Oem july 2015

MAHENG/2009/33944 Vol 7 Issue 2 • Pages 52 • Mumbai July 1, 2015 • `100 • www.oemupdate.com

OEM UPDATE

Controlled Manufacturing CNC-based machine tools offer greater energy efficiency, increased productivity, utmost accuracy with optimum reliability

GRP enclosures aid migration to wireless instrumentation networking Electromagnetic transparency simplifies installation of 2.4 GHz WSN technology

An I-Tech Media Publication

Shaping the industry How Wheelabrator is shaping the industry with the launch of shot peening machine DRT

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Controlled Manufacturing

OEM UPDATE

CNC-based machine tools offer greater energy efficiency, increased productivity, utmost accuracy with optimum reliability

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CONTENTS Jyoti CNC Automation: driven by technology

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FEATURES 24 Mitsubishi CNC: maximum output, highest productivity Mitsubishi CNC has helped the machine tools and manufacturing sector with its advanced technology and solutions.

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Let the ‘good times roll’ with Renishaw’s 5-axis CMM inspection At the Maryville plant of Kawasaki, 5-axis scanning probes speed form-data collection and feedback to machining cells.

30 GRP enclosures aid migration to wireless instrumentation networking Electromagnetic transparency simplifies installation of 2.4 GHz WSN technology.

32 Surface coating to protect steel assets Protection of steel assets is a priority running into billions of dollars.

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Gemini: the latest machining sensation

34 Shaping the industry How Wheelabrator is shaping the industry with the launch of shot peening machine DRT.

36 Testing of water parameters at textile plant Technology has enabled efficient treatment of effluent waste for the textile industry in India.

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CELOS from DMG MORI: revolutionising production process

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42 ElectroMech: Enormous plant of herculean effort A visit to the ElectroMech plant in the Pune area.

July 2015 n OEM Update

Editorial www.oemupdate.com

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Greek fallout: Is India prepared?

After a long standoff with its European creditors on the terms of a multibillion-dollar bailout, Greece is imminently heading towards a serious economic crisis. Experts believe, the crisis may be much more than what is being explained as ‘bailout’. In 2008, the world witnessed the worst economic crisis of recent time due to the collapse of US-based small investment bank called Lehman Brothers.

Economists feel the ongoing crisis in Greece may plunge the world into a financial crisis.

Now the question is how the crisis will make an impact on India Inc? According to research agency India Ratings and Research, Indian industry might face higher cost of funding in the overseas market in the short-run due to the economic fallout in Greece while the overall impact on the Indian economy will be limited. The agency expects increased global market volatility to weigh on the rupee in the near term. However, record high forex reserves at $ 355 bn and rising imports cover at eight months will provide a cushion against sharp volatility.

However, industry body Assocham feels, India may not to get direct hit from Greece, but tremors may be felt. “Indian economy is not really centric to Greece directly but if it defaults in its debt obligation and situation takes the form of a crisis in Europe, India could also feel the tremors like rest of the world,” it said.

D S Rawat, Secretary General at Assocham said, “What is worrying is that the overall situation with regard to India’s merchandise exports does not look promising this year and the troubles in Europe could only deteriorate the prospects.”

Remarkably, Europe is India’s largest trading partner with $ 129 bn of merchandise engagement in 2014-15. Of this the European Union bloc accounted for $ 97 bn with UK, Germany, France, and Italy being the leading partners.

Of late, the manufacturing sector in India started witnessing some positive growth. Its factory output for April showed a 4.1 per cent growth, against 2.1 per cent for the month before. So, the early the Greek fallout is sorted out, the firmly we can hold the momentum of manufacturing growth.

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

July 2015 n OEM Update

Quick update

DesignTech Systems inks JV pact with Integrity Tool and Mold DesignTech Systems Ltd., a leading CAD/CAM/CAE, additive manufacturing technologies and engineering services provider in India, announced a joint venture (JV) with Integrity Tool and Mold Inc. DesignTech will hold 45 per cent stake in the JV, whereas 55 per cent will be owned by Integrity Tool and Mold INC. Integrity Tool and Mold is a major automotive mould, tool and die manufacturing companies in North America. Integrity is headquartered in Canada with large operations presence even in United States of America and Mexico.

DesignTech Integrity Tool and Mold Inc. plan to expand their

operations in India by initially setting up a large engineering team to cater to various mould design and mould engineering aspects for ITM global clients.

The JV will be later expanded to add manufacturing facility to offer local mould manufacturing and mould maintenance services.

Commenting on the occasion, Scott Allen, General Manager, Integrity Tool and Mold Inc., said, “The JV has started operations with a small team, trained in Integrity Canada to meet ITM global mould design standards. We anticipate a multi-fold growth in the team size in the coming years.”

Atul Marwaha, Sr. Vice President – International Business at DesignTech Systems Ltd. commented, “Under this JV, we will not only be working for ITM global engineering requirements, but we also plan to use this as a launch pad for expanding mould design and manufacturing services in Asia. Integrity is renowned to provide highest quality, scale, and value to its customers and has capacity to develop highly specialised tooling that can range from 200 to 3,000 tonnes presses.” n

SKF India opens solution factory in Jamshedpur SKF India announced the inauguration of SKF Solution Factory in Jamshedpur, Jharkhand.

This is SKF’s third solution factory in India, after the main facility in west, in Pune and the satellite unit in north, in Manesar.

The Jamshedpur facility will serve as another satellite unit and focus on large sized bearing remanufacturing analysis process, manufacturing of customised machined seals for hydraulic cylinders, basic hydraulic cylinder repair and maintenance related training solutions from SKF. This factory will cater to the customers, primarily focusing on the metals and mining industry in the Eastern part of India with competencies across SKF’s technology platforms and specific asset management and maintenance services.

Commenting on the inauguration, Shishir Joshipura, Managing Director, SKF India Ltd said, “SKF Solution Factory is a unique global proposition through which we deliver our customised services combining SKF’s knowledge, experience and technology. We see services as one of the key drivers of growth, complementing our unmatched product range. The Jamshedpur SKF Solution 8

Factory will play a pivotal role in bringing integrated solutions at customer’s doorstep by providing asset management solutions, resulting in higher speed of service deployment for our customers in the eastern region.”

Lokesh Saxena, Business Head – OEM Business and Services, Industrial Markets, SKF India Ltd said, “The prime objective of every SKF Solution Factory is to bring SKF knowledge closer to our customers. SKF Solution Factory combines SKF’s technology, global and local knowledge and experience across geographies and will act as a catalyst to long term asset efficiency and reliability. Over the years, we have seen a rising demand for our maintenance solutions and we are confident that the new Jamshedpur facility will enable us to deliver SKF knowledge to our customers in the eastern region.”

SKF Solution Factory is a unique proposition from SKF where people and technology come together to create optimised asset performance across industries. The idea is to expand the scope of SKF services business and deliver solutions to reduce customers’ total cost of ownership. SKF India set up the first SKF Solution Factory in 2009 in Pune and gradually scaled up operations to provide a number of services to customers. Pune remains the central solution factory as it will support the local unit with central services. n July 2015 n OEM Update

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Quick update

TongJi-HARTING technology innovation contest unveiled In early 2014, Tongji and HARTING signed MoU of the cooperation to research and develop innovative and advanced railway technologies. As a part of HARTING Scholarship, this contest was organised by Tongji University Institute of Rail Transit (IRT) and HARTING, aims at inspiring students’ creativity and innovation as well as establishing a platform to integrate theory into practice. The contest opens to all students in Tongji University. HARTING provides full support in respect of technology and samples.

(from left to right): Prof.

Chu and Edgar-Peter Duening unveiled plaque and announced the opening of contest

Harting, in cooperation with Tongji University Institute of Rail Transit (IRT), has launched the first Tongji-Harting Technology Innovation Contest.

The first 2015 Tongji-HARTING Technology Innovation Contest unveiling Ceremony was held at Jiren Buiding of Tongji University Jiading Campus. Professor Chu Zhigang, Secretary of Party Committee, Professor Lu Zhenggang, Deputy Dean of Tongji University Institute of Rail Transit and Edgar-Peter Duening, Managing Director of HARTING Electric, hosted the ceremony. Edgar-Peter Duening and Professor Chu announced the opening of the contest.

Prof. Lu introduced this contest bases on “Technology Innovation”. Mr. Edgar-Peter Duening also emphasised that the contest establishes a great platform for the students to implement theory into practice.

In order to provide a better understanding of HARTING products and to provide a commercial platform for students, HARTING invited 8 volunteers from Tongji to attend booth duty on the 14th electronica Shanghai exhibition. The volunteers actively participated the 3-day fair. After a briefing on company background and product, the volunteers were able to independently explain the running RFID demo to visitors, which implies students have concrete knowledge in rail and transportation and are able to pick-up HARTING’s product basic operation theory quickly. n

MAN Diesel & Turbo to buy MaxWatt Turbines

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MAN Diesel & Turbo SE, a wholly-owned subsidiary of MAN SE - part of Volkswagen AG - acquires 100 per cent of the shares of MaxWatt Turbines Pvt. Ltd., an Indian specialist company for engineering, production and service of steam turbines for applications in power generation Dr. Lauber, , CEO and Chief Sales Officer of MAN Diesel and mechanical drives. & Turbo SE After the acquisition MaxWatt will be integrated into the Turbo business of MDT and the new entity will operate under the name MAN Turbomachinery India Pvt. Ltd.

range. At the same time we gain access to new customer groups and market segments.”

“MaxWatt is a well-established player in the Indian and Asian power generation business in the lower power segment,” says Dr. Uwe Lauber, CEO and Chief Sales Officer of MAN Diesel & Turbo SE. “By acquiring them we expand our portfolio and add steam turbines for numerous standard applications to our existing high-end product

MAN Diesel & Turbo already has a significant number of turbomachinery installations in India and runs a service shop for turbo machinery in Vadodara (Gujarat) in addition to an engineering and production centre for large Diesel engines in Aurangabad (Maharashtra), and several sales hubs all over the subcontinent. n

MaxWatt Managing Director C. G. Venkatesh, who will continue to lead the business, also welcomes the acquisition.

He said, “MAN Diesel & Turbo is a global premium brand and leading company in the power generation business.

MaxWatt customers all over the world will profit from an extended product range, a worldwide sales and service network and the know-how of a global player, all of which will be gained thanks to this merger.”

MaxWatt’s range of products would be integrated into MAN Diesel & Turbo’s portfolio after the merger. MAN’s workforce in India would increase to more than 650 employees. The MaxWatt headquarters in Bengaluru will be MAN Diesel & Turbo’s first steam turbine production site in India.

July 2015 n OEM Update

Cover Story

Controlled Manufacturing

CNC-based machine tools offer greater energy efficiency, increased productivity, utmost accuracy with optimum reliability

With the increasing focus on achieving manufacturing excellence, the computer (computerised) numerical controls (CNC) industry is going through a massive transformation. Industrial manufacturers from across the world are leveraging the benefits of advanced CNC technologies driven by new control technology and increased consumer demand.

Growth drivers Though machine tools industry was going through a slump commencing in 2013 due to slower manufacturing growth, the CNC machines markets globally have maintained positive growth due their stronger demand.

Of late, the manufacturing sector in India is experiencing growth. India’s factory output for April showed a 4.1 per cent growth, against 2.1 per cent for the month before.

Therefore, with the opening up of economy and increased manufacturing activities, the market for CNC machines is likely to witness better growth.

CNC machines are designed with unique properties to deal with energy consumption, productivity and shorter time frame. And when it comes to manufacturing output, today’s CNC-based machine tools offers greater energy efficiency, increased productivity, utmost accuracy with optimum reliability.

Major factors like growing awareness on energy efficiency and cost efficiency, increasing demand for consumer goods due to economic prosperity, and adding physical 12

infrastructure aggressively are driving the demand for CNC-based machine tools. On top of that, the government’s new ambitious ‘Make in India’ mission to promote domestic manufacturing is expected to drive the growth further.

Commenting on the latest demand-supply scenario of CNC machines, T K Ramesh, CEO, Micromatic Machine Tools Pvt. Ltd. said, “The demand for our CNC machines is stable and growing. We are in constant touch with the market requirement and are supporting the market with the required products and solutions. The first quarter demand has been to our expectation and we hope it will become better in the coming period.”

Micromatic is the marketing arm of Ace Micromatic Group. The group specialises in the manufacturing of CNC controlled turning, milling and grinding machines along with subsystems like tool turrets, ATC etc.

Widening applications Automotive and aerospace are major users of CNC systems. However, due to the demand from other enduser industries, CNC systems are now increasingly being deployed in healthcare, jewellery, and woodworking industries also. Companies like Multi Axis CNC Robotics manufactures vertical machining centres, horizontal machining centres, CNC milling machines, engraving machines, wooden routers, stone routers etc. which are widely used in dies and moulds like injection mould, press tools, pressure die casting, forging dies, metal patterns, July 2015 n OEM Update

Cover Story auto components machining, shoe moulds, graphite electrode machining, wooden doors, wooden carving, stone carving, jewellery making, dental solutions etc.

