract for Re-shafting of auxiliary motors of electric locomotives available at Electric Loco Shed, Southern Railway, Salem Division, Erode.

Location: Erode Documentation Sale from: 16-June-2014 Documentation Sale to: 14-July-2014 by post, 21-July-2014 in person Documentation Fees: ` 2,500/- by post, ` 2,000/in person EMD: ` 23,600/- Closing Date: 22-July-2014 Address: Office of the Senior Divisional Electrical Engineer, Rolling Stock, Electric Loco Shed, Erode-638002 Tel: 91-424-2402204 Fax: 91-424-2402204 Website: www.sr.indianrailways.gov.in

nPORT

Company Name: Cochin Port Trust Tender Detail: Construction of Multi-User Liquid Terminal at Puthuvypeen, Cochin Port on EPC contract basis Location: Puthuvypeen Documentation Sale from: 4-June-2014 Documentation Sale to: 16-July-2014 Documentation Fees: ` 52,500/- EMD: ` 20,500,000/Closing Date: 17-July-2014 Address: Chief Engineer’s office, Cochin Port Trust, Cochin-682009 Tel: 91-484-2666414, 2582400 Fax: 91-484-2666414 Email: philo@cochinport.gov.in Website: www.cochinport.com Company Name: Cochin Port Trust Tender Detail: RFQs for modernization of coal handling in Cochin Port (Retender) on (DBFOT) basis for a concession period of 30 years.

Location: Cochin Documentation Sale from: 16-June-2014 Documentation Sale to: 8-August-2014 Documentation Fees: ` 20, 000/Closing Date: 12-August-2014 Address: Chief Engineer’s office, Cochin Port Trust, Cochin-682009, Ernakulam, Kerala Tel: 91-484-2666414, 2582400 Fax: 91-484-2666414 Email: Coptce@gmail.com Website: www.cochinport.com

nCOALS

Company Name: Northern Coalfields Limited Tender Detail: E-tenders for procurement of bearings for CHP of Bina Project Location: Bina Documentation Sale from: 07-June-2014 Documentation Sale to: 03-August-2014 EMD: ` 19,589/Closing Date: 03-August-2014 Address: Area Purchase Cell, Bina Project, Po. Bina, Dist. Sonbhadra-231220, Uttar Pradesh Designation: Chief Manager (MM)

Mobile: 91- 8004945710 Website: www.ncl.nic.in Company Name: South Eastern Coalfields Limited Tender Detail: E-tender for supply of jumbo drill machine – 02 Nos. Location: Bilaspur Documentation Sale from: 21-March-2014 Documentation Sale to: 19-August-2014 Documentation Fees: ` 5,000/EMD: ` 1,000,000/Closing Date: 20-August-2014 Address: Chief Manager (MM)/P-III, Seepat Road, Bilaspur, Chhattisgarh – 495006 Tel: 91-7752-246321 Fax: 91-7752-246471 Email: gmmm.secl@coalindia.in Website: www.secl.gov.in

nSPARE PARTS

Company Name: Indian Air Force Tender Detail: Request for proposal for procurement of spares for MIG-29 aircraft Location: New Delhi Documentation Sale from: 01-May-2014 Documentation Sale to: 17-July-2014 Closing Date: 17-July-2014 Address: Room No. 278, Air Head Quarter, Vayu Bhavan, Rafi Marg Dist. New Delhi-110106 Tel: 91-11-23010231 Website: www.indianairforce.nic.in Company Name: Indian Air Force Tender Detail: Request for proposal for procurement of 12 lines of spares for MI-17 helicopter Location: New Delhi Documentation Sale from: 05-June-2014 Documentation Sale to: 26-August-2014 Closing Date: 26-August-2014 Address: Room No.265, Air Head Quarter, Vayu Bhavan , Dist. New Delhi-110106 Tel: 91-11-23010231 Website: www.indianairforce.nic.in

nPOWER

Company Name: NHPC Limited Tender Detail: Upgradaton /Enhancement of existing lans at Loktak power station Location: Manipur Documentation Sale from: 06-June-2014 Documentation Sale to: 30-July-2014 Documentation Fees: ` 1,000/EMD: ` 104,000/Closing Date: 02-August-2014 Address: Loktak Power Station, P.O. Loktak Power Station, Dist-Churachandpur-795124, Manipur Tel: 91-3879-261408 Fax: 91-3879-261740 Name: S. Kulabi Singh Website: www.nhpcindia.com

Note: Above information is the sole property of domexinfo.in and can not be published without prior permission.

53 n OEM Update n July 2014

Regd. No. MH/MR/NE/266/2013-15 • Posted at Tilak Nagar P.O. Mumbai - 400089 on 7th / 8th of Every Month • English • Monthly • Date of Publication: 1st of Every Month.

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