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LET’S BE PRACTICAL o, we are not debating the fact that we need to be practical in life. This expression is to define and describe this edition. Practical, easy-to-imbibe tips & tricks from shop floor to strategies is the essence of this edition. The Industry Update on Hydraulics & Pneumatics is the case in point. Like the Hose Vs Tube article, which talks about the constant debate over whether hydraulic hoses should be used in hydraulic equipment or if hydraulic tubing is the best option? It is complete with instructions to select the appropriate hydraulic pump. The hydraulics rebuild story talks about rebuilding of hydraulics equipment – which involves replacing the necessary parts that would enable it to last long and function like a new one – and how important it is for a user to decipher whether to spend money on rebuilding an equipment rather than purchasing a new one. Staying with the practical and application-oriented flavour of this edition, the Easy Steps to Maintain Hydraulic Equipment is every maintenance engineer’s delight! Then again, the green technology benefit that Parallel Hydraulic Hybrids offer is a pragmatic green technology option that is highly viable. An in-depth analysis on the same is a must read. Graduating from being practical to gauging ‘What’s Next In Hydraulics,’ provides insights into how the hydraulics segment has been at the threshold of progress over the years. It sums up with yet again some ‘must follow’ practical tips on the most common hydraulics equipment handling mistakes. And since hydraulics is here, can we miss not talking about pneumatics? Taking the green angle to the industry, this article discusses conservation of energy by improving the efficiency of pneumatic systems. The article provides numerous opportunities for savings as a result of a high leak load, intermittent demand and tubing size reduction. As is the norm of this issue, it concludes with the best practices in these areas to ensure huge returns from pneumatic equipment, be it money or energy. And saving the best for the last, a section on Smart Manufacturing, which is a prelude of sorts for our MEGA 13th anniversary issue come January, is what the future beholds. Smart manufacturing will deliver an extraordinary shift in the competitive landscape of Indian manufacturing. Flexible factories and IT-optimised future factories will transform manufacturing processes. It will also allow manufacturers to customise products to suit individual needs. This most dramatic, and competitively vital, smart manufacturing will neither be incremental nor show gradual changes, but it will demonstrate game-changing, market-disruptive innovations in products and processes. In a nutshell, to strengthen our global competitiveness quotient, we must invest in applied research and innovation centres for smart manufacturing, and gear up to grab the top slot in the profoundly changed market realities, which this decade promises to bring. So here’s summing the issue for you. Read it, relish it and implement it in your businesses…that will be the most practical thing to do!
N
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.
N O V E M B E R 2 0 1 0 | SEARCH - THE INDUSTRIAL SOURCEBOOK
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CONTENTS MANUFACTURING ZONE
SMART MANUFACTURING
| Pg 100
A Blueprint to
GenX Manufacturing 25
EDITORIAL Let’s Be Practical
38
NATIONAL NEWS Latest In The Indian Manufacturing
Aptly responding to fast changing global consumers’ demands with the right set of variety and quality is any manufacturers dream in this cut-throat competitive era. The use of smart manufacturing practices enables a manufacturer to plan and prepare beforehand with the use of the right set of technology, planning and design tools making him flexible to cater to the ever-evolving volatile markets.
106
National Manufacturing Investment Zones Propelling Manufacturing Growth
NEWS ANALYSIS 44
VIEW FROM THE TOP
Metal Industry Illuminating With Radiant Prospects
Pg 54 48
WORLD NEWS Snapshot Of Latest Global Happenings In Manufacturing Domain
VIEW POINT 112
Energy Security The Future Is Green
TECHNOLOGY TRENDS 116
Technology Update Cutting Edge Solutions
RENEWABLE MILESTONES 120
Offshore Wind Farm Attaining Remarkable Feat In Offshore Power Generation
APPLICATION ZONE 124
‘Hydraulics Capabilities Improve Shopfloor Productivity’ SHYAM KAMBEYANDA, President – APAC, Hydraulics Group, Eaton Corporation
Mechatronic Systems Smart Solutions To Complex Problems
EQUIPMENT BUYING GUIDE 130
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Energy-efficient Motors Embracing The Green Solution
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DESIGN INNOVATION 136
Global Design And Manufacturing Partnerships Collaborating For Success
CONTENTS SPECIALS IN THIS ISSUE INDUSTRY UPDATE Hydraulics & Pneumatics
78
Pneumatic Systems Compressing Energy Consumption
62
Parallel Hydraulic Hybrid Systems Gaining A ‘Green’ Edge
82
Trends & Toolkit Gauging What’s Next In Hydraulics
69
Hydraulic Equipment: Hose Vs. Tube Taking The Right Call
87
Case Study Eaton Hydraulic Motor - Speeding Operations, Maximising Output
74
Hydraulic Rebuilds Hauling Monetary Gains
88
Industrial Equipment Segment Challenged, Transformed & Poised For Growth
96
IR Heating Technology Offering Innovative Solutions For Paint Drying & Curing
PRODUCT UPDATE Hydraulics Latest Products In Hydraulics
184
Industrial Paints & Polishes Latest Products In Industrial Paints & Polishes
Drive & Control Integrating Safety Into Workplace
192
New Launches Latest Products In The Offing
202
General Products Rolling Out The Best-in-class
SME ADVANTAGE 154
Paints & Polishes ‘Coated’ With Vibrant Opportunities
168
FACTORY FUNDAMENTALS 146
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TIPS & TRICKS
SMART STRATEGIES 141
INSIGHTS & OUTLOOK Industrial Paints & Polishes
Technological Innovation Road To Perpetual Growth
233
PRODUCT INQUIRY FORM For Product Inquiries Showcased In This Issue, Fill In The Form And Send It Back To Us
CURTAIN RAISER 160
Engineering Expo Pune 2010 The Euphoria Begins
REPORT 164
Electronica + Productronica INDIA 2010 Charging Up For Growth
166
National Seminar On Challenges In Transmission & Distribution Driving Efficiency Through Automation
240 248
International Products Showcasing Product In A Global Arena
PRODUCT INDEX Alphabetical Listing Of Products Presented In The Issue
255
ADVERTISEMENT INQUIRY FORM Get In Touch With Supplier Of Products You Wish To Buy
260
ADVERTISERS’ LIST Advertisers’ List In Chronological Order
144 152
PREVIEW HiTech Material Handling Show Inspiring Innovations ENGINEERING EXPO Engineering Expo Ahmedabad 2010-11 Flying High With Bright Prospects
PRODUCT UPDATE
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Details on pg. 203, 213, 223
NATIONAL NEWS
Manufacturing sector expands at slow pace lthough India’s manufacturing sector is expanding, the pace of growth was considerably slower than that in preceding months. This is predominantly due to the dip in new orders and output. This is underlined by the fact that the HSBC Markit Purchasing Managers’ Index (PMI) slid to 55.1 in September, from 57.2 in the August survey, which marks the lowest reading since November last year. Frederic Neumann, Co-Head, Asian Economics Research, HSBC, said, “The manufacturing sector is showing signs of cooling
A
FDI Equity Inflows (Month-wise) During The Financial Year 2010-11: Financial Year 2010-11 (April-March )
Amount of FDI inflows* (In Rs. Crore)
(In US$ mn)
April 2010
9,854
May 2010
10,135
2,214 2,213
June 2010
6,429
1,380
July 2010
8,359
1,785
2010-11 (Up to July 10) #
34,777
7,592
2009-10 (Up to July 09)
51,256
10,532
% age growth over last year
Sectors Attracting Highest FDI Equity Inflows: (Financial Year-wise): Amount Rupees in crores (US$ in million)
Sector
Services Sector Computer Software & Hardware Telecommunications Housing & Real Estate Construction Activities Power Automobile Industry * Metallurgical Industries Petroleum & Natural Gas Chemicals
2010-11 % age to total (April -July Inflows 2010) (In terms of US$) 4,948 21% 1,882 9% 4,692 1,902 1,183 3,119 412 2,619 985 471
8% 7% 7% 5% 4% 3% 2% 2%
Note: Cumulative Sector- wise FDI equity inflows (from April 2000 to July 2010) - Annex-‘B’. * Earlier data has been revised, due to some figures interchange with the respective sectors.
Share Of Top Investing Countries FDI Equity Inflows: (Financial Year-wise): Amount Rupees in crores (US$ in million)
Mauritius Singapore U.S.A. U.K. Netherlands Japan Cyprus Germany France U.A.E. Total FDI Inflows *
2010-11 % age to total (April-July Inflows 10) (in terms of US $) 11,541 42% 4,416 9% 2,713 8% 1,101 5% 2,091 4% 2,210 4% 630 3% 220 2% 1,125 2% 834 1% 34,777 -
Note: (i) *Includes inflows under NRI Schemes of RBI, stock swapped and advances pending for issue of shares. (ii) Cumulative country-wise FDI equity inflows (from April 2000 to July 2010) – Annex-‘A’. (iii) %age worked out in US$ terms & FDI inflows received through FIPB/SIA+ RBI’s Automatic Route+ acquisition of existing shares only. Source: Department of Industrial Policy & Promotion, Ministry of Commerce and Industry, Govt. of India
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There will be a contraction in margin due to rising input costs and strong competitions. However, it is difficult to pass on the input cost to the customers. REVATI KASTURE, Head - CARE Research Credit Analysis & Research
constraints may be partly responsible for this, in addition to the fading fiscal stimulus.” According to the PMI survey, input cost inflation accelerated to its highest in four months, as raw material prices rose, while output costs, though on an upward trend, remained tempered due to strong competition for new business. While indexes for both new orders and output signalled a sustained expansion in new business and improvement in economic conditions, they were also among the biggest losers, with each falling below 60 for the first time since last year.
(-) 32.15 % (-) 27.91 %
# Figures are provisional, subject to reconciliation with RBI, Mumbai.
Country
after a red hot pace earlier in the year.” Stating the reasons for this dip, he added, “Capacity
India targeting 63,000 MW nuclear power capacity by 2032 ndia has an ambitious plan to reach a nuclear power capacity of 63,000 MW by 2032. This is said to be done by setting up 16 indigenous Pressurised Heavy Water Reactors (PHWR) each, including 10 based on reprocessed uranium. “Of the total target of 63,000 MW, about 40,000 MW will be generated through light water reactors (LWR) with cooperation from the overseas,” said SK Jain, CMD,
I
NPCIL. He also said that by 2032, India would export 220 MW, 540 MW and 700 MW PHWRs. Beyond 2032, large capacity addition would be taken up by setting up metallic fuel fast breeder reactors (FBRs) and introduction of reactors based on Thorium-232 and Uranium-233 fuel cycle. According to Jain, currently, India is in a position to set up its export model 220 MW PHWR in friendly countries. “Countries with existing nuclear power projects and
expansion plans have to face key challenges such as continued efforts in achieving enhanced safety and reliability in the existing and future nuclear power projects,” he said. Other challenges include retaining skilled human resource, management of spent fuel and radioactive waste and maintaining confidence in nuclear nonproliferation. “In order to meet this target, the industry will have to gear up,” said S Thakur, Executive Director, NPCIL.
EU to push for auto duty cuts under free trade pact ith the IndiaEuropean Union Free Trade Agreement (FTA) round the corner, European nations are seeking to eliminate import duties in the auto sector. Large EU manufacturers are facing fall in demand for automobiles. This is prompting them to look at growing markets like India. However, imports of completely built units attract heavy duties in
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India (60 per cent customs duty), while auto components face about 50 per cent duty of the overall tariff (10 per cent customs). Although the elimination of import duties will bring more companies to the country, India is unlikely to give in as it looks forward to safeguard potential long-term investments, and build a worldclass local industry. Jyotiraditya Scindia, Minister of State for Commerce, said,
“We take into consideration the interests of all our stakeholders while taking policy decisions. The same will be done for the auto sector’s fears regarding the Indo-EU FTA.” According to SIAM, if import duties are reduced then there is a risk that global automakers may slow down investments on manufacturing capacities in India, as they may find importing from Europe a more viable option.
NATIONAL NEWS
EVENTS
In India
PUNE Maharashtra November 19-22, 2010 Auto Cluster Exhibition Ctr, Chinchwad
AHMEDABAD Gujarat December 10-13, 2010 Gujarat University Exhibition Hall
INDORE Madhya Pradesh January 7-10, 2011 Maharaja Shivajirao School Grd, Chimanbaug
CHENNAI
Indian renewable energy sector to see more deals ccording to global consultancy Deloitte, the Indian renewable energy sector is expected to witness increased deal-making activities in the coming months. Kalpana Jain, Senior Director, Deloitte India said, “This trend will continue to move forward. The increased interest is not only a necessity to acquire technologies, but has also been on account of attractive valuations after the global financial meltdown.”
A
Tamil Nadu March 11-13, 2011 Chennai Trade Centre
India’s premier industrial trade fair on products and technologies from machine tools, hydraulics & pneumatics, process machinery & eqpt, automation instrumentation, packaging & auxiliaries, IT products, electrical & electronics, material handling, safety eqpt. For further details contact: Tel: 022 3003 4649/4651 Fax: 022 30034499 Email: engexpo@infomedia18.in Web: www.engg-expo.com INDIA LABVIEW CONFERENCE 2010 Focus: Launch of LabVIEW 2010 and showcase the India LabVIEW Sphere When: November 11, 2010 Where: Essex Farms, Delhi Tel: +91 11 42658282
Fax: +91 11 42658282 E-mail: ni.india@ni.com WIRE & CABLE INDIA 2010 Focus: Wire & cable industry When: November 18-20, 2010 Where: Bombay Exhibition Centre, Mumbai Tel: 011 2697 1745 E-mail: DughL@md-india.com IPVS - INDUSTRIAL PUMPS, VALVES AND SYSTEMS Focus: Industrial pumps, valves and systems When: December 9-11, 2010 Where: Chennai Trade Centre, Hall 3, Tamil Nadu Tel: + 044 - 22316033, 044 - 22315551 Fax: + 91 22 24102805 Email: info@ipvs.in / ho.exb1@orbitzexhibitions.com
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The solar sector is expected to see increased participation and collaboration, especially in the technology and manufacturing space. KALPANA JAIN, Senior Director, Deloitte India
India has seen an estimated 14 deals worth $1.1 billion in
the green energy space for the year ended June 2010. According to Jain, there is renewed impetus in the renewable energy sector, especially in the solar energy segment. “The solar sector is expected to see increased participation and collaboration, especially in the technology and manufacturing space,” she explained. Thus, companies will get an opportunity to bring forward their projects and help in the overall energy requirements of the country.
NI empowers engineers to innovate ith rising domestic market and a strong young talent pool, the growing economy brings many opportunities for manufacturing. In this scenario, there is a huge requirement for new product development that empowers engineers with the latest technology to innovate. One such tool is the ‘NI LabVIEW 2010’, launched recently by National Instruments, in Bengaluru. The product will help engineers through userdefined, software-based approach for developing test, control and embedded
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applications. Jayaram Pillai, MDIndia, Russia & Arabia, National Instruments, said, “Engineers today need to be exposed to
Trends such as mobile computing, cloud computing, improving education systems, entrepreneurship will together play an important role in development of future products. JAYARAM PILLAI, MD-India, Russia & Arabia, National Instruments
real industry problems and get more Indianised in terms of product capability. With our presence, we have evolved the India LabVIEW Sphere, a powerful India-ready LabVIEW ecosystem committed to serving the engineers and scientists community in the country.” LabVIEW 2010 delivers time savings with new features such as off-the-shelf compiler technologies that execute code an average of 20 per cent faster and a comprehensive marketplace for evaluating and purchasing add-on toolkits for easily integrating custom functionality into the platform.
Govt to allot power projects worth `1.4 lakh crore overnment of India has decided to make investments worth `1,40,000 crore in the next three years, to allocate power projects of total capacity of 28,000 MW. India is targeting to increase the contribution of the manufacturing sector in its GDP from 15 per cent to 25 per cent by 2022. As power plays an important role in the performance of the
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manufacturing sector, the decision of the government will be a good move towards the growth of the manufacturing sector. Power Finance Corporation, the state-owned company facilitating the development of ultra mega power projects (UMPPs) of 4,000 MW each, has identified seven locations across the country where these projects would come up. “There are about seven more UMPPs to
be developed over a period of time,” said an official from the Power Ministry. Four such projects have already been awarded to successful companies in international competitive bidding while three have been allotted to private developers. These projects will help provide enough power at lower rates to manufacturing companies, thereby increasing their productivity.
NATIONAL NEWS
EVENTS
India’s steel consumption up by 9.8 per cent
In India
wing to the constant demand from sectors like automobile and consumer durables, domestic steel consumption has seen a rise of 9.8 per cent to 29.82 MT in the first half of the current fiscal, compared to the same period last year, which was 27.15 MT. However, domestic production rose only by 4.9 per cent to 30.63 MT in the reporting period, as against 29.21 MT last year. It was observed that despite
O
Concurrent Shows
MUMBAI Maharashtra February 17-19, 2011 NSE Ground, Goregaon
One of the largest advanced design and manufacturing events in India featuring machine tools, hydraulics & pneumatics, process machinery & equipment, packaging & auxiliaries, it products, electrical & electronics with a special focus on automation & instrumentation, material handling For further details contact: Tel: 022 3003 4650 Fax: 022 30034499 Email: hitech@infomedia18.in HANNOVER MILANO FAIRS INDIA Focus: Concurrent trade shows on material handling & logistics; motion, drives & automation; building automation; energy & surface technology When: December 15-18, 2010 Where: Bombay Exhibition Centre, Mumbai Tel: +91 22 40050681/82 Fax: +91 22 40050683 Email: info@hmf-india.com EA WATER EXPO Focus: Water and Wastewater Management When: January 06-08, 2011 Where: Bombay Exhibition Centre (BEC), Mumbai Tel: +(91)-(11)-29531288 Fax: +(91)-(11)-29531291 BLECH INDIA 2011 Focus: Technology exhibition for sheet metal working When: April 14 - 17, 2011 Where: Inter Ads - Brooks Exhibitions (India), Haryana Tel: +91 (0) 124 452 4200 Fax: +91 (0) 124 452 4234
Email: blech.india@interads.in
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the domestic production surpassing consumption, the April-September period saw imports rising by 32.6 per cent to 4.4 MT, as compared to the same period last year. This has increased domestic availability and put pressure on local prices. On the other hand, steel exports declined by 4.2 per cent in the reporting period to 1.47 MT. In September, steel consumption rose by 4.1 per cent to 4.72 MT, as against 4.53 MT a year-ago. Production
during the month rose by 10.8 per cent to 5.38 MT, which is over 4.85 MT in the corresponding period last year. “Steel producers started building inventories in view of rising demand after the end of monsoon season. Also, there was recovery in demand in European and Western markets,” said a steel sector expert. Imports declined by 35.3 per cent to 3.64 lakh tonne during the month, while exports grew by 28.6 per cent to 1.75 lakh tonne.
FDI inflows down by 60 per cent in August ince world’s major economies have still not fully recovered from the economic slowdown, there has been a dip in the inflow of foreign direct investment (FDI) to India. This dip has occurred for the third consecutive month. For the April-August period of 201011, FDI inflows declined by 35 per cent to approximately
S
$8.92 billion as compared to $13.8 billion in the same period last year. Although there has been a smart recovery in the domestic economy and a rebound in exports, overseas investments have shown a slackening trend in the current fiscal. DK Joshi, Chief Economist, Crisil, says, “This is not a good news for the Indian economy. This reflects that global economic
recovery is still fragile and some impact of that would be reflected in the FDI.” The sectors that attract maximum foreign investments, include services, telecommunication, construction activities, software & hardware, and manufacturing domain. As this trend continues, industries will need to search for alternative methods and strategies to sustain growth.
CII organises waste management summit i t h u r b a n 2010’, seeking solutions for a waste management and population sustainable future. The summit recycling sector in India. Ram N Agnihotri, Chairman, increasing by 3-3.5 focussed on current challenges, Waste Management Summit per cent per possible solutions and capacity 2010 and VP & National Head annum, the per capita waste building requirements of the - Hazardous Waste generation is rising by Management, Ramky 1.3 per cent every year. Enviro Engineers, pointed Economic growth, out, “If proper disposal urbanisation and industrialisation has Effective waste management through and management options resulted in increased waste minimisation, recycling, cleaner are not applied, the of wastes will be generation of municipal technologies and proper handling is of impact enormous. Thus, solid wastes as well as waste hazardous wastes. paramount importance to protect the effective environment. management through Realising the need for waste minimisation, sound management of recycling, cleaner waste, CII-Godrej Green RAM N AGNIHOTRI, technologies and proper Business Centre recently VP & National Head - Hazardous Waste handling is of paramount organised ‘Waste Management, Ramky Enviro Engineers importance.” Management Summit
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METAL INDUSTRY
ILLUMINATING WITH RADIANT PROSPECTS The metal industry in Asia is growing at a rapid pace owning to the surge in demand from the automotive and the infrastructure sectors. However, the highly disintegrated non-ferrous metal industry is yet to exploit the plentiful of opportunities that have emerged post recession. Illuminating with radiant prospects, the industry is sure to gain growth momentum with increased emphasis on recycling. KTP RADHIKA JINOY etals comprise an important component in a wide range of key sectors such as chemical, engineering, agriculture, a u t o m o b i l e s , infrastructure, electronics and other manufacturing sectors. Hence, the metal segment plays a major role in the growth or dip of a country’s economy as proved by the financial meltdown in the recent past. While the global financial crisis hit the American and European metal market, expanding domestic demand and readjusting industrial structure in the Asian countries, especially in China and India, cushioned the crisis. Today, as the manufacturing industry – the main
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consumer of metals – is constantly exploring new initiatives, the metallurgy market in the Asia-Pacific region is all set to witness a new era.
In metal industry, one of the key concerns is the sharp rise in prices of raw materials like iron ore and coking coal, which is likely to dent the profitability of majority players. NARESH KHANDELWAL,
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Director, Rajdhani Iron Products
METAL MARKET SCENARIO A recent report by Frost & Sullivan indicates that Asia accounts for nearly 56 per cent of the total world crude steel production. “India is the primary producers’ market in the ferrous industry, which is oligopolistic and dominated by two large integrated producers – the Steel Authority of India (SAIL) in the public sector and Tata Iron and Steel Company (TISCO) in the private sector,” the report states. Non-ferrous industry also reports strong growth. With the rising demand for aluminium in India, the aluminium industry is flourishing at an enviable pace. In fact, the production is currently surpassing the demand. “In steel sector, amidst the turmoil, China and India were among the countries that stood
METAL INDUSTRY
apart with positive growth at a time when Karnataka and Jharkhand,” says Khandelwal. infrastructure, manufacturing and the world was reeling under demand Delay in executing greenfield projects also automobile. The first four months of 2010 pressure. The global downturn and the pose a threat to domestic metal industry. has seen a significant increase in steel subsequent recovery have accentuated the Large greenfield projects have not been demand led by strong boom in key endimportance of China and India in the global able to take off, owing to tough regulatory user segments like automobile, infrastructure steel industry. This clearly demonstrates environment in terms of land acquisition, and consumer goods. Not only have both countries’ strong domestic forest clearance, relief and With rapid increase in the consumption pattern of metals, rehabilitation procedures and consumption story. The current year appears to be promising recycling has become crucial to meet the expected metal most importantly grant of iron for the steel industry,” says ore mining leases. To add to the demand. Metal recycling is environmentally benign woes, poor transportation Naresh Khandelwal, Director, and requires less capital and energy for production. infrastructure (railways, road as Rajdhani Iron Products. Adding to this, Vinod Shankar, However, the recycling industry in Asia is yet to gear well as ports) also increases the Consultant, Manufacturing & up fully to meet this demand, and is highly reliant on cost, thereby affecting the Process Consulting Practice, bottom line. importing metal scrap because of its unorganised scrap Frost & Sullivan, South Asia & Remote locations of mineral Middle East, says, “The Indian deposits, protectionist metal sector. subcontinent and several other tendencies by other economies, parts of Asia are rich in enormous reserves lack of adoption of latest technologies & capacity utilisations improved, steel prices of metals and minerals such as iron ore, scientific mining techniques, etc, pose a have almost doubled over the last one bauxite, etc. This, along with their close threat to the industry players. With rapid year,” says Khandelwal. geographical proximity to the Middle East, increase in the consumption pattern of The domestic consumption of aluminium makes Asia one of the most favoured metals, recycling has become crucial to is dominated by industries like power, destinations for metal producers.” meet the expected metal demand. Metal infrastructure, transportation, etc. Due to recycling is environmentally benign and the ever-increasing demand from the DRIVING FACTORS requires less capital and energy for construction, electrical, automobiles and Reports show that India’s per capita production. However, the recycling industry packaging industry, the production of consumption of steel is around 48 kg, while in Asia is yet to gear up fully to meet this aluminium is currently growing. The total that of aluminium and copper is around 0.8 demand, and is highly reliant on importing aluminium production in India was around kg and 0.4 kg, respectively. However, with metal scrap because of its unorganised scrap 1.35 tonne last year. the economy booming, per capita metal sector. Also, mergers and acquisitions are consumption of key metals has been intensifying competition among domestic TAPPING LUCRATIVE increasing. In addition, low penetration of players in the market. This is also forcing OPPORTUNITIES key metals clearly indicates high growth them to innovate and improve their Booming automotive and infrastructure potential and an opportunity for investors to efficiency in order to sustain competition. sectors are likely to drive the future demand exploit the untapped market. “Factors such For example, Tata’s Corus deal and for steel. Besides, heavy engineering and as government policies, consolidation, Tangshan Iron and Steel Company’s deals machine tools industries are the main favourable conditions, increasing demand with two smaller rivals has aggravated the dealers of metals. Currently, these industries and consumption, etc, directly influence the market pressure in the past. are witnessing phenomenal growth resulting domestic metal industry,” says Shankar. THE DOWNSIDE in increasing metal consumption. India is He further adds, “It is noted that up to Despite the positive outlook, the metal one of the low-cost producers of steel, 100 per cent foreign direct investment (FDI) market is fraught with some bottlenecks. alumina and aluminium. This presents huge is allowed under the automatic route for The industry is highly fragmented in the investment opportunities for integrated mining of metal ores in India. FDI policies downstream sector of secondary producers steel, copper & aluminium plants, and have made global leaders like Arcelor-Mittal both in China and India. The highly recycling plants for secondary aluminium. and POSCO evince interest in setting up disintegrated non-ferrous metals industry in As the per capita metal consumption of the plants in India. Moreover, the government’s Asia is yet to exploit its full potential. Asian countries is projected to increase in thrust on infrastructure is expected to boost Another concern is the raw material the future, the metal industry is all set to steel demand and 46 per cent of total price increase. “In metal industry, one of the maintain its sheen in the long-term. planned allocations has been earmarked key concerns is the sharp rise in prices of towards infrastructure development in the raw materials like iron ore and coking coal, Union Budget (2010-11).” MANUFACTURING ZONE: which is likely to dent the profitability of This is not all. Good prospects for the Smart Manufacturing majority players. metal industry are reinforced by strong Getting It Right Also, in India, regular and uninterrupted domestic consumption. “Even though the supplies of iron ore might be at risk growth in real estate and housing sector The First Time considering the current wave of curbs marked a decline in 2009, the same was implemented on illegal mining activities in more than compensated by sustained on pg. key ore-producing areas like Orissa, progress in other sectors such as
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WORLD NEWS
EVENTS
FABTECH 2010 Focus: Metal forming, fabricating, finishing and welding When: November 2- 4, 2010 Where: Georgia World Congress Centre, 285 Andrew young Intl. Blvd. NW, Atlanta GA 30313 Tel: 040- 22340000 Fax: 404-223-4211 Tooltec Expo Focus: Tools & Tooling Equipment When: November 4-6, 2010 Where: Prague Exhibition Grounds, Prague, Czech Republic Tel: + (420)-(220)-103111 Fax: + (420)-(233)-379450 American Manufacturing Strategies Summit Focus: Manufacturing and Machinery When: November 11-12, 2010 Where: Hilton Chicago - Indian Lakes, Chicago, IL Tel: 1 416 214 1144 Fax: 1 416 214 3403 AME International Lean Conference 2010 Focus: Lean management, Manufacturing, Continuous improvement, When: November 15- 19, 2010 Where: Baltimore Convention Center, 1 W Pratt St, Baltimore, MD 21201 US Tel: 410-837-4636 / 1-800282-6632 Fax: 410-659-8398 SHEET METALEX Focus: Manufacturing and Machinery When: November 24-27, 2010 Where: Bangkok International Trade & Exhibition Centre (BITEC), Bangkok, Thailand Tel: + (66)-(2)-6867299 Fax: + (66)-(2)-6867288
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Global steel consolidation nearing completion
Abroad
a m p e n i n g disappointment for the Indian producers of key steelmaking speculations of steel companies who are on a material, because three big revival of mergers constant lookout for merger miners, Vale, Rio Tinto and and accusations opportunities with big players. BHP Billiton dominate the (M&A) in the steel industry, Despite a pick up in global market. Lakshmi Narayan Mittal, M&As, steel production has Apart from ArcelorMittal, Chairman & CEO, ArcelorMittal, seen only a few large deals Shoji Muneoka, President, has recently said that the since Mittal took over Arcelor Nippon Steel, also agreed that consolidation in the steel in 2006. The fragmented steel companies do not see a industry worldwide pressing need for is almost Achieving resource security has been a primary i n d u s t r y complete. realignment. “There is not driver behind M&A deals in steel industry. While majority of much room left Further, geographical expansion, increased players in the steel for consolidation, marketshare and an improved cost structure industry agree except in China,” with Mittal, South have been governing these transactions. he added, while Korea’s POSCO, speaking at the world’s thirdWorld Steel Association industry is in a disadvantageous biggest steel producer said that conference in Tokyo. This position with regard to price it would aggressively pursue statement comes as a talks with iron ore miners, M&As to drive growth.
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Robot training centre to meet UK manufacturing growth utomation major, ABB has decided to invest in robot training facility based in Milton Keynes, the UK’s largest dedicated industrial robotic technology training school. Nigel Platt, Manager, UK Sales and Marketing-Robotics, ABB, said, “With the current upturn in the UK manufacturing sector, the time is right to
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ensure the present and future of engineers; moreover, operators are trained to leverage on the potential growth opportunities that robotics can bring. This requires them to be equipped with the skills needed to ensure the best levels of performance from their installed robots.” New additions to the training centre include two IRB 360 FlexPicker robots, widely used
in the fast moving consumer goods (FMCG) industry for picking and packing applications. This dedicated dual cell will assist trainees in gaining a better understanding of picking and packing ‘on the fly’ by introducing them to a host of latest programming software and options such as the latest ABB vision software, product distribution techniques and conveyor tracking features.
World’s Largest Solar Cell Manufacturing Plant Underway wo years ago, Giga Watt (GW)-scale production facilities were considered a big deal. With more companies reaching the GW range, the next step is to reach multi-GW capacities. Taking an initiative in this direction, Neo Solar Power has recently announced that construction on the world’s largest solar cell facility, a plant that will cost $837 million and produce 3.4 GW of cells per
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year is underway. The first phase of the plant will be 400 MW in size. The company has 620 MW of capacity operating in North Taiwan. The company will scale these facilities up to 800 MW by the end of the year. By most accounts, 2010 will be a big year for solar installations. The consultancy iSuppli predicts that about 13.6 GW of photovoltaics (PV) will be installed this year. Despite the scaling back of incentives in
a few big European markets, iSuppli projects installations to be over 20 GW in 2011. As a result of unexpectedly high demand in the second half of this year, it is increasingly difficult to find panels. Silicon prices are rising as well. Companies like Neo Solar are ramping up quickly to ensure a steady supply of cells and modules during these high growth years. Some analysts are already worrying about supply constraints into 2012.
WORLD NEWS
Global economy may shrug off US slump all Street expansion this year and the consecutive month in economists are next, up from about 25 per September, and industrial portending that the cent a decade ago. “Direct production in India jumped global economy transmission from the US 13.8 per cent in July from a year will withstand the US slowdown. slowdown to other economies earlier, more than twice the Just three years since America through exports is not large pace observed in June. began to take the world enough to spread the US into its deepest recession in demand problem globally,” seven decades, Goldman commented Dominic Sachs Group, Credit Suisse Wilson and Stacy Carlson, Holdings and BofA Merrill Direct transmission from the US Economists, Goldman Lynch Global Research are slowdown to other economies through Sachs. “If the growth slowed 2 forecasting that worldwide exports is not large enough to spread per cent, the drag on the growth will slow down the US demand problem globally. BRIC countries of Brazil, from 0.2 percentage point Russia, India and China to 4.6 per cent in 2011, would be about 0.1 per even as expansion in the DOMINIC WILSON & cent. Developed economies US falls to 1.8 per cent STACY CARLSON, including the UK, Germany from 2.6 per cent. “The Economists, Goldman Sachs and Japan also have limited world has already become exposure. A fall of almost partially decoupled,” says David Lubin, Chief 35 per cent is more than Nobel laureate Joseph Stiglitz, Economist, Citigroup, London, twice as large as the worst Professor, Columbia University, estimates that emerging declines in the rest of the New York. economies will account for group of 10 industrial nations,” Manufacturing in China about 60 per cent of global said Wilson. accelerated for a second
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UK manufacturing recovery slows down in September ollowing the marked downshift seen in the previous month, the recovery of the UK manufacturing sector continued to slow in September, as growth of output lost further momentum and the rate of increase in new orders
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improved only slightly. The seasonally adjusted Markit/CIPS UK Manufacturing PMI fell to a 10-month low of 53.4 in September, down from a revised figure of 53.7 in August. Rob Dobson, Senior Economist, Markit, and Author, the UK Manufacturing PMI, said, “September saw the
weakest expansion of UK manufacturing for a year, but some reassurance can be gained from the fact that growth has merely slowed from an exceptionally strong rate in the first half of 2010. The sector has now also recouped over 30 per cent of its recession losses.”
Wind could provide 20 per cent of world power by 2020 ind power could meet about a fifth of the world’s electricity demand within 20 years, environmental watchdog Greenpeace predicted in its recent report. Steve Sawyer, secretary general, global wind energy council said, “The global market for wind power grew at an average of 41.7 per cent in 2009, beating average
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annual growth of 28.6 per cent over the past 13 years.” The report’s ‘advanced scenario’ projects the world’s combined installed wind turbines would produce 2,600 terawatt hours (TWh) of electricity by 2020, equal to 11.5-12.3 per cent of the total power demand. The report also says that by 2030, wind energy would produce 5,400 TWh-18.8 to 21.8 per cent of
the world’s power supply. The more conservative “reference” scenario based on figures from the UN’s International Energy Agency saw wind power triple in the next decade to cover up to 4.8 per cent of electricity. The ‘moderate’ scenario based on current industry figures would see wind power meet up to 9.5 per cent of the world’s power demand by 2020, the report says.
EVENTS
Abroad
Machine Tool Indonesia Focus: Tools & Tooling Equipment When: December 1-4, 2010 Where: Jakarta International Expo (JIExpo), Jakarta, Indonesia Tel: + (44)-(20)-78402100 Fax: + (44)-(20)-78402111 Tire Technology Expo 2011 Focus: Tire design and manufacturing When: February 15-17, 2011 Where: Cologne, Germany Tel: +44 (0) 1306 743744 Fax: +44 (0) 1306 742525 ProMat 2011 Focus: Manufacturing, Engineering, Material Handling, Supply Chain, Logistics, Distribution When: March 21- 24, 2011 Where: McCormick Place South, Chicago, IL US Tel: 800-345-1815 Fax: 704-676-1190 Hannover Messe 2011 Focus: Industrial automation, Motion, drive & automation, energy, power plant technology, etc. When: April 4-8, 2011 Where: Hannover, Germany Tel: +49 511 89-31146 Fax: +49 511 89-31149 E-mail: info@messe.de National Manufacturing Week (NMW) Focus: Mechanical or industrial engineering When: May 24-27, 2011 Where: Melbourne Convention & Exhibition Centre, 2 Clarendon Street, Melbourne, VIC 3006 AU Tel: 02 9422 8921 Fax: +61 (02) 9993 8342
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PRESIDENT – APAC, HYDRAULICS GROUP, EATON CORP
HYDRAULICS CAPABILITIES IMPROVE SHOPFLOOR
PRODUCTIVITY “The hydraulics industry is making rapid strides towards augumenting efficiency and performance of its products. Hydraulics always has been the best choice for high power density applications, but new designs, materials and manufacturing technologies are extending that advantage like never before,” avers Shyam Kambeyanda, President – APAC, Hydraulics Group, Eaton Corporation, during an exclusive interaction with Prerna Sharma. Excerpts… INDIAN MANUFACTURING LANDSCAPE IN THE YEARS TO COME Today, India is on the driver’s seat. It can control the direction it will take. The opportunity in manufacturing is slated to be more skillintensive and the industry leaders foresee India as well-poised to take advantage of this. This is benefiting the job market as several firms are on the hiring mode. The country has steadily developed its manufacturing excellence. There is an increase in efficiency of the industry and it emerged leaner, fitter and more productive over the years. From power generation to construction of several modern roads to aerospace, every sector has a huge impetus. India is now recognised as an automobile manufacturing hub for its pioneering efforts in adopting modern technology and for allowing the entry of foreign players. The construction and agriculture markets are accelerating. The Road Transport and Highways Ministry has proposed priority sector status to road development, allowing private highway developers more funds from banks. With India’s rich talent pool, young population and the current generation’s determination to break open in the international market, I am quite hopeful that the current Indian manufacturing sector, with its structured and new lean look, will stand up and deliver to the expectations in the next five years.
FACTORS THAT WILL MAKE INDIA WORLD’S FUTURE FACTORY The world is a big space and there are many players, not one. It is important for India to ensure that its primary focus is to fulfill the needs of the domestic market. Then only it can focus on augmenting the global market. India should continue to focus on delivering quality products and ensure high quality jobs. This will ensure our long-term advantage. India is and will continue to be the future factory of the world.