Jyoti CNC Automation Pvt. Ltd., one of the leading CNC machine tools manufacturers in India, offers a wide range of CNC machines consisting of series of machines in CNC Turning Centres, CNC Turn Mill Centres, CNC Vertical Machining Centres, CNC Horizontal Machining Centres, CNC Vertical Line Machines and High-tech CNC 3-axis and 5-axis machining centres. These machines find application in across the industries include defence, research institutes, aerospace, automobiles, die and mould, general engineering, power, medical, and agriculture.

Advanced technology According to a Frost & Sullivan analysis, open architecture PC-based control systems are revolutionising the CNC industry. “New technology has enabled computer networks to merge, thereby providing innovative approaches to production, monitoring and control solutions for the metal machining industries,” it added.

Another recent technological advancement in an unbundled software approach to control systems is the soft CNC (SCNC). Apart from enhancing the man-machine-interface (MMI), SCNCs helps in widening the user choice and control in terms of hardware alternatives.

With increased input costs including infrastructure and manpower costs, machine tool users are becoming cautious in the resource utilisation. To address this issue CNC machines manufacturers are developing new products. One of such products is Gemini-Mini.

Gemini-Mini, introduced by Micromatic Machine Tools, is more suitable for smaller components requiring frequent tool changes.

The machine is designed with two BBT-30 spindles driven by a single spindle motor. According to Mr Ramesh, the product is an attractive alternative to many of the faster machining centres available at a dearer price.

Continuous, uniformed production planning is a critical area as far as a production facility is concerned. Machine tool major DMG MORI presents CELOS with a total of 15 APPs and as PC version for the continuous production planning on the PC in work preparation with direct connection to the machines CELOS provides a uniform user interface for all new high-tech machines from DMG MORI. CELOS APPs provide the user with integrated management, documentation and visualisation of order, process and machine data on a unique 21.5-inch multi-touch screen.

Furthermore, the company assures, operation of the machine is simplified, standardised and automated with CELOS. In an aim to provide machine tool manufacturers and users handson experience of its latest CNC technologies and solutions, German engineering major Siemens AG opened a technology and application centre in Bengaluru last year.

Sprawled over an area of 6,500-square feet, the facility provides application support and training to customers and institutes dealing with various types of machine tools. The centre also demonstrates the company’s Sinumerik CNC controllers and CAD/CAM solutions and use SinuTrain, a simulation tool, to train users in achieving higher productivity. n

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Cover story

Jyoti CNC Automation: driven by technology Commenting on the company’s achievement Vikas Taneja, Vice President – Marketing, Jyoti CNC Automation said, “Jyoti today is the only completely integrated CNC machine manufacturer in the country with existing land holding large enough to expand capacity two times present size. Our world-class manufacturing facility includes state-of-the-art machining shop, fully-automated foundry, sheet metal and paint shop and a temperature controlled sub-assembly and assembly unit employing more than 1,300 employees.”

Manufacturing capabilities Jyoti today operates through three manufacturing facilities in Rajkot which is spread across 3,36,000 square metres. It has an installed capacity to manufacture more than 3,500 machines per annum.

Jyoti today is the only completely integrated CNC machine manufacturer in the country with existing land holding large enough to expand capacity two times present size.

Vikas Taneja, VP – Marketing, Jyoti CNC Automation

Incepted

in 1989, Jyoti CNC Automation Pvt. Ltd., India’s leading CNC machine tools manufacturer, is located at Rajkot, Gujarat. The company has a wide product basket consisting of series of machines in CNC Turning Centres, CNC Turn Mill Centres, CNC Vertical Machining Centres, CNC Horizontal Machining Centres, CNC Vertical Line Machines and High-tech CNC 3-axis and 5-axis machining centres. These machines find application in across the industries include defence, research institutes, aerospace, automobiles, die and mould, general engineering, power, medical, and agriculture.

Today Jyoti sells its product throughout India and in 37 other countries worldwide through its principal offices in Rajkot, India and Strasbourg, France and 23 regional offices in India, sales offices in Germany and Canada and a dealer network across 18 countries.

Its key customers include Hindustan Aeronautics Ltd., Volkswagen, Mahindra & Mahindra, Bharat Forge Ltd., L&T, Titan, Godrej, railways, ordnance factories, and heavy vehicle factories. Jyoti has installed over 7,000 machines across the globe.

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Jyoti has a world-class machining centre wherein it develops and manufactures components like spindles, turrets, headstock, as well other sub-assemblies etc. for captive use. The machine shop houses 5-axis machining centres, CNC universal grinding machines as well as horizontal and vertical machining centres to manufacture components with precision accuracy.

Jyoti also houses a captive foundry, sheet metal unit, paint shop, sub-assembly and assembly unit.

Its captive fully mechanised foundry (Omega, UK) has an annual capacity of 12,000 metric tonnes to cater to the needs of preparing the casting beds for its machines.

The sheet metal shop has the latest laser cutting and bending machines from Amada and Trumph respectively. The sheet metal is CED primer coated and finished with automated powder coating and painting line.

Paint shop comprises of 7 tanks pre-treatment process following by CED primer coating and conveyorised baking with powder coating booths. There are four powder coating booths in line of different colours.

The sub-assembly and assembly areas are temperature controlled and each assembly line or station is equipped with all necessary instruments for smooth assembly of the machine.

Nurturing partnerships In 2007, Jyoti acquired a 150 years old French machine tools giant – Huron Graffenstaden SAS. Huron is having two manufacturing plants at Strasbourg and a strong sales and service network all over Europe. The acquired company is a pioneer for its 5-axis machining centres, having a renowned clientele like Volkswagen, Ferrari, Rolls Royce, Siemens, Boeing, Air Bus, Fiat, BMW, Mercedes, and GE etc.

Jyoti - Huron has a strong sales network internationally at France, Great Britain, Portugal, Turkey, Netherland, Hungary, Slovakia Austria, Spain, Switzerland, Italy, Germany, Canada, July 2015 n OEM Update

Cover story USA, Iran Australia, Brazil, Middle East, Argentina and South Africa.

The series of machines offered by Jyoti - Huron are: • CNC Turning Centres • CNC Turn Mill Centres • CNC Vertical Machining Centres • CNC Horizontal Machining Centres • CNC 5-axis Machining Centres.

VTL Series (Vertical Turning Lathe)

RX-Series To match demand of greater accuracy and total reliability at higher speeds Jyoti CNC has developed RX Series Vertical Machining Centres. The high dynamic structure supports rapid axis take-off with high accelerations. Broad rigid base and column structure dampens effect of vibrations and balances whole machine while taking heavy cutting load with higher machining parameters.

USP • High dynamics support rapid up to 40m/min • High speed drilling tapping as well as milling operations • Fast toll changing, just 2.4 seconds • Supports rapid axis take-offs with acceleration of 5 m/ s² • Wider high precisions liner motion guide ways • Efficient chip disposal • 90-degree tilting operator panel • Auto and manual coolant • 8,000 RPM rigid BT 40 spindle • Electrical with quality device and panel AC • Hi-tech features like linear glass scale feedback and coolant through spindle, high speed mortised spindle and others can be incorporated in these machine.

VTL Series machines are specially designed for larger diameter components machining in heavy engineering industries such as oil and gas, earthmoving, automobile and subcontracting industries. Bed and column made from higher grade cast-iron providing maximum rigidity, thermally stability for better machine life and accuracy. X & Z Axis moves on wide harden and ground box guide ways which allows vibration free cutting and more rigid machining at greater extension from turret.

USP • Heavy and rigid single piece structure • Heavy duty box type guide ways • High performance rigid spindle • Counter balance Z axis • Hydraulic chucking • Auto and manual coolant system • Electrical with quality devices and panel with A.C. • Centralised and programmable lubrication • Efficient chip disposal.

AX Series Whether in the automotive, instruments, hydraulic or electronics industry – the AX series, offers ideal performance options for sophisticated machining for bar, shaft and chucking components. The frame sizes with different options are unique and contribute to the success of this series. They have been designed for flexible tailor-made solution to meet varying demands. Multitasking with combination of two electro spindles and live tool turrets with one component clamping with C&Y Axis. Design shows excellent vibration damping to deliver high level of

July 2015 n OEM Update

machined surface quality and accuracy even for hard part machining with high rapid.

USP • Unique single piece construction • 12 station live tool turret with Y axis • High speed electro spindle with C axis and rigid headstock • Secondary spindle available • Hydraulic chucking • Auto and manual coolant system • Electrical with quality devices and panel with A.C. • Centralised and programmable lubrication.

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Cover story

Gemini: the latest machining sensation Building on its expertise in machine tool manufacturing, the group has further diversified into manufacturing of components for various industry segments. In addition, the group also offers products to enhance its customer’s productivity through real time machine monitoring.

The key product manufacturing companies of the group are: • Ace Designers: CNC lathes, chuckers, vertical and turn mill centres • Ace Manufacturing Systems Ltd: Vertical and horizontal machining centres • Micromatic Grinding Technologies Ltd.: CNC and hydraulic grinding machines • Pragati Automation: High precision automation accessories for machine tools • AmiT: Productivity solutions for manufacturing shopfloors.

Off late, the industrial manufacturing sector in India is heading for a slow and steady recovery. Commenting on the latest demand-supply scenario of CNC machines, T K Ramesh, CEO, Micromatic Machine Tools Pvt. Ltd. said, “The demand for our CNC machines is stable and growing. We are in constant touch with the market requirement and are supporting the market with the required products and solutions. The first quarter demand has been to our expectation and we hope it will become better in the coming period.” Micromatic is the marketing arm of Ace Micromatic Group.

Gemini Mini

Gemini range of twin spindle, offered by Ace Manufacturing Systems, where the productivity of the machine is nearly double to that of single spindle machines with similar specifications.

-T K Ramesh, CEO, Micromatic Machine Tools Pvt. Ltd.

Ace Micromatic Group is one of the major machine tool players in India. It has market presence in several countries across Asia, Australia, Middle East, North and South America and Europe.

The group specialises in the manufacturing of CNC controlled turning, milling and grinding machines along with subsystems like tool turrets, ATC etc. Ace Micromatic offers its customers a wide and comprehensive range of machine to suit a broad spectrum of applications. It also offers turnkey solutions, tooled up options, innovative work holding, Cp/Cpk evaluation, TPM friendly machines and more.

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CNC machines from Ace Micromatic The group fulfils the needs of its customers in the area of turning, milling, grinding, productivity solutions, and accessories.

ACE Designers Group ACE Designers Group offers a range of turning solutions.

It is the largest manufacturer of CNC lathes in India with about 40 per cent share of the Indian market, informed Mr Ramesh. The product range comprises of machines to suit a broad spectrum of applications. It also offers turnkey solutions, tooled up options, innovative work holding, TPM friendly machines and more.

“Jobber series of machines are the highest selling machines in the turning segment in India,” Mr Ramesh adds. Other popular brands from the ACE Designers are: LT series, CNC chuckers, sliding head Automats, the Vantage series, the vertical turning centres and the special turning solutions with automatic load unload systems.

AMS Limited AMS Limited, the milling arm of the Ace Micromatic Group, offers one of the widest range of machining centres, both vertical and horizontal, they cover the entire gamut of milling applications, from the simple to the most July 2015 n OEM Update

Cover story complicated. The latest in the series are the Twin Spindle Machining centres. AMS products are used to produce critical parts for passenger vehicles, commercial vehicles, two wheelers, three wheelers, and farm equipment.

AMS is also a supplier of machines to many Indian OEM manufacturers and large size component manufacturers.

Some of the highly sought after product ranges are drill tap centres, vertical and horizontal machining centres, twin spindle machining centres and moving column machining centres.

Micromatic Grinding Technologies Ltd Micromatic Grinding Technologies produces a wide range of external, internal and universal cylindrical grinding machines in hydraulic, PLC and CNC versions. With two plants, one at Ghaziabad and other at Dobaspet, it provides customised solutions to the exacting grinding needs of the Indian manufacturing industry. “Special purpose grinding machines like valve seat grinding of I.C. engine valves, grinding of ring profile, stroke and length grinding of fuel injection components have proved to become a valuable import substitute for Indian manufacturers,” claims Mr Ramesh.

Pragati Automation Ltd Pragati Automation Ltd produces a variety of turrets including hydraulic turrets, servo turrets and power turrets.

Pragati also manufactures hydraulic chucking cylinders.

Apart from turrets, Pragati is known for its Automatic Tool Changers (ATC) for machining centres. According to Mr Ramesh, “75 per cent of its ATC production is exported to markets like Germany, Italy, Austria, Switzerland and Spain.”

AmiT AmiT is the software division of the Ace Micromatic group. It synergises its information technology expertise and manufacturing industry experience to develop ITbased productivity management platform TPM Track. It empowers industries to improve their OEE and profits significantly. It also enables to automate key business processes. TPM-Trak is a real time conveyor and assemblyline monitoring solution that automatically captures workflow, stoppages, and interactions between various stations of assembly lines/conveyors and key events are alerted through factory visual boards and SMS and email.

The company also provides TPM-Trak Secure DNC that enables shop floor personnel to manage CNC programs and track and trace solution that enables customers to track the products during various stages of production.

double to that of single spindle machines with similar specifications,” Mr Ramesh said.

