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EDITORIAL

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BLUEPRINT OF INDIA’S MFG LED GROWTH

he man at the midst of all the action insists that the inspiration behind the National Manufacturing Policy which aims to achieve enviable growth figures in the next few years is not inspired by our northern neighbour, China, which has sustained rapid growth as it successfully scaled up its manufacturing capabilities over the past years. Leaving the ‘inspiration’ debate aside, what’s important here is that as the man of the moment, Commerce and Industry Minister Mr Anand Sharma, gears to introduce the first ever National Manufacturing Policy to the nation, we caught up with him to bring you some exclusive insights as to what’s going on in the power corridors. The pace is hectic and feverish as he gets into last minute troubleshooting before the National Manufacturing Policy is unveiled. The journey from draft to blueprint is proving to be an uphill task with steep challenges. The draft manufacturing policy, which has been in the making for 18 months and aims to attract overseas investments besides increasing the share of manufacturing in the GDP, has been stuck due to interministerial differences with opposition coming mainly from the labour and environment ministries. These ministries are seen to be blocking the policy, which proposes to simplify the procedure in designated areas. The draft policy had suggested that the procedures be simplified in several ministries, including Labour and Environment, where inspector raj and a plethora of approvals make life difficult for companies. Apparently, the Indian industry had objected to the Environment Ministry’s intervention in some of the big-ticket projects that had halted the government’s development agenda and also resulted in declining foreign direct investments. The government is also concerned about an impending slowdown in the manufacturing sector and industrial production. While the industry raised concerns on the high cost of credit, investment slowdown, skill shortage, high input cost, hurdles in getting various clearances, environmental issues and debottlenecking of logistics, the ‘tool of change’ that this new policy is slated to be, promises to act like a magic wand. To start with, the draft policy promises to create 100 million new jobs and take the share of manufacturing to 25 per cent in the country’s GDP by 2025. At present, manufacturing contributes 15-16 per cent to the economy. And there are actions already being taken towards achieving this national dream. States like Rajasthan, Maharashtra and Gujarat have already initiated the land acquisition process for the super manufacturing zones, known as national manufacturing and investment zones, proposed in the new manufacturing policy. While the prospects are plum post this policy, it remains to be seen how it is implemented and practiced…therein lies the key to our fortunes.

Archana Tiwari-Nayudu archana.nayudu@infomedia18.in

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

A U G U S T 2 0 1 1 | SEARCH - THE INDUSTRIAL SOURCEBOOK

CONTENTS VIEW FROM THE TOP

‘We Are All Set To

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Create World-class Manufacturing Infrastructure’ Mr. Anand Sharma, Hon’ble Commerce & Industry Minister

Cover Photo Credits: MANDEL NGAN / AFP / gettyimages

START-UP STRATEGIES

EDITORIAL Feet On The Ground... Head On The Clouds!

NEWS, VIEWS & ANALYSIS 38

Latest Happenings In The World Of Manufacturing

OPEN PAGE: OPINIONS, ILLUSTRATIONS & INVESTMENTS

124

Gridbots Technologies Building Intelligent Machines

TECHNOLOGY TRENDS

MANUFACTURING ZONE 60

Proposed NMIZs Creating A Blueprint To Manufacturing Success

SPOTLIGHT 128

Energica SRL Competing On Quality In PV Module Manufacturing

MANAGEMENT MANTRA 132

Turning Idea Into Profitable Venture How To Transform Your Business in 90 Days

GREAT MINDS AT WORK 136

Using LED To Create New Light World’s Simplest Electronic Light-to-Light Converter

John P Condon, Vice President – Channel Sales Asia Pacific, PTC

Rohit Biddappa, Head Marketing – India, SEA, ANZ, PTC

Rafiq Somani, Area Vice President, PTC India

Benchmarking to global standards for 360-degree growth

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HIGHLIGHTS: SEPTEMBER 2011

Industry Focus: Maintenance & Ergonomics Insights & Outlook: Coolants & Lubricants Special Edition: Investment Destination - Maharashtra

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CONTENTS SPECIALS IN THIS ISSUE INDUSTRY UPDATE Steel

INSIGHTS & OUTLOOK Casting & Forging

Steel Performance Of The Steel Industry At A Glance

Auto & Infrastructure Impact Calling For Disruptive Demandsupply Dynamics

Prospects & Possibilities Paving The Boulevard Of The Great Indian Steel Dream

New Age Steel Production Processes Inspiring Innovations

Steel Superpowers Should India Emulate Chinese Strategy?

Investments Scenario Strengthening Growth Prospects

Steel Substitutes A Threat Or An Opportunity?

Ban On Import Of Substandard CRGO A Welcome Move For The Transformer Industry

Growth Dynamics Top 5 Business Trends To Watch Out For Steel Strategies Establishing The Seal Of Excellence

APPLICATION ZONE 138

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Indian Forging Industry On The Path To Prosperity

106

New Age Casting & Forging Scaling The Technology Ladder

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Green Processes Moulding A Modern Casting Industry

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High-performance Alloys Superalloy Castings Offering Applications Longevity

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Combined Forging And Punching Of Long Pieces Creating a lasting impression

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Forging Technicalities Cost Reduction Through Innovative Solutions

New Launches Latest Products In The Offing

168

Steel Latest Products In Steel

CH-47 Helicopter Taking Off At The Flip Of A Switch

172

Casting & Forging Latest Products In Casting & Forging

SHOP FLOOR INNOVATIONS

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General Products Rolling Out The Best-in-class

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International Products Showcasing Product In A Global Arena

L&T Radical Innovation To Attain Sustainability

Technology Update Cutting-edge Solutions

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157

Electronica And Productronica India 2011 Plugging In Success

158

TRADE SHOW TRACKER

PRODUCT UPDATE

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PRODUCT INDEX Alphabetical Listing Of Products Presented In The Issue

Benefits Of Implementing PDM Offering SMBs A Competitive Edge

CURTAIN RAISER

102

PRODUCT UPDATE

TECHNOLOGY TRENDS 146

Casting & Forging Casting & Forging Growth Matrix

164

Right Cable Selection Cabling Success For Variable Frequency Drives

CASE STUDY 142

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212

ADVERTISERS’ LIST Advertisers’ List In Chronological Order

Looking for a Speciﬁc Product? We will ﬁnd the product for you. Just type SRCH (space) Name of the Product and send it to 51818 eg. SRCH (space) Pump and send it to 51818.

NEWS, VIEWS & ANALYSIS L A T E S T

H A P P E N I N G S

GKN DRIVELINE CONTINUES EXPANSION IN INDIA GKN Driveline is continuing its rapid growth in India with a groundbreaking new manufacturing facility for CVJ Systems and Trans Axle Solution in Pune. This `130 crore factory will employ more than 200 people and is strategically located within 30km of a number of GKN Driveline customers including Fiat, Volkswagen, General Motors, Tata and Renault. When fully operational in August 2012, the new 8,000sqm facility will have an annual production capacity of more than 6,00,000 CVJ Systems. It is planned for the new facility to also manufacture differentials from GKN Driveline’s Trans Axle Solutions product range. “This new facility positions GKN Driveline strongly to meet the continued rapid growth of India’s automotive industry. It is the next step in our mission to remain close and accessible to our customers in west India,” said Marc Vuarchex, MD, GKN Driveline Asia Pacific. Ravindra Ojha, MD, GKN Driveline India said, “The company’s business in India has grown at an annual rate of more than 15 per cent over the past five years and we expect India to remain a high-growth market for years to come.”

INDIA, INDONESIA BILATERAL TRADE TO TOUCH US$25 BN BY 2015 The bilateral trade between India and Indonesia will touch US$25 billion by 2015, the Indonesian Ambassador to India Ani M Ghalib recently said. Presently, bilateral trade between the two countries amounts to US$12.7 billion, he said, adding that by the end of the current fiscal, this would rise to US$13.5 billion, thus making the country the second largest trading partner of India in the ASEAN region. Ghalib said that Indian companies were deeply entrenched in the coal mining sector in Indonesia. He said that the new Indonesian coal mining law will benefit Indian companies and prices of coal will not rise. Indian companies have expressed their unhappiness over provisions of the new law, which will restrict the export of coal below a benchmark price notified by the Indonesian Government.

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GOVERNMENT PASSES NEW QUALITY CONTROL ORDER FOR STEEL PRODUCTS The Central Government, after consulting the Bureau of Indian Standards in its Official Gazette, has published Steel and Steel Products (Quality Control) Second Order, 2011 on June 24, 2011. This Order shall come into force after a period of six months from the date of its publication in the Official Gazette. As per the order, no person shall by himself or through any person on his behalf manufacture or store for sale, sell or distribute any steel and steel products given in the Schedule, which do not conform to the specified standards and do not bear standard mark of the Bureau on obtaining certification marks licence: Provided that nothing in this Order shall apply in relation to export of steel and steel products required for export, which conform to any specification required by the foreign buyer. Secondly, the sub-standard or defective steel and steel products, which do not conform to the specified standard, shall be disposed off as scrap as per the scheme of testing and inspection of the Bureau of Indian Standards. All manufacturers of steel and steel products shall make an application to the Bureau for obtaining licence for use of the standard mark, within forty-five days of the issue of this Order, if not already obtained. When any person by himself or through any person on his behalf proposes to manufacture steel and steel products, he shall commence regular production only after obtaining a valid licence from Bureau for the use of standard mark. Samples of any steel and steel products bearing the standard mark and drawn by the Appropriate Authority, for ascertaining whether they conform to the specified standard, shall be tested in the laboratory approved by the Bureau and as prescribed in the relevant Indian Standard. With these measures, the steel industry will surely be able to shine high in offering quality goods globally.

HAVELLS AIMS TO DOUBLE REVENUE TO `1,800 CR IN THREE YEARS Electrical equipment-maker Havells India recently revealed its plans to double its revenue in the switchgear segment to `1,800 crore in the next three years. “Post expansion, we plan to take the switchgear business from `900 crore to `1,800 crore in the next three years,” said Sunil Sikka, President, Havells India. The company has set up a new industrial switchgear plant at Sahibabad at an investment of `50 crore. He said the firm expects its revenues from the industrial switchgear segment to double from the present `200 crore to `400 crore in the next two years. The company, which has six manufacturing facilities abroad, is looking to enter China in a big way. “Our focus area is China, where we are entering in a big way,” Sikka said. The company, which sells its

lighting products in China through its offices there, is looking to form a joint venture (JV) in the country. “We are looking for a JV partner in China, for which our agencies are working. It is in the process,” Sikka said, without confirming any timeframe. The company is also exploring various possibilities to enter the small electric appliances segment. “We are getting into garment care, food preparation and cooking appliances. The domestic market size for such products is nearly `5,000 crore,” Sikka said. The company, which has 12 manufacturing plants in India, is looking to set up a plant at Neemrana, Rajasthan, for lighting fixtures. “We are in the process of setting up a factory for lighting fixtures in Neemrana on a 10-acre plot,” he said.

RELIANCE POWER AIMS TO EARN `5,000 CR IN CARBON CREDITS FROM THREE UMPPS

NAVIS CAPITAL ACQUIRES STAKE IN CLASSIC STRIPES FOR $100 MILLION

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NEWS, VIEWS & ANALYSIS L A T E S T

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ELECTRICAL EQUIPMENT SECTOR REGISTERS 14 PER CENT IN 2010-11 The Indian electrical equipment manufacturing industry is witnessing a sustained growth momentum, with the industry registering a growth of 14 per cent in the financial year 201011, in spite of sustained imports, especially from China and South Korea. The growth represents an absolute increase in output over the last financial year and may differ from the growth in value terms, according to the Indian Electrical and Electronics Manufacturers’ Association (IEEMA). The fourth quarter of the last financial year saw a lot of pending tenders being awarded by power utilities. Bunching of orders by the utilities in the fourth quarter has been observed historically. Due to increased focus on power quality and energy efficiency by utilities, Distribution companies and user industries, demand for capacitors surged by 35 per cent in 2010-11. Buoyancy in demand from power grid, independent power producers (IPPs) and some utilities for high voltage (HV) and extra high voltage (EHV) switchgear including products like AIS and GIS has resulted in 28 per cent growth. Pent up demand of medium voltage breakers for substation projects resulted in huge growth of more than 30 per cent. Low-voltage switchgear products like contactors, miniatures circuit breakers (MCBs), moulded case circuit breakers (MCCBs), etc. continue to witness a growth of more than 20 per cent due to sustained demand from cement, steel, original equipment manufacturers (OEMs), construction and infrastructure sectors. The cable sector overall saw a rise in demand of 16 per cent, while the transformer industry has witnessed an overall growth of 15 per cent. The domestic demand is on rise. However, exports have declined by 15 per cent, mainly in the power transformer segment. “Enhanced metre procurements by state utilities translated into good business in 2010-11. The industry is now involved in the development of specifications for ‘Smart Metres’ under the guidance of Ministry of Power and Sam Pitroda, Chairman, India Smart Grid Task Force,” according to IEEMA. The energy metre sector saw a healthy growth of 15 per cent for both, single and polyphase static energy metres domestically, coupled with good export demand. Presently, Indian exports of electrical equipment are less than one per cent of the global trade. With the electricity sector being a sunrise sector across the entire developing world, there also exists a significant export potential for the domestic industry.

L&T PLANS TO INVEST `85,000 CR IN ORISSA Leading engineering company Larsen & Toubro (L&T) has planned to invest about `85,000 crore in Orissa in aluminium, power and steel sectors. “We have already given proposals to the state government. The company will proceed as soon as the State Government clears the proposals,” said Sailendra Roy, President, L&T at the sideline of ASSOCHAM’s investors meet. Stating that the company was planning to set up an aluminium plant in a joint venture with Dubai-based Dubal, Roy said that an amount of about `30,000 crore would be invested in this project.

Besides, the company was also planning to set up two thermal power stations of 2,000 MW capacity each. While one such power station will be established at Dhamra in Bhadrak district, the location for another unit is not decided, Roy said. The other power station would preferably be located at a place within 100km from the state capital, he said adding that a steel plant proposal was also given to the State Government. The steel plant would be located near Paradip over 600 acre of land, he said. Besides, Videocon had also proposed to invest `15,500 crore in the state.

VEDANTA RESOURCES BUYS 10% IN CAIRN INDIA FOR $1.5 BILLION

NALCO TO INFUSE `1,700 CRORE EQUITY IN KAKRAPAR N-PLANT

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M A N U F A C T U R I N G

MARUTI ACHIEVES 10 LAKH PRODUCTION MARK OF K-SERIES ENGINE

FORBES MARSHALL AMONG TOP 25 BEST WORKPLACES IN INDIA Forbes Marshall has been ranked No. 11 in the list of the top 25 Best Workplaces in India for 2011 based on a survey conducted by the Great Place to Work Institute. Forbes Marshall, the only Pune-based company to make it to the top 50 list, was awarded the 11th position among 471 companies, which participated in the survey across all sections in the industry. Forbes Marshall was also recognised as the second-best company in the manufacturing and production industry and the second best company in employee participation in CSR activities. “I believe it takes a combination of factors to be an employer of choice to potential as well as existing employees. For existing employees, the workplace needs to be a place they look forward to coming to each morning, a place which they are proud to call their workplace, a place which operates with the right value systems and a place which brings out the best in him as a human being and as a professional; and managers who genuinely care about both, his personal and professional development – and work towards bringing out the best in him/her. The above factors also play an important role in attracting new talent into the organisation,” said Rati Forbes, Director HR, Forbes Marshall. The list of best work places is primarily based on the rigorous ‘Great Place to Work Study’, which follows a unique employeecentric methodology. Extensive employee surveys are conducted in which the opinions of employees working at participating organisations are taken. Forbes Marshall has been rated on pillars like family spirit, culture and employee trust. A comfortable and engaging work environment, open communication, management training programmes and the absence of hierarchy, are some of the key aspects of Forbes Marshall that make it one of the top 25 places to work. A noteworthy best practice, that the study mentions, is the value digression council and its activities.

NEWS, VIEWS & ANALYSIS L A T E S T

H A P P E N I N G S

MOTHERSON SUMI TO BUY 80% IN GERMANY’S PEGUFORM

GOVERNMENT PLANS TO SET UP TWO AUTOMOTIVE MANUFACTURING HUBS IN CENTRAL, EAST INDIA The government plans to set up two automotive manufacturing hubs spread over 10,000 acre each in central and eastern India. The new hubs, aimed at consolidating India’s position as an important destination for low-cost automotive production, will be in addition to the three existing zones – Haryana, Maharashtra and Tamil Nadu. India’s automotive industry, estimated to have a turnover of $73 billion at present, accounts for six per cent of its GDP. “There is need to make India costcompetitive and a large-scale manufacturing destination that would help it emerge as a front-runner for low-cost production globally,” said Praful Patel, Minister for Heavy Industries and Public Enterprises. Patel said that India, which is already a leading manufacturer of small cars, needed to maintain its high level of efficiency in the sector and keep costs down. The manufacturing hubs should be developed as self-sustaining blocks, he added. The minister also announced the setting up of an inter-ministerial task force to resolve the industry’s concerns about high taxation and export-incentive schemes, such as the Duty Entitlement Passbook (DEPB) Scheme. The task force will drive representatives from key ministries, such as finance and commerce. India’s automotive industry is poised for a turnover of $145 billion by 2016, up from the current $73 billion. With another $11 billion coming from export of automotive components, the sector has sought a flexible tax structure & reforms in labour laws to maintain competitiveness.

MICHELIN’S INDIA PLANT TARGETS TYRE ROLL OUT BY NOV 2012

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‘MAY INDUSTRIAL OUTPUT GROWTH NOT ENCOURAGING’ Finance Minister Pranab Mukherjee said that the industrial output growth in May was not encouraging and that one needs to consider the quarterly figures instead of the monthly figure. India’s industrial output in May rose 5.6 per cent, the slowest pace of growth in nine months, indicating that a taut monetary policy and high inflation were acting as brakes on the economy. He further said that the government is working on improving the manufacturing output and will keep volatility of crude prices in account. But the RBI is still expected to raise the rates at its quarterly policy review to contain stubbornly high inflation. The government will not expand its 2011-12 borrowing programme, he said. Meanwhile, concerned over the sluggish growth in industrial output in May, Planning Commission Deputy Chairman Montek Singh Ahluwalia said that a focussed strategy would be required to accelerate growth in the manufacturing sector. “Clearly the IIP numbers continue to show a somewhat lower growth rate,” Ahluwalia said as the May numbers slumped to 5.6 per cent from 8.5 per cent in the same month last year. He, however said that the May numbers could not be seen as ‘predictive’ for the entire fiscal. The slowdown in industrial growth in May is mainly due to the poor performance of the manufacturing and mining sectors. The IIP numbers for April have also been revised downward to 5.7 per cent from the earlier estimate of 6.3 per cent, as per the new series with a base year of 2004-05. Ahluwalia said that the thrust has to be on accelerating the manufacturing sector, which constitutes over 75 per cent of the total factory output. Ahluwalia added that the manufacturing growth during the current 11th Five Year Plan has been below expectations. “It should be one of the objectives of the 12th Five Year Plan to analyse and to find out what needs to be done from the policy point of view to produce a much faster manufacturing growth,” he said. He said that the country needs to fast-pace its economic growth and manufacturing would form a major component of any such acceleration. “On an average, we have seen more than 7-8 per cent growth and actually we need to get 10 per cent. I think a lot of that has to do with improved infrastructure and better availability of power and so on. And that has to be the thrust for the next plan period,” he said.

ROYAL ENFIELD TO SET UP SECOND PLANT NEAR CHENNAI BY 2013 Eicher Motors’ two-wheeler division, Royal Enfield, will set up a new manufacturing facility at Oragadam, near Chennai, with an initial installed capacity of 1.5 lakh units per annum by March 2013. The proposed 50acre facility is likely to see a total investment of up to `350 crore over the next five years. Tamil Nadu CM Jayalalithaa officially allotted the land for the construction of the plant at the Oragadam SIPCOT Industrial Park. “We have received the letter for the land from the State Government. We will start the construction immediately after getting the possession. We should be ready with the plant by the first quarter of 2013,” said Siddhartha Lal, MD & CEO, Eicher Motors. “With the addition of new capacities, we will be able to reduce the waiting periods of our bikes. It is currently about 6-8 months,” Lal added. Following operationalisation of the new

SEARCH - THE INDUSTRIAL SOURCEBOOK | A U G U S T 2 0 1 1

plant, Royal Enfield will shift its entire vehicle assembly line here. At present, it has another facility in the state that produces 70,000 bikes every year. “We will completely shift the vehicle production in a phased manner to the new plant. Our plan is to utilise the old plant for developing and producing engines for the bikes,” Lal said, adding that engine manufacturing capacity will also be increased to 1.5 lakh units annually from 70,000 units at present. “Our long-term strategy is to invest for the next five years under a mega project on the same site,” he said. However, an official statement from the Tamil Nadu Government said that the company had proposed to expand operations at a cost of `350 crore. Eicher Motors decided to set up its operations in the state, considering the infrastructure facilities and conducive (business) atmosphere, the official statement said.

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CHINA GDP RISES 9.5% IN Q2

‘INDIA AMONG TOP 5 RENEWABLE ENERGY CAPACITY COUNTRIES’ India has an installed renewable energy base of about 20 GW, which is around 11 per cent of the country’s total power capacity and accounts for four per cent of the electricity mix, Minister of New and Renewable Energy Farooq Abdullah has said at a forum in Abu Dhabi. At a high-level consultative forum in Abu Dhabi, Abdullah said that India today stands among the top five countries of the world in terms of its renewable energy capacity. He also noted that India recently launched a unique and ambitious National Solar Mission, which seeks to facilitate the generation of 20,000 MW of solar power by 2022. The Abu Dhabi forum was aimed at providing an opportunity for Ministers of Energy from Africa to engage with experts from regional economic commissions, national entities and international partners. “In the last decade, our installed capacity in renewable energy has risen from about three per cent of the total installed capacity to over 11 per cent currently. Our aim is to take it to over 20 per cent in the next decade with a capacity of over 70,000 MW,” Abdullah told the two-day International Renewable Energy Agency (IRENA)-Africa High Level Consultative Forum on ‘Accelerating Renewable Energy Uptake for Africa’s Sustainable Development’. According to him, India is working on a National Biomass Mission, which will help tap bioenergy potential of over 25,000 MW. The minister further said that the latest initiative is to examine the possibilities of having dedicated energy plantations from fast growing species of bamboo and other tree species and using them for producing power in small 1-2 MW plants feeding into the distribution grid.

CAR SALES POST SLOWEST GROWTH IN 27 MONTHS IN JUNE

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‘JAPAN MUST REDUCE DEPENDENCE ON NUCLEAR POWER’ Japan has no choice but to reduce its reliance on nuclear power, Prime Minister Naoto Kan recently said, as the country battles to end a four-month-old radiation crisis at a tsunamicrippled nuclear plant. The unpopular Prime Minister appears increasingly sensitive to growing public concern about nuclear power, but whether he oversees an overhaul of energy policy is doubtful as he has promised to resign, although he has not specified when. “We must scrap the plan to have nuclear power contribute 53 per cent (of electricity supply) by 2030 and reduce the degree of reliance on nuclear power,” Kan told the panel. The crisis at Tokyo Electric Power Co’s Fukushima plant has sparked public debate over the role of nuclear power in quake-prone, resource-poor Japan, as well as immediate concerns about power shortages as 35 of the country’s 54 reactors are currently offline. A 2010 basic energy plan had called for boosting nuclear energy’s share of the electricity supply to 53 per cent by 2030 by building at least 14 new reactors, but many politicians agree that is nearly impossible now given the growing public anxiety. The crisis has also prompted discussions about whether to reform the way the nuclear power business, now the bailiwick of private utilities, is run. “The question arises whether private companies can bear the responsibility when considering the large risks involved with nuclear business,” he told the panel, adding, “Examples from other countries show that this has not always been the case. I agree with the suggestion that discussions (including those on nationalisation) are needed.”

‘MAJOR ECONOMIES HEADING FOR SLOWDOWN’ The world’s leading economies are headed for a slowdown, the Organisation for Economic Co-operation and Development (OECD) said in its latest monthly economic overview, highlighting signs that the US economy is reaching a turning point in its growth cycle. OECD said its May composite leading indicator (CLI) for 33 OECD member countries eased for a second straight month, to 102.5 from 102.8, pointing to a deceleration in the pace of recovery. The CLI for the euro area declined to 102.1 from 102.5, and the reading for the Group of Seven industrialised nations – Britain, Canada, France, Germany, Italy, Japan and the US – dipped to 103.0 from 103.2. The individual indicator for the US was flat at 103.4, while Japan dropped to 103.7 from 104.1. “Composite leading indicators, designed to anticipate turning points in economic activity relative to trend, point to a slowdown in most major economies. In the US, Japan and Russia, tentative signs of turning points in the growth cycle are emerging,” the OECD said. The indicators for non-OECD countries like China, India, Russia and Brazil all declined month-on-month in May, with Brazil and India remaining below their longterm averages.

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TOUGH GREEN POLICY SEEN SOFTENING UNDER NEW MINISTER India’s new environment minister is likely to be more flexible towards the industry to help power Asia’s third-largest economy, although a complete turnaround in tighter enforcement of green policies pursued by her maverick predecessor is ruled out. Jayanthi Natarajan’s arrival could help hundreds of projects held up on green worries, including Tata Steel’s $4.4 billion steel mill, ArcelorMittal’s iron and manganese ore mine and dozens of power and oil & gas projects. “We do not think that there will be any backsliding in policy because Ramesh has spotlighted it permanently,” said a senior government official on condition of anonymity, adding, “What we can see, though, is some more flexibility because she may have come with a mandate to be sympathetic towards the industry given our imperative to grow.” Under Ramesh, India halted more than 60 big-ticket projects and held up more than 450 of them, heightening the risk for investors and underlining India’s struggle to grow without damaging its environment – a tussle crucial to shaping the future of its 1.2 billion people. Whether or not Natarajan backs industry, she may have to pursue Ramesh’s agenda of compliance.

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EXIM MATTERS

It is the anxiety of the unknown around which the expectations of the yet-to-be-delivered are built. The extension period till September 30, 2011, before the Duty Entitlement Pass Book (DEPB) Scheme becomes extinct is the most trying time for the ‘expecting’ exporters, and for the government, who is all set to deliver… a brand new policy to replace the much popular 14-year old scheme. While the exporters will be living this phase on a hope and a prayer, the onus is on the government to swing into action and ascertain a better alternative option by way of a new scheme to protect the interest of both, the Indian exporters as well as preserving national interest. Going by the exporters sentiments, withdrawing incentives without an alternative would hurt export growth. Are the policy makers listening? ARCHANA TIWARI-NAYUDU

he government has decided to give one last fresh lease of life to the Duty Entitlement Pass Book (DEPB) Scheme by extending its validity till September 30, 2011, even as an alternative scheme is in the works. DEPB is a reimbursement of basic and special customs duty paid by an exporter on an imported input used in the export product. The benefit is given by way of a grant of duty credit against the export product at specified rates. The DEPB Scheme was due to end on June 30, 2011. “This is a three-month reprieve, within which time we will work out a mechanism that would ensure smooth transition from DEPB to the duty drawback, because no matter what, this scheme will have to end by September. So, ideally, this

is not an extension but a reprieve,” Commerce Secretary Rahul Khullar said in a statement. HS Goindi, President – Marketing, TVS Motor, makes a very valid point. According to him, “On one hand, extension is good and there is some logic to it. We hope and pray that full logic will be seen only after September because, as we said earlier, the point is not DEPB, or duty drawback or something else, the point along with this entire thing is also the competition with the other country. So that is where we stand. We are happy that it has been extended till September. However, we need to work around and see how it can be done later on too.” The government’s reasoning for phasing out this scheme (The $250-billion sector no longer needs it) has drawn stinging

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criticism from manufacturers. India, which is Asia’s third-largest economy, loses $1.8 billion from the DEPB Scheme, informed Revenue Secretary Sunil Mitra. Under DEPB, the government reimburses exporters around Rs80 billion of taxes paid on imported supplies. “The export sector is healthy enough and incentives are no longer needed,” Mitra added. Industry stalwarts, however, are of the opinion that about 25 per cent of India’s exports, or around $70 billion, could be affected by withdrawing the DEPB Scheme. The government has set up a committee that would seek to replace the DEPB Scheme with the Duty Drawback Scheme (DDS). The main difference between the two schemes is that DEPB Scheme is disbursed in the form of DEPB scrip, while DDS is taken as cash. Further, the DEPB

FACFACT T

EXIM MATTERS

The government has set up a committee that would seek to replace the DEPB Scheme with the Duty Drawback Scheme (DDS). The main difference between the two schemes is that DEPB Scheme is disbursed in the form of DEPB scrip, while DDS is taken as cash. Further, the DEPB Scheme is administered by the Commerce and Industry Ministry, while the DDS is administered by the Revenue Department under the Finance Ministry.

Scheme is administered by the Commerce and Industry Ministry, while the DDS is administered by the Revenue Department under the Finance Ministry. The 14-year DEPB Scheme is extremely popular among exporters, while the DDS, which reimburses the customs duty component, covers 15-20 per cent of exports. Some major beneficiaries are engineering products, chemicals, plastics, leather, sports goods, food products, handicrafts, electronics and textiles. Steel Authority of India, Bajaj, Reliance Industries and Tata Steel are some of the companies that are availing huge benefits under the scheme.

EXPORTERS’ SENTIMENTS

cent of their shipment value in lieu of local taxes in line with the government thinking that the ‘exports should be zero rated (without domestic levies)’.

INDUSTRY VOICE Experts believe that the exports, which grew sharply by over 37 per cent in fiscal 2010-11, may not increase with the same pace in the current year as India has to compete with China where the cost of capital is far less with better infrastructure. Goindi said, “It has been competition for the country; China gives about 14-16 per cent.” Rajiv Bajaj, MD, Bajaj Auto, said that the company will increase the prices of its vehicles if this scheme is withdrawn. Under the DEPB Scheme, an exporter gets duty credit on the materials that he has imported towards manufacturing the product. He added, “The discussions continue on this front. For now, we have time till the end of September. At this point, we are getting good support from various ministries and we are hopeful that a middle path of some sort would be hit upon, so that we are not immediately impacted by an entire 8-10 per cent cut. However, if the scheme is somewhat tempered, we will raise prices by an equivalent amount and protect our bottom line numbers.”

As an alternative, the Commerce and Industry Ministry may provide other market focus schemes such as Focus Market Scheme and Focus Product Scheme to the export sector in the absence of the Tax Refund Scheme aimed at boosting the country’s merchandise shipments. According to Deora, the DEPB Scheme should be extended till the introduction of the Goods & Services Tax (GST) Scheme, as it will not be possible to fix drawback rates for all the products for which DEPB rates exist, for three months. GST, which was scheduled for release from April next year, may, now, not be possible as the government has been unable to get the consent of all the states. It is also felt that ideally, DEPB should be co-terminus with the foreign trade policy that is till 2014. “In the long run, the government should definitely bring all the products under the all industry DDS. It should also involve industry bodies during the fixation of rates for accuracy of the data and transparency in the fixation,” Deora opined.

Even though the exporters are opposed to WAIT & WATCH SCENARIO Putting across the industry statement and the move and have been pleading with the sentiment, Goindi aptly concluded, “We government that either the scheme should need to see what data and scheme the remain intact or be replaced by an equally government is going to announce based on good alternative, the Finance Ministry has the Commerce Ministry’s point of view as shown reluctance to extend the scheme far as export is concerned. The Finance beyond September 30, 2011. “We have Ministry talks about so much of money asked exporters to present a case before going for these kinds of benefits. So, I think us, and we will analyse the needs on a casewe need to really get the details from the to-case basis instead of a single drawback government as to what they will come out rate for all. There can also be a fixed brand with in the next 2-3 months time. Let the rate. Today, some industries are getting exact details come, we have definitely more in the DEPB Scheme and less in DDS. informed our buyers, people know this is For some, it is the reverse. This is the right going to happen, how much we can opportunity for exporters to express pass on and how much we can cut their concerns, because after this down the cost, how we can take it period, not once will the scheme be forward. What form and shape the extended,” Khullar said. drawback rate comes in, what other Exporters had been urging the We have asked exporters to present a case before us, benefits are there or not there, all extension of the scheme in the and we will analyse the needs on a case-to-case basis this put together, we will really absence of an alternative option. instead of a single drawback rate for all. There can decide as to how much we will pass The rates of refund in DDS are much also be a fixed brand rate. Today, some industries are on to the marketplace.” lower than those available under the getting more in the DEPB Scheme and less in DDS. “Having said that we need to DEPB Scheme, according to Ramu S protect our margins, we need to Deora, President, Federation of For some, it is the reverse. This is the right take our margins forward. So, we Indian Export Organisations. opportunity for exporters to express their concerns, need to look at all these angles. Exporters have warned that their because after this period, not once will the scheme Let us see the exact details of shipments would drop to $200 be extended. the scheme before jumping to billion in the current fiscal. Overseas conclusion and look at all the soshipments in the previous financial called conflicting objectives from a year were $246 billion. Under the RAHUL KHULLAR, point of view of buyers and DEPB Scheme, exporters are Commerce Secretary customers,” he added. rebated to the extent of 8-10 per

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UOTES OF THE MONTH If we increase administered prices of petroleum products and reduce fertiliser subsidy, we allow room for some inflation. If we do not, then the consequent increase in the fiscal deficit will counter the moderating trend in aggregate demand and push inflation high anyhow. – Pranab Mukherjee, Hon’ble Minister of Finance

For the first time, we are going to have a policy dedicated to the manufacturing sector. Industry welcomes the in-principle nod given by Prime Minister to the draft National Manufacturing Policy and hopes that a final policy will be announced.

Cost of capital needs to be moderated. Because of such high interest rates, the industry is witnessing a slowdown. In the last 15 months, interest rates went up by 10 times. Any further increase by RBI will have a drastic adverse impact on the growth of the industry.

– Harsh Mariwala, President, FICCI

I am aware of the nervousness in some sections of the corporate sector, arising out of recent unfortunate power cuts. I take this opportunity to assure you that my government is seized of the issue and we are taking efforts on a war footing to correct the situation.Very soon, we will be able to make our state a power surplus state once again. – J Jayalalithaa,

– B Muthuraman,

Chief Minister of Tamil Nadu

President, CII and Vice Chairman, Tata Steel

Factory Fundas

INVESTMENT BAROMETER 13,846 ` crore 9,697 ` crore (+) 43% 4,833 ` crore

FDI EQUITY INFLOWS DURING APRIL 2011 FDI EQUITY INFLOWS DURING APRIL 2010 %AGE GROWTH OVER LAST YEAR FDI EQUITY INFLOWS DURING MARCH 2011

SECTORS ATTRACTING HIGHEST FDI EQUITY INFLOWS Amount ` in crore

Sector Services Sector

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2011-12 (for April 2011)

Mauritius

4,332

Singapore

5,214

Telecommunications

205

U.S.A.

Housing & Real Estate

167

U.K.

Construction Activities

1,381

Netherlands

Automobile Industry

1,182

Japan

Power

1,136

Cyprus

754

Germany

231

France

977

Chemicals

2,922 425

Petroleum & Natural Gas

Source: Shopfloor Series

Amount ` in crores

Country

Computer Software & Hardware

Metallurgical Industries

Using Machines Efﬁciently

2011-12 (for April 2011)

SHARE OF TOP INVESTING COUNTRIES FDI EQUITY INFLOWS (FINANCIAL YEARS):

229 28

U.A.E. 152

Total FDI Inflows *

356 19 172 1,043

91 13,846

(i) ^On the basis of clarification received from RBI, the amount of Stock Swap & Advance pending for issue of shares has been deleted from FDI data. (ii) Country & Sector specific analysis from the year 2000 onwards available, as Company-wise details are provided by RBI from January 2000 onwards only.

HON’BLE COMMERCE & INDUSTRY MINISTER

WE ARE ALL

SET TO CREATE

WORLD-CLASS MANUFACTURING INFRASTRUCTURE

As the entire nation awaits its very first Manufacturing Policy, a much needed single uniform policy for ensuring balanced growth across regions, Hon’ble Commerce & Industry Minister Mr. Anand Sharma shares his ambitious goal of boosting manufacturing as a percentage of India’s GDP with Archana Tiwari-Nayudu. Tiwari-Nayudu. Excerpts from the exclusive interview…

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HON’BLE COMMERCE & INDUSTRY MINISTER

he new manufacturing policy is being perceived as a magic wand that will transform India’s fortune and global standing. Your thoughts as you gear up to introduce this tool of change…

Over the last two decades, the Indian economy has witnessed a transformational change and has emerged as one of the fastest growing economies of the world. While the growth of GDP in India has been rapid since 1991, it has largely been led by the growth in services. The share of the manufacturing sector in India’s GDP has remained constant at around 15 per cent. There is an urgent need to accelerate and deepen the growth of the manufacturing sector given its high employment intensity and also its strategic importance. In order to develop manufacturing as the engine of national growth, the government has decided to bring out this National Manufacturing Policy.

On the issue of environment, I would like to inform that stress has been given in this policy to drive the ‘greening’ of manufacturing operations. The government will prescribe technology or design standards and mandate specific control technologies or production processes and performance standards that require producers to meet prescribed emission standards, but will allow them to choose from the available methods to meet those standards. The government will also provide continuous incentives, monetary and otherwise, to encourage polluting entities to reduce releases of harmful pollutants.

Provisions made in the new policy to turn our limiting infrastructure into an advantage

NIMZs, which are major cornerstones of the policy, will be developed as integrated industrial townships and the Central Government will provide external physical infrastructure linkages to the zone including rail, road (national highways) ports, airports and telecom, in a time-bound manner. This infrastructure will be created or upgraded The 5 most important features of this policy through public private partnerships (PPPs) to the extent possible. The The Policy will focus on special sectors like employment-intensive policy proposes to provide viability gap funding for infrastructure industries, capital goods, strategic industries and industries where development through the existing schemes. Wherever necessary, India enjoys a comparative advantage. The policy also addresses the requisite budgetary provisions for the creation of these linkages will problems of SMEs and has made a provision for offering incentives to also be made. SMEs. Since the trade policy is inextricably linked with the The state governments will also be involved in complementing manufacturing policy, it will be used as an instrument to supplement the efforts of the Central Government in developing infrastructure the efforts of this policy. Having highlighted these points, the five most for the manufacturing sector. The State Government will facilitate the important features of this policy are: creation of captive power plants by private players (including the Creation of world-class manufacturing infrastructure, augmented Special Purpose Vehicle (SPV) of the NIMZ) with full authority for with appropriate social and institutional infrastructure, through the generation, transmission and distribution. As far as possible, the state establishment of National Investment and Manufacturing Zones governments will allocate surface water from sources from which it (NMIZs) would be viable to draw water for the NIMZ. Rationalisation and simplification of business regulations to reduce An innovative feature of the policy is the proposal for leveraging transaction costs for investors and entrepreneurs the infrastructure deficit in the country into an opportunity for Financial and institutional support for innovation and technology investors. Under this proposal, the infrastructure deficit and development with emphasis on green technologies requirement of equipment being imported in areas like power, roads, Large-scale interventions for industrial training and skill railways, aviation, etc. would be assessed over a number of years to upgradation create the volumes and scales, which would enable the development Leveraging infrastructure deficit and government procurement, of domestic manufacturing capabilities in these areas as well. On the including defence, to provide basis of a very rough calculation, if the economies of scale to domestic infrastructure deficit is leveraged to the manufacturers. extent of the required equipment, manufacturing growth could be I would like to make it clear that this Gripping the further growth enhanced by close to 3 percentage policy has not been framed with a of manufacturing is land and points, which is a substantial increase. view to compete with China or for environment…what is new manufacturing policy’s stance A monitoring body is being set that matter, with any other country, on these issues? up to ascertain the smooth but to accelerate the growth of the and efficient functioning of Since land is a state subject, it would be manufacturing sector, which has not yet this new policy… do we not the responsibility of the respective state achieved its full potential. need more of implementators governments to select a suitable piece than administrators to make of land for the development of NIMZs, this policy work? including land acquisition, if necessary. According to some economists, the The land which would be occupied, main challenge in the formulation and implementation of an effective could be a government-owned land, private land falling with the manufacturing policy is the problem in correctly assessing the proposed NIMZ, to be acquired by the State Government or a land difficulties faced by the industries. To address this, the National under existing industrial areas/estates/sick and defunct units, including Manufacturing Policy has been prepared after extensive consultations PSUs. However, the guiding principle would be to use wastelands, with stakeholders and inputs from the industry, state governments infertile & dry lands and use of agricultural land to the minimum. It and subject experts. Care has also been taken to involve various would be ensured that all acquisition proceedings specify a viable stakeholders in the development and implementation of the policy to resettlement and rehabilitation plan.

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HON’BLE COMMERCE & INDUSTRY MINISTER

the maximum extent possible. A Manufacturing Investment Promotion Board, headed by the Commerce and Industry Minister, has been proposed at the apex, to seek expeditious resolution of issues being faced by the industry. I expect that these measures will ensure the smooth implementation of the policy in the coming years.

What are the biggest blocks in the way of making this policy achieve its optimum result? The increase in sectoral contribution from 16 per cent at present to 25 per cent by 2025 will require a massive effort for skill development and re-skilling since manufacturing jobs require sector and skill-specific trained workforce. Even today, it is estimated that only six per cent of the Indian workforce receives any form of vocational training and there is a pronounced ‘skill gap’ both, in terms of quality and quantity. This skill gap would be significantly larger as the manufacturing sector expands further and diversifies to add new production lines. This, in my view, is the biggest challenge in the way of making this policy achieve its optimum results. However, the policy addresses this problem through various measures for skill building among large number of minimally educated workforce, imparting relevant vocational and skill training through establishment of Indian Technical Institutes (ITIs) in PPP mode, promoting specialised skill development through the establishment of polytechnics and Instructor’s Training Centres.

The proposed NMIZs are slated to help India achieve global competency… your comments NIMZs will seek to address the infrastructural bottleneck, which has been long cited as a constraining factor for the growth of manufacturing. They will be developed as integrated industrial townships benchmarked with the best manufacturing hubs in the world. State-of-the-art industrial infrastructure, optimal land use on the basis of zoning; clean and energy-efficient technology; necessary social infrastructure; skill development facilities, etc., will be provided to create a productive environment for persons transitioning from the primary sector to the secondary and tertiary sectors. They will also help us meet the increasing demand for new urban centres in India and prevent overload on the existing civic infrastructure. In sum, the NIMZs would be among the best integrated manufacturing hubs in the world and will help India attain global presence in the manufacturing domain.

How will this new manufacturing policy help India to compete with China and other global manufacturing hotspots? At the outset, I would like to make it clear that this policy has not been framed with a view to compete with China or for that matter, with any other country, but to accelerate the growth of the manufacturing sector, which has not yet achieved its full potential. The policy is aimed at harnessing our own strengths of scientific and technical know-how, diversified industrial base and the promise of the demographic dividend with the objective of enhancing global competitiveness of Indian manufacturing and making India an international manufacturing hub. This would also create many new jobs and promote inclusive growth in the country.

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PROPOSED NMIZs

CREATING A BLUEPRINT TO MANUFACTURING SUCCESS Indian manufacturing is at the cusp of attaining global leadership and how! The much awaited new manufacturing policy draft has finally got the green signal from the policy makers. While there is no denying the fact that this policy is slated to bring new paradigms for the manufacturing industry on the global canvas, it remains to be seen how the government and the manufacturing fraternity get married to the idea of working in sync when the actual implementation happens. PRERNA SHARMA

fter much ado, Hon’ble Prime Minister has finally approved the new draft of the manufacturing policy. While a lot has been discussed and deliberated over the fortunes that this policy is slated to bring, its most crucial part i.e. national manufacturing investment zones (NMIZs), has caught the attention of policy makers and state machineries alike. Envisaged as bigger than SEZs, covering states & even groups of states and having world-class infrastructure facilities, NMIZs are going to be a game changer for the manufacturing industry. But has the road to such a progressive era been so smooth in a country of 28 varied states and 7 Union Territories having different political guards? Certainly not… troubled with land controversies, this issue has undoubtedly delayed its implementation

roadmap. But before going in depth, let us understand what NMIZs stand for.

THE OBJECTIVES Based on the foundation to promote investments in the manufacturing sector & make the country a hub for both, domestic and international markets; to increase the sectoral share of manufacturing in GDP to 25 per cent by 2022, these zones will serve as the critical manufacturing centres of the country. They will have the potential to double the current employment levels in the sector and to enhance the global competitiveness of the sector. According to Raghavendra Rao, VP – Manufacturing & Process Consulting Practice, Frost & Sullivan, South Asia & Middle East, the intent of drafting the National Manufacturing Policy is commendable. NMP throws significant clarity on the basics of

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formation of NMIZ, Special Purpose Vehicle (SPV) PPP funding, green technologies, simplification of needed licences & clearances, skill development, employment insurance & conflict resolution, etc. What is passed in mention (the policy draft) is the clarity of intent in setting up roads, rail heads and port facilities. Also, it is not clear if all the state governments have agreed to do and give all that the policy expects of them. An area would be specifically delineated for the establishment of manufacturing facilities for domestic and export-led production, along with the associated services and infrastructure. NMIZs would be a combination of production units, public utilities, logistics, environmental protection mechanisms, residential areas and administrative services. It would have a processing area, where manufacturing facilities, along with associated logistics and

other services & required infrastructure will be located, and a non-processing area, to include residential, commercial and other social & institutional infrastructure. The processing area may include one or more special economic zones (SEZs), industrial parks & warehousing zones, export oriented units, domestic tariff area (DTA) units duly notified under the relevant central or state legislation or policy. All the benefits available under the relevant legislation or policy will continue to remain available to the said zones. Commenting on the same, Kumar Kandaswami, Leader – Manufacturing, Deloitte India, says, “NMIZs seem to be a holistic concept and may have one or more SEZs. NMIZs seek to create an ecosystem for manufacturers to carry on their businesses in an efficient manner. While there may not be one answer to where they will be located, the concept has the ability to create new manufacturing centres and cities over the years. This, to a large extent, can address the issues of land being available for industry, cost of housing and other social infrastructure, etc. New industrial corridors can potentially get created in this manner. To that extent, the scope and scale of NMIZs is not

FACFACT T

PROPOSED NMIZs

India’s comparative advantage lies in its large workforce. About 800 mn people will be in the productive working age group of 15-59 by 2015, with about 12 mn people expected to join the workforce every year. Over the last few years however, the industry has encountered shortage of personnel with shop floor skills. Industry estimates have shown that only about 50% of students from various technical and vocational streams are actually employable.

SPV would have delegated authority from the State Government, ministries in the Central Government and other government agencies for issuing the necessary clearances, as may be necessary for the inception & continuation of business ventures inside NMIZ. The differences over land acquisition and tax holidays in SEZs had earlier convinced the government that it should steer clear of them in the manufacturing policy, even though the Industry Ministry was in favour of sops. “The real idea is to create zones that will house manufacturers who can feed off each other, share facilities and trim costs... the main giveaway from the government will be concentrated spending on world-class infrastructure,” say officials. Infrastructure would include full global connectivity in terms of international airports, sea and land ports, dedicated rail & highway

CII has worked closely with the government while drafting the discussion paper on the National Manufacturing Policy. The proposed policy has laid down proposals for MSMEs providing for access to adequate and timely financial support. It would enable MSMEs gain access to capital markets and venture capital & private equity funds by providing incentives to venture capitalists for investing in MSMEs. Dr Arindam Bhattacharya, Vice Chairman, CII National Manufacturing Council & MD, Boston Consulting Group (India) something we have seen so far.” When asked to comment on their extension to SEZs, Dr Arindam Bhattacharya, Vice Chairman, CII National Manufacturing Council & MD, Boston Consulting Group (India), says, “NMIZs are not extensions of SEZs. These clusters are larger than SEZs and are established to attract investments, unlike SEZs, where the main purpose of establishment is exports. NIMZs would be self-sufficient zones equipped with advanced world-class & enabling infrastructure and technologies, facilities of storing & warehousing, public amenities and residential colonies, etc.” The government would have an especially alienated governing body, which would be in the form of a SPV formed with the constituents of that specific NMIZ. The

corridors, networked cities and high-speed Internet access. Beijing had followed this path to convert southern China into the most sought after investment destination in the world. For Rao, at a visionary level, the policy can be called promising (with the need for a few inclusions and clarity). However, it will gain credibility only when actions support this. It is only then that the industry will start taking it seriously. It will also have to keep investors attracted, beyond the first few NMIZs. Only then will this experiment be deemed successful.

ROLE OF THE STATE GOVERNMENT While initially, the state governments were apprehensive of the kind of proposition being offered to them by the Central Government, after a few rounds of discussion and being informed about the kind of sops & incentive mechanisms being offered by the Central Government, the state governments have finally given their go ahead. As per the finalised policy, the State Government would play the lead role in setting up NMIZs. In particular, the State Government will be responsible for providing/facilitating the following infrastructure: Land Funding for infrastructure, which cannot

The incentive mechanism The incentives & facilities offered to the units in SEZs for attracting investments, including foreign investments, are: Duty free import/domestic procurement of goods for the development, operation and maintenance of SEZ units 100% income tax exemption on export income for SEZ units under Section 10AA of the Income Tax Act for the first five years, 50% for the next five years thereafter and 50% of the ploughed back export profit for the next five years Exemption from Central Sales Tax Exemption from Service Tax Single window clearance for central and state-level approvals Exemption from state Sales Tax and other levies as extended by the respective state governments.

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PROPOSED NMIZs

be loaded onto the sale price of allotment. Initial funding of the land cost – possibilities of long-duration low-cost loans from international funding institutions or permission to raise longterm tax-free debentures against the security of land. Subscription to special equity funds for investment into NMIZs. SPV may be eligible for capital gain benefit. Power connectivity and availability of reliable and good quality power. The units may also seek open access as per the regulations of the State Electricity

the State Government. Dr Bhattacharya is of the view that the policy interventions addressed in the National Manufacturing Policy would reduce the cost burden and time of doing business and starting a business in India, respectively; eventually attracting foreign investors as well as safeguards for the domestic industry and employees along with simplifying the rules and relaxing labour policies. With rationalising and simplifying business regulations, easy availability of financial mechanisms for upgrading technologies and developing new technologies, faster exit mechanisms, industrial training and

The SMEs would stand to benefit the most if the infrastructure, people and other facilities are made available. In fact, one would like to believe that this category of companies would be the most benefitted and entrepreneurs can focus on carrying out their business. Kumar Kandaswami, Leader – Manufacturing, Deloitte India Regulatory Commission. If the State Government is unable to guarantee uninterrupted and high-quality power supply, then the State Government would facilitate the creation of captive power plants by private players (including the SPV of an NMIZ) with full authority for: Transmission, distribution and collection of power charges Provision of bulk water requirements Road connectivity (state roads) Sewerage and effluent treatment linkages, from the edge of the NMIZ, to the final disposal sites Appropriate infrastructure to address health, safety and environmental concerns. It would identify a suitable site, prepare the proposal and seek approval. It will notify the NMIZ area under the relevant Act, and acquire/assist in acquiring the land necessary for the setting up of the infrastructure, processing and non-processing areas. The acquisition of land, if any, must be done entirely by the State Government, and then handed over to the SPV. The State Government, applying for an NMIZ, will ensure that after notifying the area, all physical infrastructure and utility linkages under its jurisdiction are provided within a stipulated time frame. The State Government will notify a nodal department, which will provide a single window and coordinate with relevant authorities from

upgradation measures, enabling & worldclass infrastructure, incentives for MSMEs, separate clusters or manufacturing zones and enabling trade policies, the Indian manufacturing industry would definitely witness expeditious growth and be able to achieve its set aspiration of creating 100 million jobs by 2025.

THE PRIORITY FACTOR Although the manufacturing policy is yet to take shape, industry gurus have been putting together their wish list to ensure fruitful results. As a priority factor, Kandaswami opines, “For a manufacturer, getting infrastructure without much trouble and at a reasonable cost, having ready-to-deploy labour force & the flexibility to align the cost of people to the scale of operations and operating in an easy-to-manage ecosystem are important. The draft policy seeks to address all these. In addition, the emphasis on being environment-friendly would mean growth without having to destroy the environment. In terms of intentions and priorities, the draft seems to have captured the important elements that add to manufacturing competitiveness.” According to Dr Bhattacharya, “As the policy has addressed the issues, which inhibits high manufacturing growth and proposed policy interventions for simplifying labour rules, creating world-class infrastructure, reducing numbers of

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inspection, attracting foreign investments, reducing transaction cost, it will make India an attractive manufacturing hub. In my view, the policy has addressed the priority areas for the growth of manufacturing in the country.” As far as skill development is concerned, Kumar claims that it appears that skill development will be vested with NMIZs up to a point. This would imply that NMIZs would develop skills that are relevant to that location. This looks like an interesting proposition as instead of talking about skill development in a conceptual form, this policy seeks to give it a context. Assuming NMIZs operate at the scale they are perhaps envisaged to operate, there has to be a good and sizeable impact.