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PRESIDENT – APAC, HYDRAULICS GROUP, EATON CORP
SUCCESS STRATEGIES THAT CAN SET COMPANIES APART FROM THE REST It is important for companies to test their systems and processes regularly. This will help set a foundation to outgrow endmarkets. A strong foundation – unified around a common vision, mission, business system and core values – gives the right direction and sets a company apart from the rest. At Eaton, we do this through Eaton Business System (EBS). The Eaton Business System is a collection of all standardised best practices that we deploy and that we teach every employee about. It is the way we run our business. There are aspects of each of our businesses that are unique, but where they are not unique and can be standardised, we try to find the best practice or process. EBS is at the heart of our strategy for becoming a premier diversified industrial organisation.
A GREAT LEADER, ACCORDING TO YOU A great leader is a person who sets a vision that continues to hold. People like JRD Tata, GD Birla, JC Mahindra and KC Mahindra have set a vision and direction that other people shared and followed. In India, Mahatma Gandhi was among the greatest leaders. He has formed and led a great team, which shared his vision. His vision was not only to achieve freedom but achieve it in the right way – by maintaining religious harmony and following nonviolence. Whatever were the circumstances, he did not waver from his belief. This vision resonates with Eaton’s valuesbased business model. We believe in ‘Doing business right’. We have been living it for years, as it is central to our vision to become the most admired company in our marketspace.
REASONS BEHIND SHIFT FROM DEVELOPED COUNTRIES TO DEVELOPING REGIONS BRIC countries were engines of global growth even before the acronym was coined in 2001. China and India have a long history of being strong players in the world economy. In the 18th century, India was the second-largest economy contributing more than 20 per cent of total world output. After 1991 economic reforms, India has begun to steadily re-integrate into the
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global economy. Brazil’s booming agricultural sector, Russia’s vast natural resources, China’s and India’s accelerating growth provide great opportunities for growth. The most important growth factor in these economies is the focus on progress and people. The diverse population provides a competitive advantage. Other factors also include stable government and opening economies. It is true that the focus has shifted to BRIC, but we should not forget the West. The key is to focus on all. That is what precisely Eaton’s strategy is.
PERFECT INGREDIENTS TO SUCCEED IN THIS GLOBAL MARKETPLACE There are three major factors for our success in the global market – manufacturing excellence, leadership in technology and being a learning organisation. Protecting and improving the environment through innovation are among Eaton’s highest priorities. Eaton’s businesses offer a wide range of products & services that help our customers conserve energy and manage power for greater efficiency.
CONTRIBUTION OF HYDRAULICS & PNEUMATICS TOWARDS IMPROVING PRODUCTIVITY ON THE SHOPFLOOR Hydraulics capabilities contribute immensely towards improving productivity on the shopfloor. Metal forging or metal cutting requires precision and hydraulics provides the precision. Hydraulics products help in achieving fast-paced actions, handling heavier loads, ensuring consistencies, achieving high degree of accuracies & tolerances, artificial intelligence, controllability, higher efficiencies, and importantly, lower fatigue levels among workforce. Thus, it has a significant impact on a manufacturing set-up with costeffectiveness, better quality of products and faster deliveries.
LATEST TRENDS SHAPING UP IN THE SEGMENT The hydraulics industry is making rapid strides towards augumenting efficiency and performance of its products. Hydraulics always has been the best choice for high power-density applications, but new designs, materials, and manufacturing technologies are extending that advantage
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like never before. But, good as they are, these new components are destined to form a smaller piece of the overall hydraulics industry pie. The real action in the coming years is going to be focussed not on components, but rather on integrated system solutions that marry hydraulics & electronics in increasingly innovative ways. In hydraulics, the latest trends point to applications in electronics, high pressure systems, compactness and systems without foundations. Customers are looking for the best usage of space, better power density, energy-efficiency and hydraulics aid in achieving these objectives. Another upcoming trend is the marriage of hydraulics & electronics that will deliver smarter products, that combines the intelligence of electronics with the power density of hydraulics to enable all of these applications and many more that have not ever been thought of yet.
HYDRAULICS MARKET IN INDIA VIS-À-VIS OTHER COUNTRIES There are high expectations from India. India is making investments in infrastructure like dams, roads, airports, power generation and connectivity. We see many of the significant sectors showing positive growth like manufacturing, automotive, power and aerospace. We supply to all these segments. Eaton’s India operations play a leading role in driving the company’s manufacturing capabilities and professional services in the region. India not only offers a huge market opportunity in itself, but it also serves as a strategic location to enhance Eaton’s global competitiveness.
THE CRUCIAL IMPORTANCE OF DESIGN IN SELECTING SUITABLE HYDRAULICS EQUIPMENT Design plays a crucial role in selecting hydraulics equipment. Understanding customers’ and users’ needs and translating them into machine design, integrating them to a system solution, achieving the optimum cost, energy efficiencies are the key elements of designing a product. Besides product design and developments, application engineering plays a vital role for the right selection of the products & components. Eaton’s engineering centre in India offers unmatched design capabilities for all the
PRESIDENT – APAC, HYDRAULICS GROUP, EATON CORP
businesses across the globe and hydraulics design team is one of the largest. This gives Eaton the strength and capability to develop machine-specific adopted products. One of our recent successes has been to design a hitch valve, which meets the Indian application conditions.
PARAMETERS THAT NEED TO BE KEPT IN MIND WHILE SELECTING SUITABLE HYDRAULIC EQUIPMENT Major things to look for while selecting suitable hydraulics equipment for a particular application are the capacity/flow, pressure, torque, power/energy consumption, envelope size/ footprint, noise level, emission norms and system cleanliness. Eaton provides the hydraulic equipment to meet customers’ most demanding standards for performance, safety, reliability and comfort. Eaton is one of the few companies, which has the capability to offer system solutions for all market segments. The products are highly engineered items and meet all the specifications, norms and the mentioned requirements.
It is important for companies to test their systems and processes regularly. This will help set a foundation to outgrow end-markets. A strong foundation – unified around a common vision, mission, business system and core values – gives the right direction and sets a company apart from the rest. NEW AGE ENERGY-EFFICIENT EQUIPMENT Hydraulics have won wide acceptance for factory and mobile applications. Traditional strengths of this key technology are centered around power, strength, durability and control. All hydraulics equipment essentially need to fit into the prescribed energy efficiency norms by default. The end users/OEMs/ consultants need highly energy-efficient machines, so that the running cost of power is kept low and consequently the total cost of ownership comes down. Eaton is answering this need of mobile hydraulics through the development of new smart electro-hydraulic technologies that shrink the footprint of hydraulics systems, improve their performance and energy efficiency and reduce emissions. These technologies provide equipment manufacturers greater design flexibility to achieve the goal that every customer desires: More function, less fuel. Our hydraulics products provide high durability, low noise vibration and harshness (NVH) levels, and newer technologies like hydro-electric applications are making systems more intelligent besides reducing overall costs. We also think that cost-effective utilisation of renewable energy resources like wind, hydropower and ocean wave power will depend on even more sophisticated hydraulics systems to capture, transmit and control the energy these systems generate.
FUTURE EXPANSION PLANS We will continue to concentrate on our existing customers as well as look for new customer base and emerging market segments, we also aim at our business, both organically and inorganically.
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PARALLEL HYDRAULIC HYBRID SYSTEMS
PARALLEL HYDRAULIC HYBRID SYSTEMS: Gaining A ‘Green’ Edge ............................................62 HYDRAULIC EQUIPMENT: HOSE VS. TUBE: Taking The Right Call .............................................69 HYDRAULIC REBUILDS: Hauling Monetary Gains ..........................................................................74 PNEUMATIC SYSTEMS: Compressing Energy Consumption ..........................................................78 TRENDS & TOOLKIT: Gauging What’s Next In Hydraulics .............................................................82 CASE STUDY: Eaton Hydraulic Motor - Speeding Operations, Maximising Output ........................87 TIPS & TRICKS ..................................................................................................................................88
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PARALLEL HYDRAULIC HYBRID SYSTEMS
GAINING A ‘GREEN’ EDGE Hydraulics offers a distinct advantage in the hybrid landscape due to superior power density as compared to competing technologies. When a hydraulic hybrid is a parallel system that supplements a conventional drive train, a fleet owner realises additional advantages over a series hybrid system that replaces the drive train. The benefits include customisation of performance characteristics, retrofitting the hybrid onto an existing vehicle and increased mission reliability, thereby giving parallel hydraulic hybrid system a green edge. ydraulic hybrid technology has so far been aimed at delivery and refuse trucks, primarily to reduce fuel consumption. For the refuse industry, hydraulic hybrids hold key advantages, particularly in terms of power density. Two major delineations exist for hybrid systems namely hydraulic vs. electric and parallel vs. series. To be more specific, hydraulic and electric hybrid technology refers to the energy transfer and storage means of a particular design. The terms parallel and series speak of the arrangement of hybrid components with respect to traditional driveline
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components. Each offers distinct advantages and Parallel Hybrid operating characteristics. Electric hybrids are common in today’s Engine Transmission Drive Shaft marketplace and are assumed to be widely understood. In contrast, the concept of a hydraulic Figure 1: Parallel hybrid block diagram hybrid may be a relatively new one. Generally speaking, hydraulic hybrids have the same types of Engine Series Hybrid components as electric hybrids. Hydraulic pumps and motors replace electric generators and motors. Accumulators supplant batteries, and Figure 2: Series hybrid block diagram
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Drive Axle
Drive Axle
PARALLEL HYDRAULIC HYBRID SYSTEMS
Power Capacity (kW)
hoses substitute the wires. Each a hybrid powered launch. In this Continuous Power Comparison approach has advantages and option, the vehicle releases 400 disadvantages for a given duty available hybrid energy Hydraulic Hybrid cycle. preferentially and uses engine 350 Electric Hybrid Parallel hybrid systems torque as needed to match the 300 supplement the conventional acceleration of a baseline vehicle. drive train of the vehicle (Fig 1). 250 The baseline launch curve is a A parallel hybrid selectively adds standard reference point for 200 and absorbs energy to the both parallel and series hybrids 150 driveline during acceleration and in order to maintain vehicle braking respectively. A parallel performance with reduced fuel 100 hybrid vehicle can continue to consumption and emissions. For 50 function with degraded a series hybrid, the desired performance even if the hybrid vehicle performance 0 system is not functional. determination becomes the 0 5 10 15 20 25 Vehicle Speed (kph) Series hybrids replace the design target for the system and conventional drive train and is weighed against system cost as Figure 3: Example of electric and hydraulic power capacity encompass the entire need of the design is established. For a power transmission and energy parallel system, the hybrid management for the vehicle (Fig 2). Fuel quickly store and release kinetic energy (Fig powered launch requires a torque limit savings are largely due to engine 3). Electric hybrid systems are limited by the signal to the engine, so that baseline management in addition to brake energy capacity to capture energy during a braking acceleration performance is matched. This regeneration. event. The area between the curves limit is sent until the hybrid indicates a Although a series hybrid can offer more fuel savings through increased engine The US has roughly 1,50,000 refuse trucks supporting garbage and management, a parallel hybrid offers several recycling collection routes. A typical refuse truck weighs 30,000 kg (65,000 advantages of its own, including options to lbs), services 1,000 households per day, travels 190 km (120 miles) per day, improve vehicle acceleration, the ability to easily retrofit to existing vehicles, and 250 days per year. These trucks typically consume between 34,000 and greater vehicle mission reliability. For 45,000 litre (9,000 and 12,000 gallons) of diesel each year. To reduce the hydraulic hybrids, which are not traditionally high yearly fuel consumption and realise the objective of low-fuel economy, used as drive systems for on-highway refuse vehicles are ideal candidates for hybridisation. vehicles, an early advantage with vehicle mission reliability is important to spread represents lost energy capture potential, adoption into the refuse industry. transition, as it begins to near the end of resulting in lower realised fuel savings. available stored energy. Fuel savings occur THE HYDRAULICS Additionally, if an electric hybrid is placed entirely during vehicle launch with this ADVANTAGE between the engine and transmission, option. Parallel hydraulic hybrid systems save fuel energy and performance will be lessened Tandem launch: The second mode offered by assisting the launch of a vehicle with by shift interruptions. The power density by a parallel hybrid is a tandem launch, kinetic energy recovered during braking. In advantage of hydraulics may be lessened which releases hybrid energy in tandem conventional on-highway vehicles, kinetic with larger electric motor configurations, with the engine power. In tandem mode, energy is wasted during the braking process but the resulting size, cost and weight no torque limit command is issued by the in the form of heat generated from brake become impractical for the application. hybrid. Without a limit, both the engine and pad friction. Hydraulic hybrids offer a distinct hybrid will operate independently to launch PARALLEL HYBRID BENEFITS advantage over electric hybrids as the vehicle based on input from the driver. The first advantage offered by a parallel regenerative braking systems due to This mode increases the vehicle acceleration hybrid over a series system is the option to superior power density. This advantage is rate from its baseline performance, and improve vehicle acceleration over a baseline highlighted in severe duty cycles such as saves fuel through the reduced work being vehicle. The second is the retrofit capability refuse trucks, where the power demands performed by the engine as well as the and last but not the least reliability impact. for braking and launch are extreme. Parallel reduced vehicle cycle time. Tandem launch Vehicle Acceleration Options hydraulic hybrids can return up to 70 per is natural for parallel hybrids since both the A parallel hybrid can be configured on a cent of braking energy and offer a 15-30 engine and hybrid are connected vehicle in different ways for optimising per cent improvement in fuel economy in independently to provide torque during vehicle performance and fuel savings for the refuse trucks, based on duty cycle. acceleration. A parallel hybrid has the end-user. Three distinct options for vehicle Hydraulic hybrids display power density capability to meet baseline vehicle acceleration are as follows: advantage and use a bladder or piston acceleration, or an increased level of Hybrid powered launch: The first vehicle accumulator to store vehicle kinetic energy, acceleration without the need to change acceleration option with a parallel hybrid is which can accept high oil flow in order to component hardware.
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PARALLEL HYDRAULIC HYBRID SYSTEMS
For series hybrids, the vehicle acceleration capacity is determined by the core design of the system. This is true because the hybrid has the single direct connection to the wheels to provide acceleration torque. Increased acceleration capability from a baseline vehicle would most likely add cost to the series hybrid, especially if the acceleration increase required a corresponding increase in hybrid component size. However, any increase in the design would need to be weighed
engines, compressed natural gas (CNG) or liquified natural gas (LNG) engines may also be considered. Typically, the use of CNG or LNG engines involves significant acceleration performance compromises. However, the addition of a parallel hydraulic hybrid would return acceleration characteristics inline with non-hybrid diesel drivelines.
a parallel hybrid simplifies design and reduces operational effects from other vehicle subsystems.
RELIABILITY IMPACT
Under this comes various aspects pertaining to reliability that include: Reliability lifecycle: The reliability of a vehicle is often characterised using the bathRETROFIT CAPABILITY tub curve model (Fig 5). The bath-tub curve Parallel hybrids may be installed to new or plots the instantaneous failure rate of a existing vehicles due to modular system vehicle throughout its lifecycle. Two key customer wants are illustrated by this model; high reliability or conversely low unreliability, and long product life. Unreliability, from the customer’s perspective, is the area under the curve during the early and useful life periods. Failures during this period may involve unplanned maintenance, unavailability of equipment and mission unreliability. Of these, the customer is most sensitive to mission unreliability. For a refuse truck, mission unreliability is the probability of not being able to complete a scheduled route during the course of a work day. The consequence of a mission critical failure is often expensive and requires vehicle towing, rescheduling of other equipment, Figure 4: Parallel Hybrid Architecture and potential for discontinuity of service. Life is illustrated by the location of the design. In other words, a parallel hybrid can against the value delivered to the application. end-of-life period, or the duration of the be integrated into a vehicle without This evaluation would be difficult within the useful life. Failures during this period maybe extensive alterations to the vehicle or refuse industry due to disparity of duty cycle considered as planned maintenance (i.e. required design changes from other major characterisation. The number of fleet overhauls), numerous unplanned vehicle subsystems. A parallel hybrid is owners who desire increased acceleration maintenance actions, and may warrant connected to the vehicle’s drive train capability is not clear, so the added expense decommissioning of equipment based on between the transmission and the differential to a series system may not make sense. repair cost. It is desired, for major sub(Fig 4). However, the option of improved systems such as driveline components, to Most class-8 vehicles have a mid-bearing, acceleration is available for no additional avoid premature end-of-life failures. That is which is replaced with the installation of the cost with parallel hybrids. to say, for a particular component to reach parallel hydraulic hybrid. The primary design Reduced baseline acceleration capacity: A end-of-life significantly prior to the desired third option exists to reduce the or expected life of the baseline vehicle acceleration Parallel hydraulic hybrid systems supplement a vehicle’s equipment. capacity and further increase In either case, useful life or drive train while a series system replaces it. Although a end-of-life, it is always beneficial fuel savings enabled by the series hybrid has the potential for additional fuel savings for the customer to lower the benefits of a hydraulic hybrid. With this option, reduced through engine management, a parallel hybrid can failure rate of equipment and it baseline capacity is offset by is especially important to lower improve vehicle acceleration, retrofit to existing trucks, the probability of mission critical torque from the parallel hybrid and reduce end-user risks of vehicle downtime. during launch. Baseline vehicle failures. Parallel hybrid acceleration is achieved with architecture positively impacts requirements for installation of a parallel both the engine and hybrid, but fuel savings both these metrics by reducing the average hybrid are space on the chassis and and emissions reductions are realised overall operating stress on mission critical bracketry to support the system. Controls through improved subsystem efficiencies in components, and by minimising the impact requirement includes the electrical addition to brake regeneration from the of hybrid-related mission critical failure connections, a hybrid display in the cab, and hybrid. The parallel hybrid vehicle may modes through hybrid system diagnostics. an engine software flash to acknowledge exhibit reduced performance if the hybrid is Reduced stress on driveline components: the hybrid as a subsystem. Independence of not active. In addition to smaller-sized diesel A parallel hydraulic hybrid system can
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PARALLEL HYDRAULIC HYBRID SYSTEMS
Failure Rate
significantly reduce brake power until the condition no longer and heat generation, engine exists, the vehicle is turned off, power output, and torque or till the next vehicle service. converter and transmission Using this management scheme, power throughput. Simulations hybrid uptime can be maximised indicate that a typical truck while protecting the system. running the environmental THE GREEN protection agency (EPA) refuse TECHNOLOGY duty cycle in the US will reduce Early Useful End of BENEFIT brake power and heat generation Life Life Life Parallel hydraulic hybrids are a 61 per cent, engine power Figure 5: A typical Bath-tub Curve Model valuable green technology with output 18 per cent, and torque an attractive risk/reward ratio converter and transmission extending into severe duty applications. throughput 17 per cent (Fig 6). failure modes of the truck when the hybrid The power density advantage of hydraulics Knowing that failure rates of equipment is decoupled. enables a more effective brake energy can be characterised generally by an Control diagnostics enables the parallel recovery over competing electric hybrids. operating stress level and time (the SN benefits of the system to be realised Hydraulic hybrids can return up to 70 per curve), a conclusion can be made that the seamlessly with a vehicle’s operation. cent of energy normally lost in braking in overall mission critical failure rate of the Embedded control logic reacts to given the form of heat. Parallel hydraulic hybrids driveline components will be lessened by conditions to not only maintain a truck’s can improve fuel economy of refuse trucks the presence of a parallel hybrid. The same mission reliability, but also determine and by up to 30 per cent and reduce can be said for end-of-life failures, where the same Although a series hybrid can offer more fuel savings emissions by 20 per cent based driveline components are through increased engine management, a parallel hybrid on duty cycle. This improvement offers a significant amount of fuel expected to last longer under a offers several advantages of its own, including options savings across the active global given duty cycle. As an to improve vehicle acceleration, the ability to easily refuse fleet, especially in the US, alternative to this benefit, driveline components can be retrofit to existing vehicles, and greater vehicle mission where gross vehicle weights can exceed 27 tonne. downsized, reducing initial reliability. Parallel hydraulic hybrid investments and further systems supplement a vehicle’s bringing down the fuel drive train while a series system replaces it. consumed for a given duty cycle. preserve the health of the hybrid system in Although a series hybrid has the potential Mission reliability through diagnostics: order to maximise performance and service for additional fuel savings through engine Parallel hybrid architecture relies on a life. The electronic control unit (ECU) of a management, a parallel hybrid can improve traditional engine and transmission driveline parallel hybrid does not treat all fault vehicle acceleration, retrofit to existing arrangement to transmit power to the drive conditions equally, but rather is programmed trucks, and reduce end-user risks of vehicle axle. The hybrid function couples to this to respond based on the suspected cause, downtime. Severe duty applications, such driveline by transfer case and clutching behaviour, and resultant effect of the fault as refuse trucks, will experience benefits in arrangement, allowing the majority of condition. For a brake regeneration hybrid fuel consumption, emissions reduction, hybrid components to decouple. system, the main breakdown of responses reduced maintenance expenses and Decoupling the hybrid from the driveline for the ECU is to shut down the system improved performance from the then becomes the commercialisation of parallel hydraulic key function in Simulated Percent Mean Power Reduction from Parallel Hydraulic Hybrid hybrids. minimising hybrid (EPA Refuse Duty Cycle) impact on mission 70% Vincent Duray, Chris Arneson, Robert Isaacs and reliability. The 60% Michael Stoner, Eaton Corporation, Eden Prairie, remaining hybrid ISL330_TC421_A3000 MN, USA component is the 50% transfer case 40% through-shaft. In many applications, 30% MANUFACTURING ZONE: the transfer case National Manufacturing through-shaft is 20% Investment Zones replacing a carrier 10% Propelling Manufacturing b e a r i n g arrangement Growth 0% Brake Power Engine Power Torque Converter Transmission resulting in few, if Power Power any, additional on pg. Figure 6: EPA refuse duty cycle simulated mean power reduction from hybrid. mission critical
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Bosch Rexroth (India) Ltd
HYDRAULIC EQUIPMENT: HOSE VS. TUBE
TAKING THE RIGHT CALL There has been a constant debate over the use of hydraulic hoses and hydraulic tubes in hydraulic equipments. However, what many fail to understand is that both are different tools meant for different functions. The key lies in critically examining the functionality required and take an informed decision by weighing the merits and demerits. hat do lifting chains, bladder-type accumulators and hydraulic hoses have in common? Well, they typically have only one mode of failure – and that is catastrophic. One minute they are working as they should, and the next thing one knows, something has gone wrong with them. Definitely, hoses can leak from around their ferrules and show obvious signs of abrasion, both of which are early warning signs that a change would be prudent. But even under these conditions, estimating their remaining service life is virtually impossible.
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THE HOSE TROUBLE Beyond the fact that their service life is finite and difficult to estimate, other disadvantages of hydraulic hoses when compared to tubes include: They expand and stretch under pressure. This flexing requires extra volume and adds to machine cycle time. They are expensive and typically have a limited operating temperature range. Their requirement for regular replacement makes them a source of contaminant ingression.
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HYDRAULIC EQUIPMENT: HOSE VS. TUBE
There is limited space (particularly in mobile hydraulics), and relative movement between machine components and superstructure. Noise and vibration need to be suppressed. Despite the above disadvantages, hoses are a necessary feature of most hydraulic systems. This is because the alternative conductor – tubes – cannot be used where: There is limited space (particularly in mobile hydraulics) and relative movement between machine components and superstructure. Noise and vibration need to be suppressed. However, hose is often substituted for tube when it is not necessary. This is because a hose assembly can usually be fabricated much faster than a tube assembly. And, the additional labour cost required to fabricate and install a tube can make hose appear to be a cost-effective solution. But this belies the fact that the same hose may need to be replaced many times over the life of the machine. This false economy is similar to buying the machine itself on initial capital outlay alone without considering its total life-of-ownership cost.
HYDRAULIC TUBING Hydraulic tubing has some compelling advantages of its own. One of these is its superior heat transfer, especially if it is painted. One aspect of heat transfer is thermal radiation. The total radiation from an object is the sum of its reflection, emissivity and transmission of heat through the object. When hydraulic tubing is painted, it reduces its reflectance and increases its emissivity, enabling better heat rejection, as illustrated by the following case study: An industrial hydraulic installation was originally designed to operate at 1200 psi and at a maximum operating temperature of 1200F (490C). Zinc dichromate-coated steel tube distributes fluid from the 600litre reservoir to the various stations around the plant. Over the years, the system had been added to (without any increase in installed cooling capacity) – the point where it was now overheating in the summer months. Because the system operated satisfactorily for 10 months in a row, the management did not want to spend the money necessary to upgrade the cooling
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Instructions to select the appropriate hydraulic pump Assess the budget before beginning to shop for the hydraulic pump. Remember that these pumps will also continue to accrue certain maintenance costs, even after their initial purchase, so making sure they fit well within the budget is important. Determine precisely which jobs will be assigned to the new hydraulic pump. With pumps ranging from 100 psi to 75000 psi and the ability to boost the pressure with certain gases, there are literally millions of uses for these versatile machines. Choose between the various kinds of hydraulic pumps available for both industrial and home use. External gear pumps are most often used in machine tooling while internal gear pumps are better able to handle heavier, more viscous liquids. Lobe pumps are great for use in foodhandling machinery, as they are able to process near-solid or solid materials. Select vane pumps for use with a liquid having low viscosity and nonlubricating properties, such as gasoline. Decide how much pressure output is needed from the pump. Overpowering of the pump can cause harm to the equipment. Inspect all the equipment that will be used along with the hydraulic pump to make sure all are compatible. Decide whether there is a need for continuous or periodic power. Some pumps are designed to give constant pressure while others are designed for intermittent use. Select a pump with the appropriate pressure rating, volumetric-flow output, speed, efficiency and fluid compatibility for the job. Review which components need to be purchased separately in order to use the hydraulic pump. Hoses, filters, air regulators and exhaust mufflers will be needed to make the hydraulic pump set-up complete. Check to see whether the chosen pump includes a power source. Most pumps are purchased separately, with no power source included. If this is the case with the pump, the user will need to find out what kind of source it needs and purchase it as well.
system. So, one of the maintenance personnel who was familiar with the thermal radiation theory suggested painting the hydraulic system’s tubing. Before proceeding, the maintenance team conducted a test. Team members applied electrical tape to two of the hydraulic tubes, and using an infrared camera, they measured the difference in temperature between the taped and untaped areas. They found that the taped areas on the tubes were 70F (40C) cooler than the untaped areas. This gave the maintenance team the confidence to proceed with the idea. Because the rest of the hydraulic system
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was painted flat white, the tubing was painted the same colour. A week and 12 cans of spray paint later, the system was running 100F (5.50C) cooler. This might not sound much, but the end result meant that the hydraulic system could now operate through the two hottest months of the year without overheating. It also meant that the need to increase installed cooling capacity was at least deferred, if not eliminated.
MANAGING HOSE REPLACEMENT Despite the superior reliability of tubing, hoses are a necessary feature of most
HYDRAULIC EQUIPMENT: HOSE VS. TUBE
QUICK TAKE Hydraulic tubing has some compelling advantages of its own. One of these is its superior heat transfer, especially if it is painted. When hydraulic tubing is painted, it reduces its reflectance and increases its emissivity, enabling better heat rejection Despite the superior reliability of tubing, hoses are a necessary feature of most hydraulic machines. hydraulic machines. And unlike tubing, hoses come under maintenance item, one which usually gives no warning of impending failure. So in a condition-based maintenance environment, it becomes essential to proactively manage the replacement of hydraulic hoses. Well, there are two considerations, which should be the foremost in one’s mind: the downtime cost of in-service hose failures, and not treating all hoses equally. For example: Two years ago, a mining client faced problems on account of ad-hoc replacement of hoses that failed in service on hydraulic shovels, resulting in machine availability falling to as low as 65 per cent. In this company’s case, when a multimillion dollar shovel stops, so does a multi-
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million dollar fleet of haul trucks. Downtime is a major cost. So, it implemented a hydraulic hose replacement programme. This involved changing every hose on the machine every 18 months. Whenever a shovel was down for planned maintenance, a portion of the hoses was changed, beginning with the oldest first. The plan worked appropriately and machine availability was soon back above 90 per cent. Of course, largediameter, multi-spiral hydraulic hoses are not cheap. However, hose expense paled to insignificance when compared to the cost of the downtime it prevented. By any economic measure, the hose replacement programme was a great success. But, it did have a fundamental flaw. It was treating all
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hoses the same. And, it was highly unlikely that each hose on the machine was equally responsible for an equal proportion of the in-service failures and downtime. A relatively small percentage of hoses were responsible for the majority of the in-service failures and downtime. In fact, the available data revealed that less than 20 per cent of the hoses on the machine were responsible for nearly 90 per cent of the failures. Armed with this information, the hose replacement programme was optimised to reduce unnecessary hose change-outs.
THE FINAL SELECTION Hydraulic hoses and tubes are not interchangeable and are used for different jobs. The benefits of hose – which make it a necessary feature of most hydraulic machines – come at a cost. It has a finite service life and usually gives no warning of failure. This makes its maintenance difficult. For these reasons, hose should only be used where tubing cannot work. Brendan Casey, Industrial Hydraulics Equipment Expert, has more than 20 years experience in the maintenance, repair and overhaul of mobile and industrial hydraulics equipment.
HYDRAULIC REBUILDS
HAULING MONETARY GAINS Rebuilding of hydraulics equipment involves replacing the necessary parts that would enable it to last long and function like a new one. Therefore, it is important for a user to decipher whether to spend money on rebuilding an equipment or rather purchase a new one. The key to cost savings lies in making the right choice.
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HYDRAULIC REBUILDS
The economics of proceeding with rebuilding ultimately depend on the cost of the repair relative to the cost of a new component. In many cases, rebuilding or repairing a component can result in significant savings when compared to the cost of purchasing a new one. As a rule, the more expensive a new component is, the more likely that a repair will be costeffective. A component’s rebuild cost is determined by many factors including: Extent of wear or damage to the component Facilities and expertise of the repairer Repair techniques employed. If one is responsible for keeping one or more hydraulic machines running and is serious about minimising operating costs, then at some point, a hydraulic component will need to be rebuilt by a specialist. There
component to be repaired, it can be exchanged with a remanufacturing unit from the dealer’s stock. It is important to understand that the exchange price is not necessarily based on the cost of repairing a particular component. It is usually based on the average rebuild cost for that component plus an inventory charge, and may be conditional on certain parts of the component being reusable. Because the dealer’s exchange price is based on an average rebuild price, if a component was to be repaired, it could cost more than the exchange price, or it may cost less. Of course, machine downtime costs money and the main advantage of an exchange programme is that downtime is minimised. If downtime is not a concern, then it is wise to obtain a repair quote for the component before opting for an exchange
Best practices Most automotive-lift needs can be satisfied with a pump from about 1300 to 2000 psi, while pumps designed to operate tools that need to generate lots of torque may need more than 10,000 psi. Smaller jobs like HVAC pumps, may only require around 600 psi. Always maintain the hydraulic pump properly. These pumps can become blocked or clogged, causing serious damage to equipment and users if not checked regularly.
are generally three options for rebuilding: the machine dealer, the component manufacturer, or an independently-owned hydraulic shop.
MACHINE DEALERS
ebuilding of a hydraulic component calls for reworking on or replacing all parts necessary to return the component to ‘as new’ condition in terms of performance and expected service life. Simply put, a rebuilt component should perform as well and last as long as a new one.
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With hydraulic component repairs, the capabilities of machine dealers vary. Some have the necessary expertise and equipment to perform most hydraulic rebuilds in-house, while others are completely reliant on outside suppliers to provide this service. If a dealer relies on a third party for repairing hydraulic components, it could end up costing more. If machine downtime is an issue and the dealer offers an exchange or ‘remanufacturing’ programme, this can be an attractive option. Exchange Programmes: The benefit of an exchange programme is that the dealer carries inventory of rebuilt components. Therefore, instead of waiting for a
unit. This is one reason for scheduling component change-outs upon completion of their expected service life. If component rebuilds can be scheduled when machine downtime is not an issue, it will not be necessary to pay a premium for an exchange unit.
HYDRAULIC COMPONENT MANUFACTURERS When a hydraulic component needs to be repaired, a logical option is to send it to the company that manufactured it. It should be noted here that the shop being referred to is a repair shop owned and operated by the hydraulic component manufacturer, rather than an independent hydraulic shop that is an authorised repairer or distributor of the manufacturer’s products. By using the services of a component manufacturer, a repair in accordance with OEM standards can be achieved, but in some cases, this can mean foregoing the opportunity to save money. Here is a case-in-point.
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HYDRAULIC REBUILDS
Six Easy Steps to Maintain Hydraulic Equipment It is important to first get familiarised with how to use an infrared thermometer, which is also called a heat gun. If not available, one can purchase it for a modest price. Next, with a permanent marker or paint stick, draw a small target on the hydraulic tank below minimum oil level and away from the cooler return. Label it 1. This marks the spot to take the tank oil temperature readings. The purpose of these targets is that regardless of who takes the temperature readings, they will be taken from the same place each time. If the system is a closed-circuit hydrostatic transmission, mark a convenient location on each leg of the transmission loop and number those locations as 2 and 3. Skip this step for open-circuit hydraulic systems. Next, mark a target on the heat exchanger inlet and outlet and number these 4 and 5, respectively. This records the temperature drop across the cooler. The benefit of this step is that if the oil flow rate through the exchanger and the temperature drop across it are known, the actual heat rejection of the exchanger can be calculated. And if the system is overheating, knowing the actual heat rejection of the exchanger can help determine whether the problem is the result of an increase in heat load (due to an increase in internal leakage, for example) or whether the problem lies in the cooling circuit itself. For example, if a hydraulic system with an input power of 100 kilowatts is overheating, and the actual heat rejection of the exchanger is 30 kilowatts, then the efficiency of the system has fallen below 70 per cent. Therefore, an increase in heat load is the likely cause. On the other hand, if the exchanger is rejecting only 10 kilowatts of heat (which in this example equates to 10 per cent of input power), then it is likely that there is a problem in the cooling circuit or there is insufficient installed cooling capacity. Install a pressure gauge or transducer to record operating pressure, if one is not already available. If the system is a closed-circuit hydrostatic transmission, install a similar device to record charge pressure. With that accomplished, now draw up a table to record the date, time, ambient temperature, operating temperatures and operating pressure(s). It needs to be noted that there is little point in recording the temperature across the heat exchanger, if the fan or water pump is not running. And, charge pressure is relevant only to closed-circuit hydrostatic transmissions. CASE-IN-POINT Suppose a radial piston motor has been removed from a hydraulic machine and shipped to the motor manufacturer for repair. Upon dismantling the motor, it is discovered that several of the pistons and bores are badly scored as a result of contamination. The manufacturer suggests that because of this damage, the motor housing and all of its pistons need to be
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replaced. As a result, the manufacturer’s price to repair the motor is almost as much as a new one. The client may not want to buy a new motor, if he can avoid it, so he decides to get a second repair quote. This time he takes the unit to an independent hydraulic shop. After inspecting the motor, the repair shop suggests that the motor can be rebuilt for around 60 per cent of the cost of a new
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one – a significant saving on a $10,000 motor. The low cost is possible by employing a money-saving repair technique that involves machining the piston bores to remove scoring, and fitting a set of oversize pistons, thereby salvaging the housing. The oversize pistons are non-genuine or aftermarket parts; however their quality has been proven in a large number of rebuilt units. The repair shop’s confidence in this method of repair is supported by a 12-month warranty.
INDEPENDENT HYDRAULIC SHOPS The aforementioned example highlights the type of savings possible by using a reputable, independently-owned hydraulic shop to carry out the component rebuilds. The motor manufacturer did not offer this low-cost solution because the oversize pistons are non-genuine parts, therefore the repair is not as per OEM standards. However, just because a repair is not carried out according to OEM standards does not mean the rebuilt component would not perform and last like a new one. It is important to distinguish between a properly engineered and proven repair technique that will save money and a dubious repair that is likely to cost twice as much in the long-run. It is important to ask two questions before opting for rebuilding equipment at a repair shop: Has the repair technique been proven successful in terms of performance and achieved service life? Is the repair covered by warranty? If the repair technique is unproven, or the shop offering the repair is not willing to back it up with a warranty, think twice before proceeding. There is a need to make an informed decision based on the amount of money the repair technique will save if it works, versus the cost if it does not. The repair shop may be willing to share some of the risk involved in finding out, given that if the technique proves to be successful, it can offer the same solution to other customers. These issues should be discussed with the repair shop before making a decision. Brendan Casey, Industrial Hydraulics Equipment Expert, has more than 20 years experience in the maintenance, repair and overhaul of mobile and industrial hydraulics equipment.
PNEUMATIC SYSTEMS
COMPRESSING
ENERGY CONSUMPTION When it comes to conserving energy by improving the efficiency of pneumatic systems, there are numerous opportunities for savings as a result of a high leak load, intermittent demand, and tubing size reduction among other issues. A few best practices in these areas can ensure huge returns from pneumatic equipment, be it money or energy.
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nergy consumption is one of the key factors that determine the efficiency of a machine or system these days. However, the energy costs generally differ as per
regional variations and over a period of time. But today, users in every region want to extract maximum gains from pneumatic equipment deployed by them in a costeffective manner. Here are four ways to boost pneumatic efficiency to get the most
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out of one’s pneumatic systems:
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BEWARE OF OVER-SIZED COMPONENTS
For decades, managers followed an interesting practice to always specify over-
PNEUMATIC SYSTEMS
sized dimension of actuators. If the need were for only 2-inch cylinder, then the specification would be the next larger size. Probably, at the same pressure, the larger actuator would bring more force to the task, and could better cope with heavier or misaligned loads. But, oversizing is equivalent to waste. The first way to increase energyefficiency is optimal dimensioning of the components used, thereby avoiding unnecessary air consumption due to oversizing. During the lifecycle of a machine, this adds up to a significant amount of money. Pneumatic components are available in a wide array of sizes, which provide optimal conditions for precise application dimensioning. A cylinder with an application-optimised diameter can reduce air consumption by at least 15 per cent, when compared to one with a commonly oversized diameter. Many vendors simplify the dimensioning with online calculation and optimisation programmes. Through some basic inputs, the practical result is clearly presented including technical data and recommended components. In typical installations, by using compact and economical designs with correctly sized cylinders & valves and optimised nominal flows, at least 15 per cent of the air volume can be saved. This equates to energy-related cost-savings of 15 per cent.
pneumatic functions at the point of use. Valves can mount directly to cylinders without hose connections. This direct connection eliminates pressure losses through long lines from the control cabinet to the pneumatic drive. In order to tackle problem areas in the harsh operating conditions, one needs to consider the decentralised valve units made of engineered polymers that are small, light, chemically resistant and able to withstand the harsh operating environment. Some valves and manifolds have sanitary designs and materials suitable for food processing, eliminating the requirement to house pneumatic valves in remote stainlesssteel enclosures with long tubes running to the actuators. Innovative pneumatics modules with high energy density offer the cycle time advantages of decentralised automation structures and also lower air consumption up to 35 per cent. These compact components are so small and lightweight that they can be integrated directly on the actuators.