To meet the requirements of high speed compact applications, a smaller twin spindle named, ‘Gemini-Mini’ has been introduced. The Gemini-Mini is more suitable for smaller components requiring frequent tool changes.

The machine is designed with two BBT-30 spindles driven by a single spindle motor. According to Mr Ramesh, the product is an attractive alternative to many of the faster machining centres available at a dearer price.

The Gemini Mini is also available with an optional rotary type automatic pallet changer. Being pioneers in twin spindle vertical machining centres, AMS is now offering Horizontals too. The launch was staged at IMTEX 2015, which was a grand success for AMS. There are varieties of Gemini series twin spindle machines to suite the exacting requirements.

“By nature the twin spindle machine has higher productivity and the automatic pallet changer enhances it further by masking loading unloading time of the components,” Mr Ramesh said.

Manufacturing capacity Ace Micromatic Group of companies are located at different locations with well-established vendor base and a strong in-house manufacturing capability. With a captive foundry inaugurated in 2013 capable of producing 12,000 tonnes of medium to large CI and SG iron casting per annum, the group is well placed to meet the production requirement of the growing Indian market.

According to Mr Ramesh, the group can produce more than 5,000 machines each year with the existing capacities and are in a position to scale up the capacities within short time if the need arises. n

MCV 700

The ‘Debutant’ From the milling section, Ace Manufacturing Systems Ltd (AMS) has recently introduced Gemini range of twin spindle.

“With increase in input costs including infrastructure and man power costs, machine tool users have become more cautious in the resource utilisation. These conditions have led to development of the twin spindle machines, ‘Gemini’ where the productivity of the machine is nearly July 2015 n OEM Update

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Cover story

CELOS from DMG MORI: revolutionising production process DMG MORI presents CELOS with a total of 15 APPs and as PC version for the continuous production planning on the PC in work preparation with direct connection to the machines • Overview of all maintenance tasks on the machine • Advance notice of all scheduled maintenance and service activities • Display of all required spare parts and equipment • Support during implementation.

Tool handling Shorter tooling times due to target/actual comparisons of the magazine assignment for follow-up jobs.

• Intuitive overview of all tools registered on the control • Display of all tools required for a job including automatic creation of a loading list • Creation of an unloading list through automatic detection of all tools not required for the next jobs.

CELOS from DMG MORI offers simplified machine operation and a holistic integration into all business operations.

CELOS provides a uniform user interface for all new hightech machines from DMG MORI. CELOS APPs provide the user with integrated management, documentation and visualisation of order, process and machine data on a unique 21.5-inch multi-touch screen. Furthermore, operation of the machine is simplified, standardised and automated.

CELOS is offered with a total of 15 APPs. Additionally, the CELOS PC version is available. It is used by customers to optimally plan and control their production process directly during work preparation. In addition, any machines or equipment can be incorporated in an integral CELOS periphery with the CELOS PC version.

Furthermore, CELOS links the machine with higher-level company structures in a unique way, thus creating the basis for consistent digitalised and paperless production.

Through direct coupling of ERP/PPS and PDM, users get to the product 30 per cent faster with CELOS. CELOS is thus setting standards and responds to Industry 4.0.

4 new CELOS APPs Similar to a Smartphone, users have direct access to all available applications via the CELOS APP MENU. The APPs are divided into five groups for production, utilities, support, configuration and machine views. The four new CELOS APPs specifically target further improvement of job preparation and company organisation here, and an optimised applications and service planning of the DMG MORI machines.

Service agent Increase of machine availability by way of intelligent maintenance system.

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Job scheduler Production planning for all machines.

• Record, manage and schedule individual jobs for production • Assign and transfer jobs to machine (s) • Overview of complete order status on all machines.

Messenger So that you know at any time what is happening in your production!

• Clear machine live status of all networked machines • Detail view of each individual machine including machine history • Evaluation of machine operating time, downtimes and failure.

CELOS as PC version In addition to the 4 new CELOS APPS, with the new PC version DMG MORI extends the range of applications and services of its revolutionary software once again.

Once users have installed CELOS on their PC, all CELOS functions will be instantly available to them. The new CELOS version is used by customers to optimally plan and control their production process directly during work preparation.

The CELOS PC version also provides the opportunity to incorporate any machine or equipment in an integral CELOS periphery. For this purpose, the CELOS PC version must simply be made available close to the machine in order to be able to retrieve the order data here for the respective machines in production. Planning and production become one with the CELOS PC version. This already provides users with a response to the requirements of the future project Industry 4.0. n July 2015 n OEM Update

Cover story

Multi Axis CNC Robotics: Meeting the needs of SMEs We are targeting SMEs and smaller entrepreneurs to provide customised CNC machines according to their budget, area, and power requirements.

- Rajesh Kushwaha, Managing Director, Multi Axis CNC Robotics A perfect start Founded in 2001 in a small workshop in Delhi, Multi Axis CNC Robotics is emerging as one of the significant players in the CNC machines manufacturing segment.

The company developed its prototype CNC milling in 2009. After making its first machine, Multi Axis CNC Robotics decided to run the same first at its own shop floor to understand breakdown, maintenance, service area etc. Later, the company contacted Maruti-Suzuki vendor for their job work on the same machine. There, the company ran the machine for one-and-a-half years successfully and earned Rs 28 lakh from job work! Since then, there is no looking back.

Today, Multi Axis CNC Robotics manufactures vertical machining centres, horizontal machining centres, CNC milling machines, engraving machines, wooden routers, stone routers etc. Its machines are widely used in dies and moulds like injection mould, press tools, pressure die casting, forging dies, metal patterns, auto components machining, shoe moulds, graphite electrode machining, wooden doors, wooden carving, stone carving, jewellery making, dental solutions etc.

Meeting the needs of SMEs CNC machines are most important nowadays in each and every tool room. They are fast replacing the conventional machines and producing high accuracy while saving time, power, money and manpower. Talking on the company’s achievements Rajesh Kushwaha, Managing Director, Multi Axis CNC Robotics, said, “Though we are catering to small and medium segments, recently we have developed bigger machines and entered in the market where others big players are selling their machines. As Prime Minister Narendra modi said SME sector is the backbone of our economy and it has to be strengthened, we are targeting SMEs and smaller entrepreneurs to provide customised CNC machines according to their budget, area, and power requirements. Even we are making CNC milling in singlephase power connection.”

Customising solutions Multi Axis CNC Robotics offers high precision CNC milling and CNC engraving machines that further used in dies and mould manufacturing. Highlighting the advantages of the company’s CNC machines, Mr Kushwaha said, “Our each and every machine is customised as per customer demands. We customise machines as per customers’ application, shop floor size, power connection and their budget. We use spares parts from leading global manufactures. We are making our machines with Mitsubishi M70V controller for better performance in dies and mould application.”

Multi Axis CNC Robotics is also using Hiwin-Taiwan products for high accuracy motion.

Manufacturing capacity Multi Axis CNC Robotics produces 50 to 60 CNC machines a year. “We are growing faster as our machines are running successfully in the market since long without major breakdown,” Mr Kushwaha avers. n

July 2015 n OEM Update

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Cover story

Mitsubishi CNC: maximum output, highest productivity Mitsubishi CNC has helped the machine tools and manufacturing sector with its advanced technology and solutions.

Mitsubishi’s offerings Introduced here is a full line-up of Mitsubishi CNCs manufactured with standards compatible for use globally. The M70 Series inherits the highly accurate nano-control technology of its M700V Series, and its models are setting new standards in the industry.

Mitsubishi E70 Series CNC Seeking easier usability and higher cost efficiency, the E70 Series, a new standard CNC Series offers high performance and high operability. With primary features such as lesser wiring, compact size, latest hardware, the E70 Series is best suited to simple lathes and milling machines.

With over 90 years of experience in providing reliable, high-quality products, Mitsubishi Electric Corporation is one of the world-leaders in the manufacturing, marketing and sales of electrical and electronic equipment used in information processing and communications, space development and satellite communications, consumer electronics, industrial technology, energy, transportation and building equipment.

Embracing the spirit of its corporate statement, changes for the better, and its environmental statement, eco changes, Mitsubishi Electric endeavours to be a global, leading green company, enriching society with technology. The company recorded consolidated group sales of 4,323.0 billion yen ($ 36 billion) in the fiscal year ended March 31, 2015.

Mitsubishi Electric in India has grown to become a company offering a wide range of innovative and high-quality products for the Indian market. This includes products and solutions for air-conditioners, factory automation and industrial systems, photovoltaic solutions, semiconductor and devices, transportation systems and visual and imaging.

Increasing footprint Indian machine tool market has good potential, as observed in last 10 years the market has improved a lot. Mitsubishi Electric Corporation entered the market in 2012. Though Mitsubishi CNC relatively new in the category, the company’s CNC division has made its presence felt by changing the machine tool sector, machining and manufacturing with its advance technologies and solutions. “As a leading CNC provider, it’s our responsibility to provide optimum technologies and support for the user taking a step forward to ensure a highly successful future. In order to increase our market share in India significantly and expand the CNC business, we continue to invest in this market,” a company spokesperson said.

To reach the success, it’s essential for companies to upgrade their system for improving production efficiency and product quality. However, Mitsubishi observed that there companies still attempting to establish market shares by incorporating the latest technology in order to increase the brand value. Mitsubishi supports its customer with advance technology, which enables reduction in cycle time and high accuracy in cutting operation.

In the past couple of years Mitsubishi CNC start working with all the major Indian machine tool builders and users who have started using Mitsubishi CNCs. Mitsubishi CNC has helped the machine tools and manufacturing sector with its advanced technology and solutions.

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Mitsubishi M70 Series CNC The M70V CNC Series is specially made for pursuing high speed and accuracy. The system can deliver remarkable reduction in cycle time, optimum performance for various applications such as compact milling machine, tapping machine, multi-axis machining centre, compact lathe etc. Additionally, it is equipped with various support functions like data back-up, program restart, ground fault detection for each motor etc., which help minimise the downtime.

Mitsubishi M700 Series CNC M700V Series is a state-of-the-art model that provides high speed and accuracy machining and advanced control technology. These functions are for customer who keeps pushing for higher production output. Mitsubishi M700 series CNC support top level manufacturing.

Mitsubishi C70 Series CNC IQ Platform compatible CNC C70 Series is incorporated with the company’s state-of-the-art technologies. High performance CNC integrated with high speed PLC offers high speed control to reduce cycle time. Also a wide range of factory automation products helps construct flexible lines.

Mitsubishi CNC: creating distinction Mitsubishi CNC is a state-of-the-art model that provides high speed and accuracy machining and advance control technology. Below are few features which Mitsubishi provide to its customers to get the maximum output with best production quality: Super Smooth Surface (SSS) This provides a smooth finish without deviation for die-mould machining. It is mainly built for high precision cutting and reduces cycle time. SSS enables judging the part program paths, which reduces unnecessary deceleration even when fine steps in the program exist.

Hence, machining time can be shortened by 5-30 per cent. SSS control also ensures high machining stability and quality with virtually no effects resulting from cutting shape or speed.

Optimum Machine Response Direct Drive (OMR-DD) A high speed, error-compensation function is used for controlling the spindle and servo motor, enabling accurate tapping. This achieves high speed drill and tap reducing cycle time. By compensating for the deflection between the motor-end and machine-end, the part shape at a high speed and acceleration rate can be compensated for. The July 2015 n OEM Update

Cover story optimal shape can be obtained at a low feed rate. It also compensates for the outward expansion of the shape at high feed rates.

Multi-axis Control With multi-axis control, it is possible to control multiple axis, multiple programs, which help to build multifunctional machine. Furthermore, it is also possible to reduce the cycle time in turning. As a result, it helps in reducing the number of machines.

iQ Platform CNC iQ Platform stands for integrated Q improved quality/intelligent and quick innovation and quest. Mitsubishi iQ Platform-compatible CNC C70 offers the maximum scale TCO reduction effects to manufacturing sites by taking advantage of MELSEC’s great convenience. High performance controllers enable optimisation of diverse production processes on the shop floor. n

NC Spot Drill: The multifunctional cutting tool The “all in oneâ€? function NC Spot Drill from Nine9, Taiwan with a patented indexable carbide insert contributes high efficiency by performing various multiple applications as: • Grooving • Helical grooving milling • Engraving • Spot drilling • Chamfer turning • Face grooving milling • Internal turning • Internal chamfering • Facing grooving.

This multifunctional cutting tool, used in CNC lathe and CNC machining centres, contributes to

increased cutting speed, long tool life, best position accuracy and reduction in cycle time.

NC Spot drill shank diameter ranges from ø5 to ø20 mm and inserts are having four cutting edges and available in 45/60/82/90/120/142-degree angles for different applications.