THE NEED GAPS For each and every policy, the rules of the game are different. Similarly, in this case, while the new policy has been able to take into consideration all the priority matters, it still has to address some key issues. Giving a different perspective, Dr Bhattacharya informs, “As mentioned earlier, the National Manufacturing Policy has tried to addresses all the major issues, which impact the growth of manufacturing in the country. It is important that the policy is implemented at the earliest. Given the current scenario, where manufacturing is showing some signs of slow growth, the policy could boost the growth of manufacturing in the country, thereby creating more jobs and making growth more inclusive.” According to Rao, one would like to see the following inclusions in this policy: Careful definition of clusters based on some location logic and national advantage rather than the policy insufficiently mentioning ‘wrong location’ as being one of the reasons why a company can fall sick. One would have expected such a scheme to promote sectors that have a natural national competitiveness and that too in locations that can be deemed technically feasible. The dilution of need for licences and clearances. It would be a relief if preapproval and pre-licencing is given as a package to all manufacturing outfits that are allotted land in the sites. The requirements can be clearly specified and routine policing can identify defaulters. Punishment in such cases can be pre-specified and exemplary. There is still too much of talk of too

PROPOSED NMIZs

many departments/agencies and Acts to be addressed. This may need a review of applicability as well as pre-approvals, so as to expedite procedures and eliminate red tapism. More focus on the technical feasibility of going green and adopting green technologies rather than promoting green as a global imperative. Thus, while it is a wise step to incentivise going green, it may be counterproductive to insist that a part of the consumption should come from renewable sources. Example of customers adopting energy ratings as being an indication that they prefer green products is factually incorrect. A survey would help prove if this assumption is correct, or if it has to do more with energy savings as a result of the spiralling costs of electricity. Green will thrive, only if it is business feasible. As a matter of fact, on an average, a manufacturing unit in India has to comply with 70-odd legislations with each clearance requiring at least one licence or registration certificate. These legislations and Acts, as identified, are given in the next section. These compliances involve multiple inspections, in some cases, monthly, while in some cases, yearly. Also, the returns to be filed are on a monthly, quarterly or yearly basis under these legislations, amounting to more than 100 returns to be filed in a year. Naturally, this involves a lot of paper work, time and effort of the manufacturers, which,

Special Incentives for Green Technologies and Manufacturing for units in NMIZs Low-interest loans for manufacturing to invest in new plans to produce clean/green technology or invest in new plants to produce green products Creation of a central fund for supporting research in the area of green manufacturing Provide grants for workers training that will lead to expanded energy efficiency and renewable energy industry workforce Preference to green units/green products during procurement by state/ Central Government If an SPV in a particular NMIZ decides to have an IPP based on renewable green technology, an investment subsidy to cover the additional interest cost per mega watt may be considered.

required to deal with only these two agencies and requisite powers should be vested with these authorities. The State Government should bring out Manufacturing Zone Act and Rules to make it mandatory on the part of various departments and authorities to provide clearances to units based in these zones. The draft recommendations for the simplification and rationalisation of clearances for these zones are in two parts namely: (a) General principles to be followed for all clearances (b) Specific Act-wise recommendations. The general principles to ensure simplification of clearance process are:

The intent of drafting the National Manufacturing Policy is commendable. NMP throws significant clarity on the basics of formation of NMIZ, Special Purpose Vehicle (SPV) PPP funding, green technologies, simplification of needed licences & clearances, skill development, employment insurance & conflict resolution, etc. What is passed in mention is the clarity of intent in setting up roads, rail heads and port facilities. Raghavendra Rao, VP – Manufacturing & Process Consulting Practice, Frost & Sullivan, South Asia & Middle East in the case of SMEs, has to be done by the proprietor himself most of the times. A majority of these compliances are required at the state levels. Keeping in view the importance of granting fast track approvals and minimising the compliance burden on the manufacturers in the national manufacturing zone, the government should designate a single window clearance authority both, at the central and state levels. The manufacturing unit should be

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Emphasis should be on ‘self-certification’ with the onus on proof of correctness of information of the applicant. Various Acts/Rules under labour, safety and environment can be covered under this self-certification scheme. The entire process of according clearances by all major central and state authorities to be web-enabled and status to be available ‘online’ at all times for monitoring. Timelines to be defined in respect of all

major clearances. In the case where no extension of timeline is specified and clearance is not given within the specified timeline, the clearance to be ‘deemed’ should be given on the expiry of the timeline.

CHANGING PARADIGMS Considered the better copy of the Chinese model, these NMIZs will be able to provide a level playing field to all the states in the country. The first NMIZ being considered, on these lines, will be spread over three states along the western railway corridor — Haryana, Rajasthan and Gujarat. According to Kandaswami, if the manufacturing policy is implemented in the manner that it is envisaged, it can significantly address the big issues constraining the manufacturing industry. And if the implementation is widespread in terms of setting up of NMIZs, it can potentially impact the competitiveness of India as a manufacturing country. To be realistic, this is unlikely to happen in a short span of time. And given the huge number of changes it proposes to the regulatory framework, getting the policy ready for implementation itself would be a challenging task. To sum it up, the big picture looks interesting and it is critical that the detailing is done properly and the implementation is top class – an area where India has always had problems. On an optimistic note, Dr Bhattacharya says that the industry is working with the government for creating a conducive policy environment. Every country would have its own policy and practices to achieve growth based on the dynamics of the respective country.

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STEEL

Top 5 Demand Trends Witnessed In The Year 2010

The world produced

• Business Restructuring to ensure efficiencies, reduce costs and maintain margins • Becoming more adept at idling and restarting blast furnaces (BFs) to meet fluctuating demand • Renegotiating contracts to match the change to quarterly raw material pricing contracts • Securing raw materials as volatility in raw m aterial pricing has increased • Improving product mix: The companies are increasing their focus on the downstream applications and solutions driven products for their higher value add.

steel industry

1.4

Billion Tonne of

crude steel in 2010.

STEEL PRODUCTION AND USE: GEOGRAPHICAL DISTRIBUTION 2010 Production

Use (finished steel products)

World total: 1,414 million metric tonne crude steel Others Other Asia 6.3% 11.5% Japan 7.8%

EU (27) 12.2% CIS 7.7%

World total: 1,282 million metric tonne Others 9.6%

Other Europe 2.4%

Other Asia 14.5%

NAFTA 8.6%

Japan 5.0%

NAFTA 7.8%

1.2% 1.4%

CIS 3.8%

China 44.9%

China 44.3%

Others comprise: Africa Middle East

Other Europe 2.3%

EU (27) 11.3%

Central and South America Australia and New Zealand

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3.2% 0.6%

Others comprise: Africa Middle East

2.0% 3.4%

Central and South America Australia and New Zealand

3.6% 0.6%

STEEL

TOP 10 GLOBAL STEEL PRODUCERS (MILLION METRIC TONNE CRUDE STEEL PRODUCTION) RANK

COMPANY

MMT

RANK

COMPANY

MMT

ArcelorMittal

98.2

Jiangsu Shagang

23.2

Baosteel

37.0

Tata Steel

23.2

2 3

POSCO

35.4

U. S. Steel

22.3

Nippon Steel

35.0

Ansteel

22.1

JFE

31.1

Gerdau

18.7

TOP 5 COUNTRIES (MILLION METRIC TONNE CRUDE STEEL PRODUCTION) COUNTRY

China Japan United States India Russia

2010 Rank

Tonnage

1 2 3 4 5

626.7 109.6 80.5 68.3 66.9

M&A and JVs bandwagon • The value of mergers and acquisitions in the world’s metals markets rose 80% in 2010 to $27 billion. • The largest deal by value in 2010 was the $2.83 billion bid for Korea’s Daewoo International Corp. by Korean steelmaker Posco. • With the aim to expand its service centres, Essar Steel in June 2010 also acquired UK-based Servosteel, the largest independent steel processor. Ruias-led Essar Global also acquired US-based Trinity Coal for $ 600-million, a move which will help the firm meet its rising raw material requirement for its steel business. • Tata Steel formed an alliance with Japan’s Nippon Steel for production and sales of automotive cold-rolled flat products at Jamshedpur. • Public sector major Steel Authority of India (SAIL) signed an agreement with Japan’s biggest steel producer Kobe Steel for working together in the field of technology and projects. • In its first quarter (January to March) of 2011 witnessed SAIL extending its relationship with Kobe Steel in jointly building a steel plant in Uttar Pradesh with an investment of Rs 10,000 crore. • The Ruias-owned Essar Africa Holdings acquired 60% equity interest of the government of Zimbabwe in the beleaguered Zimbabwe Iron and Steel Company (ZISCO) to meet the growing regional demand. Essar Steel entered into an MoU with Kobe Steel to produce autograde steel in India. • JSW acquired 41% stake at 2,157 cr in Ispat Industries to build it the leading steel manufacturer in the country. The value of global steel and other metals-industry mergers and acquisitions may double in 2011 to about $60 billion.

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PROSPECTS & POSSIBILITIES

PAVING THE

BOULEVARD OF THE GREAT INDIAN

STEEL DREAM As a key basic industry, steel underpins growth across several downstream industries and the services sector. Among the emerging markets, the structure of Indian economy, market size, strong resource base and relative cost of production is expected to drive relatively higher growth for the steel sector in India over the next decade. In addition, reforms to meet some of the challenges in the investment environment will create an opportunity that will be leveraged by several global sector players, making India a prime investment destination of choice. The global stakeholders’ dream is to access global mega markets and they should find a footprint in India to make it a dream worth pursuing. n a growing global economy, the steel industry is the backbone of modern industrialisation. Key among the basic industries, the steel industry triggers growth across several downstream industries and the services sector. The global steel outlook is optimistic, with seven per cent growth expected in 2011. The BRIC countries – Brazil, Russia, India, China – are tipped to drive maximum growth in the sector. Of the emerging markets, the

structure of the Indian economy, its stage of evolution, market size, growth rate, cost base and potential resource base should drive unprecedented growth in the Indian steel sector over the next decade. Reforms made to the investment environment should attract several global players, thus making India a prime destination for investment in steel. The Indian steel industry has witnessed robust growth during 2005-10, with production (crude steel) and consumption (finished steel) registering a compound

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annual growth rate (CAGR) of 7.05 per cent and 8.50 per cent, respectively. India was the world’s fifth largest producer of crude steel in 2009. This growth has been driven by capacity expansion and improved capacity utilisation. Even in 2010, the steel sector witnessed steady growth and has exceeded the pre-crisis level. As per the World Steel Association, the monthly average production of crude steel up to November 2010 stood at 5.5 million tonne which, when annualised, gives a production of 66 million tonne for 2010.

PROSPECTS & POSSIBILITIES

50 40

industry, such as Tata Steel and SAIL, have vertically 14 integrated to secure raw 12 materials. For example, Tata Steel is self-sufficient in iron 10 ore and coking coal supply, 8 and SAIL is self-sufficient in 6 iron ore but imports most of its coking coal requirement. 4 The rest of the players in the 2 Indian steel industry have 0 varying degrees of selfsufficiency and depend on raw material suppliers to meet their requirements. Iron ore miners, such as NMDC and Sesa Goa, represent around 35 per cent of the iron ore production in India. Though iron ore production exceeds domestic demand, its pricing is impacted by influential global majors. On the other hand, coking coal suppliers have considerable influence on the steel industry as India has a shortfall of coking coal and imports more than 70 per cent of its requirement. The cyclical and volatile nature of prices for both the commodities is a major risk to nonintegrated steel players. • Fragmented customer base drives pricing: The demand for steel depends on the needs of the end-user industries. Currently, supply cannot keep up with industry demand and India is importing cheaper steel from China and special steel from South Korea and Japan. The construction and infrastructure sector constitutes more than 60 per cent of the demand for steel in India. The supply side being more consolidated than the enduser segments generally have a greater influence on the pricing decision. 16

Growth (%)

Million tonnes

CAPACITY ADDITIONS NOT KEEPING PACE WITH THE RISING DEMAND

The Indian steel industry faces 30 a supply deficiency as capacity increases have lagged 20 increases in consumption. 10 Large greenfield projects have not been set up in India over 0 the past few years due to FY05 FY06 FY07 FY08 FY09 FY10F regulatory, social and infrastructure bottlenecks. Growth Consumption Capacity additions in the Source: Annual report 2009-10, Ministry of Steel, Government of India short-term are primarily *Data annualised untill December 2009 brownfield projects by existing Figure 1: Finished steel consumption (2005–2010) players. India imports steel as supply lags demand These companies are expected to India has been a net importer of steel since contribute to the majority of new 2007 and the demand-supply gap is capacity through their brownfield expected to widen over the next five years. projects. Demand in the sector outpaces India imported 2.1 million tonne of steel supply and this excess demand is met by during April-June 2010, which indicated imports. However, several multinational that imports during 2010 may be higher steel companies are keen to enter the than the previous year. Over the next three Indian steel market. Once they set up years, around 20 million tonne of brownfield their operations, there will be greater expansions are expected to become competition for resources, talent and operational, which may reduce steel market share, which will reinvigorate imports in the medium-term. In the competition. long-term, due to the difference between • Minimal threats from steel substitutes: A demand and supply, India may still remain a number of innovations have given net importer of steel as most of the planned aluminum and plastic properties that are greenfield expansions have been delayed comparable to steel. Materials such as due to land allotment laws and environmental carbon fibre, plastic and aluminium alloys clearances issues. have replaced steel in the automobile The competitive landscape industry. However, the usage of these The resilience of the Indian steel industry substitutes is not cost-effective and lacks and its competitive position is summarised some of the inherent qualities of steel. It in the following five forces analysis: seems unlikely that these substitutes will • Low to moderate threats from new replace steel in some key end-user entrants: The steel industry is capitalsegments in the short to medium-term. intensive, and hence, the first barrier for • Vertical integration: Major players in the new entrants is the financial outlay Sector Key opportunities involved in setting up a steel plant. The Power - Government targets adding 1,00,000MW capacity by 2012 set up period in India is also extended - Both generation and transmission capacities being significantly enhanced due to challenges posed by land Oil and gas Pipeline network, city gas distribution, refinery infrastructure installation acquisition and other regulatory and upgrading procedures. These issues have been a Roads and highways - National Highway Development Programme (NHDP) barrier to entry for many global steel - Plans to construct and upgrade more than 50,000km of national highway producers in the past, and many are by December 2015 now undertaking joint ventures with Railways Dedicated Rail Freight Corridor (DRFC) network expansion lagging freight established Indian groups. growth will need to be expedited • Low degree of internal competition: Industry Ports Port traffic is estimated to increase by a compound annual growth rate of competition is minimal as the Indian about 12 per cent during 2010-2012 steel sector is a supplier’s market. About Water and waste The Jawaharlal Nehru National Urban Renewal Mission is expected to 47 per cent of crude steel production management increase steel consumption can be attributed to four major players Figure 2: Opportunities across the infrastructure sector – Tata Steel, JSW Steel, SAIL and RINL.

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PROSPECTS & POSSIBILITIES

Strategic Accelerants Driving Develop Special Purpose Vehicles (SPVs) for Steel Hubs: The ultra mega power project model for adding capacity in power generation has been successful in India. The government can adopt a similar initiative to develop a model in the mining & metals sector. The major issues faced by steel companies in India are land acquisition, forest & environmental clearances, and allocation of raw material resources. A nodal agency, in coordination with state and central governments, can create an SPV for each major project hub, obtain all the necessary clearances and link resources before inviting globally competitive bids to undertake the project. It will help fast-forward capacity addition at most logical locations, address all socio-economic & environmental needs and ensure competition. The premium from the bidding can be partially used to develop local communities and create enabling infrastructure. As these steel hubs will be identified and planned well, the stakeholders (e.g.,

STRONG DOMESTIC DEMAND DRIVERS The key variables for steel consumption in any country are the growth rates of sectors such as manufacturing, consumer durables, construction, capital goods and services. The demand drivers in India continue to be strong and indicate far higher consumption of steel in the coming years. Infrastructure The construction and infrastructure sector is the largest consumer of steel in India, accounting for 61 per cent steel consumption in 2008-09. According to Planning Commission projections, total investment in the infrastructure sector in the 11th Five Year Plan (2007-12) is around US$450 billion and the 12th Five Year Plan (2012-17) expects investment of approximately US$1 trillion, indicating that demand for steel from the sector will remain strong. In FY10, an expenditure of around 7.2 per cent of GDP was spent on infrastructure and the government aims to increase this to around nine per cent of GDP by 2014. Primary demand is expected to come from ports, oil & gas, power and construction in the near future. Mega investments in infrastructure by China have been a prime driver of steel consumption for several years, and India’s huge investment in infrastructure should further fuel this demand. In addition, urbanisation is expected to further increase the demand for steel. The current power deficit will drive capacity additions in India. During the 10th

government, railways, ports, mining companies and steel producers) can chalk out a plan to make the infrastructure more effective and efficient. Expand rural demand: The per capita steel consumption in rural India is around 2-3kg, as compared to the national average of around 60kg, thereby indicating a huge potential market. To capture latent demand, the steel industry can innovate products/ applications to cater to the needs of rural customers. For example, the industry can partner with communities and local bodies to provide lightweight, prefabricated structures to build centers for education and health care. Partnerships can be explored with Panchayat Raj institutions, non government organisations (NGOs) and microfinance institutions, to finance the initial expenditure. Eventually, the higher volumes may help in pricing products appropriately for the market. Improve logistics and supply chain management: Every tonne

Five Year Plan (2002-2006), the demand for power increased at a CAGR of 6.2 per cent and availability by 5.8 per cent, thus widening the deficit. The Government of India envisaged capacity additions of 1,00,000MW by 2012 and launched several initiatives including the ultra mega power projects to address the chronic power shortages. However, capacity additions during the 11th Five Year Plan have fallen behind this target, leaving a widening gap to be bridged during the next plan period. The demand for steel is also expected to come from the huge network of pipelines to be laid over the next few years for oil & gas transportation. It is estimated that the pipeline network for liquid fuel transportation is likely to grow from the present 16,800km to 22,000km in 2014. Other major steel consumers in India are the automobile and capital goods sectors. Demand from both these sectors has grown significantly over the last few years. Automotive The automobile sector grew by 27 per cent year-on-year in 2008-09 and is estimated to continue to increase in double digits as the launch of low-cost passenger cars is likely to expand the market and demand. The production of two-wheelers grew by 15 per cent, while cars, commercial and utility vehicles grew by 26 per cent in 200910, and double-digit growth is expected in the medium-term. With many automobile manufacturers increasing capacity by establishing manufacturing operations in India, not only is the demand for automotive

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Growth

steel expected to be robust, but the highquality, value-added steel segment will also witness immense growth. The auto component industry grew by 20 per cent year-on-year between 2009 and 2010 to reach a turnover of US$22 billion, and is estimated to grow by 18 per cent year-onyear between 2010 and 2011 to reach US$26 billion. Capital goods sector The capital goods sector currently accounts for 11 per cent of steel consumption and has the potential to significantly increase in tonnage and market share. China’s steel consumption of more than 100 million tonne for machinery production is a strong indicator of consumption in this sector. With the return of business confidence, burgeoning internal cash accruals and greater capital availability, corporate India’s capital expenditure plans should remain on a growth trajectory and generate greater demand for steel. The shipbuilding industry is likely to undergo a fast-growth cycle due to increasing seaborne trade and coastal shipping trends, which will further push up demand for steel.

RAW MATERIAL AVAILABILITY Sufficient iron ore reserves India is the world’s fourth largest producer of iron ore after China, Australia and Brazil, and contributed 9.9 per cent of global production in 2009. The country consumed close to 100 million tonne and exported approximately 110 million tonne. Iron ore production grew at a CAGR of 10 per cent

PROSPECTS & POSSIBILITIES

Of The Indian

Steel Industry

of steel produced requires the movement of four tonne of material. Inadequate infrastructure and the immaturity of the logistics sector have significantly impacted the steel industry with serious cost implications. The steel industry should evaluate and pursue the following four initiatives to address the issues: - Transform the network structure by ensuring that material is moving on the most optimal network and mode (around 60 per cent of tonne km is covered through costly road transportation). Investing in creating the nodes at the right location and if required, teaming with integrated logistics service providers (3PL/4PL) to help build the most optimal infrastructure is likely to yield long-term results for the steel industry. Enhanced usage of inland container depot (ICDs), logistics parks, free trade warehousing zones (FTWZ), etc., is also expected to help create a more robust and economic network.

between 2005 and 2009 and reached 226 million tonne in 2009. India has about 25 billion tonne of iron ore resources with a reserves base of 9.8 billion. Though India currently has sufficient iron ore, it must consider the estimated rise in domestic steel production in the near future and work towards increasing its reserve base. Iron ore exports grew at a CAGR of 6.8 per cent between 2005 and 2009, with China taking approximately 90 per cent of these exports. The debate of rationalising iron ore exports in favour of domestic use continues, while the government has followed a mixed policy of increasing the duty on iron ore exports. Coking coal deficiencies India is deficient in coking coal. A significant percentage of Indian steel production is carried out using blast furnaces, with coking coal used as a reducing agent. India has the fourth largest proven coal reserves in the world, but these are low quality and 83 per cent of the total reserve is non-coking coal. Over the last several years, the domestic supply of coking coal has lagged rising domestic demand, and, as a result, India imports a large quantity of coking coal, particularly from Australia. Coking coal constitutes around 34 per cent of India’s total coal imports. India imported 23 million tonne of coking coal in FY10 to meet the total requirement of around 40 million tonne. The demand for coking coal is only going to increase as new steel capacities come online in the next few years, with India’s coking coal requirement expected to reach 90 million tonne by FY2023. Going

- Steel companies should leverage existing logistics assets for better throughput through improvements in maintenance and by planning. - Improve the efficiency of logistics operations as lower turnaround times in the network lead to poor operational efficiency, that, in turn, result in demurrages and detentions. Higher visibility of information along the supply chain, improved planning and collaboration between various service providers would improve the efficiency of logistics operations. Most of the additional costs currently incurred by the steel industry can be attributed to inefficiency in logistics operations. - Optimise the logistics configurations between mines, plants, railways and ports to achieve economies of scale. In fact, mining and steel companies can work together to build infrastructure assets.

forward, the scarcity of coking coal is expected to have a huge impact on the margins of steel manufacturers. The Indian coke industry is dominated by integrated steel players (ISP) as these facilities operate captive coke capacities. The ISPs annually produce around 40 per cent of total coke in India. Secondary steel producers (SSP), which require around 10 million tonne of coking coal per annum, rely mostly on imported coke as they do not possess captive coking coal facilities. The consumption of coking coal is estimated to increase at a

domestic coke market. To meet this gap, captive mining and import of coking coal is expected to grow at a CAGR of around 15 per cent between 2009 and 2014.

CHALLENGES AND ISSUES The Government of India’s plan of reaching 200 million tonne in steel production by 2020 may appear ambitious against the progress made so far. However, relative to what China has achieved over the last 10 years, this target can be achieved. Keeping in mind that India aims to be the world’s

New entrants—low to moderate ► Limited number of new players as industry is capital-intensive ► Global players keen to gain foothold

Suppliers—moderate to high

Internal competition—low

Customers—low to moderate

► The coking coal suppliers have considerable power

► Currently the competition among players is low because it is a supplier’s market.

► Demand is high and currently outpaces supply.

► Sufficient iron ore is available but price is set according to international benchmark

► Entry of global players will intensify competitive landscape.

► Price adjustments barely reflecting cost increase

Substitutes—low ► Steel industry faces a threat from aluminium and plastic industry

Source: Ernst & Young analysis

Figure 3: The state of India’s competitive steel environment

CAGR of 11.6 per cent between 2009 and 2014, whereas the production is estimated to remain almost the same during that period. This is likely to result in further widening of supply and demand in the

second largest producer of steel, there are several constraints and issues that need to be addressed. Many of the risks and challenges are the same the world over, those relevant to India include:

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PROSPECTS & POSSIBILITIES

• Scarcity of coking coal: The availability of coking coal is a key issue for the Indian steel industry because of the scarcity of the resource in the country, which will have a huge impact on the production target. The industry also would have to address the issue of volatility in coke prices, which erodes margins for steel producers. • Raw material price volatility: During 2010, there was a significant rise in global spot prices for raw materials such as iron ore and coking coal, due to a surge in demand from China. However, global steel prices have not increased significantly as demand in the Western world is still below pre-crisis levels. During the year, quarterly coking coal contracts were priced at US$200/tonne and iron ore contracts were priced at US$130/tonne. Steel prices traded in the range of US$575-US$600/tonne. This means that cost pressures are inevitable for non-integrated steel companies in India. However, the extent of the pressure would depend on the level of vertical integration. The level of vertical integration for the three largest steel companies has the following impact: - Steel Authority of India, the largest public sector steel producer, has full integration of iron ore and sells more than 95 per cent of its steel production in India, making it more resilient to changes in global price volatility. However, dependence on coking coal has squeezed margins in 2010. - Tata Steel (India), one of the world’s low-cost steel producers, enjoys healthy margins in its domestic operations as it has full captive sources of iron ore and substantially for coking coal. - JSW Steel lacks full integration within India in iron ore and coking coal, so it is more exposed to changes in raw material prices. All major steel producers in India are trying to secure raw material for their future needs by acquiring mines or entering into joint ventures. However, strict land acquisition laws can slow the process. • Complicated regulatory regime: There are many greenfield projects being planned in India by steel majors. However, the execution and implementation of these projects is presently a gray area in India’s steel growth story. Cases in point are the

greenfield projects of Arcelor Mittal and POSCO, which did not progress even after five years of their announcements. The major issues faced by the companies are related to land acquisition, mining lease securitisation, forest clearances and relief & rehabilitation (R&R) policies. While such challenges are generic to large projects in several parts of the world, India has the following specific issues: - Land required for large projects comes into conflict with the social set up – almost 70 per cent of the land is covered by agriculture and forests, further accentuating the lower landpopulation ratio. - Certain inadequacies in the land acquisition regulations (e.g., definition of public purpose, compensation benchmarking, coverage of displaced persons). - Divergence between states’ and central legislation and procedures. Of late, some projects in the mining and metals sector have been stalled under the Forest Right Act (FRA), which is to safeguard the social rights of the forest-dwelling tribal population residing in that area. The Act allows the players to acquire the land only after the consent of the residents in the area or the people dependent on that area. Most mining resources lie in the tribal belt of the resources rich states of Orissa, Chhattisgarh and Jharkhand, which have recently witnessed local community uprisings. The government is cognisant of the situation and seeks to work out solutions keeping with its inclusive growth agenda. The draft Mining Bill addresses some of these issues. The issues are complex and need sustained efforts towards building a consensus. The industry is also consciously moving to obtain this social licence to operate by partaking in the development of communities and is well advised to address the longer-term sustainability issues. • Inadequate infrastructure: The major impediment to growth in the Indian steel sector is inadequate infrastructure. A robust transport framework is required to support and facilitate the volumes of steel production planned. The lack of availability of quality infrastructure & logistics will have cost and supply chain implications. Huge investments are required in key infrastructure areas such as railways, roads and ports. • Constrained railway haulage capacity:

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The Indian Railway network was more advanced than that of China’s until 1995. Now, it is constraining the growth of the mining and metals sector due to inadequate investment. Over the last 15 years, there has only been a three per cent growth in the railway network. The railway network only has a 30 per cent transportation market share, despite being a cheaper and faster mode of freight movement than road. To help Indian Railways gain a bigger share of the freight market, in 2005, the Government of India offered licences to private players to start container operations in the country. However, the rail container sector still accounts for only about one per cent of the cargo handling market. • Congested ports: About 70 per cent of the total port traffic in India is handled by the western ports of Jawaharlal Nehru Port Trust (JNPT), Mundra, Kandla and Pipavav. The port traffic is estimated to increase at rate of approximately 12 per cent between 2010 and 2012. The port development plan established by the Government of India in FY06 predicted port traffic of 1,009 million tonne with planned capacity of major ports to be 1,002 million tonne by FY12. However, actual capacity additions are lagging. Currently, Indian ports face issues such as low productivity, high costs and large vessel turnaround periods. With dependence on low ash coking coal and export/import of steel set to increase in the future, the importance of port infrastructure to the steel industry cannot be underestimated. Inadequate road infrastructure Roads carry 57 per cent of the freight traffic in India. The flexibility and ‘last mile connectivity’ that road transporters offer have increased their share of road haulage, even though road transport is more expensive than rail. Of the total road length of 3.3 million km, national & state highways comprise six per cent, with almost no expressways. National highways comprise only two per cent of the total road length, but carry 40 per cent of the total road traffic, which indicates the stress suffered by the existing road infrastructure. The steel production target will require increased haulage via the road network, thus the road network must be expanded and upgraded.

AMBITIOUS FUTURE PLANS The Indian steel industry is expected to

PROSPECTS & POSSIBILITIES

experience robust growth, as long-term positive indicators (such as strong demand from key end-use sectors and iron ore availability) exceed challenges (such as land allotment issues, shortage of coking coal and environmental clearances). The goals set by the Government of India to enhance the growth of the steel sector are encouraging and reflected in the number of memorandums of Understanding (MOUs) the central and state governments have signed for greenfield projects. Steel growth has a direct correlation with the GDP growth of a country and as a basic industry, it propels downstream industrialisation as well. Hence, it is expected to remain in the key sector for the government. Great potential ahead due to rising demand The Indian steel industry, backed by strong fundamentals, has made significant progress in recent years. Even during the economic slowdown, the industry succeeded in sustaining positive growth, driven by strong domestic demand from the construction, automobile and infrastructure sectors. The progress made by private sector players in brownfield expansions is significant. There is much upside in per capita consumption of

steel in the country from its low base of around 60kg, with the increasing demand expected to lift the per capita consumption to much higher levels. Capacity additions by major steel producers to meet increasing demand India was the world’s fifth largest producer of crude steel in 2009 and is expected to become the world’s second largest producer by 2015-16 if all planned capacity expansion projects become operational. The projects that are expected to become operational in the next three years include those by Tata Steel, JSW Steel, SAIL and Essar. Based on collated data and estimated project completions, the total crude steel capacity in India is expected to be around 112 million tonne by 2015 – a growth rate of nine per cent. International steel majors are expanding their Indian presence Attracted by the growth potential of the Indian steel industry, several global steel players have been either planning to enter the market or have announced expansion plans for their Indian businesses. For instance, Arcelor Mittal and POSCO have planned mega greenfield projects at various locations in India. Some global players have

entered strategic partnerships or joint ventures with Indian steel majors as they feel that greenfield projects may take longer to become profitable, while established companies already have their existing customer base in the region. For instance, Arcelor Mittal has acquired a significant stake in Uttam Galva, while Sumitomo Metal has partnered with Bhushan Steel for technological and marketing collaboration, which may be extended to equity participation in future greenfield projects. JFE has also joined JSW Steel as a strategic partner, with a 15 per cent equity share. SAIL has entered into a joint venture with POSCO to have FINEX technology at its Bokaro plant. More strategic alliances and joint ventures are in the pipeline. India’s huge appetite for steel consumption and its steel production plans appear to be in line with expected demand over the next few years. However, the country and all stakeholders need to work on resolving the challenges to enable these ambitious plans for the sector to be met. Courtesy: The article is an excerpt from the report, ‘global steel 2011’ by E&Y.

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STEEL SUPERPOWERS

SHOULD INDIA EMULATE CHINESE STRATEGY? The global steel industry has been experiencing ups and downs for the last three years. Amidst this turmoil, China and India were the two countries which could withstand the turbulence and deliver positive growth figures. Though India does not need to emulate the volume achieved by China, the production must accelerate to meet the robust demand growth. The extent of increase in production growth rates will depend on how stakeholders address the challenges.

Growth (%)

ver the last per cent of GDP during the 20 decade, 12th Five Year Plan (2012-17). The difference between C h i n a 18 the two economies has been witnessed 16 the level of lending to the exponential 14 infrastructure sector. On an growth in its 12 average, lending to steel industry, registering a infrastructure as a percentage CAGR of 17.2 per cent in 10 of total lending in China was production and 14.3 per cent 8 around 28 per cent and in in consumption. In absolute 6 India, it was around 10 per terms, China is expected to cent between FY04 and FY10. produce 630 million tonne of 4 However, in India, lending to steel in 2010 – around 47 per 2 infrastructure also grew to 13 cent of global steel production 0 per cent in 2010 versus 7.9 versus 151 million tonne in 2006 2007 2008 2009 2010 2011F per cent in FY05, to support 2001. The ongoing debate is increased project activity. whether India should aspire to Real GDP growth of China India’s GDP data for the grow to such levels and, if Crude steel production growth of China past few years indicates that required, whether it can Real GDP growth of India the economy is on a strong replicate China’s growth Crude steel production growth of India growth path. Steel model in the sector. Source: IHS, Global Insights, ABARE, World Steel Association consumption, which is China’s reforms began 13 Figure 1: Crude steel production and GDP growth of China and India positively correlated to GDP, is years before that of India. Even at the commencement of the reform process, China was a more Parameters China to India’s lag Elements China India industrialised economy – industry and India ratio in years Reforms started 1978 1991 constructionfu constituted 48 per cent of its GDP 3.8 11.0 GDP composition – industry and 48% 27% GDP – in comparison to 27 per cent for Industrial output 8.0 18.0 construction – at the start of reforms India when it initiated its reforms in 1991. Steel production 12.3 18.0 Share of investments in GDP 38% 25% China has continued to focus on expenditure at the start of reforms Car sales 5.0 6.0 infrastructure. Share of investments in GDP 48% 32% Bank loans 9.2 16.0 Its share of investment in GDP expenditure (2009) Source: Sizing up India and China, IIFL, November 1, expenditure accelerated from 38 per cent 2010, via Thomson Research Share of investments in incremental 52% 38% to 48 per cent during the reform journey, GDP over five years while India’s grew from 25 per cent to 32 China has invested heavily in Share of consumption in incremental 31% 56% per cent. In 1991, China produced 71 infrastructure development to sustain GDP over five years million tonne of steel, which grew to 127 high economic growth during the Source: Sizing up India and China, IIFL, November 1, 2010, via million tonne by 2000. In the same period, period. Investment in infrastructure Thomson Research India grew its steel production from 17 development increased significantly after *Note: All ﬁgures are for 2009 or end of 2009 unless otherwise stated. For India, data is for the 12-month period ending in million tonne to 26 million tonne. the country’s GDP crossed the US$1March of the subsequent year. In China, when steel production picked trillion mark. Figure 2: Comparison of China and India up pace after 2000 and grew exponentially This, in turn, fuelled the growth in anticipated to grow in the coming years to around 630 million tonne in 2010, this China’s steel industry. India is currently in line with the expectation that GDP growth was not surprising as almost 52 per cent of following a similar trend. The country’s will continue in the eight per cent-plus China’s incremental GDP over the past five GDP crossed the US$1-trillion mark in range. Like China, the Indian steel sector years has gone into investment. Although 2009 and investment in infrastructure growth will also be infrastructure-driven. India registered significant growth during accounted for 7.5 per cent of GDP – one of this decade, in absolute terms, China’s steel the highest globally. Infrastructure Courtesy: E&Y production is 12.3 times that of India. investments are expected to be close to 9.9

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Illustration By Uttam Rane

STEEL SUBSTITUTES

According to Michael Porter’s five forces model, a critical factor that drives market competition is the threat of substitutes. The steel industry also faces a similar threat with aluminium and plastic slowly getting into the limelight as substitutes in various sectors. Despite this, a major factor that favours the use of steel is its multiple properties, which offers a fillip to this industry’s applicability in all facets of the manufacturing vertical. SUMEDHA MAHOREY

he steel industry has been 80 per cent of steel products consumed by a major enabler for all automakers. Amid such huge demand from manufacturing verticals sectors such as automotive, aviation and since the last couple of construction – the variants as well as centuries. From automotive substitutes of steel are much in demand. to aviation, no sector can The substitutes of steel include aluminium, perform without this quintessential metal. magnesium, plastic, resins, etc. When we zero in on India, a major SUBSTITUTES ON THE RISE manufacturer of steel, big furnaces with As per the Michael Porter’s five forces fuming hot iron being poured into moulds model, threat to substitute products exists reminds one of the kind of industrialisation when a product’s demand is affected by the that the country has witnessed in the last change in demand as well as the price of the decade. In the 2010 global steel rankings, substitute. As a substitute product replaces India stood as the fourth largest steel the existent product due to benefits such as producer in the world with 68.3 MT multiple variants, quality and efficiencies production, according to the World Steel such as lower carbon emission, etc., the Association (WSA). India had produced demand for the original decreases. Also, the 63.5 MT steel in 2009. With 626.7 MT production, China maintained the top position with 109.6 MT output, Japan The demand for steel is growing. Thus, I was the second highest producer. do not think that there is a threat to steel Today, steel is one of the most manufacturers because steel’s strength to consumed materials in the automotive weight ratio is very low as compared to industry, and especially flat products other alternatives like aluminium. such as hot rolled, cold rolled and SG Kulkarni, Independent Consultant, Metallurgy coated steel sheets account for about

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propensity of customers to switch to alternatives increases as the perceived level of product differentiation is achieved. With the number of substitute products increasing in the market, the threat level increases and the relative pricing of the original product is directly affected. Sometimes the substitute is far more easy to use, depending on its availability as well as applicability. In this situation, the market of the original product is adversely affected. Talking of steel, in the recent years, the market has witnessed a sudden surge in the use of aluminium, reinforced plastic and resins as they not only offer the long-term goal of reducing the weight of vehicles to increase fuel efficiency, but also ensure rustproof durability. Even as the automotive industry, which is the main consumer of the Indian steel production, is growing at a rapid rate, the demand for steel is gradually decreasing as companies are now exploring newer light materials, aluminium, magnesium, titanium, plastics and carbon fibre to replace

STEEL SUBSTITUTES

FACFACT T

steel – 50 to 60 per cent of a Aluminium has replaced iron and steel in certain automotive applications where there has vehicle – in order to meet the applications. This may happen in newer applications as been substitution by new emission norms as well as bring well. These are gradual changes and nothing that threatens materials. However, generally about weight reduction to speaking, the proposed steel overnight. Clearly, the first step for steel manufacturers infrastructure build-up would enhance fuel efficiencies. The is to develop products for all the automotive applications mean the demand for steel and use of substitutes not only helps – at present, imports cater to some of these applications. reduce weight, but also aluminum would be strong for improves fuel efficiency. In many years to come.” addition, it reduces the cost factor as perpresent, artificially suppressed and their PRODUCT INNOVATION: A vehicle steel consumption is well over one selling price is lower than their manufacturing SOLUTION? tonne. Moreover, fuel efficiency rises by 5price. Today, many people are importing With aluminium fast replacing steel, at least 10 per cent for every 10 per cent reduction steel from China and quality-wise, the in the automotive industry, the need of the in vehicle weight. Substitutes also offer imported steel is satisfactory as compared hour is to create products for all automotive improved properties and performance as to the domestic product. But in the long applications. Commenting on the same, compared to steel. run, how the import of steel from China Kandaswami elaborates, “Aluminium has Supporting this, SM Kulkarni, Joint will affect the Indian market depends on the replaced iron and steel in certain automotive President – Technology, Hindalco Industries, Chinese Government’s policy on currency applications. This may happen in newer says, “Due to factors such as growing valuation. The moment a parity is brought applications as well. These are gradual competition and high cost of production, into effect, India would be more changes and nothing that threatens steel companies are now looking for new competitive.” overnight. Clearly, the first step for steel engineering materials to make lightweight Though, this sector is witnessing a manufacturers is to develop products for all passenger cars. Aluminium is the metal of constant growth, certain issues have been the automotive applications – at present, the future due to its lightweight properties challenging the steel industry since the last imports cater to some of these applications. and durability. Aluminium cast components five years. Highlighting this, Kumar Substitution has been forced on the auto are extensively used for manufacturing highKandaswami, Leader – Manufacturing, sector by the emission requirements where end luxury cars. However, in India, the Deloitte India, avers, “The challenges need steel manufacturers are not able to do amount of aluminium used in the automobile to be looked at in two parts – the issue anything with the available technology.” industry is very less as compared to other related to the metal processing companies Thus, for new product development, developed economies. Indian companies and the threat of substitution. As far as product innovation is a must at this stage – are yet to discover the benefits of aluminium issues faced are concerned, the challenge products that can curb the use cast components.” But as we discuss the Even as the automotive industry, which is the main of steel substitutes as well as increasing use of substitutes, we consumer of the Indian steel production, is growing at a suffice the increasing demands from sectors such as must also take into consideration rapid rate, the demand for steel is gradually decreasing construction, automotive and the rising demand of steel. Over the last decade, both, the as companies are now exploring newer light materials, aviation. Supporting this, demand for steel as well as steel aluminium, magnesium, titanium, plastics and carbon Kandaswami highlights, “Given the cost pressure on the production has gone up. fibre to replace steel – 50 to 60 per cent of a vehicle – in consuming sectors, any Growth in manufacturing and order to meet the emission norms as well as bring about innovation to offer superior infrastructure has fuelled the price-performance propositions demand for steel products, weight reduction to enhance fuel efficiencies. would help. Further, given the thereby driving growth in the state of evolution of India’s steel sector, it is sector. Exports have been growing steadily that must occupy senior executives is of likely that the substitution in most sectors at a compound annual growth rate (CAGR) input costs. Relative to most of the countries would occur in India after it has happened of approximately 20 per cent; but imports India competes with, the manufacturers elsewhere – to that extent, there would be have also grown at double the rate. suffer from higher raw material, power and time for manufacturers to get prepared. Highlighting this, SG Kulkarni, Independent logistics costs. In many cases, the scale of Lastly, rather than discussing what will Consultant, Metallurgy, claims, “The operations is not at par with global replace steel, manufacturers should look at demand for steel is growing. Thus, I do not competitors and this adds to the cost what can steel replace. The pre-engineered think that there is a threat to steel pressure. Further, not all manufacturers in buildings sector is a good example of how manufacturers because steel’s strength to India operate in the high-end, high new applications can develop for steel.” weight ratio is very low as compared to realisation products on account of low Some of the sectors that steel other alternatives like aluminium.” focus on R&D. This is likely to be a significant manufacturers can aim at include the capital/ The import of steel has been majorly long-term weakness for Indian industrial goods sector, which, at present, from China and Korea. Elaborating on the manufacturers. This further makes imports steel for some of their applications. effect of the Chinese currency on the steel companies compete primarily on costs, If targeted in time, domestic steel market in India, SG Kulkarni opines, “It is a where they are not well placed.” manufacturers can aspire to offer them matter of time that China will have to form He says, “As far as substitutes are locally manufactured steel. a currency parity, their currency is, at concerned, it is true that there are

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STEEL SUBSTITUTES

Due to factors such as growing competition and high cost of production, companies are now looking for new engineering materials to make lightweight passenger cars. Aluminium is the metal of the future due to its lightweight properties and durability. Aluminium cast components are extensively used for manufacturing high-end luxury cars. However, in India, the amount of aluminium used in the automobile industry is very less as compared to other developed economies. Indian companies are yet to discover the benefits of aluminium cast components. SM Kulkarni, Joint President – Technology, Hindalco Industries Though product innovation can be one of the solutions, SG Kulkarni believes that there is no immediate threat to the Indian steel sector. Commenting on the same, he says, “Today, the demand for steel is huge, including road building, automotives and other engineering applications. There is a spurt of growth, which is supported by steel manufacturers in one way or the other. So do not think that steel manufacturers have an immediate threat from that angle. Demand is rapidly rising and investments in this sector that were made few years back are now bringing in dividends. Also, the steel industry has performed very well in terms of modernisation and improving the yield in terms of input material to finished steel.” Even as the threat due to substitute of

steel is rising, a major point in favour of use of steel remains the multiple properties that can be obtained from it. This remains as a competitive factor when it comes to the selection of steel over other substitutes. Asserting this, SG Kulkarni avers, “Steel shows many variable quantities by changing the composition as well as the treatment. We can have a wide variety of properties that can be obtained from steel. That remains a vital criterion to choose steel as the raw material. But new materials are still catching on, like aluminium, non metallics like SRP composites, which reduce the number of steps in manufacturing. These substitutes also show good resistance to corrosion and impact. It is quite possible that substitutes might come up in a big way and replace steel. At present, up to 30-35

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per cent of the auto component is made of non-metallics. This can go up to 40-45 per cent in the long run.”

FUTURE OF STEEL With the discussion neither in favour of steel nor its substitutes, one thing is certain. The use of steel cannot be eliminated though it can be reduced for benefits such as rustfree durability and weight reduction. If one industry is looking at reduction in the use of steel, there are other avenues where manufacturers need to focus on like capital or industrial goods. Also, bringing in variants with effective research & development and technological support will boost this industry’s applicability in all facets of the manufacturing vertical.

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BAN ON IMPORT OF SUBSTANDARD CRGO

A WELCOME

MOVE FOR THE

TRANSFORMER INDUSTRY The use of defective cold rolled grain-oriented (CRGO) steel sheets had been causing major losses to the transformer industry since the past many years. With the decision to ban the import of substandard CRGO in place, the transformer manufacturers have heaved a sigh of relief and steel manufacturers have come across a new opportunity, which will help them meet the demands of the industry. SUMEDHA MAHOREY

he cold rolled grainoriented steel sheets (CRGO) constitute about 35 per cent cost of a power transformer and are in India’s free trade list. The electrical sheets are produced in eight countries of the world, including Japan, Korea, France, Russia, the US and UK. As per a recent statement by Indian Transformer Manufacturers Association (ITMA), by and large unscrupulous CRGO importers/traders and transformer manufacturers have been importing defective/seconds CRGO for manufacture of transformers, which have adversely affected State Electricity Boards/Utilities as distribution transformers fail within three to four years of installation against the life span of 20 to 25 years. Even defective CRGO finds its way in manufacture of power transformers in view of the intense competition in a bid to secure the orders for supply. In this connection, ITMA has been making consistent efforts with Ministry of Steel, GOI to get the import of defective CRGO banned for the last 10 years, but the results were not forthcoming due to red tapism. The Steel Ministry issued a quality control order on June 24, 2011, mandating Bureau of Indian Standards certification for CRGO.

SUCCESS AT LAST ITMA again took up the matter vigorously with Ministry of Steel and Ministry of Power to reopen the case so that the import of defective CRGO is banned and only prime material is imported. ITMA’s efforts ultimately yielded results on June 24, 2011 when the Quality Control Order has been issued to Ministry of Steel for CRGO (IS

3024) and CRNO (IS 648) and CRNO 15391 for BIS certifications. With the mandate in place, the domestic manufacturing of CRGO will get a major boost. Commenting on the attempts, B Lal, Director General, ITMA avers, “About two decades ago, SAIL ventured for number of years to achieve success in commercially producing CRGO at its Rourkela Steel Plant, and finally the exercise was abandoned. In fact, the quality was inferior and the cost of the material was more than the imported material. Similarly, Raymond Steel at Nashik also laboured hard for production of CRGO and the plant was ultimately sold to Thyssen, the German Steel Company. Of late Government of India has initiated a move to manufacture CRGO in India and is in touch with some Indian owned companies in their subsidiaries overseas. Tata Steel has the technology available with Corus (Cogent at ORB Steel works) in the UK, and also ArcelorMittal manufacturers CRGO in their European and Brazilian plants. Further, POSCO is already considering setting up CRGO steel manufacturing at its greenfield venture in Orissa and JFE is in discussion with JSW for manufacture of CRGO in India and transfer of technology. The indigenous production shall at least take 3 to 4 years where after the material availability will be ample thereby saving lot of foreign exchange, besides it will have export market as well.” Highlighting on how to ascertain whether a defective CRGO is used in the transformer, Lal explains, “Transformer manufacturers although claim to use only prime material but factually seconds/ defective material do find way in the manufacturing of transformer as apparently there is no other use of the material.

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Basically there is no method to ascertain which lot is defective unless there is some mark stamped by the mill. As such, the transformer having defective material cannot be called back, which is in service. However, it can be ascertained only when the transformer fails prematurely against its life span of 20 to 25 years, which may indicate the use of defective CRGO as one of the reasons of failure amongst other causes.”

PROMISING PROSPECTS With the recent decision of the government, the use of prime CRGO will definitely pick up in the industry. Additionally, it will help transformer manufacturers compete on the quality front in the Indian market. Elaborating on this, Lal says, “With the use of prime material the quality of the output/final product would definitely improve resulting in rendering better service to the users. The profit margins of the manufacturers, who are using defective materials would get adversely affected with the use of prime material but may not affect the pricing of the final product due to intense competition. The main advantage would be to the utilities whose commercial losses would get reduced to some extent and indirectly reduce carbon foot print in the environment besides gain to the national industrial production due to assured continuity of power supply.” Meanwhile, the industry reaction to the decision has been a welcoming one. The transformer industry and the utilities have hailed the order of Government of India. With the directive in place, the transformer industry and steel manufacturers have got opportunities that were overlooked since the past many years.

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AUTO & INFRASTRUCTURE IMPACT

CALLING FOR DISRUPTIVE

DEMAND-SUPPLY DYNAMICS India is geared to become the steel powerhouse of the world by investing in the latest and efficient technology. This unprecedented growth has attracted many global steel players to India with several of them setting up greenfield projects, forming strategic partnerships or entering into joint ventures with Indian steelmakers. To meet the increasing demands, all steel majors in India seek to expand their capacities mainly through brownfield expansions. However, considering the overall requirement for steel, it will be important for greenfield capacities to emerge. ndia occupies an important in energy efficiency and backward integration positive economic growth, with a compound position on the global steel into global raw material sources. annual growth rate (CAGR) of over 8.2 per map. It is the third largest India was the fourth largest producer of cent over the last five years, the overall user of steel after China & crude steel in the world in 2010 and is demand for steel in 2010-11 stands at the US and accounts for poised to become the world’s second around 68 million metric tonne, with a over five per cent of the largest producer of crude steel by 2015. growth rate of 14 per cent. The infrastructure world’s total consumption. There has been The country maintains its position as the and automotive segments contributed to increased activity in the steel sector in India world’s largest producer of direct reduced over 75 per cent of the total demand. with the establishment of state-of-the-art iron (DRI) or sponge iron. Fuelled by Compared to 2009-10, the demand steel mills, domestic and global growth during 2010-11 in mergers & acquisitions, infrastructure and automotive Government Investments in the Infrastructure Segment: continuous modernisation and segments stood at 28 per cent Volume & Pattern upgradation of older plants, and eight per cent, 10th five year plan (2002–03 to 2006–07) $226.5 billion foreign technological respectively. 11th five year plan (2007–08 to 2011–12) $514 billion collaboration, improvements To meet the increased

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FAC TFACT

AUTO & INFRASTRUCTURE IMPACT

The projected finished steel supply level in 2012-13 is expected to be 95 million MT, and this supply level is anticipated to reach 162 million MT by 2019-20 through greenfield and brownfield expansion plans. The demand is expected to be around 166 million MT during the same period, thereby resulting in a minimal deficit, provided the expansion plans are all executed within their stipulated timelines and are not held up due to factors such as environmental clearances, and land acquisition issues.

demand for steel and take advantage of high growth markets, existing integrated plant owners like SAIL, JSW Steel, Essar Steel and Tata Steel are expanding their capacities on a large scale, and small & medium steel plants (viz,. secondary producers) have also drawn up large investment plans, which are: SAIL plans to invest around $16 billion to increase its capacity from 14.35 metric tonne per annum (MTPA) to 23.46 MTPA by 2013. JSW Steel has planned investments of over $16.86 billion to ramp up its capacity to 32 MTPA through greenfield and brownfield projects. National Mineral Development Corporation (NMDC) through a joint venture with Severstal plans to set up a 2 MTPA steel plant in Karnataka for manufacturing automotive grade steel. According to ‘The 2010 AT Kearney FDI Confidence Index’, India ranks third as the destination for foreign investors. Foreign direct investments (FDIs) in the Indian steel industry have shown a remarkable increase in the recent years due to increasing domestic demand attractiveness and the presence of large-scale indigenous iron ore deposits of over 25 billion tonne (BT), of which 28 per cent falls in the proved category. Companies investing in the Indian steel industry include: ArcelorMittal, which plans to set up 12 MTPA plants in Orissa and Jharkhand at a cost of over $10 billion each. It has also signed a pact with the Karnataka Government for a 6 MTPA plant at $6.5 billion. POSCO plans to set up a 12 MTPA plant worth $12 billion at Orissa and a plant worth $ 7 billion at Karnataka. JFE Steel Corporation has invested over $1 billion for acquiring a 14.99 per cent stake in JSW. The dynamics of the steel industry continue to change at a quick pace; demand has outpaced domestic supply and imports have increased in the last 3-5 years. India became a net importer of steel in 2009-10

after a while. However, this scenario is expected to reverse with a domestic capacity addition of over 25 MTPA over the next two years. India is expected to become a net exporter by 2013.

INFRASTRUCTURE The rapid growth of the Indian economy in recent years has placed increasing stress on the infrastructure segment viz., power, railways, roads, ports, airports, irrigation, urban & rural water supply and sanitation. To address this deficit, huge investments are being planned by the government and are being implemented across sectors. During 2006, the government announced a Special Purpose Vehicle – the India Infrastructure Finance Company – to lend funds for large infrastructure projects. This programme showcases the government’s focus to address and reduce the infrastructure deficit in India. The investments allocated for better infrastructure creation in power, roads,

12th Five Year Plan is estimated at around $1,025 billion. Infrastructure investment of $514 billion is expected to generate steel demand to the tune of about 125 million MT over a period of five years. However, the year-on-year future demand varies based on the funding pattern, fund releases and project stage. The finished steel consumption in the infrastructure sector is estimated at around 60 per cent of the total consumption. The demand is pegged at 40 million MT in 2011-12 and is expected to increase to be 60 million MT by 2014-15. The steel consumption in the infrastructure segment is anticipated to be primarily driven by government and private investments.