– if components are sized correctly. It is important to monitor and ensure that machine pressure remains within designated limits to avoid wastage of energy.
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MINIMISE LEAKAGE
Every pneumatic system can save energy by avoiding leaks. Statistics suggest that the problem is widespread: an average facility has to manage 30-35 per cent leakage-related issues, if it has not taken recent action. Small leakages in compressed air systems can add up to significant costs. Valves and deteriorated seals are two common sources. Some valve designs, such as lappedspool valves with metal seals, have inherent internal leakage that is constant as long as air is supplied to the valve. Switching to comparable valves with soft seals can significantly reduce leakage. Another source of leaks is deterioration of seals. If standard seals are observed to degrade, consider using extreme-service seals like viton, teflon or polyurethane. AVOID USING EXCESS Modern air-preparation units are PRESSURE available with an integrated air-volume Pneumatic systems frequently lead sensor. The sensor emits an electrical pulse to energy wastage by supplying higher each time a specific volume of compressed pressure than what an actuator needs. For air has passed through the air-preparation instance, in many applications, cylinders package. either push or pull a load, but not both. Yet The electrical pulse signals can be most often, machines use the same totalled by the controller, and therefore, pressure for both extend and retract actual air consumption (and energy costs) REDUCE VOLUME BY strokes, which is extremely inefficient. can be calculated for the machine over a CUTTING DISTANCE Using pressure regulators to supply the period. This also enables users to detect BETWEEN increases in machine air VALVES AND consumption that indicate Every pneumatic system can save energy by avoiding developing leaks or nonACTUATORS Machine efficiency can be leaks. Statistics suggest that the problem is widespread: scheduled changes to the substantially increased by an average facility has to manage 30-35 per cent operating pressures for the reducing lengths of tubing runs motions of the machine. The leakage-related issues, if it has not taken recent action. real-time cost of leakage and between components. Thus, dead volumes would be over-pressurisation can be reduced and pressure losses could be right pressure for each task can lower counted, as can be the cost-savings from avoided through shorter tube lengths. energy consumption by more than 25 per correcting these problems. In addition, valve/actuator units can cent. For instance, ‘smart’ regulators Compiled by Sandeep Pai reduce tubing connections by 50 per cent combine digital control electronics with and cut energy consumption by 35 per proportional valves. They constantly cent. Besides, decentralised systems can compare preset pressure limits with actual VIEW FROM THE TOP: also yield faster response times and higher values to ensure exact metering. Shyam Kambeyanda, President cycle frequencies. This is because, Moreover, there is one concern to – APAC, Hydraulics Group, centralised valve manifolds are typically guard against – operators generally increase Eaton Corporation cumbersome, require long air lines, and supply pressure on regulators in the hope consume considerable amount of energy. of improving performance, but this Vendors now offer small, decentralised amounts to significant wastage of money in on pg. valves and manifolds that concentrate air and operating costs for no actual benefit
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TRENDS & TOOLKIT
GAUGING WHAT’S NEXT IN HYDRAULICS
The hydraulics industry has been at the threshold of progress over the years and most of the developments in this area are offering immense benefits to hydraulic equipment owners. But, it has come at a cost. Higher operating pressures and closer tolerances make the hydraulic machine more susceptible to wear and damage resulting from oil contamination and inadequate lubrication. This means proactive maintenance is essential for optimum reliability and performance of today’s hydraulic equipment. Here are some do’s and don’ts…
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onstant progress is part of life and it manifests itself in different ways. In engineering, it is in the form of technological advancements, with
machines and their component parts becoming stronger, lighter, cheaper, smaller, more powerful and efficient. Nowhere is this more evident than in the field of information technology (IT). In fact, according to Moore’s Law, the power of
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computer chips doubles every 18 months. At the same time, the cost of this extra computing power decreases exponentially for the consumer. But as the cost of computing power to the consumer goes down, when it comes
TRENDS & TOOLKIT
to fulfilling the Moore’s Law, the cost for manufacturers heads in the opposite direction. This is because R&D, manufacturing and testing costs have steadily increased with each new generation of chips. This has led to the definition of Moore’s Second Law, which states that the capital cost of semiconductor fabrication increases exponentially over time. This means progress comes at a cost – somewhere along the supply chain, at least. The rapid and constant development that has been witnessed in the IT sector is hard to match. But like most other areas of mechanical engineering, the hydraulics industry has not been resting on its laurels, either. Component operating pressures have increased steadily over the past 30 years, and this trend is expected to continue. Seal and hose design has improved accordingly, as has oil additive and filtration technology. Advances in materials and manufacturing techniques mean that more efficient hydraulic components with higher power densities are available at lower cost. And just as Moore’s Law is expected to hold true for another generation, so will the pursuit of performance gains by hydraulic equipment manufacturers. The question that now arises is what will be next in this domain. It is seen that most of the original equipment manufacturers (OEM) demand components that can handle hydraulic system operating temperatures in excess of 110° C. This number is not for margin of safety, but for continuous operation. But heat is the biggest enemy of a hydraulic system. It is bigger than particle and water contamination these days due to the widespread understanding and adoption of modern filtration technologies. And so, a hydraulic system running at 110° C is not an ideal one. Given below are some of the reasons as to why this is so.
QUICK TAKE Increasing the temperature at which a hydraulic system is expected to operate does nothing to enhance machine performance. It only compounds a host of reliability issues, which cannot be solved with current technologies. Using the wrong viscosity oil not only results in lubrication damage and premature failure of major components, it also increases power consumption (diesel or electricity) The only way to know when the oil needs to be changed is through oil analysis A different set of problems arises from filters installed on the drain lines of piston pumps and motors, but the result is the same as suction strainers. They can reduce service life and cause catastrophic failures in these high-priced components. weeks, before it darkens in colour – a sign of oxidation. But pour the same amount of cooking oil into a frying pan – which gives the oil a large contact area with air – and then heat it, the oil will go black in a short time. Shop floor workers have revealed that when lab-testing hydraulic components at temperatures of 110°C and above for extended periods, the oil had ’turned black as ink and smelt unmentionable’.
OIL VISCOSITY The operating viscosity of hydraulic oil is crucial for both adequate lubrication and efficient power transmission. The higher the maximum expected operating temperature, the wider the temperature operating window becomes. And the wider the temperature operating window, the more difficult it is to maintain oil viscosity within both allowable and optimum limits. For example, consider a system with a cold-start temperature of 5°C and a maximum operating temperature of 110°C. To maintain viscosity between 800 centistokes at cold start and 25 centistokes at maximum operating temperature, it would require ISO VG150 oil with a viscosity index of 2291.
SEAL AND HOSE LIFE OIL LIFE According to Arrhenius’ Law, for every 10°C increase in temperature, the rate of reaction doubles. The chemical reactions – in so far as hydraulic oil life is concerned – are oxidation (due to the presence of air) and hydrolysis (due to the presence of water). This means that hotter the oil, the faster the rate of these reactions. By way of illustration, if some cooking oil is poured into a glass, it will take days, even
Like everything else, the elastomers used to make hydraulic seals and hoses are improving all the time. But oil temperatures above 82°C accelerate the degradation of most of these polymers. In fact, according to one seal manufacturer, operating temperatures recommended above 10°C limits can reduce seal life by 80 per cent or more. The constant cycle of heating and cooling – a process known as aging – is
more severe when temperature extremes are greater. Aging causes these polymers to lose their elastic properties. This results in leaking seals and hoses.
FALSE PROGRESS Increasing the temperature at which a hydraulic system is expected to operate does nothing to enhance machine performance. It only compounds a host of reliability issues, which cannot be solved with current technologies. So, it is not progress, but regress. This false progress will certainly come at a cost – to the hydraulic equipment owners who operate them. Knowing these criticalities, here are the most common hydraulic equipment mistakes made by the shop floor personnel.
MOST COMMON HYDRAULIC EQUIPMENT MISTAKES Changing the oil There are only two conditions that mandate a hydraulic oil change: degradation of the base oil or depletion of the additive package. Because there are so many variables that determine the rate at which oil degrades and additives get used up, changing hydraulic oil based on hours in service, without any reference to the actual condition of the oil, is like shooting in the dark. Given the current high price of oil, dumping oil which does not need to be changed is the last thing one would want to do. On the other hand, if one continues to operate with the base oil degraded or additives depleted, it would compromise on the service life of every other component in the hydraulic system. The only way to know when the oil needs to be changed is through oil analysis.
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Changing the filters A similar situation applies to hydraulic filters. If these are changed based on schedule, it would be like changing them either too early or too late. If it is early, before all their dirt-holding capacity is used up, it results in wastage of money on unnecessary filter changes. If it is late, after the filter has gone on bypass, the increase in particles in the oil quietly reduces the service life of every component in the hydraulic system – costing a lot more in the long run. The solution is to change filters when all their dirt-holding capacity is used up, but before the bypass valve opens. This requires a mechanism to monitor the restriction to flow (pressure drop) across the filter element and provide an alert when this point is reached. A clogging indicator is the crudest form of this device. A better solution is continuous monitoring of pressure drop across the filter.
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Running too hot Few equipment owners or operators continue to operate an engine that is overheating. Unfortunately, the same cannot be said when the hydraulic system gets too hot. But like an engine, the fastest way to destroy hydraulic components, seals, hoses and the oil itself is hightemperature operation. How hot is too hot for a hydraulic system depends mainly on the viscosity and viscosity index (rate of change in viscosity with temperature) of the oil, and the type of hydraulic components in the system. As the oil’s temperature increases, its viscosity decreases. Therefore, a hydraulic system is operating too hot when it reaches the temperature at which oil viscosity falls below that required for adequate lubrication. A vane pump requires a higher minimum viscosity than a piston pump, for example. This is why the type of components used in the system also influences its safe maximum operating temperature. Apart from the issue of adequate lubrication, the importance of which cannot be overstated, operating temperatures above 82°C damage most seal and hose compounds and accelerate degradation of the oil. But for the reasons already explained, a hydraulic system can be running too hot well below this temperature.
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Using the wrong oil The oil is the most important component of any hydraulic system. Not only is hydraulic oil a lubricant, it is also the means by which power is transferred throughout the hydraulic system. It is this dual role which makes viscosity the most important property of the oil, because it affects both machine performance and service life. Oil viscosity largely determines the maximum and minimum oil temperatures within which the hydraulic system can safely operate. If the oil used has a viscosity that is too high for the climate in which the machine must operate, oil would not flow properly or lubricate adequately during cold start. If oil with a viscosity too low for the prevailing climate is used, it would not maintain the required minimum viscosity, and therefore, adequate lubrication would be called for, on the hottest days of the year. But that is not the end of it. Within the allowable extremes of viscosity required for adequate lubrication, there is a narrower viscosity band where power losses are minimised. If operating oil viscosity is higher than ideal, more power is lost to fluid friction. If operating viscosity is lower than ideal, more power is lost to friction and internal leakage. Using the wrong viscosity oil not only results in lubrication damage and premature failure of major components, it also increases power consumption (diesel or electricity) – two things that are not desired.
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Wrong filter locations It is a general misconception that any filter is a good filter. There are two hydraulic filter locations that do more harm
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The operating viscosity of hydraulic oil is crucial for both adequate lubrication and efficient power transmission. The higher the maximum expected operating temperature, the wider the temperature operating window becomes. And the wider the temperature operating window, the more difficult it is to maintain oil viscosity within both allowable and optimum limits.
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than good and can rapidly destroy the very components they were installed to protect. The filter locations that should be avoided are the pump inlet and drain lines from the housings of piston pumps and motors. This contradicts conventional wisdom: it is necessary to have a strainer on the pump inlet to protect it from ‘trash’. The pump draws its oil from a dedicated reservoir, not a garbage can. If getting maximum pump life is the primary concern (and it should be), then it is far more important for the oil to freely and completely fill the pumping chambers during every intake than it is to protect the pump from nuts, bolts and 9/16-inch combination spanners. These pose no danger in a properly designed reservoir, where the pump inlet penetration is atleast two inches off the bottom. Research has shown that a restricted intake can reduce the service life of a gear pump by 56 per cent. And, it is worse for vane and piston pumps because these designs are less able to withstand the vacuum-induced forces caused by a restricted intake. A different set of problems arises from filters installed on the drain lines of piston pumps and motors, but the result is the same as suction strainers. They can reduce service life and cause catastrophic failures in these high-priced components. Believing hydraulic components are self-priming and self-lubricating One would not start an engine without oil in the crankcase – not knowingly, anyway. And yet, the same thing happens in case of several high-priced hydraulic components. The fact is, if the right steps are not followed during the initial start-up, hydraulic components can be seriously damaged. In some cases, they may work adequately for a while, but the harm incurred at start-up then dooms them to premature failure. There are two parts to getting this dilemma right: knowing what to do and remembering to do it. Not knowing what to do is one thing. However, if one knows the right option, but forgets to do it, that is destructive. It would not be wise to fill the pump housing with clean oil when one does not remember to open the intake isolation valve before starting the engine.
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Compiled by Sudhir Muddana
EATON HYDRAULIC MOTOR
SPEEDING OPERATIONS, MAXIMISING OUTPUT A potash mine in Canada had been exploring ways to resolve problems pertaining to hydraulic operations, while at the same time increasing productivity and work speed. Eaton’s compact Hydrokraft two-speed motor accelerated non-productive operations, such as relocating the miner and increasing cutting operation efficiency, through precise delivery of torque to the tracks during mining operations. ork output in a potash mine is dependent PROBLEM on machines with high mobility and production efficiency. As global demand Need for a compact, two-speed hydraulic motor that would increase tram speed of for potash increases, Canada’s PotashCorp a miner and default to maximum displacement in the event of pilot pressure loss of Saskatchewan (PCS) has stepped up production at its Rocanville, Saskatchewan SOLUTION mining facility with a continuous bore mining machine that Eaton’s customised Hydrokraft motor not only augmented the tram speed but extracts around 1,200 tonne of potash ore per hour. also ensured operational efficiency. Propelling the massive four-rotor mining machine are two Eaton Hydrokraft 250-cc motors that constitute the heart custom Hydrokraft motors into the hydraulic system design proposal of the hydraulic system on the X CEL 44 Series miner built by Prairie that also included Eaton DG4S4 valves, V Series vane pumps, and a Machine & Parts Manufacturing of Saskatoon. Series 2 piston pump that would operate auxiliary functions. PCS THE NEED liked the proposal and gave HyPOWER its endorsement to design PCS has relied on HyPOWER Systems of Regina, Saskatchewan, an the miner’s hydraulic system around Eaton Hydrokraft motor. Eaton distributor, to provide hydraulics muscle and hydraulics RESULTS commonality for its mining machinery. When the need for an Following assembly and testing, the miner was completely additional miner became evident, PCS asked HyPOWER to redesign disassembled in order to be transported down the mineshaft. Along hydraulic circuitry for the machine and to work with Prairie Machine with these projects, the task of carving out rock 3,200 feet below the on fit, functionality and integration requirements. Delving into the Saskatchewan prairie was performed in order to build a shop to project, HyPOWER’s Ken Pagan, technical sales representative, and reassemble the 38-foo0t-long by 22-footwide miner piece by piece. Cal Ganshorn, mechanical engineering technologist, called on Eaton’s Overall, the multi-million dollar investment is already paying off Lyle Meyer, Hydrokraft product manager, for a two-speed hydraulic for PCS. The machine has been up and running since November motor recommendation. “We explained Lyle that the motors would 2009 and is significantly faster than the other PCS miners. “Our need to increase tram speed over PCS’ current miners that move at hydraulic system design with the Eaton Hydrokraft motors has a snail’s pace. Besides, it should fit into a tight envelope on the miner. enabled the new X CEL miner to increase tram speed by 40 per In addition, motors would need default to maximum displacement, if cent,” Ganshorn notes. “The time savings enable the operator to hydraulic system pilot pressure was lost,” Ganshorn explained. help with set-up sooner and allows to move the electrical set much HYDROKRAFT TWO-SPEED MOTOR sooner as well,” Huber says. Meyer proposed Eaton’s compact Hydrokraft two-speed motor for “Eaton’s Hydrokraft motors offer twice the drive torque to the the application, after confirming with Eaton’s Wehrheim, Germany, tracks, which results in better control. Tram pressures are lower, manufacturing facility that a customised version would default to resulting in lower operating temperatures in the hydraulic system.” maximum displacement, not minimum displacement as does the Courtesy: Eaton Corporation standard version, when pilot pressure is lost. Ganshorn specified the
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& Proper and regular maintenance of hydraulic equipment is a prime concern for industries to ensure longer service life and also prevent damages. Here are 8 handy tips to consider while repairing a hydraulic equipment to increase productivity and achieve cost efficiencies.
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UALTERNATIVE PARTS IN OLD EQUIPMENT
In India, most industries use old, worn-out equipment. These equipment are strong, but unfortunately, easy availability of equipment parts is a major issue. Under the circumstances, companies choose substitutes, make alterations in components or use similar components from other manufacturers to repair nonfunctioning equipment components. This is not wrong but risky, as often the repair team is not well-equipped to check the direction of rotation of pumps and their capacity. This creates further complexities, as each hydraulic system is designed for certain capacity and all factors of heat, speed, torque are calculated closely. Skipping even a single step, can damage the equipment.
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BENEFITS OF REACHING OPERATING TEMPERATURE
Hydraulic systems are designed to work at maximum efficiency after it reaches the operating temperature. Thus, it is recommended to start the engine or the electric motor and let it run at idle speed for 5-10 minutes. This helps in case of pumps and motors, as they reach their respective operating temperatures to do the assigned work.
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PREVENTIVE MAINTENANCE
Most new equipment ranges are computer controlled with PLC programmed to stop a system, if oil level goes down or if operating temperature rises above normal. No matter how foolproof these machines are made, human errors cannot be ruled out. Proper maintenance of all hydraulic systems can enhance its life for at least five to seven
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years. Implementing simple maintenance principles like replacing filters on time to keep the oil clean, replacing hydraulic oil, etc, will keep the system running efficiently.
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REPLACEMENT ISSUES
Another simple cause of damage of a hydraulic system is replacement of hydraulic hoses. Most technicians are ignorant of what is inside the new hose. These may contain rubber particles of the same hose or iron filings from the wire that is cut when building a hose to the correct length. These filings can damage the pump/motor or even cause malfunction to control valves. In order to prevent damage, all new hoses must be thoroughly flushed from the inside and blown by air at relevant pressure to make it absolutely clean before installation.
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SYSTEM CONTAMINATION
A major fault noticed frequently on job sites is when an equipment like pump/ motor or any hydraulic component is opened, the parts are left open/loose until another alternative or part is replaced. This results in system contamination due to entry of dust from passing vehicles, rainwater, etc causing more damage to the system. In order to avoid this contamination, one must clean the component thoroughly from the outside before opening the machine.
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FAULT-FINDING
When executing fault-finding, it is necessary to analyse the problem before opening any component. A mender should first ascertain whether it is a mechanical, electrical or a hydraulic problem. In all new machines with automated systems, there is override for
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every control; one can operate it manually to determine the fault. Like solenoid can be operated manually by pushing pins at ends, overheating of defective solenoid coils also cause problems. Often, hydraulic gauges also signal towards malfunctioning processes. While troubleshooting, it is also noticed that people keep replacing components until they hit the right spot. A sequence should be followed during fault-finding. The more the number of components opened in hydraulic system, more dirt enters the system.
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HANDY TIPS
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FINDING THE RIGHT EXPERTISE
If one replaces a piston pump, it is mandatory to observe the charge pressure as soon as the driving unit is started. If the pressure is not seen (normally 150-300 psi), the unit must be immediately shut down to check fault. Also, whenever a piston pump is replaced, it is important to fill the pump with hydraulic oil to ensure a fulltime lubrication inside the housing. The drive unit RPM should not increase to the maximum, as procedures need to be followed before putting machine under full load after pump replacement.
Only skilled workers should undertake repair of hydraulic components. It may be difficult to get hydraulic technicians on the job site. In order to solve this issue, end-user/equipment owner can hire a skilled consultant to train their technical crew, which will not only cut the downtime cost but also drastically increase the machine’s performance.
Kersi M Pooniwala, Hydraulics Mechanical Consultant
PAINTS & POLISHES
PAINTS AND POLISHES: ‘Coated’ with Vibrant Opportunities ......................................................90 IR HEATING TECHNOLOGY: Offering Innovative Solutions For Paint Drying & Curing ................96
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‘COATED’ WITH VIBRANT OPPORTUNITIES A world without colours is unimaginable. Despite this fact, paints, one of the elements that add colour to life and for that matter responsible in smooth functioning of equipment and machinery, are yet to get their due importance as an essential component of manufacturing. Having said that, things are not lacklustre for the Indian paints industry, which is slowly and steadily gaining pace, thanks to a dramatic surge in the automobile & construction sectors. Time is right for the Indian paints & polishes industry when companies are looking at improving efficiencies and adopting environment-friendly practices. PURNA PARMAR & GEETHA JAYRAMAN onsidered merely as aesthetic elements, industrial paints and polishes, to a great extent, had failed to get their due importance in the entire manufacturing cycle. Considering their criticality in providing durability, protection and ease of application, manufacturers could not only have smooth functioning machinery, but also have higher productivity through the selection of right kind of paints and polishes. With the growing awareness about the benefits of paints and polishes, the industrial paint segment has seen a surge in terms of increasing marketshare and applicability to various verticals in the industrial sector.
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SUNRISE INDUSTRY Globally, the industrial paints segment accounts for a major share, indicating that this segment offers many opportunities for paint manufacturers. Since June 2009, production volumes in the sector have substantially recovered due to the recovery in realty. Production of paints grew by a robust 25.2 per cent during April-February 2009-10 compared to a 40 basis points drop in production in the corresponding year-ago period.
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The Indian paint industry consisting of decorative paints and its less glamorous counterpart, industrial paints, is coming out of the economic trough and is expected to register over 11 to 14 per cent growth in 2010-11. If that happens, the turnaround, though not staggering would still be quite remarkable, considering that this industry notched up only 10 per cent growth in the first half. The industrial paints segment is further divided into other specific categories, of which protective paints constitute 25 per cent, auto component paints - 25 per cent, OEM paints - 20 per cent, marine paints 20 per cent and speciality industrial paint another 10 per cent. Apart from the automotive sector, industrial paints are used in various sectors like power, steel, petrochemicals, oil refineries and gas pipelines, to name a few. The renewed thrust on infrastructure in the budget for 201011 will create substantial investment opportunities in the coming months. For instance, the coatings segment can expect a windfall from new projects in the power, road & road marking, port & airport and industrial sectors. Small and medium enterprises constitute 30 per cent of the Rs 15,000-crore Indian paint industry; the rest is dominated by
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bigger brands such as Asian Paints, Berger Paints, Kansai Nerolac, ICI and Shalimar Paints. The paint industry, whose fortunes depend mainly on housing & construction activity
PAINTS & POLISHES
(decorative), and infrastructure & manufacturing sector, particularly automobile (industrial), had been growing at nearly 15-20 per cent for the past 10 years till recession took its toll in 2008-09. However, now the worst seems to be over, feel those closely associated with the industry. Demand for both decorative and industrial paints has picked up as compared to last year. “The increasing demand in real estate and automobile sectors, which are key consuming markets for paint companies, has made the paint manufacturers hopeful of witnessing steady business during the current financial year,” says Dr HBS Lamba, President, Indian Paint and Powder Coating Manufacturers Association (IPPMA). The association, which claims to represent the bulk of the paint manufacturers, is confident that the sector will go past the previous year’s growth rate of 9 per cent. Early signs of economic revival and mounting demand from key user industries have put the scales in favour of the paint industry. Buoyed by these developments, paint companies are charting out expansion plans, albeit cautiously. Strategic tie-ups and alliances are in the offing; and, new and innovative products will soon find their way back into the market. “There are clear signs of the economy stabilising in India. The third quarter has shown
satisfactory results. Improved demand from end-use industries and our continuous focus on cost efficiency The per capita consumption of paint in India is low, helped us capture the even in countries like Nepal, the per capita benefits of this demand,” consumption of paint is much higher than that of Prasad Chandran, Chairman India. This is mainly due to the tax imposed by the & MD, BASF India, noted government. Currently, paints as a product category while announcing his company’s third quarter comes under the luxury segment and the tax imposed results. by the government is around 13 per cent, making the With the spotlight back product expensive. on the paint industry, there is, as usual, a keen tussle between decorative and RANJIT SINGH, industrial paints. These two Managing Partner, Balsons Paint Industries segments account for 70 per cent and 30 per cent of the foreign formulations; and modification cost paint market, respectively. Many paint in product formulation is high. As a result, companies manufacture both, though. imports are not much of a threat to Indian Experts say that in a few years, the ratio will players. In the case of industrial paints, narrow down considerably and reflect major players already have a tie-up with broad global trends. Decorative paints may global players for the latest technologies account for the bulk of the market, but it is and markets accessible to them. It negates far more unorganised than industrial paints. the further supply from the international The latter is more profitable and technologymarkets even after reduction of import driven. duty from 40 per cent to 15.3 per cent in TECHNOLOGY the last eight years.
ADVANCEMENTS The paint industry is not just growing in volume, but is also scaling up the technology ladder. There have been many technological advancements in both decorative as well as industrial paints categories. Umesh Tawde, CEO, Harlequin Chemicals, manufacturer and applicator of speciality coatings and paints, said, “There are many technological advances observed in the paint industry. Often, a new technology is introduced in the market – application techniques as well as chemicals and solvents. The latest technology that is widely used is the nanotechnology, which helps in enhancing the properties of paint and helps in achieving superior quality paints. Attributes like scratch resistant, stainlessness, gross retention, exposure can be obtained through nanotechnology. In the area of wood coating, the latest technology introduced is Polyurethane (PU) Wood Coating. Inorganic zinc coating, polyester coating, nanocrystaline zinc coating, fluro ply bond, to name a few, are also getting popular.” Meanwhile, Indian climatic conditions are not conducive for
PRODUCT CULTURE Most companies have an identical range of products for the decorative paint market. In the industrial segment, the range is more customised and guided by the technology support provided by the collaborators. In the case of decorative category, the technology has been mostly indigenously perfected over the years and the products can be divided on the basis of interior and exterior applications or in sections such as water-based and solvent-based. Moreover, most companies have been advertising their products in the interior/ exterior emulsions category, which has expanded the market and triggered a shift from distempers and cement paint. While solvent-based enamels are still popular in India, there is a clear shift from solvent to water-based glossy enamels in overseas markets; India will take some time to switch over to water-based coatings. For the decorative range, it is difficult for international companies to set up shop on a standalone basis because of existing barriers such as the strong network of established players, brand image, range of products (Indian context) and required distribution logistics. Therefore, the safer
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route has been and will be to tag along with paper industry, offshore structures, quality, the apparent ease of application and existing companies. pharmaceuticals etc. the environmental friendliness of the For industrial products, however, this technology. It has been a commercial reality TINTING SYSTEM may not apply and based on their tie-ups in now for close to thirty years. Metal polyurethanes give an unrivalled home countries and their OEM customers, GOING GREEN finish to metals and prepare it to take on the required range can be produced and The paints industry is always stereotyped as the elements of nature. These coatings can sold. There is, however, room for niche one of the most polluting industries. take on salty wind, pouring rain or the rising players, with radical and unique ranges of However, this scenario has changed and pollution levels all with equal flair. products properly conceived and marketed manufacturers have realised the importance in the Indian context and supported with of green globe and started using machines. There is a huge more eco-friendly measures to variety of industrial paints Paint is a raw material-intensive industry. It takes over 300 produce both industrial as well available in the market; following different raw materials to produce paints, most of which as decorative paints. are a few examples of industrial Conventional paints have paints. are petroleum-based. Titanium dioxide is the largest more than 1,000 chemicals and consumed raw material. It constitutes approximately 30 AUTOMOTIVE PAINTS substances such as formaldehyde per cent of the total manufacturing cost. There are various kinds of and benzene. These chemicals automotive paints used in the may lead to health problems. POWDER COATINGS manufacturing industry. Some of them are Low-level exposure to paint based on leadCustomers today demand higher quality listed below: based pigments may irritate or burn the Protective Coatings or Industrial and durability from the products they buy. eyes, nose, throat and skin and cause Coatings are used to decorate, protect Not only do they expect these products to reactions such as headaches, dizziness or the substrate. They provide resistance perform well but also they want the finish nausea, while high levels of exposure to to corrosion, abrasion, alkalis & acids to resist corrosion for a much longer some of the elements in paint, even for a salt, water, etc. period of time.The finishing processes for short period, can cause severe and lasting N C Lacquer is a nitro cellulose lacquer, powder coatings are thus designed to do impact such as kidney or liver damage or fast drying, single component ecojust that. respiratory problems. Some of the paint friendly paint which is used on cars, These are blends of resins, curing agent companies have proactively worked motorcycles, scooters, truck bodies, and pigments, which are melt-mixed and towards the elimination of lead-based etc. pulverised into finely, divided particles. pigments and have substituted non-toxic Polyurethane is more durable, attractive There are no liquids or solvents. Therefore, raw materials. and requires no rubbing. it is the ultimate coating for environmental Thus, eco-paints are non-toxic with low Auto Refinishing is similar to enamel friendliness. It is applied to metal products volatile organic compound (VOCs). These paints and takes almost 12-16 hours for by electrostatic spray, the coated item is paints have no odour and can be converted hard drying. It is mainly used on then heated and the powder melts into to any colour with non-toxic tints. They are commercial vehicles like auto rickshaws, smooth, continuous film. Powder coatings produced from fewer than 250 chemical tempos, and bus bodies where are gaining popularity because of their high components and more than 98 per cent of refinishing is required. these chemicals are derived from plant sources and minerals. The raw materials PROTECTIVE COATING are also low in toxic substances, renewable Protecting industrial asset is increasingly and feature a low environmental footprint. becoming critical owing to rising asset costs, Dr Lamba elaborates, “There is a new Paints are considered as beautifying harsh weather conditions and mounting trend observed in the market; more agents. However, while paints do add chemical pollution. Therefore, asset consumers stress on being environmentto the aesthetic value of a building or owners are looking at specialised protective friendly, right from their lifestyles to the a manufacturing equipment, it also coatings specific to their requirements. products that they use are preferred to be protects it from corrosion. It helps in Protective coatings offer a choice of higheco-friendly. Hence, keeping in mind the performance, heavy-duty coatings, and are growing trend, paint manufacturers have extending the life span of a machine designed to protect assets against the also started manufacturing eco-friendly and also helps in its smooth functioning. specific corrosive environment they are paints for both industrial and well as We as manufacturers need to highlight exposed to. These coatings are tested decorative segments.� these aspects of paints and explore under extreme conditions to ensure that While decorative paints have found new areas of application. they are durable and can withstand the their place in the market and are wellvagaries of the different climatic conditions. established, eco-friendly industrial paints Today, coatings find use across diverse are still at a nascent stage. Tawde further DR HSB LAMBA, industries such as nuclear, thermal or hydro explains, “While most manufacturers are President, Indian Paint and Powder Coating power plants, chemical, petrochemical or now producing water-based paints, Manufacturers Association (IPPMA) fertiliser plants, refineries, sugar, pulp and industrial paints like automotive paints, and
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coating still remain solvent-based. One of the major reasons for this is lack of finance and infrastructure to test chemicals. Most manufacturers in the SME segment prefer to stick to the traditional solvent-based paints, as they do not have enough finance to test and experiment with chemicals and solvents. To help facilitate this, IPPMA has planned to set up community laboratories for the SMEs in various zones.”
imposed by the government, the consumption of paints would also increase.” Paint is a raw material-intensive industry. It takes over 300 different raw materials to produce paints, most of which are petroleum-based. Titanium dioxide is the largest consumed raw material. It constitutes
ROADBLOCKS Although the industrial paints segment has witnessed an upward curve, there are still many bottlenecks to be resolved. One of the biggest challenges faced by the industry is the lack of awareness. Although paints and polishes play a vital role in smoothening the manufacturing process, very few consider it as a necessity. Paints are functional and are largely considered as beautifying agents than protective agents. Dr Lamba elaborates, “Paints are considered as beautifying agents. However, while paints do add to the aesthetic value of a building or a manufacturing equipment, it also protects it from corrosion. It helps in extending the life span of a machine and also helps in its smooth functioning. We as manufacturers need to highlight these aspects of paints and explore new areas of application.” Another challenge faced by the industry is tax and duties imposed by government. Currently, the per capita consumption of paints is only 1.7 litre, which is low as compared to global standards. Even in economies like China and other developing countries like Nepal, the per capita consumption of paints is 16-14 litre respectively. Ranjit Singh, Managing Partner, Balsons Paint Industries, explains, “The per capita consumption of paint in India is low, even in countries like Nepal, the per capita consumption of paint is much higher than that of India. This is mainly due to the tax imposed by the government. Currently, paints as a product category comes under the luxury segment and the tax imposed by the government is around 13 per cent, making the product expensive. But, if the government reduces this tax imposed on the product by removing it from the luxury segment, it would be beneficial for both manufacturers as well as consumers. Often paints are seen as cost, but with less tax
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approximately 30 per cent of the total manufacturing cost. Besides this, there are petroleum-based raw materials, which constitute 40-50 per cent of the total raw material consumed. Hence, any fluctuation in crude oil prices has an impact on the prices and profitability in the paint industry.
SELECTING THE RIGHT PAINT While eco-friendly paints are the need of the hour, selecting the right paints for the manufacturing equipment is also equally important. Singh points out, “Selection of paints depends on various factors like atmospheric conditions, chemical exposure of the area of application, acid – alkaline compound of the area of application and the surface to be painted. Moreover, the area of application has also increased in sectors like construction, machines, automotives and accessories application area has increased by 20 per cent.”
FUTURE TRENDS The Indian paints and coatings industry was riding high on the growth in the Indian automobile industry, new construction in
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the housing segment and improving infrastructure throughout the country. But the global financial crisis of the recent past had impacted the paint industry to some extent as a result of slowdown in real estate and auto industry. Top-line growth was affected to some extent while the bottomline was certainly under pressure. According to Dr Lamba, consumers are looking forward to new product launches for application in special areas. Companies are increasing the value-added services available to customers by offering a variety of finishes through specialised and trained applicators, well supported by backend support of specialised service. There has been a higher growth of emulsion paints for interiors vis-à-vis distempers. There is an increasing use of economy emulsion in place of lower-priced distempers. Similar is the trend for exteriors where emulsion-based coatings are now preferred against conventional cement-based coatings. Continuously looking for better products, more consumers are switching to marginally higher-priced emulsions where they get more durable and better-looking finishes in a wider range of colours. According to Dr Lamba, the players with aggressive marketing strategies and comprehensive product portfolios will grow at a faster rate. The emerging trends in technology and marketing indicate that the industry is likely to consolidate in the coming years with industry leaders improving their marketshare. In spite of economic slowdown, the Indian paint industry is growing upwards. It has tremendous potential for growth in the coming years. The decorative segment has outpaced the industrial segment in growth rate but the industrial segment has the greater potential for growth, as and when the automobile industry business improves.
EQUIPMENT BUYING GUIDE: Energy-efficient Motors
Embracing The Green Solution on pg.
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INFRARED HEATING TECHNOLOGY
OFFERING INNOVATIVE SOLUTIONS FOR PAINT DRYING & CURING
Considered as the most efficient form of radiation in the electromagnetic spectrum with regards to transfer of heat, infrared (IR) heating technology is being touted as the next generation practice for drying and curing paints. The biggest benefit is that IR emitters can deliver heat in exact amounts directly to a specific point, thereby saving a significant amount of energy. A quantum leap is possible in paint drying and curing efficiency, provided a radical, out-of-the-box approach is taken when planning new paint curing operations or upgrading existing facilities. magine if one could reduce the energy bills of paint shop operations by 15-20 per cent, or consider doubling the productivity of painted components while saving approximately 60 kW of energy per hour. Yes, it is possible to achieve enhanced quality, increased productivity, and yet save substantial energy in the process. In other words, it is possible for a company to beat its competitors and gain market leadership by producing higher quality products for a lower unit cost. This is now achievable through path-breaking innovation in infrared (IR) heating technology encapsulated in the design of cutting-edge IR emitters, new IR reflecting materials and
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the architecture of the heating system and its electronic controls.
THE PAINTING PROCESS It is a known fact that the painting process Convection heating *First the air is heated. *Then the paint film is heated from outside by convection which is a slow process. *Heat transfer is through the paint film by conduction ( paint is a bad conductor of heat) Note the temp profile: *High at paint surface, low at bottom *Entire mass gets heated *Slow process
serves the dual purpose of protecting any type of surface as well as enhancing its aesthetic value, thereby giving any product a higher market appeal. Recent trends and awareness in the direction of environment Infrared heating *IR does not need a medium to heat *IR rays penetrate the paint film, are partly absorbed in paint film, partly at surface and partly reflected. During reflection they reheat the film. As a result, the film is heated uniformly throughout its thickness. Note the temp profile: IR rays penetrate the film. *Hence heating throughout the film is uniform. *Entire mass need not get heated – an especially useful property when heavy castings etc are to be heated. *Fast process- Typically infrared heating takes only one-third the time of convection heating.
A brief comparison of convection heating (hot air), which is a common method of heating in the industry versus IR
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INFRARED HEATING TECHNOLOGY
FACFACT T
protection has led to worldwide legislation forces wanting to limit the emission of volatile organic compounds (VOC). This has encouraged many companies to become more responsible and adopt water-based paints and coatings (ecofriendly materials) as a replacement to
Electric infrared technology provides a paintshop with significant versatility in finishes. Switching from one paint formula or method of application to another is also much simpler with the new drying system. The infrared heaters can be easily adjusted for waterborne painting one day and for a powder-coated finish on the next.