The latest coated carbide grade helps to obtain higher speed and feed rate therefore reducing the cycle time. n Stitch Overseas Private Limited # 179 - 180, Industrial Estate Udyog Vihar, Phase-6, Sector 37 Gurgaon - 122 004, Haryana Tele: +91-124-4755400 Fax: + 91-124-4755430 E-mail: commercial@stitchtools.com, stitch@vsnl.com www.stitchtools.com

120mm x 180mm

Additive Manufacturing 3D Printing CAD/CAM system related to Dies and Moulds CNC Milling Machining Centre EDM etc Coating Cutting Tools Digitizing Die/mould Polishing/ Die Spotting machines Dies & Moulds, Press Tools, Jigs, Fixtures, Gauges Heat Treatment Hot Runner System Machine Tools and Accessories for Dies and Moulds Measuring Machines, Quality Assurance Mould base and standard parts of Dies and Moulds Toolings Moulding Machines/ Die Casting Machines; Sheet Metal Presses and Ancillaries Rapid Prototyping and Tooling Surface Treatment Texturizing Tool Steel All ancillary materials equipments accessories consumables, services and automation covering Die and Mould industry

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July 2015 n OEM Update

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Case Study

Let the ‘good times roll’ with Renishaw’s 5-axis CMM inspection At the Maryville plant of Kawasaki, 5-axis scanning probes speed form-data collection and feedback to machining cells, reduce CMM fixturing and cut probe calibration time from hours to minutes, while ultimately eliminate inspection systems for gears and cam lift.

“We use the Kawasaki Production System (KPS),” said JC Watts, Quality Control Technical Group Supervisor at the Maryville plant. “Our quality and engineering requirements are comparable to the best in the automotive industry, though our manufacturing is focused on lower volumes of many different kinds of products.” The plant has 50 machining lines, typically arranged in a U-cell pattern with start and end machines across from each other. “Primarily, it’s one-piece production with machining lines running a part through multiple processes at a high rate,” Watts explained. Kawasaki utilises automation in many die cast and some machining operations, accomplished through the integration of Kawasaki robots. On one of the crankcase lines, robots load raw materials and unload finished parts that are placed into inventory for assembly to draw upon.

Machined parts include aluminium, cast iron and steel.

Revo head inspecting a FX series small engine flywheel

Kawasaki encourages motorcycle enthusiasts to “let the good times roll,” but good times of another sort are rolling at the company’s Maryville small engine plant, where two 5-axis scanning probe systems are slashing CMM inspection and probe calibration times, and speeding up QC feedback for machining of small engine components.

The 5-axis Renishaw REVO systems, installed on Mitutoyo Crysta-Apex 121210 CMMs, replaced two PH10 articulating heads using SP25 scanning probes on traditional 3-axis CMMs. The REVO-equipped CMMs have cut inspection times by half or more on scanning intensive applications, eliminated the need for custom probe configurations, cut probe calibration times from six to seven hours to about 45 minutes, and added new capability to collect large amounts of form measurement data, improving part quality. Of primary importance, the REVO systems have greatly increased inspection throughput, data quality and flexibility of the QC department, enhancing its value as a strategic support asset to both manufacturing and R&D. The Kawasaki Production System Kawasaki’s 800,000 square-foot Maryville plant, opened in 1989, produces single and twin-cylinder air-cooled or water-cooled engines, 1000 cc or smaller, for commercial and consumer lawnmower OEMs, as well as for a sister plant that manufactures ATVs and Mule utility vehicles.

Operations at Maryville include aluminium die-casting, plastic injection moulding, and extensive amounts of machining, painting and assembly. All engines – approximately 500,000 per year – are run-off before shipping as well.

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“We’re running similar tolerances that automotive powertrain uses for high-end products, and there are probably four or five critical processes for our aluminium parts and 15 for the steel parts,” Watts added. It is not uncommon to find tolerances “in single digits in microns” for form, and 0.05 mm true position.

The QC lab is responsible for inspecting 125 different mass-produced parts, as well as vendor parts and those produced for engineering development. The environmentally controlled lab is located adjacent to the machining lines, and parts intended for routine inspection are delivered on carts or via train (an electric vehicle towing several trolley carts). Critical components may be hand delivered for priority inspection during a line changeover or if an operator suspects a problem.

5-axis scanning advantage “When I started here, we had a couple of 3-axis CMMs with PH10 articulating heads and SP25 probes, and another CMM with a fixed probe head,” Watts explained. “We were frustrated with having to make probe configurations and being limited to what we could do even with the articulated heads. We had so many different probe configurations that calibration times of six to seven hours took a bite out of our inspection throughput, too. We wanted to do better than what the industry considered the norm, so we looked at several options and the 5-axis REVO system appeared to be the fastest and most flexible available. It was the best fit for our requirements.”

Kawasaki bought a new Mitutoyo Crysta-Apex 121210 in 2009 with the REVO system installed from the factory, July 2015 n OEM Update

Case Study and retrofitted an identical machine in 2010, after the first machine was up and running with all the part programs.

The REVO 5-axis scanning probe head can collect up to 6,000 data points/ sec. It is engineered for high-speed precision measurement of contoured surfaces and complex geometries requiring high-volume data collection to validate fit and form with high accuracy. It uses two rotary axes, one in the vertical plane and one in the horizontal, for infinite rotation and positioning. Five-axis software drives the measuring head and synchronises its motion with the linear axes of the CMM. Look-ahead algorithms drive the probe path and CMM in coordinated continuous motion. The head adapts position while measuring on the move, maintaining stylus tip contact with changing contours at scanning speeds of up to 500 mm/sec.

“Though our SP25s were scanning probes, we were doing 95 per cent touch probing because scanning was too slow with a 3-axis CMM,” Watts explained. “Our cylinder and crank bores are probably the best examples of where we believed touch probing was inadequate. To accurately collect enough data points to measure the geometry of a bore 80 to 100 mm in diameter and 150 mm in length, the SP25 probe took so long we limited those inspections to machine set up or special requests from our design department. Now on every crank case we measure, the REVO does a spiral scan of bores and the system outputs the values to software. We also send a graph of the data points to our network that can be used by anyone in QC, engineering or production, and it really helps troubleshoot problems. You can VISUALISE the problem. What would take 3-4 minutes with an SP25, we’re measuring in 10 seconds with the REVO.” The REVO scanning heads have all but eliminated the need for touch probing. Now 95 per cent of inspections utilise scanning, with no “time penalty” as before, allowing Kawasaki

July 2015 n OEM Update

to collect so much data that it challenges the speed of computers doing the analysis. The REVO probe can also do “head touch” probing or be used for traditional machine-touch probing when the situation calls for touches.

“With scanning inspections, our production and engineering people have a lot more confidence that the data is valid,” Watts added. “With touch probing it is easy to get one speck of dirt that causes an out-ofround condition if you’re only sampling seven or eight points. It can throw the location of that circle off. We have specific documented examples of where there were flatness errors we would not have caught with touch probing, and cylinder bore geometries that would not have been caught with touch probing because of the amount of data sampled with the touch probe. We still caught these problems before they left the plant, but the parts were scrap. The REVO scanning capability allows us to catch form errors much more quickly, without a time penalty on our inspections. It has definitely made us more proactive in catching quality problems early in the game.”

Fewer probe configurations, more flexibility With REVO, the Maryville operation now has two probe configurations that measure all of its mass production parts, reserving custom probes in a changing rack for a few special applications. Special configurations for vendor parts have also been eliminated because the infinite positioning angles of REVO allow measuring of a part without special fixturing or consideration of which probe to use. With so few probes, calibration time has dropped to around 46 minutes. Now QC technicians monitor the calibration instead of calibrating every shift.

“We are now able to measure all our mass production parts with just two probe configurations,” said Watts. “We were able to eliminate

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Case Study about the stylus interfering with a part feature, due to size or orientation of the feature. The probe automatically aligns normal to the feature being measured, simplifying programming.

Faster inspection, better data from QC to R&D Watts says the transition from 3-axis to 5-axis programming is not difficult, and a programmer with limited ability can still program REVO inspections as 3-axis. However, when it comes to optimising speed of inspection, it is critical to use head motion as much as possible. “This allows you to scan parts the quickest, without inducing measurement error,” he added. “REVO opens up a lot of possibilities, with few limitations, so speed gains are obtainable for both the higher and lower skilled programmers.”

REVO in action

the large ball stylus configurations because of the large approach angle the REVO creates between the stylus and the work piece. During scanning the REVO maintains the approach angle which allows a large cylindrical feature such as a cylinder bore to be measured with the same stylus used for measuring a 5-mm bore, with no chance of shanking the stylus.”

Flexibility of the REVO system has also proven to be a time-saver for Kawasaki. “We can measure any part on either machine with a limited amount of fixturing and no special calibrations,” said Watts. “We measure all our parts on three types of fixturing. The REVO probe orients itself to the part after it’s initially aligned. The utilisation of special fixtures has almost been eliminated, without concerns of measurement error due to part alignment.”

Kawasaki programs all of its inspection routines in-house using Mitutoyo’s Mcosmos 3.1 software. The upgrade to REVO instigated a shift to parametric and modular programming of inspection routines through in-house development of coding. This allows a program to be used for a part family. “We might have 30 different crankshafts, for example, but because everyone has the same features, only in a different size or location, we can use the same inspection program to measure all the parts,” Watts stated. “That’s one of the big advantages we gained.”

Infinite angles of the REVO system make it simple to create parametric programs because there is no concern

Revo-equipped CMMs at Kawasaki’s Maryville

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Inspection results may be relayed to the machining lines manually or they can be accessed locally by line operators over a computer network. “Some of our inspection reports supply offsets directly back to the machining centres coordinate system; this allows the CNC operator to read the offset adjustment right off the report, allowing no misinterpretation of what offsets the operator needs to input,” Watts explained. “We take advantage of some of the ‘best fit’ algorithms and work with our production engineers, especially on parts that require more complex algorithms to get the adjustment right, and to utilise multiple process adjustments simultaneously. We had limited ability to do this before the REVO; the REVO allowed us to utilise parametric programming, which in turn allowed us to expand our capability across the board more easily.”

Five-axis CMM scanning has been a game-changer for QC at the Maryville plant in terms of speed, data quality, and inspection capacity, according to Watts. “We’ve enjoyed big gains from having two machines that are completely redundant, so if one machine breaks or is down for calibration, it’s no problem to measure critical parts on the other machine. That’s a big advantage in the QC lab, because we were the ones who, in a pinch, had to get the large part on the small CMM, or the part requiring the odd angle probe on the machine that didn’t have it. We used to get requests from R&D to measure certain geometries, and it was next to impossible to achieve in the time allotted. Now we can provide the data much quicker and, being scanned data, our people have greater confidence in it. This new flexibility, the reduced fixturing, form measurement, the parametric programming – these are all collateral advantages, in addition to the raw inspection speed.”

The Maryville facility has run more than 50,000 parts through the two REVO equipped CMMs, and Watts indicated there are plans to expand the use of the REVO system to gear inspection and cam lift if it proves feasible.

“We’ve developed our own algorithm and sub-routine in our software for cam lift, and, that’s something that would have been more difficult to do without the REVO system due to the angle the probe requires to measure the lift on the lobes.” n July 2015 n OEM Update

Feature

GRP enclosures aid migration to wireless instrumentation networking Electromagnetic transparency simplifies installation of 2.4 GHz WSN technology

Intertec’s electromagnetically transparent GRP enclosures are ideal for field protection of wireless process monitoring instruments such as pressure, flow and level transmitters.

Until recently, process industry take-up of wireless sensor network (WSN) technology has been relatively slow, possibly because competing wireless standards have made systems designers wary of making the wrong choice. However for mainstream industrial process applications, the field has now narrowed to just two standards – WirelessHART and ISA100.11a.

Both standards define secure, self-healing wireless mesh technology operating in the 2.4 GHz ISM band, using IEEE 802.15.4 standard radios.

ISA100.11a systems use Internet protocols and are designed for multiple wireless communications purposes, while the simpler WirelessHART systems are primarily intended only for use with process instruments; they are also backward compatible with wired HART devices, which are used extensively within the process sector for remote data acquisition.

Field instrumentation protection specialist Intertec is seeing increased customer demand for equipment housings to contain wireless process monitoring equipment in outdoor environments. This is partly due to increased use of industrial WSN technology, but mainly to the growing industry awareness that the glass-reinforced polymer (GRP) composite material it uses for all its protective enclosures is electromagnetically transparent.

Advantage GRP One of the many benefits of its GRP composite material is electromagnetic transparency – it produces a wide range of frangible environmental protection cabinets and shelters for radar and instrument landing systems at airports which are designed not to reflect or interfere with radio signals. The housings are also used extensively for cellular and satellite communications applications, as well as satellite navigation systems; the GRP material causes no measurable loss of received or transmitted RF signals, so the equipment antennas can be contained within the enclosure. GRP is also ideally suited to field-based 2.4 GHz wireless sensor networks, especially for applications where external antennas are inadvisable because of their susceptibility to accidental damage.

According to Intertec’s CEO, Martin Hess, “More and more process industries are starting to deploy wireless field instrumentation, although at this stage it’s only for

monitoring and diagnostics – I think that it will still be a long time before wireless is used for process control purposes. Having said that, the technology offers huge benefits for companies with large remote data acquisition needs, completely eliminating the cost and inconvenience of cables. We believe that our GRP composite enclosures provide plant engineers with a future-proof path for WSN technology – even if they choose to install cabled instruments today, by selecting the right type of enclosure at the outset they will make it easy to deploy wireless instrumentation whenever they wish, without having to change the entire installation.”