AUTOMOTIVE The overall automotive segment (comprising the passenger, commercial, three-wheeler, and two-wheeler segments) production volume is estimated to grow at a CAGR of 10.3 per cent over the next five years. The growth of production volume of passenger vehicles is expected to be the highest at a CAGR of 14.5 per cent, followed by that of two-wheelers at 10.3 per cent, over the next five years. The key growth drivers are the growing population with increased income & spending levels and attractive financing options. Government policies and initiatives

Production volume (in million) growth: CAGR %, FY 2011–15 16% 14.5% 12% 10.3% 9.5%

8% 7.0% 4% 0% Passenger Vahicles

Commercial Vahicles

Three Wheelers

Two Wheelers

Source: siam, frost & sullivan analysis

telecommunication, railways, irrigation, water supply, ports and airports in the 11th Five Year Plan are around $ 514 billion. Of the total amount, private investment increased to 30 per cent, from 17 per cent during the 10th Five Year Plan, with the government contributing the balance amount. The projected investment level in the

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are positive, in order to bring in new investments into the automotive segment. Factors such as skilled human resource talent pool, low-cost sourcing abilities and increased domestic demand have made India an attractive destination for global automakers and auto component manufacturers, for both their technology and manufacturing platforms.

AUTO & INFRASTRUCTURE IMPACT

The restraints are increase in fuel prices, be land acquisition and environmental auto OEMs requirements through R&D freight charges, infrastructural bottlenecks clearances for mining activities. The activities through technological collaborations and fluctuating interest rate scenarios. Other projected finished steel supply level in with Japanese steel majors like Kobe Steel, factors are policies pertaining to emission 2012-13 is expected to be 95 million MT, Daido Steel, etc. They are also entering norms (levels), aging norms and loading and this supply level is anticipated to reach into enhanced capacity addition through limits in the commercial vehicle segment. 162 million MT by 2019-20 through joint ventures with foreign companies. The automotive steel greenfield and brownfield demand in 2011-12 is The automotive steel demand in 2011-12 is anticipated expansion plans. The demand is anticipated to be around 3.7 to be around 3.7 million MT, with cold rolled products expected to be around 166 million MT, with cold rolled million MT during the same accounting for over 65 per cent. The demand is expected period, thereby resulting in a products accounting for over 65 per cent. The demand is minimal deficit, provided the to reach 5.5 million MT in the next five years. expected to reach 5.5 million expansion plans are all executed MT in the next five years. Passenger cars, within their stipulated timelines and are not The demand for high strength steel is closely followed by the commercial vehicles held up due to factors such as environmental expected to increase significantly in the segment are expected to drive steel demand clearances, and land acquisition issues. future and OEMs are anticipated to rely on in the automotive segment. The key reasons imports. The reasons for imports are due Courtesy: Metals & Minerals Practice, South Asia, are the high steel consumption norm, per to demand growth and non availability & Middle East and North Africa, Frost & Sullivan vehicle category (steel forms about 60-65 non compliance to quality expectations. per cent of the total weight of the vehicle) EXPANSION IS KEY and the high production volume growth. To meet the increasing demand levels, all The automotive original equipment START-UP STRATEGIES: steel majors in India have plans to expand manufacturersâ&#x20AC;&#x2122; (OEMsâ&#x20AC;&#x2122;) reliance on steel Gridbots Technologies their capacities. This is currently taking place import is relatively high due to the non Building Intelligent primarily through brownfield expansions. availability of specific high strength steels Machines However, considering the overall (such as Advanced High Strength Steel, requirement for steel, it will be important Dual-phase Steel and TRIP Steel) at the for greenfield capacities to emerge. desired quality levels. However, domestic on pg. Challenges for greenfield expansions would suppliers are trying to develop and match

124

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NEW AGE STEEL PRODUCTION PROCESSES

INSPIRING INNOVATIONS The steel making industry has undergone a rapid transformation over the decades and the global steel outlook for 2011 is cautiously optimistic as the possibility of a double-dip recession has eased. Growth in developing economies will remain strong and continue to boost total global steel demand. Yet there is a need for the industry to offer consumers value added products rather than mere alternatives. Therefore, the steel industry ought to adopt the right technology to boost its growth prospects. Here’s a sneak peek into new age steel production processes that are sure to offer manufacturers a competing edge...

HOT-ROLLED BLACK STEEL PICKLING PROCESS Innovation: American sheet metal specialist, Red Bud, is pushing a new ‘green’ acid pickling process of hot-rolled black steel, while it is said to open pickling up for use by smaller activities, such as material distributors and service centres. Functionalities: The new process, called Eco Pickled Surface (EPS), has been used to process millions of kilogram of material, claims the company, and is proven to be interchangeable with acid-pickled material for roll forming, stamping, laser and plasma cutting, as well as punching and tube production. EPS coils have also been successfully cold reduced, annealed and galvanised. Additionally, the EPS process can be changed from one job to the next to produce a rougher or smoother surface, based on the intended use of the finished product. The process can produce a designer finish on the material, which is clean and uniform and can mitigate minor flaws such as roll marks or pitting. Applicability: Used for decades, traditional acid pickling uses strong caustic acids to remove scale and dirt from the material. While progress has been made to reduce the impact that this chemically based process has on the environment, many issues persist, says Red Bud. Process: The EPS process does not use acids to strip scale and dirt from the steel, but, rather, a wet slurry, which should not be confused with shot blasting, as it is a very different and less productive dry process, says the company. EPS sees a slurry spray, which consists of an engineered angular grit, a cleaning agent, corrosion inhibitor and water, fed into a series of impellor pumps that spray the slurry across the steel. The result is pickled steel without the environmental issues of acid-pickling. The closed-loop slurry system does not discharge any effluent. The EPS process is currently operational in the US and in South Korea.

CHEMICAL BONDING PROCESS ADD NEW FUNCTIONS TO STEEL Innovation: A new chemical bonding process can add new functions to stainless steel and make it a more useful material for implanted biomedical devices. Developed by an interdisciplinary team at the University of Alberta and Canada’s National Institute for Nanotechnology, this new process was developed to address some of the problems associated with the introduction of stainless steel into the human body. The process: Implanted biomedical devices, such as cardiac stents, are implanted in over two million people every year, with the majority made from stainless steel. Stainless steel has many benefits – strength, generally stability and the ability to maintain the required shape long after it has been implanted. But it can also cause severe problems, including blood clotting, if implanted in an artery, or an allergenic response due to the release of metal ions such as nickel ions. For the transplantation goals of the project, sophisticated carbohydrate (sugar) molecules need to be attached to the stainless steel surface to bring about the necessary interaction with the body’s immune system. Its inherent stainless characteristic makes stainless steel a difficult material to augment with new functions, particularly with the controlled and close-to-perfect coverage needed for biomedical implants. The Edmonton-based team found that by first coating the surface of the stainless steel with a very thin layer – 60 atoms deep – of glass silica using a technique available at the National Institute for Nanotechnology, called Atomic Layer Deposition (ALD), they could overcome the inherent non-reactivity of stainless steel. The silica provided a well-defined ‘chemical handle’ through which the carbohydrate molecules prepared in the Alberta Ingenuity Centre for Carbohydrate Science could be attached. Once the stainless steel had been controlled, the researchers demonstrated that the carbohydrate molecules covered the stainless steel in a highly controlled way and in the correct orientation to interact with the immune system.

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NEW AGE STEEL PRODUCTION PROCESSES

FLASH PROCESSING Innovation: A Detroit entrepreneur recently introduced a new process, a heat-treatment that makes steel seven per cent stronger than any steel on record – in less than 10 seconds. The steel, now trademarked as Flash Bainite, has tested stronger and more shock-absorbing than the most common titanium alloys used by industry. The genesis: The entrepreneur is working with researchers at Ohio State University to get a better understanding of the science behind the new treatment called flash processing. Gary Cola, the inventor, has a proprietary lab setup at SFP Works, LLC, where rollers carried steel sheets through flames as hot as 1100ºCelsius and then, into a cooling liquid bath. Though the typical temperature and length of time for hardening varies depending on the industry, most steels are heat-treated at around 900ºCelsius for a few hours, while others are heated at similar temperatures for days. Cola’s entire process took less than 10 seconds. He claimed that the resulting steel was seven per cent stronger than martensitic advanced high-strength steel. Cola further claimed that his steel could be drawn, i.e., thinned and lengthened, 30 per cent more than martensitic steels without losing its enhanced strength. If that were true, then Cola’s steel could enable carmakers to build frames that are up to 30 per cent thinner and lighter without compromising on safety. Or, it could reinforce an armored vehicle without weighing it down. Future: What they have discovered may hold the key to making cars and military vehicles lighter, stronger and more fuelefficient.

T-STEEL Innovation: Astra Mining, an Australian diversified mining company, has received an independent expert opinion from Hungary University of Miskolc confirming the potential of its revolutionary new steel manufacturing process. Astra claims that the end product, T-Steel, is significantly stronger than regular steel and provides vast production, operational and environmental benefits. The company has taken the opportunity with the devolution of the Eastern bloc countries to acquire the technology and roll it out globally. Dr Jaydeep Biswas, CEO, Astra Mining, said, “It also confirms that the CO2 emission in its manufacture can be up to two times less than the emissions with traditional steel making technologies, thereby reducing a manufacturing plant’s carbon footprint, which is highly beneficial to the environment. Astra has a substantial 30 per cent ownership of T-Steel IP and has full operational and management control of its business, so we are very excited to receive this independent verification.” The genesis: The basic product, which includes the use of unique alloy-based formulas invented over a 30-year period in Hungary is based on a process, which can modify the metallurgical properties of steel at a molecular level. Dr Biswas said, “T-Steel can be produced by the existing steel mills with little or no retrofitting needed. However, this can only be done if the mills have access to T-Steel technology and the correct steel plant operation conditions.” Future course of action: Astra is in negotiations for a long-term cooperation agreement with one of the world’s largest steel traders for DAM Steel Works in Hungary, which will annually produce 5,00,000 tonne of T-Steel. The acquisition of the DAM Steel plant is not a prerequisite for the rollout of T-Steel technology; it is one part of a comprehensive business plan.

LOW CARBON STEEL MAKING Innovation: New technology and process innovations have put Tata Steel at the forefront of low CO2 steelmaking processes. Tata Steel is a leading member of the Ultra-Low CO2 Steelmaking (ULCOS) project. Under ULCOS, 48 companies from all over Europe have been working together since 2004. The big aim is to halve CO2 emissions per tonne of steel by 2050. Several exciting new technologies, such as HIsarna, a direct smelting technique that is now being pioneered at Ijmuiden, have been identified. Features: The HIsarna process saves energy by eliminating the sintering and coke production steps within iron making and has the potential to reduce CO2 emissions from iron production by 20 per cent. Over the past year, a 60ktpa HIsarna pilot plant has been built at IJmuiden. By April, it was ready for commissioning and now, its first test phase is well underway. Tata Steel RD&T, led by Koen Meijer, is heading up this long-term project. If successful, full-scale production could begin around 2020. Alternatives: Another technique being explored is to remove and store carbon safely. Tata Steel is a member of the Carbon Capture and Storage Partnership in the UK, which is looking for ways to capture and store large volumes of CO2 inside disused oil & gas fields in the North Sea. The company’s £5 million Thermotec high-temperature research centre in Teesside is being established to carry out development work into new sources of fuel and energy, as well as recovery of raw materials and reducing waste. An exciting new technology being pioneered at Scunthorpe is using algae. The technique involves passing process off-gas through a reactor containing algae, which can feed on and take out some of the CO2. The algae can then be used in the production of biofuels and animal feed.

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INVESTMENTS SCENARIO

STRENGTHENING GROWTH PROSPECTS The steel industry is riding high with the increase in demand from automotive and infrastructure. Investments have also increased in the last one year, primarily led by state-owned SAIL and Tata Steel. While these companies have led the investment rally, there have also been some other significant investments that are slated to change the future course of action. Here’s a sneak peek into the major steel investments… ARINDAM GHOSH AND SUMEDHA MAHOREY

TATA STEEL Total Investment: £

million

Location: Cambuslang, Glasgow, Scotland Status: Work on the project is in the planning stage.

Total Investment: £

1.2

million

Location: Scunthorpe, England Status: Two machines will be commissioned in October 2011.

Total Investment: `

34,500

crore

Location: Orissa Project Description: A greenfield steel project is being established. Status: The company has arranged for the equipment required to meet the initial target. The project will begin production from 2014.

Investment: `

5,700

crore

Location: Jamshedpur Project Description: There are plans to expand capacity at its parent Jamshedpur plant to 10 million tonne, up from the current 6.8 million tonne. The company aims to increase annual iron ore production within the country by 55 per cent, to 17 million tonne, over the next two years.

SIGNS AGREEMENT WITH RIO TINTO Purpose of Agreement: Tata Steel and Rio Tinto have signed a licencing agreement to further support the technological and commercial development of the environment-friendly direct iron smelting process called HIsarna. Project Description & Location: Funded jointly by ULCOS, the European Commission and the Dutch Ministry of Economic Affairs, a HIsarna pilot plant is being commissioned at Tata Steel’s IJmuiden steelworks in the Netherlands.

JINDAL STEEL AND POWER Total Investment: `

50,000

crore

Location: Orissa Project Description & Status: The Ministry of Environment and Forests (MoEF) has given a go-ahead to the company’s (JSPL) 6 MTPA integrated steel plant.

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INVESTMENTS SCENARIO

ESSAR STEEL Total Investment: `

million

Project Description: A tonne pellet plant is being set up in two equal phases. Location: Orissa Status: Commercial production is expected by October 2012. After commissioning, the company will have a total pelletisation capacity of 20 mt yearly. At present, it has an eight MT pellet plant at Vizag, Andhra Pradesh.

Total Investment: `

30,000

crore

Project Description: Expanding the production capacity at ESSAR’s Hazira complex from 4.6MTPA to 10MTPA. This will be India’s largest flat steel facility at any single location and among the 10 largest facilities in the world. It will also be one of the few fully integrated steel facilities and will produce the entire range of flat products. Place: Hazira, Gujarat Status: The company has commissioned a compact strip production mill under the expansion.

SESA GOA Investment: `

25,000

crore

Project Description & Location: A five million tonne plant in Orissa Status: The Orissa Government’s approval has been sought to transfer the memorandum of understanding (MoU) signed with Vedanta Group firm Sterlite Industries India onto Sesa Goa’s name as all procedures in the iron ore and steel space in the Group will have to be undertaken by the latter company.

INNOVENTIVE INDUSTRIES

Investment: `

163.06

crore

Location: Pimple Jagtap, Pune Status: Plans are afoot to expand capacity at the company’s existing manufacturing facility.

SAIL SIGNS MoU WITH KOBE STEEL Purpose of Joint Venture: SAIL and Kobe Steel will work together to meet the requirements of steel products for India. SAIL is India’s largest steelmaker and has numerous iron ore and coal mines. Kobe Steel not only has world-class technologies for producing high valueadded steel products, but also has the raw material processing and iron unit production, including pellets, direct reduced iron and the ITmk3 iron-making process. Status: Kobe Steel and SAIL have already begun a feasibility study for a joint venture that utilises the former’s ITmk3 iron-making process.

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GROWTH DYNAMICS

BUSINESS TRENDS TO WATCH OUT FOR

The growth of the steel industry in India has been marred by various regulatory and environmental hurdles apart from challenges posed by land acquisition delays and social opposition. But steel players are finding ways to expand their capacities as the demand for steel races in India – one of the fastest-growing economies of the world. With steel players implementing global best practices in their new projects, the long-term growth story of the Indian steel industry remains intact. s the world economy closely interlinks with businesses, India, as a country, cannot remain decoupled much longer from the global markets. Consequently, the developments in the global steel sector affect the market dynamics of the Indian steel sector. After witnessing the ramifications of the recent downturn in the global economy, Indian steel companies are now looking to become more proactive to counter any such adversity in the sector. The domestic steel industry is now more in sync with global activities prevalent in the sector as players have now formulated business plans after considering domestic as well international issues. The following are the top five business trends in the steel industry in India:

Association (WSA), India’s finished steel consumption has grown at a compound annual growth rate (CAGR) of 9.4 per cent from 2004 to 2010. As indicated in Figure 1, the per capita consumption for steel usage in India is low at 51.7kg as compared to the world per capita consumption of 202.7kg in 2010. This indicates that there is scope for significant development of the sector in India. End-use demand to remain robust The demand drivers for the steel industry in India are predominantly in the construction space, with 61 per cent of the total demand. Investment in infrastructure in the first three years of the 11th Five Year Plan has already surpassed the target of about US$245 bn. The government is aiming to allocate approximately US$1 trillion in infrastructure

Total Finished Steel - India

FOCUS ON THE DOMESTIC MARKET

60.0 (mn tonne)

50.0 40.0 30.0 20.0 10.0

Production Source: Ministry of Steel, Annual Report 2010-11 and JPC

Figure 1: India’s Total Finished Steel

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Consumption

2010-11

2009-10

2008-09

2007-08

2006-07

0.0 2005-06

Growth opportunities galore India has emerged as the second-largest growing economy after China in 2011 with a GDP growth of 8.5 per cent. Industrialisation and a boom in economic activity have resulted in a robust demand for steel in the country. India emerged as the fourth-largest producer of crude steel in the world in 2010. As per the World Steel

70.0

development in the 12th Five Year Plan (2012-2017). Foreign auto-makers have set up shop in India to capitalise on the ongoing demand. This is likely to spur demand for automotive steel in India. With demand for the auto and white goods industries witnessing high growth in the recent years, companies have now started expanding capacities in the flat steel segment. India as a net importer of steel With inadequate supply to meet demand, India, from a net exporter of steel in 200607 has turned into a net importer. Realising the demand potential, steel players have set up capacity expansion plans. Foreign players have also entered into India to set up capacities post stagnation in developed markets. The global steel consumption CAGR growth, excluding India and China, has been nil from 2004 to 2010. India with the competitive advantage Apart from strong demand conditions acting as inducement to set up capacities in India, the country has abundant mineral resources, which are yet to be fully exploited, as well as young, cheap workforce of skilled and unskilled labour. A case in point is Tata Steel India. Although it is fully captive in iron ore and 50 per cent in coking coal, it remains one of lowest cost producers in the world and also impervious to

GROWTH DYNAMICS

(mn tonne)

volatility in commodity prices. Increase in rural penetration by expanding distribution Net Imports - India Finished Steel network 5 In order to push steel 4 consumption in rural areas, a number of companies are 3 expanding their distribution network. Essar Steel, under 2 the brand name Essar Hypermart, has set up one of 1 the largest retail chains for 0 steel. It offers customised services to original equipment 2005-06 2006-07 2007-08 2008-09 2009-10 -1 manufacturers (OEMs), small and medium enterprises Source: Ministry of Steel, Annual Report 2010-11 and JPC (SMEs) and retailers. SAIL, as Figure 2: Net Imports of India’s Finished Steel on January 2011, had 2,579 dealers in 630 districts against 200 dealers in 2006. JSW Steel, too, in JSW-JFE and Bhushan-Sumitomo – will order to make the most of the demand in provide them access to the latest semi-urban and rural areas has expanded its technologies that will enable them to distribution points. From 50 in 2008-09, produce high-end value-added steel. A JSW Shoppe has 280 outlets as of March number of global auto majors have set up 2011. operations in India, which, in turn, should result in demand for auto-grade steel.

2010-11

divestment programme. SAIL is likely to come out with a Follow-on Public Offer (FPO) in this fiscal year. Tata Steel after raising `34.7 bn in FPO in January 2011 had raised `15 bn in March 2011 through perpetual hybrid securities, perpetual in nature with no maturity or redemption and callable only at the option of the company. Such instruments are common in Europe and the US. We can now expect them to gain prominence in Asia as well.

BACKWARD INTEGRATION FOR RAW MATERIAL SECURITY

Mine production in India and the world has not kept pace with the rise in steel production. Unlike steel, which is a largely fragmented industry, the mining industry globally is being dominated by select players, who enjoy an upper hand in bargaining for ALLIANCES WITH GLOBAL pricing contracts. India is self-reliant in iron PEERS STRENGTHENING THE ore and is the net exporter of iron ore with BALANCE SHEET A number of joint ventures (JVs) have been at least 80 per cent exported to China, During the meltdown in the late 2008-09, announced between Indian steel players whereas coking coal is imported by most Indian players were plagued with low and their global counterparts. Developed steel players. The sharp volatility in iron ore volumes, increased interest costs and markets have stagnated over the years, and coking coal prices has made it difficult declining steel prices with costs remaining while emerging markets, such as India and for steel players to make their business high, all of which ultimately resulted in low China, have showcased strong growth plans. In the recent past, a sharp increase in profitability. As economic activity rebounded numbers. As per WSA, India’s finished steel inputs has resulted in a severe decline in from its lows in 2010, Indian companies consumption has grown at CAGR of 9.4 company margins. The cost of iron ore took advantage of strong capital market per cent from 2004 to 2010, while the from captive mine is approximately US$30flows and raised funds through equity world consumption growth has been 4.6 40 per tonne, while the prevailing spot dilution. Hence, balance sheets became per cent for the same period. Global players price in the market is US$150-160 per stronger as leverage was brought down and are optimistic about the domestic tonne. This entails cost savings of high-cost debt was refinanced. consumption story in India and are looking approximately US$160 per tonne of steel Companies have earmarked funds for to gain a foothold in India by setting up production for a player fully captive in iron integrated greenfield plants ore. So, while companies are notwithstanding the current expanding their steel capacities The goals set by the Indian Government to grow the steel – both greenfield and brownfield slowdown in the economy, sector are encouraging and are reflected in the number of – they are also looking to which hopefully is a temporary blip. Memorandum of Understandings (MOUs) the central and simultaneously increase their With greenfield projects for backward integration. state governments have signed for greenfield projects. companies such as POSCO and Mine allocation in India is Steel growth has a direct correlation with the GDP long and cumbersome as it is a Arcelor Mittal stuck, other global counterparts have signed growth of a country and as a basic industry it propels multi-stage procedure required strategic alliances with local downstream industrialisation as well and hence it is to avail clearances from both, players and are in talks to jointly the state and the Centre. It takes expected to remain the key sector for the Government. set up facilities in India. Arcelor anywhere between three and Mittal and JFE Steel have seven years to complete the further expansion in steel as well as to scout acquired stake in Uttam Steel and JSW entire process and begin mining. Thus, for mining assets. PSUs such as MOIL and Steel, respectively. It is a win-win situation apart from mine acquisitions, companies Coal India have released their initial public for Indian steel players, as strategic alliances are employing best practices to increase offerings (IPOs) as part of the government with global peers – Tata Steel India-Nippon, exploration activities in their existing mines.

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FACFACT T

GROWTH DYNAMICS

Like all countries rich in natural The Indian steel industry is expected to experience to adopt environment-friendly resources, India is also in the robust growth, as long-term positive indicators (such technology as carbon costs are midst of coming out with a new as strong demand from key end-use sectors and iron expected to rise. The UK mining bill, which is likely to ease ore availability) exceed challenges (such as land Government has proposed to procedural delays and facilitate introduce the carbon floor price allotment issues, shortage of coking coal and for power generation from April mine development and environmental clearances). investment in the country. Local 2013. The floor price will start steel players have shown intent from GB£16 per tonne of carbon records, deed titles, resistance from locals in acquiring mineral resource assets abroad dioxide and rise linearly to GB£30 per and opposition from environmental activists given that mining assets are difficult to come tonne in 2020. This proposal is aggressively are the roadblocks. A case in point is by domestically. JSW Steel has purchased contested by the steel industry as this POSCO’s US$12-bn proposed investment mines in Chile, Mozambique and the US, additional cost will make plants economically in Orissa. while Tata Steel has mining interests in unviable in the UK. The Centre is in the process of drafting a Mozambique, Canada and Australia. An THE NEXT MOVE new Land Acquisition Bill that aims to allay interesting development is that pure play Although presently the Indian steel industry all concerns & hindrances and provide iron ore mining companies such as Sesa is witnessing slow demand, the long-term realistic compensation to the affected Goa and NMDC have shown intent of story remains intact. With steel players parties. The Environment Ministry, which diversifying into steel production. implementing global best practices in their had earlier put many industrial projects on INVESTMENTS TOWARDS new projects, the focus has shifted to hold, has now softened its stand. Some ENVIRONMENT manufacture environment-friendly specialised projects are likely to be granted conditional CONSERVATION AND LAND steel products. Further, reforms in land clearances with riders. Thus, companies ACQUISITION acquisition and the proposed mining bill are will have to adhere to these norms and As mentioned earlier, new mine allocation likely to remove impediments to development amend their investment plans accordingly. is a long-drawn tedious process owing to of the steel industry in India. Carbon emission norms are also delays in securing forest and environment becoming stringent, thereby forcing Tapan Ray, Executive Director & Leader – Metals clearances. Apart from that, land acquisition companies to invest in technologies that will & Manan Tolat, Knowledge Manager – Metals, has been a critical reason for delays in curtail emissions to acceptance limits. PwC India projects in India. Lack of clarity on land Globally, steel companies are already open

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STEEL STRATEGIES

ESTABLISHING THE SEAL OF EXCELLENCE India has carved a niche for itself in the global steel industry and the country’s steel industry is catching up pace as well as luring steel majors from all over the world. Ranked the fifth major crude steel producer in the world in 2008, India offers vast scope for the steel industry in future. However, the current market turmoil has had an adverse impact on the Indian steel industry. In order to help India regain its strength, the Indian steel industry needs to consider the following strategies…

IRON ORE – ASSESS, PROCESS AND VALUE-ADD

NEW TECHNOLOGIES OFFER COST REDUCTION AVENUES

Although there has been considerable debate on iron ore export versus retention for value-add, no policy framework has been developed for the long-term. The government and other stakeholders should conduct a comprehensive economic impact assessment of ore exports versus steel production. A strategic long-term view on the subject has to be formed, keeping in mind the relatively lower reserve-to-production ratio of iron ore. However, in the short-term, India is a surplus producer of iron ore and exports mainly comprise of fines, which are not used much at present by the Indian steel industry. With the installation of pellet and sinter plants, Indian players can look forward to adding more value domestically as pellets and sinters bring significant premiums compared to fines. Moreover, the conversion of iron ore fines at the mine head arrests environmental pollution and waste.

The productivity of Indian steel majors has been low as compared to their global peers. New technologies may not only increase the productivity of Indian companies, but could also help reduce raw material costs or even address constraints. For instance, SAIL has entered into a joint venture with POSCO to use FINEX technology at its Bokaro facility. In FINEX, molten iron is directly produced using iron ore fines and non-coking coal, rather than processing through sintering and coke making, which is essential in the traditional blast furnace methods. The construction of a FINEX plant costs less than a blast furnace facility of the same scale. Furthermore, reduction in production costs is expected through cheaper raw materials and lower facility costs, pollutant exhaustion, maintenance staff and production time. In addition, it is ecofriendly and produces less pollutants, such as sulphur dioxide, nitrogen dioxide and carbon dioxide, than the traditional methods of producing steel.

INCREASE IN EXPLORATION AND DEVELOPMENT ACTIVITY India has abundant natural resources, but the country has not been able to fully leverage these resources. With the future growth of the steel industry dependent on the secure supply of resources, survey and exploration are important activities in the value chain. Exploration and survey activities in India are very limited. The annual budget of the Geological Survey of India, which is responsible for geological mapping and resource assessment, was US$87 million. This is substantially low as compared to other major steel-producing countries. Scientific exploration can help discover new reserves and mining organisations can jointly work on mega projects to consolidate mining areas for greater efficiency, reduced wastage and risk minimisation.

SECTOR-LEVEL STRATEGY FOR SOURCING RAW MATERIALS Indian players can attempt to develop sector-level alliances to increase the buying power and exchange knowledge for mutual benefit. The China Iron & Steel Association (CISA), on behalf of China’s steel industry, has been negotiating raw material prices with global mining majors. India, which imports a large amount of coking coal, can have a sector-level strategy in place for its sourcing. Similarly, the consolidation of iron ore resources can make sourcing easier and may bring down production costs.

SPECIAL STEEL PRODUCTION STRATEGIC FOCUS ON RISK The steel sector is undergoing significant structural changes, viz., vertical integration by players, shifts in value creation towards resources and cost curve changes. These changes increase the need for agility, risk-reward ratios and rebalanced expectations of return on capital expenditure. Steel companies would be well advised to continuously refresh their understanding of strategic risks and evaluate related mitigation plans.

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The present product spectrum of major Indian steel producers is tilted towards commodity steel. But now, there is a gradual change in this trend. The value-added steel not only commands higher margins, but its demand is growing fast due to global automobile players aggressively expanding their presence in India. Indian steel majors are collaborating with foreign players to access advanced technologies in specialised steel. Also, several partnerships are being announced between Japanese & South Korean companies and Indian players.

CASTING & FORGING

CASTING & FORGING INDIAN FORGING MARKET CLASSIFICATION Worldwide casting shipments in 2009 fell to

80,343,048 tonne, down 14% from 2008.

Warm forging

Rest of the methods

Precision die forging

Closed-die forging

63%

Upset forging

9% Open-die forging

12%

Recent Developments • Bharat Forge through its wholly owned subsidiary, BF Infrastructure Ventures (BFIVL) & David Brown Systems India (Holdings), part of David Brown Group entered into a Shareholders Agreement to form a JV Company, ‘David Brown Bharat Forge Gear Systems India’. • Amsterdam based AMG Advanced Metallurgical Group NV acquired intellectual property and manufacturing assets related to the ‘Mono2’ suite of solar casting technologies from BP Solar. Mono2 is a proprietary process whereby high-efficiency monocrystallinelike silicon ingots are produced utilising standard SCU furnaces using a variety of feedstock including polysilicon and upgraded metallurgical silicon. • ArcelorMittal Kryvyi Rih has recently begun installation of its continuous casting billet mill. The beginning of construction on its new continuous casting complex began one year ago and the complex is due to start production operations in September 2011. The capacity of the six-strand billet conticaster No. 1 is estimated at 1.2 million MT of steel per year. Upon completion, the mill will produce square billets with 150mm cross-section and 9-12m in length. • Precision Castparts Corp. (PCC) will acquire Primus International (Primus), manufacturer of various machined and fabricated aerospace components. This move coincides with Precision’s latest expansion into the market for high-value finished products. It also recently acquired the rings operations of Unison Engine Components (Tru-Form) from GE Aviation, an operating unit of GE. A manufacturer of flash-welded and cold-rolled rings for jet engine and gas turbine applications, Tru-Form’s line of products include spacer rings, combustion casings and liners, LPT casings, and fan cases.

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CASTING & FORGING

GROWTH MATRIX Indian Forging Stats • The total size of the forging industry is estimated to be around Rs 13,200 crore with over 25% attributed to exports. • Production of forgings increased to about 1.8 million metric tonne in the year 2009-10 from 1.05 million metric tonne in 2008-09, registering a strong growth of over 71%. • India exported forgings worth about US$800 million in 2010-11. • With the automotive industry poised to maintain a remarkable growth rate, the domestic forging industry is expecting a 30% growth in the year 2010-2011 and is likely to produce 2.3 million metric tonne this year.

TOP-10 CASTING PRODUCERS IN THE YEAR 2009 China

1 India

2 U.S.

3 Japan

4 Russia

35.3 million tonne Gray iron 17 million tonne Ductile iron 8.7 million tonne Steel 4.8 million tonne Nonferrous 4.2 million tonne 7.4 million tonne Gray iron Ductile iron Steel Nonferrous

5.05 million tonne 800,000 tonne 900,000 tonne 650,000 tonne

7.4 million tonne Gray iron Ductile iron Steel Nonferrous

2.4 million tonne 2.6 million tonne 690,000 tonne 1.7 million tonne

4.4 million tonne Gray iron Ductile iron Steel Nonferrous

1.7 million tonne 1.4 million tonne 200,000 tonne 1.1 million tonne

4.2 million tonne Gray iron 1.7 million tonne Ductile iron 1.2 million tonne Steel 700,000 tonne Nonferrous 500,000 tonne

Germany

6 Brazil

7 Korea

8 France

9 Italy

3.9 million tonne Gray iron Ductile iron Steel Nonferrous

1.8 million tonne 1.2 million tonne 180,000 tonne 690,000 tonne

2.3 million tonne All iron 1.9 million tonne Steel 170,000 tonne Nonferrous 210,000 tonne 2.1 million tonne Gray iron Ductile iron Steel Nonferrous

1 million tonne 610,000 tonne 150,000 tonne 310,000 tonne

1.74 million tonne Gray iron Ductile iron Steel Nonferrous

560,000 tonne 870,000 tonne 60,000 tonne 250,000 tonne

1.67 million tonne Gray iron Ductile iron Steel Nonferrous

570,000 tonne 370,000 tonne 65,000 tonne 665,000 tonne

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INDIAN FORGING INDUSTRY

ON THE PATH TO PROSPERITY The Indian forging industry has emerged as a major contributor to not only the manufacturing sector of the Indian economy, but also on a global scale. Since the forging industry is largely dependent on the automotive sector, it will also continue to grow and do well. The industry is fast emerging and has managed to carve its niche in the global market. Thanks to outsourcing, opportunities for exports are huge. An increasing number of companies from all over the world are coming to India to procure components & products and many companies are working hard to capitalise on this. Hence, there is optimism that the industry will sustain its growth trajectory. he forging industry has emerged as a major contributor to the Indian manufacturing industry. The total size of the industry is estimated to be around `13,200 crore with over 25 per cent attributed to exports. The Indian forging industry is highly fragmented, with around 400 units, 9-10 of which are large units scattered all over India. Briefly, the composition of the Indian forging industry can be categorised into four sectors – large, medium, small and tiny, with small and medium enterprises (SMEs) forming the backbone of the industry. The organised sector accounts for about 65-70 per cent of the total forging production in the country and mainly caters to the closed-die forging segment, while unorganised players, who are mainly small and tiny units, cater mainly to job and replacement market or tier 3 or tier 4 component manufacturers and predominantly focus on the open-die forging segment having lower capital costs.

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CURRENT MARKET SCENARIO In terms of market classification, closed-die forging contributes to around 63 per cent, open-die forging contributes to around 12 per cent, upset forging contributes to around nine per cent, precision die forging contributes the remaining nine per cent, warm forging three per cent and the rest is attributed to other methods. A wide range of products are manufactured, each being a diverse market structure and technology requirement. Over 60 per cent of the forgings produced are utilised by the automotive sector. However, the industry’s efforts in upgrading technologies and diversifying its product range have enabled it to expand its base of customers to construction, petrochemicals, power, diesel engines, aviation, defence, agriculture, etc. The market potential continues to grow for the forging industry.

MARKET TRENDS The growth of the automobile sector has provided a strong impetus to the forging industry. The newer generation of cars will

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require better quality forgings. Gauging the overall long-term picture, the vehicle industry seems well poised. The industry has witnessed a few domestic consolidations; the trend has been to cater to or set up base in global markets. It is one of the leading industries in mergers and acquisitions (M&As) overseas, which have primarily been in Europe and the US because the auto ancillary industry in these countries has been collapsing. Indian forging companies like Amtek Auto, Bharat Forge and Sundram Fasteners among others have also set up bases through M&As in other emerging economies to establish themselves as global players.

PRODUCTION TRENDS Owing to changing market trends, the need to have high-quality products has become imperative for companies. In fact, the use of ‘simulation software’ in many Indian forging processes has proved beneficial for companies and has helped them produce accurate and precise forgings, thus, saving valuable time, skipping the earlier ‘trial-

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INDIAN FORGING INDUSTRY

error-correction’ method, saving on wastage of material or flash. Apart from that, the use of alternative fuels such as LPG & biodiesel and also, the increased use of induction furnaces for overcoming the scaling problem, etc. are some trends observed in the industry. Most units now also provide ‘machined forgings’ after installing CNC machines for the same. Similarly due to stiff competition posed by alternative materials and the everincreasing demands from manufacturing processes, the steel suppliers are under constant pressure to innovate and make available forging quality steel grades of a very high quality for the auto sector. The conventional forged components were heat treated for high strength applications. However, they suffered cost penalties apart from other shortcomings. Due to the safety requirements imposed by the automotive manufacturers, improved toughness became a major requirement for microalloyed forging steel. Components such as connecting rods, crankshafts, camshafts, etc. are now commercially made with this steel elsewhere in the world. The recent development of low carbon micro-alloyed steels in direct quenched condition have attracted the attention of automotive manufacturers in view of their fulfilling properties without post forge heat treatment, amenability to surface treatments such as induction hardening/nitriding and generation of properties over large section sizes & uniformity across the cross section. All these efforts have helped in saving energy, operation time, material handling, etc. towards the production of automotive components at much lower costs in the western world. Similar actions can be taken up in India.

EQUIPMENT AND TECHNOLOGIES The forging industry in India has been investing in concurrent technologies on a continuous basis from the early 1980s as they were introduced internationally. The investment in technology was initially driven with the commencement of indigenisation of forged parts by Maruti Udyog, followed by the production of light commercial vehicles as well as motorcycles through Japanese collaborations. The Indian forging industry today uses the latest up-to-date manufacturing technologies and practices, in line with the best in the world. The surge in the demand of specific products has necessitated opting

FORGING IN OTHER SECTORS

to a more balanced customer portfolio. Identified drivers of growth in the non-auto sector are aerospace, energy, oil & gas and heavy engine parts. The Indian forging industry needs to leverage the market opportunity through focussed increase in productivity rather than mere capacity expansion, technology upgradation & modernisation of the units to comply with global quality standards. The following measures will be crucial for growth: The small sector forging units need to improve their operational efficiencies by allocating a certain percentage of their capital investment to technological upgradation. This will help them maintain consistent surface quality requirements of the product and meet strict pollution control norms. Testing and inspection facilities can be outsourced for these units. The organised sector should continuously acquire the latest technologies with added emphasis on IT, CAD/CAM, and other forms of computer-based technologies to produce quality forgings conforming to international standards with best yields. The use of quality tools such as SPL studies is going to be essential to reduce rejections. Energy audits are also an important way to reduce consumption of costly oil and power. Forging units should be involved in reduction in plant inventory through ‘just in time’ procurement and ensure prompt delivery commitment of the products for sustainable confidence of automobile manufacturers. Inorganic growth is another strategy to expand the global footprint and establish a global presence in some of the world’s largest markets. Also, considering that different geographies follow separate business cycles, it is necessary to reduce one’s over dependence on a single market. Plus, this strategy can help the industry take advantage of the varying differential growth opportunities across different geographical regions/different parts of the globe. Restructuring strategies – consolidation of capacities, backward/forward integration and specialisation to end product (component).

The production of forgings for the nonautomotive sector is on the rise, thus leading

Courtesy: Association Of Indian Forging Industry

for automated forging press lines for forged products. However, the cost is prohibitive for SMEs. Some of these units have brought in some degree of automation, thereby increasing safety and achieving better productivity & cost efficiency. For instance, limited conveyor systems were installed by some units to carry material from and to the furnaces, thus obviating the need to manually carry the material. This not only made the process safer, but also ensured that the procedure was faster and enhanced productivity. From the late 1990s, the Indian automotive industry has seen rapid growth across all the segments, thus fuelling the demand for forgings and increased demand of specific parts necessitated investments in automated forging press lines.

GROWTH PROSPECTS The Indian forging industry has been growing at a compound annual growth rate (CAGR) of 29 per cent from 2003 onwards, and on an average, exports contribute to around 25 per cent of the industry’s production. FY2010 was a good year for the forging industry. The revival, which started in October 2009, picked up momentum last year. Overall production of forgings increased to about 1.8 million metric tonne in the year from 1.05 million metric tonne in 2008-09, thus registering a strong growth of over 71 per cent. The production is expected to reach 2.3 million tonne by March 2011. India exported forgings worth about US$800 million in 2010-11. This was a result of several industry initiatives including capacity expansion, modernisation, cost rationalisation, coupled with a revival in demand from the automotive sector and particularly, the passenger car segment, which recorded excellent growth. The market potential for the forging industry continues to grow. The growth of the automobile sector has provided a strong impetus to the forging industry. The newer generation of cars will require better quality forgings. Looking at the overall long-term picture, the vehicle industry seems well poised to maintain a remarkable growth rate of around 25 per cent. This, obviously, will require the production of the Indian forging industry to shift to a higher gear. The industry is expected to grow by about 25 per cent to reach `16,500 crore.

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NEW AGE CASTING & FORGING

The burgeoning demand for steel has given rise to the growth of allied industries such as casting and forging. As the industry climbs a steep growth curve, it has become imperative for companies to invest in cost-effective production processes and technologies to help support this growing demand. Here are a few latest production processes and technologies that can help companies gain a competitive edge and ensure better profit margins. ith the advent of industrialisation, the need to have more efficient production processes and technology upgradations became paramount. Moreover, the increase in the demand for better quality castings and forgings products has prompted the industry to invest in better production processes and technology upgradation. Apart from using highly efficient robots and software products to reduce production time and improve the quality of products, most companies are looking forward to incorporating green manufacturing processes, which offer low or no emissions and more cost-effective ways of production. Hereâ&#x20AC;&#x2122;s profiling a few state-of-the-art production processes and technologies that can help companies gain a competitive edge and enhance their overall profit margins: Application of micro-alloyed forging quality steel grades Due to stiff competition posed by alternative materials and the ever-increasing demands of manufacturing processes, steel suppliers are forced to constantly innovate new forging quality grades of steel possessing extremely high quality. The conventional forged components were heat treated for high-strength applications, but the process brought with it several shortcomings apart from cost penalties. Due to the safety requirements imposed by manufacturers, improved toughness became a major

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requirement for micro-alloyed forging steel. As a result, components such as connecting rods, crankshafts, camshafts, etc. are now commercially made using this steel elsewhere in the world. The recent development on low carbon micro-alloyed steels has attracted automotive manufacturers in view of their fulfilling properties without post forge heat treatment; amenability to surface treatments, such as induction hardening/nitriding, and the generation of properties over large section sizes & uniformity across the cross section. All these efforts have helped save energy, operation time, material handling, etc. towards the production of automotive components at much lower costs in the western world. Similar initiatives can be taken up in India as well. Graphite casting process Turbulence may be annoying at 35,000 feet, but it is trouble when it affects the quality of cast parts. The use of graphite moulds to cast parts from ZA-12, a zincaluminium alloy that is harder, stronger and more durable than aluminium, brass, bronze, or plastic has proved to be beneficial for companies. The best possible casting results are obtained by using automated casting machines that fill each mould from the bottom up. The turbulence in the molten metal greatly reduces porosity. Using a process controller to simultaneously control fill rate, cycle time and temperature, these machines yield parts of high quality and repeatability at a

NEW AGE CASTING & FORGING

relatively low cost per part. graphite mould will not warp or corrode, it accelerate drying at this stage as the ceramic For instance, National Optronics, in can be stored indefinitely and reused. shell is very thin and could crack. Dipping Charlottesville, Virginia, US, is a These parts have typical surface finishes and sanding is repeated for seven more manufacturer of lens processing equipment of 63 microns or less and are better than times and heating is employed for this part that relies on the casting process for one of finishes from other casting processes. In of the process as it is less critical. The final its products. The product was previously many cases, these parts require little or no result is a thick, protective covering that can made up of four individually withstand the 1,0000C temperature of the furnace. machined pieces. Now, it is However, before casting, the produced as a single casting wax has to be removed using that is more rigid and more high-pressure steam. After stable. The company’s shop casting, there are various was machining four sections machining operations. The separately and screwing them first involves degating i.e. together. The part supports a removing the part that drill inside the company’s attached the coated moulds automated three-axis to the tree. This is followed patternless edger. After backby a vibration process that and-forth design discussions, removes the coating. The National Optronics and final metallic castings are sand Graphicast agreed on a new blasted, machined, visually design optimised for the inspected, ground, heatcasting process. National treated and then are finally Optronics now orders 4-5 inspected. The whole production runs per year, process, from wax mould with 50 or 60 parts per run. through to finished products According to the company’s A German company recently introduced a new generation of casting process simulation. These solutions are takes around two weeks and buyer, Andy Irvine, the new used by foundries worldwide in order to optimise their cast component production. involves seven robots and production method saves throughput is around 1,000 castings a National Optronics about $11,000 a year. machining, but for non-castable features, it week. These savings result from lower costs for is machined as easily as brass or bronze and Emission-free process raw materials, machining and assembly. more easily than cast iron or aluminum. Another emission-free process launched by The casting process is suitable for annual Similarly, with the help of robots, a a company is for casting cores for the production runs of 200-20,000 parts. For a company could save on both, time and production of engine components at BMW typical medium-volume production run, money. Manufacturing small precision Group’s light metal foundry. A leading global the cost to machine each part from scratch castings with consistent quality and output specialty chemicals manufacturer is is too high, yet the quantity is too low for for the automotive industry requires successfully running a new production plant high-volume manufacturing methods to be specialised skill that can be provided by of one of its Fuldabrück-based subsidiary, cost-effective. Based on the total acquisition industrial robots for the environment-friendly production of cost (cost-per-part times volume plus The 14-step process starts with injection casting cores for BMW Group with the tooling costs), the graphite mold/ZA-12 moulding, which creates a wax model of newly developed INOTEC process. The casting process is a lower-cost alternative to the product and an extension that allows new INOTEC plant produces a core CNC machining, die casting, sand casting them to be placed on a tree. An IRB 2400 package consisting of various cores, including and investment casting for medium-volume robot removes the moulds and creates the those to be used for the casting of cylinder runs. The high accuracy and lustrous surface tree, each of which can carry up to about blocks for the new highly efficient sixfinish of parts virtually eliminate additional 80 moulds. These trees allow other robots cylinder diesel engine of BMW Group. In finishing steps required with other casting to transport the moulds to various parts of the next two years, this INOTEC core techniques, for a much lower total cost per the manufacturing process, the first of which production plant, in which the company has part. is to clean the wax patterns. Finished trees already invested in a low single-digit million Tooling costs for the graphite mould are dipped into a bath of molten ceramic, euro range, will create new jobs in doubleprocess are lower than for die casting or they are rotated in order to allow the excess digit numbers at the site. In the current injection moulding, as graphite costs less liquid to fall back into the bath, and then the start-up phase of the production plant than tool steel and requires no heat treating. same robot takes them to a rainfall sander. commissioned in May 2009, the number of Graphite’s machinability further shortens Robots handle parts in a critical process employees is currently still in a single-digit the mould-making phase. Graphite mould Subsequently, the trees are left to dry. This range. can often be produced weeks faster than a process takes around two hours. An IRB 60 The INOTEC binding system, a unique, die-casting mould, for approximately onerobot, in operation for over 1,00,000 inorganic and thus emission-free version of fifth the cost. The typical turnaround time hours, handles the moulds as this is a critical core binders based on silicate for the casting from finished CAD design to production part of the process that requires strict quality industry, in particular aluminium casting, was samples is 4-6 weeks. And because a control. Heating cannot be used to

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NEW AGE CASTING & FORGING

developed by a company and optimised for software, this is made possible through completely reworked and for the first time, automotive series casting production in different perspectives, which can be offers the option to simulate thermally close collaboration with BMW Group’s light simultaneously used by the user. induced casting stresses for the complete metal casting house in Landshut. The In all the steps necessary for casting, manufacturing route. A new and company managed to accomplish this in a process simulation can be specified and comprehensive plasticity model provides short span of time. The environmental performed from a process perspective. This improved accuracy, because it considers benefit is that the inorganic temperature-dependent as binding agents used in the well as time-dependent process emit virtually no effects on stresses & strains. emissions harmful to the Simulation results such as environment, unlike many 3D graphics, diagrams and organic binding agents. That tables can be shown in is why, the core production multiple views and can be can dispense with expensive displayed in selectable levels and time-consuming of detail. This means that processes, such as air results can be evaluated extraction and amine reliably in order to allow an washing. optimisation of cast The task of a binding agent components and casting system is to bind the quarry processes. sand used in the production The new methodology of casting cores so stably that that the software provides is it can withstand extreme mirrored in the software temperatures of up to 900°C architecture. Technically, the encountered in aluminium software is built on a casting. This enables precise completely new platform Due to the safety requirements imposed by manufacturers, improved toughness became a major requirement and faultless casting of and, as it is also modularly for micro-alloyed forging steel. As a result, components such as connecting rods, crankshafts, camshafts, complex mouldings such as extendable and scalable, it etc. are now commercially made using this steel elsewhere in the world. cylinder heads and water will offer development cooling jackets. In the casting process, the allows the complete production process potential in the coming years. Due to casting cores represent the cavity model of from geometry input, through the design of standard interfaces that allow the free the cast part to be produced. gating, risering and tooling, on to solidification import and export of data, the software can With the INOTEC binder system, the and finishing processes such as heat be completely integrated into the user’s company and its affiliated companies further treatment, to be described and simulated. work environment. strengthen the Group’s position as the In the process perspective, all information ENABLING GROWTH European market leader for foundry about the used materials, metallurgy and FY2010 was a good year for the casting and chemicals and tools. Moreover, the melting practice, production conditions and forging industry. The revival, which started company strengthens its broad green finishing processes such as heat treatment in October 2009, picked up momentum chemistry portfolio consisting of process come together. This allows the user to get a last year. This was a result of several industry and environmental catalysts, bentonitecomplete overview of the entire initiatives including capacity expansion, based additives, water treatment, catalysts manufacturing process he wants to simulate. modernisation and cost rationalisation, for second generation biofuels and heavy Altogether, the process orientation of the coupled with a revival in demand from the metal free plastic additives. software sets the basis for a profitable automotive sector, particularly the passenger New generation casting process manufacture of cast components – through car segment, which recorded excellent simulation software improved casting layouts, achieving the growth. All these factors have helped the Recently, a German company introduced a required casting quality and saving costs. industry grow and gain a competitive edge new generation of casting process The software provides important new over their foreign counterparts. simulation. These solutions are used by casting process simulation capabilities. New foundries worldwide in order to optimise advanced turbulence models as well as the Compiled by Purna Parmar their cast component production. The consideration of surface tension improve software is based on more than 20 years of the mould filling prediction for gravity development, during which the Aachencastings. And, tracer particles can be MANUFACTURING ZONE: based company has continued to innovate modelled with mass and size to evaluate Proposed NMIZs on and establish casting process simulation slag inclusions. Burn-on and penetration Creating A Blueprint To as a standard. Following this standard, the criteria help identify sand-related surface Manufacturing Success software delivers a profound understanding defects. Moreover, a new module for the of the casting processes that allows simulation of as-cast local microstructures optimisation along the complete process and properties of aluminium alloys is on pg. chain of the cast component. Within the available. The stress module has also been

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GREEN PROCESSES

MOULDING A MODERN CASTING INDUSTRY The Indian casting and forging industry is well established and has undergone equipment & quality systems upgradation to be in sync with international best practices. This industry, however, has serious repercussions on the environment. With the advent of green initiatives apart from other technology upgradations, the industry has been able to not only lower its emission levels, but also produce better quality products. This has further helped Indian casting and forging companies gain a competitive edge over their overseas counterparts. As a result, India is no more considered a dumping ground for European foundries, but a sourcing hub for good quality products the world over. PURNA PARMAR

asting and forging is an integral part of the steel making process. The industry has witnessed tremendous growth in the past few years thanks to the boom in the automotive sector. The casting and forging industry has a lot going for it in terms of the shift that is taking place with the industry moving away from developed markets, seeking a lower cost of compliance to ever intensifying stringent environmental conditions being set on the industry. India’s low labour cost and advanced technology will make the country a highly attractive destination for sourcing casting and forging products for years to come.