Wide spectrum of infrared (IR) for diverse applications 30 Short Wave (2200oC) (SW)
Percent Of Total Energy
25 Fast Medium Wave (1650oC) (FMW) 20 Medium Wave (900oC) (MW) 15 Long Wave (650oC) (LW) 10 5
0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0 5.5 6.0 6.5 7.0 7.5 8.0 8.5 9.0 Wavelength in Microns
HOW IR WORKS FOR PAINT FILMS IR is the most efficient form of radiation in the electromagnetic spectrum with regard to transfer of heat. In other words, the IR emitters heat the object without heating the air in between. It has virtually similar properties as light. It travels in straight lines from its source and can be focussed into specific zones by special reflectors. IR is categorised into short wave, medium wave and long wave. Popular emitters of IR (made in quartz) have low thermal inertia; hence, they are instant on/off type (i.e. heat-up/ cool down times of about 1 second). A few advantages of radiant (IR) heat for surface painting applications are as follows: Non-Contact Heating: As there is no physical contact of the air, there is no contamination due to airborne dust particles. This in important in cases where such contamination can mar the quality of
the surface of any product. Fast Response: Low thermal inertia of an IR heating system eliminates the need for long pre-heat cycles. As IR emitters require only a few seconds to reach operating temperatures, they can be switched off even during small breaks in production, thus saving energy. Shorter Time Cycles: Due to one-stage heat transfer, IR heating times are typically one-third of convection ovens. High Efficiency: IR is energy in the form of electromagnetic waves. Since IR does not impact the air or surroundings, the energy radiated may also be concentrated, focussed, directed and reflected in the same
IR BOOSTERS INTEGRATED WITH EXISTING CONVECTION OVENS Most existing paint curing processes involve a ‘heat-up’ stage followed by a ‘holding’ stage. The heat-up stage often occupies up to 50 per cent oven length in conveyorised operations. In the case of convection heating systems, oven lengths are long. A successful innovation in such a case is to install an IR booster ahead of the convection oven. Here an initial quick boosting of temperature by IR reduces heat-up time, leaving more space for the holding. In practical terms, this can mean 50-100 per
Hold time without IR Temperature
solvent-based coatings. However, waterbased paints are known to require longer drying times, which results in extended process times and reduced throughput, thereby affecting manufacturing operations. By using IR heating, water-based paints are effectively force dried and cured within a few minutes.
manner as light. This greatly increases its flexibility and adaptability and reduces energy losses. Control Accuracy: Electric IR emitters can be easily and precisely controlled. They can be zoned wherever required. IR sensors can sense the actual product temperature and be used to control the heater temperature or line speed. Clean heat: Unlike gas-fired ovens, electric radiant heaters do not produce combustion by-products, so the product is not contaminated. Low air velocities reduce the possibility of surface contamination by airborne dirt. IR can enable breakthrough innovations in the whole of painting process including drying and curing. This is possible by way of using IR boosters, compact IR ovens, infrared heating systems, to name a few.
Hold time with IR Time A typical graph after the installation of IR booster
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A few path-breaking IR heating solutions achieved in India: Curing of water-based paint on metal strips by raising the temperature to 1500C in 3 seconds Water based paint cured on filters in 8 minutes @ 6 m/min. Conveyor length inside IR oven - 48 m instead of 180 m required for a typical convection oven Paint drying achieved on heavy valve / actuator / engine components in 15-30 minutes. Turnaround time after primer coat reduced from one day to one hour PU Paint drying achieved in IR – Convection hybrid oven on plastic components in 4 minutes Drying of pre-treatment chemicals (PVA) on plastics done in 1 minute Drying of anti-corrosive coating done on MS plates, 3.2m wide, 10m long and 50mm thick , travelling on a conveyor at 2m/min.
COMPACT IR OVENS FOR CURING PAINT ON LARGE COMPONENTS The practice of high temperature drying is most commonly accepted for all industrial products. However, for heavy components
like valves, pumps, actuators, etc, the weight and size of component pose problems in designing a conventional hot air oven. Such an oven would be large in size, requiring considerable energy and time to generate hot air to encompass the oven. Sudden shut-downs or start-ups in such systems would be both impossible and impractical. This challenge can be overcome by using IR ovens, which are modular, compact and can be designed optimally in terms of materials. Infrared Such applications also have paints that are cured at elevated temperatures 0 only. However, forced drying of air drying paints gives many benefits such as time span between each coat gets reduced from one shift to one hour or less. In practical terms, it means that the second coat can be completed on the same day and the product or material can be packed and shipped out the very same day. This can also helps in reducing work-in-process inventory drastically.
Method of curing
cent increase in line speed with 10-20 per cent increase in length. IR boosters have been an immense success in industry, and they have been used in various ways. Popular applications include curing of paint on automobile bodies, consumer goods, industrial components, etc.
IR HEATING SYSTEMS DESIGNED FOR ‘JUST-IN-TIME’ OPERATIONS
Automated Touch-up IR curing of water-based paints on automobile bodies
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Heating equipment in most operations work on the age-old concept of ‘heat-up time’, i.e. the ovens have to be started much in advance before the production starts and even when the components are
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not processed, the oven has to be kept ‘on’. Short duration, instant switch on/switch off IR ovens are an effective solution in many such situations. With the advent of PLCs, machines are automated and ovens switch on automatically upon sensing the components and switch off automatically when there are no components. Coupled with short-duration time cycles, this leads to efficient just-in-time operations. In fact in many cases, IR ovens can be switched on/off even for every single component.
USING IR EFFECTIVELY For drying and curing operations, one can consider alternative technologies such as IR heating, which provides several opportunities for improving the efficiency of existing paintshop operations. IR technologies work well for drying inks, coatings, finishes or adhesives applied to materials, especially the sensitive ones such as film, release paper or some types of fabric where the more controlled IR drying helps to avoid damage to the material from excessive heat.
Time Cycle
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As illustrated above, a quantum leap is possible in paint drying and curing efficiency provided a radical, out-of-the-box approach is taken when planning new paint curing operations or upgrading existing facilities. Established market players who can offer the right combination of IR sources, equipment design and process controls can elevate your operations to world-class and environment-friendly levels. The sun’s rays are considered the purest Infrared (IR) energy, but remember, the sky is the limit when it comes to innovative and energy efficient IR solutions! Nilay M Shah, Director, Litel Infrared Systems E-mail: exim@litelir.com
SMART MANUFACTURING
A BLUEPRINT TO
GenX MANUFACTURING Aptly responding to fast changing global consumers’ demands with the right set of variety and quality is any manufacturers dream in this cut-throat competitive era. The use of smart manufacturing practices enables a manufacturer to plan and prepare beforehand with the use of the right set of technology, planning and design tools making him flexible to cater to the ever-evolving volatile markets. SUMEDHA MAHOREY ost liberalisation, the Indian manufacturing industry witnessed a wave of improving quality in the manufacturing process, in contrast to countries like Japan, where the manufacturing sector focussed on ‘just-in-time’ right at the start. In India, the manufacturing process evolved through ISO, total quality management (TQM), TPM, six sigma and then lean processes. But over the last few years, volatility in oil prices, fast changing customer preferences, need for just-intime, etc have triggered another wave in manufacturing, which is ‘smart’ and at the same time futuristic. Today, companies have started looking
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at the manufacturing process as an enhancing and enabling point that can make them competitive, cost efficient and quality manufacturers in the future. The ability to flex as per the demand, as per quality requirements and as per the time limits has come with the adoption of smart manufacturing practices in the global manufacturing landscape. Suneel Aiyar, Associate Director – Consulting PWC avers, “Today, companies have started process improvement by using various value stream mapping tools which measures what a customer values and what he is ready to take and then look into the processes which are nonvalue adding from the customer’s point of view.”
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INSIGHTS INTO SMART MANUFACTURING Looking at the fast pace at which changes are shaping up the future, companies are increasingly adopting tools & technologies that add to their productivity and enhance efficiency. Though these companies have taken one step towards attaining operational efficiency, the question that arises is that are we really being futurist in our approach or are we just taking short-term measures to grow? For any company that dreams to be sustainable and lead the future growth trajectory, there is an urgent need to imbibe smart manufacturing practices. In a true sense, smart manufacturing is an integrated, knowledge-enabled, model-rich enterprise
SMART MANUFACTURING
in which all operating actions are determined and executed proactively applying the best possible information and a wide range of performance metrics. Smart manufacturing extends from requirements, product and process design to execution, delivery and life-cycle support. To accomplish this, smart manufacturing encompasses a suite of products, tools and applications, which are Information Technology (IT) enabled and can be used as a strategic tool to enhance manufacturing competitiveness. The smartness can be visualised in two layers: first, by the inherent smartness introduced into the equipments & processes and, second, by capturing real-time data and enhancing the smartness of business decisions through the integration of enterprise applications, creating in an efficient, safe, flexible and an environmentfriendly manufacturing facility. Andy Kalambi, President Dassault Systemes, South Asia explains, “Smart manufacturing ensures adoption of technologies that use premium manufacturing intelligence in terms of predictive analytics that enable better visibility and visualisation across the entire manufacturing enterprise. The ability to plan ahead of time the manufacturing process virtually, in a simulated environment helps in reducing the cost and wastes that are generated in the manufacturing process.”
THE TRANSFORMATION BEGINS… With the advent of smart manufacturing solutions, profound transformations are coming within this decade in the way goods are manufactured – changes that will fundamentally alter the worldwide competitive marketplace. These changes are happening in three phases: Phase 1: The integration of all manufacturing data throughout individual plants and across enterprises will facilitate significant, immediate improvements in costs, safety and environmental impacts. Phase 2: This data, paired with advanced computer simulation and modelling, will create robust ‘manufacturing intelligence’ that will enable variable-speed, flexible manufacturing, optimal production rates and faster product customisation. Phase 3: As that manufacturing intelligence grows, it will inspire innovations in processes & products that comprise smart manufacturing’s promise.
PLANT- AND ENTERPRISEWIDE INTEGRATION In its first phase, smart manufacturing will interconnect and better harmonise individual stages of manufacturing production to advance plant-wide efficiency. A typical manufacturing plant uses information technology, sensors, intelligent motors, computerised controls, production management software and the likes to manage each specific stage or operation of a manufacturing process. However, each is an island of efficiency. Smart manufacturing will integrate these islands, enabling data sharing throughout the plant. The convergence between machine-gathered data and human intelligence will advance plant-wide optimisation and enterprisewide management objectives, including substantial increases in economic performance, worker safety and environmental sustainability. The emergence of this ‘manufacturing intelligence’ will usher in the second phase of smart manufacturing.
FROM PLANT-WIDE OPTIMISATION TO MANUFACTURING INTELLIGENCE Connecting in-plant modelling and data technologies with high performance computing platforms (cloud computing) will make it possible to build significantly higher levels of manufacturing intelligence and connect it throughout the factory. Complete production lines and entire plants will run at variable speeds with real-time flexibility – which is not feasible now – in order to conserve energy and optimise outputs. Businesses will be able to develop advanced models and simulations of manufacturing processes to improve current and future operations. For instance, manufacturers will be able to develop models for the massmanufacture of products & devices that use nanotechnology. It is widely expected to revolutionise technology and industry with smaller, stronger, lighter weight materials and powerful precision devices for nearly every industry.
MANUFACTURING KNOWLEDGE WILL INEVITABLY DISRUPT MARKETS Smart manufacturing’s third phase will transform industry in a similar way... as to how the strategic use of information
technology transformed the business model and consumer shopping behaviour. For example, by capturing extensive data about consumers’ book-buying habits, Amazon developed extensive knowledge about its customers’ lifestyles that enabled a ‘disruptive’ shift in its business model. Within a decade, Amazon expanded its product offerings to span many new categories. It is now the largest US-based online retailer. Smart manufacturing will deliver a similar, extraordinary shift in the competitive landscape of the Indian industry. Flexible factories and IT-optimised supply chains will change manufacturing processes to allow manufacturers to customise products to individual needs, such as medications with specific dosages and formulations. Customers will ‘tell’ a factory what car to manufacture, what features to build into a personal computer or how to tailor a pair of jeans for a perfect fit. This most dramatic and competitively vital – the third phase of implementing smart manufacturing will come from innovation spurred by a growing body of manufacturing knowledge. These will not be incremental or gradual changes – they will be game-changing, market-disruptive innovations in products & processes. Changes at this phase will push down prices, open new markets and offer a broader array of choices to a wider range of people.
IN VOGUE TECHNOLOGIES To start with, smart manufacturing can be achieved through various communication technologies that include machine to machine communication, field buses, ethernet networks, bluetooth enabled devices and wireless networks. Apart from these, some sensor technologies like wireless sensors, MEMS sensors, virtual instrumentation and smart field devices help in curbing the waste rate in the manufacturing process. Other IT platforms used in manufacturing such as product lifecycle management with digital manufacturing capabilities for product and process simulation, manufacturing execution systems, enterprise manufacturing intelligence, plant asset management, advanced control and optimisation, quality management systems, non-destructive testing and emissions monitoring and measurement of carbon credit footprint are shaping for GenX manufacturing. Elaborating on the technologies that are in vogue in the
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industry currently, Aiyar says, “Waste reduction can be achieved with the help of the right kind of technology. One such technology is the value stream mapping tool that identifies different types of wastes that are created due to use of excessive resources, high idle time, excessive handoffs, poor quality, etc. Once the wastes are identified, measure can be taken to eliminate the waste.” Adding further he says, “Earlier companies used to focus on finding out where the wastes are happening in the
simulated virtually, leading to zero prototyping. 3. Digital continuity: Linking up the manufacturing environment with the digital manufacturing or the virtual manufacturing environment and designing the front end process as per the back end plan is another big thing that has changed the landscape of the manufacturing sector. Adding to these, Aiyar avers, “Automation is going to be one of the key enablers for companies to gain an edge over others. In factories, robotics is slowly taking place of manual work, thereby improving efficiency 10 Attributes of Smart Process Manufacturing: manifolds. The reason for its widespread Intelligent actions and responses adoption is the shortage Operating assets are integrated and self-aware of skilled labour and Adapts to abnormal situations labour costs that have increased by over 20 Data when, where, and in the form needed per cent as compared to Proactive failure prevention other developed countries where the Rapid response for proactive control increase is only 3-5 per Environmentally sustainable cent in the last 5 years.” People: knowledgeable, empowered and trained Elaborating further, he explains, “The basic level Recognise the limits of automation of automation is Drive strategic enterprise performance mechanisation which allows the manufacturer company itself but now they are also looking to produce a product continuously with at their partners, suppliers to find out where greater flexibility.” the wastes are and how they can be TRIGGER POINTS: THE eliminated. The mindset has changed FUNDAMENTAL DISCONNECT towards the adoption of technology and Many issues like high rate of waste increased the scope of its application in the generation, high idling time, need for manufacturing process.” efficient product designs are being witnessed Manufacturing technologies are demand in the current manufacturing process. In driven and depend on the how these Japanese term, it is called ‘Muda’. Elaborating technologies are being adopted. Technology on these wastes, Kalambi avers, “Waste is adoption is a continuous process. Over the generated due to defects that arise in the past five years there are many technologies product because of the fundamental that have influenced the way in which disconnect between design and the manufacturing is done today. As per Kalambi, manufacturing environment. This is technologies that have changed the popularly known as the inventory bomb landscape of the manufacturing world are: mismatch. This also results in building up of 1. Digital planning & digital simulation of inventories.” the factory: Every stage of the manufacturing Apart from this, sometimes process is digitally simulated and IT tools are manufacturers don’t have an optimal layout used to find out the most optimal way to for managing the material flow in the manufacture the product. This also helps in organisation. This increases waiting time, reducing error rates and wastages out of it. generates the need for extra transport, the 2. Move from rapid prototyping to zero material comes in and is held up at the prototyping: Earlier, companies used to workstation. This is because the process is create one model after the other with the not synchronised. There are also cases smallest possible change leading to high where manufacturers end up having extra tooling costs and wastage of man hours. capacity. Other issues include improper Today, the manufacturing process is
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layout planning and inappropriate manufacturing materials that create a situation where manufacturing becomes sup-optimum. Another issue is that not many companies have implemented a digital factory where digital continuity is required. In many companies, the design process is digitised, the execution process is digitised but the whole planning process is not digitised. That is where smart manufacturing comes into picture. It helps in digitising the factory and ensuring that manufacturers get the desired production right the first time. This saves the costs involved in tooling for a product design, which was earlier prototyped. Today, every product can be digitally simulated and manufactured virtually so as to reduce costs involved in creating a manufacturing design. There are other tools also which help in clearly simulating the whole manufacturing process in a virtual environment. Which means manufacturers can actually define the whole production of the factory virtually along with resource planning. Additionally, as per Aiyar, manufacturers need to be agile, adaptable and have an alignment towards customers’ wants and needs. Agile manufacturing means manufacturing that can respond to fast changing requirements in the shortest possible time. It also includes catering to demands in small lots with multiple varieties. Adaptability of the manufacturing process can be gauged from the flexibility the manufacturer shows towards currency rate fluctuations and trade slowdowns. The decision to reach the market with macroeconomic, geopolitical variables by sourcing from different locations and factories can be enabled through implementation of smart manufacturing practices. Manufacturers, today, need to align their manufacturing process with that of customer expectations as this would enable them to take the right decisions amid changing market and customer preferences.
BARRIERS TO IMPLEMENTATION Factors that act as the barriers towards the implementation of smart manufacturing practices include the high cost of adoption and integration of manufacturing-IT related solutions, and the costs involved in the installation of energy-efficient equipment, wireless networks and sensors. According
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to Kalpesh Padhye, Senior Research Analyst – South Asia and Middle East, Automation & Electronics, Frost & Sullivan, a major barrier for implementation if smart manufacturing practices is the lack of awareness among Indian manufacturing companies about the technologies and benefits of smart manufacturing. Apart from this, a lot of businesses in India don’t have the scale of production, Pointing this out, Aiyar elaborates, “Today, most small scale businesses focus primarily on labour cost competitiveness but here, the advantage is short-time term in nature. In order to reach that scale significant investments in training people, building infrastructure, manufacturing systems, etc are required.” On the other hand, there are another set of companies that are large, and are doing really well. They don’t find investing in manufacturing systems as the need of the hour. Commenting on adoption of technologies in these companies, Aiyar says, “Over the last 2-3 years, these companies have identified that they would be at risk if they don’t change. But, internally, within the organisation there are many cultural barriers which are resistant to change. Factories are insulated from customers, so when put forth a concept of customer to TQM manufacturing a lot of them don’t appreciate.”
SMART ADOPTION: A KEY TO REMAIN COMPETITIVE With growing manufacturing emphasis on India, smart manufacturing opportunities are abundant and necessary to remain competitive globally. Adoption of smart manufacturing concepts has been relatively slow when compared to other industrial nations. The Indian oil & gas and automotive sectors are usually the earliest adopters of new manufacturing technologies in the Indian industry. However, with increasing number of Indian companies competing globally and setting up manufacturing facilities outside India, the need to integrate and efficiently operate their plants will necessitate faster adoption of smart manufacturing. Also, the need to comply with drug and food safety regulations will promote the adoption in the Indian pharmaceutical and food & beverage industries. Introduction of the perform achieve trade (PAT) scheme by the Ministry of Power enabling power trading will also drive the Indian industrial
sector towards initiatives.
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BENEFITS OF BEING SMART Some of the benefits of implementation of smart manufacturing have been discussed below. Absorbing shift in volume According to Aiyar, today’s manufacturing industries look into its process as an enabling point to create a great deal of variety for its customers. For example, if we assume a consumer durable like motorcycle, as a manufacturer, we need to cater to the changing market demands as within six months of the launch of the motorcycle, it may land in the economy segment from the premium segment. Smart manufacturing tools help manufacturers tackle such situations by enabling them with tools that can absorb this significant shift in volume. With the implementation of smart practices, the mix of products has grown up in the last 4 years and given the manufacturers the capability to provide variety of products in small lots to the market. Capital productivity Implementation of smart manufacturing has over the years resulted in very high rate of return and higher shareholders value due to high confidence amongst the investors regarding the quality of the product and reliable manufacturing processes. Manufacturing competitiveness Smart manufacturing technologies help manufacturers achieve customer expectations through their ability to make the product at the most competitive cost at the time they need.
VANTAGE POINTS: ATTAINING SUSTAINABILITY & ENERGY EFFICIENCY The other major advantages of implementing smart manufacturing practices are: Integrating equipments in the plant will enable better control of plant processes and lead to improvement of plant efficiency and reduction of costs Reduced plant cycle time and plant downtime Efficient production scheduling and tracking key performance indicators Measures overall equipment effectiveness Data between plants can be compared and benchmarked for better management visibility Enables faster innovations in product
and processes by streamlining design and testing Enables real-time data acquisition and communication between equipments Reduces energy consumption and emissions, thereby reducing the carbon foot print of the manufacturing facility Continuous plant monitoring also improves plant safety
ROLE IN ENERGY MANAGEMENT Smart manufacturing technologies help in monitoring energy consumption across the plant in real time by means of energy dashboards and set energy saving targets. Tools like remote plant management enables remote switch on/off of the plant equipments and identifies unnecessary equipments utilisation. This removes redundancy in plant operation and brings in better cost efficiencies. Another advantage of using smart practices is proper load management by assessing load patterns on motors, generators and critical plant equipments which provides for setting optimal operational parameters for plant efficiency.
INDIA: GETTING SMARTER BY THE DAY Implementation and adoption of smart manufacturing is an ongoing process. Delving in-depth on India’s position in the adoption of smart manufacturing practices, Kalambi avers, “India is good at frugal engineering. We have been able to create products which are very different and unheard of. Companies have been able to successfully deliver these products as well. An example of this is Nano. The challenge is now to ensure that our manufacturing practices are also at the same level. To achieve this balance, we need to exploit use of digital tools to the fullest.” With the manufacturing industry taking bigger strides with every passing day, adoption of smart manufacturing practices is the only solution for companies to achieve cost & energy efficiency, reliability and flexibility in the manufacturing process and gain a strategic upper hand that enables them to remain globally competitive. Inputs from Kalpesh Padhye, Senior Research Analyst & Ashwin Haleyur, Research Analyst – South Asia and Middle East, Automation & Electronics, Frost & Sullivan; and Sujeet Chand, Chief Technology Officer, Rockwell Automation
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NATIONAL MANUFACTURING INVESTMENT ZONES
PROPELLING MANUFACTURING GROWTH With India positioning itself to become a world leader in manufacturing, the proposal to set up national manufacturing and investment zones (NMIZs) is an excellent step in this direction. These zones will provide the required impetus to the manufacturing units by way of providing the much-needed infrastructural support, a progressive exit policy, structures to support clean and green technologies, appropriate investment incentives, and business-friendly approval mechanisms. SANDEEP PAI ears ago, well-known economists Colin Clark and Jean FourastiÊ formulated a fascinating three-sector hypothesis. The hypothesis divides any country’s economy into three sectors of activity: extraction of raw materials (primary), manufacturing (secondary), and services (tertiary). It points out that countries with a low per capita income are in an early state of development; the main part of their national income is achieved through
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production in the primary sector. Countries in a more advanced state of development, with a medium national income, generate their income mostly in the secondary sector. Moreover, in highly developed countries with a high income, the tertiary sector dominates the total output of the economy. This hypothesis stands true in the modern day world. While advanced economies of the West are driven by the services sector, developing nations such as India have extended their focus on the
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manufacturing sector. Such a focus is reflected from the fact that manufacturing has grown by 7.6 per cent (on an average) between 1994 and 2010. In fact, the Indian manufacturing sector has undergone a revolutionary change since 1991, leading to opening up of the manufacturing sector to foreign players who were absent prior to liberalisation and globalisation of the economy. Though manufacturing sector has high growth potential, contribution of manufacturing to GDP has nearly stagnated
NATIONAL MANUFACTURING INVESTMENT ZONES
and has fluctuated at around 15 National manufacturing and investment zones would agencies for issuing necessary per cent between 2000 and clearances for the inception and be run by a special purpose vehicle (SPV) that would continuation of business 2010. Explaining the reasons, be responsible for their development and management. ventures inside the NMIZ. Nalinee Giri, Research Associate, Economic Research The SPV would, after notification of an NMIZ, prepare a Thus, the concept of NMIZ & Analytics-Global, Frost & detailed master plan consisting of a regional development combines the framework for Sullivan, says, “Complex more business-friendly policies, plan specifying land use and zoning for processing and procedures and approval administrative procedures involved in starting a business ecosystem, combined with non-processing areas. and poor infrastructure have superior physical infrastructure.” been identified as the main greater efficiency through the use of BOON TO MANUFACTURERS factors affecting the business climate and has common infrastructure and support Nonetheless, if everything works according offset the advantages of labour cost and services. Also, non-processing area would to the plan, NMIZs will be a definite boon growing internal demand.” include residential, commercial and other for the manufacturing sector. Giri says, “The social & institutional infrastructure. Throwing NATIONAL MANUFACTURING advantages to the manufacturing units can light on the same, Revati Kasture, GM & ZONES: A BEGINNING be classified in the form of providing suitable Head – CARE Research, reflects that the To overcome these challenges and increase institutional framework leading to paradigm setting up of such dedicated zones would the share of the manufacturing sector in shift in the overall manufacturing trend, provide a conducive environment for GDP to 25 per cent by 2022, the liberalised legal framework, appropriate manufacturing sector to flourish in India. government has proposed to set up the fiscal incentives and accomplishment of Furthermore, these zones would be run NMIZs. Giri points out, “A series of policy green initiatives in support of sustainable by a special purpose vehicle (SPV) that initiatives are under proposal stage to development.” would be responsible for their development increase the competitiveness of Under the institutional framework, the and management. The SPV would, after manufacturing sector and promote growth suitable benefits to the manufacturers are notification of an NMIZ, prepare a detailed through increased investment. In order to advocated in terms of provision of external master plan consisting of a regional achieve full potential of the manufacturing physical infrastructure facilities including rail, development plan specifying land use and sector, the government has taken the road (national highways), ports, airports and zoning for processing and non-processing initiative to create NMIZ.” telecom through government’s funding and areas. Anand Sharma, Union Minister for According to the discussion paper on public-private partnership. The coCommerce & Industry, confirmed this NMIZ, an area would be specifically ordination between Central Government recently at a forum and declared, “NMIZ delineated for the establishment of and state governments in terms of advocated would have a governing body, which would manufacturing units for domestic and SPV, which will involve specific member be in the form of a SPV formed with the export-led production, along with associated from NMIZ, delegates from respective state constituents of that specific NMIZ. The SPV services and infrastructure. The area would government as well as Central Government would have the delegated authority from have a high-class infrastructure and reap authority, will lead to the creation of firm the State Governments, Ministries in the benefits of co-sitting, networking and institutional framework governing the Central Government and other government manufacturing units. In terms of institutional accomplishments, General incentives for units in the NMIZs the advantages to manufacturers are further In order to encourage industrial units in taking on training/retraining of reflected in the form of provision of the workers, such expenditure be treated at par with R&D expenditure. common infrastructure facilities, support services, economies of scale and scope Tax exemption on expenditure incurred in taking national/international observed from combination of production process/product certification/approvals like ISO 9000, BIS 14000, BEE, units, public utilities, logistics and IS, CSA, UL, VDE, etc. environmental protection mechanism. 50 per cent of the expenditure incurred in filing international patents to The proposal has also been made to be shared by the government. advance the labour laws in terms of Subvention of interest on working capital by 4 per cent to create parity providing women employee with three flexible shifts, flexibility to downsize, nonwith international counterparts. applicability of Contract Labour Abolition In government purchases, preference should be given to units located in Act and provision of security benefits to the the NMIZs. workers. This will provide significant In order to encourage supply chain development, Income Tax exemption advantages to the manufacturers leading to to suppliers in proportion to the supplies made within the NMIZ. more liberalised legal framework. Furthermore, the national manufacturing Special incentives for certain crucial industries where import and investment policy proposal provides dependence is high. opportunities to go green to the Courtesy: CARE Research manufactures. The policy document
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NATIONAL MANUFACTURING INVESTMENT ZONES
focusses on opportunities to rapidly growing carbon trading market, greening of operations to reduce carbon footprints, greening of manufacturing products, and developing local green technologies in order to create local and global leadership in the form of comparative advantage. The shift in manufacturing mix of the products will help India achieve the path of low carbon and high growth of the manufacturing sector leading to sustainable development. Apart from these incentives by the Central Government, the state governments may also notify a package of incentives for the development of the NMIZ. Kasture says, “This may include moratorium on all municipal and other local taxes for 10 years, for the NMIZ developers as well as the units that are located in the zone.”
The advantages to the manufacturing units can be classified in the form of providing suitable institutional framework leading to paradigm shift in the overall manufacturing trend, liberalised legal framework, appropriate fiscal incentives and accomplishment of green initiatives in support of sustainable development. NALINEE GIRI, Research Associate, Economic Research & Analytics-Global, Frost & Sullivan
the Delhi–Mumbai Industrial Corridor Project. If this gets implemented properly, then there will be a domino effect across the country.
CROSSING OVER With the initiative of the Jaipur Zone project, the start has been made. Now what remains is the implementation of the policy to create a suitable institutional framework and bring about a paradigm shift in the overall manufacturing process, which accomplishes green initiatives and supports sustainable development. A few hurdles are bound to emerge, but they should be dealt tactically. If that is done then India would be all set to become a manufacturing bliss. With inputs from Frost & Sullivan
THORNS IN THE WAY While the industry at large is satisfied with the initiative, some reservations do exist among the experts. Highlighting this, Kasture observes, “There will be few challenges during the initial stages of setting up of NMIZs. Firstly, poor infrastructural facilities at ports, roads will be a huge bottleneck to promote manufacturing, and secondly, easy
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availability of land will be another major hindrance as the same is being observed for special economic zones and power projects.” These aspects are to be looked at during the planning stages, starting from the first proposed zone. Currently, the government has decided to set up the first integrated manufacturing zone in Neemrana, Jaipur–Rajasthan along
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DESIGN INNOVATION: Global Design And Manufacturing Partnerships
Collaborating For Success on pg.
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ENERGY SECURITY
issue. If we fix the problem of energy shortage, it will go a long way in combatting water and food shortages. While climate change is widely recognised, its impact is not well understood. The most severe impact of climate change will be on basic life systems – food and water. Drastic climate change will only make food and water shortages worse. What we need is sustainable economic and ecological development. And I feel there are three important parts in achieving this. First is attaining energy security. This calls for affordable energy that can be accessed by all to power a low-carbon economy. It needs to be noted here that there are over 1.4 billion people in the world who have no access to electricity – ‘The People Who Live in the Dark’. Second, we need to embrace new technologies available to deliver energy-efficiency. With many developments happening, from LED lighting systems to lowenergy appliances, energy-efficient buildings and building methods, fuel-efficient transport – the
per capita annual energy consumption is just over 500 kg-of-oil-equivalent, whereas it is 7,500 units in the US, and even higher in many parts of the world.
MAKING A DIFFERENCE It is the way we think about energy. We need to see energy as what it is – a precious and scarce resource – something to be used carefully and responsibly. The government, business leaders, and every one of us have a clear role here. All of us, as individuals, have to accept a new way of using energy, as well as play a meaningful role in educating others. As an entrepreneur, I am an optimist. So although the shortages of energy, food and water are critical, I see opportunities in those challenges. The renewable sector has already created thousands of ‘green jobs’, but if we really exploit some of our natural resources – wind and solar, for instance, which are available in abundance – then we will be able to create hundreds of thousands of secure jobs. I am here referring to manufacturing, engineering, research and development and much more. Talking about economic development,
THE FUTURE IS Energy concerns are looming large over the world on account of the exploding population and shortage of power to meet the spiralling demands. To deal with this scenario, renewable majors are exploring ways to ensure energy security. In this backdrop, Tulsi R Tanti, Chairman and MD, Suzlon Energy, reflects on the drivers of investment, the commercial challenges and the future of clean energy in India.
hile the world is full of opportunities, it is fraught with many challenges as well. Globally, we face three critical shortages: food, water and energy. Given that the world’s population is forecast to increase from six billion currently to over eight billion by 2030, these issues need to be resolved urgently.
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RESOLVING ENERGY CRISIS I believe that energy is the fundamental
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possibilities are endless. There is a myth that energy-efficiency is expensive. Our experience has been the opposite. Our global headquarters – Suzlon One Earth – is among the greenest headquarters in the world. Meeting LEED Platinum standards and running wholly on green power, the construction of the facility cost 10 per cent less than a conventional building. Proof that efficiency works is all around us and so is the need to embrace this. This brings me to my third point, energy responsibility. In India, the average
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here is an example from India. The major cities in the country are crowded and the infrastructure is pushed to the limit. But thousands flock to the cities everyday in search of work. This, in turn, increases the pressure on the cities, threatens the rural way of life and breaks up family units. But wind farms typically come up in the remotest parts of the country. So, we have started training people in rural communities in wind energy. This means they have secure jobs, and do not add to the migration and our customers get quick and efficient localised
ENERGY SECURITY
service. I think this small example shows what can be done: inclusivity is responsible business. And we need much more of this at both a micro and macro level.
REALISING THE POTENTIAL We need proper and sustained investment in R&D, both for technology solutions and turbine development. At Suzlon, we have set up research, development and innovation centres, which focus on product
MAKING ENERGY SELFRELIANCE A REALITY
All countries should set clear CO2 reductions between now and 2050; utilities should target 20 per cent of renewables by 2020; CONVENTIONAL POWER VS governments should introduce feed-in tariffs RENEWABLE or green certification mechanisms What we need is sustainable economic and ecological as soon as possible. Additionally, Indeed, we need to protect this debate from simply development. And I feel there are three important parts governments need to encourage becoming nuclear vs coal vs oil in achieving this. First is attaining energy security. innovation to deliver the next vs wind vs solar and all the generation of technological Second, we need to embrace new technologies available advances. I also believe the others. In order to close the to deliver energy-efficiency. Third important factor is governments worldwide should gap between energy the world needs and the energy currently mandate banks to make minimum energy responsibility. generated, we have to maintain investments in renewable assets. development, and also the fundamental, a dynamic and mixed energy portfolio. I propose this to be 20 per cent. Finally, in terms of policies, dynamic game-changing technologies. We need to Renewables have an important role to play, time-based tariffs are required, with built-in look at the bigger picture. A total review of but as part of the solution – not the only price escalation. In other words, the more the grid needs to take place: where should solution. energy you use, the more you should pay. we expand? What should we upgrade? As I said earlier, wind has an important With the right mindset, policies and business How can we be effective across borders? contribution to make to a comprehensive support, there is no reason why we can How can our grids be smarter? Where do energy portfolio. The scope of what could not attain energy efficiency in the future. governments need to invest? be done is enormous. First, today the world The future can be green. Let’s make it a We also need more countries to adopt consumes 19,000 TWh of electricity. reality. policy regimes, which encourage and Second, by 2030 that is forecast to rise to a support the renewable sector. India is at the consumption of nearly 29,000 TWh. Third, This article is an excerpt from the speech given at forefront of this, as is Europe – including there is enough wind potential – in other the Global Clean Energy Forum held in Lisbon, Portugal – with aggressive targets and words, windy places – to deliver about Portugal recently. strongly supportive policies. twice what we will need in 2030.
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CUTTING EDGE SOLUTIONS
GEARED MOTORS HELP SOLAR PANELS TRACK SUN ALL DAY With the help of energy efficient geared motors by NORD, Solarpark Rodenäs GmbH has developed solar modules, which can track the sun’s changing position all day. This enables 25-30 per cent greater efficiency of solar collectors in comparison with fixed collectors. SUMEDHA MAHOREY olarpark Rodenäs GmbH has recently developed an intelligent tracking technology that increases the efficiency of photovoltaic plants by enabling it to track the sun’s position through the use of powerful geared motors from NORD Drivesystems. Solarpark Rodenäs GmbH specialises in fastening systems for solar panels. As solar cells are most efficient when the sunlight falls onto them vertically, precise tracking of the sun considerably increases their efficiency, at least if the tracking does not consume too much energy. Here, energy efficiency is achieved through NORD motors. The module, developed by Solarpark Rodenäs GmbH, requires robust geared motors in order to position and securely hold solar modules against strong winds. Commonly available drive units use conventional brakes and require heaters to prevent them from freezing. These are cost and maintenance-intensive components, which also increase the energy consumption of the drive unit. NORD solution fulfills the requirements for weather-resistant, precision, energy-efficient and economic motors.
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THE MECHANISM The tracking control is calculated on a daily basis from the data for sunrise and sunset. At sunrise, the solar panels turn to the east in order to track the sun over the course of the day. Every 15 minutes, NORD geared motors are activated by an impulse from the central control unit to track the sun for Rodenäs Solar Park, with more than 700 solar modules four degrees and then switch off again. Due to the tracking, the solar collectors achieve a maintenance. Highlighting the role of this 25-30 per cent greater efficiency in technology in enhancing productivity and comparison with fixed collectors. With a efficiency, Joerg Niermann, Head – surface of 16 m² each, the panels offer a Marketing, NORD Drivesystems, avers, large area of resistance to the winds. The “This technology mainly helps to increase gear units from the modular Universal the efficiency of the solar energy production. series, which combine two worm gear Firstly, it optimises sun tracking, and units, hold the panels in position without secondly, as gears consume low energy, it additional brakes. They position the panels increases the efficiency of the system. Taking precisely and firmly against winds, which this into consideration, this technology can often exceed force of 10 gales. Over 700 be implemented in India as well.” With this geared motors are doubly protected by tracking technology in place, the solar corrosion resistant one-piece aluminium power production is slated to reach major housing and a special paint. A high quality highs in the future with enhanced synthetic lubricant ensures reliability even at productivity and the ability to track the sun sub-zero temperatures and also minimises to the last hour on the horizon.