Intertec manufactures all its protective enclosures for field instrumentation from proprietary GRP, either in the form of a single layer or a multi-layer composite containing one or more cores of special insulating and/or fire resistant materials. As well as being electromagnetically transparent and an excellent electrical insulator, the material has multiple advantages for plant designers seeking to protect field instrumentation against environmental effects, especially for long lifecycle applications and where harsh media or severe local climatic conditions might be encountered.

GRP is inherently inert and immune to damage from most common chemicals and petrochemicals. It has a similar strength to steel, but weighs about four times less, and will not corrode in the presence of salt – which is why it is increasingly becoming the enclosure material of choice for offshore and coastal oil and gas applications. GRP also has low flammability and is self-extinguishing, as well as having a very low thermal conductivity that makes it easier to implement efficient, condensation-free enclosures.

Performance evaluated A number of Intertec’s customers, as well as manufacturers of wireless process monitoring automation, have started to evaluate the electromagnetic performance of its GRPbased enclosures for housing field-based WSN equipment.

Initial results are very promising: third-party tests involving a WirelessHART gateway and a WirelessHART field device, both with built-in antennas and sited in different rooms, found that when the field device was placed inside a standard GRP instrumentation enclosure it continued to function properly, with no measurable loss of signal.

The tests were conducted using a model from Intertec’s Multibox range, but the same results are likely to be obtained from many of the company’s enclosures that use a similar form of construction, including its Diabox range.

Both types of enclosure are moulded from hot-pressed GRP. They are optionally available in ATEX-compliant antistatic versions for use in hazardous environments and can also Continued to 31

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July 2015 n OEM Update

Feature

Advanced instrumentation and control technology enhancing products quality The technology developments and indigenisation of instrumentation systems reduce the investment cost in small and medium scale manufacturing industries.

Bipinchandra Chaudhari, Director, BR Instrumentation & Controls

Instrumentation and control plays a very critical role in the manufacturing sector. Nowadays vast instrumentation and controls systems are used in the steel plants, power plants, sugar industry, oil and gas industry and automobile industry.

According to Bipinchandra Chaudhari, Director, BR Instrumentation & Controls, “Today most of the machineries used in manufacturing sector are controlled by PLC and HMI systems. These technology developments help manufacturers to produce world-class quality products in the competitive markets.”

instrumentation products are also helping to prevent natural resources like water by applying system like automatic meter readings in large cities and towns.

BR Instrumentation’s products and solutions BR Instrumentation & Controls is having a manufacturing facility at Chakan near Pune to produce electromagnetic flow meters and control panels.

Its products and solutions are widely used in industries like power, water, waste water, automobile, environment monitoring etc.

DCS panels

BR Instrumentation & Controls offers complete instrumentation and control solutions. It can offer customised instrumentation panels. The company designs, develops and manufactures PLC, DCS and SCADA-based control panels.

BR Instrumentation & Controls also offers its expertise services for turnkey instrumentation project execution. n BR EMF

The latest instruments and control systems help to reduce production cost, maintenance cost and reduce the down time in any case of failure. During shutdown, the analysis of system is possible in comparatively less time. The manufacturing time is reduced with the help of latest instrumentation systems. The robotics systems are playing a major role in automation of process in the manufacturing plants. “The technology developments and indigenisation of instrumentation systems reduce the investment cost in small and medium scale manufacturing industries,” Mr Chaudhari adds.

The real time monitoring of different systems is one of the major parts of instrumentation and controls. The latest

GRP enclosures aid migration to wireless instrumentation networking Continued from 30 f

be fitted with an internal layer of polyurethane foam for additional thermal insulation – all of the materials are electromagnetically transparent and have no effect on signal reception or transmission.

Many of the wireless process monitoring instruments on the market, including a number of pressure, flow and level transmitters, offer the option of local (on-instrument) or remote antennas. However, if the instrument needs to be housed in some form of enclosure to protect it against a July 2015 n OEM Update

harsh environment, this choice will not be available if – as is commonly the case – the enclosure is made from a metal such as steel or aluminium; its RF shielding effect will necessitate use of a remote externally mounted antenna to secure adequate signal strength. Aside from incurring additional implementation costs, use of an external antenna also involves drilling an extra hole in the enclosure – probably in its top, which is potentially the worst place for leaks – and leaves a delicate structure open to physical impact. n 31

Feature

Surface coating to protect steel assets Protection of steel assets is a priority running into billions of dollars

Blastline

is one of the world leaders in blasting, abrasives. Blastline India is an acknowledged leader and provides accessories for protective coating industries.

Blastline India boasts of major international clients who have their base in India.

Jolly Lonappan, Managing Director, Blastline India Pvt Ltd, shares his views on the status of the surface coating and abrasives industry in India.

Painting Sytems

Abrasive blasting is a cost effective procedure Abrasive blasting is a time-tested method of removing rust, old paint, foreign particles and other surface contaminations. This helps to achieve the right profile to ready a surface for coating. Abrasive blasting is the operation of forcibly propelling a stream of abrasive material against a surface under high pressure to smooth a rough surface, roughen a smooth surface, shape a surface, or remove surface contaminants. A pressurised fluid, typically air, or a centrifugal wheel is used to propel the blasting material. The abrasive blast cleaning was first introduced by the Greeks who were the pioneers in the marine industry as we know it today, maintained a large fleet of vessels for transportation between their numerous islands. Subsequently, it was established as the most costeffective and efficient cleaning procedure for coating applications. There are several variants of the process, such as bead blasting, sand blasting, soda blasting, and shot blasting.

Investment in infrastructure largely goes for steel In every major project, whether it is an oil refinery, shipbuilding, petrochemical plant, pipeline systems or government infrastructure, 80 per cent of the

Presently almost 5 per cent of the GDP in every nation is used for corrosion protection and the costs run into billions of dollars.

Jolly Lonappan, Managing Director, Blastline India

32

investment is used to buy steel. So, safe-guarding such investment basically boils down to the protection of these infrastructures, which in turn, demands protection of steel. “Surface coating is nothing but asset protection as much as protecting steel from corrosion. Presently almost 5 per cent of the GDP in every nation is used for corrosion protection and the costs run into billions of dollars,” observes Mr Lonappan New shot blasting technology reduces carbon emissions Over a period of time, the abrasive media used in this process has undergone a sea change from sand - slag garnet - steel grit as demanded by health reasons, economy of usage, pollution regulations and more stringent performance specifications. The 21st century slogan to protect the planet is ‘Reduce, Re-cycle and Re-use’. “It is our duty to adopt and innovate in all ways possible to protect the small blue pale dot in the galaxy of our planet ‘Earth’. This is where steel shots and grits become relevant.

They can be recycled more than a 100 times, thereby cutting cost to such an extent that it becomes cheaper than the good old sand-blasting which made use of plain sand,” remarks Mr Lonappan Steel grits and shots are now ‘Made in India’ In order to use the steel shots and grits, the end-users have innovated and improvised on the conventional methods resulting in the creation of blast rooms, blast cabinets or blast chambers, coupled with air blasting or wheel blasting gadgets, this reduces the dust generation, noise levels and general pollutions.

“For years, steel grits and shots were being imported from Europe and the US. However, currently doing justice to the new government’s ‘Make in India’ campaign under Prime Minister Narendra Modi, these materials are now being indigenously produced at 3 or 4 factories in India, while there are more than 40 factories making the same products in China,” says Mr Lonappan.

Blastline India observes compliance set by international bodies Jolly Metal Abrasives located at Tuticorin in Tamil Nadu, is a subsidiary of Blastline India Pvt Ltd, and is actively involved in the manufacture and trade of steel shots and grits that meet up with international specification standards like SAE in both physical and chemical composition of the material. Mr Lonappan says, “Our products are quality tested in a state-of-the-art material lab before being sent to our clients in the market. The shots and grits can be used for various applications.

These include shot blasting for corrosion protection, shot peening to increase the surface hardness to take cycle loads, foundry cleaning, for cleaning of castings, granite cutting, as an additive in concrete and to add weight, strength, hardness and to increase resistance of radiation in nuclear plants.” n July 2015 n OEM Update

Technology

Shaping the industry How Wheelabrator is shaping the industry with the launch of shot peening machine DRT are fitted with Variable Frequency Drive (VFD) to ensure that the wheel rotates at set RPM controlling the shot impinging velocity of the components. The number of independent rotary table has to be between six and 12. The drive used for the table indexing is mounted on top of the machine and the indexing time can be as low as three seconds for 30 degree rotation. Normally for shot peening, conditioned cut wire shots are preferred. The size of the shots is selected based on the component size, shape and profile that need to be peened. The machine shot recirculation system is fitted with multi-deck Gyro screen for the classification of the shots and allowing only the chosen size shots for the shot peening needs. The screen normally used is off line and continuously in operation. The machine is also equipped with safety and operation interlocks.

Shot Peening

The

automotive market is becoming more and more demanding with increased expectations from the components being used in terms of better life, increased efficiency and higher workloads. Since safety and speed are important aspects in this industry, manufacturers are constantly upgrading their processes and adapting international norms. Components which are subjected to cyclic loading such as crankshafts, springs, transmission gears, connecting rods, etc are increasingly subjected to shot peening operation. To achieve the perfect solutions for automotive industry, Wheelabrator peening machines incorporate programmable control and automated component handling systems. These operate in line with pre-set programs to ensure the precise repeatability of the peening effect, which is essential for volume production.

Shot peening, which is a means of controlled blasting, induces compressible stresses in the component thus increasing its fatigue life.

Wheelabrator, one of the leading surface preparation technology manufacturers, offers multi-table wheel shot peening machine – DRT. The machine is installed with one or two Roto-Jet blast wheels for standard applications and Saturn HD blast wheels for heavy duty applications. The main chamber is made from Mn (manganese) steel with replaceable liners in the direct blast zone. The wheel drives

Shor peening components

34

DRT is offered from DISA India Ltd’s state-of-the-art manufacturing facility based at Hosakote, Bengaluru. The application, engineering and services play an important role in the peening solution implementation. Hence, the Wheelabrator team has been trained including MFA training to ensure perfect installation. The machine is assembled and tested in the Hosakote plant before dispatch.

Shot peening Shot peening is used widely to enhance the fatigue resistance of highly stressed metallic components. This in turn will improve the performance of safety-critical components. Any metallic component that is subjected to cyclic stresses within its elastic limit can benefit from the shot peening process. Peening is achieved by propelling a stream of media (precisely manufactured round steel shot, glass or ceramic beads) at components, at high velocity under fully controlled conditions utilising a compressed air stream or, centrifugally, by means of a vaned wheel.

Components that would benefit from this technology include aero engine fan blades, aircraft structural parts and automotive transmission systems. Peening is different from cleaning on various functions such as media velocity, media size, shape to name a few.

Measuring effectiveness with almen strip Effectiveness of the peening process is important to ensure that the correct intensity of stress is being created.

This is achieved with the aid of almen strips. This strip is manufactured from spring steel for strict tolerance of hardness, size and flatness, and is peened on one side only. The effect of the induced compressive stress on the strip results in bowing or curving. The extent of the curve is proportional to the energy imparted by the shot and is measured on an almen gauge. This gives the amount of energy imparted by the stream of shot and absorbed by the strip thus measuring effectiveness of the process. X-ray diffraction techniques also provide an accurate method of measuring the actual stresses within the component July 2015 n OEM Update

Technology and quantifying the actual effect of the peening process. Results are achieved by measuring the angle of reflection in relation to the angle of incidence that varies dependent on material composition and residual stresses.

Advantages In addition to enhancing performance, there are other important benefits from the process: Compressive stress helps prevent crack formation The compressive stress helps to prevent crack initiation; as cracks cannot propagate in the compressive environment generated by peening.

Reduced friction Components which are moving in relation to each other, such as bolting, riveted assemblies, sliding or rolling parts, can wear and fail as a result of microscopic transfer of material from one surface to the other. The surface finish produced by the peening process provides pockets for lubricant retention; it also reduces the surface area in contact under rolling or sliding conditions, thus reducing friction.

Increased wear resistance Peening also has a surface hardening effect and helps the ‘skin’ of the material to resist wear. These characteristics, when combined provide excellent anti-galling properties making the components more resistant, work better and with increased efficiency.

Less corrosion Intergranular and stress corrosion cracking can be inhibited by shot peening which modifies the properties of the metal at a metallurgical level. The process advantageously alters the granular structure at and

July 2015 n OEM Update

DRT - Shot peening machine

near the surface, producing a condition less prone to corrosion.

Defining equipment choice An important and complex aspect is the selection of correct equipment and process parameters. Component variables such as size, shape, material, hardness, application and operating environment all have to be considered. The topography of the component is also an important factor. For instance, if a radius is smaller than that of the shot, then it will result in a non-peened area. Sharp edges, blind holes or hidden areas also need special attention to ensure good coverage and to avoid damage. Independent of the type of media propulsion, shot peening requires monitoring and closed loop feedback for critical process parameters such as media velocity and flow. The ‘science’ of peening rests in all such parameters and close adherence will result in a final product that performs to or above expectations. n

For more information on shot peening, write at bangalore@ noricangroup.com or call at +91-80-40201400/13. Visit www. wheelabratorgroup.com for more details.