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TAKING THE GREEN ROUTE As a result of the increasing awareness about conserving the environment and the need to make profits in the long run, companies are now investing in green manufacturing processes and technologies. Investments in installing pollution control systems and other processes may have increased the overall production cost, but it has helped companies enhance their profits and improve the quality of products in the long run. This, in turn, has helped Indian companies reposition themselves as a sourcing hub for quality products in the global market. The fact that these green technologies help in achieving higher quality products has further encouraged more companies to take the green route. According to Anil Vaswani, Director, The

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Wesman Engineering Company, there are two types of casting processes – green sand process and no-bake process. In the green sand process, Bentonite, a kind of clay, which can be recycled and reused, is used. The technology used for this process is cooling, as in the hot sand technique, there are chances of developing casting defects. “Many companies generally take hot sand and recycle it. But if you take hot moulded sand and recycle it, you may develop casting failures,” says Vaswani, adding, “We have a joint venture with Simpsons Technologies, an American company manufacturing automated coolers that can control the temperature. These not only help us keep a check on the environment, but also brings down the rate of production failure.” Describing the no-bake process, Vaswani

GREEN PROCESSES

informs, “In the no-bake process, chemicals are added to the sand, which makes the sand very hard and thus, difficult to recycle. As a result, foundries throw away that sand, which is not only harmful to the environment, but also proves to be costly as companies have to buy new sand. But now, equipment to segregate the sand and chemicals are available. The equipment either burns the chemicals or crushes the sand mixed with chemicals fine and then processes it.” According to Manufacturing Consultant Rajiv Laxman Harolikar, “The foundry industry generates more waste through used sand, furnace fumes, fettling fumes and slag. Comparatively, the forging industry mainly has furnace fumes, fuel handling and fettling issues to deal with. Heat treatment of chemicals is also one of the significantly polluting processes, mainly in the forging industry. The typical green technologies used are based on the basic ‘Reduce, Reuse and Replace’ principle. The foundries and forge shops have to focus on power/water/ air/sand consumption. The first step is to compile the data, analyse it for per tonne production and then work out measures for reduction & reuse. Every manufacturing step in both, forge shops and foundries, which work with high-temperature metals, is amenable to the above objective, be it covering a ladle or a hot product, or controlling the power input to furnace.” Seconding Harolikar’s views, Prashant Panchal, Overseas Head – Marketing, Ardee Business Services (Tianjin), claims, “The casting and forging industry is one of the most polluting industries in India. The maximum pollution is generated during the iron making process in the blast furnace and the steel making process in the electric arc furnace & convertor and the ladle furnace.” Suggesting measures to prevent the same, Panchal says, “Initially, there were not many pollution control systems to prevent air & water contamination. But now, we have the technology and processes to prevent it. Strong fume extraction systems, filtering bags, gas reutilisation systems and water recirculation systems are available. As far as new technologies are concerned, the plants have developed good air filters with strong fume extraction systems to reduce the emission level in arc furnaces.” Apart from these green processes and technologies, a green process in the forging industry is powder forging. However, this process is yet to gain widespread usage in India. Harolikar says that powder forging is

not considered a lucrative option in India as it is based on powder metallurgy principles with additional forging operations. So, unless it involves high-quantity products on a monthly basis, it is not an economically viable option. However, many components are now being replaced by ‘near-net shape’ processes. Apart from reducing costs incurred towards utilising energy, these processes also help reduce the cost of machining operations and increase the strength of the formed metal. ‘Microalloyed steels’ are now becoming commonplace in the Indian automotive industry, which offers the high energy advantage, through elimination of further heat treatment operations without compromising on mechanical properties. Many users have also adopted the process of replacing some of the forgings with high strength casting alloys. A very striking example of this is Austenitic Ductile Iron (ADI). Despite its widespread usage in western countries, ADI is yet to catch roots in the Indian market. ADI has equivalent, if not more strength than heat-treated steel, and with typical characteristics, it is popularly used in gears and brake drums.

ROADBLOCKS ON THE WAY The Indian casting and forging industry seeks to adopt more green manufacturing processes and offer value-added services along with high-quality products despite the many hurdles that the industry faces. Shedding light on the same, Harolikar says, “The major challenge is the lack of awareness about the available options, focus and past data. Without these, no progress is possible. Today, most of the options are available through private industries, which bring in the technology from companies in the West. Cost is another concern as a majority of the industry falls under SMEs and cannot individually afford to pay up the expenses. The last important aspect is that there is no enforced regulation for measures, which promote the chalta hai attitude of companies.” Elaborating on the cost factor, Panchal adds, “The initial investment is the biggest hurdle that companies face today. These green processes & technologies are not easy to adopt and involve a lot of efforts from the company’s end since they do not merely have to install the new technologies, but also have to include it in their manufacturing process. We need to change the mindset of the people towards green

manufacturing processes and technologies. This will not only help achieve lower emission levels, but also improve the production quality of products.”

FROM DUMPING GROUND TO SOURCING HUB Earlier, with growing production cost and increasing awareness of environmental issues, manufacturing companies in Europe had to either shut shop or shift their base to countries offering lower production cost. India, with its growing automotive and engineering industry landscape, proved to be the best option for them. Moreover, the Indian environmental laws were also not as strict as compared to the European countries. However, this scenario is slowly changing with the Indian casting and forging industry witnessing a steep growth. Explaining the same, Vaswani says, “India is no more a dumping ground for European companies. With so many foundries in the European market either shutting down or shifting base due to high production cost and other environment issues, these companies prefer to outsource casting and forging components from countries like India. Gradually, the industrial mindset is changing. Companies are now looking at Indian products as quality products.” Moreover, there is a huge demand for skilled labour in the Indian casting and forging industry. Unfortunately, the country is facing acute talent crunch due to the technology divide that exists in the country. Moreover, while foundries in India are coping with high-cost labour, they are also grappling with high cost of raw material, equipment and technology upgradation. With the growing awareness of environmental issues in the country, Indian foundries have a mandate to follow, which involves high investments for installing, pollution control systems, green manufacturing processes and technologies.

GROWTH PASTURES With the growing use of green process technologies, the Indian casting and forging industry is stepping into a new industrial phase. More and more companies are now investing in green and cost-efficient technologies & mordernising their plants by installing kilns, which can help minimise pollution levels in the plants. Such valueadded services will help Indian companies gain a competitive edge over their foreign counterparts.

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HIGH-PERFORMANCE ALLOYS

OFFERING APPLICATIONS LONGEVITY Excellent creep resistance, anti-oxidation properties and strong surface stability are what make superalloy castings a necessity for today’s high-temperature industrial applications. The ability of superalloys to operate at higher temperatures provides greater opportunity for efficiency and extended component life over typical alloys. High-temperature applications, such as aerospace and power generation turbines, require the unique mechanical properties of superalloys. With scope for limitless number of new applications, this industry certainly has a very bright future. he ‘Metals Handbook’ published by ASM did not recognise the term ‘superalloy’ in the 1990s. This clearly implied that the nomenclature then was commercial and not technical. Fortunately today, superalloys are a distinct class of super materials in the metallic domain. Superalloys are defined as highperformance alloys that exhibit excellent mechanical strength & creep resistance at high temperatures, possess good surface stability and are corrosion & oxidation resistant. In the metallurgy terminology, superalloys typically have a matrix with an austenitic face-centered cubic crystal structure. This means that the crystalline matrix is not too hard, but is rather suited to mechanical deformation treatments and also to welding. Austenite is a phase in steel that has an ideal combination of hardness and toughness, which not only makes it highly suited to mechanical deformation but also ensures that it is unlikely to become brittle. Commonly

PROPERTIES Fatigue strength and creep resistance are the two main properties of all hightemperature metallic

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alloys. High-temperature fatigue strength is different from the usual mechanical fatigue strength i.e. the ability of a metallic material to withstand cyclic loading (for e.g. hammering or rotating), which causes fatigue failure, as it leads to fatigue cracks. Fatigue cracks, which initially form microscopic cracks, eventually turn into large cracks that can lead to catastrophic failures. Therefore, high temperature fatigue strength is desirable here. Creep resistance is similar, but it appears when there is nonstop loading. For example, in gas turbines, when there is high temperature loading for long hours. The other physical properties that make superalloys useful are fatigue life, phase stability, as well as oxidation & corrosion resistance. Phase stability prevents the changing of materials; for instance, from the austenitic phase to martensitic phase, hypothetically speaking. Corrosion resistance includes oxidation resistance.

APPLICATIONS

The development of superalloys has long been dominated by nickel alloy producers, who for the last half a century or so, have constantly enhanced the wear & corrosion resistance, including oxidation resistance, especially at elevated temperatures. The use of nickel-based superalloys came to the fore soon after the discovery of jet engines, which were scaled up to power the larger airlines. Thus, the aviation industry, aerospace & power industries and chemical processing have been the prime beneficiaries. Superalloys castings are widely used in automotive, aerospace, biomedical and other niche areas. However, its typical applications are in the aerospace, industrial gas turbine & marine turbine industry, for e.g. in turbine blades used in hot sections of jet engines and bi-metallic engine valves used in diesel & automotive applications. In the hot zones of gas turbines, nickel-based superalloys could only be relied upon to retain the rigidity at temperatures close to their melting points. In used superalloys these applications, there Hastelloy, Inconel, Waspaloy, Rene alloys (e.g. Rene 41, Rene are no competing materials 80, Rene 95, Rene 104), Haynes alloys, Incoloy, MP98T, TMS of metallic compositions alloys and CMSX single crystal alloys are all registered as of now. trademarks of their respective producers. Designers use superalloy cast parts in

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HIGH-PERFORMANCE ALLOYS

Thermal barrier coatings

1300 Y-PSZ TBC limit

1200

Temperature / C

superalloys to resist softening or deforming at very high temperatures, very often, advanced ceramics are applied with plasma spray or high-velocity oxy-fuel (HVOF) process, to raise the limit even higher. The illustration in Figure 1 summarises this trend.

TBC beneﬁt Substrate limit

1100 1000

FUTURE SCOPE

Single crystal alloys

Conventionally cast alloys

Directionally solidiﬁed alloys

800 Wrought alloys

800 1950

1960

1970

1980

1990

2000

2010

Year Figure 1: Decade-wise enhancement of performance of superalloys, duly coated with thermal barrier materials.

Since the advent of the jet engine in the post World War II scenario, the role of high temperature-resistant metallic materials with a high degree of hot hardness (so that they do not soften at more than a 1,0000C temperature) was attributed to nickel-based superalloys. A wide range of compositions followed, and soon, castings were available. Further progress saw these metallic materials being coated with advanced ceramics, and today, we have materials that routinely withstand temperatures very close to their melting points i.e. 1,6000C. Such miraculous performance was beyond imagination about five decades ago. But it is common in today’s commercial airliners. Turbine blades are generally cast from such superalloys and coated with a high-performance technique such as plasma spray or HVOF. Castings made of superalloys have been increasingly used in biomedical fields as well, because human body fluids can easily ruin stainless steels, titanium alloys and even chrome-cobalt alloys. Corroded parts inside a human body tend to encourage internal infections, which can lead to severe complications. Thus, the future of cast superalloys seems very exciting. With the availability of investment casting, powder metallurgy and metal injection moulding, very highprecision castings are being produced for the most demanding applications. The use of single crystal type castings has gone up in aerospace applications and vacuum plasma melting and laser beam melting or electron beam melting are being used quite often as these maintain the highest purity in melting and casting. This is an industry with a very bright future, commanding limitless scope for new applications.

Haynes 230

Inconel 625 Haynes 25

304 SS 321 SS

Inconel 718

MP35N

ph13-8Mo S15500 17-4ph

ULTIMATE TENSILE STRENGTH, KSI 100 200

300

high temperature applications, which gas turbines (commercial & military aircraft, require high strength, creep resistance, as power generation and marine propulsion); well as corrosion & oxidation resistance. Air space vehicles; submarines; nuclear cooling and thermal barrier coatings (TBCs) reactors; military electric motors; racing & also play an important role in blades. TBCs high-performance vehicles, chemical not only ensure that the blades operate processing vessels, bomb casings and heat well in such conditions, but also make sure exchanger tubing. that the base material is protected from the WHY ARE SUPERALLOYS thermal effects as well as factors like MORE COMMONLY USED? corrosion and oxidation. In addition, In elevated temperature services, apart turbocharger turbines also use superalloys, from the inherent ability of nickel-based typically electron beam welded or laserbeam welded to a steel shaft (for e.g. Inconel 713 and Mar-M 247). Here, all the physical properties discussed above are needed for reliable service. They are also used where corrosion by media would not allow the use of other metallic materials like, for instance, in place of stainless steel or in acidic or saltwater environments. Superalloys (such as Nimonic 80A) are also used in the poppet valves of piston engines, both for diesel and gasoline engines. This is either in the form of a single solid valve or as a bi-metallic valve. Corrosion resistance is particularly useful when dealing with high temperatures and pressures found in a diesel engine. The superalloys resist pitting and degradation, thereby allowing operating 600 750 1200 1600 1800 2100 conditions that would not have OPERATING TEMPERATURE, ‘F been possible in the case of regular stainless steel. Additional Figure 2: A comparison chart of ultimate tensile strength versus working temperature for a range of popular superalloy compositions. applications of superalloys include:

MAK Babi, Advanced Trainer in Metallurgy E-mail id: maxbabi@gmail.com Website: www.maxbabi.com

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COMBINED FORGING AND PUNCHING OF LONG PIECES

CREATING A

LASTING IMPRESSION The need to enhance cost efficiency and quality of production processes has led manufacturers to innovate their tool and machine technology. Till date, there is no information available on how the process parameters influence factors like dimensional accuracy, surface quality and fibre orientation in the pierced area when forming and piercing operations are combined. Forging of alloys can produce an almost limitless variety of 3D shapes that range in weight from mere ounces up to more than 25 tonne. ver the last few years, precision forging reduces the required numerous new amount of raw material since surplus developments have material is not forced out as flash. In addition, significantly changed the due to the near-net-shape quality, expensive hot forging of steel. machining steps can be omitted. Innovations in tool and In contemporary process chains, the machine technology along with additional part is formed with flash in the first step and process developments have increased the in the second, it is deflashed and pierced. efficiency and quality of production Often, this subsequent step is realised while processes. These developments result from the forged part is still hot. Since a second an ever growing pressure of competition and the need to increase resource and cost efficiency. Enhancements in close tolerance and precision forging permit the production of prefinished parts with high grades of dimensional & shape accuracy as well as high surface quality. Until now, these characteristics could only be achieved through machining. In comparison Figure 1: The forming stages of the used long ﬂat piece to conventional forging, flashless

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tool for punching and deflashing of the work piece is required here, this second process step increases the costs of production. In addition, the subsequent process step entails increased handling efforts and lead times as well as additional costs for logistic operations (for e.g., the retooling of the press). The additional technical and logistical activities result in an increased process susceptibility to failures based on the position or the changed temperature of the work piece. A separate punching process has complex effects on the process time. The combination of punching and flashless forging constitutes considerable shortening of the manufacturing process. The combination also entails a reduction of material usage because it is done ‘flashlessly’. A new production method developed at the IPH –

COMBINED FORGING AND PUNCHING OF LONG PIECES

Figure 2: Tool design

Institut für Integrierte Produktion Hannover gemeinnützige GmbH – enables the implementation of combined forging and punching in one tool.

TOOL TECHNOLOGY, FORGING PROCESS

is filled, the movement of the punch continues to perform the piercing. As a result, the cavity pressure increases. To pierce through the work piece, the lower punch is set free by a release mechanism. The releasing is initiated once a preset dwell force upon the lower punch exceeds a preassigned level. The release mechanism guarantees both the complete filling of the cavity and the prevention of a die’s structural failure. The implementation of the release mechanism is realised with a shearing device as indicated in Figure 2. This device comprises of one upper and two lower cutters, which shear off a slice of shear pins from their centre. The shear force can be adjusted via the quantity and diameters of the shear pins. The pierced material of the work piece, called web, is pushed by the upper punch further down until the piercing is completed. Finally, the upper punch is retracted from the work piece. After the dies open, the pierced and forged part as well as the web can be removed from the tool.

The tool concept for the SIMULATION combined flashless forging and The forging process was punching was developed in the simulated using Forge 2008. The research project ‘Analysis of simulation results were used for Combined Forging and the iterative identification of Punching Processes’ (Hu suitable applicable part geometry. 1002/2-1), which was funded To prevent tool failure, the stress by the German Research occurring in the die cavity and the Foundation (DFG). Only stress acting upon the forging rotational symmetric parts were Figure 3: Deformation degree and compression stress occurring within the tool (using punch shape punch had to be kept below the analysed. In a follow-up project A and pre-forming by dies) tool-steel’s yield point. Simulation (Be 1691/77-3), the concept results reveal that the closing of was adapted for the production dies without forming is not suitable since of flat parts with a distinct longitudinal axis into two stages. In the first stage, the dies the subsequent forming entails a die stress called long flat pieces. close and a flashless preforming of the work exceeding the maximum value of Rp0,2 = The forming stages of the used example piece occurs. In this step, the die cavity is 790 N/mm2: the results show stresses long flat piece can be seen in Figure 1. The not completely filled in the lug and the bar. between 1,540 and 3,500 N/mm2 in the analysed long flat piece has a distinct In the second stage, the upper punch moves lug area. Thus, a forging operation using longitudinal axis with a material accumulation into the die cavity, thereby displacing the only the upper punch is not feasible. at one of its ends called lug. The lug is material from the centre of the head area Flashless preforming of the work piece produced by through hole piercing. The until the die cavity is completely filled. Gassteel 16MnCr5 was used as work piece springs are used to ensure material. The tool was made of hot working that the dies remain closed steel 1.2365 (32CrMoV12-28) coated with despite the rising cavity TiB2 to reduce die wear. The tool consists pressure. They also permit of the following elements – upper die, the required relative upper punch (forging & piercing punch), movement between the gas-springs, lower die, lower punch and a upper die and punch. release mechanism as indicated in Figure 2. The preforming of the Forging and punching process work piece by the dies The combined forging and punching process leads to a reduction of die Figure 4: different punch geometries can be described as follows. Forging is split stress. After the die cavity

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COMBINED FORGING AND PUNCHING OF LONG PIECES

Figure 5: Reading points and measured values measurements of hardness (Rockwell measurement of hardness, DIN ESN ISO 6508-1)

reduces the maximum stress as shown in Figure 3. The lateral forces, as a result of the material flow path, were analysed with the help of the simulations. This was made to prevent any deformation of the punch. The wear of the punch is determined mainly by the thermo-mechanical load. This load spectrum is affected by the geometry of the cutting edge and the punch front surface. For sheet metal, cutting the effects of different cutting-edge geometries upon wear behaviour, cut quality and part quality were determined. However, the findings of sheet metal cutting could only be limited to the extent transferred to the combined forging and piercing process because there are different process conditions. The forging and piercing with different punch geometries were simulated to examine wear behaviour and effects upon punch surfaces during the practical tests. Based on stress and forces occurring during forging four different punch geometries as shown in Figure 4 were selected for the subsequent forgings trials. The edge radii and punch surfaces of these selected geometries varied with the knowledge of the specific material flow and the complete filling of the engraving. The shearing forces have no significant impact on the punch. Hence, a deformation of the punch during forging was not to be expected.

forging temperature of the work piece was set to 1,200°C. The input material was heated in an electric chamber furnace. To reduce surface scaling, the work pieces were heated in neutral annealing carbon, which was preheated and kept at a constant 1,200°C in the chamber furnace. To unlock the lower punch at the appropriate moment for every trial, the release mechanism was filled with the number of shear pins calculated before. To determine the appropriate quantity of pins, the resulting forces of the punch (forces of 295 to 426 kN, different punch geometries) extracted from the simulation results were consulted. To estimate the effects of different punch geometries on the surface properties of the hole-wall or the wear of the punch front surface, the punches were changed over the course of the trials.

EVALUATION OF FORGING TRIALS Subsequent to the forging trials the parts were analysed in detail regarding: Macrohardness The tests for macrohardness were performed according to Rockwell’s specifications (DIN EN ISO 6508-1, hardness scale B) using a durometer CV-

PROCESS PARAMETERS Forging trials were performed to verify the simulation results. All trials were conducted on a 11,000 kN screw press manufactured by Müller-Weingarten. Heating cartridges and heating oil were used to increase the temperature of the tool to 110°C. During forging, the temperature was monitored with a pyrometer and a thermographic camera. The

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Figure 6: Micrograph areas (punch shape A)

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600MA made by CV Instruments. Hardness testing was conducted at four measuring points on the part as shown in Figure 5. To estimate the effect, the combination of forging and punching in one process step may have upon the hardness three of these four measuring points lie in or directly beside the punched hole. The fourth measuring point indicated as position 3 in Figure 5 is located at the end of the part’s bar to facilitate detection of decreases in hardness or the likes. The billets exhibit an initial hardness value of 86 HRB on an average. This value, which averages between 94 and 97 HRB, increases after forging. Microstructure and Fibre Orientation To analyse microstructures, the parts were cut along the longitudinal axis. To locate the ascendancies of piercing upon the microstructural composition of the forged part three positions around the pierced hole, as marked in Figure 6, were selected to be examined. The parts exhibited a consistent ferrite-pearlite structure during all the inspected positions. No discernible differences due to varying punching geometries were found. To gain additional information about the microstructural formation, the cut sections of the parts were subjected to etching processes according to Oberhofer. Since all the fibres are oriented parallel to each other, the parts show an even fibre orientation. Wear behaviour of the punch After performing small batch forgings (approximately 250 pieces per punch geometry), the influence of the forging on the dies and the punches were analysed in view of their wear behaviour. The punches were measured with an optical measuring device of ATOS II class produced by the Gesellschaft für Optische Messtechnik (GOM). To capture every alteration, various images were taken from different angles both, before and after forging. Subsequently, the images were superimposed to facilitate the detection of variations as indicated in Figure 7. A significant wear of the punches could not be detected. However, the test results for the punch geometry D found a negligible upset in the head area of the punch due to various frictions and stress. Abrasive wear was not detected. Visual inspections of the

COMBINED FORGING AND PUNCHING OF LONG PIECES

punches surfaces as well as upper and lower die indicated no further wear out. Despite the flashless forging process, the loads of the tool steel seem low and cause no serious wear out. Dimensional accuracy of the punched holes and surface roughness of the through holes The test-results regarding the dimensional accuracy of the pierced hole, surface roughness and finish quality proved satisfactory. With the target value for the punch diameter set at 30mm, the average hole diameter measured 29.65 mm. The surface roughness (Rz) ranges between 1.48 and 12.63 μm with a mean roughness index (Ra) of 0.18 to 2.13 μm. The results show that the forged parts have a high surface finish and an expensive drilling step is not necessary.

should be expanded to include multiple punches. Applying multiple punches can eliminate the preforming of the parts during the closing of dies. The forming could be done solely by the forming and piercing punches. An additional opportunity for further research is the serial operation of the tool concept (for e.g., a study of a tool’s industrial application spectrum for fast-moving horizontal presses). These days, many parts like beads or pinions are produced on fastmoving horizontal presses. For this kind of industrial process, 100 passes per minute would be a realistic working hypothesis. The tool concept should be modified to the applicability for horizontal presses. The existing experimental tools have to be adapted accordingly. The locking device and the release mechanism of the tool have to react fast enough to permit the production of such large quantities per minute. Hence, a hydraulic release mechanism should be tested.

FEASIBILITY OF FORGING The feasibility of a combined forging and punching process for flashless precision components has been demonstrated by research projects. In addition, the parts’ applicability without any further processing of the piercing could be proved. The studies were conducted with only one punch. Due

Figure 7: Wear measurement punch shape D (analysis made with ATOS by GOM)

to the complex nature of the existing part geometries (for e.g., axle stubs), the method

Judith Kerkeling, Project Engineer, Institut für Integrierte Produktion Hannover gemeinnützige GmbH (IPH) Email: Kerkeling@iph-hannover.de

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Illustration By Uttam Rane

FORGING TECHNICALITIES

The nature and type of steel depends on the conditions and processes imposed on the molten metal during the steelmaking process. With stiff competition in the steel industry, it is essential for an enterprise to develop the correct grade of steel before forging it. Hence, it is important for the company to identify the parameters that not just optimise processes and assets, but also enhance it and enable the process to run at an optimum performance level without incurring the revenue and productivity loss of a trial and error method. he steel industry requires precise knowledge of steelmaking processes, feed stocks and products in order to address inefficiencies that lead to yield losses. An enhanced understanding of these processes will help reduce these inefficiencies. Advanced technologies, operating practices and materials that increase steelmaking productivity and yield will also generate sizeable energy savings. Hot forging, hot rolling and metal

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working industries throughout the world suffer enormous losses every year due to a number of factors. These losses are not only the losses incurred by a particular company, but are losses faced by the entire nation in terms of resources like material, energy and processing time for the same. While the industry is gearing itself to become competent by adopting innovative practices and latest technologies, owing to its largely unorganised status, the path to prosperity looks a little grim. It is thus of utmost importance for players in the forging

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industry to look inwards and introspect inefficiencies arising out of each operational process and aim at resolving the minutest of issues at the earliest. This will not only mean high productivity and efficiency, but also enhance the top line and bottom line of the companies following this path. The forging industry has been suffering from various challenges which need to be addressed on an immediate basis. In order to ascertain the same, the industry needs to practice the following list of doâ&#x20AC;&#x2122;s and donâ&#x20AC;&#x2122;ts.

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FORGING TECHNICALITIES

LOSSES SUFFERED Oxidation/Scaling and Decarburisation: Material loss is caused due to scaling and decarburisation during heat treatment, hot forging and hot rolling of steel. The rejections of metal components and loss of aesthetic appeal of forged and cast components are caused due to scale pit marks. Also, non-value adding operations like sand blasting, shot blasting and acid pickling after heat treatment of metals give rise to polluting effluents and disposable waste, which cannot be recycled in any manner. As a result, the time taken between the production and dispatch of components is increased due to these processes. Low Forging Die Life: In hot forging operations, die life is the prime determinant of cost of production and productivity. Increased load on forging presses & hammers, fast wear of forging dies and improper flow of metals in die cavity are some of the causes of losses in the hot forging industry. This is evident in the form of reduced die life, die failure and rejection of components. Most of these causes are attributed to the use of improper lubricants during forging. High Fuel Consumption and Maintenance Downtime in Furnace Operations: Energy losses caused during furnace operation are due to thermal shock cracking of refractory lining. Low emissivity results in increased fuel consumption. Frequent furnace maintenance downtime is caused due to the required change in refractory lining, energy leaks due to thermal shock cracking of refractories, carbon deposits on burner blocks and increased time for achieving the desired temperature. Low Tool Life: Metalworking operations like tapping face productivity shortages due to breakage of taps, increase of friction and cutting-edge temperatures. The problems are acute especially in the case of stainless steel tapping.

COST REDUCTION METHODS Some of the methods for reducing cost in heat treatment, hot forging, hot rolling and metal working through innovative methods are explained below: Preventing Scaling and Decarburisation: Anti-scale compounds manufactured by Steel Plant Specialities have substantially reduced scaling and decarburisation during heat treatment, hot forging and hot rolling. Some of the benefits include: Rejections of hot forged and cast components due to scaling during heat treatment can be eliminated. Pit marks caused on components due to scaling and loss of aesthetic appeal can be prevented. Operations like shot blasting, machining, grinding, etc., which have to be conducted due to scaling after heat treatment, can be substantially reduced or eliminated. Quicker deliveries immediately after production are enabled. Increasing yield is possible as allowance for machining and grinding of scale pits on surface of components can be reduced. ESPON anti-scale compounds have proven to achieve

excellent results in case of high-value components and salvaging a large number of forged and cast components from rejection. Increasing Hot Forging Die Life: Eco-friendly, non-polluting hot forging lubricants that help increase die life have become the need of the hour for the hot forging industry. Steel Plant Specialities manufactures graphiteless, water-soluble, non-polluting lubricants, which have increased hot forging die life from 30 per cent up to 100 per cent. It ensures: Wearing of dies is greatly reduced by good lubrication. Load on forging presses and hammers are reduced. Improved surface finish of forgings Zero smoke and clean forge shop floor. Energy Saving in Furnace Operations: The refractory lining life of billet reheating furnaces in hot rolling is increased due to the application of a special refractory coating. It also saves fuel. The benefits of using heat reflective refractory coating include: Increased thermal shock resistance of refractory lining Prevention of energy leaks due to cracks in refractory lining Increased emissivity of refractory lining due to application of refractory coating enables faster heat up time of furnaces Reduced fuel consumption Reduced maintenance downtime as life of refractory lining is increased. Refractory coating has been found effective in a number of hot rolling mills, hot forging units and sealed quench furnaces. Increasing Tapping Tool Life: In metalworking, tap teeth are most susceptible to damage due to heat than most other cutting tool surfaces. Chips are most likely to get congested in tapping than in other operations where the cutters are not surrounded by work metal. Special tapping lubricants have enabled substantial savings especially in stainless steel tapping and in various metal working operations: Productivity is increased due to increased tapping tool life. Reduced friction and cutting edge temperature. Retained sharpness of threads. ESPON tapping lubricants have been found useful in a number of metalworking operations. SP Shenoy, CEO, Steel Plant Specialities E-mail: info@steelplantspecialities.com

VIEW FROM THE TOP: Exclusive Interaction With

Honâ&#x20AC;&#x2122;ble Commerce & Industry Minister Mr. Anand Sharma on pg.

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GRIDBOTS TECHNOLOGIES

BUILDING

INTELLIGENT

MACHINES Dreaming big and turning them into reality is what Pulkit Gaur, a technology geek-turned-entrepreneur, always strives to achieve. Passionate about robotics, Pulkit started his own firm, Gridbots Technologies. Started in 2007 and driven by innovation and persistence towards achieving perfection in robotics, machine vision technology and artificial intelligence, the company envisions making robotics a part of oneâ&#x20AC;&#x2122;s day-to-day life. With innovative professionals on board, Gridbots Technologies believes in making a big difference through small incremental changes. Technology firms such as Gridbots are surely going to be the trendsetters for emerging start-ups in the years to come.

Robotic arm

Pulkit Gaur has done BE in Production & Industrial Engineering from MBM Engineering College, Jodhpur. He is currently a TED Fellow. The TED (Technology, Entertainment, Design) Fellows program is designed to bring together young world-changers and trailblazers who have shown unusual accomplishment and exceptional courage.

The man & his machine: Pulkit Gaur with his creation

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GRIDBOTS TECHNOLOGIES

PRERNA SHARMA n an era where things get done at the click of a mouse, a lot goes into making this big dream a reality… It is the constant pursuit and zeal to achieve better than the best that drives the leading start-ups of today to challenge conventional thinking. Instilling the seeds of innovation among start-ups is the entrepreneur and technology geek Pulkit Gaur, the founder and the Chief Technology Officer of Gridbots Technologies, who not only defied conventional practices, but also brought out a whole new dimension to adopt smart technology in day-to-day life. Gridbots is an Ahmedabad-based technology and innovation company. Started in August 2007, the company is driven by innovation & persistence towards achieving perfection in the domain of robotics, machine vision technology and artificial intelligence. It is incubated at the Centre for Innovation, Incubation and Entrepreneurship (CIIE), Indian Institute of Management (IIM), Ahmedabad. The company’s unique product offerings include indigenous combat robot for defence forces, lightweight programmable manipulator, automatic tracking cameras, automatic surveillance robots, autonomous guided vehicles for industry, human machine interfaces and robotic development platforms for research.

AN ENTICING JOURNEY With `10 lakh as initial capital, Gaur promoted Gridbots in August 2007 and managed to break even in the same year in December. When asked why he did not approach private investors, he claims, “Investors are good for any business to scale and grow, but we are not turning to investors as of now.” With a seed funding of `25 lakh provided by the Department of Science & Technology, Government of India, Gaur thinks that he and his team can manage with this sum, at least, for now. This go-getter team of young talent believes in thinking big and having fun at work. Talking about his journey so far, Pulkit says, “The journey has been fun and a constant learning experience for us. We do not worry about competition

because we believe in the mantra of ‘survival of the fittest’. In this continuous journey, we are constantly experimenting with robots, which can be used in homes and industries.” Calling it the result of great team work and dedication, Pulkit has been able to steer the company onto the path of success in an exceptional manner. On the opportunities in store for upcoming entrepreneurs, he opines that there are a lot of opportunities with the growing marketplace. Anyone who has a great idea can definitely expect a lot of support because of this ecosystem.

THE SOURCE CODE With a vision to make robotics a part of one’s day-to-day life and building machines, which are more intelligent, more efficient and can save time, Pulkit and his team have traversed a long way in such a short span of time. When asked about his source of inspiration in achieving such an enviable feat, Pulkit promptly replies, “The inspiration came from watching sci-fi movies during childhood. After I got into engineering, robotics technology became my passion.” Describing the uniqueness of their products & services, Pulkit informs, “The ideas behind our technologies and products are unique

UP, CLOSE & PERSONAL Entrepreneurial hurdle Finding right people and ﬁnance to help us scale Mantra to excel Be passionate about what you do Breakthrough imperative The ‘never say die’ attitude and ‘try until you succeed’ The role model Pulkit admires Steve Wozniak for his personal traits and vision. He believes Wozniak is a genius and a constant innovator. He is also inﬂuenced by Steve Jobs and his business & technology philosophy. One project closest to Pulkit’s heart ALIAS is the project closest to Pulkit’s heart as it took him about a year to complete it and required a lot of his time & resources. He designed and fabricated it without any external help. ALIAS is a state-of-the-art robot. It functions on advanced techniques and approaches used in modern robotics.

and innovative – both in terms of technology and the application of that technology.”

FROM CURIOSITY TO A MILLION DOLLAR BUSINESS The techno-geek was quite a curious lad and always believed in learning using methodology. Sharing his childhood memories, Pulkit deliberates, “After coming from school, I would get into my room, which I called a lab. There, I would work with circuits, old electronic devices, computer and other electronic devices. To understand the concepts of electronics s u o nom better and uto Robot) a t mar ervice S efficiently execute ( sR rs SaU erwate my ideas, I would read a Und lot of books on electronic design and digital electronics.”

FASCINATION GIVES BIRTH TO PASSION Pulkit has always been fascinated by robots and wanted to make his own robots. By constantly keeping a tab on the latest technologies, he discovered that to make advanced robots, he needed to be good at both, software and hardware. He started honing his skills in both and tried to practically implement whatever he learnt, which quickly turned into his passion. “Today, it has become my life I live, dream and think robotics,” avers Pulkit. His robots can clean sludge from the bottom of a water tank, help out a pickle factory & clean a house, and, that too, at an affordable price. The proud owner says that “we are bringing the technology of the future to the Indian market”. Pulkit adds, “We, at Gridbots, do not work. We enjoy every day... every hour... every second, because we do not do anything, which is obvious! This gives us the refreshing creative energy while working on problems, challenges and hardships. For us, every problem is new, every challenge is new and we

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GRIDBOTS TECHNOLOGIES

take it head on. This is the motive behind creating Gridbots Innovation Labs, which churns out new big ideas to transform them into huge business opportunities.”

NECESSITY INSPIRES INNOVATION Undoubtedly Pulkit has a passion and the desire to experiment with the impossible, but his whole innovation journey has a very interesting story behind it. Hailing from the water scarce region of Rajasthan, Pulkit understood the value of creating a mechanism, which could clean water storage tanks without having to empty them or waste water. “I come from Rajasthan and I have seen people drinking dirty water

else so that it would fit in well in a multitudes of conditions,” says Pulkit. But developing SaUsR has not been an easy feat. Pulkit and his team had the challenge of not only creating an indigenous waterproof and rustproof device, but also of adding a camera feed and making everything work on a single-phase power supply. Currently, SaUsR costs `7.5 & `12.5 lakh.

CIRCUMVENTING ADVERSITIES Although not risk averse, Pulkit has faced his share of difficulties while setting up Gridbots. Enumerating the same, he says, “When we started Gridbots, we wanted to develop an

THE WINNING STREAK Pulkit has been nominated in the MIT’s young innovators’ list. Gridbots developed India’s first underwater robot that can perform underwater operations in 2009. from dirty municipal tanks or overhead tanks,” Pulkit says, adding, “So, it was my dream to develop something for these people using robotics.” Passionate about robots, Pulkit developed a smart waterproof robot capable of carrying various underwater operations with ease. His invention SaUsR (Smart autonomous Underwater service Robot) ensures smooth and foolproof operations for such machines. SaUsR uses visual sensors with high-resolution cameras mounted on its back, which are also capable of giving the feedback of a live video, thus ensuring better control. Its light emitting diodes are used for lighting. The robot has sensors for direction, temperature and acidity measurement. It is made of anodised aluminum and coated by hard chromium and is therefore, rendered waterproof. The robot is controlled from an external source such as a keypad and a monitor. It weighs 30kg and comes in two models – a 2ft-wide, 2ft-long model for domestic purposes (since tank openings are small), and a 3ft-wide and 2ft-long model for industrial purposes. “We tried making indigenous smart cleaning robots, which would be light, small and costeffective than what was available anywhere

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intelligent machine vision technology and use it in robots and intelligent machines. As this is a research field, you need to make a lot of efforts and have the necessary resources. We did not have a constant revenue stream and soon ran out of cash & savings. Hence, we had to look for alternative sources of revenue. I opted to start with educational robotics – the main reason being that revenue generation was quick and there was no requirement of huge investment to begin with. Moreover, I always wanted to do my bit for society by spreading awareness about robotics.” Talking of several other challenges, he points out the scarcity of talent as the next major issue. Currently, the company operates with a very small team of highly motivated and talented individuals. But they need more and more people who are

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passionate about this field. Their small size and lack of experience posed great difficulty in cracking their very first deal with the defence establishment. But his ‘never say die’ and ‘try until you succeed’ attitude managed to circumvent all such adversities.

CHANGING DYNAMICS Envisioning Indian manufacturing as semiautomated using robots, Pulkit thinks that robotics is a very big opportunity waiting to be tapped if appropriately executed. Robotics definitely has the capability to change the game, especially for sectors like defence and nuclear power plants. He claims, “Robotics is a field that is completely unexplored. People think of it as a field that is only useful in industries, where heavy objects have to be moved, or in top-secret military operations. But the scope of robotics is much larger and can only grow with creative inputs.” As the future course of action, the company will be getting into infotainment and medical robotics. Their intent is to change the way some traditional processes are currently executed. As Pulkit states, “It will definitely reflect in certain sections of the industry – if everything goes right.” A firm believer in the ‘believe in yourself’ attitude, Pulkit thinks that patience, the ability to dream big and achieve the set goals are the key performance boosters in every business’ success.

CHALLENGING THE OBVIOUS A true innovator at heart, Pulkit thinks that innovation is just the beginning. Converting innovation into a product and then ensuring that it actually serves a purpose is essentially the task of an entrepreneur. He suggests that the students of today need to concentrate more on practical aspects of science and technology, which will give them insight into the complex concepts and help them understand things in better. Having achieved such an enviable feat in such a short span of time, Pulkit has truly become an icon for GenX entrepreneurs.

INDUSTRY UPDATE: STEEL Prospects & Possibilities

Paving The Boulevard Of The Great Indian Steel Dream on pg. GridSURV Surveillance System

Photo by Sumedha Mahorey

ENERGICA SRL

COMPETING ON QUALITY IN PV MODULE MANUFACTURING With assured quality as its hallmark, Energica Srl’s highly automated manufacturing facility at Turin, Italy, has fast emerged in the PV module manufacturing market in the last two years. With plans to expand its production as well as enter new markets, this niche player with 4.5 per cent more energy generation capacity aims at exploring high-quality PV modules market in India.

SUMEDHA MAHOREY

ocated amid lush green fields at the foot of the snow-clad Alps is a start up company guided by precision, quality & innovation, and a highly qualified professional team that offers the market the right configuration of the photovoltaic (PV) module to meet most of the energy demands. Founded two years ago by entrepreneurs operating in international markets, Energica Srl, based in Turin, Italy, today boasts of a 10,000 KW capacity plant covering an area of 3,000sqmt. Highlighting the company’s market positioning, Luca Manfredi, VP – Sales & Marketing, Energica Srl, claims, “We are a new brand in the PV market. Our line of production is specialised in the manufacturing of monocrystalline and multicrystalline PV modules. At this plant, we manufacture modules with 60-cell capacity. Our brand value stands on quality-efficient manufacturing practices used in our shop floor.”

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MANUFACTURING THE SOLAR DREAM The modules are built using highly efficient cells, which allow for better harnessing of the sun’s radiant energy. The company guarantees savings on electricity bills, better profitability and lower CO2 emissions. But how does the company ensure the quality of its modules? The production line is completely automated and involves minimal manual operations. The company’s production technology allows it to guarantee a very high quality product free from defects. It also allows the company to manufacture a consistent product with much lower tolerance than those required by the European Union certifications. Criticality of Design As we enter the production line, a brightlylit shop floor with a clean yet silent environment comes to the fore. Elaborating on the set up of the manufacturing unit, Manfredi says, “The automated machinery is placed in a direct line without any corner. This means that the flow of materials is from the stocking area at the start of the line to

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manufacturing machinery, testing and storage of the final products at the end of the line.” Utmost care was taken while the single line production unit was being designed. Manfredi elaborates, “While designing the manufacturing facility, we placed the stock in the front and the final product at the end to avoid corners in the production line. This design has helped us to process and effectively move the material inside the plant. Also, we made sure that employees have full accessibility to the machinery and time is not wasted in moving around for spare parts, etc.” Premanufacturing storage The company stores raw materials like stainless steel frames and glass, which do not require standard storing temperature, at the point in the manufacturing facility where processing commences. This material then moves into the manufacturing line where the temperature is automatically monitored. The company acquires solar cells from the market, which are subsequently tested

The strings being laced with EVA

Photo by Sumedha Mahorey

ENERGICA SRL

The 60-cell module ready for lamination

Photo by Sumedha Mahorey

at the company’s facility. After testing the the atmosphere. This material exhibits time of the lamination process is crucial as it quality of the solar cells, a string i.e. a unit of excellent tolerance against fluctuating eliminates bubble formation, thereby 10 solar cells, is formed. These units are temperature, rain, snow, humidity and high producing a high quality product. In this then subjected to the soldering process winds. stage, the module is given a definite shape wherein each solar cell is shouldered into Lamination and all extra material is cut from the main the panel. After this process, the positioning At the lamination stage, the PV module is frame. Subsequently, the positioning as well and quality of the string is tested. After laminated in vacuum for 80 minutes. The as the condition of the solar cell is rechecked testing, the strings are set in six lines as there are chances of it breaking. – required for a 60 cell module. The solar frame is then clamped into Founded two years ago by entrepreneurs Both monocrystalline and the aluminium frame. operating in international markets, Energica multicrystalline PV modules are Elaborating on the criticality of Srl, based in Turin, Italy, today boasts of a manufactured in this plant. The this frame, Manfredi says, “During 10,000 KW capacity plant covering an area of strings are then combined into one winter, snow creates a mechanical 3,000sqmt line of EVA i.e. plastic material for the force on the frame. Hence, if the The company’s automated production lamination process. frame is not closed properly, it could technology allows it to guarantee a very high Explaining the functionality of break the material it is holding. Also, quality product free of defects EVA, Manfredi states, “We use Glassthe type of frame used is very critical I EVA in our modules. During the as during winter snow, which The company’s new module produces 4.5 per combination phase, solar cells are liquefies during the day, could enter cent more energy in a year placed on the top. A layer of EVA the frame. This liquefied snow would Cooperation interest in India followed by a paper called bed sheet eventually get converted into ice Technology & Business is then placed on the solar cells. We during the night, which might end up have a robotic arm that positions the breaking the glass. To overcome this, Manufacturing strings on the glass, and the EVA is we have studied the thermal Sales and Service Partner. placed between the solar cell & the expansion of materials used in the glass. Once through with the module with the help of a material complete production line, we have research company.” to control and check the complete “We now know that during the process and solder it. This step day, the module could reach up to requires manual control on the 80 degrees centigrade and the frame modules as at present, there are no could enlarge. The glass reaches the high-precision automation same temperature after some time. technologies that can take care of During the night, the frame cools the process.” In the next step, the down & contracts and the glass modules are laced with the bed returns to the standard temperature. sheet, an important material of the In the case of traditional modules, The customised aluminium frame designed for Energica modules module that comes in contact with the thermal expansion of the material

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The specially designed plastic corner that separates modules and helps in safe transportation.

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The solar simulator that derives a data sheet detailing the exact thermal expansion of the materials

specialty lies in the fact that our glass is 4mm thick and can withstand rain, high-pressure snow, temperature fluctuations, humidity, high wind, etc.”

AIMING AT A VAST EXPANSE The company plans to double its capacity in the next one-and-a-half years. Describing in brief, the company’s plans, Manfredi says, “Our policy is to position ourselves as a top quality player. At present, the manufacturing line is on the left hand side of the facility. We plan to double the line and arrive at a production of 30 MW in the next one-anda-half years. We are also aiming at a market of €15million. We also have the same area on another floor, where we will have our office and an academy for renewable energy where we wish to distribute knowledge to the public.”

MESSAGE TO INDIAN COMPANIES With an aim to reach a vast consumer base, Energica Srl plans to enter new markets as soon as possible. The company has plans to make inroads into India. Elaborating on the same, Manfredi states, “Our target is to collaborate with Indian companies, which can buy our high-quality products and offer it to the Indian market high. We are not aiming at large distribution, but wish to be known for our quality products in the Indian market.” With a clear focus, planned endeavours and technological backups, this entrepreneurial dream is fast catching the attention of renewable companies. It remains to be seen, how best the company can leverage on its capacities and emerge as a leader in its niche space.

Photo by Sumedha Mahorey

is not taken into consideration, and thus may lead to short durability,” he adds. Testing After the aluminium frame is prepared, it is sent for the final test, which is conducted on a solar simulator. The solar simulator flashes the modules to derive a data sheet detailing the exact thermal expansion of the materials. At this stage, the power derived from the module is tabulated and the quality of the material ascertained. Storage The company has devised a new way of stocking the solar modules. Commenting on the same, Manfredi explains, “Normally, traditional producers place the modules vertically or placed one on top of the other. But if modules, weighing, say 22 kg, are placed on one top of the other, the module right at the bottom of the stack could break. To avert this, we we have designed a plastic corner that does not let the modules touch each other.” This corner has also enabled the company to ensure proper transportation of the modules. New products and technologies The company’s new module produces 4.5 per cent more energy in a year. Highlighting the same, Manfredi comments, “The new module’s increased production capacity means that our modules work well even at the end of the day when the light is not bright. With 4.5 per cent enhanced production capacity, the customer is likely to have two weeks more of the sun in a year.” The new technology uses a new type of glass that enables better transmission of light on the solar cell. Additionally, with best quality material, the solar modules give out the best result. Manfredi adds, “4.5 per cent in a year on a normal solar grid is about 100 KW, which is a lot of money. Another

Photo by Sumedha Mahorey

ENERGICA SRL

The in-house end of line warehouse is completely temperature and humidity controlled

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TURNING IDEA INTO PROFITABLE VENTURE

A 90 D

S ES

YOUR BUSI N RM YS FO S TO TRAN

Are you willing to spend the next 90 days making your company more profitable? If you have the discipline, you can. Turning bright ideas into action is a problem most companies face. However, a daily implementation schedule will benefit the team, department and organisation as well. Here is a 90-day blueprint to make this a reality...

be possible when everyone’s fingerprints nnovation is the central other organisation resources to the cause are on the strategic plan. For this, it is issue in economic for at least a year. essential that spectators in the organisation prosperity,” said Professor According to research, most CEOs pay are asked to be genuine participants willing Michael Porter of Harvard lip service to innovation and a few focus on to dive into action. Take, for instance, the Business School. innovation by the top team. Very few Indian case of HLL. HLL’s mission ‘Bushfire’ led by Companies, which adopt companies commit to a long-term the MD and CEO Nitin Paranjpe inspired innovation, fare better in the marketplace. innovation initiative to build a systematic 4,000 employees to visit 15,000 shops This was proved by research, which culture of innovation across the organisation. over six days only to get suggestions to indicates a clear link between better A few trained fast trackers, like the 35 create perfect stores. Even the Idea Bank innovation practices, employee involvement chosen at the Brakes India, Foundry Scheme at ICICI harvests the ideas of and customer satisfaction. A higher market Division, can ensure that innovation thousands of employees and provides builtshare is the hallmark of an innovative practices seep down to the shop floor, thus in rewards for teams that actually ‘tame the company. building a sustained culture of innovation. wild ideas’ and implement them. So, when it is a known fact that The 35 trained innovation leaders create Companies, which have practiced the innovation is essential for generating profits, commando action teams around them. All 90-day innovation plan over the last 20 why do more companies not embrace the teams track the core goals of the years, have reaped the fruits. These innovative practices? The answer is simple. company. The feedback follow-ups and companies have not only increased their Innovation does not happen by wishful rewards systems ensure the rest. market share, but have also achieved higher thinking. Commitment, resources and a V Narasimhan, Executive Director, Brakes progressive mindset is required to India, is of the view, “Innovation create a culture of innovation. Innovation can be the secret ingredient that transforms ensures fun and excitement at the The involvement of the whole a company. It is about new ideas. Creative ideas may workplace. Why should the top organisation, including the top management only have fun be new, but they need to be tamed to work in the thinking, while all the others just management, in planning; a system to go through suggestions, do as they are told?” corporate world. tame wild ideas and a system to Swami Vivekananda had said, levels of customer satisfaction and enhanced reward innovators is required. Only the “This world is just a gymnasium in which we employee participation. The result: greater best companies manage to do all this. play; our life is an eternal holiday.” Carrying profitability. However, any company this thought forward, a company needs to CREATE A WILDFIRE undertaking an innovation initiative should first install a positive field, wherein everybody Creating a conflagration of enthusiasm will be willing to dedicate time, budget and is full of the joyous, ‘can do’ spirit. This is the

‘I

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‘field’ in which creativity and innovation Plan of action works best and playfulness enhances ideas. A creative environment is supportive The 90-day blueprint has a plan or a thinking tool attached. As per the and nurturing. It is an environment in which plan, one has to create a few small cross-functional commando teams of 5 everyone feels free to play and to be to 7 action warriors. All the teams have to follow the 90-day plan, led by intuitive & bold. It encourages people to an innovation champion who has direct access to the CEO. Innovation take risks and think out of the box. requires going away from normal practices, cutting against the grain. Every organisation is either surrounded Therefore, the top management’s support is critical. The 90-day plan will by a positive or a negative field. This field help companies: begins within the individual as every individual has a positive or negative field Create a climate, which empowers everyone in the company to achieve within himself. The development of an inner their full potential field – a positive mind space – is essential for Launch an initiative, which will invigorate the whole organisation creativity. Continuously developing positive Build young, proactive, commando teams, or innovation spirals, emotions creates a positive field within designed to think outside the box which a person interacts with others who Inspire team leaders to transform their departments and the bring in their own respective fields. Those organisation through their youthful, proactive ideas who operate in positive fields suffused with love, compassion, laughter, courage and Develop a daily plan to institutionalise innovation and establish longwonder, are likely to be more creative term culture change. when supporting others during their On day one, start by giving the team a bird’s eye view of the 90-day action innovative best moments. To present this agenda. The first step is to create a ‘problem bank’, which involves all the concept more clearly, I have used the team members. ancient Indian concept of Navarasas – the nine emotions. Learning to enhance the positive field materials, machinery, methods, markets problems together. and reducing the effect of the negative field and money. Let all the team members analyse and is an important part of creativity and Sometimes people state the symptoms discuss the problem. Study the past, present innovation. Thinking out of the box is and not the problems. For instance, consider and future of the problem as team members possible only in a positive field. The positive the question, ‘How to build a better mouse perceive it. Let everyone have a chance to field is sustained by certain tools and trap? or ‘How to keep mice out of my imprint their personal viewpoints of the behaviour – verbal, tonal and non-verbal. It space?’ This could throw open the field to problem. Certainly a person on the is a win-win field. Within such a field, all gas, poison or improving hygiene. The first assembly line will see the problem in a who operate together are enabled and question would ensure that the person is totally different way from the way the CEO nurtured. obsessed with the architecture of mouse perceives it. The problem of the mouse is As American writer Alvin Toffler claims, traps. Scarce resources could be spent on different from the solutions seen by the “The essence of creativity is a willingness to mouse traps, which would not really get housewife. When everyone understands play the fool, to toy with the absurd, only rid of mice. Get everyone to ask the the problem together, they commit to find a later submitting the stream of ideas to harsh right questions and identify the core solution common to all. Problem analysis by critical judgment. The application the whole team ensures that people take a of the imagination to the future holistic view without turf protection. therefore requires an environment “Instead of pouring knowledge into in which to safely reflect, in which people’s heads, we need to help them grind novel juxtapositions of ideas can be a new set of eyeglasses so that we can see There are dreams that do not let you sleep. freely expressed before being the world in a new way,” opines JS Brown, Mine, is of seeing India as the innovation capital critically sifted. We need sanctuaries former Chief Scientist, Xerox Corporation. of the world. For the last twenty years, creativity for the social imagination.” Give the team a chance to look at the and innovation have filled my life with a sense of problem together, so that their minds are mission. This journey has taken me into noisy PROBLEM STATEMENT expanded to achieve a holistic view. This It is important to involve everyone map of problems will enable everyone to workshops and hushed corporate boardrooms. in identifying problems in the have a unified view of the geography of the It has led me into debates with captains of system. Give everyone a chance problem. Encourage people to keep refining industry and economists. It has opened my eyes and encourage them to throw light the problem and adding more sub problems. to the potential of grassroots workers. on the problems. Once main Remember, when the problem map is clear, points are identified, it becomes the optimum path through the thickets and easy to deal with them. The mountains becomes easy and clear. Maintain DR REKHA SHETTY, problem finding exercise will be the growing problem bank on the intranet. MD, Farstar Distribution Network facilitated using the 6 Ms – men, Replace problems which are solved with

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new problems. This exercise enhances THE MINDSPOWER PROCESS MAP collaboration. It reduces needless conflict and eliminates turf protection. Problem Idea Implementation Incubation Analysis Identifying and formulating the statement generation problem is the most difficult part of creative problem solving. Very often, Identify action Train teams in Put ideas on white Group Create in People teams minds power tools board presentations innovation spirals we state symptoms of the problems Define document Define goals and end up wasting scarce resources Assess existing Analyse solution Management Policies & and gain approval and impact 6M management and choose best systems chasing the illusionary ‘golden deer of practices for recommended implementation practices solutions implementation problem statements requirements the epics’. Management then becomes Open moodi Switch on so emotionally committed to the Ice breaker; Install positive Left brains logical Mind space problem to subanalytical mind; nurturing climate nava rasas mind wrong path that we can end up conscious mind 5W and 1H accelerating along the wrong road. It is Execute Implement Change Identify top management support, stakeholder impact and communication communication, management design communication & training requirements like a man who drills an oil well in a training, compliance training complaince bad spot. More and more money is spent with no resulting strike. But Challenge Detailed Create linkages; List of ideas ensure top Cost benefit identification, those involved, refuse to fill up the implementation performance and management support analysis ensure strategic plan rewards importance unproductive well and move on to a new location. They continue throwing good money after bad because they INCUBATION AND ANALYSIS do not want to admit that a mistake had delivered overnight. Many years as a pilot During idea generation, a list of alternative been initially made. flying missions into Vietnam, he refined the solutions is generated, i.e. seeds are sown. idea. When he returned, he created Federal IDEA GENERATION During incubation, the seeds are allowed to Express. It is rumored that the legendary It was Ravi Venkatesan of Microsoft India, sprout and grow unobstructed. Dhirubhai Ambani got Boeing to cut open who focussed on Innovation Blow Back During analysis, the plants are pruned the hull of an aircraft to transport a huge (IBB) in his company. IBB happens when and weeds are removed, till only the usable machine, which was needed to reach India innovations developed for the poor, for alternatives remain. before major taxes came into effect. Let Implementation involves choosing the ideas appear and be recorded. Leave them final solution, planning, developing a detailed alone to germinate and grow in people’s The process over 90 days roadmap, communicating it to the teams minds. No criticism during idea generation. follows the path of: and finally, acting on the blueprint. “Analysis kills spontaneity. The grain once Creating a wildfire of Each of us has a strict censor board ground into flour, springs and germinates no enthusiasm sitting in our minds. Whenever an unusual more,” says Swiss philosopher Henrie idea pops up, the censor board sits up in Fredric Ammiel. Stating the problem horror and suppresses it before it can throw Generating ideas TAMING WILD IDEAS us open to ridicule. The censor board Incubation Innovation can be the secret ingredient that protects us against laughter and contempt. Taming wild ideas and analysis transforms a company. It is about new ideas. As a result, only 200-year-old, run-of-theImplementation. Creative ideas may be new, but they need mill ideas pass through this formidable filter. to be tamed to work in the corporate Consider all these statements that were instance, Tata Nano, are bought by rich world. Take a wild idea like ‘zero cost’. Start considered nonsense: A person can communicate with 173 nations. Venkatesan’s company offers a the process of taming it by enclosing it in a countries simultaneously at the click of a computer with three mice, so that poor sanctuary where it cannot be attacked but button. children in village schools can work on the only developed. Suspend judgement, Men can fly like birds. computer, three to a screen. Innovation is postpone reaction and extend effort. Get Photographs can be instantly printed. often born of adversity. It is about doing your team to start thinking about impossible Marriages can be fixed on the Internet. things differently. The surefire method is to goals and making them possible bit by bit to “There is no likelihood that man can think about the exact opposite of what the extent possible. Challenge them to turn ever tap the power of the atom,” said everyone is doing. Dr Edwin Land, the every cost centre into a profit centre. Robert Millikan, winner of the Nobel founder of Polaroid Corporation, made a Wal-Mart turned inventory into a profit Prize in Physics in 1923. killing with instant pictures when he made centre by getting its suppliers to deliver on Often nonsense, a silly question playing the his little daughter’s wish come true. She the shop shelf 40 minutes before it was sold fool, can lead to breakthrough ideas. A wild wanted to see her birthday pictures and paying them after six weeks. With a idea tamed can be a brilliant innovation. immediately, before they were developed. single stroke they could eliminate Imagine Sam Walton who made inventory a warehousing, logistics and even stacking on IMPLEMENTING profit centre, instead of a cost centre. Fred the shelf. Remember, the laboratory of the INNOVATIONS Smith, a senior in college, wrote a team mind can test a hundred alternative futures “You see things: and you say’ why? But I paper where parcels worldwide could be at very low cost.