CMOS IMAGE SENSORS: A BOON TO CAR MANUFACTURERS mage sensors are used for quality control in production systems and car parking lots. Many times, these sensors have to face very high and extremely low temperatures that prevail in the environment. In order to maintain their functions in such extreme conditions and to overcome the possibilty of the sensors getting spoilt, the Fraunhofer Institute for Microelectronic Circuits and Systems IMS in Duisburg has developed a complementary metal oxide semiconductor (CMOS) image sensor, which can withstand temperatures ranging from -40 to +115°C. This is a boon for car manufacturers as the charged coupled device (CCD) image
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sensors available up to now fail when the temperature goes beyond 60 degrees. “Our chip is not only heat-resistant, it even functions at arctic temperatures,” says Werner Brockherde, head of department, IMS. A special feature of this sensor is its image size of 2.5 x 2.5 cm, which can be used for special applications with weak illumination or for capturing images in the infrared or UV range. The sensor can be connected directly to an electronic image intensifier. In addition, the sensor has a high resolution of 256x256 pixel. Its high dynamic range of 90 decibels provides increased contrast and optimised detail accuracy both in shadow as well as in
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very bright areas. A rolling shutter also permits a higher image frame rate and continuous image recording. This minimises image noise. “We produced the sensor in a standard process using 0.5 micrometre CMOS technology in our own semiconductor factory. We also produce special components here for industrial customers,” states the scientist, reflecting the expertise of the Institute. He further adds, “Our chip is suitable for deployment in chemical and steel production facilities, where it can be used for process and quality control. Very high temperatures prevail, for example, in rolling mills where sheet metal is produced.”
CUTTING EDGE SOLUTIONS
TURNING WASTE HEAT INTO POWER By analysing the quantum effects of molecules, physicists from the University of Arizona have discovered a new way of converting waste heat into electrical power. The development of this technology paves way for more efficient power plants, factories and solar panels. hysicists from the University of Arizona have discovered a new way of harvesting waste heat and turning it into electrical power, using a theoretical model of a molecular thermoelectric device. The technology holds great promise for making cars, power plants, factories and solar panels more efficient. In addition, more efficient thermoelectric materials would make ozone-depleting chlorofluorocarbons, or CFCs, obsolete. “Thermoelectricity makes it possible to cleanly convert heat directly into electrical energy in a device with no moving parts,” says Justin Bergfield, a doctoral candidate in the UA College of Optical Sciences. Elaborating on the power generation capacity, Charles Stafford, Associate Professor of Physics, UA College of Optical Sciences, says, “We anticipate the
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With a very efficient thermoelectric device based on our design, we could power about 200 100-Watt light bulbs using the waste heat of an automobile. Put another way, one could increase the car’s efficiency by well over 25 per cent, which would be ideal for a hybrid since it already uses an electrical motor. JUSTIN BERGFIELD, Doctoral Candidate, UA College Of Optical Sciences
thermoelectric voltage using our design to be about 100 times larger than what others have achieved in the lab.”
A LOOK AT THE BASICS Unlike existing heat-conversion devices such as refrigerators and steam turbines, the devices require no mechanics and no ozonedepleting chemicals. Instead, a rubber-like polymer sandwiched between two metals acting as electrodes can do the trick. Car or factory exhaust pipes can be coated with the material, less than 1 millionth of an inch thick, to harvest energy otherwise lost as heat and
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A “forest” of molecules holds the promise of turning waste heat into electricity.
generate electricity. The physicists take advantage of the laws of quantum physics, a realm not typically tapped into when engineering power-generating technology. The key to the technology lies in a quantum law physicists call wave-particle duality: Tiny objects such as electrons can behave either as a wave or as a particle. “In a sense, an electron is like a red sports car,” Bergfield says. “The sports car is both a car and is red, just as the electron is both a particle and a wave. The two are properties of the same thing. Electrons are just less obvious to us than sports cars.”
BACKGROUNDER Bergfield and Stafford discovered the potential for converting heat into electricity when they studied polyphenyl ethers, molecules that spontaneously aggregate into polymers – long chains of repeating units. The backbone of each polyphenyl ether molecule consists of a chain of benzene rings, which in turn are built from carbon atoms. The chain link structure of each molecule acts as a molecular wire through which electrons can travel. Bergfield designed the benzene ring circuit in such a way that in one path the electron is forced to travel a longer distance around the ring than the other. This causes the two electron waves to be out of phase once they reunite upon reaching the far side of the benzene ring. When the waves meet, they cancel each other out in a process known as quantum interference. When a temperature difference is placed across the circuit, this interruption in the flow of electric charge leads to the build-up of an electric potential - voltage - between the two electrodes.
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Using computer simulations, Bergfield grew a forest of molecules sandwiched between two electrodes and exposed the array to a simulated heat source. “As you increase the number of benzene rings in each molecule, you increase the power generated,” Bergfield adds. Analogous to solid state versus spinning hard drive type computer memory, the UA-designed thermoelectric devices require no moving parts. By design, they are self-contained, easier to manufacture and easier to maintain compared to currently available technology. “You could just take a pair of metal electrodes and paint them with a single layer of these molecules,” Bergfield says. “With a solid-state device, you don’t need cooling agents, you don’t need liquid nitrogen shipments, and you don’t need to do a lot of maintenance,” he adds. The effects of this experiment were not unique to the molecules used in the simulation process. Explaining further, Bergfield says, “Any quantum-scale device where you have a cancellation of electric charge will do the trick, as long as there is a temperature difference. The greater the temperature difference, the more power you can generate.”
USE FOR THE FUTURE Molecular thermoelectric devices could help solve an issue currently plaguing photovoltaic cells harvesting energy from sunlight. “Solar panels get very hot and their efficiency goes down,” Stafford says. “You could harvest some of that heat and use it to generate additional electricity while simultaneously cooling the panel and making its own photovoltaic process more efficient.” According to Bergfield, “With a very efficient thermoelectric device based on our design, we could power about 200 100-Watt light bulbs using the waste heat of an automobile. Put another way, one could increase the car’s efficiency by well over 25 per cent, which would be ideal for a hybrid since it already uses an electrical motor.” With the world facing severe energy crisis, the new experiment has paved the way for generating electrical power from non-conventional sources. Courtesy: University of Arizona
OFFSHORE WIND FARM
ATTAINING REMARKABLE FEAT IN OFFSHORE POWER GENERATION With rapid capacity addition in renewable energy production, many companies are looking out for opportunities offshore. Attaining remarkable feat in power generation, Vattenfall’s offshore wind farm launched recently at Thanet, England, has set a record for itself by being the world’s largest offshore wind farm producing 300 MW electricity, which can suffice the energy needs of over 2,00,000 households. The success of this project has set inspirational benchmarks for others to follow... SUMEDHA MAHOREY enewable energy has reached a clear tipping point in the global energy supply, with supporting investment in new renewable power capacity installed over the last two years accounting for more than 50 per cent of the total capacity added in power generation. A milestone in this rapidly evolving renewable era is the recent development of the world’s largest offshore wind farm at Thanet, off England’s south east coast, by Vattenfall, one of the biggest wind power operators in Britain and the fifth-largest energy producer in Europe.
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turbines and is expected to generate electricity equivalent to the annual consumption of over 2,00,000 British households. Between 2009 and 2011, Vattenfall plans to double its wind power electricity generation by constructing nine wind farms in six countries to supply electricity equivalent to the demand of
Energy Generation & Potential
FARM SPECIFICITIES The Thanet Offshore Wind Farm has 100
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8,00,000 households annually. The electricity generated from the English Channel winds will constitute a significant increase of green energy in the UK and is slated to add substantially to Vattenfall’s efforts in decreasing the amount of carbon dioxide emissions from its electricity generation.
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The Thanet Offshore Wind Farm will generate a total of 300 MW of renewable electricity, enough to power 2,00,000 homes. The connection of Thanet’s 300 MW of capacity in 2010 will boost UK’s offshore wind capacity by more than 30 per cent. The Thanet Wind Farm is only one of the five potential offshore wind farms in the Thames Estuary Strategic Environmental Area.
OFFSHORE WIND FARM
Technical Specifications The Thanet Wind Farm is the largest operational wind farm in the world. The Thanet Wind Farm is located in water depths of 20-25 metre and covers an area of 35 km, which is equal to 4,000 football fields. Each turbine is up to 115 metre tall at its highest point, with a minimum clearance above sea level of 22 metre. The nearest turbine is located approximately 12 km northeast of Foreness Point. Thanet Wind Farm consists of 100 Vestas V90 wind turbines. The distance between the turbines is approximately 500 metre along rows and 800 metre between rows. The total investment for the Thanet Wind Farm is around £880 million. THE LAUNCH The opening of the wind farm took place at sea in the auspicious presence of Øystein Løseth, CEO & President, Vattenfall, and Chris Huhne, British Secretary of State for Energy and Climate Change, among other participants. “With Thanet Offshore Wind Farm, Vattenfall has taken a major step towards doubling its power generation from wind until 2011 and we continue to lead the way in offshore wind development. Wind power will be a cornerstone of delivering both profitability and sustainability for Vattenfall in the years to come,” says Øystein Løseth. Pointing out that Thanet Offshore Wind Farm’s 300 megawatt (MW) will take UK’s installed wind power capacity across the 5,000 MW line, Chris Huhne hailed Vattenfall’s impressive engineering achievement and praised the energy company’s commitment towards wind power generation in the UK. He said, “I am pleased that we have reached the point where 5 GW of our energy comes from onshore and offshore wind – that is enough electricity to power all the homes in Scotland. Getting these massive structures here into the sea is a tremendous feat of engineering and I applaud all involved with this awesome achievement.” He adds, “We are in a unique position to become a world leader in this industry. We firmly believe that we should harness wind, wave and tidal resources to the maximum. I know that there is still more to be done to bring forward the large sums of investment we want to see in low-carbon energy in the UK, and the government is committed to playing its part.”
The construction of the 300 MW Thanet Offshore Wind Farm has taken just over two years and the wind farm is expected to operate for at least 25 years. At 300 MW, it is the largest offshore wind farm in the world. Each turbine is up to 115 metre tall at its highest point. The wind farm covers an area of 35 square kilometre, which is enough to cover 4,000 football pitches.
BREAKING INTO THE MAINSTREAM Vattenfall is slated to double its wind power production to 4 TWh by 2011 and provide a total of 8,00,000 homes with electricity
Getting these massive structures here into the sea is a tremendous feat of engineering and I applaud all involved with this awesome achievement. CHRIS HUHNE, British Secretary of State for Energy and Climate Change
from wind power alone. With this rapid addition to the global offshore wind power generation, renewable energy is slated to break into the mainstream of energy markets sooner than later, and witness accelerating private & public investment along with numerous technology advances in the future. Image courtesy: Vattenfall
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MECHATRONIC SYSTEMS
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echatronic systems constitute the stateof-the-art technologies in automation systems, intelligently integrating
motor shaft is mounted out of alignment with a pillow block bearing or gearbox input planetary gear. Moreover, motors should be placed on the machine in the best location, so that
Mechanical and electrical engineers often overlook important issues when specifying different parts for an electromechanical system. This tends to create complexities and affects smooth functioning of a machine. Mechatronic systems, with their sheer capability of intelligently integrating mechanical and electrical elements to perform increasingly complex and demanding functions, prove to be a boon for engineers. By taking into consideration five elementary factors, engineers can resort to smart solutions to drive productivity.
mechanical and electrical elements to perform increasingly complex and demanding functions. When designing electromechanical systems, mechanical and electrical engineers may tend to emphasise on the technologies, components and design principles from their single area of expertise, which can result in systems with higher operating costs, increased maintenance demands and less than optimal performance. However, in the process, often inefficiencies and unnecessary complexities can be unintentionally designed into machines. In order to resolve these problem areas, the following measures can be considered.
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CREATE A CLEAN DESIGN
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Good mechatronic design starts with good mechanical design – the best electronics and electrical systems cannot compensate for poor mechanical design. The most successful designs are ‘clean’ – they feature a strong & rigid frame, and utilise materials and structural principles to ensure that whatever motion the machine undergoes, its long-term stability is engineered-in. It is important to make sure that rigid bearings and support are utilised where motors are mounted on machines. This helps to prevent shafts from getting sheared off due to microfractures that occur if the
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operators do not accidentally step on cables and connectors causing damage. It is also essential to design machine guarding with easy access points to get to motors mounted under the wing base of the machine while still protecting them against harsh environments. Most importantly, a clean design balances mass and motion: sturdy, durable framing that withstands years of vibration and shock, combined with light-weight components for the moving parts of the machine. This helps reduce mass, provides more energyefficient motion, and makes it easier to sizeup smaller motor/drive components for the machine.
MECHATRONIC SYSTEMS
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DIRECTLY COUPLE THE MOTOR TO THE LOAD
Effective mechatronics starts with a clean slate design. In the past, machines were often built around a single AC motor powering a machine line shaft, to which gearboxes, pulleys, sprockets, chain drives and other mechanical devices were attached for moving individual areas of the machine in synchronisation. This powering approach can be traced back to the dawn of the Industrial Revolution. Now let us consider replacing this architecture with individual servomotors coupled directly to the load that is being moved. There are multiple design, machine cost and operational advantages to this solution. First comes cost: every time a gearbox is added, it results in multiple costs – it is an additional point of failure, which has to be lubricated and needs spare parts. Plus, there is a need to add mechanical backlash that has to be compensated for during machine commissioning. But now, thanks to technological developments, every time there is a product changeover, the motion and axes synchronisation complexity is eliminated by today’s intelligent drives and servomotors. When servomotors are strategically located as close as possible to the area of motion they are serving, the incremental cost of electric drive components is almost completely offset by eliminating the cost of labour and mechanical components that must be purchased, machined, assembled and configured. In particular, not having to stock multiple sets of sprockets, gears and cams, as well as saving the time involved in changeovers with mechanical drives, can really drive down the total cost of ownership for the machine. A clean
Important Electrical Considerations for Mechanical Engineers The five considerations mentioned here simplify mechanical design challenges and provide resources for driving innovation and creativity in machine design. Create a clean mechanical design to ensure that whatever motions the machine undergoes, its long-term stability is engineered-in Couple the motor directly to the load to greatly reduce wind-up and backlash, improving machine commissioning time Utilise electronic gearing and camming to dramatically improve axes synchronisation and accuracy Incorporate energy-efficient technology to cut down on operation costs and reduce wasted energy Use HMIs for troubleshooting to show where a problem is and measures to put the machine in a safe mode for maintenance. and accuracy – from 1/16th or 1/32nd of an inch typical with mechanical line shafts, down to motion precision closer to hundredths or even thousandths of an inch with electronic line shafting. And this synchronisation can be accomplished with zero mechanical backlash and fewer product jams. It also eliminates a host of mechanical adjustments to bring the machine online, as well as the operator adjustments each time the machine is stopped and restarted. Electronic gearing and camming makes machine changeover completely programmable. The camming technology makes it possible to build multi-segmented cam profiles based on position, velocity or time-based motion profiles. When a section of the electronic cam is altered through a recipe change with the help of HMI, the control platform will automatically optimise
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INCORPORATE ENERGYEFFICIENT TECHNOLOGY
One of the fastest growing costs for any manufacturing operation is energy. A good mechatronic design can help control these costs through the application of electric drive and motor systems designed to save energy. In machines that utilise servomotors directly coupled to critical axes of motion on the machine, and also employ electronic synchronisation and camming, the proper sizing of the servo system can create a highly energy-efficient machine. Proper sizing requires an accurate assessment of several motion factors (motor by motor) such as how fast the axis needs to accelerate, the size of the mass that needs to be moved, and how precise the acceleration and deceleration needs to be. Undersizing will lead to strains on the drives and motors; oversizing will draw too much power to design balances mass and motion: sturdy, do too little work. Some of the durable framing that withstands years of vibration and UTILISE most cutting-edge systems ELECTRONIC available now include a highly shock, combined with light-weight components for the GEARING AND energy-efficient feature: bus moving parts of the machine. This helps reduce mass, CAMMING sharing. Multiple drives are provides more energy-efficient motion, and makes it The electronic drives and daisy-chained together and easier to size-up smaller motor/drive components for motion control platforms share power from the same available today give the bus; in many multi-axis the machine. mechanical engineer a machines, some motors are powerful, flexible tool to improve the the rest of the cam profile across all the accelerating (drawing power), others are accuracy and performance of the machines. machine’s motion elements. This enables decelerating (regenerating power). With This technology enables to create an the machine to run a shorter cycle time, or bus sharing, rather than having to deliver ‘electronic line shaft’ that can electronically provide smoother dynamics for the maximum power to the accelerating motors synchronise all the drives and motors on machine, even though a change has and bleed off the decelerating motors into the machine, eliminating the mechanical occurred – a different bag seal-time or flap heat across a bleeder resister, power is line shaft. In the process, one can tucking cam position – on a cartoning shared, so the machine’s energy dramatically improve axes synchronisation machine. consumption is significantly reduced. A
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MECHATRONIC SYSTEMS
further energy-efficient technology is called regenerative power supplies. In many machines, multiple servomotors will decelerate at the same time, boosting the voltage to excess levels on the power bus. Older generation electrical drives would bleed that excess electrical energy as heat – wasting the power and adding to the factory floor’s heat production, requiring additional cabinet cooling. With regenerative power supplies coupled to a shared bus system, what was once wasted power can now be fed back through the shared bus and sold back to electric companies.
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USE HMIs FOR BETTER TROUBLESHOOTING
The computer revolution has spread to today’s machine control panel, replacing knobs and pushbuttons with sophisticated PCbased and embedded HMIs with advanced programming and Windowsbased operating systems. For instance, when there is a paper jam in a typical office copier, a touchscreen control indicates where the jam is, which door to open, how to correct the problem, and prompts what needs to be done next, once the jam is cleared. The same user-friendly intelligence is now available to machine designers through the latest touchscreen HMIs featuring the latest graphical user interfaces. Machine layout drawings and schematics can be incorporated into control menus and diagnostic tools to better manage the machine’s day-to-day operation and troubleshooting ease. Drawings and interactive instructional tools can not only show the precise point where a problem is, but also show how to open enclosures and what steps an operator can take to put the machine in safe mode for initial maintenance. Besides, these also give indication on other support resources to resolve a problem and step back through the tasks to restart production. Advanced graphics can be combined with the distributed intelligence inherent in servomotor-driven machines to prevent machine failures or faults before they happen. Called predictive maintenance, this capability lets machine designers set fault tolerance bands in drives and then monitor drive performance. Electric drives and motors allow a broad range of conditions directly associated with mechanical performance to be monitored. Variations in load, temperature, vibration, torque, belt tightness, gear meshing are all mechanical events that generate changes in the torque profile of an electric drive and motor moving those machine elements. Mechanical engineers can set tolerance bands for these components, and if they exceed them, then predictive maintenance alerts can be clearly and intelligently displayed via the HMI to operators, along with specific advice about next corrective measures to tackle the issue before it becomes a serious production problem that can damage the machine.
BLENDING TECHNOLOGIES FOR OPTIMAL VALUE Every electromechanical system should perform its designed function through minimal use of energy, motion and components required to get the job done – that is the fundamental goal of any engineer. Electrical drive and servomotor systems now offer a wealth of reliable, energy-efficient, digitally intelligent platforms to power the integrated vision of VIEWPOINT: mechatronics to greater Energy Security value an more innovative manufacturing and The Future Is Green automation solutions. Courtesy: Bosch Rexroth Group
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ENERGY-EFFICIENT MOTORS
Embracing The
green
S LUTION The goal of any green technology is to eliminate waste. In many facilities, old motors are the primary culprits and the biggest energy ‘offenders,’ making them costly in the long run on account of additional expenses necessary to keep them functioning. This calls for green solutions such as energy-efficient motors and other green technologies for doubling the gains, both profit and environment-wise. he growing emphasis on technological efficiency is just one of the several forces behind the pressure on companies to ‘go green’ despite a trying economy. Yet green investments, particularly those related to motors in plants, are likely to lead to conflict between two forces. One is plant management, which is convinced that the best path to a green operation is to operate motors at the highest efficiency; and the other is accounting department that always questions whether expenditures lead to an acceptable return on investment (ROI) in the shortest possible time. Some will argue that investment in a large motor with a higher efficiency rating than equipment currently in use may be more expensive. But it will pay off in the long run because of enhanced productivity, output and lower long-range costs – a point inevitably debated by accountants who may not be so enthusiastic about long-range ROI and may consider a green initiative as costprohibitive. It is a classic battle fought in corporations large and small, but it does not have to be zero sum – all or nothing. Technology can
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help resolve this issue through detailed computerised analysis of the motor, the power environment in which it operates, and even its reliability. All of these relate to cost savings as much as they do with the growing green movement in industry.
APPLYING GREEN TECHNOLOGY TO MOTORS The ultimate criterion that determines whether a motor is truly green is energyefficiency. In this case, it is all about less use of electricity or other resources, such as water. Clearly, any motor that offers optimum levels of production and energy conservation qualifies for a green or environment-friendly design. Considering that electric motors at most facilities are the largest sources of energy consumption and costs, efficient, outlay-reducing green machinery should be in demand. Companies leery of additional capital expenditures, particularly during a difficult business climate, are content with the status quo under the mistaken assumption that the motors producing at optimum levels are as efficient as can be reasonably expected. However, there is another parameter of measuring a motor’s
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efficiency, and it is one that is usually overlooked when discussing motor technology. That standard is reliability, and it deserves to be included as part of any efficiency evaluation. It needs to be kept in mind that if an old motor requires maintenance well above routine scheduled work, the end result is most likely higher costs due to maintenance, parts, labour, and the additional electricity required to keep it operational. Elevated costs and power usage due to unreliability fall far short of green standards. Another impact on a motor’s efficiency is the process in which it operates. When a motor functions at well below its rated horsepower, the motor’s environment is considered ‘unloaded’ and its troubles are attributable to an inefficient power system. It is a process failure that is more accurately described as waste rather than unused capacity. The energy required by every piece of rotating machinery can vary, particularly in the method of delivery. A brand new high efficiency motor will be flawed, if it is operated in an unreliable application. One example is a voltage imbalance from the transformer to electric lines to the motor – a classic case of a high-
ENERGY-EFFICIENT MOTORS
performance asset in a low-performance environment. Imbalance always has a negative impact on efficiency and performance, regardless of the motor’s efficiency rating. The green movement as it relates to motors is the result of industry becoming environmentally conscious and more aware of reducing its carbon footprint. Today, the term which was originally applied to the release of greenhouse gases has been broadened to include waste and inefficiency associated with factory operations in general and motors in particular. Still, a company regardless of its green intentions has to factor in the costs of reducing carbon emissions when making the important decision to repair or replace. New green technology provides some tools that can help companies make the right choice.
EFFICIENCY AND FAULT ZONE ANALYSIS One such tool is the technology used to conduct a real-time analysis of six crucial areas of motor function. These areas are referred to as fault zones, and all require independent testing because problems in any one of the six is likely to impair efficiency and output. An effective analysis of each fault zone will play a major role in determining whether replacement or repair will achieve maximum efficiency and a green production environment. The fault zones include: Power Quality: The focus on this fault zone follows the increasing use and reliance on AC and DC drives. An ongoing concern about power quality is the possibility of distortion of voltage and current levels from variable frequency drives. Other sources of trouble with power quality include harmonic distortion, voltage spikes (sometimes resulting from excessive cable length between the drive and motor), and unbalanced voltage. Another factor that wreaks havoc with power quality, in particular, and efficiency, in general, is heat. Harmonics in a distribution system produce excessive heat because of the increasing current demands. Left undetected, heat above acceptable levels can either lead to malfunctions or shorten the motor’s lifespan. Power Circuit: This fault zone is defined as the system of conductors and connections running from the point of origin of testing to connections at the motor. The circuit can include breakers, fuses, contactors and lug
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connections. There should be no doubt that a problem in the power circuit impairs efficiency. A study conducted in the mid1990s determined that more than 46 per cent of the faults found in industrial power distribution systems stemmed from difficulties within either the connectors or conductors. Faulty power circuit conditions place the most efficient and well-maintained motor at risk for reduced horsepower that can lead to excessive heat and insulation damage. Insulation: There is potential damage to insulation between the windings and the ground, which is generally caused by dirt contamination, high temperatures, moisture and age. A faulty power circuit is a culprit in insulation damage, but advanced testing is required to ascertain if the damage was the cause of a motor disruption or something else – a symptom of another problem yet to be analysed. It should also be noted that a system that ensures the dryness of insulation could as much as double the life of the motor as can testing and maintaining the ground insulation. Stator: This fault zone is sometimes misunderstood. A stator consists of copper windings connected with solder joints between the coils. Electrical engineers sometimes differ on the role of the stator as the root cause or symptom. Apart from design or manufacturing defects, the stator is often the symptom of another fault mechanism. The real goal for stator-related incidents is to identify conditions conducive to stator faults and correct them before they result in a stator failure. Stator failures can often be catastrophic, resulting in unplanned outages and defective products, which increase the use of energy and create waste. Rotor: In more specific terms, the rotor fault zone refers to the rotor bars, laminations and end rings. The percentage of motor failures attributed to rotor problems is low, but its trouble spots can cause extensive damage to the motor if left unchecked. The stator is also at risk because of its close proximity to the rotor. For example, a cracked rotor bar will lead to a heat build-up, intense enough to melt insulation on its laminations as well as on the nearby stator. Again motor efficiency will be compromised without the advanced technology necessary to detect a crack or break in the bars. Air Gap: The gap between the rotor and stator assures efficiency when it is evenly
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distributed around 3600 of the motor. When distribution is uneven or nonsymmetric, the usual result is an unbalanced magnetic field that can lead to failure of the stator windings and stress on bearings that are also likely to fail. All six fault zones have one requirement in common: ongoing testing of the highest standards and tolerances that will help ensure efficiency. Chances of achieving green-oriented goals are unlikely with anything less.
GREENWASHED VS GREENWISE Going green can be compared to a pressure point applied to companies seeking to reduce waste in their usage of electricity and water while maximising efficiency. Constant pressure to be environmentally responsible is bound to take its toll on firms trying to balance out green-related efficiencies with cost. Sometimes, the balance tilts unfavourably. That, in essence, is what happens when a company is ‘greenwashed’. It decides to invest in new motors based solely on high-efficiency ratings. Certainly, no company is going to make such a decision without a serious cost/ROI analysis. In a bid to achieve two outcomes (green energy and increased profits), a company may find itself yielding to its laudable desire to show its green colours. It is not that the firm has placed its ROI on the backburner; it is more likely that the company has not adequately considered the possibility of attaining its green goals without a massive investment in new motors. Any assumption that purchase of a higher-efficiency motor is an automatic step into green nirvana may well be viewed as a greenwashed-based decision. This is because the decision was reached through a simple math process based on motor design information (usually referred to as the nameplate) instead of evaluating a number of critical variables. Simple math is limited to rated horsepower and production output, use of energy to achieve that output, savings due to less energy requirements and the time it takes to achieve ROI. At first glance, the savings from the massive investment may be viewed as astronomical and a ‘no-brainer’, but there is a caveat: these calculations should be recognised as limited and the savings that they project may not be close to accurate. Variables such as distribution system, load history and accurate efficiency calculations are left out of the equation.
ENERGY-EFFICIENT MOTORS
Things you must know about energy-efficient motors Energy efficient motors are much better off than standard-efficiency motors under full, partial, and unloaded conditions. The efficiency of any motor varies with factors as size, speed, and loading. Most manufacturers are designing their energy efficient motors to provide peak efficiency at 75 to 100 per cent load. Typically efficiency stays fairly constant from full down to 50 per cent load. Generally, the initial cost is about 15 to 30 per cent more than standard motors, but depending on the specific motor manufacturer and market competition, they can be even less expensive. The price premium per horsepower is lower for the larger motor ratings. As the population of energy efficient motors increases, the initial cost will come down and may be available at the same cost as a standard motor in the near future. For new purchase decisions, the simple payback on the incremental cost of a continuously operated energy efficient motor can be recovered through energy savings from few months to 2 years depending on the hours of use and efficiency of replaced motors and tariff. Source: International Copper Promotion Council India
The technology is available to measure the data of these variables, which may determine whether being green means a full-scale motor replacement or a less costly repair. A ‘greenwise’ decision examines all the variables and projects’ actual savings. True, manufacturers are providing the highest-efficiency motors available in the market, but their value and performance have to be predicated on the plant environment where they will operate. Greenwise testing and computations take into account the actual running conditions of the motor in addition to the motor’s nameplate rating. The company may conclude that the payback for the purchase of a new motor may be less than preliminary calculations indicated because of information revealed through fault zone testing. That is especially true when utility costs, the largest expenditure in a motor’s lifecycle, are factored in along with wasted capacity – the result of a power condition that forces the motor to work at less than its rated horsepower.
GREEN TECHNOLOGY FOR MOTOR MAINTENANCE AND MANAGEMENT Software for motor maintenance has evolved to the point that its use can be considered a valuable step towards going green. The introduction of reliabilitycentered maintenance (RCM), which
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created a centralised base to co-ordinate motor asset management, is one of the recent advancements. RCM became the first step in the evolution to predictive maintenance software that represents a ‘cradle to grave’ diagnosis of a motor and its fault zones – a co-ordinated package that communicates between separate software analysis systems. The lesson these advanced systems provide is that motor maintenance and management must be co-ordinated throughout the entire lifecycle. Without it, a company could waste money, energy, labour and utilities trying to repair a recurring problem without recognising the actual cause of the breakdown. Some businesses have responded with the creation of the machinery information management open system alliance (MIMOSA) – a consortium that promotes a standard protocol to reduce difficulties in data conversion from disparate software applications. This too should be considered a step in the green direction since it aids enterprise resource planning while providing useful data to determine ROI for either motor replacement or repair. Its goal is maximum efficiency, which is rapidly becoming a synonym for green industrial operations. One of the newest types of software, the energy cost analysis module, produces real data for any existing motor application. The actual running condition is analysed
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prior to any consideration of replacement. Additionally, the nameplate data is considered along with the variables that impact operations. Following information input, the software produces data on actual efficiency, repair based on fault analysis, or necessity of replacement. Equally important, one must not forget reliability. High-efficiency ratings mean little if the motor is unreliable, especially after its warranty has expired. The new technology can accurately assess the motor’s reliability while projecting its years of useful life.
ROI DECISIONS FROM A GREEN PERSPECTIVE By now, it would be clear that going green requires a significant reduction of energy consumption, which is what the newest maintenance software is designed to determine. Motor circuit evaluation has unified everything from fault zones inside the motor to the exterior environment and all of those variables associated with it including a realistic assessment of the motor’s lifespan – all necessary for the projection of ROI. It is the software revolution that may turn the tide to green’s favour and bring an end to those ‘greenwashed’ decisions based solely on motor efficiency ratings. Accountants who tend to equate conversion to green technology with questionable ROI may be swayed by the bigger picture that the new software information can provide. It is not a stretch to consider upgrades in energy-efficiency among the most important steps a company can take with its green conversion. One may not immediately connect the operation of a 1000 hp motor with environmental improvement, but consider that the more efficient the operation of the motor and its environment, the less the requirement for electricity and power, which means lower operating costs. That merits the green label by any contemporary standard. Motor reliability should be considered the same way. Analysis technology can improve motor efficiency and reliability, and its sophisticated evaluation software may well be one of the best opportunities to maximise a motor’s lifespan while limiting its carbon footprint. One does not have to be an ardent environmentalist to appreciate the value of this green strategy. Noah Bethel, CMRP, VP – Product Development, PdMA Corporation
GLOBAL DESIGN AND MANUFACTURING PARTNERSHIPS
COLLABORATING FOR
SUCCESS
Achieving effective global design, engineering and manufacturing partnerships have become imperative for every company to make a mark in the market. But often organisations struggle to reap success from collaboration. When these relationships are strong, one gets designs that delight consumers and produce bottom line results. When they go awry, even the best brands find themselves struggling to answer uncomfortable questions about design flaws and conditions in the factories they partner with.
oday, the design element is essential to business success. Yet it seems like only yesterday, although it has been decades, since designers simply handed off their work to be executed by engineering and manufacturing departments, later only to be surprised that the product has greatly deviated from the original vision or intent. However, things are changing now, and currently, the industrial design, engineering and manufacturing functions truly constitute a team effort. This is especially valuable, given that companies now source from a global supply chain, and both manufacturers and designers offer value-added services to their clients and partners. But, the issues of distance, time, speed and culture act as frequent impediments to successful collaboration.
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AIMING AT SUCCESSFUL COLLABORATION The definition of successful execution of a design has shifted within various professions, and the stakes for declaring a design successful have also been elevated considerably. Hence, it has become pivotal to build effective partnerships among design, engineering and manufacturing departments. If this strategy is pursued successfully, the
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result is breakthrough design, and if such partnerships fail, the end result is unhappy customers. There was a time when handing over a promising rendering was the end-goal for designers. Then mock-ups and models were needed to help teams visualise, and more recently, fully functional prototypes with engineering detail to provide alignment became the need of the hour. Designers soon became involved with the details of
production. Today, design strategy illuminates a clear path from sketches to empowered consumers. For this to happen, the realities of implementation – business models, distribution methods, and budgets – have to be integrated into the strategy and design process and collaboration between the innovation and production teams must be ensured. As the design process has evolved in complexity, so too has the world of
Just as the worlds of design, strategy and brand are converging within executive circles, so too are the fields of design engineering and manufacturing amid an increasingly truncated production process, often spread across the globe. Each profession must make the mental leap from designing objects to designing experiences – and work collaboratively in order to do so.
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GLOBAL DESIGN AND MANUFACTURING PARTNERSHIPS
manufacturing and distribution. The most HAVE A CONVERSATION shared ownership of the idea, true ABOUT VALUES, NOT JUST profound change has been the decoupling innovation can happen. PROCESSES of the location where designs are created, Companies and consumers know that the BE REALISTIC ABOUT COSTS where they were made vs. where they are It is a competitive world and the pressures choice of a manufacturing partner is one that sold. Many companies, especially those in on both designers and manufacturers to can communicate the values of the company North America, send their designers over reduce costs can be enormous. However, to the general public. It is up to both parties to the manufacturing floor to understand it is in the interest of all parties to be as to ensure that they share knowledge about how things work. However, maintaining forthright as possible about the the constant connection between the functional teams is Today, design strategy illuminates a clear path from true costs of various design often extremely difficult, and sketches to empowered consumers. For this to solutions and manufacturing processes. Consumers generally the focus on consumer priorities happen, the realities of implementation – business pay for value when they see it, can get relegated to the back burner. models, distribution methods, and budgets – have to even in tough times. They are Yet, manufacturers play a be integrated into the strategy and design process and unlikely to embrace products vital role in delivering a consistent that are cheaper, but provide an collaboration between the innovation and production inferior experience and deplete and meaningful user experience teams must be ensured. – a key ingredient in creating brand trust over time. and maintaining brand trust. USE IT TO OPTIMISE the guiding principles of each organisation. Products often form an impression of the COMMUNICATION The sharing of values shifts the focus from brand and the country in the minds of the The benefit of IT to enable 24/7 real-time legal compliance to one where people are consumer. In 2009, the US imported an communication does not need to be connected and concerned with one estimated $296 billion worth of emphasised. When selecting IT solutions, another’s welfare. Data from across manufactured goods from China, and $21.9 simplicity should be paramount. Relying industries supports the fact that satisfied billion from India. heavily on IT for all communication employees create more innovative products So, the need for collaboration across the purposes can actually hamper outcomes, and pave the path for high-performance globe is now clear, but the tools to create especially in the final stages of a project. companies. This understanding should an effective collaboration are not wellPicking up the phone can be more effective extend to partners as well. The outsourcing known. Here are some tips that would in achieving alignment while saving time. of services has shown that this broadening make the process smoother and lead to of values buy-in is possible in a timely and better results: SHARE TECHNOLOGICAL cost-effective manner.
DEVELOPMENTS
CONSIDER USING VISUAL TOOLS
EXPLAIN THE ‘WHYs’
Designers and engineers are no strangers to sketches, renderings and CAD drawings. But the visual understanding needed should go beyond the bill of materials and assembly. Sharing the usage scenarios that have been developed during the design process, the vision of the consumer experience that is sought, and the retail setting that the product will live in are all equally important. This is the type of understanding that can lead to breakthroughs or the meaningful tweaks that can transform a good design into a great one. Being visual helps align stakeholders and can also catch potentially costly mistakes or oversights early in the process. A leading company has achieved huge success by utilising a highly visual process called ‘Psycho-Aesthetics’, which incorporates basic psychological teachings and product interaction understanding to help guide its strategy process and lead to compelling design solutions for consumers with better regularity.
This point may seem obvious, but under deadlines, it is often missed. Both designers and manufacturers tend to focus on ‘what’ needs to be accomplished, and ‘when’. However, explaining ‘why’ certain design decisions have been made and ‘what’ they are intended to accomplish can lead to creative solutions. It is essential to understand what can be streamlined, alternative ways to deliver solutions and have a meaningful dialogue about how to customise for different markets. Going forward, this level of dialogue will be critical in the era of cradle-to-cradle design, with increasing demands for sustainability. Companies are gradually bringing the design function into higher levels of their corporate culture, and consulting designers earlier in the process. The same needs to be done with manufacturing. There is nothing more disheartening than a great concept being shelved in which everyone has invested emotionally because it cannot be manufactured as desired. However, when the ‘whys’ are clear, and there is a
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Jonathan Ive’s intense dedication to keeping Apple at the forefront of what modern manufacturing can accomplish is a major aspect of the company’s product and commercial success. For example, Apple is reportedly experimenting with liquid metal manufacturing, which combines the conveniences of precision injectionmoulding of plastics with new metalic materials. Their actions should be noticed and their lead should be followed. With design processes and manufacturing techniques being improved and streamlined constantly, collaboration between designers and manufacturers around new capabilities can be valuable in terms of design enhancement, cost reduction and the corresponding impact on profitability.