35

Innovation

Testing of water parameters at textile plant Technology has enabled efficient treatment of effluent waste for the textile industry in India, to prevent local water bodies from getting polluted factories was not done properly leading to pollution of local water bodies beyond the given limits. For several years, the local textile industries in India have continued to give quality and cost effective clothing material to India and the world. However, as a result of ecological factors around the world, a new government regulation made it mandatory for textile companies to make sure that they treat their effluents before letting them off into local water bodies. In this article, Kondiba Metkari, Business Manager, Hanna Equipments India shares his views on the treatment of effluent wastes in the textile industry giving us insight on the various technologies that Hanna Equipments India has to offer.

HALO HI11312 Worlds First pH electrode with SMART Bluetooth technology.

36

The textile industry in India has had a steady growth rate since the economic liberalisation in the 90’s. It is the second largest exporters of textile in the world and is expected to become the largest exporter of textile material to the world.

The Indian textile industry which is mainly concentrated in Tirupur in Tamil Nadu, Surat in Gujarat and Ludhiana in Punjab and other parts of India has been exporting clothing material and readymade garments to several countries across the world. India has its place in the world when it comes to quality clothing being exported to foreign countries and being branded and sold there. However, a few years ago the government had laid several rules and regulations on the textile industry in India. Since 2008, several amendments and changes in laws and the turbulent global market forced several textile factories in India to shut down. An important thing to look at was that the effluent treatment in the textile Disposal in surface water

Disposal in Marine

In Irrigation

pH

6.0 to 8.5

5.5 to 9.0

5.5 to 9.0 100 ppm

BOD

30 ppm

100 ppm

COD (Chemical Oxygen Demand)

250 ppm

250ppm

Ammonical Nitogen

50 ppm

50ppm

Color (Hazen Unit)

400

Hexavalent Chromium

0.1 ppm

1.0ppm

Copper

2.0

3.0

Chloride

1000

Lead

0.1

2.0

Manganese

2.0

2.0

Zinc

5.0

15.0

Nickel

3.0

5.0

Textile industry – significant contributor to the exchequer Since the economical liberation in 1991, India has been constantly developing its industrial sector. Textile industry plays a major role in Indian economic. India earns 27 per cent of its total foreign exchange through textile exports. The Indian textile industry is presently estimated to be at around $ 108 billion and is expected to reach $ 141 billion by 2021. After the agriculture sector, Indian textile industry is the second largest employer that has generated huge employment for both skilled and unskilled labour alike. Textile companies are mainly located in Tirupur and Karur in Tamil Nadu, Surat in Gujarat, some part of Punjab, and Maharashtra region.

Textile industry is water intensive The textile industry is very water intensive and thus it produces huge volume of waste water. Textile manufacturing process includes sizing, desizing, scouring, bleaching, mercerising, dyeing, and finishing. The main release of pollution during manufacturing occurs during the dyeing and finishing processes. Dyeing and finishing processes account for 90 per cent of the total textile wastewater. Dyeing and finishing requires wide range of chemicals and dyestuff, chemicals such as acetic acid, sulphuric acid, sodium hydroxide, hydrogen peroxide, sodium hydrosulphite, phenyl phenols etc and others. These chemicals are dangerous and can have a high environmental impact if not treated effectively before discharge.

Government regulations on industrial effluents have become strict Indian government has made strict rule for releasing waste water in environment and these rules are mandatory for all manufacturing industry. As per government act for environmental protection of 1986, waste water should be treated before it is released back to the environment.

For manufacturing and processing unit there are certain restrictions on the disposal of effluents in land, marine and in irrigation land. Textile industries have to pay attention to control the following critical parameter before discharging.

July 2015 n OEM Update

Innovation A combination of technology helps to measure and test the water These parameters can be tested in laboratory, on field or directly during the inline process. Most textile manufacturing units rely on all three options. Customer now wants an instrument that not only measures all the parameters, but also records and saves data for analysis and audit purposes. Different testing methods and technology are now available, namely photometric method, chromatography, titration method, Ion selective electrodes and inline testing.

Hanna Instrument helps textile manufacturers to find out the contents in the water. Hanna offers instruments for lab analysis, field analysis and inline testing. Hanna offers more than 3,000 products to industries across verticals. The R&D teams at Hanna continuously strive to develop new techniques that simplify the testing procedures. Hanna has products for testing major parameters of water. This includes parameters like pH, conductivity, and turbidity, TDS, ammonia, COD/ BOD, dissolved oxygen, chloride, ammonia, various ions and many more.

Hanna’s bench photometers HI 83099 and HI 83214, specifically meet the requirement of textile manufacturer. These photometers can measure COD along with major water quality parameters. HI 83099 can measure 47 different water parameters. This is best option for lab analysis. COD measurement is very simple and it’s a three step process – The 1st step is to fill the pre-dosed vial with the sample. The 2nd step would be to place the vial in the reactor and set the timer and in 3rd step, place the vial in the photometer and then read the results.

series of controllers and transmitters for pH, coductivity, ORP, chlorine.

For pH controlling we offer HI 504. The HI 504224 is a dual set point with a measurement range from a pH level of -2.00 pH to 16.00 pH that has an accuracy of +/- 0.02 pH with dual analog outputs. The dosing pumps that add in acid or base to perform the neutralisation can be connected to the dosing relays or to a PLC that is connected to the analog output. The dosing relays can be configured for either On/ Off or PID control. The pH of the effluent can be recorded by either connecting the second analog output to a chart recorder for a paper record or sent to a PC in a central point with the RS 485 connection.

The HI 504 series can log up to 6,000 pH/C samples and be recalled by a PC located 1.2 Km away using the RS 485 connection and HI 92500 software. The HI 504 offers many advanced safety features including temperature level alarm and sensor check capabilities.

Hanna is driven by Innovation Apart from water testing Hanna supplies instruments for agriculture, aquaculture, environmental, food, dairy, beverages and for other industry. Hanna believes in providing right instrument to the customer according to the applications and that is why we have developed instruments that are specific to the application. Hanna works continuously to offer innovative products in the market. The testimony being that we recently launched the world’s first tablet sized laboratory meter which can measure pH, EC, TDS and DO. Hanna has further revolutionised the world of analytical instruments with the introduction of pH electrode that works on Bluetooth technology.

n

All measurements can be accessed through a computer Nowadays it became more important to monitor these parameters at each stage of the process. Inline testing, monitoring and controlling is a critical job. Considering this, Hanna Instruments offers an advanced

Authored by_ Kondiba Metkarri, Business Manager, Hanna Equipment India Pvt Ltd

International Summit on water, waste water treatment, waste management & pollution control

29 – 30 September 2015 Le Meridien, New Delhi www.wwc-india.in For more information, please contact: Prashant Lade | prashant.lade@india.messefrankfurt.com | +91 22 6144 5900

July 2015 n OEM Update

37

Speak Out

‘WOOW’ enables recovery of chemicals from industrial waste

Geist Research’s ‘new to the world’ technology of recovering chemicals from industrial waste is a sustainable technology.

Sandra D’sa, General Manager, Marketing, Geist Research Pvt. Limited

Geist Research has come up with a very unique concept to eliminate chemical waste without having to worry much about the costs. The implementation of WOOW or waste out of water is helping clients to leverage the benefits of this unique technology. OEM Update spoke with Ms Sandra D’sa, General Manager, Marketing, Geist Research Pvt. Limited. Ms D’sa discusses about a novel concept of recovering chemical waste from effluents or plants that generate chemical waste. By implementing the concept, companies are able to make money from selling the chemical recovered from the effluents. Ms D’sa calls it a strategy that is very different from conventional methods of disposal of chemical waste. Geist Research Pvt. Limited is a part of Earth Water Group and is partly funded by the Clean Technology Fund of CLSA Capital Partners. In the interview, Ms D’sa gives us detailed inputs on the technologies that Geist research provides for the use of several industries that generate chemical waste.

What is the innovative technology that Geist research provides?

Geist Research offers innovative, proprietary and complete technology solutions to industrial waste water problems but with a difference. Geist generates guaranteed profits from Zero Liquid Discharge. We have developed 4 novel WOOW (Wealth out of waste) technology platforms that enable us to recover pure chemicals from a wide variety of industrial waste waters and completely recycle the water back to the parent process. These recovered pure chemicals can generate a revenue stream that makes the whole venture profitable.

What makes it a distinct technology?

Currently chemical processing companies are managing their effluent either by treating it in ETPs and then discharging into receiving water bodies. However, this system is clearly inadequate to deal with increased industrialisation and increasing complexity of manufacturing processes. This does not even consider secondary and tertiary effects of millions of chemicals 38

being discharged into the water bodies, because there is no data available for these. The chemical processing industry is one of the largest contributors to contamination of water bodies by adding millions of chemicals daily reducing the assimilative capacity of the receiving water body.

Geist offers systems with guaranteed performance and profitability based on our proprietary technologies and assures a payback on investment of less than 2 years. This ensures voluntary compliance in this era of global competitiveness.

The complete solution can be offered on a turnkey basis or a risk-free Design-Build-Own- Operate basis.

How does it make it a green technology?

Geist’s Wealth out of Waste (WOOW) technology platforms enable the recovery of chemicals that are present in the industrial effluent generated by chemical processing industries individually and in their pure form and presents these chemicals for either recycle or sale. The recovered water can then be recycled back to the parent process. This process of ‘recover and recycle’ rather than the conventional process of ‘treat and throw’ makes it sustainable and therefore a green technology.

How do you look at its acceptance?

As is the case with any ‘new to the world’ technologies, there is always a ‘fear of the unknown’ and a ‘resistance to change’. The regulatory bodies play a huge role is driving change towards more sustainable solutions to preserve the environment keeping in mind the dual objective of ‘Economy’ and ‘Environment’. However, due to limitations in technology, some of the current technology solutions are energy and cost intensive. For example, to ensure Zero Liquid Discharge, Multiple Effect Evaporators or Incinerators are used. These solutions have high operating costs which do not make it attractive to the industry to implement. These solutions at best, convert one form of waste to another, ultimately ending up at a landfill site.

Geist’s WOOW technology platforms generate profits making organisational compliance voluntary, since payback is a few months to less than 2 years. This paradigm makes it easier to be accepted as a technology solution that is sustainable.

What points should be considered for the implementation of WOOW technology?

First and foremost, at Geist, we encourage a change in the mindset that currently characterises effluent in terms of Chemical Oxygen Demand (COD), Total Dissolved Solids (TDS), etc. This thinking and the attendant technology solutions, destroy the inherent value of the effluent. The first step to recovering the resource from the effluent is by calling it a ‘Resource’ stream rather than an ‘effluent’ stream. What follows then is characterisation of the July 2015 n OEM Update

Speak Out locate away from water bodies. It also leads to a significant reduction in capex and opex in comparison with conventional processes

resource stream to identify its individual components. By characterisation, one is now focussed on recovering the organics that contribute to COD and the inorganics that contribute to TDS. The customisation process adapts Geist’s four WOOW technology platforms to recover the required chemicals in pure form. The customised WOOW technology is then implemented on either a Turnkey or a Design-Build-Own-OperateTransfer (DBOOT) basis with Process, Product

July 2015 n OEM Update

and Performance guarantees.

What are the benefits from WOOW technologies?

There are several benefits from WOOW technologies. The implementation of WOOW technologies eliminates Incinerators, Multiple Effect Evaporators and conventional ETP leading to a reduction in the land required for production. There is a potential to expand production capacity and the freedom to

What are some of the chemicals that you have recovered from industrial waste?

Geist has recovered several chemicals from industrial waste, having recovered both inorganic and organic chemicals. Some of the inorganic molecules recovered from the industrial waste are - Aluminum Chloride Hexahydrate, Ammonium Sulfate, Anhydrous Sodium Sulfate (Caustic Soda Plant), Phosphoric Acid, Potassium Carbonate, Potassium Chloride, Potassium Hydroxide, Potassium Nitrate, Potassium Sulfate, Sodium Bisulfite, Sodium Chloride, Sodium Hydroxide, Sodium Metabisulfite, Sodium Sulfate, Sodium Sulfite, Sodium Thiosulfate, Sulfuric Acid, Silica, Sodium Bromide, Sodium Silicate, Sodium Carbonate, etc.

The organic molecules which Geist has recovered include Acetaldehyde, Acetic Acid, Butyraldehyde, Cellosolve, Formaldehyde, Formic Acid, Glycerol, Glycolic Acid, Glycols, N-Methyl Pyrrolidone, Phenol/Phenolics, Polyglycerol, Para-Toluene Sulfonic Acid (PTSA), Sodium Formate, Dimethyl Sulfoxide, Dimethyl Sulfide, etc. n

39

Expert Column

Self cleaning disc filtration systems: advanced tertiary treatment technologies Tertiary cleaning systems from Amiad India offer promising solutions for effluent treatment in textile industries ETP Tertiary Treatment Schemes. These filters offer particle filtration based on micron cutoff philosophy, working on absolute filtration principle rather than nominal.