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TURNING IDEA INTO PROFITABLE VENTURE

dream things that never were: Companies need to innovatively design their future way to ensure profitability! and say ‘Why not?”, said Irish when they are doing well. Learning exactly how Innovation requires dedicated efforts and adequate resources. It playwright George Bernard Shaw to get ideas, develop them and implement them as also requires the wholehearted in Back to Methuselah. innovations require discipline and direction. The involvement of the top Companies need to innovatively design their future journey can lead one to new strategies, new products management. There is no use when they are doing well. asking the rank and file to use or even new ways of working and managing. Learning exactly how to get ideas, innovation thinking tools, when develop them and implement the top management does not them as innovations require discipline and bother to learn or recognise them when two-step manoeuvre: direction. The journey can lead one to new they are used. Thinking tools are effective 1. Create a unified dream strategies, new products or even new ways only if they are regularly used and become 2. Act to finish. of working and managing. Practicing the a natural way of being. Ideas are easier. Implementation is step by step tools that lead to innovation for It is important to note that people are difficult. 90 days can ultimately enable reinvention of not concerned about what is said. Rather, A few years ago, topnotch American an entire organisation. Whether it was an they are keen to know about what is done. Research Company came up with the IAS Officer like SR Rao who transformed Get down, lead from the front and finding that the next global economic plague-ridden Surat to one of the healthiest participate! powers will be the Indian Elephant and the cities in the world or the Tata’s making Chinese Dragon. India is the largest Dr Rekha Shetty is MD of Farstar Distribution Nano the world’s most inexpensive car, laboratory for bottom-of-the-pyramid Network, a unique consultancy company devoted everything starts with a dream goal, an innovations for the poor. Most countries exclusively to innovation and creativity under the impossible vision which ignites the cannot come up with such reverse brand name Mindspower. Dr Shetty is an author, an imagination. The journey to transformation innovations, created by the poor but used entrepreneur and an original thinker. Popularly starts with a decision to chase a stretch goal, by the rich. known as the ‘Corporate Doctor’, Rekha Shetty has to reach for the farthest star. created a new tool for Indian Managers to develop INNOVATION – TURNING Dream the impossible dream and make the competitive edge: Innovation and Creativity BRIGHT IDEAS INTO ACTION sure your whole team dreams the same through Mindspower. It is the Age of Innovation. Constant and clear dream. If you want your company to E-mail: rekhashetty123@gmail.com consistent innovation is the only surefire pursue stretch goals, you need to do this

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USING LED TO CREATE NEW LIGHT

S E L P M I RLD’S S

C I N O R T ELECT

T H G I L O T T LIGH

R E T R CONVE

light. By irely new essfully t n e n a o c ssor suc rmed int e transfo , a physics profe b n a c t cathode sors, ligh onic sen and cathode to r t c le e o t op to anode ED. various D anode om the second L hors or E p L s o l h a p ic t n in fr e a t d id r e e t c emit econd d by D to a s tercepte low when When in a red AlGaAs LE ght into a dim g g shli connectin light from a fla d e transform

hysics professor Marcus types of components that, when illuminated complicated than a phosphor card. At Lichtmeister planned to by a flashlight, could light an LED. But only midnight, the proverbial LED flashed in his illustrate a lecture with one type of component would perform this mind, and he quickly built an all electronic demonstrations of how function on its own and without using two light-to-light converter by using only an LED light can be intercepted by or more components to achieve the and one other component from his parts certain phosphors or forward voltage necessary to drive an LED. cabinet. The resulting circuit is shown in various optoelectronic sensors and For example, a silicon solar cell provides Figure 1. transformed into an entirely new light. His only 0.6 volt. Achieving the voltage required WHAT IS THE MISSING demonstrations included a light-sensitive to forward bias a typical LED would require COMPONENT? phosphor card, charge coupled device a series string of three silicon solar cells. After several hours of experimenting, (CCD) & complementary metal oxide Figure 2 shows the two AlGaAs red Prof Lichtmeister suddenly thought of an semiconductor (CMOS) video cameras and LEDs directly connected together. The ultra-simple two-component solution to ultraviolet and near-infrared image LEDs are connected anode to anode and the problem: He connected a red AlGaAs converters. The optoelectronic devices cathode to cathode. When light from a were much more complex than the flashlight with either an incandescent phosphor card, and Prof Lichtmeister bulb or a white LED is directed at wanted an ultra-simple the first LED, the second LED will demonstration of how an LED glow dimly. This arrangement would glow when biased by a works, because the voltage provided forward current provided by a by the illuminated LED matches the suitable sensor. He rummaged necessary forward voltage of the through the optoelectronic drawer second LED. Figure 1: The resulting circuit of an all electronic light-to-light converter using an LED. in the parts cabinet on his workbench GOING FURTHER and found two silicon solar cells, One can easily experiment with several cadmium sulfide photo various kinds of LEDs. For best resistors, a couple of Aluminum results, use super bright orange and Gallium Arsenide (AlGaAs) red red LEDs. LEDs, some silicon phototransistors and half-a-dozen silicon photodiodes. Forrest M Mims III has been an electronics In his parts cabinet, he found some Figure 2: The two AlGaAs red LEDs directly connected anode to anode and cathode & science writer and photographer transistors, miniature chokes and to cathode. since 1969. He received an IR 100 Award assorted resistors & capacitors. from Industrial Research Magazine for How did he combine the smallest developing an eyeglass-mounted infrared travel LED to a second identical LED. When a number of components to do what the aid for the blind. He received a Rolex Award in flashlight was pointed at one LED, the phosphor card did? 1993 for developing a handheld instrument second LED emitted a dim glow. Thus, light that measured the ozone layer accurately PUZZLE HINTS from the flashlight was transformed into enough to find an error in a NASA ozone Prof Lichtmeister stayed up late designing light from the second LED. satellite. He was named by Discover Magazine several circuits that converted incoming (December 2008) as one of the ‘50 Best Brains in HOW IT WORKS? light into enough current to drive an LED. Science’. Prof Lichtmeister’s parts cabinet had several But these circuits were much more

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RIGHT CABLE SELECTION

CABLING SUCCESS

FOR VARIABLE FREQUENCY DRIVES

Variable frequency drives (VFDs) are among the most useful devices in the industrial world. They allow the speed of a 3-phase AC electric motor to be altered whenever the behaviour of the motor’s load - ie, the device the motor is driving, such as a pump, fan, conveyor belt or lathe – changes its demand on the motor. By changing its output frequency and voltage, VFD allows the motor to modify its revolutions per minute and respond to those demands. hy is a motor’s speed Several types of VFDs are available, but changing ability so the pulse width modulation (PWM) design important? AC (induction) has become the most common, because it motors are extremely works well with motors that range in size common in discrete from about a half horsepower (HP) up to manufacturing and 500 HP. It is also reliable & affordable and processing plants throughout the world. offers significant electrical energy savings. Imagine if all those motors could only spin When a motor is run at half its maximum at one speed, even when their loads are speed, it consumes only about one-fourth modifying their demands and/or when of the energy it needs at full speed. In this process variables like temperature, sense, it can be said that VFDs represent pressure, force, etc., are varying. With green engineering solutions. The list of motors delivering products at a constant benefits goes on… A VFD can provide a speed, regardless of new or changing ‘soft-start’ capability for a motor, decreasing conditions, scrap would pile up and energy the mechanical stress associated with full would, hence, be wasted. However, when using a variable frequency drive (VFD), a motor’s speed can be changed almost instantaneously to address load and process changes. And, as a bonus, VFDs can increase the precision of process control, given their ability to control motor speeds up to within 0.1 Figure 1: Diagram of a typical VFD system. per cent tolerance.

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voltage start-ups. In other words, a motor can be ramped up to the desired speed instead of being abruptly thrown on line at full Revolutions Per Minute (RPMs). The result is lower maintenance costs and a longer motor life. Use of a VFD can also help avoid overheating that can gradually destroy a motor. The way in which the components of a VFD system – drive, cable and motor as represented in Figure 1 – are selected, matched with each other and operated, will impact the reliability of all of the components of the system, as well as of adjacent systems. The cable connecting the VFD to the motor – positioned centre stage within the drive system – plays a vital role in optimising the VFD system’s component longevity and performance. The cable must be able to withstand the operating conditions caused by the drive system itself, yet at the same time, influence, in a positive way, the life of other drive system components.

RIGHT CABLE SELECTION

WHY CHOOSE A PURPOSE DESIGNED VFD CABLE?

QUICK TAKE

Like many engineering solutions, VFDs Tips for Better Management of Cable Noise Interference present not only benefits, but drawbacks as Unshielded VFD cables can radiate more than 80V of noise to other unshielded well. For example, the same fast switching communication wires and cables, and more than 10V of noise to shielded instrumentation rate of the transistors inside a PWM VFD that can accommodate an abrupt speed cables. When VFD cables are installed in close proximity to low-level communication cables change in a motor and offer precise control and other susceptible devices, it is necessary to ensure that shielding is present in the VFD of processes is also capable of generating cable. In addition, the use of unshielded cables in conduits around a VFD setup should be unwanted noise in the drive system cable limited or eliminated altogether, since the conduit is an uncontrolled path to ground for the and in the drive itself. noise it captures. If the radiated noise is an issue in an existing VFD installation, consider Electrical energy flowing in the cable how the instrumentation and control cables are physically routed and located in the contains frequencies as high as 30 MHz. If surrounding area. Maintain as much separation as possible between noise susceptible this radio frequency energy is not cables and VFD cables — a minimum of one foot for shielded instrumentation cables and contained within the cable, it three feet for unshielded instrumentation cables. If the two types of cable must lie close to can radiate out to interfere with the operation of each other, try to minimise the amount of parallel runs between them; it is wise to limit these nearby electronic stretches to 10” or less to reduce the likelihood of picking up radiated noise. Finally, if the e q u i p m e n t ; less than robust or two types of cable must unavoidably cross, it is preferable to cross them perpendicularly, commercial-grade Ethernet systems, simple at a single point. instrumentation wires and even circuits that have absolutely nothing to do with the VFD system. This noise emission can sometimes cable can sometimes cause a corona should be paid to the cable’s insulation type, be very difficult to track down & eliminate discharge to occur between the conductors; impedance and shield/grounding system. and hence, is the single-most significant an effect that can damage not only the cable The payoff will be drive/motor system problem associated with VFD systems, itself but also the motor, motor bearing and longevity and reliability. Unfortunately, some today. Unless a proper cable shielding the drive. This can lead to the failure of the users attempt to use unshielded tray cables design is present to control it, noise emission entire system ensuing production or hook-up wire for their drive system from a drive system cable can disrupt plant downtime. cabling. VFD installations with these and factory operations. Moreover, because The problems of noise emissions, products can suffer from low reliability, a a longer cable radiates more noise, the voltage reflections, over voltages and complex & costly installation, or both. length of the cable runs must be limited. corona discharge can be substantially Neither construction effectively mitigates That, in turn, puts a limitation on the factory reduced or even avoided by choosing an the problem of noise emissions generated layout. appropriate VFD cable. Special attention by VFDs, nor do they properly address There is another potentially corona discharge. serious concern associated with A VFD can provide a ‘soft-start’ capability for a motor, ATTRIBUTES OF A the use of VFDs. With an decreasing the mechanical stress associated with WELL-DESIGNED VFD improperly selected cable, voltage full voltage start-ups. In other words, a motor can CABLE waves reflected from the motor towards the VFD along the cable be ramped up to the desired speed instead of being It is important to select a motor drive cable that has been properly can produce excessively high abruptly thrown on line at full RPMs. designed and engineered to voltages in the cable’s conductors address all the key technical issues because they add to the voltage faced by such a component. These include: that is already there. A well-designed grounding configuration: Peak voltages of up to 2.5 times the An electrical grounding system provides nominal system voltage are a reference voltage; ideally zero, sometimes present in the for all other VFD system cable. As a result, voltage voltages. Sometimes it is reflections have been not possible to bring the known to cause a ground voltage to a true number of in-service zero voltage level, but the motor failures. There ideal reference can be is also some concern approximated by bringing all over the possible grounded points to the same ‘very long-term cable low’ potential. As long as a VFD cable damage under high voltage – is well grounded, it can avoid the especially with VFDs operating at 575 problem of excess current flowing into volts and above. other devices or other systems. In addition, high voltage levels in the

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RIGHT CABLE SELECTION

In other words, having a suitable ground portion of the cable jacket that lies inside small in gauge size, though when taken means that it is possible to control where all the fitting is removed, so that the braid or together, they add up to the equivalent the excess energy from the VFD drive goes. the copper tape of the shield is exposed for gauge size of the circuit conductors. These Any extraneous induced voltage in the mechanical contact. A conductive spring or are connected to the shield. So, when they system is undesirable because a certain gasket in the coupler touches the shield in are terminated together at the ground lug amount of useful power is lost. Proper this exposed zone and also contacts the on the motor case, the shield is automatically grounding also helps to overcome the housing to complete the ground circuit. terminated. problem of impedance Noise immunity: The noise mismatches and over voltages. The problems of noise emissions, voltage reflections, radiated from a VFD cable is One approach for grounding a over voltages and corona discharge can be proportional to the amount of cable is via the use of an insulated varying electric current within it, substantially reduced or even avoided by choosing as well as the cable length. More ground conductor, terminated, both, at the motor and at the current and greater length means the appropriate VFD cable. drive. The shield surrounding the more radiated noise. However, circuit conductors should be tied, both, Having a full-sized ground in a cable, i.e., by properly shielding the VFD cable, noise physically and electrically to the insulated one with a large cross sectional area of can be controlled. Belden’s research has ground at the point where the cable enters copper in the ground wires, means a low concluded that shielding systems including the motor housing or drive enclosure. The ground resistance from one end of the copper tape and combination foil/braid goal is ‘360° coverage’ at this connection. cable to the other, to minimise ground types are the most appropriate for VFD This prevents openings in the shield where loops and common mode current. By applications, due to the low impedance electromagnetic energy can possibly radiate contrast, with the higher resistance of a path they provide for common-mode noise out. smaller-sized grounding conductor, a to return to the drive. Foil shields are simply A less effective approach would be to voltage drop across the cable is more likely. not robust enough to restrict the volume of connect a single conductor drain wire from Such an offset in potential encourages noise generated by VFDs. the shield to the motor housing or ground loops. It is possible to get by with a Low dielectric constant: An important connector. Unfortunately, this creates an single ground conductor of a small gauge property of the cable insulation is its opening in the shield; a place where the size, but this may ultimately have a negative dielectric constant, or relative permittivity. shield is no longer continuous and where impact on instrumentation or communication This refers to that property of the insulation, the energy can leak from. circuits in the local area, if energy leaks out which determines the amount of One way to assure ‘360° coverage’ is to and is conducted into those adjacent electrostatic energy that can be stored use a coupler – a mechanical fitting with systems. when a given voltage is applied. In a cable, male and female components. It is threaded Alternatively, in what is known as a the dielectric constant should have a low into the motor or drive enclosure housing symmetrical design cable, three conductors value if the cable is to have a low capacitance, and the cable end passes between it. The are used for the ground – each relatively and consequently, eliminate voltage

Figure 2: Belden’s Classic, Classic Symmetrical and Classic with Signal Pair VFD cables

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RIGHT CABLE SELECTION

reflections from the motor back to the drive. Of course, shielding helps suppress noise, but cross-linked polyethylene (XLPE) insulation with its low dielectric constant also helps diminish noise. Insulation with a low dielectric constant, such as XLPE, allows engineers to closely match the impedance of the drive to the motor. With minimal mismatch, it is possible to substantially eliminate the occurrence of over voltages and high frequency spikes; either of which can generate noise. With better impedance-matching between the drive, the motor and the cable, it is also possible to get an incrementally higher degree of energy efficiency. In other words, more of the energy coming from the drive is converted into useful rotational energy in the motor, instead of being reflected back (which can heat up the cables and cause a corona effect and high voltages). This is yet another green benefit. As a bonus, a low dielectric constant insulation like XLPE permits longer cable runs. Suppression of overvoltage: Without a proper cable design, reflected waves caused by a cable-to-motor impedance mismatch can be problematic in any VFD application. The magnitude of this problem depends on a number of factors including the cable length, rise-time of the pulse width modulated carrier wave coming from the drive, VFD voltage and the degree of the impedance mismatch between the motor & cable. XLPE insulation, a material with a high impulse voltage breakdown rating, significantly reduces the risk of failure from reflected waves and voltage spikes. It is much more robust than polyvinyl chloride (PVC), a common insulation material that is not recommended for VFD applications. Thick insulation wall: A thick insulation wall is an advantage because of its proven electrical benefits (like lower cable capacitance) and the improved high temperature stability a heavier wall exhibits. Thicker cable insulation also helps guard against corona discharge. A thicker, industrial-grade XLPE insulation provides: More stable electrical insulation than PVC Lower cable capacitance, providing for: - Longer cable runs - Reduced peak motor terminal voltages for extended motor life

- Greatly reduced likelihood of corona discharge - Reduced magnitude of standing waves - Increased efficiency of power transfer from drive to motor. Low risk of corona discharge: Use of XLPE insulation reduces the likelihood of either the cable or the motor voltage reaching its corona inception voltage (CIV) â&#x20AC;&#x201C; the point at which the air gap between two conductors in the cable or between two windings on the motor breaks down via electrical arcing. A corona discharge produces extremely high temperatures. If the insulation system of the cable is a thermoplastic material; PVC, for example; the effect can cause premature cable burnout or a short circuit due to a gradual, localised melting of the insulation. By contrast, the heat generated from corona discharge forms a thermally isolating charred layer on the surface of XLPE insulation in the cables; preventing further degradation. Proper bonding: Bonding refers to how the components of grounding systems are physically connected or joint, in order to electrically tie them together. In the case of a VFD cable, this has implications as to how well you connect the shield and the ground conductors to the motor case or drive enclosure, and ultimately, to earth ground potential. Typically, bonding entails a mechanical connection involving a nut and bolt connection, though there are other possible methods.

A METHODICAL WAY TO CHOOSE A VFD CABLE When selecting a VFD cable, you should ask yourself the following key questions: Is it a VFD application? Does the motor speed need to be controlled? If so, you must choose between several types of cable that provide different features and benefits. What is the most suitable impedance of the cable to match the impedance of the motor? The impedance realised by the cable at the motor is generally low. So, it is desirable to choose the lowest cable impedance possible. However, it is not feasible to match cable impedance to motor impedance over a range of motor speeds since motor impedance varies with RPM. Therefore, the appropriate strategy is to minimise the impedance mismatch. By selecting insulation with a low dielectric constant and thick wall

such as XLPE, the impedance mismatch can be minimised successfully. Does the motor in your system have a fairly high horsepower rating, i.e. 100 HP or more? A higher motor horsepower translates into a higher current flow through the cable. What is the voltage rating of the VFD itself? The cable must be able to support it. Are there sealing requirements for the cable? A round cable should be selected to provide a good seal as the cable passes through circular openings and connection glands. Are there instrumentation and communication applications located close to where the motor drive and cable will be installed? If they are far apart, there is less concern about any possible emissions from the VFD cable, but if they are close, a cable with the classic design should be considered. Its foil and braid shielding provides extra coverage against the impact of radiation on neighbouring circuits. Do you need a line running between the drive and motor to carry brake signals, e.g. for slowing down or stopping the motor when necessary? If so, consider a cable having a signal pair integrally packaged inside the same outer jacket as the drive cable. How long is the cable run? Usually, the drive manufacturer can provide the specific information needed to make decisions about gauge size and cable run length. Keep in mind, if a cable length is too long, it acts like a large capacitor that must be charged up when the system is turned on. After that initial phase, electrical energy continually pumped into the cable from the drive can surge into the motor, possibly causing motor bearing burnout or damage to windings.

CABLING SOLUTION The user should be suspicious of a low-cost cabling solution, which, in the long run may end up costing more; as much as the price of a new motor or drive. By choosing welldesigned, robust VFD cables, an investment is made in the uptime and reliability of the VFD system, as well as that of any sensitive instrumentation and control systems adjacent to it that need protection. Brian Shuman, Senior Product Development Engineer, Belden

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CH-47 HELICOPTER

TAKING OFF AT THE FLIP OF A SWITCH Ever since its conception and design, the Chinook CH-47 helicopter has been the workhorse of the US Army and has served many other countries around the world. However, operating this helicopter is not an easy task and involves hand-pumping the accumulator for at least 20 minutes to start the auxiliary power unit to get the main engines up and running. Putting an end to this time and labour-intensive step is Eaton’s EPUSHA electric accumulator recharge system, which can be initiated simply by the flip of a switch to pressurise the accumulator in less than two minutes.

magine you are a member of a Chinook CH-47 helicopter crew. You have received orders to deploy, and as always, time is of the essence. Within minutes all positions are manned and your squadron is ready to fly. But before the helicopter can get off the ground, you and a fellow soldier must spend an intense 20 minutes hand-pumping the accumulator to start the auxiliary power unit in order to start the main engines. For a modern military force that aims for 24/7 readiness and rapid response, the last sentence seems out of place. But until recently, this time and labour-intensive step was part of the normal start-up sequence for the CH-47.

CHALLENGES The US Army recognised that the requirement to manually pressurise the accumulator was diverting manpower and resources from critical missions and causing costly delays, not to mention, increasing the potential for personnel injuries. Their search for a faster, easier and safer start-up mechanism for the CH-47 ended successfully with a system developed by Eaton called EPUSHA, which is an electric pump for utility system hydraulic accumulator.

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SOLUTION The EPUSHA electric accumulator recharge system can be initiated simply by the flip of a switch to pressurise the accumulator in less than two minutes, which is a tenth of the time it took for the manual process. “This improvement provided by Eaton makes life a lot easier for our soldiers. It enhances safety and resource reduction as well as aircraft readiness, which is of utmost importance in supporting our operations. When they need the aircraft, it is ready to go,” said Sgt Paul Phillips, Alabama Air National Guard. Eaton’s Aerospace Group supplies the two main components that make the EPUSHA system work. The electric motor pump is made by the Hydraulic Systems Division in Jackson, Mississippi, and the electronic control box is provided by the Electrical Sensing & Controls Division in Sarasota, Florida. In the old process, at least two people had to go to the back of the helicopter to hand-pump the accumulator in an up-anddown motion, like a car jack, for 18-20 minutes until the pressure reached 3,200 psi. With EPUSHA, one person flips a

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TRIGGER Getting the main engines of Chinook CH47 helicopter to start would require an intense 20 minutes hand-pumping of the accumulator to start the auxiliary power unit. The US Army recognised that the requirement to manually pressurise the accumulator was diverting manpower and resources from critical missions & causing costly delays, not to mention, increasing the potential for personnel injuries INNOVATION The search for a faster, easier and safer start-up mechanism for the CH-47 ended with a system called EPUSHA, which can be initiated simply by the flip of a switch to pressurise the accumulator in less than two minutes, which is a tenth of the time it takes for the manual process.

CH-47 HELICOPTER

This improvement provided by Eaton makes life a lot easier for our soldiers. It enhances safety and resource reduction as well as aircraft readiness, which is of utmost importance in supporting our operations. When they need the aircraft, it is ready to go. SGT PAUL PHILLIPS, Alabama Air National Guard

momentary toggle switch on the control box to start the electric motor pump, which pressurises the hydraulic start accumulator in less than one-and-a-half minutes. The rest of the start-up process is done automatically. When the auxiliary power unit is up and running, it turns a starter pump that provides hydraulic power to starters on the main engines. “The beauty of the accumulator recharge system is that with a full battery charge, it can be done up to four times before having to return to hand-pumping. That is four flips of a toggle switch to start the APU as opposed to manual pumping that takes 20 minutes each time,” said Chris Carson, product support manger, Eaton. The addition of EPUSHA also provides a redundant accumulator start-up system for the aircraft. If EPUSHA is unavailable for any reason, such as motor pump low voltage, the hand-pump can still be used. With direction from the Army, Eaton started developing the new accumulator start-up system in 2005, and in less than three years, the EPUSHA system was ready for testing.

RESULTS The Army has now made EPUSHA a condition of deployment for its entire fleet of CH-47 helicopters. The technology is being integrated into new production and back-fitted into older models. Other helicopter groups in the armed forces have also accepted EPUSHA for their aircraft, including the US Marine Corps’ CH-46 Sea Knight, and it is currently under review for incorporation into the H-60 Black Hawk fleet. “Eaton developed a great technical solution that can be easily transferred from one helicopter to another and be used by different branches of military service. We have also been working with Boeing to qualify EPUSHA for international users,” said Mike Ruple, Military Account Manager, Eaton. The improved time-to-start provided by EPUSHA matches a multitude of advanced capabilities that make the CH-47 one of the world’s most successful heavy-lift helicopters. The CH-47 fulfills crucial service roles around the world, not only moving troops and equipment but also flying missions for medical evacuation, aircraft recovery, firefighting, parachute drops, heavy construction, civil development, disaster relief and search & rescue. “We are excited about our teamwork with the Army in developing an improved start-up feature on the CH-47, as well as the impact it has made to support US troops. I congratulate Eaton employees for their skill and ingenuity in developing the EPUSHA technology. This is yet another example of their focus on customer satisfaction and their desire to deliver quality and value,” said Eric Alden, Director – Customer Support, Eaton. Courtesy: Eaton Corporation

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L&T

RADICAL INNOVATION TO ATTAIN

SUSTAINABILITY Radical sustainable innovation aimed at adding value to the customers has become the need of the hour for manufacturers. Metric, project initiation and the process itself are the three parameters that ensure a sustainable innovation process. By introducing sustainable innovations at its shop floor, L&T has not only attained direct benefits in terms of improving the floor time of the machine building process, but has also gained indirect benefits such as improvement in delivery time, flexibility to handle more variety and reduced energy consumption. hanges are inevitable. Any changes in the product, process or customer requirements make the old process redundant. It is widely recognised that sustainable innovation will play a critical role in sustainable development. It will also play a critical specific role in addressing environmental problems such as climate change. Radical sustainable innovation is the need of the hour rather than the incremental innovations, which is the present scenario. L&T believes in innovations mainly by involving people. Innovation brings radical or incremental changes to the product, processes or systems. This innovation ultimately should result in adding value to the customers. There are three parameters, which decide the success of an innovation – metric, project initiation and the process itself. Inappropriate metrics result in misplaced expectations, misguided project initiation clogs the development process and a poor process management, of course, results in failed innovation. Therefore, one has to take care of all the three parameters to ensure a sustainable innovation process. One of the examples of innovation from L&T is moving the materials on wheel. Unlike other companies, the company’s material handling is different as it handles materials weighing anything from a few grams to a load as heavy as 60T, and different shapes & different degrees of precision.

CHANGE AGENT When L&T did a value stream mapping for

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its production process, it found that one of the major muda is waiting time. The company opted for two approaches to eliminate this muda, viz: Converting their products from series assembly to parallel assembly, which in other terms is called modular assembly Eliminating the waiting time during the movement of materials. L&T has successfully eliminated about 80 per cent of this muda. Other factors, which have contributed towards the innovation process are increase in demand and, of course, the pressure on reducing their carbon footprint.

INNOVATIONS INTRODUCED Movement of material on wheels L&T’s practice of handling the material by overhead crane resulted in high waiting time. The waiting time was mainly due to waiting for a trained operator to operate and crane/ sling unavailability among other miscellaneous reasons. Hence, they converted the possible material movement on wheels. While doing so, they ensured that the parts were moved as kit or sub assy so that the process of machine building would speed up. Changing from conventional assembly method to doctor-nurse concept The throughput time for their machines using the conventional method of assy is around 43 days. L&T has changed the design to bring in modularity i.e. to make individual sub assembly and integrating this as and when the customer needs it.Further, this modularity is enhanced by making individual tested sub assembly and integrating it. This concept has reduced the throughput time to

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nine days.

HURDLES ENCOUNTERED The biggest hurdles encountered when implementing any innovative thought is changing the people’s mindset. In any innovation, people are the ones who decide its fate. Therefore, the simple logic, which L&T followed, was involving people in the process of innovation, which, in a way, brings in the sense of ownership. Proving the techniques was yet another challenge. This happened in iterations. L&T adopted simple techniques such as bigger wheel size to facilitate the movement.

INNOVATION IMPACT Ultimately, any production process will be measured with its results. Such an innovation should help in improving the results. L&T’s innovation has also resulted in improving the floor time of the machine building process, which has helped in serving the customer with optimum lead time. In addition, the indirect benefits are many – improvement in delivery time, improvement in the flexibility to handle more variety and reduced energy consumption to name a few. M Kumar, Sr DGM – R&D, QA & VDC; K Ganesh, Assistant Manager – Manufacturing Engineering & VDC; Prashanth KR, Assistant Manager – VDC.

CUTTING-EDGE SOLUTIONS

DEVELOPING PROCEDURES TO AUTOMATE ASSEMBLY PROCESSES n the automotive industry, combustion engines are still mostly assembled manually. However, researchers from Fraunhofer are developing procedures and methods to automate assembly processes in order to continuously improve the quality of engines. The use of the latest technologies helps in eliminating uncertainties during engine assembly. Valves, nozzles, pistons, spark plugs and camshafts – the heart of each car is its engine. It is a complex structure with many levels and individual parts and must therefore be assembled in a correspondingly precise way. Parts that are slightly damaged, malformed or assembled wrong can damage the engine. While the assembly is mostly automated for the construction of the body, the engine is still assembled by hand over long stretches. The current methods for automating engine assembly have proven either futile or too expensive. The work of the project group ‘Resource-efficient

mechatronic processing machines’ of the Fraunhofer Institute for Machine Tools and Forming Technology IWU under the management of Prof Dr-Ing. Gunther Reinhart shows greater promise. The engineers initiated the project in cooperation with car manufacturer Audi, “Forwardlooking methods and processes for precision assembly and process monitoring for novel combustion engines.” The objective is clearly defined: The quality of the engine assembly is to be optimised continuously, thereby increasing customer satisfaction. The use of the latest technologies in the areas of robotics and sensor technology is intended to help eliminate uncertainties during engine assembly. “Monitoring the process throughout is not possible, since the engine continues to be assembled mostly manually. And engines are becoming more complex all the time. This can cause increased levels of rework,” said Christoph Sieben, Graduated Engineer, IWU. The automated assembly technology of the IWU scientists would identify the defect

LASERS TAKE THE LEAD onserving energy is top priority for auto manufacturers today. Laser technology can help as lasers can be used to process thin light-weight components made of fibercomposite materials, as well as to manufacture more efficient engines and more powerful batteries. The era of gas guzzlers that clatter through streets and pollute the air is over. Cars rolling off the assembly line today are cleaner, quieter and – in terms of their performance weight – much more efficient. Ever-stricter environmental regulations and steadily Laser light is an ideal tool in the manufacture of rising fuel costs are vehicles. increasing the demand for cars that further reduce their impact on the environment. But customer demands are often tough for manufacturers to meet: car bodies should be safe, yet lightweight and engines durable, yet efficient. Year after year, new models must be developed and built that can claim to be better, more efficient and more intelligent than the previous one. The race against time and competitors places high demands on manufacturers and their suppliers. Lasers can help them win the race. Resistant to wear and universally applicable, laser light is an ideal tool in the manufacture of vehicles. Lasers can be used to join, drill, structure, cut or shape any kind of material. Lasers are not only a decisive key towards faster, more efficient and economical production, but also towards energy-saving vehicles.

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early, during engine assembly, and forward the corresponding information or, for certain assembly processes, would not let the defect occur in the first place. The researchers first catalogued the status quo, evaluating current data on documented, assembly related engine problems for in-line and V-type engines over the past five years. The focus of the analysis was on the parts used and on the processes involved. “We generalised the engine assembly sequence and broke it down into eight blocks. The individual assembly functions are also recorded in a standardised way,” declared Sieben. This makes it possible to assign errors during assembly to uniformly defined assembly sequences and assembly functions. As a result of this generalisation of engine assembly, the analysis can be utilised for all kinds of engines. “We now know which assembly sequences require action,” said Sieben. The project group wants to next develop new automation solutions.

WEIGHT-LOSS PROGRAMME IN AUTOMOTIVE MANUFACTURING xtra pounds cost energy. They have to be accelerated and slowed down every time you drive – over the entire lifespan of the car. To reduce weight, manufacturers are increasingly turning to the use of fibre-reinforced plastics, which are 30-50 per cent lighter than metal. The disadvantage, however, is that these new materials are difficult to process. Fibrereinforced plastics are brittle, meaning cutting and drilling tools are quickly worn out and the conventional assembly techniques used for metal components are often not appropriate. “Lasers represent an ideal alternative here,” explained Dr Arnold Gillner of the Fraunhofer Institute for Laser Technology ILT in Aachen. “Lasers can cut fibre-reinforced plastics without wear and can join them too. With the appropriate lasers, we can cut and ablate components with minimal thermal sideeffects. Lasers can also be used for welding light-weight components – a viable alternative to conventional bonding technology. We can even join fibre-reinforced plastics to metals with laser welding. The laser roughens the metal surface, while the plastic, briefly-heated, penetrates the pores of the metal and hardens. The results are very stable.” Weight reduction can also be achieved with high-strength metallic materials. These, however, are difficult to process. “Joining combinations of various materials allows us to make optimal use of the individual materials’ specific properties. But this proves to be difficult in many cases. With our newly developed integrated laser tools, we can now even weld together combinations of materials, free of fissures or cracks,” explained Dr Anja Techel, Deputy Director, Fraunhofer Institute for Material and Beam Technology IWS in Dresden.

CUTTING-EDGE SOLUTIONS

MICRO-ELECTROMECHANICAL SYSTEMS DEVELOPED USING ETCHING TECHNIQUE iniaturised thermal imaging sensors see more than the naked eye and could make traffic safer; but are difficult to manufacture on a commercial scale. Researchers have now developed a new system. On it, special micro-electromechanical systems can be produced with the correct etching technique. Thermal imaging cameras are already used in certain applications (for e.g. in the military and construction industry). Such infrared cameras, however, are hardly available in the mobile area like automotive safety systems. The reason: long-range infrared micro sensors are difficult to produce commercially. Researchers of the Fraunhofer Institute for Microelectronic Circuits and Systems IMS in Duisburg, Germany, are now offering a solution. Researchers have launched a new facility in which the production of such micro-system technology (MST) is possible. MST involves minute sensors, valves or

MSTs, tiny sensors integrated into semiconductor chips, are produced in the MST laboratory and clean room.

other mechanical components that are integrated into semiconductor chips. For instance, in airbags they serve as motion sensors, and they are no thicker than a human hair. If MST is to be applied on semiconductors and integrated, one has to master the art of etching, which is where the researchers at IMS come in. To apply MST to a semiconductor, one essentially puts three layers on top of each

HIGH-SPEED FIBRE PLACEMENT ON LARGE COMPLEX STRUCTURES educing aircraft weight is essential to boost fuel efficiency. It is important not only in terms of cost, but also given the everincreasing distances that airplanes of the future are expected to travel, more capacity is essential. Carbon fibre’s high strength to weight ratio is one of the main innovations today, but the need for high production rates requires extremely complex machines. Electroimpact has developed Automated Fibre Placement (AFP) technology, an outstanding solution that offers a 2,000-inch per minute (50-metre per minute) automated fibre placement speed. This sophisticated control system allows cutting and adding carbon fibre strips (tow) within customer-end placement tolerances over ramped & complex surfaces. All layups can be performed fully bi-directionally and with operator control over the feed rate with no effect on end cut accuracy. The AFP machine is designed to manufacture large commercial aircraft structures and features fully modular, quick change heads with 30 second automatic head change. In order to make these large aerospace

other. The bottom layer is the substrate, namely the silicon wafer; in the center there is a sacrificial layer that serves as a spacer, and this is topped by the function layer. The sacrificial layer is later etched away, leaving only the desired sensor structure behind. “However, traditional etching methods only allow us to etch vertically into the layers. However, unsupported structures are decisive for the mechanical functions of many items of MST,” explained Dr Marco Russ, Project Manager, IMS. In other words: the etching must work not only vertically but evenly in all directions. Experts call this process ‘isotropic etching’. This ensures that the etching substance not only eats vertically into the substrate, but also digs itself under the function layer, like a tunnel. What remains is an unsupported structure of the function layer that is only 100 nanometre thin and connected to the substrate only at certain suspension points.

SAVING ENERGY WITH LOW FRICTION MOTORS

parts, the machine structure that controls the X, Y and Z motion of the fibre placement head - post mill or gantry designs - weighs 3.50,000 lbs (175 tonne) and is accelerated at 0.2g carbon fibre tows i.e. narrow strips of impregnated carbon fibre are placed on multiple material forms on the same part (1/4” or 1/8” wide tows in high contour areas, 1/2” or wider in low contour areas) for the highest possible productivity. It is a 100 per cent no-twist, 100 per cent no splice breakage and fully bi-directional operation. The X, Y, Z and barrel rotation axes work together to let the carbon fibre follow the contour of the part being manufactured. The carbon fibre tows are placed on the tool, which is machined into the shape of the final part. Furthermore, the carbon fibre has to be applied in different layers and different directions to optimise the strength of the final part. The point is that carbon fibre is very strong in tension, so all of the loads acting on the part must be supported in tension. The strokes can vary from short. ~ 2 metres (6.6 ft) of X-axis travel up to the full X-axis travel length which is ~30 metres (98.4 ft). The travel depends on the part being manufactured.

aser technology is in demand in engine optimisation. Engineers strive to keep friction as low as possible to improve efficiency. “That is true not only in the case of electric engines, but also for classic internal combustion engines and diesel motors and transmissions & bearings,” said Arnold Gillner, Ablation & Joining Specialist, ILT. Ceramic, high-performance coatings are desirable, as they are resistant to wear, smooth and generate less friction. Coated metal components are expensive as they are produced in plasma chambers in which the ceramic was vapourised and applied to the surface of the components. Fraunhofer scientists have developed a less expensive and faster method in which work pieces are coated with ceramic nanoparticles, and then, treated with a laser. This finishing process has already been applied to gear wheels and bearings. Lasers can even be used to make specific modifications to the properties of engine parts. “Friction between the cylinder wall and piston is responsible for a big part of a motor’s energy consumption. That is why we try to minimise it. This is important for engines featuring modern, automatic startstop functions that are stressed by frequent ignition,” said Gillner.

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BENEFITS OF IMPLEMENTING PDM

Small and medium-size manufacturing businesses (SMBs) are implementing product data management (PDM) software to enhance efficiency and reduce time-to-market. Despite limited resources, several organisations have been quick to fill this gap by taking advantage of preconfigured PDM solutions to get control of their engineering data quickly and, at the same time, achieve rapid and extendable long-term benefits. he benefits of implementing product data management (PDM), which include, reducing the time spent searching for data, improving accuracy of the product data provided to all users and faster new product development & engineering change processes, are well documented for larger enterprises. However, PDM is equally important to ensure the success of small and medium-size manufacturing organisations. Despite this, many small and medium-size manufacturing businesses (SMBs) have not yet implemented PDM as they are concerned about factors surrounding the initial cost of the software and the ongoing cost of maintaining & developing the system. Moreover, they may not have access to a large IT department, which could take on

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responsibility for the implementation and ongoing support of the PDM system. However, with careful planning and by selecting a solution that includes a preconfigured environment, these risks can be minimised and benefits can be quickly reaped. Several PDM systems specifically targeting SMBs are now available. These systems typically claim to be out-of-the-box and are easy to implement. Some of these systems started as a ‘workgroup’ or ‘document management’ system and have been developed to try and meet the more comprehensive PDM requirements of today’s SMBs. Other systems started as an established enterprise product lifecycle management (PLM) solution that was then tailored to the specific needs of SMBs. An example of this latter approach is Teamcenter Express from Siemens PLM Software. This

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approach has key advantages for SMBs in terms of proven scalability to handle the growing volume and complexity of data that will be managed, and the possibility to easily add-on applications to meet specialised requirements that may not be foreseen at the time of initial implementation.

KEY AREAS OF BENEFIT A recently published research study from industry analyst Tech-Clarity, based on interviews with leaders from mid-size manufacturing companies, shows how these organisations were able to address their product data management issues by implementing a preconfigured PDM solution. In this research, Tech-Clarity identified three basic themes where these organisations successfully applied PDM to achieve significant benefits. These include:

BENEFITS OF IMPLEMENTING PDM

Controlling and securing product data Lauding the system, Kim Guk Hyeon, GM, Seung-Uk, Principal Research Engineer, PDM systems, like Teamcenter Express, KC Samyang Water Systems, says, “After SATREC Initiative, a satellite manufacturer, restrict access to authorised personnel and using Teamcenter Express to manage our claims PDM has made it possible to easily go further by making that access dependent customers’ requests for revisions, we find and re-use information. “For example, on both, the person’s role and on the stage turned 100 per cent operational in very a fast blueprint distribution process, enabling the product is at in its lifecycle. For example, little time.” quick internal inspections, is a great manufacturing personnel can be restricted advantage,” Seung-Uk explains. PHASED APPROACH TO PDM to only seeing designs that are released to Sharing data more effectively with other SUCCESS manufacturing and not those that are departments SMBs should plan their implementations currently under development. The result is PDM also helps make the right information carefully and adopt a phased approach excellent control of product data with a available across the business. Purchasing while deploying PDM in order to ensure corresponding reduction in errors in both, and manufacturing depend on the data from that a positive return on the design process and in manufacturing. Commenting on Smaller manufacturers are turning to PDM in order to take investment is achieved typically the same, Arun Gupta, Head – control of their product information and get more value during the first phase. For each phase of the implementation, it Design Engineering, Flovel from it. PDM helps these companies achieve business is important to establish Engineering, a manufacturer of hydro power equipment, avers, benefits including increased efficiency, improved quality, achievable goals and to collect “Without PDM, we had no reduced cost and the ability to bring products to market metrics on the before and after situations. For example, control over our information much faster. the average time taken to and different engineers had their complete an engineering change own data. Now, with PDM, we order is one metric that can be used as have access and security.” engineering to play their role in developing input to the return on investment calculation. Elaborating on how the PDM system’s and delivering profitable products. With the proven success of each phase, it restricted access is proving to be a boon in Teamcenter Express incorporates industry will be easier to get commitment from disguise, Pinakin Mate, CEO, Veeraja leading lifecycle visualisation capabilities that senior management for further Industries, a manufacturer of coolant render 3D models from multiple CAD implementation phases. Some areas to filtration and management systems, systems into portable, lightweight files that focus on for successful PDM implementations comments, “Our primary objective was to can be easily viewed and analysed by other include: sort out the data to get it in line. Earlier, departments, and by external resources Manage all CAD data: With the move engineers used to have a free ground, but such as suppliers and customers. These from 2D to 3D CAD systems, SMBs are now, the process is streamlined and locked capabilities result in more accurate experiencing a large increase in the down so they cannot store data communication of design intent and more amount of CAD data that must be anywhere.” efficient processing of design changes managed. 3D CAD systems utilise Finding and reusing data requested by suppliers and customers. separate part, assembly & drawing files Companies use Teamcenter Express to Discussing the same, Seung-Uk says, “We and create many links between these improve their ability to search for and share are converting more prospects to customers files. With multiple versions and revisions product data. Using this PDM system, due to our ability to accelerate product of these files also being created, one can companies have been able to decrease the time-to-market, as well as achieving a 30 see the explosion in the volume and amount of non-productive time that their per cent faster process for product complexity of data that is occurring. designers spend while doing tasks like development.” Implementing PDM enables these files searching for data and recreating designs. As RAPID BENEFITS: and their relationships to get captured a result, their designers have more time to OPPORTUNITY TO EXPAND automatically and then managed in a focus on innovation and adding value, To ensure quick returns, manufacturers controlled way, thereby resulting in thereby improving time-to-market and ought to focus their selection process on improved reusing of existing data and profitability. Explaining how PDM has solutions that support industry best practices more standardisation. facilitated the functioning of engineers and Manage multiple CAD formats: The need in the form of a preconfigured product data enhanced efficiency, Gupta says, “Without to manage data from multiple CAD management environment. A rapid PDM, engineers cannot find information systems is not just an issue for large implementation of Teamcenter Express and as a result, the next engineer might end enterprises but also a common with minimum customisation ensures up doing the same job. We want to make requirement for SMBs. A manufacturer significant opportunities to expand the information available to everyone, including whose primary 3D CAD system was scope of the system. Talking about the technical catalogues, standard technical Solid Edge software, also had a large benefits of adopting the same, Gupta says, information and quality standards. Using number of legacy 2D drawings in “An expert audited our process and saw PDM, finding this information will be faster.” another system and, after acquiring a some advantages in doing things differently. Complementing Gupta’s views, Mate says, small company, ended up with a third For example, we implemented clients at the “All of our products are custom-made, and CAD system to deal with. A PDM distant manufacturing plants so that they we realised we were reinventing the wheel solution that integrated these three CAD could easily access technical information.” with each one.” On the other hand, Yang

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BENEFITS OF IMPLEMENTING PDM

data formats and enabled SMBs should plan their implementations carefully conflicts, PDM will have an consistent execution of increasing role to play in and adopt a phased approach while deploying PDM in improving the competitiveness everyday tasks and processes irrespective of the type of SMB manufacturing order to ensure that a positive return on investment of data being managed was companies. is achieved typically during the first phase. For each essential to their success. phase of the implementation, it is important to establish SCOPE FOR MORE Focus on areas of highest achievable goals and to collect metrics on the before Smaller manufacturers are business impact: Identify the turning to PDM in order to take key issues that are impacting and after situations. control of their product the business. Is faster information and get more value introduction of new products from it. PDM helps these companies critical? Is improved management of can be of great benefit in this area. These achieve business benefits including increased engineering change a critical issue? flash media-based utilities simulate the efficiency, improved quality, reduced cost Further phases of implementation PDM environment and enable users to and the ability to bring products to market should focus on the areas identified and work through common use cases much faster. By selecting a preconfigured could include improving efficiency interactively without the need for the PDM system tailored to suit the needs of through electronic workflow processes installation of a training database. Plan for the future: With increasing costs SMBs and with a long history of success, for new product development and of raw materials and higher employment smaller manufacturers are achieving these engineering change, integrated costs, the application of PDM to the area benefits faster than ever before and with a management of other technical of resource optimisation will ensure higher degree of confidence. documents and their associated increasing focus. Whether this is done processes, or automated transfer of Dave Chadwick works for Siemens PLM Software by reducing the amount of scrap and bills of materials to a manufacturing where he is the Product Marketing Manager for rework in the manufacturing process by system. Teamcenter Express, a Product Data Management Training: In all phases, training of users is giving all authorised users access to a (PDM) solution targeted at SMBs. Prior to this, critical, but with their limited resources, single source of product data, or by David spent 15 years implementing PDM solutions it can be difficult for SMBs to find the integrating project management into the across a range of small to large manufacturing time to do this. New training tools, such PDM environment for early identification companies. as flash-based self-paced training tools, of potential bottlenecks and resource

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PRODUCT LIFECYCLE MANAGEMENT

Benchmarking to global standards for 360-degree growth With global companies forcing innovations into their products, it has become imperative to have the best technology in hand if they have to sustain in the game of the survival of the fittest. In their bid to set benchmarks in terms of quality, design and service, technology companies are looking at integrated PLM software as a one-stop solution to all their manufacturing-related problems. Providing their insights on the PLM segment of the industry, John P Condon, Vice President – Channel Sales, Asia Pacific, PTC; Rafiq Somani, Area Vice President, PTC India and Rohit Biddappa, Head Marketing – India, SEA, ANZ, PTC, discuss their views on the niche, yet critical, technology for the manufacturing process, with Sudhir Muddana. Excerpts…

HE GROWTH MARKET FOR PLM

John P Condon: We have observed that despite lagging behind with respect to manufacturing maturity, big markets like India and China, are growing fast. Companies across the whole of Asia Pacific are recognising the importance of product lifecycle management (PLM) for their business and are adopting it. So, on the whole, it has been an interesting ride for the PLM market in Asia Pacific. Over to you, Rohit... Rohit Biddappa: I think, most Indian companies are now benchmarking to global standards in terms of quality and innovation. There has been a leap in the thought process. Around 20 years back, the preferred way to work was to go in for a joint venture, wherein you would have a transfer of technology and use your logo & brand to sell products in India and manufacture under contract. However today, the scenario is different. Companies are internally forcing innovations into their products. This is where PLM has a role to play in terms of managing the CAD data and designing & developing hardware, embedded software, electronic data, documentation, service information, etc.

technology that may not be adding value to their business and are also getting rid of the multiple disparate systems. Regulations and standards are becoming more important to businesses and companies are devising ways to become more compliant with them. They are thinking progressively and are constantly preparing themselves to ensure that they stay ahead while complying with those standards. Rafiq Somani: Adding to what Condon said, we have seen two emerging trends in India. First is the consolidation of IT. Most companies – large, mid-sized or SMEs – earlier used to have a number of disparate systems. But now, since they are working in

ROLE OF IT IN MEETING GLOBAL STANDARDS Condon: IT is starting to drive a lot of the enterprise decisions around the technology used to improve business. There is a lot of standardisation across all industries. Companies are trying to eliminate

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Raﬁq Somani, Area Vice President, PTC India

Rohit Biddappa, Head Marketing – India, SEA, ANZ, PTC

a global environment, they are moving towards consolidation. So, while ERP plays an important role in consolidating the manufacturing needs and product development – from concept to the time the manufacturing bill is ready – there is a lot of consolidation happening. Thus, companies like PTC are flourishing as we have an enterprise-wide product lifecycle management solution. The second trend is global product development. Most Indian manufacturing companies are either collaborating with the foreign auto

PRODUCT LIFECYCLE MANAGEMENT

John P Condon, Vice President – Channel Sales Asia Paciﬁc, PTC

OEMs or are doing offshore work for companies like Volkswagen, General Motors, etc. IT plays an important role here as well, as one needs tools for collaboration. So, the concept of build-design-manufacture anywhere is seen today. This is also applicable to Indian companies setting up base in places like China, Malaysia, Thailand, etc. So there is a need to have global product development.