DESIGNING EXPERIENCES The challenges of working with global teams are daunting at times – but the reward is winning in global markets. Ravi Sawhney, Founder & CEO and Deepa Prahalad, Lead – Global Insights, RKS Design
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INDUSTRIAL EQUIPMENT SEGMENT
CHALLENGED, TRANSFORMED & POISED FOR GROWTH Fuelled by rising demand for different categories of equipment for varied applications, the industrial equipment segment is witnessing a growth spurt. While the opportunities are many…unforeseen challenges in its way pose major threat to its growth. Braving all odds, the segment has been adopting key success levers such as operational excellence to be globally competent and cost-efficient. he industrial equipment segment has attained a significant stature over the years. However, like any other sector, it faces increased competition in domestic and overseas markets, and has to deal with bottlenecks on account of volatile fuel prices and stricter environmental regulations. But certain challenges are particularly pronounced. Some of these are elaborated below:
North America and Europe has slowed as customers started reducing or delaying capital spending, thereby leading to a slash in production by manufacturers. Increasing globalisation, growth in emerging markets Rapid globalisation is generating new opportunities and at the same time resulting in rising competition in emerging regions, as some former ‘low-cost’ economies transform into attractive markets for selling goods. This has led to increasingly complex supply chains and growing competition from domestic manufacturers in these BALANCING SUPPLY AND DEMAND markets. Industrial equipment Volatile energy costs & stricter manufacturers (IEMs) are To achieve operational excellence, industrial equipment regulations striving to succeed in highly manufacturers must focus on issues such as supply chain Highly volatile energy and competitive and slow-growing commodity costs, together with visibility & optimisation, demand & inventory planning, government and public pressure markets in their home countries. For instance, the demand in while also rationalising their supplier base. have led IEMs to focus on
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INDUSTRIAL EQUIPMENT SEGMENT
PRODUCT AND SERVICE INNOVATION
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Key Levers to Manage Industry Challenges Key Levers
Transformation to a service organisation Complete functional integration internally and externally
Operational Excellence
Supply Chain
Improved value chain performance Customer Centricity
COST REDUCTION
– Sourcing – Supply Chain – Logistics
Product offering bundled with value-added aftersales services for better customer service and integration
Service Transformation
Devising and deploying sustainable products
Green IT
Implementing green IT strategy
Best-in-Class Networked Value Circle Model for Industrial Equipment This model helps industrial equipment manufacturers focus on three strategic capabilities: identifying global competencies by realising core competencies and connecting to other value chains; identifying relationships that will be either long-term assets or strategic assets to gain competitive advantage in a value chain; and using their management skills and technology to form, manage and exploit relationships whether they are two-company partnerships or wide, open, network relationships. SUPPLY CHAIN PARTNERS AND NETWORKS
SERVICES FOCUS AND SALES GROWTH
A
A ,S I NG MAR K E T I CE p ma ip i V AND S E R ions h ers h From relat r partn to cus tome
INNOVATION PARTNERS AND NETWORKS
LE S na ge me nt
OPERATIONAL EXCELLENCE
MA Fro NUF to wm w AC ma orld orl na ge
IT-FACILITATED COORDINATION SUPPORT FUNCTIONS: From supporting a chain to managing a value-creating network
turing G anufac R IN ss m ufacturing TU - cla s man d las t c en m
SIGN T DE N UC VATIO OD NNO ing it to R I P D do ing it N om ourc Fr res
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MANUFACTURING PARTNERS AND NETWORKS
CUSTOMER CENTRICITY
As the industrial landscape becomes more global, partnerships grow in importance. Critical success factors include an improved understanding of the customer’s business and closer collaboration. Long-term customer relationships will be achieved via approaches such as integrated after-sales services. Solutions designed to improve customer centricity include customer relationship management (CRM), call-centre operations, service parts management and repair and business information management (BIM).
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Outsourcing – IT – Procurement – Finance & Accounting – Customer Care & Insight
standard, harmonised processes and controls
To achieve operational excellence, IEMs must focus on issues such as supply chain visibility and optimisation, and demand & inventory planning/integrated business planning, while also rationalising their supplier base.
5
Enterprise Performance Transformation
and process innovation
Service Focus & Sales Growth
With slow revenue growth and tight margins, some IEMs are beginning to shift their focus towards services, while at the same time taking advantage of emerging markets and multi-channel sales and distribution strategies. Solutions to help IEMs focus on this lever include service strategy and transformation, multi-channel optimisation, sales/market roadmap development, campaign and loyalty management, sales effectiveness, and price & revenue optimisation.
4
Innovation & Lifecycle Management
Cost Reduction
Key elements of this lever include shifting some portion of manufacturing offshore, outsourcing non-core business processes and restructuring initiatives such as consolidation, standardisation & harmonisation of processes and systems.
3
Select Solution Areas
Collaboration with customers and suppliers earlier in product lifecycle and across the value chain
Product & Service Innovation
This lever focusses on bundling the product offering with valueadded services and leveraging Green Initiatives technology partner relationships. Establishing close collaboration with customers and suppliers earlier in the product lifecycle and across the value chain is essential to manage this lever.
2
Action Towards Excellence
tn ers hip s
minimising their impact on the environment and reducing energy bills. In many cases, this has resulted in operational challenges as they look for greener ways to source, manufacture and ship their products. But just as every challenge has some or the other solution, the industrial equipment manufacturers can use the following six key levers to address their problems:
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GREEN INITIATIVES
To address environmental, ecological and ethical concerns, IEMs need to focus on designing and developing sustainable products, as well as implementing a green IT strategy. These solutions not only help IEMs optimise business processes but also help in creating newer standards in the industrial equipment manufacturing industry. Courtesy: Capgemini
HITECH MATERIAL HANDLING SHOW
INSPIRING INNOVATIONS Mumbai | 17-19 Feb, 2011
To keep pace with the increasing demands and manufacturing advances, the Indian material handling industry needs to innovate and deliver futuristic solutions. HiTech Material Handling is a first-of-its-kind show exhibiting futuristic products & services across the material handling spectrum. A one-stop shop for GenX material handling solutions, the event is all set to provide a success ladder to one & all...
SHIBANI GHARAT aterial handling plays a fundamental role in today’s manufacturing setup. Right from raw material handling to the final dispatch of the product to the endcustomers, material handling plays an indispensable role. In a nutshell, an efficient material handling equipment (MHE) increases throughput, controls costs and maximises productivity. While the applications are many, every industry vertical demands a unique set of equipment to store inventories as well as to dispatch the final product. Justifying the same, Tushar Mehendale, MD, ElectroMech, avers, “Any manufacturing unit, in any sector, requires equipment to handle materials in the factory. Different verticals require different solutions to cater to their MHE needs. Chemical industry, pharmaceutical, construction, electronics, energy, food & beverage, metalworking, metal casting, plastics, aerospace manufacturing, automotive industries – all are dependent on the MHE industry. This reflects the critical significance of material handling in every industry vertical.” Elaborating on how efficient material handling brings profits to the industry, Sudhanva Jategaonkar, Associate Vice President - B2B Publishing, Infomedia18 (A Network18 Company), opines, “Efficient material handling and smart storage solutions are the means for enhancing profitability for small and medium enterprises (SMEs).” In order to cater to the growing needs of the customers and to create an awareness about the GenX material
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handling solutions for the industry, Network18 Group is organising a mega industry event in February 2011. The event is aimed at providing a conducive platform for showcasing best in class solutions that aid in attaining manufacturing efficiency. HiTech Material Handling is a first-of-itskind event showcasing latest material handling innovations under one roof. From MHEs like forklift trucks and automated logistics systems to innovative and costeffective ideas in racking, shelving, storage solutions, transport and distribution, packaging; handling system design & warehousing, the event will display the best of new-age material handling solutions. HiTech Material Handling Show will be concurrent with HiTech Automation, under the umbrella show HiTech Manufacturing.
AN ERA OF EVOLUTION In the past few years, material handling has become a new, complex and rapidly evolving science. For moving material in & out of warehouse, a variety of equipment and system are in use, depending on the type of products and volume to be handled. According to Vijay Devta, Senior Sales Executive, Safex ElectroMech, some of the new-edge technologies in India for MHE are hydraulic conveyors, hydraulic working platforms and material lift, passenger cum material lift in construction industries and inprocess industries roller conveyor. Manufacturers have a wide variety of choice in the types of MHE available in the market. To add to this, globalisation and international trade & commerce are propelling competitiveness and driving the
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development of novel and efficient material handling technologies in the market. According to Mehendale, the size of the Indian MHE industry is estimated at approximately `5,000 crore and is likely to grow at 20 per cent year-on-year over the next five years, in terms of the overall economic growth. Domestic production and foreign trade are the two growth drivers for this segment.
ONE-STOP SHOP FOR MATERIAL HANDLING HiTech Material Handing will help the entire material handling industry converge into a single lucrative platform that will serve as a foundation for the future growth of this industry. The event will display cutting-edge technology, breakthrough innovations and interactive demonstrations from the leaders in the material handling industry. “HiTech Material Handling showcases the best and the latest in the industry. This show is a must attend for all SMEs. For those who will be a part of this extravaganza, the exhibit will provide tremendous networking opportunities and scope for business generation,” avers Jategaonkar. With this show, the material handling industry will be witnessing a slew of exciting new developments, which, in turn, will help the businesses maximise their return on investment (ROI). HiTech Material Handling show is poised to equip India to shape its futuristic aspirations of building a robust innovative material handling equipment industry, with an objective of achieving a world-class position.
DRIVE & CONTROL
INTEGRATING SAFETY into WORKPLACE
Eliminating potential injuries to personnel and increasing safety aspects of machines in a manufacturing facility have become a priority today. Thus, often, equipment manufacturers need to strengthen functional safety of machines by implementing servo control in existing machines or processes. This will ensure enhanced productivity as well as prevention of new risks, thereby making the workplace safer. ystem integrators with motion expertise are often in demand with regard to retrofitting servocontrolled motion to an existing machine or process. This is because servo control offers advantages of greater speed to reduce cycle time, increase changeover speeds for different product variants, or provide a motion profile that eliminates existing mechanical problems. However, modification of existing or addition of new motion features should take into account the functional safety aspect of the machine.
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FUNCTIONAL SAFETY Functional safety forms the part of machine or safety equipment and depends on the proper operation in response to its inputs, including safe response to equipment failure
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and operator errors. It provides a workplace free of unacceptable damage (direct physical damage to equipment or product in process or indirect damage such as loss of productivity, environmental hazard or financial impact of medical and litigation costs) or risk of injury to personnel. Functional safety is best applied from the base as part of the overall machine design process rather than adding at the end. It must be designed as part of the control system. Earlier, the conventional approach of considering safety as the last step may have worked to an extent when the safety approach comprised hard guarding and fencing. The electrical, electronic and programmable systems (E/E/PS) of a machine or process carry out system control and monitor operations; however, safety depends on proper functioning of the entire system. The functional safety analysis
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should include even non-electric sources of motion, or a potentially hazardous stored energy like hydraulic or pneumatic systems under pressure, or suspended weights that may fall under gravitational effect. Functional safety is an integral part of the system, and not simply a guard to prevent personnel from entering hazardous areas.
RETROFIT CONSIDERATIONS While implementing a retrofit, it is often difficult to convince the owner of the equipment about the requirement of safetyrated components and methods. Explaining a situation, Steve Cortese, Controls Integrator, Automation Works, Mount Prospect, IL, says, “When an existing user has not had an accident or a runaway with normal machine controls, he may not see the need for redundant safety-related control architecture. The earlier practice
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was to open a guard door and engage a setup bypass circuit that allows normal jogging. Hence, the user may not see the need for a monitored, safely limited speed to ensure that even a single failure does not result in unexpected or uncontrolled motion. This may put the machine operator in danger.” Here is another example. A high production automotive airbag assembly manufacturer described the method for improving cycle time followed by the company. The company connected a light curtain at the access to the load-unload station to the forward overtravel limit input of the servo drive that moves the bag folding arms. If the operator enters while the machine is still moving towards the unload station, the axis would stop. If it were moving away after releasing the completed airbag, motion would be allowed even though the operator’s hands were through the curtain. With the use of a standard (non-safety) input with no redundancy or diagnostics, it is possible that a single failure could cause loss of the stopping function and allow rapid motion towards the operator’s hands – the hazard they were attempting to avoid. Overtravel input is a circuit in the drive designed with normal good practice that has not failed in a hazardous situation till date. In retrofits, the original system may not be updated on the basic guarding and interlocking systems when using the conventional methods of removing power when doors are open. This would prevent unexpected motion that may present a risk
Safety steps Determine the limits of the machinery Identify hazards through individual hazard analysis or task-based analysis Evaluate the risk, and determine if it has been adequately reduced After each step in the process, it is also important to evaluate if new hazards have been created The hazard evaluation process is then successively iterated until all identified risks have been mitigated Human factors must be considered, especially in retrofits, where the process executed by an operator is being changed. It is better to design, in advance, the special modes of access and motion required to clear jams, perform cleaning operations, etc, to ensure that added safety features do not complicate the operator’s job.
to personnel involved. Further, in conventional methods, often a simple, single-channel, non-redundant emergency stop to remove power is the maximum facility that was provided. Adding a proper guarding and door interlocking that decreases power to servo drives may result in new errors and sequence restart issues. Decreasing input power contactors also puts stress on servo drives’ bus capacitors, wastes energy from discharging & recharging and takes more time to restart, which could otherwise be used for enhancing the production cycle. Dave Stuber, Controls Integrator, Custom Controls Solutions, St. Charles, IL, points out, “One should use the Safe Stop 2 functionality, as defined in standard IEC EN 61800-5-2, which allows the drive to
maintain torque and hold position while stopped. All axes in a complicated system can maintain position and synchronisation while doors are opened for set-up adjustments. The safety function monitors motion and shuts down to no torque, if motion is beyond the determined safety limit. These help avoid power cycling stress, contactor wear, time delay, errors and additional logic for mid-cycle restart. These new techniques are allowed under changes to standards like NFPA 79-2007, permitting a servo drive designed for stopping functions without requiring power disconnect by an electromechanical device.
SAFETY DESIGN PROCEDURE The overall steps to applying safety are the
By using a standard (non-safety) input with no redundancy or diagnostics, it is possible that a single failure could cause loss of the stopping function and allow rapid motion towards the operator’s hands.
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basis of most standards today. The first step includes determining the limits of the machinery, and the second is identifying hazards through individual hazard analysis or task-based analysis. Further, it is important to estimate & evaluate the risk, and determine if the risk has been adequately reduced. If the risk is still at unacceptable levels, one should proceed with the risk reduction for that hazard. The priority for risk reduction is eliminating the risk by inherent design or change in the process (e.g. move the column where an operator might be injured, if struck by a moving machine). If this is not possible, add safeguards (e.g. create a mechanical barrier to keep the operator away from the area and automatically reduce the speed of motion, if he must enter and still move the machine for recovery or jam removal operations). For any residual risks, it is essential to provide information for equipment use so that the operator can avoid the potential hazards. If the protective measure involves safety-related parts of the control system, standards define an iterative process (the ‘V-model’) for specification, design, coding, testing,
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integration and validation of the control system. Also, risk evaluation after each step is important to know whether the changes made have created new hazards. For example, if a mechanical guard that has been added to protect an operator from possible hand injury is positioned such that it can trap the operator between the guard and a wall, it indicates that a new hazard may have been created. The hazard evaluation process then undergoes successive iterations until all identified risks are mitigated. In particular, in retrofits, where the process that an operator executes is being changed, the human factors must be considered. Incorporating protection that makes it difficult or impossible for the operator to perform the concerned job will most certainly result in finding a way to work around or disable the intended protection. Thus, one should design, in advance, the special modes of access and motion required to clear jams, remove bad product, perform cleaning operations and tasks other than the normal automatic cycle of the equipment. In this way, the accepted solution does not outrun the safety
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measures incorporated to prevent injury and damage.
CURRENT TECHNOLOGY IN SERVO DRIVES The safety motion functions defined in IEC EN 61800-5-2 Adjustable Speed Electrical Power Drive Systems, Safety Requirements – Functional come into play in special modes. Servo drive safety functions defined in IEC EN 61800 are now offered in safety-certified servo drive equipment that allow continuous application of power to enable motion in special modes. These features include safe operating stop, maximum speed, limited speed, direction and limited increment. It also includes safe homing, braking & holding system, as well as safely monitored position, deceleration & stopping processes. These drive safety solutions can easily be integrated into existing & new machines, and reduce risks to acceptable levels, while enhancing machine productivity and making machine safety functions transparent to the machine operator. Gary Thrall, Senior Product Support Engineer, Bosch Rexroth Corp.
Engineering Expo Ahmedabad 2010-11
FLYING HIGH WITH BRIGHT PROSPECTS Belonging to the ‘state of businessmen’ that is Gujarat, Ahmedabad is never out of business and investments. Supported by excellent road network, railway connectivity and port proximity, and ofcourse, the most pro-active government, the opportunities that Ahmedabad provides for companies to set up their base are aplenty. With increase in the number of investments, companies need to spread awareness about their innovative offerings in the relevant segment. Providing such lucrative opportunities to companies, Engineering Expo Ahmedabad, in its 9th edition is all set to break its own records in generating business, and providing opportunities. SHIBANI GHARAT Since the time immemorial, Gujarat has been known for its ‘business-friendly’ attitude. Experts have always attributed the growth of Gujarat to its proactive approach towards entrepreneurship and innovations. Its citizens are known for their leadership and entrepreneurial skills, risk-taking abilities and aspiration to explore new avenues of growth. Thriving with booming investment prospects, Gujarat is a state that every company would want to associate with. The reasons are many. First and foremost, Gujarat houses a number of multinational corporations, private sector companies, public sector enterprises and medium & small-scale units. This is not all. The business-friendly policies add to the immense opportunities that the state holds. At the heart of business in Gujarat is the city of Ahmedabad. The city, which pumps
in opportunities and growth prospects in the state, has become a commercial hub of Gujarat. As per September 2009 figures, investment projects worth `1,80,000 crore had already been implemented and projects worth `4,90,000 crore were under various stages of implementation. Investments particularly in power, gas, ports and infrastructure has given a boost to the progress of the state. When it comes to providing a conducive working environment, Ahmedabad was ranked fifth after Ludhiana, Hyderabad, Bhubaneswar and Gurgaon in a citywise analysis by the World Bank reported in ‘Doing Business in India, 2009’. The presence of several industrial firms like Adani Group, Reliance Industries, Nirma Group of Industries, Arvind Mills, Claris Life Science, Shell, Bosch and many others, justifies the tremendous business potential existing in Ahmedabad. Many
investors prefer this region because of the presence of excellent infrastructure, availability of land, and negligible presence of trade unions. Moreover, the government has made all possible efforts to drive the growth of industries here. The proposed Delhi-Mumbai industrial corridor, Dholera (special investment region) and Gujarat International Financial Tech (GIFT) city are also expected to fuel the industrial growth of Ahmedabad.
AHMEDABAD INDUSTRIAL BASE Talking of industrial base, Ahmedabad accounts for 21.5 per cent of factories and employs 18 per cent of workers in the state. Of the total industrial productivity of the state, 60 per cent is contributed by the city alone. Ahmedabad is an industrial base for sectors like chemical, textile, drugs & pharmaceuticals, agro and food processing industries.
Ahmedabad | 10-13 Dec, 2010 Engineering Expo, organised by Infomedia 18, is one of the engineering industry’s biggest events in the country. The 200910 edition of Engineering Expo saw business transactions worth over `150 crore. Launched in Ahmedabad in the year 2002, the event today boasts of a fabulous visitor turnout. The Expo is a preferred destination for SMEs and manufacturing & engineering companies to transact, network, form tie ups, and exchange ideas. The Engineering Expo 2010-11 is scheduled to take place in four cities, starting off at Pune in November 2010 and proceeding to Ahmedabad, Indore and Chennai in subsequent months. Such promising avenues call for the increased awareness about latest product offerings of companies to broader audience. Having been established as an undisputed leader in providing a trade platform to manufacturers and service providers, Engineering Expo Ahmedabad 2010-11 is stepping into its 9th edition from December 10-13, 2010. Abuzz with prospects, the Expo is set to offer a cornerstone for companies that aspire to set up base in and around the city. It would also be an ideal platform for companies willing to strengthen their base in Ahmedabad. Exhibitors are also upbeat on the possibilities that the Expo presents. Talking about the business benefits, Paresh Talsania, Proprietor, Talsania Engineering
We exhibited precision measuring instruments aimed at mechanical, piping and fabrication industries and pharma sector during last year’s Ahmedabad Edition. In a span of four days, we sold more than 500 units of our products. With the number of inquiries we have received, we are sure to have a 10 per cent rise in our business. Parag Patel, Proprietor, Samruddhi Industries Works, a Vatva-based company, says, “The return on investment in Ahmedabad is very good. Not only are short-term gains possible, but the long-term business growth is also achievable.” Talsania is participating at the Expo for the first time and is optimistic about creating awareness about the company and interacting with various prospective buyers. Seconding his thoughts, Kailash Katkar, CEO, Quick Heal Technologies, informs, “We expect good number of enquiries from corporates and SMEs, since clients from these segments are expected to visit the show.” In a similar vein, CB Panchal, Director, Modern Power Semiconductor, a five-year-old company based in Vijapur, notes, “Engineering Expo offers us a platform to advertise and promote our products, and hence, generate more awareness about our company and our diverse range of products.”.
RENDERING SUPPORT TO NEIGHBOURING CITIES Ahmedabad plays a vital role in rendering commercial resources and market access for the economies of neighbouring cities. The city of Ahmedabad, which in itself is a successful industrial hub, has also helped trade and industry to flourish in neighbouring cities like Gandhinagar, Rajkot, Surat, etc. Engineering Expo is thus, a platform that brings together decision-makers and visitors from leading industrial centres such as Vadodara, Rajkot, Gandhinagar among others, who are in search of latest engineering solutions to improve business prospects.
ENGINEERING EXPO: AN IDEAL BUSINESS DESTINATION Engineering Expo is a perfect manufacturing & engineering trade fair to display latest products & services. As proved by 1,000+ companies that participated
in the previous editions of the Expo, it is one of the most preferred platforms to grow business. Exhibitors like Parag Patel, Proprietor, Samruddhi Industries, who had participated at the event earlier, are reaping huge benefits. “We exhibited precision measuring instruments aimed at mechanical, piping and fabrication industries and pharma sector. In a span of four days, we sold more than 500 units of our products. With the number of inquiries we have received, we are sure to have a 10 per cent rise in our business,” says Patel. Garnering such leads, the company has decided to be a part of this year’s Ahmedabad edition as well. This speaks of the might that Engineering Expo has been able to harness in its eight years of existence. Highlighting on the performance of Engineering Expo in helping the growth of SMEs, Sudhanva Jategaonkar, Associate Vice President B2B Publishing, Infomedia 18, a Network 18 company that will be organising this mega industry event, says, “The brand Engineering Expo is a brilliant example of starting humbly and achieving an enviable feat over the years. We celebrate the entrepreneurial spirit of Gujarat and are partners in our customers’ progress. With the coming months looking promising for the manufacturing sector, we aim to provide more business development opportunities through our Expo.”
OPPORTUNITIES CALLING… Being an all-inclusive engineering show, Engineering Expo-Ahmedabad will provide an ideal opportunity for the exhibitors from allied sectors in engineering and manufacturing to improve their business prospects. The exhibitors are expected to receive an overwhelming response from the visitors, and hence, generate tremendous business leads and new partnerships in Gujarat.
TECHNOLOGICAL INNOVATION
ROAD TO PERPETUAL GROWTH
SMEs are generally known for information innovations due to the resource constraints they face owing to their small size. It is the combination of internal and external factors, which drive the majority of SMEs to undertake both product and process innovation. A recent research carried on Bengaluru SMEs provides a classic example of how small incremental innovative approaches drive the growth of the Indian SMEs to be globally competent. mall and medium enterprises (SMEs) have been considered one of the ‘driving forces’ of modern economies due to their multifaceted contributions in terms of technological innovations, employment generation, export promotion, etc. Of these, the ability of SMEs to innovate assumes significance because innovation lends a competitive edge to firms, industries, and ultimately, economies. Therefore, technological innovation has the potential to spur growth of individual enterprises at the micro level
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and aggregate industries & economies at the macro level. Given this fact, it is essential to understand issues such as factors driving SMEs to innovate; nature of SME innovations and the resulting achievements and their outcomes. Overall, it needs to be understood whether SME innovation facilitates the growth of firm size, and if so, how can SMEs tap this promising avenue.
THEORETICAL FRAMEWORK Technological innovation is a key factor in a firm’s competitiveness. It is unavoidable for firms that want to develop and maintain a
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competitive advantage and/or gain entry into new markets. Among firms of different sizes, SMEs are generally more flexible, adapt themselves better and are well-placed to develop and implement new ideas. The flexibility of SMEs, their simple organisational structure, low risk and receptivity are the features facilitating them to be innovative. Therefore, SMEs across industries have the unrealised innovation potential. There is a substantial evidence to show that a number of SMEs in a wide variety of sectors do engage in technological innovations, which play a significant role in their success. However, the innovative
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capacity of SMEs varies on the basis of sector, size, focus, resources and the business environment in which they operate. Particularly, innovation in the manufacturing sector is a complex process that is propelled by numerous factors. This leads us to the question as to what drives manufacturing SMEs to technologically innovate. If a firm has to do so, it should have in-house technological competence in the form of technically qualified and motivated entrepreneurs or managers with innovative ideas and skilled employees. Similarly, there must be a market demand for the innovative products in the form of explicit customer demands or implicit market opportunities. Of course, the relative importance of these internal as well as external factors might vary from firm to firm or from industry to industry or even from economy to economy from time to time.
FACTORS INFLUENCING INNOVATION There are four primary issues concerning innovation and growth of SMEs, which include driving forces, dimensions, achievements and outcomes. Internal factors comprise self-motivation, technical education background, work experience and innovative ideas of entrepreneurs. On the other hand, external factors involve customer requirements, information given by suppliers of equipment/materials, market opportunities, availability and accessibility of institutional support, economic incentives, competition, etc. However, for successful innovation, a combination of both internal and external factors may be required. It is also important to note here as to whether SMEs are exclusively product focussed or process focussed or do they necessarily have to undertake both together. Firms might focus on the development of new products with either old or new technology, or on the improvement of existing products by changing the shapes/ designs or on quality improvement and cost reduction through substitution of raw materials, etc. However, the question that arises is what are the achievements of innovation by SMEs. If innovation is successful, it is important to assess whether new or improved products emerge due to product or process innovations, and whether the share of such innovative products is likely to increase the total sales of the firm. If this happens, such firms would
be able to achieve growth in their sales turnover, investment and employment resulting in the growth of firm size. In this backdrop, a study was conducted with respect to auto components, electronics and machine tool manufacturing SMEs in both rural and urban districts of Bengaluru. The objectives were: To ascertain the growth rates of sales turnover, investment and employment rates in innovative SMEs vis-Ă -vis noninnovative SMEs To probe the relationship between innovation and growth of sales turnover in SMEs
TECHNOLOGICAL INNOVATIONS BY SMEs A description of general features of SMEs in the three sectors is meant to set the stage for subsequent analysis. Almost 90 per cent of SMEs in these sectors were started as new ventures and the rest were either inherited or acquired. Technical education background in the form of diploma or degree (BE/ME/PhD) is a significant feature of entrepreneurship of these SMEs: 70 per cent entrepreneurs of auto, 69 per cent of electronics, and 81 per cent of machine tool SMEs were technically qualified. What is more significant is that majority of the entrepreneurs in these sectors had set up their firms to gain self-employment by implementing their innovative ideas and/or to exploit market opportunities. Their size characteristics revealed that structure of the SMEs was more skewed towards micro and small enterprises than towards medium-sized enterprises. Given this, it would be appropriate to know how many SMEs in the three sectors are innovative and how many are not. A majority of SMEs are innovative in all the three sectors. A greater proportion of SMEs in the auto sector is innovative, relative to electronics and machine tool sectors. SMEs are generally known for informal innovations – they carry out their innovations along with their day-to-day manufacturing operations within the same premises. The obvious reason is resource constraint. The same holds good for the SMEs surveyed in Bengaluru in all the three sectors. About 95 per cent of the SMEs in auto and machine tool sectors and 77 per cent in the electronics sector carry out innovations informally, without any exclusive innovation department. Given this, it is
important to know the driving forces of innovation. A sizable majority of the SMEs identified both internal and external factors as the driving forces of their innovations. However, a considerable number of SMEs in the machine tool sector have also identified external factors as the only driving force of their innovations. By and large, it is clear that both internal factors such as selfmotivation, technical education background, work experience, and innovative ideas of entrepreneurs on the one hand, and external factors such as customer requirements, information given by suppliers of equipment and materials, competition, etc, are responsible for a majority of SMEs to innovate. This implies that both firm-level technological competence (technology push) and market demand (demand pull) are important, if innovations have to emerge. Given this, it is appropriate to understand the dimensions of SME innovations. In general, SME innovations may be product focussed or process focussed or both.
PRODUCT AND PROCESSFOCUSSED INNOVATION A higher proportion of SMEs in auto and electronic sectors have undertaken both product- and process-focussed innovations whereas a majority of machine tool SMEs have undertaken only process-based innovations. Product-focussed innovations comprised the introduction of new products and/or the improvement of existing products through changing product designs and dimensions or quality improvement to suit customer requirements. Process-based innovations involved the introduction of new process technology for existing products, adoption of cost reduction techniques, etc. What SMEs achieve out of their innovations is an important issue. Only if they are able to convert their product and process innovations into sales, their innovations will be fruitful and not otherwise. Irrespective of whether new or improved products emerged due to improved designs, quality improvement, cost reduction, material substitution, introduction of new or improved processes, innovative firms must be able to sell innovative products in the market as part of their total sales. More successful innovative firms might realise a higher share of innovative products in total sales compared to less successful innovative firms.
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and employment for innovative and noninnovative SMEs is appropriate.
QUICK TAKE Most of the innovative SMEs attributed the origin of their innovations to a combination of: Firm level technological capability owing to internal factors such as self-motivation, technical qualification, knowledge, experience, and innovative ideas of entrepreneurs, Market pressure due to external factors like customer requirements and demand, information provided by suppliers of equipments and materials, market opportunities, and competition.
A higher percentage of innovative SMEs have succeeded in converting their innovations into sales in the auto component sector relative to electronic and machine tool sectors. Among those SMEs that have succeeded in converting their innovations into sales, the majority accounted for a share of innovative products in total sales in the range of 10-25 per cent in all the three sectors. A more significant reflection of achievements of SMEs through innovation will be in terms of recognition won by them. The recognitions won in terms of citations, and particularly national awards, are more impressive in all the three sectors. Overall, the ‘patenting culture’ is low among innovative SMEs, as has been observed internationally. The limited resources of SMEs generally constrain them from going for obtaining product and process patents. Finally, it is interesting to find out the outcomes of achievements of these innovative SMEs. If innovative SMEs are able to convert their innovations into sales,
they might be able to increase their sales turnover and increase capacity utilisation, or energy or manpower utilisation. Besides, they can also improve inventory management or enter the international market. It is clear that the majority of the SMEs in all the three sectors have identified increase in sales turnover as the most significant outcome of their innovation – achievements indicating that innovation has helped them to achieve growth in sales. To sum up, it is the combination of internal and external factors, which drive the majority of the SMEs to undertake both product and process innovations. As a result, many of them have been successful in selling innovative products in varying proportions of their total sales. Though the recognitions won, particularly in terms of patents are not noteworthy, a considerable number of them have won national awards. Also, more than half of the innovative SMEs have achieved sales growth due to their innovations. In this context, a comparative growth analysis in terms of sales, investment
CASE IN POINT Karnataka has been an industrially progressive state in the country. Bengaluru, the state capital, is one of the 46 ‘global hubs of technological innovation’ and the highest ranked global hub in Asia (UNDP 2001). Among the districts of Karnataka, urban and rural districts in Bengaluru had the highest proportions of small-scale industry (SSI) engaged in R&D and innovation. Similarly, among the two-digit level industries (as per National Industrial Classification 1987), machinery & equipment and transport equipment & parts industries had the highest proportions of small-scale enterprises engaged in R&D and innovation. The former comprises electronics & machine tools industries, and the latter includes auto component industry, among others. Bengaluru being industrially developed with a relatively high concentration of engineering and electronics industries in the country, it was only appropriate to focus on SMEs in this region to find out the technological innovation prospects in small businesses and their benefits, if any.
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INNOVATIVE AND NON-INNOVATIVE SMEs: GROWTH OF SALES, INVESTMENT AND EMPLOYMENT The growth performance of SMEs has been analysed in terms of sales turnover, investment and employment for all the SMEs of each sector – be it innovative or non-innovative. For measuring growth, all the SMEs are clubbed together in each sector. Further, in terms of innovative and non-innovative SMEs, the growth was measured for the respective group of SMEs together, without segregating growing ones from the rest. The same holds good for further analysis in terms of innovative SMEs, which have claimed to develop new products/processes, and those that have claimed to only improve products/ processes. It is clear that innovative SMEs have registered a higher rate of growth compared to non-innovative SMEs in terms of sales, investments and employment in all the three sectors. However, the growth rates of the three variables differ within as well as between sectors. In the auto component sector, both innovative and non-innovative SMEs registered a higher growth of investment followed by sales and then employment. In fact, employment of noninnovative SMEs declined to a great extent. In the electronics and machine tool sectors, sales growth was higher than that of investment and investment growth was higher than that of employment for both innovative and non-innovative SMEs. In the electronics sector, non-innovative SMEs registered negative growth in terms of investment and employment. Overall, the growth analyses for the three sectors clearly indicate that innovative SMEs perform better relative to non-innovative SMEs. In auto and electronic sectors, innovative SMEs engaged in the improvement of existing products/processes registered a higher sales growth than innovative SMEs engaged in the development of new products/processes. However, in the machine tool sector, sales of the latter grew faster than that of the former. How far SMEs have benefited from their innovations to increase their sales and grow in terms of investment and labour would depend more on their ability to satisfy customers’ needs and requirements rather than on the nature
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of innovations in terms of new products/ processes or improved products/processes. If improvement of existing products/ processes as required by their customers is appropriately done, it may prove to be more useful to increase sales rather than developing new products/processes. What might be more decisive is customer satisfaction to expand the market base of an enterprise and grow. Given this, it would be difficult to say whether new products/ processes or improved products/processes are more helpful to SME growth.
INNOVATION AND GROWTH OF SMEs If innovation helps a SME to improve sales performance, the following may hold good: There is a positive relationship between the percentage of innovative products in total sales and rate of growth of sales of innovative SMEs. Higher growth SMEs will have more share of innovative products in total sales relative to medium growth SMEs, which in turn will have higher share of innovative products in total sales compared to low growth SMEs. Share of innovative products in total
sales, along with rate of growth of capital as well as that of labour, has a significant influence on the rate of growth of sales turnover of innovative SMEs.
RIDING HIGH ON INNOVATION Most of the innovative SMEs attributed the origin of their innovations to a combination of firm-level technological capability owing to internal factors; and market pressure due to external factors. Thus, both ‘technology push’ and ‘demand pull’ have contributed to the emergence of innovations. The major objective of SME innovations was enhancement of competitiveness in the form of quality improvement, cost reduction, extension of product range and replacement of phased-out products, apart from penetrating the international market. Accordingly, they have primarily focussed on both product and process innovations in the auto and electronics sectors and process innovations in the machine tool sector. What is significant is that a substantial majority of the innovative SMEs could convert their innovative efforts into sales, as they realised varying proportions of innovative products in their total sales.