A 55 micron disc filtration system for 10 – 20 ppm of TSS in Secondary treated water can offer considerably high level of protection to downstream equipment such as UF Membranes, provide high quality process water or comply with the pollution control norms for safe disposal.

This offers a greater level of credibility to ETP designers when accessing downstream water parameters for ETP schemes in Tertiary Treatment. To top it they are completely automatic in operation with dedicated PLC controllers to monitor filtration and backwash sequence, thus eliminating labor intervention.

Customer

Bombay Rayon Fashions Limited, Tarapur

Application

ETP Tertiary Filtration in Textile

Flow Rate

100 cumh

Filtration Degree

100 mirons

System

Arkal - Amiad Disc Filtration System

Year of Installation

March, 2011

Filtration of suspended impurities, both inorganic and organic in nature, is one of the most important steps in Effluent Treatment Schemes since efficient removal of these suspended impurities is very critical for sophisticated downstream technology like UF membranes or even for quality process water. With the long due pollution control norms now in place, even disposal of treated effluent mandates suspended solids from tertiary treated water to be a bare minimum.

The Filtration Sequence The grooved discs are stacked on the filtration spine and assembled according to pre-determined water filtration requirements. During filtration, the discs are compressed by means of a pre-loaded spring and differential pressure, forcing the water to pass through the grooved disc surface, thus trapping the solids.

Pressure sand filters, dual media filters etc. have been used extensively in the past with well-known operation and maintenance issues such as bio fouling, sand slippage, channeling effect etc. which hampers the downstream water quality. However with the advent of newer filtration technologies, we now have options available to fine tune filtration scheme and downstream application in ETP systems.

The Backwashing Sequence Activated by a pre-determined time command or differential pressure, the system enters backwash mode.

The inlet valve port shuts as the drain valve port opens.

During the backwash process, pressure is released and the spine’s piston elevates, releasing the compression on the discs. Tangential jets of filtered water are then forced through the nozzles positioned along the spine. At this stage the discs spin freely, loosening the trapped solids which are then flushed out. During the flushing cycle each filter pod is backwashed sequentially, while the other pods continue to supply filtered water downstream.

When a pod begins the backwash cycle, the system valves automatically reverse the flow in the pod, allowing filtered downstream pressurised water to backwash the filter. The backwashing sequence lasts 15 – 20 sec per filter pod, during which time the rest pods are still in filtration mode and provide uninterrupted filtered water, downstream.

A good filtration system in Tertiary Treatment must be capable of handling organic and inorganic suspended load with ease, along with minimum cost towards civil construction, small footprint, minimum water rejection in backwash and 24x7 uninterrupted operations. This is where Self Cleaning Disc Filtration Systems offer a very good alternative.

Self-Cleaning Disc Filtration Systems Self-Cleaning Disc Filtration System offers a plethora of advantages over conventional filtration technologies in 40

Self-cleaning Disc Filtration System Description Disc Filtration Systems essentially comprises of an assembly of Filter Pod which houses the filtration spine, along with header manifolds, 3 way valves, DP switches, hydraulic command tubes, pressure gauges and a PLC controller. The heart of the system is the filtration spine which is essentially a stack of grooved discs which acts as the filtration media. These filters essentially have a filtration and backwash sequence.

July 2015 n OEM Update

Expert Column Filtration mode

Disc Filtration System advantages • Micron-precise depth filtration of solids.

• Innovative disc technology captures and retains large amounts of solids.

• Short automatic backwash with regulated water volume for a small water footprint. Reject water wastage during backwash usually in the range of 0.5 to 2 per cent.

• The complete system is polymeric in construction, made of polypropylene, offering flexibility of operation in wide range of pH and resistance to a lot of oxidising agents, such as chlorine.

• Permanently eliminates the need to replace filter media.

• Modular design and operation.

• Skid mounted systems, requiring approximately onethird of the footprint required by conventional PSF systems.

• Uninterrupted filtration. Long-term operation with minimal maintenance or manual intervention.

Conclusion With the advent of Self-Cleaning Disc Filtration system technology, ETP tertiary treatment schemes can be optimised based on micron specific, absolute filtration. ETP designers can look into optimising downstream schemes, higher flux rates, increased life of critical components, safer treated water disposals and a hassle free, low maintenance, low OPEX filtration technology.

Amiad Water Systems Limited is one of the leading

Backwash mode

Inlet To Drain

Outlet

Backwash water inlet

companies in filtration solutions for variety of applications in steel, power, oil and gas, and municipal sectors. With more than 300 successful installations in India since 2010, it offers expertise in particle filtration requirements from 2 microns to 3,000 microns, based on Self Cleaning Filtration Technologies. n Authored by _ Abhishek Pancholi Manager – Sales, Amiad India www.amiadindia.com

Leading Trade Show for Manufacturing Technology and Intralogistics

World of Industry 9 – 11 December 2015 Pragati Maidan, New Delhi win-india.com

K BOO CE PA S YOUR W! NO

To participate, please contact : +91 22 6687 5528 Email : sales@hmf-india.com

July 2015 n OEM Update

41

Fam Trip

ElectroMech: Enormous plant of herculean effort In a visit to the ElectroMech plant in the Pune area, OEM Update saw the magnificent plant sprawled over an area of 80,000 sq. metres buzzing with activity and innovation

ElectroMech was established in 1979 and today claims to be the largest manufacturer for industrial overhead cranes in India by volume as well as value. It provides material handling solutions for manufacturing, infrastructure, construction, oil and gas, power and steel industries.

ElectroMech has a diversified list of client spread across 35 countries.

Several processes and innovations have been deployed at the plant to produce high quality cranes.

Lower level store for workers

A plant replete with technology and innovation As we take a look around, Tushar Mehendale, Managing Director, ElectroMech Material Handling Systems (India), briefed us on the intricate details of the functioning of the plant. He told us about the processes, logistics and technologies that are involved in the plant.

Highlighting the uniqueness of the ElectroMech plant, Mr Mehendale, said, “The plant is sprawled over an area of 80,000 sq. metres, with a covered area of 20,000 sq. metres. It is the largest of its kind for the manufacturing of industrial cranes and the first of its kind in India to adopt a unitised process flow for the material. It is an adoption of the assembly line concept, where the raw materials come into one end and the finished goods leave at the other end.”

CNC in action

Plant uses unitised work flow

Work in progress

42

We then took a quick look at the material input area.

Speaking of the storage area for the components, Mr Mehendale explained, “The material input area is where all the parts come from outside. Several of the high value components are stored in vertical racks, which is served by a stacker crane, operated through a remote control. It is made with a view of using vertical space, which most manufacturing facilities have an abundance of! A fork lift is not used here for several reasons. It can’t reach very high. Also if it is diesel operated, it leads to pollution and if it is battery operated, it will lead to a lot of downtime.”

Speaking of the automation of cutting process, Mr Mehendale said, “All cutting of steel plates is done using CNC machines – we completely avoid cutting by hand. All the reference drawings and measurements are fed into the machine along with the numerical figures. The entire process is automated. All the measurements and relevant details are stored in the machine.”

According to Mr Mehendale, “The semi-automated jig for a girder welding is an in-house innovation. The girder is made up of four steel plates. We have a semi-automated girder fixture. There is always a possibility that the welding may not be perfect if done manually, leading to waviness in the girder.

July 2015 n OEM Update

Fam Trip

Design efficiency of equipment key to being cost effective Highlighting the design efficiency of the equipment, Mr Mehendale noted, “Design is very important in terms of customised products. Design efficiency can play a huge role in the overall cost of the operation for the buyer. If the cranes are designed well, it saves, say 2% on structural costs. 2% saving in absolute numbers is a huge thing. We make sure our products derive value for the customer.”

The company has done an innovation in the process by building a small store for the workers at the assembly area to take required components. The store in the lower deck for workers helps to easily access quick consumables that are required from time to time and these are kept in the area. If a worker needs to recharge his welding electrodes, it can take time to go to the other end, so the store in the lower deck enables easy functionality and helps save on time. Within the factory there is every type of crane - single girder crane, double girder crane, wall travelling crane, torsion box cranes.

ElectroMech ensures that its products meet the highest standards of operations as well as sustainability. The cranes are manufactured within the factory. Then tested, disassembled and shipped to the clients. Some of the components go for shot blasting and then they go for painting. Being conscious about environment, the company has its own shot blasting facility, along with exhaust system. The paint booth is one of the largest in Pune. The paint fumes are extracted and processed in a wastewater treatment plant and then used for landscaping around the factory.

The scope for industry growth fuelled by demand Analysing the crane industry and the prevalent market conditions, Mr Mehendale says, “The crane market is estimated to be anywhere between ` 1,200 to ` 1,800 crore. Currently, the market is fragmented but more than 60 per cent of the market is made up of the top 10 manufacturers. The fragmentation in the industry makes it difficult to achieve economies of scale. There is a requirement for consolidation in the market, failing which, the volumes won’t be achieved.” However he adds that ElectroMech enjoys some advantages as opposed to the other players in this segment, “Our partnerships with Abus, Zoomlion and Stahl cranes help us to deal with a spectrum of options. Our presence in 35 countries helps us leverage a much needed advantage especially when the crane market is poised to grow and become a ` 2,500-crore market in the next few years.”

Indigenously developed stacker cranes

Despatch area

Assembly area

With streamlined processes and innovations that pervade every aspect of the production as well as delivery, ElectroMech is setting new standards for the Indian as well as the international cranes industry. With its objective to always be ready to meet and excel in the challenges and opportunities of the future the company is confident that it will continue to lead from the front. n July 2015 n OEM Update

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Brand Report

Locking and sealing of fasteners: Reliably, cost-effectively One of the most common assembly methods in any machinery manufacturing is using fasteners to secure two or more parts together.

However, all fasteners are prone to loosening due to vibrations and impacts.

Conventionally, mechanical locking devices viz. spring washers, lock nuts, pins or nylon inserts are used to prevent the fastener loosening. It is proven that while these aids add on to the cost of assembly and but do little to increase the area of contact – the major factor in retention of clamp load.

Failure to increase the contact area Racecars on dry tracks run best on “slicks”. But Why? More surface contact between tire and track means less slipping on the curves.

The same holds true for bolt, nut, set-screw and stud assemblies. Bolts, studs, set screws and other threaded fasteners are what keep industrial equipment together. Too little surface contact in threaded assemblies can endanger high-performance assemblies. The loosening of one single fastener could break a costly piece of equipment. Once one fastener loosens, vibration increases, loosening another fastener, and then another, until finally – downtime.

Considering that fastener loosening is a leading cause of catastrophic failure in any piece of machinery, maintaining proper clamping forces are an important element in fastener effectiveness. In order to hold tightly together, threaded fasteners need the proper initial torque, plus metal-to-metal friction between threads.

Figure 1: In a typical assembly, metal-tometal contact area can be as little as 15%.

In a typical assembly, however, metal-to-metal contact can be as little as 15 per cent — the rest is just air. Air space — poor surface contact — is the reason flat washers, split-ring lock washers, nylon insert nuts and other devices may not keep fasteners in place (Figure 1).

They don’t fill the gaps or prevent sideways, rotational or tipping thread movement.

Anaerobic liquid threadlockers, however, perform where

mechanical devices fail. Just as slicks on a racecar grip the track, threadlockers help fastener threads grip one another.

Solution: Loctite Anaerobic Theradlockers Starting nearly 50 years ago with a unique liquid resin that hardens in the absence of air, anaerobic technology was invented by Henkel Loctite. This revolutionary method was developed to positively lock and seal threaded fasteners.

Today, the use of anaerobic technology continues to hold together complex machines that are used to build everything from automobiles to dishwashers and tractors, to the trucks that deliver them. Loctite products have helped make these machines and inner assemblies less expensive, more reliable, and longer lasting.

Anaerobic adhesives are single component liquid resins that harden to a tough solid when exposed to metal ions in absence of air when confined within the mating surfaces.

This anaerobic cure mechanism allows these adhesives to flow and settle evenly between the mating surfaces without curing prematurely. As the liquid anaerobic adhesive cures, it forms polymer chains that find way into every tiny surface imperfection of the mating surfaces, thereby ensuring a 100% metal-to-metal contact. The cured adhesive has a very high cohesive strength and can join the mating parts to their ultimate assembly strength. The surface friction increases because of these interfacial connections lending strength to the assembly. The adhesive completely fills up the microscopic gaps between the mating surfaces to prevent a lateral movement and at the same time sealing the assembly to protect it from corrosion that may result from moisture, gases or fluids.

Based on the anaerobic technology, Loctite Thread lockers do what the mechanical aids cannot: applied liquid on the bolt, they completely fill up microscopic gap between the interfacing threads. After assembly Loctite threadlockers cure in absence of air and in presence of metal ions to a tough solid that prevents the relative movement between the threads. What’s more, the cost per application is lower as compared to the conventional mechanical aids (Figure 2).