OUTWITTING COMPETITORS Condon: We have some industry-specific technology, which is rebuilt using our Windchill and Arbortext technologies. While building software for our customers, we first understand their requirements and then build a system that best fits their needs. Over the past few years, we have made a number of acquisitions. We take the acquired software, get to the core coding of the software and then build them on Windchill platform. So, we first understand the needs of the industry, analyse how the technology fits into the role and then determine what improvements and enhancements we need to make to round up the offering and solve the business problems of our customers. I would like Rohit & Rafiq to give the India perspective. Biddappa: Well, Windchill has been in the market for over 15 years. It has been a consistent stable unified integral platform, the core of which we have been augmenting and improving over the years. Our latest Windchill 10 has a number of new fundamental improvements. It is now fully capable of web O2 technology and social media, collaboration, new Microsoft technologies & cloud computing concepts are an integral part of the software. This is

something our competitors do not have. We also have certain unique additional features such as building different products on our Windchill platform. Also, we offer customers a standard, out-of-the-box solution as too much customisation can increase the cost of maintenance for the customer. However, there are certain modules that are specific to the verticals. Somani: I completely agree with Rohit’s inputs. PTC is a unique PLM company, which offers industry-specific processes. We have 24 processes, which are needed to consistently build quality products. Secondly, over the last 7-8 years, PTC has acquired many unique products, such as MathCAD. The best part about such a technology is that it captures all the intellectual engineering calculations over a period and so, if someone leaves the company, his work can be viewed by the new recruits. In addition, Arbortext is a software that most automotive companies such as Mahindra & Mahindra, Tata Motors, etc. use today. It helps create world-class documentations for different products.

GLOBAL DEALS BAGGED Biddappa: We have recently won big global accounts such as Volvo Truck. But why did Volvo Truck choose us over our competitors? The credit for this goes to our PLM solution. Our PLM solution will enable the company to offer their customers – small or big trucking companies – 10,000 truck configurations. These variations are not only based on external features such as the colour and size, but include different engineering configurations as well. Also, ordering online and getting a truck delivered is what Volvo Truck can do and what the

future beckons. Talking about the Hyundai and Kia Motors Corporation (HKMC) and Airbus (EADS) deals, the benchmarking processes were based on comprehensive technical evaluations. These benchmarks were in terms of the attributes of the PLM systems, the capabilities, solutions offered, processes supported and more importantly, on how it could support the complicated internal processes of companies like HKMC and EADS. These deals validate the power of our technology. Somani: We successfully bagged the HKMC deal due to three main reasons. Firstly, we gave Hyundai Windchill, a solution that could help it leverage on and integrate all the existing technologies. Secondly, Hyundai’s evaluation team realised that Windchill was way ahead in terms of the technology and future vision. Thirdly, we bagged the deal because of Windchill’s ability to scale up more licences and implement ease of use. Condon, we would also like you to also share your views... Condon: It’s a known fact that Hyundai is one of the largest original equipment manufacturers (OEMs) in the automotive market. They are building good quality cars at lower costs. Hence, for PTC to bag that deal is very significant as we have the flexibility to continue to scale to their business as well as to work as a business partner rather than a vendor or software supplier.

DEVELOPING A TECHNOLOGY FOR PLM Condon: At a high level, every industry vertical has a unique recipe for product development. Each industry has different needs & regulations and PTC looks at it more holistically. We first understand the industry, study our customers & their needs and take their feedback. We also study leading academic universities that are into product development and take their inputs. We visit consulting groups and then create a roadmap that will take the high-level needs of the customer to drive value, growth and profitability. Somani: That’s same strategy we adopt in India as well. Our market and competitive products have all started as in-house software, which were later sold commercially. But to give our software an edge over our competitors’, we began to work closely with the customers and sold products that would cater to their needs. Even today, we work very closely with all our customers.

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PRODUCT LIFECYCLE MANAGEMENT

Somani: To make our software user-friendly, we rewrite the GUI, while the core algorithm and the process remains the same. We make sure that our products are as easy to use as Google. For example, our Windchill technology is user-friendly when it comes to searching any data about any project. Also, we are the first company to take things a step ahead. We are using new generation technologies, which today’s young engineers are fully aware of. This helps companies having offices all over the world to discuss and provide solutions to different design and process-based challenges that they individually face.

CHALLENGES FACED Condon: While developing new software, some of the time-consuming processes that we face are capturing customer requirements, bringing them into the test environment and evaluating technology to make sure that it suits their needs. We emphasise on high-quality standards and so, we will not ship out a product until it has passed all the quality tests. Rafiq, would you like to elaborate some of the hurdles encountered? Somani: Sure...well, depending on the kind of industry verticals we serve, one of the challenges that we face is choosing between depth and horizontal features. We can customise a software for one industry to the extent that it becomes a niche software only for that industry to use. But doing so would make it difficult for us to move the special features that are built for one industry and migrate it to the newer version while upgrading the software. On the other hand, we can include horizontal features in a software, wherein the software remains the same till a certain level and then, depending on the needs and the industry, we can customise it. So, we can either customise the process level software for a particular industry or keep it flexible to facilitate changes in its version. Currently, we are making our software horizontally templatised so that each vertical can take it from that level and customise it accordingly.

TECHNOLOGY ADOPTION BY SMEs Somani: Mid-sized companies and SMEs in India are early technology adopters. Today, all the large OEMs are now becoming more like system integrators. This has intensified the pressure of quality production on SMEs. Hence, SMEs need to manufacture

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innovative and cost-effective quality products to give their global counterparts a run for their money. SMEs that have adopted a progressive approach and have invested in technology are doing very well. Moreover, their size makes it easier for SMEs to upgrade their software as the processes involved are few. Biddappa: In addition to Rafiq’s views, the business for most Indian SMEs is driven by big customers. So, if a company like Tata Motors or Mahindra & Mahindra decides to enhance its efficiency, the pressure mounts on auto component manufacturing SMEs. Therefore, SMEs need to gear up by adopting the latest technologies and processes. Moreover, since there are a few decision makers in SMEs, the procedure involved in adopting newer technology takes lesser time. This, in a way, acts as an added advantage for SMEs.

FACTORY OF THE FUTURE Condon: With globalisation phasing in, the future is going to get more accentuated. In other words, a company will have its manufacturing, engineering and all other departments spread worldwide. In such a scenario, the ability to be able to communicate effectively, collaborate while driving towards lesser cycle time and getting to the market faster, bringing quality and lowering costs will be key as we will have to ensure that we scale up to the required level and have a competitive edge in the future. Somani: Thanks Condon for your valid points. In terms of technology and software, we see two emerging trends in India. One is that manufacturing companies face disparity in terms of data as different departments use different versions of the technology. Another trend is that people from different departments can acquire a new customer by communicating via laptops, iPads and PDAs to discuss the possibility, timeframe and processes involved while developing a product for a customer and take decisions on the same without being physically present.

GAUGING INDIA PERSPECTIVE Somani: Technology adoption by Indian companies can be seen from two perspectives. Firstly, companies that do not opt for new technologies as they are satisfied with their existing technology and secondly, companies that have skipped one generation of old technology and adopted a

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technology that is much more advanced. The latter scenario is evident in the telecom sector, which has skipped one generation – from using standard landlines to having the latest mobile technologies. Another instance is Tata Motors, which has skipped the generation of 2D drawing and directly went into 3D parametric mode, when the world moved from the drawing board era to 2D designing software. This can come across as an advantage for India when it comes to adopting the best and latest technologies.

GROWTH POTENTIAL Condon: Manufacturing is booming in Asia and many companies are outsourcing manufacturing to India, China, Vietnam, Thailand, etc. So, the evolution of manufacturing in Asia is going to be around development. In fact, in China the government is taking initiatives to not only encourage products that are ‘Made in China’, but are also promoting products ‘Designed in China’. So, we will probably see a lot more design engineers coming from China. India, on the other hand, is very different. It already has a very strong design engineering and manufacturing base. So, India is further ahead. The Indian market has a blend of some very big traditional and strong companies like Tata, Mahindra & Mahindra, Larsen & Toubro, etc., some new companies that have their manufacturing needs being met here and SMEs. These will help India stay at the top for years to come. I think, Rafiq & Rohit will have many more aspects to add... Somani: We have an opportunity as well as face a threat. There is no doubt that as far as mass-scale manufacturing is concerned, China is the leader and is way ahead of India. However, India has a number of competent design engineers and outwits China when it comes to innovative designing. But the threat for India is that China, along with being a leader in manufacturing, also aspires to become leaders in design as well. This makes it imperative for India to work towards retaining its niche if it wants to stay ahead in the competition. Biddappa: No major economy has become big on the basis of services; rather it has achieved its status owing to manufacturing. So, if we want to achieve the government’s target of attaining 20 per cent growth by 2020, we need to drift away from being a service-oriented economy and build a strong manufacturing base.

SEARCH August 2011 Ad Name: Engineering Expo Pg No. 155 SEARCH August 2011 Ad Name: Engineering Expo Pg No. 155

SEARCH August 2011 Ad Name: Engineering Expo Pg No. 156 SEARCH August 2011 Ad Name: Engineering Expo Pg No. 156

PLUGGING IN SUCCESS In the recent years, the electronics industry has become the backbone of almost all the products & equipment. Thanks to the ever-growing advancements in the field, the industry at large has been able to offer enhanced products to its customers in the shortest span of time. Bringing a plethora of opportunities for the manufacturers and customers alike is the 12th edition of Electronica and Productronica India 2011 to be held in New Delhi from September 13-16, 2011. Backed by SEARCH as the media partner, the trade show will prove to be one-stop shop for all your electronics needs. A preview… KIMBERLEY D’MELLO

he fast-paced growth in the core sectors of the economy has a significant impact on the future of allied industries such as electrical & electronics. The stupendous growth in the Indian automotive and aerospace industry has further cemented its growth prospects. While opportunities are abuzz, the industry still requires a platform to showcase its operational capabilities to the ultimate customers. This was the breeding ground of the annual event Electronica and Productronica India. Scheduled to be held from September 13 to 16, 2011, at Pragati Maidan, New Delhi, this year’s edition is slated to provide exhibitors with new opportunities and prospects. Since its inception, this trade fair has not only managed to get the electronics industry together but has also established itself as a leading platform for the Indian and SouthAsian electronics industry. Like the earlier editions, the show has been supported by the Department of Information Technology, Ministry of Communications & Information Technologies and over 15 industry associations, who are working for the development of the industry. The show will also feature country pavilions from Germany, UK, Hong Kong, China, Singapore, Taiwan and Korea, including participation from

These shows are closely interlinked to the world’s leading trade fairs Electronica and Productronica in Munich. The coming together of the industry will drive further growth in the next few years and will boost the business for the Indian electronics industry. Darryl Dasilva, CEO, Messe München International India

Japan, Switzerland, US, Italy, Spain, Korea & Malaysia among others.

BASKING IN THE GLORY The two concurrent shows viz., Electronica India and Productronica India are one of the best promoted brands in India. In 2010, the two shows receive over 12,000 trade visitors and in 2011, with 1,000 exhibitors, the number of visitors is expected to be much higher. The show, like its earlier editions, will also host a series of highpowered technical conferences. This year, it will feature two conferences – an EMS conference and one joint MMI ELCINA conference on the first two days of the show. These conferences will go a long way in keeping the Indian electronics industry abreast with the fast-changing global technology trends and will showcase the latest investments opportunities.

year’s show are semiconductors, sensors, relays, switches & interconnection technology, passive components, motors/ drives, cables, assemblies and subsystems, ED/EDA and measurement technology, etc.

VISITORS’ DELIGHT Electronica and Productronica India 2011 will be packing in a lot of punch by showcasing the latest in electronic gadgets, consumer appliances, automotive components on automotive electronics and contract manufacturing. Demand for electronic gadgets, appliances and equipment is growing briskly and companies are increasingly turning to EMS firms to fill the gap. Productronica India will reflect this hot topic in India in its top-class conference. Some of the key exhibitors include Advancetec, Agilent, ASYS, Avalon, etc.

UNIQUE OFFERINGS WHAT IS IN STORE? The key product and exhibit areas at this

Why should one participate? Electronica India and Productronica India have proved to be the No. 1 leading electronics trade shows in India and South Asia. The fairs clearly demonstrate their close links to the world’s leading trade fairs Electronica and Productronica in Munich. The synergies created will lead to further growth in the next few years. The shows are supported by IPCA, which is India’s most powerful association for printed circuit boards and ensures a good number of exhibitor and visitor turnout at the show.

One of the special features of the show would be Automotive Pavilion, which will witness participation of key companies like NXP, Delphi, Fusion Electronics, etc. Automotive markets worldwide are rapidly changing and the electronics content in cars has been on the rise. The visitors will get to see the latest technologies in automotive electronics. For the first time, the show will have a country pavilion from Korea with companies showcasing a wide spectrum of Korean technologies. With all these and more, participating & visiting the trade show is a sure shot way to attain success.

A U G U S T 2 0 1 1 | SEARCH - THE INDUSTRIAL SOURCEBOOK

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10-12 August 2011

COMPREHENSIVE PACKAGING EXPO Focus: Manufacturers of packaging machines, materials and logistics providers Where: Chennai Trade & Convention Centre, Chennai Tel: 044 28604087 Email: info@smartexpos.in Web: www.smartexpos.in

CHINA (BEIJING) INTERNATIONAL PIPE FITTING & VALVE EXPO Focus: Steel pipe, infrared thermometer, printing marking machines, cleaning equipment and pipeline inspection technology Where: Beijing China International Exhibition Center (CIEC), Beijing, China Tel: +86 10 68659226 E-mail: haiwen2002@126.com Web: www.hwexpo.com

10-12 August 2011

16-19 August 2011

GREEN AUTOMOBIL 2011 EXPO Focus: Renewables and environment Where: Pragati Maidan, New Delhi Tel: 011 4279 5000 E-mail: anshult@eigroup.in Web: www.greenautomobil.com

SHANGHAI INTERNATIONAL AUTOMOTIVE MANUFACTURING TECHNOLOGY & MATERIAL SHOW 2011 Focus: Automotive manufacturing, engineering and technology solutions Where: Shanghai New International Expo Centre (SNIEC), Shanghai, China Tel: +86 21 64681300; E-mail: info@for-expo.com Web: www.shanghaiamts.com

NATIONAL

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1-3 September 2011

22-24 September 2011

13-14 September 2011

HIMTEX 2011 Focus: Engineering, machine tools, precision tools, automation systems, instrumentation & controls, machinery and equipment Where: HITEX Exhibition Centre, Hyderabad Tel: 040 23112121; Fax: 040 23112124 E-mail: js@hitex.co.in; Web: www.himtexexpo.co.in

METEX INDIA 2011 Focus: Metal and metallurgical equipment, technologies and supplies Where: KTPO Trade Centre, Bengaluru Tel: 022 42107804 E-mail: n.seth@koelnmesse-india.com Web: www.metex-india.com

THE ENERGY EVENT 2011 Focus: Energy procurement, energy efficiency, metering, carbon reduction, energy policy, cost reduction Where: NEC, Birmingham, West Midlands, England Tel: +44 (0)78 1857 4300 E-mail: steve.swaine@emap.com Web: www.theenergyevent.com

NATIONAL

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9-12 November 2011

23-26 November 2011

17-20 October 2011

BIZ-BRIDGE 2011 â&#x20AC;&#x201C; ENGINEERING & MANUFACTURING EXPO Focus: Metals & minerals, power & energy, oil & gas, railways & wagon building, defence, MSME and material handling system Where: Science City, Trade Fair Grounds, Kolkata Tel: 033 22307727; Fax: 033 22301721 E-mail: tarun.tapadar@cii.in Web: www.bizbridgeexpo.com

INDUSS 2011 Focus: Industry supply & subcontracting Where: BIEC, Bengaluru Tel: 080 66246600 Fax: 080 66246661 E-mail: raghu@bies.co.in Web: www.bies.co.in

CANADIAN MANUFACTURING TECHNOLOGY SHOW 2011 Focus: Machine tools, automation technologies Where: Direct Energy Centre, Toronto, Canada Tel: +1 313 4253000 Fax: +1 313 4253400 E-mail: exposales@sme.org Web: www.sme.org

TRADE SHOW TRACKER

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1-3 December 2011

6-9 December 2011

7-10 December 2011

ENERGY EXPO 2011 Focus: Technology for power, coal, gas, renewable energy, non-renewable energy, clean & green energy, power transmission and distribution equipment and financing options Where: Gujarat University Exhibition Hall, Ahmedabad, Gujarat Tel: 022 24931790 Fax: 022 24939463 E-mail: romaldine.ayire@cii.in Web: www.cii.in/Events.aspx

HANNOVER MILANO FAIRS INDIA Focus: Five concurrent shows on materials handling and logistics, hydraulics & pneumatics, electro mechanical transmission, process and production automation, surface technology, laser systems and laser technology for manufacturing Where: Bangalore International Exhibition Centre, Bengaluru Tel: 022 40050681 Fax: 022 40050683 E-mail: info@hmf-india.com Web: www.hmf-india.com

CONBUILD VIETNAM 2011 Focus: Construction machinery, building material machines, construction vehicles and building materials, technology and services Where: Saigon Exhibition & Convention Center, Vietnam Tel: +65 62360988 Fax: +65 62361966 E-mail: mmi_sg@mmiasia.com.sg Web: www.mmiasia.com

NATIONAL

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19-24 January 2012

18-22 January 2012

18-20 January 2012

IMTEX FORMING 2012 Focus: International Forming Technology Exhibition Where: Bangalore International Exhibition Centre, Bengaluru Tel: +91 (080)66246600 E-mail: imtma@imtma.in Web: http://www.imtex.in

ELECRAMA 2012 Focus: Power transmission & distribution equipment Where: Bombay Exhibition Centre, Mumbai Tel: +91-22-2498 4226/ 4227 Fax: +91-22-2497 5140 E-mail: mumbai@ieema.org

ELE TRADE 2012 Focus: Electronic components Where: Tokyo Big Sight, Japan Tel: +81-3-3349-8502 Fax: +81-3-3349-4900 E-mail: inw-k@reedexpo.co.jp

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9-11 February 2012

14-16 February 2012

9TH EVERYTHINGABOUTWATER EXPO 2012 Focus: Water & wastewater management Where: India Expo Centre And Mart, Greater Noida Tel: +91-11- 4310 0568/ 0572/ 0500 Mob: +91 98910 54929 Fax: +91 11 4310 0599 E-mail: enquiry@eawater.com

IPTEX12 Focus: Power transmission Where: Bombay Exhibition Centre, Mumbai Tel: 080 - 2556 7028 Fax: 080 - 2556 7028 E-mail: info@virgo-comm.com

TIRE TECHNOLOGY EXPO 2012 Focus: Tire design & manufacturing Where: Cologne, Germany Tel: +44 (0) 1306 743744 Fax: +44 (0) 1306 742525 E-mail: colinscott@ukintpress.com

RUDRAPUR (Uttarakhand) 23-26 Sept’ 2011 Gandhi Park

AHMEDABAD (Gujarat) 14-17 Oct’ 2011 Gujarat University Exhibition Hall

PUNE (Maharashtra) 18-21 Nov’ 2011 Auto Cluster Exhibition Centre, Pimpri-Chinchwad

CHENNAI (Tamil Nadu) 8-11 Dec’ 2011 Chennai Trade Centre, Nandambakkam

INDORE (Madhya Pradesh) 6-9 Jan’ 2012 Poddar Plaza, Near Gandhi Hall

Mobile: +91 98195 52270 • E-mail: engexpo@infomedia18.in • Web: www.engg-expo.com

AURANGABAD (Maharashtra) 17-20 Feb’ 2012 Garware Stadium

Network with Engineering Expo Exhibitors Now you can meet and discuss business with Engineering Expo’s exhibitors, much prior to the actual exhibition. Just let us know about the exhibitor that you want to get in touch with and we will fix the meeting for you. Contact us on 09819552270

UPDATE 2 Rudrapur 23-26 September, 2011 Gandhi Park

Advanced Micro Services Pvt Ltd Products: Repair Services & Retroﬁtting For CNC Machines; Industrial Automation, Control Systems W: www.amsindia.net Participating in: Pune

Arhan Technologies Pvt Ltd Products: Total Automated Assembly Lines, VMCs, HMCs, Turning Centres W: www.arhan.co.in Partici pating in: Rudrapur, Aurangabad

Ahmedabad 14-17 October, 2011 Gujarat Univesity Exhibition hall

Pune 18-21 November, 2011 Auto Cluster Exhibition Centre

Bearing & Tool Centre Products: Measuring Instruments, Testing Instruments, Surface Plates, Thread Gauges, Plain Gauges W: www.bearingtoolcentre.com Participating in: Ahmedabad

Best Quality Fasteners Products: Fastners, Nuts, Screws, Washers W: www.rkctrades.com Participating in: Rudrapur, Aurangabad

Chennai 8-11 December, 2011 Chennai Trade Centre

Bhagwati Filters Pvt Ltd Products: Hydraulic And Lubricating Oil Filters, Filters W: www.bhagwati-ﬁlters.com Participating in: Ahmedabad, Aurangabad

Indore 6-9 January, 2012 Poddar Plaza, MG Road

Aurangabad 17-20 February, 2012 Garware Stadium

Book Your Stall Now Contact www.engg-expo.com T: 09819552270 E: engexpo@infomedia18.in SMS: EXPO to 51818

Calitron Calibration Laboratory Products: Calibration Facility For Pressure, Temperature, Mass, Volume & Electrotechnical Parameter W: www.calitroncalibration.com Participating in: Pune

Compucare Products: Fingerprint And Card-Based Time And Attendance Systems, Access Control Systems, CCTV Solutions W: www.compucareindia.com Participating in: Ahmedabad

CTR Manufacturing Industries Ltd Products: Pallet Trucks, Electric Pallet Trucks, Forklift Trucks, Scissor Lifts, Diesel Engine Telescopic Horizontal Lifts, Hydraulic Trolley Jacks, Forklift Truck Jacks, Floor Cranes Servicing, Scissor Platforms W: www.ctr.in Participating in: Rudrapur, Ahmedabad, Pune, Chennai, Indore, Aurangabad

Dijet Industrial Co Ltd Products: Modular Head, Indexable Tools, End Mills, Drills, Turning Inserts, Wear & Impact Resistant Tools, Cabide Blanks, Carbide Tools W: www.dijet.com Participating in: Ahmedabad, Pune, Chennai, Indore

Elesa-Ganter India Pvt Ltd Products: Fixed Handles, Revolving Handles, Safety Fold-away Handles, Control Elements, Rotary Controls, Indexing Elements, Joints, Levelling Elements, Hinges, Latches, Hooks, Toggle & Power Clamps, Tube Clamp Connectors, Castors & Wheels W: www.elesa-ganter.com Participating in: Pune

Garg Machines Products: Cleaning Machines, Floor Polishing Machines, Floor Grinding Machines, Vacuum Cleaner, Floor Cleaning Machines W: www.gargmachines.net Participating in: Rudrapur

Himanshu Enterprise Products: V-belts, Roller Taper Roller Bearings, Pillow Block Bearings W: www.ﬂir.com Participating in: Ahmedabad

HMB International Products: Carbide Cutting Tools, End Mills, Drills, Reamers, Special Tools W: www.kelten.co.in Participating in: Rudrapur, Chennai

Igus India Pvt Ltd Products: Cable Carriers, Cable Connectors, Connectors, Bearings, Chains W: www.igus.in Participating in: Ahmedabad

Intech Surface Coating Pvt Ltd Products: Powder Coating Plants, Paint Shops, Liquid Painting Plants, Spray Pre-treatment Plants, Dip Pre-treatment Plants W: www.intechﬁnishing.com Participating in: Rudrapur, Ahmedabad, Pune, Chennai, Indore, Aurangabad

K Engg Products Products: Machine Tools Accessories, CNC Tooling Systems, Hydraulic Tapping Machines, Air Tapping Machines, Drill End Mill Protable Machines, ER Collets, Stanny Fine Boring W: www.kenggproducts.com Participating in: Indore, Aurangabad

Mass Engineers & Supplier Products: Fat Monitor, Weighing Scales, BP Monitors W: www.massengineers.co.in Participating in: Pune, Aurangabad

N B Technologies Products: Hydraulics & Pneumatics, SPMs, Test Equipment Development, Power Packs, Cylinders & Accumulators, Plant Automation W: www.nbtindia.in Participating in: Pune

Omron Automation Pvt Ltd Products: Industrial Control & Sensing Devices, Relays, Timers, Counters & Power Supplies, Temperature Controllers, Level Controllers, Sensors, Encoders, Safety Light Curtains, RFID, PLCs, Inverters/Variable Frequency Drives W: www.omron-ap.com Participating in: Pune

Samson Controls sets up new plant in Pune ermany-based valve manufacturer Samson Controls Pvt. Ltd. has set up a plant at Ranjangaon in Pune. It will manufacture products such as globe control valves, conventional positioners; self operated pressure and temperature regulators. The company has invested `225 crore to expand its business in India. Speaking on this, Atul Raje, managing director, Samson Controls said, “We will be focusing on growing Indian and Asian markets for the products and service that we offer. The company will be making huge investment to develop new technology and equipments. Offering customised solutions to our customers has always been our prime focus.” The company has shifted its base from Thane to Ranjangaon and has completely refurnished as green ﬁeld facility. It is operational in India since 1991. Over 200 people are employed for this plant.

–Courtesy: Business Standard

GKN Driveline continues expansion with new Pune facility ontinuing its growth trajectory, GKN Driveline will invest `130 crore to set up a 600,000 per annum sideshaft manufacturing facility in Pune by August next year that will also make trans-axle solutions. The 8000 sq. meter facility will employ more than 200 people. Apart from sideshafts, the plant will also manufacture differentials from GKN Driveline’s transaxle solutions product range. “This new facility positions GKN Driveline strongly to meet the continued rapid growth of India’s automotive industry. It is the next step in our mission to remain close and accessible to our customers in west India,” said Marc Vuarchex, Managing Director, GKN Driveline AsiaPaciﬁc.

– Courtesy : Business Standard

Nissan clocks 1 lakh Micra production at Chennai facility ithin a year of its launch in India, Japanese auto maker Nissan has clocked production of one lakh Micra from their manufacturing facility near Chennai. The ﬁrst hatchback Micra was launched in India last July and about 15,000 units have been sold, while nearly 70,000 units were shipped to overseas markets. “I am very proud of the effort that our Chennai staff, supported by our suppliers, have put in order to produce 100,000 Micras in such a short period of time. Nissan Motor India Managing Director and CEO (Chennai plant) Kou Kimura said. The Chennai plant has a capacity of two lakh units which would be ramped upto four lakh units. –Courtesy: PTI

Peugeot Citroen to set up `4,000 crore unit in Tamil Nadu rance-based automobile manufacturer PSA Peugeot Citroen (PSA) is finalising plans to set up its first car manufacturing facility in Tamil Nadu at an investment of `4,000 crore. With this facility, PSA Peugeot Citroen joins the list of automobile manufacturers like BMW, Hyundai, Ford and RenaultNissan that have already set up a plant near Chennai. According to an official release, PSA has identified land at Sriperumbudur to set up a plant with an initial capacity of three lakh cars per year, catering to the domestic and overseas market. The company would provide direct and indirect employment to 20,000 people at the facility, also attracting a large number of auto-component manufacturers from France.

Courtesy : PTI

P K Transmission Products Pvt Ltd Products: V-Belts, Auto Fan Belts, Industrial Chain & Engineering Products, Lubricating & Engineering Tools, Hacksaw Blades, Files & Drills, Hand Tools W: www.pktraders.co.in Participating in: Ahmedabad

Phoenix Contact India Pvt Ltd Products: Industrial Connectors, PCB Terminal Blocks, Plug Connectors, Solutions For High Power And Signal Quality, Signal Converters, Sensors, Components And Systems Automation W: www.phoenixcontact.co.in Participating in: Ahmedabad, Pune

Power Tech Marine Welding & Cutting Products: Welding & Cutting Machines, Stick (SMAW), TIG (HTAW), Plasma Cutter, Saw, Stud Welding, MIG (GMAW) W: www.weld-ptws.com Participating in: Aurangabad

Precimac Solutions Products: Spindle, Clamping Systems, Tool Holders W: www.precimac.com Participating in: Rudrapur, Ahmedabad, Pune, Chennai

Production Aids & Consultant Pvt Ltd Products: Milling & Grinding Machines, Lathe Machines, Radial Drilling Machines, Digital Readouts, Presses, Bending & Shearing Machines, Laser Cutting Machines, Gear Hobbing Machines, Gear Shapers, Gear Shaving Machines, Gear Grinder Machines, Hypoid Testers, Injection Moulding, Pressure Die-Casting Machines W: www.pacindia.net Participating in: Rudrapur, Indore

Raj Nut Bolts Products: Industrial Bolts, High-Tensile Hex Bolts, SS Bolts, Screws & Allen Key Bolts, High-Tensile Allen Bolts, High-Tensile Nuts W: www.rajnutbolts.com Participating in: Pune

Rajendra Kumar & Company Products: Screws, Nuts, Bolts, Hex Key Wrenches, Spring Washers, Spring Dowell Pins, Circlips, Self-drilling Screws, Blind Rivets W: www.rkctraders.com Participating in: Pune, Chennai

Ravi-Raj Anodisers Products: Electronic Micro Products, Name Plates W: www.ravirajanodisers.com Participating in: Ahmedabad

S&T Engineers Pvt Ltd Products: CNC Machines, Convention Precision Machines, Machine Tools Accessories, EDMs W: www.stengineers.com Participating in: Rudrapur, Ahmedabad, Pune, Aurangabad

Sahil Technocrats Products: CNCs, VMCs, Proﬁle Projectors, DROs, 2D Height Master, Rotary Unions, Spindles W: www.sahiltechnocrats.com Participating in: Pune

Samtec Tools & Accessories Pvt Ltd Products: Threading Tools, Hole Finishing Tools, Hole Making Tools, Grooving Tools, Die & Mould Tools, Machine Tool Accessories, ZX Tool Systems, Deburring Tools, Shopﬂoor Accessories, Carbide Products W: www.samtectools.com Participating in: Rudrapur, Chennai, Indore

Seventh International Products: Magnet Chucks, Magnet Lifters, Magnet Filters, V-blocks, Hopper-Grates, Sinebar Chucks, Dial Stands, Instruments, Separators, Welding Positioners, Electromagnetic Chucks, Demagnetisers W: www.sevox.co.in Participating in: Rudrapur

Shivani Engineers Products: CNC Cylindrical Grinding Machines, Hydraulic Cylindrical Grinding Machines, Centreless Grinding Machines W: www.shivaniengineers.com Participating in: Aurangabad

Suvik Electronics Pvt. Ltd. Products: Voltage Stabilisers, Static Stabilisers, Ultra Isolation Transformers, Online UPS Systems, AC Drives, MV Motors, Small Motors & Gearboxes, Battery Chargers, Customised Products W: www.suvik.com Participating in: Ahmedabad

Swift Industrial Corporation Products: SMC/DMC Insulators, Wiring Accessories W: www.swiftindustrial.in Participating in: Aurangabad

Trident Products Pvt Ltd Products: Hydraulics, Pumps, Valves, Seals, Hoses, Hydraulic Cylinders W: www.hydrauliccylinder.co.in, www.trident-precision.com Participating in: Rudrapur

Universal Instruments Products: Calibration Services W: www.universalinstruments.co.in Participating in: Pune

Venus Enterprises Products: Castors & Wheels, Polishing Rolls, Mops, Sleeves, Belts, V-belts, Pressure Gauges, DP Test Cleaners, Welding Electrodes & Accessories, Bearings, Safety Items, Hand Tools, Cutting Tools, Toggle Clamps Participating in: Pune

VI Automation Pvt Ltd Products: Data Loggers, Data Acqusition Systems, Vision Inspection Systems, PLCs, SCADA, Control Panels, Sensors, Instrumentation, Relays, Power Supplies, Energy Monitoring Systems, Software W: www.viapl.com Participating in: Rudrapur, Ahmedabad

Vinayak Industries Products: Power Tools, Non-Ferrous Foundry Participating in: Pune

Gujarat to host Asia’s largest solar energy park in two years ujarat would house the largest solar energy park in Asia in two years, with a power production capacity of 500 MW. This would be set up with an investment of around `8,000 crore ﬂowing from companies such as GMR and Lanco, which have been assigned generation capacities under the Gujarat Solar Mission. The park, on the lines of an industrial estate, is being developed by Gujarat Power Corporation Ltd (GCPL), as the sectoral nodal agency, on around 2,000 hectares of wasteland bordering the Rann of Kutch, in Patan district. When commissioned, the project would provide 800 million units of power. In the ﬁrst phase, 15 solar power generation companies would produce 176 MW and Gujarat Energy Transmission Corporation would set up a power pooling station. – Courtesy: Business Standard

Alstom, HCC win `1,843 crore hydro power contract in Uttarakhand lstom, in consortium with Hindustan Construction Company, has been awarded a contract worth over `1,843 by Tehri Hydro Development Corporation to install a 1000 MW variable speed pumped storage hydro power plant on the river Bhagirathi in the state of Uttarakhand. It will be India’s ﬁrst pumped storage power plant to use variable speed technology. Alstom’s share of the contract is worth around `1,164 crore. Alstom will supply four 250 MW variable speed turbine & generator units and other equipments including main inlet valves and control and protection systems. –Courtesy: Economic Times

NEW LAUNCHES This section gives information about products, equipment and services available in the market. If you know what you want. . . refer to Product Index on Page 200 to find it quickly

FIBRE LASER CUTTING SYSTEMS

ypertherm has announced the release of its HyIntensity fibre laser cutting systems (model HFL015) an all-in-one package that includes the power source, cutting head, gas supply, operator interface consoles, motion controls, and software. Hypertherm believes this solutions-based approach will make it much easier for partners and customers to use laser cutting for their fine-feature cutting requirements. The systems operate on familiar Hypertherm control platforms, with pre-developed cutting processes for significantly simplified table integration and operation, as well as higher levels of efficiency when compared to other laser cutting solutions. A single-emitter diode-based design enables extremely reliable performance. Fibre laser offers several advantages over CO2 laser systems. It requires virtually no maintenance, is more energy efficient, and takes up less space. The power supply is much smaller than CO2, yet fiber delivery enables the beam to travel greater distances allowing for installation on larger tables.

Hypertherm (S) Pte Ltd - Singapore Tel: +65-68412489, Fax: +65-68412490Email: technology. hypertherm@hypertherm.com, Website: www.hypertherm.com

VIBRATORY BOWL FEEDERS

ALITY

lscint Automation has recently manufacturedU special small vibratory bowl feeders for feeding of thin silver A P P contacts. R O V E DThe size of the silver contacts is from 4 mm x 3.2 mm and the thickness only 0.40 mm. A very small vibratory bowl feeder having a bowl of diameter 100 mm is used. The problem in case of such thin parts is that they tend to overlap, especially at the outlet chute. Elscint solved this problem by ensuring that any parts coming over one another were re-circulated back into the bowl. Further, customers required the outlet chute at an angle of 35degrees. This too was achieved in the specially designed outlet track. A small X-Y table with a 15 mm adjustment on each side and a small height adjustment stand having a ±50 mm adjustment on both sides is provided. The height adjustment stand provided is a standard one which has a modular design. Q

Elscint Automation, Pune 411 026. Tel: 020-2712 2059, Fax: 020-2712 2994, Mob: 09923040210 Email: sales@elscintautomation.com Website: www.elscintautomation.com Certification: An ISO 9001 Certified Company

VISIONPRO SOFTWARE

ognex Corporation has announced the addition of 3D vision in the new release of VisionPro, the software that set the industry standard for machine vision performance. VisionPro 3D delivers accurate, real-time, three-dimensional position information to automate challenging assembly verification,

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logistics, and robot applications. It works with any number of fixed or robot mounted cameras for complete application flexibility. VisionPro 3D uses multiple sets of two-dimensional features found by field proven Cognex alignment tools, including PatMax, PatFlex and other geometric pattern matching tools. Application performance is enhanced by high-precision Cognex calibration tools that adjust for optical distortion and camera position, and synchronise cameras with vision-guided robots, key to the success of any 3D application. VisionPro 3D is designed for a variety of stationary and robotic applications, such as racking/de-racking and de-palletising, as well as kitting and assembly verification in automotive and other precision manufacturing industries. Cognex Corporation - Massachusetts - USA Tel: +1-508-6503000, Fax: +1-508-6503333 Email: contactus@cognex.com, Website: www.cognex.com

LABORATORY BATHS & CIRCULATORS

ole-Parmer has launched Polystat circulating water baths and immersion circulators. Polystat offers excellent temperature stability for a range of laboratory applications. The company has redesigned and updated its line to offer even more versatile models. High-stability Polystat heating immersion circulators provide temperature control up to 200°C and inlet/outlet connections for circulation to external open- or closed-loops. Polystat open heating circulating baths that offer an economical alternative to stainless steel baths and are operated by a two-speed pump with adjustable nozzle. Polystat stainless steel heating circulating baths offer performance while remaining budgetfriendly. Driven by a two-speed pump, these units are available in standard or advanced models. For broad temperature ranges from -35°C to 200°C, Polystat cooling/heating circulating baths include a powerful refrigeration system. These baths are available in standard digital or advanced digital models.

Cole-Parmer India, Mumbai 400 076. Tel: 022-6716 2222/ 209, Fax: 022-6716 2211 Email: response@coleparmer.in,vinita.singh@coleparmer.in Website: www.coleparmer.in

SOFTWARE LICENSE STRUCTURE

atrix Comsec has introduced a new software license structure by implementing logical partitioning in COSEC (Time Attendance and Access Control System). With this new structure, COSEC application servers-COSEC PE/GE/ME/LE PLATFORM, targeting to different customer verticals will come with basic features. These platforms are completely web-based with key features like: basic report generation, hardware configuration, export and import data and many more. Software modules, such as Access Control Module (ACM) and Time Attendance Module (TAM) with advanced access control and time attendance features can be added easily on any COSEC platform depending on the requirements. As per the existing requirement, if users need only basic features and require attendance data for

NEW LAUNCHES

their own software, then they can go with only the platform and need not pay for other modules. Depending on the future requirement, users can easily add other modules on the platform by just entering a license key. This will increase simplicity and reduce the cost of the software. Matrix Comsec Pvt Ltd, Vadodara 390 010. Tel: 0265-2630555, Fax: 0265-2636598 Email: mary.thomas@matrixcomsec.com Website: www.matrixcomsec.com

SYRINGE PUMPS

olmarcâ&#x20AC;&#x2122;s SPLF series syringe pumps are versatile and costeffective products for precise dispensing of fluids in laboratory experiments or factory automation. These pumps can operate with standard off-the-shelf syringes in plastic, glass and stainless steel. The dispensing rates/flow rates possible with the device are very wide in range and can vary from 2.8 micro-l/hr to 19 ml/min. The units have built-in electronics with keyboard and display for programming the operational attributes to work in standalone mode. Salient features include: operates in standalone or through a personal computer; microprocessor-controlled mechanism; front panel with keyboard & display for programming; silent & smooth operation; and compatible with glass, plastic & SS syringes. Technical specifications are: syringe: standard off-the-shelf syringes, 10-60 ml, any

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NEW LAUNCHES

manufacturer; flow rate range: 2.757 micro-l/hr to 19.6 ml/min; temperature control up to 60°C (in select models); and dispensing accuracy: ±1 per cent. Holmarc Opto-Mechatronics Pvt ltd, Kochi 683 503. Tel: 0484-2540075, Fax: 0484-2540882 Email: sales@holmarc.com, Website: www.holmarc.com

SABIN CHAINS

ontrolwell introduces Sabin chains (E-type) the progressive next generation cable chains, made of recyclable high quality engineering plastic. By virtue of the design, these chains drastically reduce the dust and noise problem existing in enclosed type cable chains. The Sabin chains use band connection method, for the first time in the world, eliminating the link pin connection method. Elasticity of band connection method of the Sabin chains makes them operate smoothly and resist the highspeed of machine, improving the productivity to more than 30 per cent. The Sabin chains have been designed to protect cables perfectly from the external dust and foreign substance and this condition protects the cables safely from many of dangerous factors at the car welding production line. The Sabin chains are RoHS compliant and are most suitable cable protection system.

Controlwell India Pvt Ltd, Navi Mumbai 400 705. Tel: 022-2763 6293, Fax: 022-2761 8767 Email: sales@controlwell.com, Website: www.controlwell.com

ONLINE DIGITAL PRINTING TECHNOLOGY

he non-contact online digital printing technology attributes to printers with high resolution piezo inkjet technology thereby offering packaging industries the most efficient and state-ofthe-art technology in terms of hardware, software, accessories, consumables. In terms of application, it is the most cost effective modern technology, used for marking, printing and helps in traceability. This is very user-friendly, robust, compact and not only reduce the man power and cost, but also rewrites the efficient supply chain management. This system can be associated with online weighment as an added package and the system provides one step solution to the packaging industries, where the printing and traceability plays an important role. The printing can be made on coated or uncoated corrugated boxes, aluminum foil, glass, metal for address printing, pharmaceutical primary, secondary package printing, and even on pallets.

M&M Technologies Pvt Ltd, Navi Mumbai 400 710. Tel: 022-2778 1580 Email: mp@mmtechnologiesindia.com Website: www.mmtechnologiesindia.com

SYNCHRONISATION MODULES & REMOTE CONTROLLERS

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ational Instruments Corporation has introduced industry’s highest performance PXI Express synchronisation module and industry’s fastest PXI Express remote controllers. The

NEW LAUNCHES

NI PXIe-6674T timing module is the industry’s highest performance timing and synchronisation module, and the NI PXIePCIe8388 controller is the industry’s first 8 GB/s/direction remote controller. Engineers can use the new products to create high-performance PXI Express systems with tight synchronisation and high system data throughput. The NI PXIe-6674T timing module unlocks the most advanced timing and synchronisation capabilities for PXI Express systems. It generates and routes clocks and triggers between devices in a PXI Express chassis. The NI PXIe-PCIe8388 kit uses x16 Gen 2 PCI Express link that provides up to 8 GB/s/direction of sustained throughput. Engineers can use the NI PXIe-PCIe8388 remote controller to control PXI Express systems from x16 Gen 2 PCI Express slot in an NI rack-mount controller. National Instruments Corporation - Texas - USA Tel: +1-800-5315066, Fax: +1-512-6838411 Website: www.ni.com UALITY

DIGITAL PANEL METER MODULES Q

A P Pmeter R O Vmodules ED eco-G has introduced 3½ digital panel that have bright red LED display. These modules operate on 5 V DC power supply for measuring DC voltage ranging from 0-20 mV up to 200 V DC; and current ranging from 0-200 uA up to 200 mA. The digital panel meter modules are highly reliable, accurate and compact in size.

Goliya Instruments Pvt Ltd, Mumbai 400 015. Tel: 022-2414 9657, Fax: 022-2413 0747 Email: goliya@mtnl.net.in, Website: www.goliyainstruments.com Certification: An ISO 9001:2008 Certified Company

MOBILE DEVICES

oneywell has announced the introduction of Dolphin 6000, a new class of mobile device that bridges the gap between consumer mobile phones, industrial mobile computers and bar code scanners, empowering mobile information workers to connect, collect and communicate at the point of customer service. The compact, yet durable Dolphin 6000 scanphone automates the data collection process and delivers real-time access to business data, leading to improved productivity, more informed decision making and lower operating costs. It delivers more reliability, more powerful scan performance and greater line of business application support than any smartphone in the market (claims the company). It is an improvement over consumer-grade smartphones used for enterprise applications. The Dolphin 6000 offers advanced productivity features geared towards today’s vertical enterprise, including field service, field sales, and retail and logistics operations.

Honeywell Automation India Ltd, Mumbai 400 059. Tel: 022-67650579 Email: shailesh.deshmukh@honeywell.com Website: www.honeywellaidc.com A U G U S T 2 0 1 1 | SEARCH - THE INDUSTRIAL SOURCEBOOK

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STEEL STRAPPINGS

STEEL PLANT EQUIPMENT

agnus is a cold-rolled, medium carbon steel strapping. These steel strappings are heat-treated with a Signode process that combines fine surface and controlled physical properties with high strength and excellent shock resistance. The strap finish is blue waxed, painted waxed and zinc-plated waxed. Tolerances are: width: ±0.13 mm and thickness: ±0.05 / 0.03 mm. Yield calculation is based on nominal width and thickness. Applications include: light-duty, medium-duty, heavy-duty, lashing, bailing, etc.

R Enterprises manufactures and offers steel plant equipments as per customer’s specifications. These equipments include: real shafts, tension reel parts, such as gripper plates, spring retainers, anvil plates, drum segments, payoff reels, hollow shafts, liners, etc. Machining is carried on eight plano millers, two horizontal boring machines, eight milling machines and six lathes. Spares of hot rolling plants are also made as per customer’s specifications.

ITW Signode (I) Ltd, New Delhi 110 065. Tel: 011-2642 4984, Fax: 011-2622 6552 Email: info@itwindia.com, Website: www.itwsignodeindia.co.in

STEEL SPRINGS & RUBBER HANGERS

anwal Industrial Corporation offers a comprehensive range of steel springs and rubber hangers that give users a choice U A L I T Y and optimum between low frequency vibration isolation performance at higher audible frequencies if noise control is of paramount importance. Wide load A P P R O V E D ranges and fixing requirements are catered for including wire suspension of acoustic ceilings. Features include: steel frame tested to 5x rated load, with other steel parts zinc-plated including ACH casing; colour-coded steel springs with nominal deflection up to 50 mm, laterally stable with 50 per cent overload capacity; rubber inserts for high frequency attenuation on type SH also to prevent drop-rod contacting hanger frame; failsafe steel overload washers supplied with rubber hangers; 15 angular misalignment capability; and stud or wire fixing on type ACH. Typical applications are in acoustic ceilings, axial fans and fan coil units, ductwork and attenuators, exhaust systems, pipework, etc. Q

Kanwal Industrial Corporation, Noida 201 305. Tel: 011-2462370, Fax: 011-2460540 Email: kic@vsnl.com, Website: www.kanwalindustries.com Certification: An ISO 9001: 2000 Certified Company

STEEL TRICLOVER CLAMPS

odern Enterprise manufactures and offers steel triclover clamps in sizes ranging from ½” to 4”. These clamps are available in grades of SS-304, SS-304L, SS-316 and SS-316L. They also come in weldable and expandable types. Development and manufacturing of steel triclover clamps are also undertaken as per drawings, specifications and samples provided by customers. The steel triclover clamps have applications in pharmaceutical plants, food processing plants, dairy plants, fertilizer plants, oil and gas field plants, etc.

Modern Enterprise, Rajkot 360 003. Tel: 9228222631, Fax: 0281-236 5376 Email: modern_engg@rediffmail.com

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M R Enterprises, Pune 411 026. Tel: 020-2712 0726, Fax: 020-2712 0139 Email: poonaudyog@vsnl.com

STEEL BODY POWER PRESSES

ew Kabir Industrial Corporation offers pillar-type steel body power presses that come with pneumatic clutches or rolling key clutches with all electrical and fittings. Special features of these power presses and guillotine shearing machines include: manufactured from quality castings produced in-house in a modern foundry; quality control and components assembly assured by alignment checks; 24-hour test brake is powerful and works on dead centre; cam type brake provided up to 150 tons; rolling type of key: repeat and non-repeat clutch is fitted at extra cost; and lubrication cup is fitted at every moving part (oil pumps fitted at extra cost). Most of the models are available for immediate delivery. In special cases and for an extra charge, the ram can be provided with an inner guide press with a capacity of 200 to 500 tons.

New Kabir Industrial Corporation, Ludhiana 141 003. Tel: 0161-5056168, Mob: 09815835038 Email: kabirexpo@rediffmail.com

LITY MILD STEELU AWIRES

recise Alloys manufactures and

R O V E Doffers mild steel wires that are

basically iron that contains up to about 0.25 per cent of carbon, whose presence makes it stronger and harder as compared to pure iron. With the increase of carbon present the hardness of the steel also increases. Custom packaging of these products are also offered as per the specifications provided by clients. L

NTRO

Precise Alloys Pvt Ltd, Mumbai 400 604. Tel: 022-2876 8081, Fax: 022-2876 8081, Mob: 09821233381 Email: precisealloys@gmail.com, Website: www.precisealloys.net Certification: An ISO 9001 & OHSAS 18001 Certified Company

STEEL WELDED TUBES & TUBULAR SECTIONS

ahul Industries manufactures and exports stainless steel welded tubes, stainless steel tubes, stainless steel welded tubular sections (round, square, rectangular) made from various grades of high quality steel coils. The use of state-of-the-art welding techniques and equipment, ensure that these products conform to both domestic and global quality. Also offered are elegantly designed steel beds, which are made from quality steel and are crafted to perfection by our master craftsman. These steel

STEEL

beds are designed in accordance to the latest trend and assure complete comfort. They are available in ethnic styles and contemporary designs. The steel beds are designed to cater to diverse tastes. With a unique blend of aesthetics and style, the designer steel beds are designed using the finest quality steel. Rahul Industries, Jodhpur 342 001. Tel: 0291-2748705, Fax: 0291-2746705, Mob: 09799182000 Email: info@rahulindustries.com, Website: www.rahulindustries.com

STAINLESS STEEL HOLLOW BARS

andvik offers stainless steel hollow bars in larger diameter sizes, between 300 mm outside diameter by 200 mm inside diameter and 420 mm by 300 mm, produced in stainless steel grades 304L and 316L. All these are available from stock in lengths of 3.5 to 5 metres. By reducing feed rates to 0.3 mm/rev for both materials, it is possible to increase tool life to 15 minutes but significantly. Cutting speeds of 200 m/min is achieved compared to 125 m/min for the competitor material. The stainless machining steels are produced with optimum chemical composition, optimised non-metallic inclusions and closely controlled production and process parameters. The stainless steels reduce machine tool wear, increase cutting speeds, improve productivity and result in significant cost reductions per produced component.

Sandvik Asia Ltd, Pune 411 012. Tel: 020-2710 4725, Fax: 020-2714 7031 Email: nitin.pathak@sandvik.com, Website: www.coromant.sandvik.com/in

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STEEL CIRCLES

hanti Metal Syndicate offers steel circles in both ferrous and non-ferrous metals. The range of circles is known for its hardness and durability. Also offered is the range of circles in customised form at cost-effective prices. The range of circle is corrosion-free and has found wide applications in various industries. Circles are also offered to clients in stainless steel, carbon steel and alloy steel in rolled and annealed conditions.

Shanti Metal Syndicate, Mumbai 400 004. Tel: 022-6615 1943, Fax: 022-2381 1047, Mob: 9820533105 Email: shantimetalsyn@yahoo.co.in

STEEL DOOR FRAMES

ehgal & Sehgal Industries manufactures and offers pressed steel door frames and windows as per IS:4351. These steel door frames are manufactured using CRC sheets of 1.25 mm thick, including hinges jamb, lock jamb bead and if required angle threshold of mild steel angle of section 50 mm x 25 mm, or base ties of 1.25 mm pressed mild steel welded or rigidly fixed together by mechanical means, adjustable lugs with split end tail to each jamb including steel butt hinges of 2.5 mm thick, lock strike-plate and shock absorbers as specified and applying a coat of steel primer after pre-treatment of the surface.

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

STEEL PLATES

teel Mart offers wear-resistant steel plates in Hardox-500, Hardox-400, Weldox series, Sail Ma-350 HI, Sail Ma-410 HI, 12 per cent to 14 per cent high manganese steel and other alloy steels in EN19, EN24, EN31 and stainless steel AISI316 and AISI.

Steel Mart, Mumbai 400 011. Tel: 022-2308 0096, Fax: 022-2307 9961, Mob: 09820038501 Email: smartbom@bom8.vsnl.net.in, Website: www.steelmartmumbai.com

STEEL WIRE ROPES

acklers manufactures and offers steel wire ropes. A wire rope is a number of strands laid helically around a core. A strand is an arrangement of wires laid helically about a centre. The strand centre consists of a wire or fibre. A core is the centre of a wire rope. It may consist of fibre (natural or synthetic) or stranded wire or a complete independent wire rope core (IWRC). The number and size of wires in a strand, and the number of strands in a trope vary according to the rope application. Strength, flexibility, resistance to abrasion and other characteristics dictate the rope one ultimately selects. The equipment must also be considered, such as the type and size of drums & pulleys, the load and speed at which they will operate, etc.