Innovative SMEs registered higher growth relative to non-innovative SMEs not only in terms of sales turnover, but also employment and investment in all the three sectors. There was a statistically significant positive correlation between innovation sales and sales growth. Innovative SMEs, which experienced higher growth, accounted for a higher share of innovative products in their total sales relative to those that experienced lower sales growth. Innovation sales, along with investment growth and employment growth, had a positive influence on gross value added (GVA) growth, in all the three sectors. To conclude, it can be said that innovation contributes immensely to the growth of firms. This article is an excerpt from the white paper, ‘Importance of Technological Innovation for SME Growth’ by M H Bala Subrahmanya & K N Krishnaswamy, Indian Institute of Science and M Mathirajan, Anna University. E-mail: bala@mgmt.iisc.ernet.in
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ENGINEERING EXPO PUNE 2010
PUNE
19-22 Nov ’10 Auto Cluster Exhibition Center
THE EUPHORIA BEGINS The fast emerging global mega trend of an economic boom is opening up new opportunities for businesses. While entrepreneurs leave no stone unturned to make the most out of these upcoming opportunities, trade fairs have emerged as a catalyst to help businesses flourish. In an endeavour to help engineering and manufacturing industry further leverage these opportunities, Engineering Expo-Pune 2010 is all set to roll out its fifth edition from November 19-22, 2010, at Auto Cluster Exhibition Centre. A preview… iding on the global upswing, the Expo has become a brand to reckon capture the emerging business potential. the Indian engineering with. Through its vast experience in The Expo has managed to generate business industry is reviving at a fast providing exhibitors and visitors a trade worth more than `155 crore during the last pace. The growing business platform to boost their bottom line, the fiscal. It has not just facilitated business, but prospects that have Expo has been setting milestones every also promoted new product launches and surfaced as a result of year. Critical locations like the four most joint ventures between companies.” galloping stock market and huge foreign prominent and emerging industrial hubs in ENGINEERING EXPO-PUNE investment inflow suggest that it is the right the country namely Pune, Ahmedabad, 2010 time to spread our wings and make the Indore and Chennai, and relevant themes Taking the legacy forward and being one of most out of these opportunities. in niche industrial segments such as machine the most successful editions of Engineering As the market improves and opens up tools, hydraulics & pneumatics, material Expo, the Pune Expo has gained an edge new avenues to be explored, it has also handling, automation and various other over other trade fairs in the business highlighted new challenges like the changing segments of engineering, make it a unique community. Engineering Expo-Pune is back business dynamics and high customer event that play the role of trade facilitator. in its strikingly optimistic fifth edition from demands. However, in order to survive the Highlighting the path-breaking November 19-22, 2010, at Auto Cluster challenges, it is of paramount importance to performance of Engineering Expo in its Exhibition Centre, Pimpri-Chinchwad, keep a keen eye on the upcoming trends earlier editions, Sudhanva Jategaonkar, Pune. and have regular interface with customers Associate Vice President - B2B Publishing, With more than 200 exhibitors, 25,000 to understand the market demands. Infomedia18, says, “Looking at the current business visitors, 6,900 business leads and Here lies the significance of trade fairs economic boom and the advent of MNCs business worth `65 crore last year, it is a where buyers and sellers network and offer in the country, it has become important for much-awaited event for the manufacturing real-time innovative solutions to each other. companies to be proactive in tapping the fraternity. Emphasising on the importance of opportunities that have emerged. The The event has already elicited high exhibitions, Anand Rajadhyaksha, Advertising Engineering Expo provides the right expectations from the exhibitors. Upbeat Manager-Nilkamal, says, “An exhibition environment and enables companies to with booming prospects, always helps exhibitors to exhibitors at the Pune spread awareness of their edition are looking forward products among potential to be a part of this year’s customers. Moreover, for exhibitors extravaganza. Reflecting his visitors, it increases their thoughts on the same, options to know about the business visitors Rajadhyaksha adds, “We latest products or Business generated worth are looking forward to technologies available in the business leads generated promote our enhanced market.” product range to buyers in Further talking of trade exhibitors were highly satisfied with the quality of visitors the automotive and allied fairs, Engineering Expo Product launches: Engineering Files by Pilot India, ancillary sector, who are stands tall and has earned a CNC Lathes & CNC Turning Machines by Electronica Hitech expected to visit Engineering well-deserving position Automation Partner: AVG Electronics Expo-Pune 2010.” among its counterparts. Agrees K Jagannathan, Having proved its mettle Power Partner: Kirloskar Oil Engines & Goel Power Controls Executive Director – Sales during the last eight years,
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ENGINEERING EXPO PUNE 2009 STATS 200+ 25,000+ `65 crore+ 6900+ 92% +
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Engineering Expo 2010-11: Season begins
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ENGINEERING EXPO PUNE 2010
Epitomising on the fast recovering engineering and manufacturing industry, the Engineering Expo 2010-11 is all set to contribute its humble share towards this growing surge of health among the Indian Inc. A complete manufacturing and engineering trade fair to display various products and services, the Expo is one of the most preferred platforms to grow business, as proved by 1,000+ companies, which participated in the previous editions of the Expo. More than 75,500 industrial buyers benefit from the Expo every year. Having generated a business of more than `155 crore and 17,200 business leads in the last fiscal, the Expo is expected to attract 1,00,000 footfalls by way of visitors from domestic and overseas markets in this year’s edition. The Engineering Expo will be held in four cities − Pune, Ahmedabad, Indore and Chennai. It will be held at Pune from November 19-22, 2010; Ahmedabad from December 10-13, 2010; Indore from January 7-10, 2011; and Chennai from March 11-13, 2011. All large, medium and small industries from the manufacturing & services sector will be showcasing their latest products and technology at the event. Leading engineering companies comprise the esteemed exhibitors list at the Expo. Some of these include: Autotech Machine Tools, Gandhi Automation, CTR Manufacturing, Atlas Copco, S&T Engineers, Omron Automation, Tussor Machine Tools, Boge Compressed Air Systems, Elgi Equipments and Igus India, among others. With the dedicated pavilions on machine tools & accessories, process machinery & equipment, electrical & electronics, hydraulics & pneumatics, automation & instrumentation, packaging & auxiliaries, IT products & services, safety & environment, general engineering, material handling equipment, logistics, testing & measuring equipment, banking and finance services, the Engineering Expo 2010-11 edition is all set to surpass its own expectations.
promises to provide a growth trajectory for manufacturers. The testimony to the fact is that in the last one year alone, three massive new plants owned by General Motors, Volkswagen and Mahindra & Mahindra were inaugurated here. Further establishing this fact, Jagannathan opines, “Pune has always been an important region for our products. We are hoping to make inroads in the CMM market as well as find new markets for our workholding, work positioning and machine tool products.” Another factor that has increased Pune’s manufacturing competitiveness is the proximity it has with the financial capital of India, Mumbai. Jagannathan further adds, “Pune is the leading centre for the automotive sector in India as well as one of the densest automotive clusters in the world. Automotive manufacturers like Tata Motors, Bajaj Auto, Mercedes-Benz and Fiat have their units here. Recently, three massive new plants from General Motors, Volkswagen and Mahindra & Mahindra were inaugurated here. Apart from this, there are other global players too in this region. Thus, Pune combined with good infrastructure and skilled workforce has become an ideal investment destination.” What adds to the confidence of exhibitors in participating at Pune edition is the presence of leading companies such as Misumi India, Alfa Laval, Praj Industries, Thermax, Bharat Forge, Kirloskar Oil Engines and Atlas Copco, among others.
& Marketing, Guindy Machine Tools, “Engineering Expo-Pune provides exhibitors with an excellent opportunity to showcase their latest products as well as interact with a wide spectrum of customers. For the visitors, it is not only a purchasing resource, but a source to see the latest technology trends. This is the first time we are participating in Engineering Expo-Pune and we have high expectations both in terms of sales and consolidating our position as India’s premier manufacturer of workholding products and indigenous coordinate measuring machine (CMM).”
CREATING A LEGACY With the advent of major MNCs setting up their base in the city, Pune has become a preferred investment destination in the country. Driven by innovation and design competence, Pune is being recognised as the nerve centre of manufacturing in India. More so, the investment spread in the city
The 4th Edition of Engineering Expo in Pune had an overwhelming response of over 25,000 business visitors.
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INNOVATIVE PRODUCTS & COLLABORATIONS Gauging the lucrative prospects of the Indian economy, companies are vying for a major share of the pie. In order to achieve this goal, companies are coming up with a new range of products & services. While the Expo provides a lucrative platform for launching new products & services, it also sets the stage for forging JVs and new partnerships. The Pune Expo shall witness a gamut of new product launches and technology developments in the market. Vikram Mane, VP- Saatveeka Trading Company, says, “We will be announcing a tie-up with M/S Schmolz + Bickenbach as its Channel Partner. With this tie-up, we will be in a position to service our customers for their total needs.” While talking about the products planned to be launched by Ferreterro India, Saurabh Khandelwal, Director of the company avers, “We are launching three new products at the Expo for the first time in Asia. These include ‘PEWAG – World’s strongest chain manufacturer’, ‘First Sling – World’s first and most transparent lifting sling’ and ‘Ferreterro Exxtreme – World’s strongest
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Engineering Expo-Pune provides exhibitors with an excellent opportunity to showcase their latest products as well as interact with a wide spectrum of customers.
a platform to showcase them.” Jagannathan adds, “Apart from our topof-the-line workholding products like the power operated auto indexing chuck and special workholding tailor-made to meet customers’ requirements, we will be showcasing our newly launched GMT Co-ordinate Measuring Machine– Grano 7-10-6.”
COUNTING BACKWARDS K JAGANNATHAN, Executive Director – Sales & Marketing, Guindy Machine Tools
sling to lift 300 tonne goods.” Talking about the latest technology products, Milan Supanekar, Director – Welding Technologies India, says, “We have added few latest technology products. So far, we have been mainly focussed on welding products (welding machines and consumables) and all range of products related to welding & cutting. We have recently established new partnerships for environment-friendly products used for welding & cutting as well as in welding consumables. We will use the exhibition as
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Time and again, Engineering Expo has proved to be a preferred display point of latest innovations in the field of engineering. And this time again, it is expected to surpass all the industry expectations. Gauging from its past experiences, it is believed that the Engineering Expo-Pune is geared up to offer the best platform for the engineering fraternity to explore new product offerings and technology advancements by bringing in tremendous opportunities for them. It is now action time for the manufacturing industry to reap the maximum benefits by taking the lead in encashing on the booming prospects that Engineering Expo – Pune Edition 2010-11 is slated to offer. Curtains open on November 19, 2010…
ELECTRONICA + PRODUCTRONICA INDIA 2010
CHARGING UP FOR GROWTH The electronics industry has been a sunrise industry globally. Its rapid growth is evident from the huge success of the recently held trade exhibition, electronica India 2010 and productronica India 2010 at Bengaluru. Organised by Messe München International and its subsidiary MMI India, with SEARCH as media partner, the event had an electrifying impact and proved to be a leading platform for the electronics industry in India and Southeast Asia. he electronics industry in India is growing rapidly and investments are flowing in to augment the manufacturing capacity. To provide an effective platform to sustain the growth of the electronics industry, in India and Southeast Asia, electronica India 2010 and productronica India 2010 was organised at the Bangalore International Exhibition Centre Esteemed dignitaries lighting the traditional lamp during inauguration ceremony (BIEC) from September 7-10, 2010, by Messe München International and its clients, we were surprised to see a huge subsidiary MMI India. number of budding engineers at the exhibition.” Meanwhile, a first-time exhibitor, EVENT AT A GLANCE Praveen Madaan, Regional Sales Manager, The event encompassed 869 exhibitors and ASYS Group Asia, said, “This is the first time represented companies with 331 direct we are exhibiting here, and MMI has exhibitors, recording a 21 per cent increase surpassed our expectation with their as compared to last year. In two halls, professional approach. We are aiming to use covering an area of 13,000 sqm, exhibitors from over 25 countries including Japan, Switzerland, the US, Italy, Spain, Korea, Malaysia and Hong Kong showcased their Having seen the response to this products. Countries like Germany, UK, year’s edition of the exhibition, it is China, Singapore and Taiwan showcased evident that India is emerging as an their innovative offerings for Indian customers. The exhibitors witnessed important port of call for companies closures of major deals and an increase in from around the world. the number of quality inquiries. Altogether, the show attracted over 12,245 visitors NORBERT H BARGMANN, which is an increase by 18 per cent. Deputy Chairman & CEO, Highlighting their experience, Yukihiro Messe München International Terada, Deputy General Manager, Manufacturing Systems Division, Sony Thai Co, said, “We are highly satisfied by the this platform on an ongoing basis to showcase turnout and have received several new our product and service offerings.” inquiries. We are looking forward to FOCUS ON CONFERENCES participating in the Delhi exhibition next year The fair featured LED in the special focus too. In addition to meeting prospective
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area. Two high-profile international conferences were also held at electronica India and productronica India. The ‘Conference on Contract Manufacturing: The Indian Perspective’ held on September 7, 2010, highlighted trends, new technologies, opportunities and requirements of the Indian EMS/ contract manufacturing industry. The second conference on September 8, 2010, titled the ‘Symposium on the Trends and Future Requirements in Automotive Electronics’ focussed on various developments in the area of automotive electronics. Commenting on the success of the event, Norbert H Bargmann, Deputy Chairman & CEO, Messe München International, said, “Having seen the response to this year’s edition of the exhibition, it is evident that India is emerging as an important port of call for companies from around the world. This country has one of the fastest growing economies globally and has made its presence felt in international trade fairs and exhibition industry.” Darryl Dasilva, CEO, MMI India, further added, “With the high growth that the electronics industry has witnessed over the past few years, platforms such as electronica India and productronica India will play a vital role in building the future of this industry.”
ON A PROMISING NOTE The event ended on a positive note, with over 42 per cent of the exhibitors rebooking themselves for electronica India and productronica India 2011. The next electronica India and productronica India will be held from September 13-16, 2011, at Pragati Maidan, New Delhi.
NATIONAL SEMINAR ON CHALLENGES IN TRANSMISSION & DISTRIBUTION
DRIVING EFFICIENCY THROUGH AUTOMATION Capacity addition has been high on the agenda of the power sector, but efficient transmission and distribution through optimal utilisation of power grid through automation is the need of the hour. Highlighting the significance of automation to ensure effective T&D, the ‘National Seminar on Challenges in Transmission & Distribution & Role of Automation’ was organised by the Confederation of Indian Industry with SEARCH as a media partner on October 1, 2010, in New Delhi. A report... GEETHA JAYARAMAN utomation has definitely worked wonders in the area of transmission and distribution (T&D), but it needs to be deployed on a wider scale for the benefit of the power sector and the people at large. This was the general sentiment witnessed at the ‘National Seminar on Challenges in Transmission & Distribution & Role of Automation’ held recently in New Delhi. While inaugurating the event, Gireesh B Pradhan, Additional Secretary, Ministry of Power, Government of India, said that with ever-increasing demand, and the resources available for power transmission unevenly spread across the country, the guiding objective lies in the optimal utilisation of the national grid through automation. “Keeping in view the critical role of the power sector in promoting the overall development of the country and consequent poverty alleviation, adoption of automation in power T&D is the key to furthering the goal of ‘Electricity For All’ and in providing electricity to the unelectrified villages. Efficient T&D would make a real difference in how we manage the supply and demand situation,” he said. A smart grid will be essential to the power sector, and keeping this in mind, the Power Ministry has constituted a task force as well as a smart grid forum to address the issues pertaining to this. In building the smart grid, the stakeholders should not lose sight of the entire chain of T&D, Pradhan said.
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EVENT FOCUS The event brought to the fore various challenges faced by the power sector. SK Chaturvedi, Chairman and MD, Power Grid Corporation of India (PGCIL), in his address, said that the focus on sustainable development
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would pose challenges as well as create opportunities for the power sector. The challenge lies in ensuring 24x7 quality power supply with stable voltage to all, he said, while adding that over the next two decades, the Indian power sector will occupy the centre stage of development and attract world’s attention. According to Chaturvedi, the key challenges with respect to T&D include: Non-availability of price preference to domestic industry in domestically-funded projects having international competitive bidding Bunching of orders leading to sub-optimal utilisation of manufacturing capacities Lack of standardisation in technical specifications Absence of price variation clause Lack of adequate testing facilities and limited trained manpower base Taxation-related issues Barriers to the use of automation. Though automation finds various applications in the power T&D segment, more needs to be done. Standardisation of processes and practices is the need of the hour and all states should seek to follow specific industry standards while pursuing power T&D programmes, voiced industry experts present at the seminar. Pradhan pointed out, “The Power Ministry is keenly focussed on enhancing domestic equipment and services employed in the sector. Moreover, as it realises the need for a large pool of trained manpower to complement the modernisation of the sector, the ministry has encouraged the establishment of industrial training institutes (ITIs) for developing a cadre of skilled manpower for the power sector.” Adding further, he said, “Excess reliance on overseas suppliers often
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leads to bottlenecks in the after-sales services, availability of spares, etc. The adoption of appropriate technologies and designs will help the sector in overcoming some of these barriers.”
MAKING INDIA THE POWERHOUSE The growing use of gensets, voltage stabilisers, and other electrical appliances is an endorsement of the vibrancy of the sector. Adding to this, Ramesh Chandak, Chairman, CII Transmission Line Division, & MD, KEC International, said that for India to become a major powerhouse in the global economy, the power generation sector would have to become the backbone of the economy. In terms of transmission, he said that bulk transmission of power has increased from 3,700 ckt km in 1950 to over 1,65,000 ckt km now, indicating a 40-fold growth. Supporting the organisation of such events, Vimal Mahendru, President, Indian Electrical and Electronics Manufacturers Association (IEEMA), & Executive Director, Indo Asia Fusegear, said that major events like ELECRAMA have demonstrated robust character of the power sector.
PROMISING OUTLOOK From 3,000 electrified villages in 1951, there are 4,98,000 electrified villages today. This demonstrates the government’s effort for rural electrification through various schemes including Rajiv Gandhi Grameen Vidyutkaran Yojana. The experts urged the government to address the issues related to payment terms in financing of the projects on priority. The power sector would greatly benefit if bank guarantees were provided against release of funds upon completion of projects, they noted.
HYDRAULICS 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 248 to find it quickly
HYDRAULIC PRESSES
HYDRAULIC CYLINDRICAL GRINDERS
owercom hydraulic presses (IR P 55) offered by Qureishi Enterprises have been designed to compress joints on conductors and steel cables during stringing operations. Hydraulic presses of 55-ton compressive capacity are suitable for compression of joints on conductors and steel ropes for electric lines. Excellent weight/power ratio (2.9 ton/kg), easy to operate on suspension working platforms and steel towers, are some of the features of these hydraulic presses, thanks to the specific cover fitted on the press body. Maximum hexagonal key of 44 mm allows pressing of an electric cable of 31.5 mm diameter. Power/weight ratio is good and pressing cycle is very short. All the components are interchangeable and all the presses can be supplied with motorised (petrol or electric engine) or hand pumps. All presses comply with European safety standards (CE). The hydraulic presses come in two types, ie, dual pipe and single pipe.
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Qureishi Enterprises, Mumbai 400 050. Tel: 022-6785 9999, Fax: 022-2643 4462 Email: sales@slingset.com, Website: www.slingset.com
Pitroda Utility Industries, Wadhwancity 363 030. Tel: 02752-243795, Fax: 02752-243167, Mob: 09825416108 Email: response@pitrodautilityindia.com Website: www.pitrodautilityindia.com
itroda Utility Industries offers hydraulic cylindrical grinders (model PUI-300) available in hydraulically and mechanically operated versions. The base of these cylindrical grinders is made of close-grained and heavily ribbed casting for high rigidity. The hand-scraped V-flat table guideways have continuous lubrication. Longitudinal hand travel of the table is by rack & pinion arrangement and automatic travel by hydraulic mechanism. The hydraulic system consists of hydraulic pump, valve, lever, piping, etc; conveniently housed in the base as well as separate powerpack. Wheel head spindle is made of case hardened nickel chrome alloy steel ground and micro-finished and runs in adjustable Phosphorous bronze metal bush bearings to achieve high accuracy adjustable and long life. Drive to the wheel head is transmitted by two V-belts. Workhead spindle is made of special alloy steel and runs in taper roller/angular contact bearings. The hydraulic cylindrical grinders are supplied with all electricals suitable for 400/440 V AC, 50 Hz.
HYDRAULIC TANK ACCESSORIES luden hydraulic tank accessories offered by Fluid Power Engineers are designed to suit all hydraulically operated machines. These tank accessories include strainers, breathers, oil level indicators, check valves, tube clamps and curved tooth gear couplings. The accessories are of small prices but of big value for any hydraulic system (claims the company).
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Fluid Power Engineers, Ahmedabad 382 415. Tel: 079-2289 1665, Fax: 079-2289 1666, Mob: 09426068483 Email: info@fluden.com, Website: www.fluden.com
HYDRAULIC PRESSES anel board operated hydraulic presses manufactured by Dowel Engineering Works range from 15 ton to 300 ton capacity in mild steel robust construction. The crown, column and bottom are solid without bend and welded. Table is vertically operated by worm winch gearbox and rest on load pins placed in holes in column at desired height. Here is an option to operate bed-by-bed lifting attachment electrically operated. Rollers are provided with the bed for easy handling of heavy jobs. The cylinder is made from honed tube and hardchrome plated ram is made from mild steel, operated by doubleacting cylinder. Good quality seals assure long working life. The ram is provided with replaceable socket to facilitate attachment of dies and tools, on customer’s request. These presses are equipped with high-pressure hydraulic pump, DC valve, pressure relief valve, etc.
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Dowel Engineering Works, Rajkot 360 002. Tel: 0281-2362465, Fax: 0281-2362465, Mob: 09824231975 Email: dowel@thedowel.com, Website: www.thedowel.com
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HYDRAULIC PALLET PUMPS enith Hydromatic offers pallet pumps in capacity ranging from 1 ton to 5 tons with 115 mm stroke. The sealing arrangement imported PU seal/bronze filled for long life and frequent replacement by a new one is not required. Piston rod and plunger is hardened, hard chrome plated and internal bore honing for longer life of the seals. The mounting arrangements can be altered to suit the mounting dimension as specified by customers. Also manufactured are hydraulic cylinders, force feed lubricators, hydraulic power packs, valves, auto bike lifters and double plunger pumps. Special-purpose lubricators, hydraulic cylinders, valves, pumps and lifting jacks are also developed as per specifications given by customers.
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Zenith Hydromatic, Ahmedabad 382 330. Tel: 079-2281 2945, Fax: 079-2281 2945, Mob: 09824167178 Email: response@hydraulicsystemsindia.com Website: www.hydraulicsystemsindia.com
HYDRAULIC CYLINDERS
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rident Products manufactures and offers tie rod hydraulic cylinders for machine tools as per ISO 6020 specifications. These hydraulic cylinders are available in bore sizes ranging from 40 mm to 100 mm and stroke of 100, 150 & 200 mm. They are also be available in 32 mm to 160 mm bore sizes. The hydraulic cylinders are designed and manufactured as per customers’ requirements, these are also available with position feedback systems.
Trident Products Pvt Ltd, Gurgaon 122 016. Tel: 0124-4300626, Fax: 0124-4300627 Email: trident.sales@tridenthydraulics.com
HYDRAULICS
HYDRAULIC POWER PACKS ce Automation Engineers offers hydraulic power packs for machine tool industry. For the machine tool industry a number of applications have been covered. These include standard applications, like auto lathe, surface grinding, milling & also special-purpose machines like gap grinding machines (piston ring plants), button removal (piston plants), caulking machines (automobile plants), drilling & milling (brake shoe plants). Operations performed are job clamping, fast tool approach, slow machining feed, fast retraction & de-clamping. The feed rate is controlled using pressure & temperature compensated valves to ensure constant feed rate irrespective of temperature & pressure variations.
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Ace Automation Engineers, New Delhi 110 015. Tel: 011-2511 8561, Fax: 011-2515 3917 Email: sales@acefluidpower.com, Website: www.acefluidpower.com
HYDRAULIC FLOOR JIB CRANES andy hydraulic floor jib cranes manufactured by Technical Enterprises are available with extendable boom, in 1-, 2- and 3-ton capacities and vertical height reaching up to 4 meters. These cranes are also provided with extended base in the rear for putting counter weight, in case the boom is extended beyond the base
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wheels. They are suitable for loading/unloading heavy materials from trucks in the open yard and carry them inside the shop. The cranes are extensively used in engineering workshops for loading/ unloading jobs on the machine tools where there is no provision of an overhead crane or it is busy elsewhere. In repair garages, these are required for handling engines and its parts. They are equipped with high precision hydraulic cylinder and hard chrome plated ram, which provides upward thrust to the boom while lifting. Lowering is hydraulically cushioned to avoid jerks. Technical Enterprises, Meerut 250 103. Tel: 0121-2440660, Fax: 0121-2440666 Email: techent@ndf.vsnl.net.in, Website: www.handyonnet.com
HYDRAULIC FLOOR CRANES ikas Hydro Inc offers hydraulic floor cranes that provide an efficient low-cost alternative to other material handling equipment. These cranes are strong, robust, sturdy and built to very high standards. They are easily maneuverable and have a very small turning radius. The cranes are ideal for loading, unloading and shifting of heavy loads. Structure of the cranes consists of chassis, vertical column, derrick (inner & outer boom) and the hydraulic cylinder assembly. All models above 1-ton capacity have a double column box frame made of steel pipes. The box frame can take heavy loads, while its wide bearing on the chassis effectively avoids twisting and damage to the crane under rough and unskilled
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handling. Advantage of this structure is that it diverts the resultant force to the centre of the chassis thereby greatly reducing the possibility of imbalance about the longitudinal centre of the chassis. Vikas Hydro Inc, New Delhi 110 044. Tel: 011-3098 9505, Fax: 011-2989 3217, Mob: 09313807583 Email: vikashydroinc@rediffmail.com
HYDRAULIC CYLINDERS ertex Hydraulics manufactures and offers hydraulic cylinders that are suitable for heavy-duty applications up to 160 kg/cm² and 250 kg/cm². These cylinders are available in bore sizes of 40, 50, 63, 80, 90, 100, 125, 140, 160, 180, 200, 220, 240 and 260 mm. Some of the construction features are: welded construction to rigidity; surface finish of micro honed tubes of ones 0.4 Ra; piston rods (ground), hardchromeplated and reground to finish better than 0.1 Ra for longer seal life; fine adjustable cushioning with locking arrangements; provision of bleed screw at both ends; and option of minimum two rod sizes for each bore. Special purpose adjustable stroke cylinder is provided with 30 to 35 per cent adjustment in stroke. These hydraulic cylinders find application in plastic injection moulding machines, where moulded goods are picked up by robots.
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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
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PNEUMATICS
PNEUMATIC NAILERS aymo Fastener Company offers pneumatic nailers (model PNKF-38100) that weigh 5.24 kgs and have coil nail type of 16-degrees. Salient features include: top exhaust deflector to direct air away from the operator; ergonomically designed handle with a soft rubber grip; high nail loading capacity nylon magazine; special screwable handle fitted near the nose for proper maneuverability; side metal guard to prevent tool body getting damaged; reversible bumper for longer durability; operate at air pressure between 75 psi to 120 psi; and air consumption @ 5.38 LPM. Technical specifications are: head dia of nails 5.8 mm to 7.2 mm; nail diameter from 2.5 mm to 2.9 mm; shank lengths 60, 65, 70, 75, 80, 90 & 100 mm; and shank type as smooth, ring & screw. Applications are in pallet manufacturing, packaging (wooden crates), furniture, door frames, fencing, wooden decking, etc.
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Kaymo Fastener Company, Mumbai 400 011. Tel: 022-2495 2966, Fax: 022-2493 6823 Email: sales@kaymo.com, Website: www.kaymo.com
PNEUMATIC ROTARY ACTUATORS ira Euro Automation offers pneumatic rotary actuators as per ISO:5211 International standards for quarter turn ball valves, butterfly valves, damper controls, etc. Torque values up to 4500 Nm are available in size range suitable for ball valves up to 10� and butterfly valves up to 24�. These provide sliding skates between the piston and inner surface of the actuator. This prevents metal-tometal friction and enhances the life of the actuator. The actuators
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are compact in design and offer high torque value by consuming more air due to the deep hole in the racks. They contain preloaded spring cartridges, which prevent accident risk during disassembling. Accessories include: solenoid valve as per Namur standard; limit switch box with position indicator as per Namur standard; filter + regulator with gauge; manual override; pneumatic valve positioner; and I/P converter. Aira Euro Automation Pvt Ltd, Ahmedabad 382 405. Tel: 079-4024 7003, Fax: 079-4024 7012 Email: info@airaindia.com, Website: www.airaindia.com
PNEUMATIC VALVES eljan Hydrair manufactures and offers pneumatic valves that are 2/3/4-way directional control valves with air pilot, hand lever, roller cam and solenoid operators. The detented three-position mechanism provides stable positioning. Stainless steel spool moves on thin film of air with micronic clearance. There is no wearing contact, no seals to wear and low shifting forces. Other features include: quick response & high cycle rates; extremely long service life; unique advantages by direct mounting onto the cylinder; and available from 1/8� to 1� with BSP or NPT port threads.
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Veljan Hydrair Pvt Ltd, Hyderabad 500 037. Tel: 040-2377 2794, Fax: 040-2377 2794 Email: info@veljan.com, Website: www.veljan.com
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PNEUMATICS
PNEUMATIC PLUG VALVES otex Automation offers pneumatic plug valves with rotary actuators. These plug valves are ideally suited to aggressive corrosive and potentiality hazardous media. They have absolute tight shutoff in case of sleeved plug valve. Other features include: long life due to taper plug construction, frequency operations possible, suited for slurry application, line plug valve suited for corrosive service on/off or control duty. The design of the plug valves is as per BS:5343 (with sleeved plug valve); and fire safe as per APED, fre tested to AP16FA. Various types are available, such as lubricated, taper plug valves, pressure balance sheet plug valves, and sleeved plug valve. Materials of constructions include: cast iron, double iron, cast steel/cast stainless steel, alloy steel. Special materials are available upon request.
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Rotex Automation Ltd, Vadodara 390 010. Tel: 0265-2638136, Fax: 0265-2638130, Mob: 09727766313 Email: rotexbrd@rotexindia.com, Website: www.rotexindia.com
PNEUMATIC CLUTCHES & BRAKES irtorq India offers pneumatic clutches & brakes that consist of an air actuated disc clutch and spring applied disc brake. The compact design combined with high thermal capacity and low air consumption makes them ideal for high-speed, high cyclic, heavyduty industrial application. When the cylinder is pressurised, the piston clamps the clutch disc to the hub, which transmits the torque
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PNEUMATICS
to the shaft. When the cylinder exhausts, the springs moves the piston in the opposite direction clamping the brake disc and stopping the shaft. Overlap between the clutch and brake is completely eliminated. Some of the advantages are: high thermal capacity, stable coefficient of friction, low air consumption, low operating & maintenance cost, easy removal of worn out linings, etc. Applications are in power presses, press brakes, guillotines, printing machines, woodworking machines, etc. Airtorq India, Delhi 110 042. Tel: 011-2783 5798, Fax: 011-27834798, Mob: 09810120341 Email: info@airtorq.com, Website: www.airtorq.com
PNEUMATIC CYLINDERS TA Engineers manufactures and offers a wide range of air cylinders, designed for reliability and trouble-free operations. These cylinders are available up to bore size of 200 mm and stroke length of 500 mm with different rear and front mountings, like clevis, trunion, flange, etc. The cylinders are also offered as per customer’s specific requirements. Pneumatic systems to suit various pneumatic applications are also manufactured.
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Eta Engineers, Mumbai 400 003. Tel: 022-2344 9893, Fax: 022-2342 3189 Email: sales@etaengineer.com, Website: www.etaengineer.com
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PNEUMATICS
PNEUMATIC STIRRERS uji air Tools offers pneumatic stirrers (model APAM-3-4TS) that can be mounted on a flange. These stirrers have free speed of 500 rpm. They have stainless steel rod and a set of four blades. The pneumatic stirrers can be used continuously for stirring of paints, chemicals, fluids, etc. Being pneumatic, they are completely flameproof, shock-free and spark-free. If there is an excess load during stirring, the stirrers will just stall temporarily, and when the excess load is gone, they will start working normally, without any damage. Exhaust air can be left to the atmosphere through a silencer, or it can be piped away to another location. Applications are in paint industry, pharmaceutical industry, processing and petrochemical industry, etc.
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Fuji Air Tools (India) Pvt Ltd, Pune 411 043. Tel: 020-2439 1152, Fax: 020-2439 0955 Email: fujiindia@rediffmail.com, Website: www.fujindia.com
PNEUMATIC FEEDERS
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KI Automation fabricates a wide range of vertical pneumatic self-feeders that are manufactured using superior quality steel and aluminum. These pneumatic feeders are appreciated for their high tensile strength and anti-corrosive properties. The range can also be customised as per the requirements of customers. The pneumatic feeders are both durable and safe to use.
SKI Automation Pvt Ltd, New Delhi 110 027. Tel: 011-6545 2401, Mob: 09312593170 Email: info@skifeeder.com, Website: www.skifeeder.com
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PNEUMATICS
PNEUMATIC FASTENING TOOLS an Air Tools offers pneumatic fastening tools that are used as drilling tools. The range of air drills is made from high-grade steel, brass and other alloys. These handy air drills are offered with straight and gun handle design. They have a chuck capacity of 6 mm and can operate at a speed of 1600 and 2500 RPM. These costeffective drills are capable of executing mass drilling of holes that is very much required in aircraft industry, rail coach, bus body assembly and other similar applications. They are operational at working pressures of 6 kg/cm². The pneumatically or air-operated drill machines are available in straight-type or gun-type.
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San Air Tools, Thane 400 601. Tel: 022-2534 1981, Fax: 022-2534 2692, Mob: 09819747122 Email: sanairtools@vsnl.net, Website: www.sanairtools.com
PNEUMATIC MACHINE VICES rcan Products of India manufactures pneumatic machine vices. Gripping through manual screw adjustment and rigid clamping is done through these pneumatic machine vises. The machine vices have in-built sophisticated piston mechanism. They have clamping power of 4500 N at 7 bar (100 PSI) air pressure. Ground and hardened tool steel jaws are provided for perfect parallelism.
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Orcan Products of India, Faridabad 121 001. Tel: 0129-2230063, Fax: 0129-4033248, Mob: 09811043930 Email: orcan@vsnl.com, Website: www.orcan.com
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INDUSTRIAL PAINTS & POLISHES
PAINTS & ALLIED PRODUCTS alark Chemicals manufactures and offers pigment raw materials like liquid chlorine, caustic soda lye, caustic soda flakes, aluminum chloride, cotton bales, anti-corrosive paints, etc. A wide range of products starting from anti-corrosive coatings, like polyurethane, epoxy, chlorinated rubber paints, epoxy base floor coatings, special polymer base paints, heat resistance aluminium paints, coatings for rubber, leather, plastic, FRP, for architectural and hygienic wall coating, peelable coatings, glass coatings, matching primers and thinners, etc, are also available. Job work in supply and apply basis, ie, on turnkey basis is also undertaken in case of considerable job value and for corporate clients.
CHEMICAL-RESISTANT PAINTS gam chemical-resistant paint products offered by Leader Paints Marketing, have excellent chemical resistance and are widely used in chemical industries. Special products are also manufactured as per requirements for special chemical resistance on request. The chemical-resistant paints provide chemical resistance to all mild
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Balark Chemicals, Ahmedabad 380 014. Tel: 079-3008 9006/09, Fax: 079-3008 7007, Mob: 09824001010 Email: info@balarkchemicals.com, Website: www.balarkchemicals.com
PNEUMATIC PISTON PUMPS echnochem Service Corporation offers pneumatic piston pumps. These piston pumps supply paint continuously to the gun. They can be used for transferring of paints and inks. Ratio available is 1:2.5,5. Operating pressure is 7 kgf/cm². Maximum paint output is from 4 to 20 LPM.
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Technochem Services Corporation, Pune 411 018. Tel: 020-2766 0862, Fax: 020-2766 0862, Mob: 09922556565 Email: tscorp@hotmail.com, Website: www.tscspraypaintgun.com
PAINT COAGULATION SYSTEMS rism Surface Coatings offers compact online paint coagulation and sludge removal systems manufactured by HydoItalia, Italy. These systems eliminate all the shortcomings of the conventional sludge pit type paint removal system. In automatic paint sludge removal systems, paint content in the water circulated in the booth is maintained constantly below 0.2 per cent. Hence, there is no sludge clogging the venturi, pipes or eliminating the necessity to clean the scrubber resulting in uniform performance of the booth, less maintenance work and reduction in maintenance work by 90 per cent. Due to this, changing the water needs to be carried out only once in a year as compared to 3 months in the conventional pit type system. The size of the pit required for this system is 1/6th of the conventional systems greatly reducing capital cost and freeing valuable floor space. BBOT model is available for large plants.
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acids and mild alkalies. Leader Paints Marketing, Pune 411 030. Tel: 020-2443 4075, Fax: 020-2443 4075, Mob: 09371012245 Email: ugamchem@hotmail.com, Website: www.leaderpaintmarketing.com
AUTOMOTIVE PAINTS mperol Colours manufactures and offers automotive paints. NC automotive finish is a single component, air-drying, and nitrocellulose based paint. Refinishing coating is ideal for auto car, and other vehicle to get good abrasion resistance, petrol and oil resistance with better polishing property. NC super finish is economical single component, airdrying, nitrocellulose based paint. Refinishing is coating ideal base coat for auto car, and other vehicle to get good abrasion resistance, petrol & oil resistance with better polishing property. These paints are also good for furniture and appliances coating where fast drying is required.
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Emperol Colours Pvt Ltd, Mumbai 400 075. Tel: 022-2506 5576, Fax: 022-2506 5253, Mob: 09869711706 Email: emperol@rediffmail.com Website: www.emperolcolours.tradeindia.com
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PAINT REMOVERS
Prism Surface Coatings Pvt Ltd, Bengaluru 562 158. Tel: 08810-417999, Fax: 08119-417900, Mob: 09844400285 Email: sales@prismsurface.com, Website: www.prismsurface.com
Hero Paints Pvt Ltd, Delhi 110 035. Tel: 011-2831 3601/3782, Fax: 011-2831 1493 Email: info@heropaints.com, Website: www.heropaints.com
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ero Paints offers paint removers or strippers that are solvent mixtures designed to remove paint and other finishes and also to clean the underlying surface. The principal active ingredient is usually dichloromethane. Formulations with orange oil (or other terpene solvents), N-methyl pyrolidone, esters (often di-methyl esters of shorter dicarboxylic acids, sometimes aminated, for eg, adipic acid or glutamic acid), aromatic hydrocarbons, dimethylformamide, and other solvents are known as well. The formula differs according to the type of paint and the character of the underlying surface. Paint strippers come in a liquid, or a gel (thixotropic) form that clings even to vertical surfaces. The principle of paint strippers is penetration of the paint film by the molecules of the active ingredient, causing its swelling; this volume increase causes internal strains, which, together with the weakening of the layer’s adhesion to the underlying surface, leads to separation of the layer of the paint from the substrate.
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INDUSTRIAL PAINTS & POLISHES
TOUCHUP SPRAY PAINTS om-Paint touchup spray paints manufactured and offered by Aeroaids Corporation are the first Indian original touchup spray paints (claims the company). These touchup spray paints are specially formulated to touchup cars, motorcycles, refrigerators, washing machines and other components. Features include unique easy-to-spray paint, dry in minutes; no more trips to the painter, save money and time; available in original shades for cars & motorcycles; and clear lacquer for metallic shades available separately. The ComPaint touchup spray paints are available in three sizes, ie, 100 gms for motorcycles, 160 gms for cars, and 300 for general use.
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Aeroaids Corporation, Delhi 110 033. Tel: 011-2722 0190, Fax: 011-2713 1455 Email: aeroaids@vsnl.com, Website: www.com-paint.com
POLYURETHANE THINNERS ustin Paints & Chemicals offers a wide range of chemicals and paints in order to ensure that the demands of different clients are perfectly met. A wider variety helps customers to select the required products as per their needs. An extensive range of top quality polyurethane thinners are offered that has excellent wear or scratch resistance and can be used for durable finish.
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Austin Paints & Chemicals, Kolkata 700 056. Tel: 033-2564 7407, Fax: 033-2553 5788, Mob: 09836001985 Email: chinmoy.austin@gmail.com, Website: www.indiamart.com/austinpaints
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INDUSTRIAL PAINTS & POLISHES
CORROSION-RESISTANT PAINTS tar Paint & Oil Industries offers Rubberex acid, alkali, chemical and corrosion-resistant paints that are based on a highly stable rubber hydrocarbon compound of uniform quality, which gives a highly durable and anti-corrosive protective coating. These are fast airdrying paints with which the coating obtained is of excellent hardness elasticity and free from pores. Due to the chemical inertness, the paints shield the effects of water, moisture, stream, acid fumes, alkalis, salt vapoors and transitory wetting organic solvents on metal surfaces. Applications include: protection from effects of acid fumes, industrial pollution and corrosion on steel structures and pipelines in refineries and petroleum complexes, stresses (Kate) of overhead roofs in sugar and chemical plants, suspension springs of motor vehicles, ship body from salty sea conditions, etc.