In response to industry needs, Henkel Loctite pioneered Threadlocker Adhesives with precisely controlled strength, resistance to extreme environments, and even varying viscosities to meet virtually any application need. All Loctite

15% Metal to Metal

85% AIR

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Threaded assembly without Threaded assembly treated Loctite Threadlocker with Loctite Threadlocker Figure 2: Loctite Threadlockers fill up the gap between threads

July 2015 n OEM Update

Brand Report Clampload Retention Comparison 100

Threadlocker Adhesives can be applied with manual, semiautomatic or automatic dispensing systems.

Bolt with elastic stop nut 60 40

Clampload %

80 20

Six facts about fastener assemblies Here are six points that all design, assembly and maintenance engineers should know about using liquid anaerobic threadlockers to improve the reliability of fasteners, thereby enhance assembly effectiveness and maximise efficiency:

0

1. Thread space allows movement.

Mechanical locking devices are designed to keep fasteners from rotating by gripping or exerting pressure at the component’s surface.

Bolt with Loctite liquid threadlocker and nut

Bolt with tooth lock washer and nut Bolt with spilt ring lock washer and nut Unassisted bolt and nut

0 200 400 600 800 1000 Number of load cycles

In tests on a transverse shock and vibration machine, liquid threadlockers drastically outperformed mechanical locking devices (Figure 3).

They fail because the root of the problem lies below the surface, in the threads. There can be as little as 15 per cent metal-to-metal contact between the threads of a nut and bolt. The empty space leaves room for movement that leads to self-loosening and loss of clamping force.

Bolts secured with threadlocker retained nearly all their clamping force after more than 1,000 cycles. Mechanical devices began to fail almost immediately.

2. Side movement causes failure.

Fasteners work themselves loose for different reasons, but a key cause is side movement. Bolted surfaces can slide sideways as a result of thermal expansion, bending of the assembly, impact or vibration. As this happens, the bolt takes on a rocking motion that causes the threads to wear against each other.

5. Threadlockers are cost efficient.

Mechanical locking methods are somewhat effective, but are difficult to justify based on cost. A special nut or washer can cost up to four times as much as an application of liquid threadlocker. Mechanical devices also require extensive and costly inventories to keep the right kinds and sizes (SAE and metric) on hand. Three or four kinds of threadlockers -easy to carry and colour-coded -serve the same purpose.

In time, the bolt becomes almost frictionless, and the threads can easily unwind. Once side movement starts, a bolt may loosen in as few as 100 cycles.

3. Threadlockers stop all types of movement.

Loctite anaerobic threadlockers attack the root cause of loosening by filling spaces between the threads, thus stopping sideways, rotational, tipping and other motion.

This is how they work: When threadlocker is applied to fastener assemblies, normal torquing action “pushes” the fluid to lubricate the threads and fill the air spaces.

After the assembly is tightened and the air spaces are filled, the absence of oxygen causes the threadlocker to bond to the metal and cure. This bond creates a secure, one-piece assembly that will not loosen under stress.

By sealing between thread spaces, threadlockers also keep out air and fluids that can cause corrosion- another common source of fastener failure.

4. Threadlockers hold better.

Traditional devices for holding fasteners tight - elastic stop nuts, serrated lock washers, split ring lock washers and others - often lead to frustration because they treat only a symptom, the tendency of fasteners to “back out” under stress. Liquid anaerobic threadlockers, by contrast, keep fasteners firmly in place by attacking the root cause of the problem – side movement.

An effective way to evaluate fasteners’ performance is to test them under load in a dynamic test machine. The more clamping force retained after testing, the more reliable the assembly.

July 2015 n OEM Update

Figure 3: Transverse Shock test shows that Threadlockers retain clamping force much better

Figure 4: Threadlockers improve reliability

6. Threadlockers are removable.

All threadlocked fasteners can be removed. Different grades of threadlocker can be used depending on the job. Fasteners secured with low- and medium-strength grades can be removed with common hand tools. Those secured with high-strength grades can be removed by applying heat for a specified time (e.g., 450 F for five minutes).

Conclusion Loctite Threadlockers, when used on standard fasteners, can eliminate expensive locking devices and provide increased reliability and quality to your assemblies. One drop prevents loosening and ensures a secure hold. Compare for yourself.

Loctite Threadlockers can drive reliability up and costs down. Some of the biggest benefits of Loctite Threadlockers, other than reliability and low cost per application, are that you can pick the strength you need, stop corrosion, seal threads, improve torque control, reduce galling, and minimise inventories. Loctite Threadlockers provide lubricity to achieve controlled torque during assembly, and in operation, they hold critical clamp load pressures under the most severe environments.

Used routinely and universally, liquid threadlockers will enhance reliability, reduce equipment downtime and maximise productivity.

Fastener loosening cannot be predicted, but liquid threadlocker provides the critical ounce of prevention needed to keep equipment up and running smoothly. n For more information, contact: marketing.ag@henkel.com or visit www.henkel.in/enquiry.

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Brand Report

Designed for corners: Curved linear guides from igus

New lubrication-free drylin solutions for custom design concepts Examples for the versatile use of curved section rails in the driver’s cab of an agricultural machine: lubrication-free mobility in all directions, even in the most confined of spaces.

Individual

requirements and space optimisation calls for new ideas in the field of design. In the instance of linear plain bearings, the straight structured rail guide has caused certain limitations. Now the plastics expert igus also offers curved drylin rails, which give the designers more freedom such as, in the cabins of construction and agricultural equipment.

Utilising the drylin W linear plain bearings, igus has developed a new offer for linear guides that provide a functional reliable and cost-effective solution even for curved travel paths. The curved guide rails are made of aluminium and have an exceptionally resistant hardanodised coating. Customised guide carriages thereby implement cornering without tilting or seizing.

In addition, appropriate hand clamps can be added. Low installation effort and maintenance-free operation are the strengths of the new system, which like all drylin systems combine low friction coefficients with dirt-repellent dry operation. The drylin aluminium rails are also easy to machine individually and are characterised by their light weight.

Use in driver’s cabs The driver’s cab of an agricultural machine is a good

example of how curved guide rails can increase flexibility in the adjustment of monitors, seats or fittings and ideally adapt to the general design of the machine. Every agricultural machine has its specific frame sizes and design requirements. Adaptable, modular components create the necessary leeway to achieve custom solutions. The curved drylin rail can be configured. Within certain physical limits, users can choose their own bending radius and therefore optimally fit in the driver’s cab. igus manufactures the section rail according to these specifications and provides the individual rails and linear bearings from the range of drylin W and drylin T. n

Contact Vinayak Shetty Product Manager igus (India) Private Limited 36/1, Sy. No. 17/3, Euro School Road, Dodda Nekkundi Industrial Area - 2nd Stage Mahadevapura Post, Bengaluru - 560048 Mobile: +91-9341136381 vinayak@igus.in www.igus.in

The curved guide rails are made of aluminium and have an exceptionally resistant hardanodised coating. In the maintenance-free application, cornering becomes trouble-free without tilting or seizing.

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July 2015 n OEM Update

Brand Report

Rockwell unveils on-the-go HMI access with MobileView tethered operator interface Mobile terminal allows operators to make real-time changes to out-of-view applications of back and forth for personnel, for certain applications,” said Matt Hansen, senior product manager at Rockwell Automation. “The MobileView tethered operator interface puts the terminal in the operator’s hands to increase productivity and safety. Tasks are made more efficient and machines are set up faster.”

Rockwell Automation has introduced its new Allen Bradley MobileView tethered operator interface. The mobile terminal gives plant and industrial personnel the freedom to take a machine’s human-machine interface (HMI) with them to make real-time adjustments to out-ofview applications.

The MobileView tethered operator interface is ideal for maintenance tasks, machine setup or calibration activities, and other HMI applications that require the operator to see the machine. The inclusion of a hardwired e-stop button and three-position enabling switch also supports applications that require local safety functionality.

“Between making an adjustment on the terminal and viewing the results on the machine, fixed operator terminals can require a lot

July 2015 n OEM Update

The MobileView tethered operator interface complements the AllenBradley PanelView graphic terminals, giving manufacturers and industrial operators a range of fixed and mobile terminals for different applications. It also uses the FactoryTalk View Machine Edition (ME) HMI software from Rockwell Automation, allowing users to develop and re-use their software applications across the MobileView and PanelView platforms.

Three cable-length options, ranging from 16.4 feet to 49.2 feet, offer flexibility for different machines and production lines. The MobileView tethered operator interface also uses a 10-inch display with resistive touch screen, 2 GB internal SD card for application storage, and USB 2.0 port for high-speed data transfer. Software assignable functions are available as an option with either a hardwired momentary illuminated pushbutton or three-position key switch. n For more information, visit www.rockwellautomation.com or, email at indiamarketing@ra.rockwell.com Customer Care (Toll Free): 18002000121

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event

AMTEX 2015 completes its maiden run in Mumbai Maharashtra, amidst several top echelons of the machine tool and engineering industry.

Welcoming the gathering the Minister appreciated the efforts of the organisers in giving a start to AMTEX being organised in Mumbai - the financial capital of the country and added such shows helps the manufacturing and tooling sectors in the country.

The maiden venture of AMTEX Exhibition held between 29th May and 1st June at Bombay Exhibition Centre (BEC), Mumbai. An array of machine tools, machineries and allied products were displayed in an expanse of 65,000 sq. ft.

Besides giants in the machine tool and engineering segment from across the country, the event had participation from Germany, Japan, USA, Spain, Turkey, and UK among others with separate pavilions from China and Taiwan being the major highlights.

The exhibition was inaugurated by Ms. Vidya Thakur, Minister of State for Consumer Protection, Govt. of Salient features Exhibition area

65,000 sq. ft

Exhibitors

217 companies

International exhibitors

47 companies

Business visitors

12,000

Business generated

` 380 crore

Associate companies

Sahajanand Laser Technology Ltd., Tsugami Precision Engg. India Pvt. Ltd., Ravik Engineers Pvt. Ltd., Mahr Metrology India Pvt. Ltd., Fibro India Precision Products Pvt. Ltd., Golden Laser India Pvt. Ltd.

Exhibitions of such nature encourage the Indian manufacturers to do better to exhibit their achievements and breakthrough and staying ahead of the updated technologies thus achieving the vision of becoming a manufacturing hub.

The present government’s manifesto also considers the MSME sector as crucial for the development of the country. AMTEX 2015 was supported by NSIC (National Small Industries Corporation) demonstrating the strength of medium and small scale industries of the country.

The visitor response for AMTEX 2015 was overpowering with a healthy attendance from sectors like automobiles and auto components, textile machine manufacturers, and pharmaceutical industry. According to the organisers, most of the exhibitors suggested that AMTEX exhibition be held every year.

AMTEX 2015 concluded on a positive note with the valedictory and award distribution function. The stall awards were bagged by: Best Stall: Fibro (I) Precision Products Pvt. Ltd. 2nd Best Stall: Dalmec Inds. Manipulators Pvt. Ltd 3rd Best Stall: Tsugami Precision Engineering (I) Pvt. Ltd. Consolation prizes were given to the stalls of Miranda Tools, Intec Capital Limited, and Mahr Metrology (I) Pvt. Ltd. n

Cold Chain Strategy Summit unleashed the potential of cold chain industry The 4th edition of Cold Chain Strategy Summit took place on 9th June in Mumbai was a great success.

There were more than 150 attendees included professionals from FMCG, pharma, quick service restaurants and hardline retail sectors. This also included service providers and IT solution providers catering to cold chain industry. More than 20 speakers shared their knowledge and expertise on various topics.

The exhibition area showcased stalls of the sponsors and partners. The sponsors included Koolex, Future Supply Chains, Maini Material Movement Pvt. Ltd., CHEP, TCI, Gandhi Automations to name a few.

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The much awaited Cold Chain Industry Awards which were presented by Future Supply Chain recognised the leaders in the cold chain industry. The winners included TESSOL, Jubilant Foodworks Ltd., Mondelez India Foods Ltd., GUBBA Cold Storage, ITC Limited, HUL, TCI Supply Chain Solutions, and Emerson Climate Technologies. n July 2015 n OEM Update

COMMERCIAL PARTNERS Omron Automation Pvt Ltd................................................................... IFC

HARTING India Pvt Ltd ......................................................................... 27

Ace Micromatic Group.............................................................................. 7

Henkel Adhesive Technologies India Ltd.................................................. 3

Blastline India Pvt Ltd ............................................................................ 35 Bosch Rexroth India Ltd........................................................................... 5 Disa India Ltd ........................................................................................ 33 DMG MORI SEIKI India Machines and Services Pvt. Ltd................. 16-17 Electromech Material Handling Systems (I) Pvt. Ltd...............................11 Gati Kintetsu Express Pvt Ltd .............................................................. IBC

igus India Pvt. Ltd..................................................................................... 9 Makino India Pvt Ltd......................................................................... 22 -23 Power Build Ltd..................................................................................... BC Sai Associates........................................................................................ 49 Sai Enterprises ...................................................................................... 49

Book Space Now ( 09821575178 or 022-32682214 / 15 Visit: www.oemupdate.com July 2015 n OEM Update

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