STEEL

Tacklers, Pune 411 001. Tel: 020-2612 2595, Fax: 020-2612 1468 Email: tacklers@vsnl.net, Website: www.tacklers.co.in

STEEL CASTERS

ex-Mech Engineers manufactures and offers steel casters that incorporate wheels, balls, or sliding shoes mounted for moving equipment, furniture and other similar goods. These casters can tolerate capacity up to 300 kg per caster. They can provide an exceptional fusion of strength, durability, and quality. All the rig and hardware parts, made of heavy-duty steel, are used in the steel casters construction. The steel casters offer smooth movement without vibrations and a problem free performance. These casters can resist temperatures up to 800째F. A unique shiny finish beautifies the appearance and also provides a smoother, less penetrable covering that is more resistant to dust and easy maintenance. The steel casters of various sizes are best suited for medium heavyduty platform trucks, food service equipment, large stock carts, etc. Steel caster wheels are available in two categories, viz, forged steel casters and stainless steel casters.

Tex-Mech Engineers, Mumbai 400 104. Tel: 022-2872 3382, Fax: 022-2620 0292 Email: mohan@texmech.com, Website: www.texmech.com

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INVESTMENT CASTINGS

mnicast Precision Products manufactures investment castings in ferrous and non-ferrous alloys to radiographic standards. These investment castings are used by manufacturers of valves, boilers, pumps, tyre and glass products, launching vehicles, electronic components, etc. Materials used are of ferrous and non-ferrous to ASTM, BS, IS DIN, GOST, JIS specifications and grades. The investment castings are approved by Indian Boiler Regulations, Ministry of Defence and Engineers India Ltd.

FORGING SCREW PRESSES

ardev forging screw presses manufactured by Chhajju Singh & Sons are used for accurate production. The forging screw presses are suitable for forging hexagonal, square and round head bolts as well as for nuts, rivets, motor parts, cycle parts and varieties of other such parts. These presses are simple to operate and their stroke can be achieved by depressing a lever provided on the left hand column of the presses. The additional accessories with the presses are die boxes and electrical equipments. A wide range of products comprising of hydraulic thread rolling machines, thread rolling machines, etc, are also offered.

Omnicast Precision Products Pvt Ltd, Cuddalore 607 005. Tel: 04142-239264, Fax: 04142-239364 Email: omnicast_chennai@yahoo.co.in, Website: www.omnicastindia.com

Chhajju Singh & Sons, Ludhiana 141 003. Tel: 0161-2534220, Fax: 0161-2531955, Mob: 09814147000 Email: gurmail_s@rediffmail.com, Website: www.chhajjusingh.com

CAST IRON CASTINGS

aruti Casting takes up cast iron castings in weight ranging from 500 grams to 1000 kgs single-piece according to drawings, specifications, material details, quantity details & samples provided by customers. The company specialises in cast iron castings of lathe machine beds, CNC machine body, axle hub, flywheels, bearing housing, bearing stands, gear cases, gear cast VTR, manifolds, motor body, NRV body, oil sumps, shaft seal housing, manhole covers, sheaves, valve plates, water chambers, casings, stators, bonnets, butterfly valve bodies, coupling flanges, etc. Cast iron castings have applications in agricultural & farm equipments, diesel oil engines, all kinds of machineries, cement plant equipments, compressors, defence equipments, electric motors, general engineering, lifts & elevators, nuclear power plants, marine ship building, pumps & valves, thermal power plants, oceanography equipments, oil refineries, mining & boring equipments, power generators, etc.

Maruti Castings, Rajkot 360 003. Tel: 0281-295249, Fax: 0281-295249, Mob: 09979993093 Email: ci_casting@rediffmail.com

PRECISION INVESTMENT CASTINGS

Manek Investment Cast Pvt Ltd, Rajkot 360 002. Tel: 02827-252355, Fax: 02827-252117, Mob: 09824226454 Email: manekcasting@yahoo.com Certification: An ISO 9001:2000 Certified Company

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Lava Forge Pvt Ltd, Dist Rajkot 360 002. Tel: 02827-253670, Fax: 02827-253770, Mob: 09879521427 Email: info@lavaforgepvtltd.com, Website: www.lavaforgepvtltd.com

anek Investment Cast offers precision investment castings under lost wax moulding process. These investment castings are offered in capacity of making a fewA grams to U L I T Y any 70 kgs single piece. It is their arrangement to cast virtually metal-alloys, such as steel, alloy steel, carbon steel, A P nickel-based PROVED steel, super alloys, hast alloys, inconel, monel, dunctile irons, O aluminium alloys, copper-based alloys, bronze alloys Nand T R Omany other ferrous and non-ferrous metals. Quality precision investment castings as per drawings, specifications, material composition and samples provided by customers are also undertaken.

PRECISION FORGED COMPONENTS

ava Forge manufactures all types of small and long precision forged components. They make open forgings, close die forgings and forging dies. Forged components are developed and manufactured as per drawings, specifications, material compositions and samples received from customers. Components are supplied as forged, heat-treated, in partially or fully machined condition. The forging plant has a facility and arrangement of forge shop, machine shop, heat treatment, shot blasting, laboratory and computerised management. Generally the forged components are available in materials of MS, SS, EN, brass, aluminium or from any other materials of Indian or International standards. In quality and accuracy maintenance, processes at different stages of production are taken up, like visual examination and spark testing of raw material, chemical, metallurgical and physical testing, heat treatment, hardness and doing normalising, annealing, hardening, tempering, solution annealing, isothermal annealing, shot blasting, visual inspection for scale pit, folds, unfeeling and dimensional inspection and packing inspection, etc. The precision forged components have vast applications for fasteners, textile components, automobile components, electrical components and electrical insulators, diesel engine parts, submersible pumps, gears, engine valve and industrial valves, machine tools components and other critical components of small and long sizes as per customersâ&#x20AC;&#x2122; need.

INVESTMENT CASTINGS

eena Cast manufactures investment castings for material handling equipment components. These investment castings are manufactured in ferrous metals, alloy & super alloys of the finest quality. The company is equipped with latest, sophisticated & ultra modern infrastructure and machines, testing equipment, instruments & facilities to maintain quality assurance to a high-precision degree of accuracy required in process. Tiny

CASTING & FORGING

product as minimum few grams and up to 30 kgs, single piece as cast, linear up to 600 mm. Investment castings done for material handling equipment components include: hooks, brackets, shackles, chain links, pins, fork links, U-bolts, claves, centre pivots, TC pins, ball pins, rings, etc. Development and manufacturing of any kind of ferrous or non-ferrous industrial components, is undertaken by investment castings as per drawings, specifications and samples provided by customers. Meena Cast Pvt Ltd, Dist Rajkot 360 002. Tel: 02827-252117/8, Mob: 09824226380 Email: info@meenacast.com, Website: www.meenacast.com

SPHEROIDAL GRAPHITE IRON CASTINGS

erfect Auto Cast manufactures and supplies quality spheroidal graphite (SG) iron castings (nodular cast iron/ ductile castings). Manufacturing of any components by SG iron castings is undertaken as per drawings, specifications, material details and sample provided by customers. Quality, accuracy and timely delivery are maintained. Development of SG iron castings are taken up in the capacity of weight range of 0.5 kg to 500 kgs per single piece, while the production capacity is up to 3000

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tons per annum in materials as per ASTM, BS, DIN, EN, SAE, ISO, IS and other international standards or as per the need of customers. The spheroidal graphite iron castings have application in the field of automobiles, internal combustion engines, compressors, machine tools, hydraulics, pumps & valves, pipe fittings, electrical power transmission & switchgear industries, heavy equipments, material handling equipments, food process machineries, leather machineries, rolling mills, etc. Perfect Auto Cast, Dist Rajkot 360 002. Tel: 02827-253870, Fax: 02827-253880, Mob: 09824225830 Email: perfect_auto_cast@yahoo.com Website: www.perfectautocast.com

MECHANICAL FORGING HAMMERS

attan Hammers manufactures and offers mechanical forging A L I T Yare motorised type, equipped with foot lever hammersU that operated clutch to control strokes. These forging hammers A P P R O V have E D spring loaded hand lever for adjustment of strokes. Rams and anvils are adjustable on RO the eccentric and the vertical pull rod. The mechanical forging hammers come complete with AC motors and starters. Features include: more number of blows per minute, high efficiency work, most economical forging, higher productivity, more profits, useful for small and big industries, etc. Technical specifications include: Ram weight of 75, 100 and 125 kgs; maximum stroke 5”, 7”, and 9”; power input of 3 HP, 5 HP, and 7.5 HP; and drive in V-belt type. Rattan Hammers, Ludhiana 141 123. Tel: 0161-268 5234/5, Fax: 0161-268 5236, Mob: 09876120925 Email: info@hammersindia.com, Website: www.hammersindia.com Certification: An ISO 9001:2000 Certified Company

FORGING FOR DIESEL ENGINE PARTS

uper Forge manufactures forging for diesel engine parts by ferrous and non-ferrous materials. There are facilities and arrangements of forge shop, die shop, machine shop, heat treatment unit, shot blasting unit, testing laboratory and computerised management. Open die and close die forging process is maintained. Forging as per drawings, specifications and samples provided by customers are undertaken. Full care is taken to maintain the quality, accuracy and timely delivery for forging. Diesel engine parts, marine engine parts, aircraft engine parts, automobile engine parts, power generating engine parts, etc, are developed by forging, like camshaft gears, timing gears, small crankshafts, connecting rods, bearing caps, rocker arms, rocker levers, governor levers, tappet sets, brackets, shackles, housings, sprockets, universal joints, yokes, crosses, pinions, etc.

Super Forge, Rajkot 360 003. Tel: 02827-287115, Fax: 02827-287215, Mob: 09825425199 Email: superforge2004@yahoo.com

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CASTING & FORGING

FORGED AUTOMOBILE COMPONENTS

amrat Forgings offers a variety of forged automobile components for OEM and aftermarket requirements. In addition, all types of forged components are custom-designed to meet specific requirements of customers. The forged automobile components are designed and developed using modern production technologies. These components are available in various profiles, like materials and grades.

Samrat Forgings Ltd, Mohali 140 506. Tel: 01762-655733, Fax: 01762-280931, Mob: 09216514444 Email: samratforge@satyam.net.in, Website: www.samratforgings.com

FORGED PRODUCTS

ALITY

U aghav Industries manufactures and offers an extensive selection of forged products for vehicles, like A P P R O V EFord. D These products include tie rod ends, ball joints, inner tie rods, idler arms, Pitman arms, drag link arm and kits gears, hubs, rings, cups, flanges, propeller shaft items, chain links, hooks, auto parts, etc. These parts are also manufactured as per clientsâ&#x20AC;&#x2122; specifications. Round items are forged at very low margin forging for direct CNC, which reduce the production cost, and reduce production time. All modern machines in toolroom, laboratory, and forge shops, are available. Round profiles and all types of items from 100 gms to 50 kgs are forged at hammers and presses.

Raghav Industries, Delhi 110 085. Tel: 011-2755 6914, Fax: 011-2794 6324, Mob: 09811060161 Email: raghav_forging@yahoo.com, Website: www.raghavindustries.net Certification: An ISO 9001:2008 Certified Comapny

FORGED COMPONENTS

GP Engineers manufactures and offers forged components that are especially used in trucks, tractors and auto industry. These forged components are commonly found at points of shock and stress, such as wheel spindles, steering arms. The forged components are ideal for vital automotive and truck applications.

SGP Engineers Pvt Ltd, Ludhiana 141 010. Tel: 0161-2672001, Fax: 0161-5026193, Mob: 09914523023 Email: che_tan05@yahoo.co.in , Website: www.sgpengineers.com

CONTINUOUS CASTING MACHINES

toker Concast manufactures and offers continuous casting machines that are used to melt and cast in continuous lengths a wide range of copper and copper-based alloys. These casting machines find application as semi-finished rods, strips, tubes or in any other profile. They help in cutting down costs drastically. The machines process recycled expensive scrap, which

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results in reducing scrap wastage to the minimum. They cover a wide range from 10 kg/hr to 250 kg/hr for precious metals. Selection of the machines depends on a particular application. Product sizes can range from as small as 6.0 mm diameter rods to billets of 150 mm diameter. The widest strip and section, up to 150 mm width may be produced on large machines. Every model of the range of machines features great flexibility in terms of product profile and product alloy. Stoker Concast, Faridabad 121 002. Tel: 0129-2410172, Fax: 0129-2415774, Mob: 09811144671 Email: stokerconcast@vsnl.net, Website: www.stokerconcast.com

CASTING FLUXES etal Aids manufactures and offers casting fluxes that are engineered to provide uniform distribution on molten metal P Rsurfaces, O V E D good communication, excellent melting O Nproperties, uniform heat transfer, good inclusion TRO absorption superior lubrication properties.

UALITY

Metal Aids, Hardwar 249 402. Tel: 01334-230406, Fax: 01334-230566, Mob: 09837072210 Email: info@metalaids.com, Website: www.metalaids.com Certification: An ISO 9001:2000 Certified Company

FORGED COMPONENTS

nispares Umanufactures and offers forged components. The ALITY range includes a variety of forged automobile components for APP R Oaftermarket VED OEMs and requirements. In addition, also custom-designed are all types of forged R O components to meet specific requirements of customers. These are designed and developed using modern production technologies. The forged automobile components are available in various profiles like materials and grades. L

Unispares, Noida 201 305. Tel: 0120-2460261, Fax: 0120-4274676, Mob: 09899269600 Email: info@unispare.com , Website: www.unispares.com Certification: An ISO 9001:2000 Certified Company

CASTING & FORGING EQUIPMENT

asting India is basically into the production of casting and LITY forging and manufactures various fully machined U Aequipment parts for various industries. The product range includes: A Pcomponents, P R O V E D chemical process equipment, alloy steel cast iron components, paper making equipment, O aluminum & all other non-ferrous parts, earthmoving equipment, components for pumps & valves, mining equipment, automotive components, agriculture equipment, aircraft components, and forestry equipment.

Casting India, Coimbatore 641 027 . Tel: 0422-4373702, Fax: 0422-421 2021, Mob: 09360334161 Email: sales@castingindia.com , Website: www.castingindia.com Certification: An ISO 9001:2008 Certified Company

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PISTON DIE-CASTING MACHINES

echnomachines manufactures piston die-casting machines (GC series) complete in all respects consisting of power packs, hydraulic cylinders, direction control valves, PLCs, pendent controls, proximity switches, etc. These diecasting machines are provided with motorised central lubrication systems, which deliver the right amount of oil to all the sliding surfaces without fail every 2 hours. The core is basically a 5-piece construction. Additionally other die parts, such as crown, moulds, etc, are also provided. Hydraulic cylinders are used to give movements to moulds, eye pads, crown, and lock, tilting. Lock cylinders provide delayed movement to small tools. All other tool movements during assembly and disassembly, including air/water cooling are automatic. PLCs from Siemens, Germany provides the complete controls in the machine. AS-cast crown piston can be made on the machine; as well as both RC and non-RC pistons can be cast on these machine.

Technomachines, Bengaluru 560 034. Tel: 080-2553 1075, Fax: 080-2553 1075, Mob: 09845025552 Email: info@technomachines.in Website: www.geocities.com/technomachines

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MACHINED CASTINGS

ndespa Technical Services offers a wide range of products, such as machined castings in grey iron or in nodular iron, as per the DIN/ANSI specifications. Stainless steel and carbon steel castings in sand, shell, investment casting, etc, are also available. All types of forging and nonferrous castings as per standards in machined and unmachined condition are provided. Also offered are valve components, like gland, washer, gasket, stems, as per specifications of the customer; including municipal castings and garden furniture castings, etc.

Indespa Technical Services Pvt Ltd, Coimbatore 641 017. Tel: 0422-2648565, Fax: 0422-2648586 Email: indespa@hotmail.com, Website: www.indespa.com

FORGING PRESS BOLSTERS

R Enterprises manufactures and offers bolsters that are used in 1000, 1600 and 2500 tons forging presses. The top and bottom of the bolsters is made from die steel. Pillars are made from En24 material. Gunmetal bushes are used to guide the pillars. Design of the bolsters can also be done as per specific requirements.

Poona Udyog, Pune 411 026. Tel: 020-2712 0726, Fax: 020-2712 0139 Email: poonaudyog@vsnl.net

FORGINGS

ijay Commercial House offers beryllium copper, chrome copper and aluminium bronze forgings. Beryllium copper forgings are high-performance plastic mould tooling materials. These combine the properties of high thermal conductivity and hardness resulting in substantial economic and production benefits for plastic processing moulders and tool makers, like rapid heat transfer, faster cycle times, low processing cost and low mould fabrication cost. Applications of the product are in plastics & polymer industry for automotive (injection), consumer products (luggage, toys), electronics (computers, connectors), medical (hospital equipment, testing equipment) containers/caps (trash cans etc) as well as injection/blow mould applications. The forgings are offered in plate, block, bar and rings. Speciality copper alloy forgings are available for plastic mould tooling and resistance welding applications. The company offers forged, machined-to-print copper alloy, beryllium copper and aluminium bronze products in hard-to-find and custom-made sizes and designs pieces up to (1,800 kg) 4,000 lbs with short lead times.

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Vijay Commercial House, Mumbai 400 002. Tel: 022-2201 7128, Fax: 022-22016629, Mob: 09821236275 Email: berylliumindia@gmail.com, Website: www.berylliumindia.com

CASTINGS

elco Precisions manufactures and offers castings in alloy steels and irons for heat, wear and corrosion resistant applications. A wide range of castings conforming to Indian and International standards/specifications is offered. The foundry operation offers an integrated range of facilities, from pattern making to the machining of the finished castings. These castings are used for diverse applications in chemical & fertilizer plants, iron ore mining & pelletisation, construction & road building, railways, defense, food & beverages, power plants, cement industry, petrochemicals, etc. The product range includes: wear resistant steels (tooth points, jaws, slurry pump casting, blow bars (for crusher), crusher spare parts); heat-resistant steels (grate bars, base tray, baskets, heat treatment fixtures for automobiles, fasteners & gear rods); corrosion resistant steels (pump castings); nickel alloys (valve seat inserts); hi-chrome irons (slurry pump casting & blow bars); manganese steels (jaws, hammers & crusher spare parts); and stainless steels (valve bodies).

Melco Precisions Pvt Ltd, Faridabad 121 003. Tel: 0129-4041349, Fax: 0129-4041350, Mob: 09818436295 Email: info@melcocastings.com, Website: www.melcocastings.com

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BUS PLUG CONNECTORS

hoenix Contact GmbH manufactures TMSTBP 2.5 bus plug connectors with screw connection. These connectors save space and wiring materials. Common potentials are looped from module-to-module with two screw connections per contact point so that the function of the other modules is maintained when one connector is disconnected. Four to twenty conductors with a connection crosssectional area of 2.5 mm² and a current carrying capacity of 12 A and a nominal voltage of 250 V can be connected to the 2-10 position connector with a 5.08 mm pitch. A separate test connection is provided for each plug contact. The polarised coding option excludes the possibility of inadvertently interchanging several connector sections. A connector with screw flange is also available for vibration-proof screw connection to the respective pin strips.

Thermocab Instronics, Mumbai 400 060. Tel: 022-2820 3531, Fax: 022-2820 3958, Mob: 09821026792 Email: thermocab@vsnl.com, Website: www.thermocabinstronics.com

CELL TESTERS

oliya Electricals manufactures cell testing voltmeters (cell testers) that conform to IS:1248 and are approved by the Dept AofL I TPost & Telegraph. Accuracy class offered is 2.5. Y U These cell testers are housed in ABS plastic case with front acrylic cover. They are supplied with ROVED spikes. Movement is permanent magnet moving N T coil R O system spring controlled with an externally operated zero adjuster, pivots and jewels. The instruments have white matt enamelled finish aluminium dial provided with 60 divisions. These have excellent reliability and electromagnetic damping obtained by the metal former over which the moving coil is wound. The cell testers are manufactured with voltage ratings of 3-0-3 V and 30-0-30 V. Other specific range can also be supplied on request (claims the company).

Phoenix Contact (I) Pvt Ltd, New Delhi 110 020. Tel: 011-3026 2800, Fax: 011-2638 3285 Email: response@phoenixcontact.co.in, Website: www.phoenixcontact.co.in

digit LCD display that are battery-operated mobile/ portable units available for source & measure mode having ranges 0-199.99 mV DC which can cover calibration of K, J, T, R, S, etc. All thermocouples and other range source and measure range is 0-19.999 mA covering all types of pressure transmitters. The portable model is so handy that a field engineer can easily carry it with him and with the help of this he can calibrate all temperature & pressure instrument onsite easily at a particular point. There is separate portable handy available for calibration of RTDs.

HYDRAULIC/MANUAL SURFACE GRINDING MACHINES

hurji Machine Tools manufactures and offers hydraulic and manual surface grinding machines (model AH-600) in a wide range. These surface grinding machines available in Y U A L I Tare manual oil dip version of 150 x 300 mm, up to 300 x 600 mm; RO V ExD1000 mm. and hydraulic version of 225 x 500 mm,A P upPto 400 Some of their salient features include: heavy duty robust base structure and slides; column guideways ground finished; magnet slide immersed in oil bath; spindle running on preloaded super precision anti-friction imported bearings; microfeed up to 0.002 mm; electric control panel having L&T/TC contractors, AGI rotary switches and soft touch pushbuttons; hydraulic models equipped with imported seals, hard chrome plated rod and honed cylinder; power pack equipped with relief valve, pressure gauge, suction and return line filters, UK collaborated hydraulic pump and works on low pressure. It is situated outside the machine body for better cooling. All hydraulic connections are connected by imported copper pipes, leakproof hydraulic fittings and Gates/Markwel hydraulic hose pipes. After completion of the job, the machine stops automatically. C

Bhurji Machine Tools, Faridabad 121 004. Tel: 0129-2288905, Fax: 0129-2291482, Mob: 09818439150 Email: bmtfbd@yahoo.com, Website: www.bhurjee.com Certification: An ISO 9001-2000 Certified Company

DIGITAL CALIBRATORS

hermocab Instronics offers digital calibrators for temperature/pressure indicators suitable for temperature range of -200°C to +2200°C to be used with different thermocouples (K, J, T, R, S, N, C, etc), RTDs and for pressure transmitters. These portable temperature calibrators have 4½-

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Goliya Electricals Pvt Ltd, Mumbai 400 015. Tel: 022-2412 0456, Fax: 022-2416 8498 Email: geplmumbai@mtnl.net.in, Website: www.goliya.com Certification: An ISO 9001:2008 Certified Company

BENCH GRINDERS

ower Master heavy-duty bench grinders offered by Prem Brothers come with built-in dust collectors specially designed for collection of dust generated during the grinding process. These are mounted on a rigid steel frame. The machines are directly driven by heavyduty drive 2.2 kW 3 HP, 3-phase 50 cycles 1440 RPM complete with starters, two grinding wheels 14” x 2” aluminium oxide, heavy-duty MS wheel guards, job rests dust collector motor 1.5 HP 3-phase. The dust collectors are fitted with a manual shaker, dust drawer, bag filters, 2 nos suction inlets dia 100 mm ID (model BIDC–314). These have high filtering efficiency to enable them to grasp even the finest dust particles. Cotton filtering sleeves provide them with total security against inflammation. Other size of grinders is available on request.

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

GENERAL PRODUCTS

PTFE SEALS

riumph Engineers & Associates offers MESET spring energised PTFE seals and metal encased sealing systems. The MESET seals are special variety seals with metallic springs encased in a sealing jacket. Other common varieties include a metal jacket moulded together with a variety of elastomers for optimum sealing performance. These seals are widely used in areas where manufacturing tolerances or the presence of side loads make the requirement for a flexible seal lip mandatory and at the same time facing high wear. Some of the advantages include: low breakout & running friction in dynamic applications; high resistance to thermal & fluid pressure shocks; long service life with superior installability; and no stick-slip & adhesion effect. Applications are in rotary, reciprocating, oscillating & static areas; piston, rods & shaft seals; face seals; and cylinders, actuators, valves, pumps, manifolds & chemically aggressive media.

Triumph Engineers & Associates, Bengaluru 560 034. Tel: 080-2572 0371/7678, Fax: 080-2572 0643 Email: dtm@vsnl.com, Website: www.triumph-diamant.com

CENTRIFUGES & HYDRO-EXTRACTORS

nited Engineering Enterprises specialises in centrifuges and hydro-extractors for effluent treatment plants. These centrifuges and hydro-extractors are of heavy-duty, 3-point pendulum suspension type. The main shaft is of steel and is amply proportioned to with stand heavy loads. Basket is designed to withstand off-balance loads of 4-5 per cent during centrifuging. The centrifuges are V-belt driven through TEFC motor. These are fitted with heavy-duty disc or horse shoe brakes. Materials of construction can be of stainless steel (SS) contact parts and MS non-contact parts. The centrifuges and hydro-extractors are available in various models with basket diameters ranging from 300 mm to 1950 mm; basket heights ranging from 200 mm to 700 mm; and batch capacities ranging from 50 kgs to 600 kgs.

United Engineering Enterprises, Mumbai 400 011. Tel: 022-2308 3990, Fax: 022-2308 9445 Email: uenggent@gmail.com, Website: www.united-centrifuges.com

ROTARY VACUUM PUMPS

cmevac Sales offers direct-drive, multi-vane, oil-lubricated UALITY type rotary vacuum pumps (series BKV) that are of monobloc design andAhence compact. PPRO V E D Carbon fibre vanes are used in place of steel vanes. The advantages are silent running and negligible wear on stator, end covers and rotor slots. Continuous filtration of oil at separate oil reservoir keeps the pumps free of contamination. The non-return valve prevents oil entry into the system. The exhaust gas is free of oil mist. The pumps utilise less than 10 per cent of oil as compared to oil immersed pumps. These pumps are vibration-free, silent in operation and are fan-cooled. The C

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complete unit with motor and base plate is suitable for mounting inside the equipment. The pumps are available with displacements of 150 to 3500 LPM and ultimate vacuum up to 0.5 mbar (A). Acmevac Sales Pvt Ltd, Mumbai 400 099. Tel: 022-2837 5837, Fax: 022-2836 4977, Mob: 092233 88105 Email: acmevac@vsnl.com, Website: www.acmevac.com Certification: An ISO 9001:2000 Certified Company

FORCE-FEED LUBRICATORS

ertex Hydraulics offers force-feed lubricators that are used by leadingA Lmanufacturers of compressors and pumps. The U ITY vertical drive has driving shaft at the bottom in the drive unit. These A Plubricators P R O V E Dhave two main parts, ie, drive unit-cumreservoir: available at 3.5 ltr to 8 ltr with O gear ratio of 1:22; and pumping unit: available in working pressures of 25 bar, 85 bar, 210 bar, 410 bar, and 560 bar. Piston sizes are 1/4”, 3/8”, and 5/16” (depending on the use of oil & delivery required). Accessories available on these units include: LOL switch, hand priming arrangement, ratchet drive, heater connection, etc. The vertical drive units are available in 2, 4, 6, 8 pumping units. L

Vertex Hydraulics Pvt Ltd, Ahmedabad 380 009. Tel: 079-6521 4825, Fax: 079-2676 5650, Mob: 09824039374 Email: info@vertexhydraulics.com, Website: www.vertexhydraulics.com Certification: An ISO 9001:2000 Certified Company

UNIVERSAL BEVEL PROTRACTORS

risteel Shinwa Industries offers universal bevel protractors that are high-precision angle gauges used for setting and inspecting all types of machines, metal moulds, jigs and fixtures. These can be attached to height gauges. Blades are available in lengths of 150 mm (6”) and 300 mm (12”) and with acute attachment. Salient features include: minimum reading (least count) is 5 minutes; main scale and vernier scale are on the same plane to eliminate, reading parallax; and fine adjustment of the blade ensures precision measuring & laying out of angle. The main parts are of hardened stainless steel to prevent rust combines with an attachment or height gauge, with a wide range of measurement available. These international class measuring instruments comes handsomely packed in a thermocol box.

Kristeel Shinwa Industries Ltd, Mumbai 400 072. Tel: 022-4225 6666, Fax: 022–4225 6690 Email: sales@kristeel.com, Website: www.kristeel.com

HIGH-SPEED ROLL-UP DOORS

andhi Automations offers Sector counterweight balanced and interchangeable–section, high-speed roll-up doors that are reliable and equipped with modular counterweights. These roll-up doors are rugged and compact, also available in stainless steel version. They are self-bearing, easy and quick to install. Compact size, both in terms of height & width, enables trouble-free installation even when there are space problems. The reliable modular counterweight balancing system,

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with sturdy driving belt, allows the motor to work with minimum effort, thus extending the operational lifespan of the automation. Sector comes with a wide range of safety devices, such as: emergency reopening mechanism, available on both sides of the door; standard safety photocell couple and additional provision for another photocell couple; IP55 external electronic control panel, with open-close push-button station, emergency stop; and self-test function. Sector offers great structural flexibility, thanks to its modular interchangeable systems. Gandhi Automations Pvt Ltd, Mumbai 400 064. Tel: 022-6672 0200, Fax: 022-6672 0201 Email: sales@geapl.co.in, Website: www.geapl.co.in

STEPPING MOTOR DRIVES

TY trategi Automation Solutions offers reliable and U A L Ipowerful, compact range of 2-phase stepper motor drives manufactured by RTA, Italy. These drives areA P P R O V E D available in both AC and DC input versions. The range begins with the CSD series of drives for currents up to 4.4 A and DC input voltage up to 45 V for low-to-medium speed applications. This progresses to the NDC series of drives, which are ideally suited to drive NEMA 34

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series of motors with currents up to 6 A and 75 V DC operation. AC input drives are available operating from 55 V AC to 230 V AC. These drives are suited for high speed applications. Drives are also available with networking capabilities and to operate with motors fitted with encoders. Special drives have been designed to operate with NEMA43 size motors and for motors designed to operate at high voltages. Strategi Automation Solutions Pvt Ltd, Bengaluru 560 048. Tel: 080-3248 9798, Fax: 080-4116 3047 Email: corporate@strategiautomation.com, Website: www. strategiautomation.com Certification: An ISO 9001:2000 Certified Company

GRAPHITE MACHINING

aras Flowform Engineering offers graphite machining. Several high-speed machining centres for milling, few turning centres for turning & also conventional machines for doing bigger size blocks & plates are available. The company has very big setup to cater to any quantity and any accuracy as per customersâ&#x20AC;&#x2122; drawings. Also supplied are components made from high-grade graphite imported from Europe. CMM inspection for ODD type and highprecision components are also provided.

Paras Flowform Engineering Ltd, Dist Thane 421 506. Tel: 0251-2620333, Fax: 0251-2621222, Mob: 08805029911 Email: rajamani.pal@shahgroup.biz

ACID FUME EXTRACTION SYSTEMS

rvind Anticor offers acid fume extraction systems that are specially developed for extraction and neutralisation of hydrochloric acid, sulfuric acid, nitric acid and hydrofluoric acid fume. These systems have been highly successful in the plants using acids of higher concentration up to 30 per cent. The systems mainly consist of polypropylene scrubbing tower with heavy-duty centrifugal fans. They are completely made from anti-corrosive materials. The acid fume extraction systems ensure compilation of stringent environmental conditions stipulated by pollution control authorities and a very long working life.

Arvind Anticor Ltd, Ahmedabad 382 445. Tel: 079-2589 1941, Fax: 079-2583 0287, Mob: 07878883400 Email: arvindanticor@hotmail.com, Website: www.picklingplant.com

INDUSTRIAL PLUGS & SOCKETS

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onnectwell Industries offers industrial plugs and sockets that provide a versatile and robust connection system for industrial field and factory connection applications. These are designed and manufactured as per IEC 60309-1 and IEC 60309-2 standards. Housings of the plugs and sockets are made of halogen-free, V0 grade polyamide 6 materials and hence are non-flammable

GENERAL PRODUCTS

with a very high impact resistance. Contacts are made from electroplated copper alloy offering high corrosion resistance and very low contact resistance. By virtue of their design these industrial plugs and sockets enable low insertion and extraction forces while maintaining excellent electrical contact. A wide range is available in 16, 32 and 63 A versions with a choice of IP44 or IP67 protection class and in 3-, 4- and 5-pin configurations to suit various applications. The industrial plugs & sockets are extremely safe and reliable for field & factory connections. Connectwell Industries Pvt Ltd, Dist Thane 421 204. Tel: 0251-287 0766, Fax: 0251-287 0889 Email: sales@connectwell.com, Website: www.connectwell.com

INTERNAL GRINDING SPINDLES

ahnot Grindage Industries offers internal grinding spindles, manufactured with international standards suitable for internal thread, profile, flute, surface and tool & cutter grinding operations. These spindles can be straightaway used on indigenous grinding machines as well as on imported grinding machines. One can choose the spindles up to 80,000 RPM by selecting diameter, length and RPM to suit the machine and components. Speed can be increased by 25 per cent in case of oil mist lubrication. The internal grinding spindles are manufactured with international standards and are suitable for internal thread, profile, flute, surface and tool and cutter grinding operations. Four or more super precision bearings of grade P4 or ABEC-7 in machined pairs, with accurate

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LINEAR SIDE RAIL ASSEMBLIES

ollon Bearings offers linear slide rail assemblies for machine door assembly and many other sliding applications. These linear slide rails assemblies are contoured rails available in stainless steel versions. The sliders are mounted on lubricated UALITY rails. Raceways for the slide rail assemblies are internal, for better protection and Acompactness. P P R O V E D Some of the features of these assemblies are: low co-efficient of friction, very smooth movements, resistant to high temperatures, extremely compact, high performance over several years, lower product cost, simple & east installation, corrosion resistant, etc. Application fields include: machine tool door enclosures, protective of packing machines, guides for medical equipments, automation, pharmaceutical machinery, assembly lines, etc.

Mahnot Grindage Industries, Mumbai 400 059. Tel: 022-2920 1753, Fax: 022-2920 8807 Email: satishmahnot@mahnotspindles.com Website: www.upmdpmdiamond.com

preloading and calibrations make the spindles matchless in quality and suitable for heavy-duty precision grinding operations.

endt offers laser shaping machines (model Spectra-820) that have solid granite base in portal design with high weight and good damping. The movement of the workpiece under the stationary laser beam is to achieve higher accuracies. Highly dynamic directly-driven linear motors with accelerations of up to 3 g are provided. Modular axis concept with three linear axes; 3D measuring probe for centering the workpiece and for process control; class-1 laser protection housing with easy access; special laser exhaust system; proven industrial control and drive system; 3D CAD/CAM postprocessor to import the workpiece model in current data exchange formats, etc. Three-dimensional geometries with complex forms and high requirements of the size and form accuracy and surface quality; contours on cutting inserts made of PCD, CBN, tungsten carbide, ceramic and cermets.

Wendt India Ltd, Hosur 635 126. Tel: 04344-405500, Fax: 04344-405620 Email: venkateshms@wendtindia.com, Website: www.wendtgroup.com

Rollon Bearings Pvt Ltd, Bengaluru 560 052. Tel: 080-2226 6928, Fax: 080-2225 0319 Email: rollon@rollonbearings.com, Website: www.rollonbearings.com Certification: An ISO 9002 Certified Company

THERMOCOUPLE TERMINAL BLOCKS

lmex Controls offers thermocouple terminal blocks. A thermocouple is a bi-metallic junction, ie, a junction between two different metals that produce a voltage related to temperature difference. are classified depending ennce. ncce nce cee.A. LThermocouples Therm Ther The Thhhe T herm eerm r U ITY on different alloyss used temperature ranges. For uusssed se eedd for ffo or different o d temperature measuring requirement, wherein measuring point is aasuring as asu uuring ur iP nnggRrrequirem req requir eeqqqu quirem iEreem irem Assuring Prring O Vuire Dm far from the measuring O instrument, intermediate connections have to be made for extending the path. For such application, conventional type terminal blocks cannot be used to create the required extension, since current carrying parts are made of either copper or copper alloy which are different than the thermocouple metals or alloys as mentioned above. Thermocouple terminal blocks are constructed using the same type of metal/alloy as that of thermocouple intended for measuring temperature. Thermocouple terminal blocks are used in pairs.

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r Pu g e r â&#x20AC;&#x2122; a Man

Striving to get the best deal

In the present business scenario, the Internet is the best option for us suppliers as we can find information at the click of a mouse. We make our purchase decisions based on the product quality, reliability and price negotiations. We seek quotations from at least 3-4 manufacturers to compare the prices and select the manufacturer, which offers us the best deal. The problems we face while ordering/buying a product/equipment varies from company to company as all companies look for good quality reasonably priced products.

Elmex Controls Pvt Ltd, Vadodara 390 010. Tel: 0265-2642021, Fax: 0265-2638648 Email: niravparikh@elmex.net , Website: www.elmex.net Certification: An ISO 9000:2000 Certified Company

MELT FLOW INDEXERS

ultiflo Instruments offers high quality melt flow indexers (model 4000 series) manufactured by Dynisco, USA, for plastic processing industry for rheological testing. These are most precise instruments for the measurement of melt flow rate or melt volume rate in quality control and research applications. Model LMI 4000 is the first melt flow indexer to utilise a powerful 32-bit microprocessor to provide test parameter control, self-diagnostics and digital calibration. Four melt indexer models are offered in the advanced Dynisco LMI 4000 series, each

M K P SHENOY Director, Multiflo Instruments Pvt Ltd Email: k_p_shenoy@yahoo.co.in Web: www.multifloinstruments.com

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LASER SHAPING MACHINES

GENERAL PRODUCTS

with features designed to meet specific application requirements. Features and benefits are advanced microprocessor design, designed to cover ASTM D1238 and ISO 1133-2005 testing standards, selfdiagnostics capability, comprehensive statistical capability, simple push-button RT D calibration, smart keys for easy programming, bright, 4-line by 20-character vacuum fluorescent display, Windows software for test database and analysis. Multiflo Instruments Pvt Ltd, Navi Mumbai 400 710. Tel: 022-2778 0880, Fax: 022-2778 0882 Email: sales@multifloinstruments.com Website: www.multifloinstruments.com

AUTOMOTIVE CABLES

-Flx Wires & Cables (a div of Cybele Industries Ltd) offers a wide range of quality automotive cables to wiring harness manufacturers A for their supplies to heavy-duty U LITY vehicles, like buses, trucks, tractors, earthmovers, etc; and all four-wheelers and two-wheelers A P P R O Vfor E Dthe purpose of lighting, igniting, wiping, battery charging, starter, steering column, horn, signaling, motor antenna, motorised outside rear view mirror, power windows, stereo systems, communication, etc. Automotive cables are manufactured to reference standards BS:6862, JIS:3406 and IS:2465 with bright

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annealed high conductive electrolytic copper conductor conforming to the requirements of IS:8130/BS:6360 and insulated with specially designed dielectric grade Q-Flx brand PVC compound as per IS:5831/BS:6746, which is impervious to water, oil, petrol, acid and greases. The automotive cables are also manufactured as per conventional sizes prevailing in the market where the copper and the PVC insulation meets the above standards requirements and impervious to water, oil, petrol, acid and greases. Q-Flx Wires & Cables, Chennai 600 098. Tel: 044-2625 0549, Fax: 044-2625 7580, Mob: 09884522777 Email: investor@qflexcable.com , Website: www.qflexcable.com Certification: An ISO 9001:2000 Certified Company

TRANSPARENT LIQUID LEVEL GAUGES

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lowtech Instruments Services offers transparent liquid level TY U A L Ifor gauges measurement of liquid level of coloured liquids Aand P Pchemicals R O V E D in the tank. In these level gauges, glasses are without groves and arranged at the front and rear of T R aO slotted liquid chamber. These transparent liquid level gauges consist of a main chamber, cover plates, isolation valves at bottom & top, studs, nuts & washers, transparent glass, gaskets, etc. On each window a special high-resistant plate, transparent glass is applied with sealing joint and metal cover plate held by studs and nuts. Technical specifications include: pressure rating: up to 100 kg/cm²; temperature rating: up to 400°C; materials of construction: CS/SS304/SS316/PVC/PP/PTFE; size

r Pu g e r ’ a Man

Seeking quality innovators

We already have an approved base of suppliers/vendors and prefer to stick with them, unless we face issues pertaining to quality and/or delivery. We trace vendors close to our manufacturing unit by browsing through the Internet, referring to industrial/trade publications or through word of mouth. However, we finalise on vendors based on their quality, adherence to delivery timelines and willingness to innovate. Hence, our purchase decisions are based on the references of vendors, quality, delivery period and credit terms. We are having problems trying to locate vendors for machining/fabrication job work in Mumbai as most small-scale units find it difficult to maintain because of labour shortage and also spiralling labour costs (due to factors like inflation), etc.

E J TARAPORE Director, Acmevac Sales Pvt Ltd Email: acmevac@vsnl.com Web: www.acmevac.com

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& CC range: up to 3000 mm; process connection: from 15 mm to 65 mm flanged; up to 25 mm screwed/socket weld (other on request); and gasket: CAF, PTFE, graphoil (others on request). Flowtech Instrument Services, Vadodara 390 010. Tel: 0265-6508171, Fax: 0265-2636795, Mob: 09824049988 Email: flowtechinstruments@yahoo.com Website: www.flowtechinstruments.com Certification: An ISO 9001:2000 Certified Company

WHEEL BALANCING MACHINES

igital wheel balancing machines (model HWB-560) offered TY U A L I& by Hanu Autonics are compact, economical computer controlled wheel balancers, that can balance care APPRO V Eand D light industrial vehicle wheels. Salient features of these machines include: high-capacity & high- O stability microprocessor control; 3-alu program & static program; automatic gauge for measuring wheel distance & diameter; automatic brake for stopping wheels at the end of spin; auto start when protective guard is lowered; equipped with inch to millimeter & gram to ounce conversion function; selfcalibration & sell-diagnosis functions; and equipped with safety guard switch for operator protection. C

Hanu Autonics Pvt Ltd, Alwar 301 001. Tel: 0144-3203674, Fax: 0144-2703674, Mob: 09413303674 Email: hanuautonics@gmail.com , Website: www.hanuautonics.org Certification: An ISO 9001:2008 Certified Company

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RADIO CONTROL SYSTEMS

ccording to the wireless remote control specialists, the Tiger system for cranes, lift tables and other hoisting applications includes abilities, such as Duplex, Canopen and Modbus. The systems-stop function and two specifically chosen relays in the receiver are reportedly approved according to SIL 3 EIC 61508. Among the configuration options to choose between, one is the possibility for each user to log in with a specific RFID tag. The system transmits on 433434 MHz with 69 selectable channels. The receivers are able to communicate with one or several external units via Modbus, for instance in the case of a weight sensor. The user then receives feedback from the application via the transmitter display, for example information about the weight of the load if a weight sensor has been connected. Handheld transmitters are available with 10x2 functions and display or 12x2 functions without display.

Tele Radio AB - Askin - Sweden Tel: +46-31-7485460, Email: info@tele-radio.com, Website: www.tele-radio.com

AUTOMATIC TEST PANEL SPRAY MACHINES

praymation offers automatic test panel spray machines that are available from highly sophisticated custom units to a variety of standard models with various speed ranges and panel spray areas. With all models, the operator can select all spray parameters including gun traverse speeds, panel indexing distance, spray on distance, and all other variables. Standard power requirements are 120 V AC, 50-60 Hz, single-phase. The 310940 series machines are industry standard in design and function. Index mechanism is relocated to the left and near the front of the unit, away from the paint overspray area. Periodic maintenance and lubrication of the index mechanical components are reduced significantly. The new frame design allows easier access to place and remove panels. A two-line, 24character per line LCD display, a single data input knob and a few push buttons are the operator interface. The machines are controlled by functions and data from various menu selections.

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

FIXED THERMAL IMAGERS

aytek manufactures and offers high-performance fixed thermal imagers (ThermoView Pi20) for moving or stationary targets in industrial process control applications. ThermoView Pi20 is offered in two temperature ranges: -40°C to 500°C (-40°F to 932°F) and 200°C to 2000°C (392°F to 3632°F). For each temperature range, two lens options are available: 21.7° x 16° or 30° x 22°. Raytek online interactive ThermoView Pi20 field of view calculator helps users select their camera model, lens

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and distance to their target, and calculate the maximum field of view and estimated pixel size for detection and temperature measurement. ThermoView Pi20 provides easy networking over long distances, using the standard Ethernet interface. This interface allows for the PC operating the DataTemp Pi (DTPi) intuitive and easy-to-use software, to be located far away. The Ethernet interface transmits up to 30 frames per second of imaging data and also allows for camera control. For long Ethernet cable runs beyond 90 m (300 ft), additional fibreoptic Ethernet accessories are available. Raytek GmbH - Berlin - Germany Tel: +49-30-4780080, Fax: +49-30-4710251 Email: raytek@raytek.de, Website: www.raytek.de

NEEDLE ROLLER BEARINGS

uality Bearings & Components manufactures and offers shell-type open end 1-inch needle roller bearings. Features of these bearings include: extremely high-speed; high load capacity; low profile, lightweight caged; caged needle bearings offer up to 3x the speed of uncaged designs; extremely low rolling friction; high lubrication capacity; low sensitivity to misalignment; and needles have high length to diameter ratios. Technical specifications are: 52100 hardened chrome steel needle bearing, low carbon steel bearing cage, cage guided, case-hardened steel roller cup, drawn cup, etc.

Quality Bearings & Components - New York - USA Tel: +1-516-6160436, Fax: +1-516-6160443 Email: qbcsupport@qbcbearings.com , Website: www.qbcbearings.com

TURNED EDGE RING BINDERS

dvanced Looseleaf Technologies offers turned edge ring binders manufactured using a variety of materials that include book cloths, imitation leather, and high strength paper. One of the most popular types of binder is the film laminated litho wrapped binder with 4-colour process printing, which allows users to dress their binders with any kind of graphics. The turned edge binders are available in standard sheet sizes (binding side first dimension) of 8½ x 5½, 9 x 6, and 11 x 8½. Applications are in accounting publications, cancelled check storage/catalogue & directory binders, education publications, expandable & file binders, handbooks, legal publications, magazine binders, manuals, menu covers, photo albums, presentation & registry binders, sports card collectable & stamp albums, storage cases, etc.

Advanced Looseleaf Technologies - Massachusetts - USA Tel: +1-508-6696354, Fax: +1-508-6696143 Email: sales@binder.com, Website: www.binder.com

INTERNATIONAL PRODUCTS

TWIN WHEEL STRIPPERS

-series twin wheel strippers offered by The Eraser Company cover many applications Afor stripping magnet, U LITY enamel, and film insulated wires. Round, rectangular, and square section wires with insulations, A P Psuch R O VasE Dformvar, ML, dayglass, isonel, polythermaleze, and many more can be stripped. The DV1 O has an integral dust collection system to trap insulation residue as it is removed from the wires during stripping. FybRglass or wire brush wheels may be utilised with the DV1 to strip wires. FybRglass wheels rotate at high speed and generate frictional heat that softens the insulation on the wire and the nap of the wheel wipes it away. A clean polished surface is produced with no risk of nicking. Wire brushes remove insulation by the cutting action of their many bristles. These are more abrasive than FybRglass wheels and are recommended for larger wires where a roughened surface aids subsequent soldering.

The Eraser Company, Inc - New York - USA Tel: +1-315-4543237, Fax: +1-315-4543090 Email: info@eraser.com, Website: www.eraser.com Certification: An ISO 9001:2008 Certified Company

HANDHELD SPECTROMETERS pectro Analytical Instruments offers handheld ED-XRF spectrometers (Spectro-xSORT) that provides all important elements in just a few seconds. Some of the salient features

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INTERNATIONAL PRODUCTS

of these spectrometers include: all relevant elements, from Si to U, in a single measuring cycle; ultra fast RoHS & lead screening; laboratory-like results for environmental & geological samples in just a few seconds; and comprehensive safety features & functions. Spectro Analytical Instruments GmbH & Co KG Deutschland - Germany Tel: +49-2821-892106, Fax: +49-2821-8922206 Email: gisela.becker@ametek.com, Website: www.spectro.com

ELECTRIC CHAIN HOISTS

hejiang Shuangniao Machinery Co mainly develops/designs and manufactures hoisting equipment and crane systems. These products are involved in production industries that require lifting of heavy parts and equipment during the production process or when loading/unloading for transport purposes. The HHXG series suspended electric chain hoists offered, have most tensile safety hooks. Both the top and bottom hooks are made of high tensile alloy steel with special treatment. Compact & beauty chain container features high strength plastic containers that have outstanding durability. Limit switch devices fitted at both top & bottom ends switch off power automatically to prevent load chain from running out. The compact & high efficient motor consists of DC brake system without asbestos, low power consumption. The hoist body pressing steel structure is of high strength body, light & compact. Phase error relay is a specially designed current-post, prevents motor from running at incorrect wire connection.

Zhejiang Shuangniao Machinery Co, Ltd Huangze Shengzhou Zhejiang - China Tel: +86-575-8350007, Fax: +86-575-8351765 Email: sales@tbmhoist.com, Website: www.tbmhoist.com

VERTICAL MACHINING CENTERS

ou Ji Machine Industrial Company manufactures CNC vertical machining centres (model VMC-850) that are installed with high accuracy C3 level ball screws with special structure pre-pulled, rapid and accurate. Salient features include: main structure with high-level casting, stable & high quality; box guideway design provides high rigidity & stable structure; Y-axis supported by 4 rails (VMC-1350) provides the best carrying capacity of workpiece; dual speed gearbox provides ability of heavy cutting (optional); spindle head with boonstructure provides stable support for the spindle; umbrella type ATC system (arm-type ATC for option on VMC-850, VMC-1100); full enclosed guard cover keeps safe & clear working surrounding for operator; auto-lube system provides lubrication of railways and the ball screws; oil skimmer device keeps using time of coolant; and Germany TUV NORD and ISO 9001:2000 quality control system.

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

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INTERNATIONAL PRODUCTS

RESETTABLE THERMAL CIRCUIT BREAKERS

hoenix Contact GmbH manufactures and offers resettable thermal circuit breakers in the form of flat-type automobile fuses. The area of application is the fusing of 12 V or 24 V on-board systems and devices in trucks, buses, boats and low voltage installations. These are also frequently used in chargers for solar systems. High system availability is guaranteed by the resettable TCP.../ DC32V. It is also no longer necessary to carry replacement fuses in the vehicle. Errors caused by mixing up the fuses are ruled out by the clear colour coding and the trip values printed in large letters. The TCP-.../DC32V thermal circuit breakers fit in all fuse holders designed for flat-type fuse inserts in accordance with ISO 8820-3 (DIN 72581-3). It is thus possible to plug them onto both the UK 6-FSI/C... fuse terminal blocks with the screw connection method and onto the ST 4-FSI/ C... with the spring-cage connection method.

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

SANDWICH PLATES

itte Far East manufactures and offers sandwich plates that are often used as base for complex measuring fixtures. These sandwich plates in high-tensile aluminium are manufactured in different versions and dimensions. In particular the so-called hovercraft plates, which can be moved by linking up to

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INTERNATIONAL PRODUCTS

compressed air have become widely accepted. These hovercraft plates have been set free by a further new development. Whereas previous versions were always permanently connected to a compressed air supply, the new type is self-sufficient. Several air tanks were integrated into the plate allowing independent movement for up to 5 minutes. Connection to the compressed air supply is only necessary to refill the tanks. The self-sufficient sandwich plates are developed particularly for transport and positioning of heavy fixtures. Load-carrying capacity can be as high as 4 or 5 tons. Despite heavy loads the sandwich plates can be moved very easily in all directions. Due to their size of 5200 mm x 2000 mm they are suitable for horizontally transporting whole passenger car bodies. Vertical versions are also available for mounting, ie, complete truck side panels. Sandwich plates are manufactured according to customer request. The self-sufficient plate version allows increased freedom of movement and is more user-friendly. Witte Far East Pte Ltd - Singapore Tel: +65 6248 5961, Fax: +65 6898 4542 Email: info@witteasia.com, Website: www.witteasia.com

INDUSTRIAL IRONS

IET manufactures and offers industrial irons (model VEIT HP2003) that have consistent steam quality for constant use. The temperature control is accurate within ±2°C (±3°F) to iron temperature sensitive fabrics without marks. The iron sole is of high quality and especially smooth, suitable for ironing without Teflon frame sole. Ergonomically shaped iron handle is provided with a soft-touch microswitch to release steam. Integrated steam and heat protection is provided for comfortable and safe ironing. The electronically controlled temperature regulation and the special chamber system of the ironing sole provide a condensatefree steam quality. These high-pressure irons are optimally suitable for ironing of sensitive fabrics by its exceptionally smooth steam distribution and the accurate temperature control. Pointed design of the ironing sole guarantees an excellent ironing result even for areas, which are difficult to access. Weight is approximately 1275 gms and ironing surface is 220 mm x 105 mm.

VEIT GmbH & Co - Landsberg - Germany Tel: +49-8191-479204, Fax: +49-8191-479199 Email: info@veit.de, Website: www.veit.de

OPTICAL CABLE FILLING COMPOUNDS

nigel International manufactures and offers optical cable filling compounds (series 300N) that are non-melting, soft, non-sticky hydrophobic water blocking gels that have been formulated for easy processing. These cable filling compounds exhibit zero oil separation and excellent resistance to oxidation for long stability. The gels are suitable for buffer tubes and interstitial filling between ribbons and open slot designs. They are available in a range of viscosity to meet specific processing and performance requirements.

Unigel International - England - UK Tel: +44-1342-825235, Fax: +44-1342-825554 Email: info@unigel.co.uk, Website: www.unigel.co.uk

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INTERNATIONAL PRODUCTS

CONTROL SYSTEMS

riangle Microsystems offers BASYX control systems that are specifically designed to provide accurate control of HVAC equipment and lighting systems for owners of convenience stores and gas stations. These systems can control time of day scheduling, temperature and humidity control for HVAC systems as well as monitoring electrical usage and demand. Programmable lighting outputs control interior and exterior lighting. The remote access feature connects via modem or the Internet to provide access to all historical data and programming features. The control systems are designed for smaller convenience store facility but can be expanded with the addition of multiple panels to control stores of any size. The BASYX CW systems are designed for free standing car wash systems, controls, fans, and heating stages to maintain proper temperatures and automatically adjust bay setpoints based on outdoor temperatures.

Triangle Microsystems, Inc - North Carolina - USA Tel: +1-800-3345548, Fax: +1-919-8722071 Email: jluther@trianglemicrosystems.net Website: www.trianglemicrosystems.net

EMISSION SPECTROMETERS

uantron GmbH offers emission spectrometers (Columbus) for laboratory and onsite analysis. These Columbus emission spectrometers redefine the rules and surprise with the high-end technique that has been proven by the Magellan spectrometers. Digital source, channeltron photomultipliers, real-time read-out system with single spark evaluation, highresolution vacuum optics, optional maintenance-free and oil-free turbo molecular pump in addition to most modern software are few of the impressive innovations the spectrometers use to redefine the standards in this class. The Columbus emission spectrometers attracts with features such as oil-free vacuum technique eliminating optical system maintenance, a full size low maintenance spark stand that guarantees stable analytical results, optimised argon flow and argon-stop-function. Some of the benefits include: improved stability and reproducibility; significant lower limits of detection than comparable CCD instruments due to the channeltron photomultipliers; and minimised operating cost and easy operation, due to a design based on practical requirements.

Quantron GmbH - Kleve - Germany Tel: +49-2821-977080 Fax: +49-2821-9770810 Email: info@quantron.info Website: www.quantron.info

The information published in this section is as per the details furnished by the respective manufacturer/distributor. In any case, it does not represent the views of

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PRODUCT INDEX

To know more about the products featured in this magazine, fax (at 022-30034499) or tear & post to us the Product Inquiry Card by following the 5 easy steps given in the coupon. Alternately you may also write to us at search@infomedia18.in or call us on 022-30034684, and we will send your inquiries to the advertisers/companies directly to help you source better. S. No Product

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47

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Pg No

Abrasive systems 17 AC motors 47, Cover-on-cover AC servo 121 AC/DC panels 187 Accessories 24 ACCLs 41, 200-204 Acid fume extraction systems 186 Acid tanks 166 Acoustic enclosures 137 Actuators 180 Aerosol sprays 107 Air density monitoring systems 131 Air treatment 97 Air-cooled heat exchangers 65 Air-cooled steam condensers 65 Alarm-gas 171 Alloy steels 186 Aluminium pressure die casting lubricants 107 Aluminium worm geared motors 104 Aluminum extrusion 195 Analogue transducers 89 Anchor-type light poles 179 Anemometers 193 Appliance switches 29 AS-interface systems 99 Assembly technology 67 Asynchronous motor protection devices 58 Automatic rolling shutters 23 Automation 15 Automation & storage systems 49, 99 Automation equipment 127 Automobile performance testing systems 131 Automotive cables 189 Automotive component testing systems 131 Auxiliary equipment 169 Axial flow fans 181 Ball bearing extractor kits 198 Ball bearings 184 Bars 175 Battery chargers 177 Battery-operated pallet trucks 69 Bearing fitting tool kits 198 Bearing mounting heaters 198 Bearings 22, 184 Bed mills 175 Bench grinders 182 BFTs 189

S. No Product

48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94

Pg No

Bin vibrators 166 Blast hole drills 205 Blowers & fans 181 Bollards 23 Bottle cap torque testing systems 131 Brake motors Cover-on-cover 21, 47, 68, 104 Brine chillers 187 BTA/ejector counter boring machines 6 BTA/ejector drilling machines 6 Bus plug connectors 182 Cable carriers 22 Cable conduits 29 Cable connectors 22 Cable glands 43, 183 Cable trays 179 Cables 19, 41, 86, 200-204 Cables & leads for fixed instaction 49 Cables for bus systems 49, 99 Cables handling & processing systems 49, 99 Cables scanps 49, 99 Cam followers 176 Capacitive & magnetic sensors 99 Cast iron castings 172 Cast/extruded components 197 Castellated sockets & wrenches 96 Caster wheels 169 Casting & forging equipment 178 Casting fluxes 178 Castings 181 Castors 189 Cell testers 182 Centerless grinders 169 Centrifugal air blowers 181 Centrifugal pumps 39 Centrifuges & hydro-extractors 183 Ceramic processing furnaces 169 CFTs 189 Chain electric hoists 150 Chain hoists 8 Chain pulley blocks 8, 68, 150 Chains 22 Channel magnets 185 Chemical process equipment 166 Chemical tanks 190 Chrome bars/shafts 175 Circular connectors 185 Circular/gyrator vibro machines 185

PRODUCT INDEX

S. No Product

95 96 97 98 99 100 101 102

103 104 105 106 107 108 109 110 111 112 113 114 115 116 117 118 119 120 121 122 123 124 125 126 127 128 129 130 131 132 133 134 135 136 137 138 139 140 141 142 143 144

Cleats CNC lathes CNC machines

Pg No

179 11, 127 14, Back inside cover CNC milling machines 127 CNC press brakes 77 CNC shears 77 CNC turning centres 14, Back inside cover CNC vertical machining centres 14, Back inside cover CNCs 9, 14, Back inside cover Cold storage dockhouses 23 Cold storage doors 23 Collars 205 Compressed air divisions 178, 196 Compressors Front inside cover, 181 Conduit systems 185 Connectors 22, 24, 59, 43, 183 Connectors accessories 49, 99 Contactors 41, 200-204 Containers 190 Continuous casting machines 177 Contrast/colour scanners 103 Control & automation 19 Control cabinets 59 Control cables 86 Control panel accessories 29 Control panels 59, 177 Control systems 59 Conventional precision lathes 11 Conveying blowers 181 Conveyors 189 Conveyors & automation systems 23 Cooling tower motors 104 Cooling towers 65, 97 Core drill rigs 205 Corrosion preventives 165 Counters & power supplies 5 Crab assemblies 195 Crab hoists 68 Crane kits 195 Crane-duty motors 68, 104 Cranes 8, 68, 82, 195 Crawler drill rigs 205 Crimp contact & tools 49, 99 Crimp testers 131 Cross- arms 179 Cross connection acc 24 Cushion dock shelters 23 Custom moulding 190 Custom-made cables 49, 99 Cutting heads 17

S. No Product

145 146 147 148 149 150 151 152 153 154 155 156 157 158 159 160 161 162 163 164 165 166 167 168 169 170 171 172 173 174 175 176 177 178 179 180 181 182 183 184 185 186 187 188 189 190 191 192 193

Pg No

Cutting oils & coolants 107 Cutting systems 17 CVTs 177 Cylindrical sensors 103 Dai steels 186 Dampers 180 Data cables 49, 99 DBs 179 DC motors 47, Cover-on-cover Deephole drilling machines 6 Demagnetisers 165 Didactic equipment 59 Digital calibrators 182 Digital panel meter modules 167 Digital panel meters 181 Digital temperature controllers 181 Digital transducers 89 Direct burial-type light poles 179 Distribution boards 12, 179 Dock levellers 23 Dock shelters 23 Doors 23 Double girder EOT cranes 195 Double sheet monitoring 103 Double-drum & triple-drum magnetic separators 165 Drawer magnets 165, 185 Drawing oils 107 Drill chucks 178, 196 Drill rods 205 Drilling machines 119, 197 Drilling-cum-milling machines 119, 197 Drives 50, 67 Drums & carboys 190 Drum-type magnetic separators 185 Dry vane pumps 137 Dust collector systems 181 Ear plugs 45 Electric controls 67 Electric drives 67 Electric forklift trucks 23 Electric wire rope hoists 8, 68, 176, 195, Electrical actuators 180 Electrical measuring instruments 187, 193 Electrical products cable ties 43, 183 Electrical systems 19 Electro magnetic feeders 166 Electro magnetic vibratory feeders 185 Electro mechanical feeders 166 Electro-lifting magnets 166

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PRODUCT INDEX

S. No Product

194 195 196 197 198 199 200 201 202 203 204 205 206 207 208 209 210 211 212 213 214

215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235

236 237 238 239 240 241

Electronic connectors 181 Electronic timers 181, 30-36 Electronics products 43, 183 Element shrink discs 176 Emergency lights 177 En view software 13 Encoders 5 End carriage assemblies 195 End clap/shops 24 End plates 24 Energy efficient motors 104 Energy meters 181 Energy monitoring systems 13 Energy saving gas burners 169 Engineering plastic plugs & sockets 30-36 Engineering Expo exhibitions 155, 160, 162, 211 Enginneering plastics 197 EOT cranes 8, 68, 150, 176 EOT jib cranes 82 EP cutting oils 107 Exhibitions 20, 54, 151, 155 160, 162, 208 211, 218 Explosive meters 171 Extended trolleys 195 Extrusion compounds 107 Eye-wears 45 Fall protection gears 45 Ferrous castings 195 Fiberglass cable tray systems 179 Fiberglass cable trays 179 Fiberglass ladders 179 Fiberglass light poles 179 Fiberglass luminaries 179 Fibreoptic amplifiers 103 Fine & auto feed radials 119, 197 Finishing machines 185 Finishing school in production engineering 217 Fire dampers 180 Fire shutters 23 Fishing taps 205 Fixed mounting hoists 195 Flameproof motors Cover-on-cover, 47 Flange mounting motors Cover-on-cover 47,

Flat cables Flexi panels Flexible cables & wires Fluids Force Force & pressure calibration & testing equipment 242 Force & torque gauges

202

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Pg No

49 122 49 18 131 131 131

S. No Product

243 Force actuation 244 Force-feed lubricators 245 Forged automobile components 246 Forged components 247 248 249 250 251 252 253 254 255 256 257 258 259 260 261 262 263 264 265 266 267 268 269 270 271 272 273 274 275 276 277 278 279 280 281 282 283 284 285 286 287 288 289 290 291 292 293 294

Pg No

143 184

177 177, 178 195 Forged products 177 Forging for diesel engine parts 176 Forging press bolsters 180 Forging screw presses 172 Forgings 24, 107, 180 Forked photoelectric sensors 103 Forklift trucks 145 Freewheel-oneway-clutches 176 Frequency meters 187, 193 FRP anchor-type light poles 179 FRP cable tray systems 179 FRP cable trays 179 FRP cleats 179 FRP crossarms 179 FRP direct burial-type light poles 179 FRP high-bay luminaries 179 FRP light poles 179 FRP luminaries 179 FRP medium-bay luminaries 179 FRP streetlight luminaries 179 FRP underground fuel tanks 190 FRP utility poles 179 FRP well-glass luminaries 179 Fuel burners 181 Funnel magnets 185 Gantry cranes 68, 82, 195 Gap frame presses 77 Garments 45 Gas analysers 171 Gas detection systems 171 Gas detectors 171 Gas monitors 171 Gas sensors 171 Gear motors 18, 176 Gearboxes 18, 176 Geared & flexible couplings 18 Geared boxes 53 Geared motors 53, 68 Geared radial drilling machines 119, 197 Geared drilling machines 119, 197 Gears 18, 111 Glass processing furnaces & lehrs 169 Glassfibre-filled trefoil clamps 179 Glide wheels 189 Gloves 45 Goliath cranes 68 Goods lifts 82 Graphite machining 186

PRODUCT INDEX

S. No Product

295 296 297 298 299 300 301 302 303 304 305 306 307 308 309 310 311 312 313 314 315 316 317 318 319 320 321 322 323 324 325 326 327 328 329 330 331 332 333 334 335 336 337 338 339 340 341 342 343 344 345

Pg No

Grill magnets 185 Grinding machines 63, 111 Grinding tools 63, 111 Group marker holders 24 GRP anchor-type light poles 179 GRP cable trays 179 GRP cross arms 179 GRP direct burial-type light poles 179 GRP highbay luminaries 179 GRP ladders 179 GRP light poles 179 GRP luminaries 179 GRP medium-bay luminaries 179 GRP streetlight luminaries 179 GRP utility poles 179 GRP well-glass luminaries 179 Guide rods 175 Gun drilling machines 6 Gun reaming machines 6 Gyratory screens 166 Haconan-free cables 49 Hand magnets 185 Handling system modules 59 Hannover Fairs-2011 20 Hard chrome plating bars 175 Harness 45 Heat shrink tubings 43;183 Heat treatment salts 165 Heavy duty CNCs 177 Helical gearboxes 176 Heli-worm geared motors 104 Helmets 45 High-bay luminaries 179 High-efficiency standard motors flame proof motors 104 High-intensity rare earth magnetic separators 185 High-intensity roller-type magnetic separators 185 High-pressure jet clean equipment 170 High-pressure pumps 17 High-pressure tubes 17 High-speed doors 23 High-speed precision centre lathes 175 High-speed roll-up doors 184 Hi-Vi jackets 45 HMM technical guidelines 104 Hoist drives 8 Hoist with trolleys 195 Hold backs 176 Hole hammers & bits 205 Hooper magnets 165, 185 Horizontal CNC lathes 175 Horizontal CNC machines 14, Back inside cover

S. No Product

Pg No

346 Horizontal machining centres 9, 14, Back inside cover 347 Horizontal screens 166 348 Hose clamps 190 349 Hospital equipment 170 350 Hot & cold rolling oils 107 351 Hot cranes 150 352 HRC fuse fittings 181 353 Humidity 180 354 Hump magnets 165, 185 355 Hydraulic cylinders 171, 186 356 Hydraulic dock levellers 23 357 Hydraulic dock shelters 23 358 Hydraulic manual pallet trucks 69 359 Hydraulic presses 77 360 Hydraulic seals 61 361 Hydraulic shearing machines 77 362 Hydraulic/manual surface grinding machines 182 363 Hydraulics - linear motion 67 364 Hydro fracturing equipment 205 365 IC counterbalanced forklifts 23 366 Identification systems 99 367 Inclinometers 135 368 In-cylinder sensors 135 369 Induction heating machines 51 370 Induction heating systems 51 371 Induction machines 51 372 Inductive proximity switches 29, 99, 103, 180 373 Induss-2011 exhibition 151 374 Industrial automation 15 375 Industrial batteries 19 376 Industrial cable glands 185 377 Industrial connectors 49, 99 378 Industrial control & sensing devices 5 379 Industrial coolers 97 380 Industrial cooling systems 187 381 Industrial electric power distribution systems 12 382 Industrial ovens & dryers 169 383 Industrial overhead doors 23 384 Industrial plugs & sockets 186 385 Industrial stethoscopes 198 386 Inline drum-type magnetic separators 185 387 Inline helical geared motors 104 388 Instrument lathes 127 389 Instrumentation & controls 27 390 Instrumentation made cables 49, 99 391 Insulated boxes 190 392 Insulated doors 23 393 Intelligent automation & protection device 58 394 Intelligent controlling & protection devices 58

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PRODUCT INDEX

S. No Product

395 396 397 398 399 400 401 402 403 404 405 406 407 408 409 410 411 412 413 414 415 416 417 418 419 420 421 422 423 424 425 426 427 428 429 430 431 432 433 434 435 436 437 438 439 440 441 442 443 444 445

204

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Pg No

Interface modules 24 Interface modules acc 24 Interlocking doors 23 Internal grinding spindles 187 International Engineering & Manufacturing-2011 208 Inverter duty motors 104 Inverter/variable frequency drives 5 Inverters 121, 177 Investment castings 172 Isolators 85 JB 179 Jib cranes 68, 195 Joining 143 Joystick controllers 135 Junction boxes 179 Keyless transmission elements 176 Kilns & baths 169 Kuman machine interfaces 121 Laboratory baths & circulators 164 Laboratory furnaces 169 Ladders 170 Ladders FRP ladders 179 Large diameter welded pipes 193 Large helical & heli-bevel gearboxes 104 Laser shaping machines 63, 111, 188 Lathes 9 LCS 179 Leak detectors 171 LED module pilot lights 181 LED signal tower lights 30-36 LEDs 29 Level controllers 5 Lift & conveyor cables 49 Lifting bails 205 Lifting magnets 165 Light poles 179 Limit switches 181, 30-36 Linear position sensors 135 Linear potentiometers 135 Linear rods 175 Linear side rail assemblies 188 Liquid ring vacuum pumps 181 LM shafts 175 Load break switches 29 Loaders 145 Loading bay equipment 23 Local control stations 179 Long travel machines 119, 197 Loom switches 181 Lorry loaders 145 Low lift pallet trucks 23

S. No Product

446 447 448 449 450 451 452 453 454 455 456 457 458 459 460 461 462 463 464 465 466 467 468 469 470 471 472 473 474 475 476 477 478 479 480 481 482 483 484 485 486 487 488 489 490 491 492 493 494 495 496 497 498 499 500 501

Luminaries LVDTs Machined castings Machined components Magnetic coolant separators Magnetic equipment Magnetic floor sweepers Magnetic grills & housings Magnetic head pulleys Magnetic pulleys Magnetic racks Manual pallet trucks Marker plotters Markers Masks Material handling Material handling containers Material handling equipment

Pg No

179 135 180 195 185 166 185 166 166 165 165 23 24 24 45 83 190 69, 68 MCBs 85 MCCBs 19, 41, 200-204 Measuring & monitoring relays 5 Measuring instruments 187, 193 Measuring sensors 103 Mechanical forging hammers 176 Medium-bay luminaries 179 Melt flow indexers 188 Metal cutting systems 17 Metal cutting tools 7 Metal treatment chemicals 165 Metallurgical furnaces 169 Metering solutions & relays 19 Meters 19, 187 Micro control switches 181 Micro PLCs 121 Micro switches 181, 30-36 Mild steel wires 168 Milling centres 9 Mini sensors 103 Miniature micro switches 181 Mobile devices 167 Modern Machine Shop-2012 218 Modular plc 121 Molded cable assemblies 181 Mono rail trolleys 150 Motion controls 5, 121 Motor control centres 19 Motor protection circuit breakers 29 Motor testing systems 131 Motorised boom barriers 23 Motorised valves 180 Motorised vibratory feeders 185 Motors 47, Cover-on-cover Motors & drives 15 Mounting brackets 24 Mounting rails 24 Multi-function meters 13

PRODUCT INDEX

S. No Product

Pg No

S. No Product

502 Multi-speed motors

104

522 Parallel shaft helical geared motors

503 Multi-stage centrifugal air blowers

181

523 Partition plates

504 MV switchgears

505 Non-ferrous castings

195

506 Office lighting

41, 200-204

507 Ohms meters

187, 193

Pg No

104 24

S. No Product

Pg No

540 Piston die-casting machines

179

541 Piston rods

186

524 PBEGL geared motors 47, Cover-on-cover

542 Plaining machines

525 Pedestrian & rider-operated counter-

169, 177

543 Plano millers

169

544 Plano milling machines

177

526 Pedestrian low lift pallet trucks

545 Plat trucks

189

546 Plate magnets

balanced pallet trucks

508 Oil seals

198

527 Pedestrian pallet stackers

509 Oil/coolant coolers

187

528 Permanent lifting magnets

166

547 Platforms

510 Oil/gas firing equipment

181

529 Permanent magnetic chucks

165

548 Plotter accessories

511 Oils & dispersions

107

530 Permanent magnetic drum pulleys

185

549 Plugs & sockets

512 Online b2b marketplace 513 Online digital printing technology 514 O-rings 515 Overband magnetic separators 516 Overhead doors 517 Pallet stackers

109, 213

531 Permanent magnetic

165, 185

550 Pneumatic conveying systems

170

181

166

drum-type separators

165

551 Pneumatics

532 Photoelectric sensors

5, 99

552 Polyacetal

197

533 Photoelectric switches

180

553 Polyproplene tanks

166

534 Pick & move cranes

145

554 Polypropylene

197

535 Pickling tanks

166

555 Polyurethane

197

181

556 Portable loaders

181

166, 185

518 Pallets

190

536 Pilot lamp holders

519 Panel air-conditioners

187

537 Pilot lights

557 Power & energy monitors

520 Panels

187

538 Pipe bending machines

558 Power cables

521 Parallel shaft gearboxes

539 Piston bars

175

559 Power magnets

A U G U S T 2 0 1 1 | SEARCH - THE INDUSTRIAL SOURCEBOOK

165

205

PRODUCT INDEX

S. No Product

Pg No

S. No Product

560 Power monitors

602 RFID

561 Power presses

603 Robotic cables

562 Power quality management systems

563 Power transmission

564 Precision bearings 198 565 Precision forged components 566 Precision investment castings 567 Precision steels

570 Press technology

143

571 Pressure die castings

107

572 Pressure sensors & indicators

131

573 Process automation & control equipment 574 Product assemblies

59 195

575 Programmable logic controllers

576 Programmable terminals

577 Protective conduit systems

49, 99

578 Protective covers

579 Proximity sensors

5, 30-36

580 PTFE products

189

581 PTFE seals

183

582 PTFE/Teflon products

197

583 Pump testing units 584 Pumping filtering units 585 Pumps

181

604 Roller-type magnetic separators

185

645 Sockets & switches

605 Roots blowers

137

646 Software license structure

606 Rope guides

195

647 Solar water heating systems

608 Rotary drill rigs

569 Press brake machines

643 SMPS systems

172

Pg No

644 SNU worm gears

607 Rotary

568 Precision switches

S. No Product

172

63, 111

Pg No

9 205

609 Rotary encoders

164 169

648 Solderless terminals

43;183

649 Solid carbide drills & mills

650 Solid carbide reamers

610 Rotary position sensors

135

651 Solid carbide special drills & mills

611 Rotary potentiometers

135

652 Solid carbide special reamers

612 Rotary rock roller bits

205

653 Spare parts

613 Rotary shaft seals

654 Special application motors

104

614 Rotary switches

655 Special refrigeration equipment

187

615 Rotary vacuum pumps

183

656 Special tools

205

616 Rubber products

198

657 Special-purpose machines

177

617 Rust preventive oils

107

658 Specialty lubricants

107

618 Rust preventives

165

659 Spheroidal graphite iron castings

619 Sabin chains

166

660 Spiral cables

620 Safety & security

171

661 Spiral-cum-helical gearboxes

621 Safety light curtains

175 49, 99 18

662 SPMs

622 Safety protection devices

663 Spray guns

623 Safety shoes

664 Spring testers

131

205

624 Scissor lifts

665 Stabilisers

205

181

625 Scroll-type oil-free compressors

175

666 Stainless steel hollow bars

169

626 Sealing systems

186

667 Stainless steel pipes

193

39, 137, 181, Back cover

178, 196

586 Pushbutton stations

179

627 Seals

198

668 Steel body power presses

168

587 Pushbutton switches

181

628 Seamless pipes

193

669 Steel casters

171

670 Steel circles

170

671 Steel door frames

170

672 Steel plant equipment

168

673 Steel plates

170

674 Steel springs & rubber hangers

168

588 Pushbuttons

629 Sectional overhead doors

589 PVC flap & strip doors

630 Sensors

590 Radio remote controls

178

99, 171

631 Separator plates

591 Rapid flexible & roll-up doors

632 Shafts

592 RCCBs

633 Shearing machines

593 Reach trucks

634 Shunts

187

675 Steel strappings

168

594 Rear cylinder hydraulic press brakes

635 Side channel blowers

181

676 Steel triclover clamps

168

595 Reciprocated oil-free compressors

175

636 Side holding plates

677 Steel tubes

186

596 Reciprocating lubricated compressors

175

637 Signal conditioners

135

597 Rectifiers

177

638 Single & multiple precision switches

598 Refurbished water well drill rigs

205

639 Single girder EOT cranes

599 Relay sockets

181

600 Remote controls for industrial applications 601 Reverse circulation

206

640 Single limit switches 641 Slipring crane-duty motors

178 205

642 Smart turn electronic lathes

SEARCH - THE INDUSTRIAL SOURCEBOOK | A U G U S T 2 0 1 1

175 77

678 Steel welded tubes & tubular sections

168

679 Steel wire ropes

170

195

680 Stepping motor drives

185

681 Straightening machines

169

682 Streetlight luminaries

179

683 Super finishing films

179

175

684 Suspension magnets

Cover-on-cover,

166, 185

PRODUCT INDEX

S. No Product

Pg No

S. No Product

685 Switch socket outlets

179

726 Tubing accessories

686 Switchboard meters

187

727 Turkkit strips & sheets

687 Switches

41, 85, 200-204

Pg No

S. No Product

Pg No

767 Wellglass luminaries

179

189

768 Wheel assemblies

176

728 Turned components

195

769 Wheel balancing machines

193

688 Switchgear products

729 Turnmill centres

175

770 Wheel barrows

189

689 Switchgears

730 Turret mills

175

771 Wheels

189

731 UHMW-PE products

197

772 Winches

773 Wind mill gearboxes

690 Switching relays

691 Syringe pumps

165

732 Ultrasonic sensors

692 Systems

179

733 Universal bevel protractors

693 Tail lifts

694 Tanks

734 Universal radial drilling machines

99, 103 184 119, 197

166

735 UPS systems

177

736 Utility poles

179

737 U-tubes

193

738 Vacuum booster pumps

137

739 Vacuum pumps

181

699 Tensile testing systems

131

740 Vacuum systems

137

700 Tensioner nuts

176

741 Valve position transducers

135

695 Telescopic doors 696 Temperature

180

697 Temperature controllers

698 Temperature-resistant cables

701 Terminal blocks

24, 181

702 Terminal strips 703 Testers

181 187, 193

704 Textile & yarn trolleys

170

774 Wire connectors

43, 183

775 Wire rope drums

176

776 Wireless crane controls

178

777 Wires

778 Worm gearboxes

779 Worm gears

780 Yield testing units

205

INTERNATIONAL PRODUCTS

742 Valve terminals

743 Valves

781 AC gearmotors

181

782 AC servomotors

744 Vane dampers 745 Variacs

705 Thermal imaging cameras

199

746 Ventilators

706 Thermocouple terminal blocks

188

747 Vertical machining centres

177 196 9, 127

S. No Product

783 Analogue modules

Pg No

784 Apparels & footwears

167

785 Automatic test panel spray machines

194

786 Automation solutions

707 Three-phase voltage protection relays

748 Vertical order pickers

787 Control systems

199

708 Tiling solutions

749 Vertical turning lathes

177

788 Digital modules

135

750 Vibrating equipment

166

709 Tilt sensors 710 Timers

711 Torque 712 Torque motors

187

792 Fixed thermal imagers

104

753 Vibrating screen machines

185

793 Handheld spectrometers

195

794 Industrial irons

198

795 Industrial products

167

754 Vibratory bowl feeders

164

755 Vibratory bowls

185

715 Track rollers

176

756 Vibratory motors

166

716 Transducers

193

757 Vices

177, 187 190 185 8

758 Vision sensors 759 VMCs 760 Voltage stabilisers

178, 196 5

194

798 Optical cable filling compounds

198 194

800 Resettable thermal circuit breakers

197

177

801 Sandwich plates

197

761 Water chillers

187 205

762 Water well drill rigs

722 Trim handling systems

181

763 Waterjet cutting systems

723 Trolley wheels & casters

170

764 Water-ring vacuum pumps

181

724 Trolleys

189

765 Welded pipes

193

766 Welding equipment

797 Needle roller bearings 799 Radio control systems

179

193, 205

796 Motion control products

127

721 Trefoil clamps

725 Tubes

194

752 Vibrating reed-type

145

720 Travel drives

164

131

719 Trap magnets

199

791 Fibre laser cutting systems

185

714 Tower cranes

718 Transparent liquid level gauges

196

790 Emission spectrometers

751 Vibrating motors

713 Torque tool testers

717 Transformers

789 Electric chain hoists

178, 196

802 Screw compressors

803 Synchronisation modules & remote controllers

166

804 Turned edge ring binders

194

805 Twin wheel strippers

195

806 Vertical machining centers

196

807 VisionPro software

164

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207

ENGINEERING EXPO - PRODUCT INDEX

S. No Product

E1 E2 E3 E4 E5 E6 E7 E8 E9 E10 E11 E12 E13 E14 E15 E16 E17 E18 E19 E20 E21 E22 E23 E24 E25 E26 E27 E28 E29 E30 E31 E32 E33 E34 E35 E36 E37 E38 E39 E40 E41 E42 E43 E44 E45 E46 E47 E48 E49 E50 E51 E52 E53 E54 E55 E56 E57 E58 E59 E60 E61 E62 E63 E64 E65 E66 E67 E68 E69 E70 E71 E72 E73 E74 E75 E76 E77 E78 E79 E80

Pg No

2D height master 162 AC drives 163 Access control systems 160 Accessories for hydraulic systems 161 Air tapping machines 161 Auto fan belts 162 B P monitors 161 Battery chargers 163 Bearings 161, 162 Belts 163 Bending machines 162 Blind rivets 162 Bolts 162 Cabide blanks 160 Cable carriers 161 Cable connectors 161 Calibration facility for pressure 160 Calibration services 163 Carbide cutting tools 161 Carbide products 163 Carbide tools 160 Castors 163 Castors & wheels 161 CCTV solutions 160 Centreless grinding machines 163 Chains 161 Circlips 162 Clamping systems 162 Cleaning machines 161 CNC cylindrical grinding machines 163 CNC machines 162 CNC tooling systems 161 Components & systems automation 162 Connectors 161 Control elements 161 Control panels 163 Convention precision machines 162 Counters & power supplies 161 Customised products 163 Cutting tools 163 Cylinder & accumulators 161 Data acqusition systems 163 Data loggers 163 Deburring tools 163 Demagnetisers 163 Developers 163 Dial stands 163 Die & mould tools 163 Diesel engine telescopic horizontal lifts 160 Digital readouts 162 Dip pre-treatment plants 161 DP test cleaners 163 Drill end mill protable machines 161 Drills 160, 161 DROs 162 EDMs 162 Electric pallet trucks 160 Electromagnetic chucks 163 Electronic micro products 162 Encoders 161 End mills 160, 161 Energy monitoring systems 163 ER collets 161 Fastners 160 Fat monitors 161 Files & drills 162 Filters 160 Fingerprint/card-based time & attendance systems 160 Fixed handles 161 Flap wheels 163 Floor cleaning machines 161 Floor cranes servicing 160 Floor grinding machines 161 Floor polishing machines 161 Forklift truck jacks 160 Forklift trucks 160 Gear grinder machines 162 Gear hobbing machines 162 Gear shapers 162 Gear shaving machines 162

S. No Product

E81 E82 E83 E84 E85 E86 E87 E88 E89 E90 E91 E92 E93 E94 E95 E96 E97 E98 E99 E100 E101 E102 E103 E104 E105 E106 E107 E108 E109 E110 E111 E112 E113 E114 E115 E116 E117 E118 E119 E120 E121 E122 E123 E124 E125 E126 E127 E128 E129 E130 E131 E132 E133 E134 E135 E136 E137 E138 E139 E140 E141 E142 E143 E144 E145 E146 E147 E148 E149 E150 E151 E152 E153 E154 E155 E156 E157 E158 E159 E160 E161

Pg No

Grinding machines 162 Grinding wheels 163 Grooving tools 163 Hacksaw blades 162 Hand tools 162, 163 Hardware 163 Hex key wrenches 162 High-tensile Allen bolts 162 High-tensile hex bolts 162 High-tensile nuts 162 Hinges 161 HMCs 160 Hole finishing tools 163 Hole making tools 163 Hooks 161 Hopper-grates 163 Hoses 163 Hydraulic & lubricating oil filters 160 Hydraulic cylinders 163 Hydraulic cylindrical grinding machines 163 Hydraulic tapping machines 161 Hydraulic trolley jacks 160 Hydraulics 163 Hydraulics & pneumatics 161 Hypoid testers 162 Indexable tools 160 Indexing elements 161 Industrial bolts 162 Industrial chain & engineering products 162 Industrial connectors 162 Industrial control & sensing devices 161 Injection molding 162 Instrumentation 163 Instruments 163 Inverters/variable frequency drives 161 Joints 161 Laser cutting machines 162 Latches 161 Lathe machines 162 Level controllers 161 Levelling elements 161 Liquid painting plants 161 Lubricating & engineering tools 162 Machine elements 161 Machine tool accessories 161, 162, 163 Magnet chucks 163 Magnet filters 163 Magnet lifters 163 Measuring & monitoring relays 161 Measuring instruments 160 MIG (GMAW) 162 Milling machines 162 Modular heads 160 Mops 163 MV motors 163 Name plates 162 Non-ferrous foundry 163 Nuts 160, 162 Online UPS systems 163 Paint shops 161 Pallet trucks 160 PCB terminal blocks 162 Penetrants 163 Photoelectric sensors 161 Pillow block bearings 161 Plain gauges 160 Plant automation 161 Plasma cutters 162 PLCs 163 Plug connectors 162 Polishing rolls 163 Powder coating plants 161 Power packs 161 Power supplies 163 Power tools 163 Presses 162 Pressure die casting machines 162 Pressure gauges 163 Profile projectors 162 Programmable logic controllers 161 Proximity sensors 161

S. No Product

E162 E163 E164 E165 E166 E167 E168 E169 E170 E171 E172 E173 E174 E175 E176 E177 E178 E179 E180 E181 E182 E183 E184 E185 E186 E187 E188 E189 E190 E191 E192 E193 E194 E195 E196 E197 E198 E199 E200 E201 E202 E203 E204 E205 E206 E207 E208 E209 E210 E211 E212 E213 E214 E215 E216 E217 E218 E219 E220 E221 E222 E223 E224 E225 E226 E227 E228 E229 E230 E231 E232 E233 E234 E235 E236 E237 E238 E239 E240

Pg No

Pumps 163 Radial drilling machines 162 Reamers 161 Relays 163 Repair & retrofitting services 160 Retaining magnets 161 Revolving handles 161 RFIDs 161 Roller tapper roller bearings 161 Rotary controls 161 Rotary unions 162 Safety fold-away handles 161 Safety items 163 Safety light curtains 161 Saw 162 SCADA 163 Scissor lifts 160 Scissor platforms 160 Screws 160, 162 Screws & Allen key bolts 162 Seals 163 Self-drilling screws 162 Sensors 162, 163 Separators 163 Shearing machines 162 Shopfloor accessories 163 Signal converters 162 Sinebar chucks 163 Sleeves 163 Small motors & gearboxes 163 SMC/DMC insulatros 163 Software 163 Solutions for high power & signal quality 162 Special tools 161 Spindles 162 SPMs 161 Spray pre-treatment plants 161 Spring dowell pins 162 Spring washers 162 SS bolts 162 Stanny fine boring 161 Static stabilisers 163 Stick (SMAW) 162 Stud welding 162 Surface plates 160 Switching relays 161 Temperature controllers 161 Test equipment development 161 Testing instruments 160 Thread gauges 160 Threading tools 163 TIG (HTAW) 162 Timers 161 Toggle & power clamps 161 Toggle clamps 163 Tool holders 162 Total automated assembly lines 160 Trolley wheels 163 Tube clamp connectors 161 Turning centres 160 Turning inserts 160 Ultra isolation transformers 163 Vacuum cleaners 161 Valves 163 V-belts 161, 162, 163 V-blocks 163 Vision inspection systems 163 Vision sensors 161 VMCs 160, 162 Voltage stabilisers 163 Volume & electrotechnical parameters 160 Washers 160 Wear & impact resistant tools 160 Weighing scales 161 Welding & cutting machines 162 Welding electrodes & accessories 163 Welding positioners 163 Wiring accessories 163 ZX tool systems 163

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211

ADVERTISERS’ LIST

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

Advertisers’ Name & Contact Details

AC Automation

Pg No

Advertisers’ Name & Contact Details

Pg No

Advertisers’ Name & Contact Details

A-One Material Handling Equipment Pvt Ltd 150

Classic Polymers & Resins

T: +91-11-27674839

T: +91-265-6546922

T: +91-22-24465251

E: ac@ac-automation.com

E: aoneent@yahoo.co.in

E: sales@classicpolymers.co.in

197

W: www.classicpolymers.com

W: www.ac-automation.com Acropolis Engineering Ltd

Pg No

Arvind Anticor Ltd 178

T: +91-22-26441180 E: acropolis@vsnl.net

166

T: +91-79-25894692

CNP Pumps India Pvt Ltd

E: arvindanticor@hotmail.com

T: +91-22-25818400

W: www.picklingplant.com

E: sales@nanfangpumps.com

W: www.nanfangpumps.com W: www.acropoliscranes.in

Atlas Copco (India) Ltd

Action Construction Equipments Ltd 145 T: +91-11-40549900

FIC

T: +91-20-30722222

Confederation Of Indian Industry

E: marcom@in.atlascopco.com

T: +91-33-22428196

W: www.atlascopco.com

E: tarun.tapadar@cii.in

E: marketing@ace-cranes.com

W: www.bizbridgeexpo.com Avcon Controls Pvt Ltd

W: www.ace-cranes.com Actuators India Pvt Ltd

180

T: +91-22-26736864

165

T: +91-22-61504150

Connectwell Industries Pvt Ltd

E: sales@ashokindustry.com

T: +91-251-2870636

W: www.ashokindustry.com

E: connect@connectwell.com

Bhagirath Heavy Transmission

W: www.tscindia.com 82

176

T: +91-11-32222661

Danfoss Indus Pvt Ltd

E: bht_india1998@yahoo.co.in

T: +91-44-66501555

BIES W: www.amsakcranes.com

E: danfoss.india@danfoss.com

T: +91-44-26273486 E: sales@amsakcranes.com

W: www.connectwell.com

E: actuatorsindia2007@rediffmail.com

Amsak Cranes Private Limited

208

151

W: www.danfoss.com

T: +91-9845363917 E: raghu@bies.co.in

Dolphin Automation

W: www.induss.co.in

T: +91-120-2341784

180

E: dol_kamal@rediffmail.com

Looking for a Speciﬁc Product?

Bosch Rexroth (India) Limited

W: www.dolphinautomation.com

www.boschrexroth.co.in Elecon Engineering Company Limited 18 C&S Electric Ltd.

We will ﬁnd the product for you. Just type SRCH (space) Name of the Product and send it to 51818 eg. SRCH (space) Pump and send it to 51818.

T: +91-2692-236469

T: +91-11-30887520-29

E: infogear@elecon.com

W: www.cselectric.co.in

W: www.elecon.com

Central Steel Corporation

186

Electro Flux Equipments Pvt. Ltd.

166

T: +91-22-23436809

T: +91-44-26243317

E: censtreel@vsnl.com

E: marketing@electrofluxequipmentspvtltd.com

W: www.centralsteelcorpn.com

W: www.electrofluxequipmentspvtltd.com Our consistent advertisers

212

SEARCH - THE INDUSTRIAL SOURCEBOOK | A U G U S T 2 0 1 1

ADVERTISERS’ LIST

Advertisers’ Name & Contact Details

Pg No

Advertisers’ Name & Contact Details

Pg No

Advertisers’ Name & Contact Details

Electromech Material Handling Sys Pvt Ltd 83

Flir Systems India Pvt Ltd

T: +91-20-66542222

T: +91-11-4560 3555

T: +91-20-32935433

E: getcranes@emech.in

E: manpreet.kaur@flir.com.hk

E: sales@haasindia.com

W: www.emech.in

W: www.flir.com

W: www.HaasCNC.com

Empire Cable Industries Pvt Ltd

G L Brothers

T: +91-11-23874632

T: +91-22-66047000

E: empirecables@yahoo.co.in

E: info@pilotindia.com

W: www.empirecables.com

W: www.pilotindia.com

Emtex Marketing Pvt. Ltd.

127

178

Hafa Hoists Pvt Ltd

195

W: www.hafahoists.com 7 Hannover Milano Fairs India Pvt Ltd

T: +91-22-40050681 E: info@hmf-india.com

W: www.gwindia.in

W: www.emtexmarketing.com

E: response@hafahoists.com

E: info@gwindia.in

E: apsinghal@emtexmarketing.com

Haas Automation India Pvt Ltd

T: +91-22-27694837

T: +91-80-40431252

T: +91-11-41540362

Engineering Expo

G W Precision Tools India Pvt Ltd

199

Pg No

W: www.hmf-india.com

155;160;162;211

T: +91-09920401226 E: engexpo@infomedia18.in W: www.engg-expo.com

Gandhi Automations Pvt Ltd

T: +91-22-66720200

Havells India Ltd.

41;200-204

E: sales@geapl.co.in

T: +1800-11-0303;011-41660303

W: www.geapl.co.in

E: marketing@havells.com W: www.havells.com

Essen Deinki

181

T: +91-172-4600600 E: info@essendeinki.com

Gem Equipments Ltd

T: +91-422-3267800

Heattrans Equipments Pvt.Ltd.

E: sales@gemindia.com

T: +91-79-25840105

W: www.gemindia.com

E: info@heattrans.com

W: www.essendeinki.com Goliya Electricals Pvt Ltd Everest Blowers

137

T: +91-11-45457777

187

T: +91-22-24120456

W: www.goliya.com

W: www.everestblowers.com Goliya Instruments Pvt Ltd 59

193

E: goliya@mtn.net.in

E: info_in@festo.com

W: www.goliyainstruments.com

W: www.festo.com Grundfos Pumps India Pvt Ltd 175

Looking for a Speciﬁc Product?

T: +91-22-24149657

T: +91-80-22894100

Finechrome Shafts Pvt Ltd

W: www.heattrans.com

E: geplmumbai@mtnl.net.in

E: info@everestblowers.com

Festo Controls Ltd

195

T: +91-44-24966800

T: +91-22-29204209

E: salesindia@grundfos.com

E: finechromespl@yahoo.co.uk

W: www.grundfos.in

We will ﬁnd the product for you. Just type SRCH (space) Name of the Product and send it to 51818 eg. SRCH (space) Pump and send it to 51818. Our consistent advertisers

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213

ADVERTISERS’ LIST

Advertisers’ Name & Contact Details

Pg No

Hensel Electric India Pvt. Ltd.

Pg No

Advertisers’ Name & Contact Details

Indian Machine Tool Mfg. Association 218

Klipco Pvt Ltd

T: +91-44-24541669

T: +91-80-66246600

T: +91-22-28684221

E: henselelectric@vsnl.com

E: info@imtma.in

E: klipco@mtnl.net.in

W: www.hensel-electric.de

W: www.mmsinfo.in

W: www.klipcohoseclamps.com

Hindustan Motor Mfg Co

Advertisers’ Name & Contact Details

104

Jaibalaji Control Gears Pvt. Ltd.,

30-36

190

Knowell International Pvt Ltd

T: +91-22-42500500

T: +91-44-26251279

T: +91-33-22304627

E: sales@hindmotors.com

E: dchandramohan@jaibalaji.firm.in

E: hktrading@vsnl.com

W: www.hindmotors.com

W: www.jaibalaji.firm.in

W: www.knowell.co.in

Hummel Connector Systems Pvt Ltd 185 T: +91-11-26894005 E: info.in@hummel.com W: www.hummel.com Igus India Pvt Ltd

T: +91-80-39127800 E: info@igus.in

Jaykrishna Magnetics Pvt Ltd

185

Lapp India Pvt Ltd T: +91-80-7826000

E: info@jkmagnetics.com

E: sales@lappindia.com

W: www.magneticequipments.com

W: www.lappgroup.com 205

184

T: +91-79-22970452

JCR Drillsol Pvt. Limited

Pg No

Larsen & Toubro Ltd

T: +91-80-28390165

T: +91-22-67525656

E: vinod@jcrdrillsol.com

E: ss-ccd@lth.ltindia.cm

W: www.jcrdrillsol.com

W: www.larsentburo.com

W: www.igus.in Jyoti Architectural Products Pvt.Ltd IMTMA

217

T: +91-80-66246600

169

107

T: +91-22-28510183

T: +91-79-25841912

E: info@jyotiarch.com

E: lubgraf@vsnl.com

E: augustin@imtma.in W: www.imtma.in

Lubgraf Products

W: www.lubgraf.com Jyoti Cnc Automation Pvt. Ltd.

BIC

T: +91-2827-287081

M+V Marketing - Leuze Electronic

IndiaMART InterMESH Limited 109; 213

E: info@jyoti.co.in

T: +91-80-40854444

T: +1800-200-4444 / 91-120-3911000

W: www.jyoti.co.in

E: manish.sahay@leuze.in

E: pr@indiamart.com W: www.indiamart.com

Looking for a Speciﬁc Product? We will ﬁnd the product for you. Just type SRCH (space) Name of the Product and send it to 51818 eg. SRCH (space) Pump and send it to 51818.

103

W: www.leuze.in K2 Cranes & Components Pvt. Ltd

T: +91-44-42022895

Macpower Cnc Machines Pvt Ltd

E: gm@k2cranes.com

T: +91-2827-287930

W: www.k2cranes.com

E: sales@macpowercnc.com

W: www.macpowercnc.com Karolin Machine Tool Pvt Ltd

T: +91-22-28572494

Macro Tech Equipment Pvt Ltd

E: info@kmt-waterjet.com

T: +91-33-24666261

W: www.kmt-waterjet.com

E: info@macrotechcal.com

W: www.macrotechcal.com Kaycee Perfect Systems

177

T: +91-22-65933933

Mgm-Varvel Power Transmission (P) Ltd 21

E: krishnavk@netscape.net

T: +91-44-64627008

W: www.kayceeperfect.com

W: www.mgmvarvelindia.com Our consistent advertisers

214

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ADVERTISERS’ LIST

Advertisers’ Name & Contact Details

Mipox

Pg No

179

Advertisers’ Name & Contact Details

Paharpur Cooling Towers Ltd

Pg No

Advertisers’ Name & Contact Details

Rexello Castors Pvt Ltd

T: +91-80-65830898

T: +91-33-24792050

T: +91-22-40917777

E: rag-rao@mipox.co.jp

E: pctccu@paharpur.com

E: rexello@vsnl.com

W: www.mipoxindia.com

W: www.paharpur.com

W: www.rexellocastors.com

Mitsubishi Electric Asia Pte. Ltd.

121

Pepperl+Fuchs(India) Pvt Ltd.

Riat Grinders

T: +91-80-28378030

T: +91-161-2530805

E: marketing@mspl.messung.com

E: info@in.pepperl-fuchs.com

E: msriat@sify.com

W: www.messung.com

W: www.pepperl-fuchs.com

W: www.riatgrinders.com

Pilot Pneumatics Pvt Ltd

196

Sahyog Enterprise

119

T: +91-22-42554700

T: +91-22-66047000

T: +91-278-2446848

E: bhupinder.singh@mmi-india.in

E: info@pilotindia.com

E: sahyogdrills@dataone.in

W: www.mmi-india.in

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W: www.sahyogdrills.com

NI Systems India Pvt Ltd

T: +91-80-41190000 E: ni.india@ni.com W: www.ni.com Ningbo Xinda Screw Compressor Co., Ltd 79 T: +86-574-8833-6868

Precihole Machine Tools Pvt Ltd

T: +91-1871-223893

E: info@precihole.co.in

E: sarabsukhbatala@yahoo.co.in

W: www.precihole.co.in

W: www.sarabsukhmachines.com 198

177

T: +91-22-23436717 E: precisionranjit@hotmail.com

E: satra-international@yahoo.co.in W: www.satrainternational.com

W: www.augustcompressor.com

Premium Transmission Ltd

NMTG Mechtrans Techniques Pvt Ltd. 176

T: +91-20-66314100

Selec Control Pvt Ltd

W: www.premiumtransmission.com

T: +91-22-40394200

T: +91-79-22821527

E: sales@selec.com

E: nmtg@nmtgindia.com

Prism Control Gear Pvt Ltd

W: www.nmtgindia.com

T: +91-22-28761387 58

171

W: www.selec.com

E: prism@lpgsafety.com

Sensotech

W: www.lgsafety.com

T: +91-44-32972779

T: +91-11-43089550

E: sensotech@vsnl.in

E: india.sales@novatek-electro.com

Pshtech Technology Inc.

W: www.novatek-electro.com/en

T: +886-3-329-9968

Oil Seals Mfg Co Pvt Ltd

Satra International T: +91-11-25415437

E: inquiry@xindaworld.com

Novatek Electro India Pvt Ltd

Sarabsukh Enterprises

T: +91-22-25836780

Precision Industrial Co.

189

169

T: +91-124-4630300

MMI India Pvt Ltd

Pg No

198

W: www.sensomaticindia.com

E: pshtech@gmail.com

Shailesh Sales Corporation

W: www.peei.com.tw

T: +91-281-2461102

E: info@shaileshmachines.com

T: +91-22-22047943 Reid Supply Company

E: omcoseal@rediffmail.com

167

W: www.shaileshmachines.com

W: www.reidsupply.com Omron Automation Pvt. Ltd. T: +91-80-40726400 E: in_enquiry@ap.omron.com W: www.omron-ap.com

Shende Sales Corporation Renu Electronics Pvt Ltd T: +91-20-27292840 E: info@renuelectronics.com W: www.renuelectronics.com

122

189

T: +91-20-24488005 E: shende@shendesales.com W: www.shendesales.com Our consistent advertisers

A U G U S T 2 0 1 1 | SEARCH - THE INDUSTRIAL SOURCEBOOK

215

ADVERTISERS’ LIST

Advertisers’ Name & Contact Details

Pg No

Advertisers’ Name & Contact Details

Pg No

Advertisers’ Name & Contact Details

Shikovi Heat Gen Technologies Pvt Ltd 169

Sri Yantra Engineering Agencies (P) Ltd 175

Trident Precision International

T: +91-22-27607758

T: +91-80-40710555

T: +91-11-41425326

E: sales@shikovi.com

E: info@yantraengineers.com

E: trident.sales@tridenthydraulics.com

W: www.yantraengineers.com

W: www.trident-precision.com

W: www.shikovi.com

Sumip Composites Pvt Ltd Shilpa International (Impex) Pvt Ltd

135

179

Trident Products Pvt Ltd

T: +91-79-26933456

T: +91-124-4300626

T: +91-40-27849020

E: sales@sumip.com

E: trident.sales@tridenthydraulics.com

E: replysearch@shilpagroup.com

W: www.sumip.com Tussor Machine Tools Ind P Ltd

W: www.shilpagroup.com/si Sumitron Exports Pvt Ltd. Siemens Ltd

43;183

T: +91-11-41410631

T: +91-422-3200183 W: www.pinachoindia.com Tyrolit India Superabrasive Pvt. Ltd

W: www.siemens.com

Suraj Stainless Ltd

193

T: +91-79-27540720 190

T: +91-2764-253500

Sushma Industries

131

T: +91-80-28397463 16

T: +91-80-40953259 W: www.tylolit.com

W: www.surajgroup.com

W: www.sintex-plastics.com

E: subrahmanya.kumar@tyrolit.com

E: suraj@surajgroup.com

E: icontainers@sintex.co.in

Softlink Automation System Co., Ltd.

171

W: www.sumitron.com

E: motors.in@siemens.com

Sintex Industries Ltd

186

E: info@tussorindia.com

E: sumitron@vsnl.com

T: +91-22-27623727

Pg No

Vacunair Engineering Co Pvt Ltd

181

T: +91-79-22910771 E: info@vacunair.com

E: marketing@sushmaindustries.com

W: www.vacunair.com

W: www.sushmaindustries.com T: +86-755-2533-6812 E: info@softlink.cn

Syndicate Industrial Corporation

165

E: enquiry@venusengineers.com

W: www.siddhapuradrills.com

W: www.venusengineers.com

Teknic

W: www.sonalmagnetics.com Spareage Seals Ltd

E: urmish@siddhapuradrills.com

T: +91-79-22872349 E: info@sonalmagnetics.com

Venus Engineers T: +91-11-32222661

T: +91-278-2445148

W: www.softlink.cn Sonal Magnetics

197

Wendt India Ltd

111

T: +91-22-26592392

T: +91-4344-405500

E: teknic@vsnl.com

E: vijayvernekar@wendtindia.com

W: www.tecknic.co.in

W: www.wendtgroup.com

61 Werner Finley Pvt Ltd

T: +91-22-25800972

The Indian Electric Co

E: sales@spareage.com

T: +91-20-24475845

T: +91-80-23289889

W: www.spareage.com

E: iecmktg@indianelectric.com

E: info@wernerfinley.com

W: www.indianelectric.com

W: www.wernerfinley.com

Sreelakshmi Traders T: +91-44-24343343

196

Tox Pressotehnik India Pvt Ltd

47; C0C

143

Wont Industrial Equipments

T: +91-20-66538300

T: +91-261-2894847

E: sreelakshmitraders@gmail.com

E: RNamboodiri@tox-in.com

E: info@wantindia.com

W: www.sreelakshmitraders.com

W: www.tox-de.com

W: www.wantindia.com

187

170

Our consistent advertisers

216

SEARCH - THE INDUSTRIAL SOURCEBOOK | A U G U S T 2 0 1 1

RNI No: 67827 /98 Postal Regd No G 2 / NMD / 81 / 2011 -13 Posted at Mumbai PatrikaChannel Sorting Office- GPO, Mumbai 400 001 on 22nd & 23rd of Every Previous Month Date Of Publication: 18th of Every Month

Vol 14 No 08

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August 2011 220