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Star Paint & Oil Industries, Mumbai 400 023. Tel: 022-2265 2243, Fax: 022-2265 3201 Email: info@starpaintindia.com, Website: www.starpaintindia.com
WATERPROOFING & DECORATIVE OUTDOOR PAINTS hura Consultants offers Phencoat (white) a very high quality waterproofing-cum-decorative outdoor paint. It is off-white in colour and can be stained with standard paint stainers to any required shade. The paint is based on chlorinated rubber, which gives excellent long term waterproofing on concrete or plaster and has outstanding resistance to UV rays in sunlight and all other weathering factors. It has high adhesion to China mosaic and is fungus-resistant.
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Ahura Consultants, Mumbai 400 007. Tel: 022-2388 7771 Email: ahuraconsultants@hotmail.com, Website: www.ahuracontractors.com
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INDUSTRIAL PAINTS & POLISHES
SYNTHETIC ENAMELS roma Paints offers full gloss hard drying synthetic enamels (Aroma No 1) based on special synthetic resins and selected light fast and chalk resisting pigments. These synthetic enamels are recommended for all types of exterior and interior surfaces, such as wood, sheet metal, castings, transport and passenger vehicles, sign board painting, agricultural implements, machinery and plasters. They are tough & durable and highly resistant to marine and industrial atmospheres. The synthetic enamels come in packing of 1, 4, 10 & 20 ltrs; and 50, 100, 200 & 500 ml.
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Aroma Paints Ltd , Sonepat 131 001. Tel: 0130-6534070, Fax: 0130-2256558, Mob: 09812043070 Email: aromapaints_23@yahoo.co.in, Website: www.aromapaints.com
INDUSTRIAL PAINTS ajrang Paints manufactures and offers industrial paints in various thicknesses and colours that perfectly suit the requirements of clients and are also cost-effective. These paints provide good shine and superior finish to the walls, floors as well as ceilings. All paints are made after intensive research so that they provide the desired effect in just one coating. The range of paints include polyurethane, acrylic, polyester, epoxy-coating (single pack/two pack), synthetic, stoving, fast drying, metallic shades, hammer-tone, wrinkle finishes, flooring, heat resisting silicon, aluminum (30째C to 100째C), nonconductive, black Japan and stack black.
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INDUSTRIAL PAINTS & POLISHES
Bajrang Paints, Gurgaon 122 001. Tel: 0124-2321491, Fax: 0124-2300183, Mob: 09810119966 Email: bajrang_paints@yahoo.co.in
PAINTS/THINNERS & ALLIED PRODUCTS hemico Paints (India) manufactures and offers paints, industrial paints, domestic paints, and lead-free thinners. The range of coatings is used in a variety of painting applications, such as automobiles, interiors and exteriors of buildings. The entire range of products is available in various chemical specifications. However, to suit the individual requirements of clients, customised solutions are also offered. The products are manufactured using latest technology that has been appreciated all over the world (claims the company). The product range includes: commercial thinners, industrial & decorate paints, water-resistant & enamel paints, epoxy paints, acrylic paints, natural paints, glasscoat paints, exterior paints, oil paints, interior paints, coating industrial paints, NC paints, lacquer paints, etc.
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Chemico Paints (India), Meerut 250 005. Tel: 0121-4024689, Mob: 09837021306 Email: chemicopaintsindia@yahoo.com
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INDUSTRIAL PAINTS & POLISHES
PAINT SYSTEMS ansai Nerolac Paints develops and supplies cost-effective paint systems that are used on finishing lines of major electrical components, cycle, and material handling equipments, bus bodies, containers and furniture industries. The product spectrum includes a comprehensive coating system starting from PT chemicals, primers, top coats and lacquers, coil coats, heat-resistant paints, metal decoration coating, etc. A diverse range of PT chemical is offered for various substrates and applications ensuring excellent surface prior to painting. Primers are used to cover minor surface defects, protect corrosion, and improve adhesion, finish and durability of subsequent topcoats. Topcoats and lacquers are available in a wide range of customer specific colours offering excellent finish, gloss, gloss retention and durability suiting diverse application conditions. Heat resistant paints are offered in technical collaboration with Oshima Kogyo Co Ltd, for speciality paints possessing varied areas of application and temperature resistance from 200째C to 650째C.
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Kansai Nerolac Paints Ltd, Mumbai 400 013. Tel: 022-2499 2825, Fax: 022-2493 5743 Email: shashibhalla@nerolac.com, Website: www.nerolac.com
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NEW LAUNCHES
EARTH RESISTANCE TESTERS usam-Meco has introduced new clamp-on type earth resistance testers (model KM-1620/KM 1720) that are major breakthrough in traditional grounding resistance measurement. These earth resistance testers are widely used in grounding resistance measurements of power, telecommunications, meteorology, oil-field construction; as well as in industrial and electrical equipment. They are safe, fast and simple to use. Both models function of easy operation, high accuracy & good adaptation of testing environment and beyond the limitation of traditional methods and can be applied in the situation not in the range of the traditional methods. They can measure the integrated value of the grounding body resistance and the grounding lead resistance. The earth resistance testers are equipped with standard testing coil, which can be used to do the self-testing with accuracy, as well as with a long jaw, particularly suitable at places where the grounding is done using Bus bar.
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Kusam Electrical Industries Ltd, Mumbai 400 015. Tel: 022-2412 4540, Fax: 022-2414 9659, Mob: 09867000456 Email: response@kusamelectrical.com, Website: www.kusamelectrical.com
PERIPHERAL EXPLORER KITS iving students and new real-time control developers an easyto-use, cost-efficient foundation for jumpstarting designs, Texas Instruments Inc, USA has announced its enhanced floatingpoint F28335 Delfino microcontroller (MCU) peripheral explorer kit and free C2000 MCU teaching ROM. The new C2000 teaching ROM is a comprehensive guide to C2000 MCUs, also providing an introduction to real-time control design considerations. The teaching ROM includes labs based on TI’s F28335 peripheral explorer kit for superior hands-on learning. This new F28335 peripheral explorer kit brings increased integration over previous explorer kits to reduce development cost and enhance learning exercises. Together, the teaching ROM and peripheral explorer kit will enable more engineers to leverage the performance of C2000 MCUs to develop more energy-efficient real-time control applications, such as motor control, digital power, renewable energy and lighting. All exercises are provided in two versions to run under code composer studio IDE v3.3 and v4.
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Texas Instruments India Pvt Ltd, Bengaluru 560 093. Tel: 080-4138 1665, Fax: 080-2504 8308 Email: tiasia@ti.com, Website: www.ti.com
DC POWER SUPPLIES ektronix, Inc has announced two additions to its line of bench instruments: the PWS4000 series programmable DC power supply and the PWS2000 series DC power supply. These power supplies smoothly integrate with other Tektronix bench instruments, such as oscilloscopes & digital multimeters, and deliver wide current & voltage ranges for maximum versatility across a variety of applications. The new power supplies are ideal for design engineers who require high performance, feature-rich power supplies at competitive price points. Series PWS2000 and series PWS4000 offer performance
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and ease-of-use advantages compared to similar offerings currently available in the market (claims the company). These new power supplies compliment the FCA3000/3100 and MCA3000 series timers/counters/analysers also introduced by Tektronix separately. With wide current and voltage ranges, plus up to 0.1 mA and 1 mV resolution, engineers using the PWS2000 or PWS4000 series can precisely generate the power needed for a variety of applications. Tektronix (India) Pvt Ltd, Bengaluru 560 025. Tel: 080-2227 5577, Fax: 080-2227 5588 Email: india.mktg@tek.com, Website: www.tektronix.com
DATA ACQUISITION MODULES ational Instruments has announced the NI PXIe-4331, latest in the NI SC Express family of high-performance data acquisition (DAQ) modules with built-in signal conditioning. These DAQ devices are simultaneous high-speed bridge input modules that provide signal conditioning for dynamic measurements from strain, pressure, torque and load sensors. The NI PXIe-4331 increases the speed of bridgebased measurements and, with PXI Express, provides 250 MB/ s of dedicated bandwidth per device to give engineers the freedom to increase channel count without compromising sampling rates or data throughput. It features eight channels with 24bit analogue-to-digital converters (ADCs) per channel and 102.4 kS/s per channel sampling rate. To improve accuracy and reject noise, the module offers antialiasing and digital filters per channel. Additionally, the module includes an independent programmable 0.625 to 10 V excitation voltage on each channel for flexibility and fault protection. The NI PXIe-4331 also provides remote sensing, internal bridge completion and shunt calibration options per channel.
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NI Systems (India) Pvt Ltd, Bengaluru 560 103. Tel: 080-4119 0000, Fax: 080-4119 0010 Email: ramya.nair@ni.com, Website: www.ti.com
VIBRATING TABLES lscint Automation has introduced a new line of vibrating tables. The vibratory motion of these vibrating tables is particularly suited for settling granular to coarse materials. These are also very effective for handling a wide range of metal parts, such as nuts, bolts and rivets. The vibrating tables are of electromechanical construction and are available in various models. The most popular is the VT 50 model. It has a capacity of 130 kgs with a VA rating of 70 VA. Even with this VA rating, the highly efficient design takes a current of just 1 A, just saving on energy costs. All models of the vibrating tables are totally enclosed, dust-tight and splashproof.
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NEW LAUNCHES
Elscint Automation, Pune 411 026. Tel: 020-2712 2059, Fax: 020-2712 2994 Email: sales@elscintautomation.com Website: www.elscintautomation.com
FPGA DESIGN FLOW SYSTEMS ingle FPGA design flow support range of embedded processor offerings based on ARM, Intel, MIPS architectures. To accelerate the integration of programmable logic and processors in embedded systems, Altera Corporation has announced its embedded initiative. With this initiative, Altera provides designers a single FPGA design flow based on its Quartus II development software, including the new Qsys system, level integration tool, a common FPGA intellectual property library, and new ARM Cortex-A9 MPCore and MIPS Technologies MIPS32 embedded processor offerings. The design flow allows embedded designers to quickly and easily target Altera’s Nios II, ARM- and MIPS-based embedded processors and the recently announced configurable Intel Atom-based processor. The Qsys system-level integration tool leverages the industry’s first FPGA-optimised network-on-achip technology to support a wide variety of industry-standard IP protocols, improved quality of results and numerous productivity features.
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Altera Corporation, USA Tel: +1-408-5446397, Fax: +1-408-5446403 Email: dcheng@altera.com, Website: www.altera.com
LASER DISTANCE METERS luke Corporation has introduced the most advanced and capable distance measurement device, the Fluke 421D laser distance meter. Their advanced features include: audible feedback for taking room angle and incremental measurements, a Âą45-degree tilt sensor for taking indirect measurements in hard-to-reach areas and enhanced pythagoras calculation for indirectly determining distance. These laser distance meters automatically store last 20 measurements for quick recall of previous measurements. They measure distances up to 100 m (330 ft) with one push of a button. Laser distance measurement technology makes them far more accurate and dependable than devices using ultrasonic technology (claims the company). The instruments are IP54 rated for resistance to water spray and dust. Like other Fluke distance meters, the Fluke 421D helps electricians, facilities managers and HVAC contractors save time and labour. The laser distance meters have a bright laser for easy targeting and large liquid crystal display.
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TTL Technologies Pvt Ltd, Bengaluru 560 008. Tel: 080-2525 1859, Fax: 080-2529 1285 Email: tmidirect@ttlindia.com Website: www.ttlindia.com
Mr Ashish Bhatt Director V.R.VALVES Pvt Ltd “SEARCH magazine is a delight in every sense, whether it’s response, inquiries or content. We have been associated with SEARCH magazine for the last 9 years. We promote our products through this magazine and receive many genuine inquiries in response. This has played significant role in our growth. We look forward to a long-term value laden relationship with Infomedia 18. It is undoubtedly the leading industrial magazine & we wish them all the very best in their endeavours for the years to come.�
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NEW LAUNCHES
COLOUR PRINTERS erox India, a part of Xerox Corporation, offers a choice of four technology platforms in colour Laser, LED, solid ink and inkjet to give customers a wide choice of printing solutions and improve efficiency, enhance productivity and reduce overall cost of ownership. As part of the four technology platforms in colour, Xerox has launched four colour printers and production equipment. These include Xerox WorkCentre 7120 multi-function system, Xerox ColorQube 9201/9202/9203 multi-function systems, Xerox 7142 & Xerox 8264ETM colour wide format printers. Solid ink is a proven colour printing technology by Xerox that uses solid sticks (or blocks) of no-mess, non-toxic ink instead of toner or inkjet cartridges. Solid ink is easy to use, produces incredible color print quality, is cost-effective and environment friendly. Xerox also announced its foray in the AO wide format inkjet printer category unveiling the Xerox 7142 & 8264E colour wide format printers.
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Xerox India Ltd, Gurgaon 122 018. Tel: 0124-3940 0400, Mob: 09873012762 Email: askus@xerox.com Website: www.xerox.com
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NEW LAUNCHES
MULTI-CORE MEDIA PROCESSORS SI Corporation has announced that the LSI StarPro SP2600 family of multi-core media processors has been selected by ZTE Corporation, a leading global network and telecommunications equipment supplier, for integration into their next-generation wireless platform. ZTE chose the SP2600 because it will enable them to develop their next-generation media gateway with minimum risk, cost and time to market. LSI StarPro multi-core media processors are designed to meet the increasingly stringent demands of high-density wireless infrastructure applications. Scalable to 12 DSP cores per SoC, the SP2600 family is designed to cost effectively meet the demands of high-density voice and video processing. The SP2600 provides a single platform for a wide range of telecommunications applications from entry-level multi-service business gateways through wireless carrier-class media gateways. All LSI StarPro media processors support multiple DSP cores, embedded CPUs and co-processing engines.
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LSI Corporation, USA Tel: +1-800-372-2447 Email: victor.lee@lsi.com Website: www.lsi.com
ANALOGUE FRONT ENDS exas Instruments Inc has introduced two new fully integrated analogue front ends (AFEs) with a continuous wave (CW) doppler mixer for mid- to high-end, spectral doppler ultrasound equipment. The AFE5807 and AFE5808 analogue front ends address ultrasound designers’ need for superior performance and image quality with the best noise performance at 0.75 nV/rtHz.
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In addition, the integrated CW mode measures and displays blood flow velocity in ultrasound images. These new devices are 25 per cent smaller than competing solutions and ensure a compact system footprint for higher channel count. Key features include: integrated CW doppler mixer & summing amplifier with a very low close-in phase noise better than -155 dBc/Hz; model AFE5807 is a low-power solution with 88 mW/Ch at 1.1 nV/rtHz, 40 MSPS, 12-bit sampling; and model AFE5808 is a high-performance solution with low-noise optimisation of 0.75 nV/rtHz, 149 mW/ch, 65 MSPS & a 14-bit analogue-to-digital converter (ADC) with 77 dBFS SNR (signal-to-noise ratio). Texas Instruments, Inc, USA Tel: +1-972-6445580, Fax: +1-972-9276377 Email: support@ti.com, Website: www.ti.com
CONTROL & AUTOMATION PRODUCTS midst global recession where customers are expecting high quality products at low price, Omron has launched new range of high quality control and automation products. This new range cover products, like temperature controllers, power supplies, timers, sensors, monitoring relays, switches and programmable controllers. The introduction of these new models is a part of Omron’s expansion plan to cater to the needs of Indian customers who want high quality & reliable products but are weighed down by the need for reduction in cost due to intense competition from low cost solution providers.
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Omron Automation Pvt Ltd, Bengaluru 560 042. Tel: 080-4072 6400, Fax: 080-4146 6403 Email: in_enquiry@ap.omron.com, Website: www.omron-ap.co.in
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GENERAL PRODUCTS
CIRCLIPS
PRESSURE FEED SPRAY GUNS
K Engineering Co manufactures and offers a wide range of circlips that are used for restraining axial movement of components of shafts. These circlips are used particularly where space restrictions are applicable and also in small mechanism. External circlips are manufactured as per DIN 471 (IS:3075), internal circlips as per DIN 472 (IS:3075) and E clips as per DIN 6799 (IS:3075). The circlips are manufactured from EN42J high carbon spring steel. They are hardened and tempered. The circlips are also available in SS-304 materials.
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R K Engineering Company, Mumbai 400 023. Tel: 022-2267 1141, Fax: 022-2265 5255 Email: rkeng@vsnl.net
ost’s Engineering Company offers pressure feed spray guns (model Bullows 230) that are available with forged aluminum gun body for strength and durability. These are lightweight and slim body spray guns. The extra side port control in the air circuit making them suitable for various finishes, viz, stipple, hammer tone wrinkle, etc. The pressure feed spray guns have versatile wide range of nozzle setups for different applications and requirements. Other features include: feather light nylon gravity cup; PTFE packing for extended work life; forged aluminum air nozzles for sturdy lightweight life; and special maintenance kit for spray gun provided along with each spray gun. Jost’s Engineering Company Ltd, Pune 411 038. Tel: 020-2543 4350, Fax: 020-2543 4393 Email: salespune@josts.in , Website: www.josts.com
TRAVEL DRIVES rident Precision International offers travel drives that are available as helical hollow shaft geared motors. All standard drives come with two-speed motors in 1:4 ratios. They have built-in flywheel in all travel drives. All drives unit consist of gearbox, motor and brake. All drives come with special rotor for soft start and stop. These drives have low weight and are highly corrosion-resistant. The drives are also available with ABM frequency controlled drive system.
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Trident Precision International, Gurgaon Tel: 011-4142 5326, Fax: 011-2592 7181 Email: info@trident-precision.com, Website: www.trident-precision.com
UNIVERSAL DIE-BENDING MACHINES echno Crafts offers CNC universal die-bending presses (model Profi-56) manufactured by Boschert GmbH & Co KG, Germany. These machines are used for efficient, economical folding, bending & pressing in the workshop and on the production floor. Standard Profi 56 CNC die-bending presses are available in the versions Profi 56/1000 CNC and Profi 56/2200 CNC with working lengths of 1,000 and 2,200 mm. The clearance between the stands is 890 and 2,100 mm respectively. Stroke is 200 mm and the clearance between the folding beams is 310 mm, so that tall tools can also be used, thanks to the maximum installation height of 325 mm. The worktable is 2 mm x 270 mm and accepts correspondingly wide tool systems for universal use as a press system for folding, die-bending or press work of all types. The machines have a stable, rigid design for reproducibly accurate.
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Techno Crafts, Pune 411 004. Tel: 020-2542 5551, Fax: 020-2544 6496, Mob: 09422319755 Email: infoak@boschert.de, Website: www.boschert.de
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ABRASIVE BLASTING MACHINES arbide inserts of different sizes and shapes after sintering process are required to be cleaned for removal of wax/ foreign materials without effecting surface integrity and finish. MEC Shot Blasting Equipments have developed vapour honing machines based on suction induction principle of blasting. Fine particles are suspended in liquid [usually water] and are then pumped into the blast guns as slurry. At nozzles, the slurry is introduced into air stream & propelled against job. The machines are rotary indexing type having number of satellites for placing the inserts on the fixtures. Indexing satellite carries the fixtures into the blast chamber where it starts rotating at blasting station. Reciprocating mechanism with multi-blast gun is provided for covering the entire surface of the fixture, thus cleaning the surfaces of the inserts. The machines incorporate precise controls of blasting parameters to achieve high performance.
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MEC Shot Blasting Equipments Pvt Ltd, Jodhpur 342 005. Tel: 0291-2740609, Fax: 0291-2742409 Email: mail@mecshot.com, Website: www.mecshot.com
CNC MILL TRAINERS owerMill CNC mill trainers (model SSPM-200) offered by Square Systems are PC controlled 3-axis CNC mill trainers. These mill trainers are available with Windowsbased software with 2D-3D graphics. They have Fanuc compatible programming codes. Other features include: 6-station automatic tool changer; compatible to FMS technology; fully enclosed machine with strong base frame; and powerful cutting on mild steel as well as on non-ferrous materials.
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Square Systems, Pune 411 038. Tel: 020-6528 6482, Fax: 020-2545 2764, Mob: 09326775821 Email: sales@squaresystemsindia.com Website: www.squaresystemsindia.com
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PROFILE PROJECTORS anbros Engineering offers profile projectors (model JT 12 AZb) with digital data processors. These profile projectors are efficient optical measuring instruments that have easy operation. They are suitable for measuring different shapes of workpieces with complicated profiles and surfaces, such as punched pieces, gears, cams, thread cutters, templates, etc, by means of profile compare measure. Technical specifications include: screen diameter Ø300 mm; rotating range 0-360-degrees; rotating indicator scale 1”; work table size 340 mm x 250 mm; X-coordinate 200 mm; Y-coordinate 100 mm; Z-coordinate 90 mm (focusing travel); X-Y coordinate accuracy (2+L/100) μm; motorised movement in Z-axis; magnification of 10x (standard), 20x & 50x (optional); view-field on object Ø30 mm; and working distance 75 mm. Illumination source include contour illumination 12 V, 100W; and surface illumination of 24 V, 150 W. Dimensions are 450 mm x 700 mm x 1150 mm. Weight is 135 kgs.
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Banbros Engineering Pvt Ltd, New Delhi 110 092. Tel: 011-2241 8432, Fax: 011-2241 8432, Mob: 09810149486 Email: banbros@vsnl.com, Website: www.banbrosengg.tradeindia.com
MITRE CUTTING BANDSAW MACHINES TL Industries offers fully-automatic motorised swiveling-type mitre cutting bandsaw machines that are used to cut angles in the range of 30°-90°-30°. Model LMG mitre series is equipped with swiveling cutting head enabling to cut the job at various
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angles. Swiveling arrangement is available in manual as well as automatic mode. The machines are developed for meeting demands of fabrication industries, construction industries, transmission tower manufacturing and general cutting applications where jobs are required to be cut at various angles. Features include: cutting feed & rapid reverse of cutting arm; blade tensioning when hydraulic power is on & tension release no sooner the machine is off to minimise fatigue stresses; automatic clamping before cutting arm starts moving down for cutting; shuttle vice release & clamps as the cycle is set/synchronised with length indexing table; apart from fully automatic cycle, manual mode is provided to facilitate initial setting; and automatic machine stop when blade fails. ITL Industries Ltd, Indore 452 015. Tel: 0731-3044400, Fax: 0731-2721110 Email: itlindia@sancharnet.in, Website: www.itl.co.in
AIR COMPRESSORS eep Pneumatics offers single-screw air compressors in joint venture with Shangha FEIHE Industrial Group Co Ltd, China. The air end is composed of one cylindrical worm and two symmetrical plane star wheels, which are engaged and mounted in a casting. The worm groove, casting and tooth surface form a sealed cavity. When the star wheels moving in the worm groove,
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the air in the groove is compressed and exhausted. The worm has 6 grooves and is separated horizontally by two star wheels into two working cavities; each of realises separately suction, compression and exhaustion. Therefore, one single screw air compressor equals one unit six-cylinder double piston compressor. When the tooth grooves in the suction end of the worm, all connect with the suction cavity. When the worm rotates to certain position and tooth groove cavity is separated from the cavity by the engagement with convex tooth of star wheel. Deep Pneumatics Pvt Ltd, Ahmedabad 382 330. Tel: 079-2280 3684, Fax: 079-2280 3684, Mob: 09374635199 Email: deeppneumatics@hotmail.com Website: www.deeppneumatics.in
SINGLE-PASS HONING MACHINES hushbu Engineers offers CNC singlepass honing machines (model SP-650) for higher productivity and accuracy of bore geometry. Very close tolerances can be achieved consistently with required surface finish through single pass honing process. In CNC single pass honing, a rotating diamond impregnated tool is passed once through the bore. High wear resistance of diamondimpregnated tool ensures repeatability of the bore size within 0.001 mm to 0.003 mm.
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CNC single-pass honing operation reduces the cycle time resulting in higher productivity. Features include: 2-axes CNC controller for vertical motion & indexing, Siemens/Fanuc or Mitsubishi controller, CNC index table, ball screw & LM guide, automatic lubrication system, overload sensors, precision class spindle bearing, stroke length 450 mm, variable spindle speed, compact machine base, interlocks, 8 HP power consumption, etc, with one-year warranty. Benefits are higher production rate, low operation cost, low labour cost, quality consistency and bore geometry improvement. Khushbu Engineers, Kolhapur 416 122. Tel: 0230-2468859, Fax: 0230-2468443, Mob: 09371658016 Email: honing@khushbuindia.com, Website: www.khushbuindia.com
AGITATOR SEALS echnomech Engineering manufactures and offers agitator seals that are specially designed for agitators, reactors, mixers, autoclaves, rotary driers, etc. Special seals are designed for glasslined reaction vessels to handle arrangements of doublemechanical seals and dry seals, depending on temperature, pressure, nature of fluids, etc. For higher temperature application, the seal assemblies have jacketed chamber to circulate chilled water to bring down the temperature. Also normally chilled/plain water is passed through the cooling coil of thermo siphon to bring down the temperature of compatible barrier fluid circulated in seal housing to maintain the continuous cooling. Bottom portion of the seal housing is designed with heat trapping jacketed
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cooling to reduce the temperature around the bottom seal face. Operating limits are: temperature: -30째C to +300째C, pressure of 75 bar (max); and shaft diameter: range from 25 mm to 150 mm, pressure of 75 bar (max). Technomech Engineering, Mumbai Tel: 022-2678 9468, Fax: 022-2678 9468, Mob: 0986709809 Email: technomech.seals@gmail.com
LATHE MACHINES alaji cone pulley heavy-duty lathe machines (VH series) offered by Vinit Engineering Works, are available in different height of centres ranging 267 mm to 1000 mm; length of bed ranging from 1675 mm to 12000 mm; admit between centres ranging from 525 mm to 11000 mm; and main spindle hollow ranging from 50 mm to 150 mm. The main spindle nose is threaded-type and made from alloy steel. Dynamically balanced spindles enable the spindle to run at vibration-free motion at 700 RPM. Norton gearbox is able to cut the any of metric, modules and diametric pitch. Bed is made from graded cast iron and flame hardened up to 400 BHN. Also available are face plates, carrier plate steady rests, follow rests, motorised coolant pumps with tank & fittings, rear tool posts, quick change tool posts, etc. The machines are maintenance-free & easy-to-use; and come with interchangeable parts.
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Vinit Engineering Works, Rajkot 360 004. Tel: 0281-2311734, Fax: 0281-2312091, Mob: 09879022052 Email: vinit@balajilathe.com, Website: www.balajilathe.com
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CONVEYOR PULLEYS & ROLLERS ynamic Rubbers manufactures and offers conveyor equipment and accessories, such as conveyor pulleys duly rubber lined having dynamic balancing troughing idler, impact idlers, return rollers, self-aligning troughing and return idlers. These are manufactured as per customer’s design and drawing in most of the modernised workshop. All equipments are supplied subjected to water ingress test, slurry test, ingress test, friction factor test and free rotation test.
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Dynamic Rubbers Pvt Ltd, Ahmedabad 380 008. Tel: 079-2272 1567, Fax: 079-2272 1758, Mob: 09824006913 Email: info@dynamicrubbers.com, Website: www.dynamicrubbers.com
CYLINDRICAL GRINDING MACHINES niversal cylindrical grinding machines (model UC-150) manufactured by Devco Industries are available in eight different models. Castings are close grained and well ribbed, minimise vibration and distortion. Regulating wheel spindle runs in taper roller bearing. Tailstock, wheelhead and workhead spindle are heat-treated to achieve dimensional stability, and performance roundness of <0.005 mm. Optional accessories include: mechanical/hydraulic/self-feeding/ internal grinding attachments; two-point steady rest, three-point steady rest, wheel balancing stand, etc. Also available are model UC-150 mini grinders that have specifications such as: distance between centre 160 mm, height of centre 102 mm, swiveling angle Âą9-degrees, traverse
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speed 140-260-370-700 mm/min, infeed of hand wheel 0.01 division, grinding wheel size of 250 mm (D) x 25 mm (W) x 76.2 mm (B), grinding wheel speed of 2300 RPM, workhead spindle speed of 90-210-360 RPM, and spindle in taper MT-3. Devco Industries, Wadhwancity 363 035. Tel: 02752-243997, Fax: 02752-240917, Mob: 09825343097 Email: devco1980@yahoo.com
AC MOTORS riental Motor offers electromagnetic brake motors, synchronous motors, torque motors, AC speed control motors and watertight motors to meet specific application requirements. A wide variety of standard AC motors in frame sizes ranging from 1.65 inch to 4.09 inch square with output power of 1 W to 200 W are also available. There are two basic types of AC motors: standard induction motors that run continuously and reversible motors that allow for bi-directional operation. AC motors with additional functionality are also available. These types of motors include: electromagnetic brake motors to hold loads in a power-off situation; clutch & brake motors for quick starts and stops; synchronous motors and low-speed synchronous motors for a fixed speed in synchronisation with the power frequency; watertight motors for applications where the motor is splashed or washed with water; and torque motors for tension control and winding applications.
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Essence Engineering, Hyderabad 500 047. Fax: 040-2705 1259, Mob: 09866964469 Email: business.essence@gmail.com, Website: www.essenceengineering.com
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VACUUM BOOSTERS ulcan three-phase voltage boosters offered by Canary Electricals are applied with an objective of using three-phase power safely and properly by increasing the voltage as needed in areas where low voltage is a chronically severe problem. All types of electrical equipments, appliances or gadgets like, submersible pumps, monoblocks, three-phase motors, special electrical equipments used in factories, tubelights, fans and similar items are designed to work properly on a specific voltage level only. The voltage boosters are primarily designed to raise very low input voltage to the required level of output voltage to be used by other devices like submersible pumps. Normally, one should get 415 V line-to-line AC 3-phase power everywhere. The voltage boosters are basically users own step-up transformers to serve their individual needs and a simple and cost effective way out of the above impasse.
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Canary Electricals Ltd, Morbi 363 641 . Tel: 02822-250431, Fax: 02822-250433 Email: info@vulcanwelding.com, Website: www.vulcanwelding.com
REAR CYLINDER PRESS BRAKES ear-cylinder press brakes offered by Kawa Press Systems are available in a wide range of sizes from 2000 mm to 4000 mm length x 2 mm to 20 mm thickness with capacity ranging from 30 tons to 500 tons. These rear-cylinder mounted press brakes offer many superior advantages compared to competition
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like synchronised operation due to superior hydraulic systems; bending operation at slow speed with faster return travel to cut down idle time optional ball-roller tables for easy movement of jobs; quick die changing system; staggered tooling can be used for multiple operations; builtin overload protection systems, etc. Both CNC and PLC-based versions are available. Also offered are hydraulic variable rake angle guillotine shearing machines up to 25 mm thickness; hydraulic deep drawing presses for automotive and utensils industries, hydraulic punch, notching, shearing, and cropping machines for fabrication industries as also large capacity mechanical power presses up to 350 tonnes capacity. Kawa Press Systems Pvt Ltd, Rajkot 360 002. Tel: 0281-2461102, Fax: 0281-2461665, Mob: 09825389169 Email: info@kawapresses.com, Website: www.kawapresses.com
TRUCK LOADING CONVEYORS rvali Engineers manufactures and offers truck loading conveyors for loading/unloading bags, cartons, boxes, crates, etc, from trucks. These truck conveyors come with completely motorised operation with operator control panel on loading/unloading end. The height of the
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GENERAL PRODUCTS
loading and unloading ends can be changed, independently. The conveyors are completely mobile, mounted on sturdy wheels for easy mobility. They have telescopic arms for greater reach inside the truck. The truck loading conveyors have: choice of powerised rollers or heavy duty belt; choice of various belts depending on the application; choice of lighting on the conveyor to facilitate unloading/loading of containers; and various customisations of conveyor length, loading/unloading heights possible. Other features are: conveyor speed can be easily varied through the control panel; rough top belt for greater traction; heavy-duty & durable chassis; reputed makes of geared motors used for long trouble-free operation; and heavy-duty hydraulic systems with leakproof seals. Aravali Engineers, Noida 201 307. Tel: 0120-2401105, Fax: 0120-2402083, Mob: 09810076877 Email: sales@aravaliengineers.com, Website: www.aravaliengineers.com
SUPER BLASTER MACHINES urface International offers super blaster machines that are widely used for sand/shot blasting of automobile components, like aluminium die-casting, precision machined components, castings, forgings, heat-treated components, etc. These machines are also used to provide rough surface on granite tiles for general-purpose finish or for carving on granites. They work on suction principle of lifting abrasives from storage tank. The machines are
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manufactured in three models, namely SSB-606060, SSB-9182, and SSB-12090 to suit different sizes of components and output application. Standard machines can be provided with optional features, like rotary table, tumble basket, and mounted track extension, with/without drive unit. To achieve decorative finish, glass beads can be used in the same machine. Apart from this, alumina, quartz, sand, grits, etc, can be used to achieve a variety of finish. The machines are provided with a cyclone dust collector/ reclaimer with fabric bags. They are pollution-free and warranted machines that are easy-to-operate. Surface International, Jodhpur 342 008. Tel: 0291-2787749, Fax: 0291-2721778, Mob: 09413329749 Email: info@surfaceint.com, Website: www.surfaceint.com
CONDENSATE DRAINS eko Compressed Air Technologies offers the 3rd generation of condensate drains: Bekomat 20, 21, 12, 13, 14 and 16. Together they represent the standard programme of Bekomat condensate drains. These models are designed for operating pressures up to 16 bar, and the programme is rounded off by a 25 bar pressure version of the Bekomat 13 and 14, a 40-bar version of the Bekomat 13 as well as by a 63-bar high-pressure version of the Bekomat 12 device. In addition to the aluminium version for normal condensates, the devices can also be provided with hard coating for handling aggressive condensates. These devices have a triple LED display for indicating the
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different operating states. A potential-free contact can be used for relaying an alarm signal to a control centre. The condensate drains are designed for compressor performances up to 1,400 mÂł/min (temperate climate), depending on the type. Beko Compressed Air Technologies Pvt Ltd, Hyderabad 500 037. Tel: 040-2308 0275, Fax: 040-2308 0274, Mob: 09393002464 Email: rkreddy@bekoindia.com, Website: www.beko.de
ULTRASONIC THICKNESS GAUGES ndia Tools & Instruments Co offers ultrasonic through-coating thickness gauges. Some of the technical specifications include: range from 0.8 mm to 300 mm in steel (depending of the probe); through coating range from 2.5 mm to 18 mm (depending on the probes); tolerance of Âą0.05 mm in steel; and display resolution of 0.01/0.1 mm. Also available are digital ultrasonic thickness gauges, digital coating thickness gauges, portable digital hardness tester and other related instruments.
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India Tools & Instruments Co, Mumbai 400 003. Tel: 022-2342 8862, Fax: 022-2341 2578, Mob: 09819345050 Email: itico@vsnl.com Website: www.indaitools.net
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GENERAL PRODUCTS
UNIVERSAL TESTING MACHINES inewave Engineering offers universal testing machines that are ideal for tensile and compression testing applications. The accurate and rigid test frame is powered by Windowsbased sophisticated and user-friendly software to perform almost every test in tensile and compression mode. Key features include: wide range from 10 kg up to 10 ton capacity; ball screw based test frames ensure excellent length accuracy; variable speed stepless speed servo drive; extremely quiet operation; high accuracy load cells; and auto load cell recognition/configuration.
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Sinewave Engineering Pvt Ltd , Pune 411 041. Tel: 020-6523 4870, Fax: 020-2439 0916, Mob: 09763719531 Email: info@sinewaveengineering.com Website: www.sinewaveengineering.com
PH TESTERS aterproof pocket pH testers offered by HiTech Engineers have large display screen with dual display LCD for enhanced readability, providing comprehensive meter information. The waterproof & dustproof housing that are IP67 rated, maintain the integrity of the testers even in harsh conditions. Double junction sensors offer longer lasting usage. Userreplaceable sensors reuse the same meter body many times. The pushbutton calibration with auto buffer recognition gives quick & easy
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calibration with no calibration mistakes. The pH testers are ideal for quick & accurate pH checks in pools and spas, aquariums & hydroponics operations, or wherever frequent pH testing is required. They are also used for cooling towers, food processing water testing & process/wastewater testing in metal finishing, photo development, printing and chemical industries. Hi-Tech Engineers, Thane 400 606. Tel: 022-6523 3952, Fax: 022-2588 3965, Mob: 09821255016 Email: business@hi-techengineers.com Website: www.hi-techengineers.com
THERMIC FLUID HEATERS lankar Boilers & Pressure Vessels manufactures and offers thermic fluid heaters (model TFH) that are made from premium quality materials, which ensure durability and strength of the heaters. Technical specifications of these thermic fluid heaters include: horizontal heli-coil type, multi-pass package; fuel (on GVC): wood (12 per cent moisture) of 2800 kcal/kg, lignite of 3500 kcal/kg, coal of 4800 kcal/kg; fuel consumption: wood 82 kgs/hr, lignite 66 kgs/hr, coal 48 kgs/hr; capacity of 6,00,000 kcal/hr; working/outlet temperature 120/150°C; heating surface 82 sq mt; induced type of draught; maximum flue gas 200 ±20; heater circulating media quality: hitherm 500 oil/synthetic 230; thermal efficiency: 72 ±3 (with a H unit); and overall size (horizontal): 2000 mm (L) x 2000 mm (W) x 4000 mm (H). The thermic fluid heaters are widely used in process houses, sugar paper mills,
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textiles, rubber industries, pharma industries, wooden pallets, rice mills, food industries, etc. Alankar Boilers & Pressure Vessels Pvt Ltd, Ahmedabad 382 445. Tel: 079-2584 0242, Fax: 079-2584 2613, Mob: 09427030365 Email: info@alankarboiler.com, Website: www.alankarboiler.com
LABORATORY DISSOLVERS/MIXERS & MILLS hushboo Scientific offers Dispermill laboratory dissolvers, mixers and mills manufactured by ATP Engineering BV, The Netherlands. These are universal machines meant for all laboratory and pilotplant needs. With the Dispermill, one can mix, disperse, homogenise, emulsify and mill. The machines perform almost any mixing task in the modern laboratory, whether gentle stirring or where high shearing is required. They can produce outstanding results on most applications, and have low noise drive system with continuous adjustable speed. Hightech PID electronics ensures constant speed even when viscosity changes. All Dispermill dissolvers are complete with safety protection according to CE. Salient features include: adjustable quick fit clamping device, integrated adjustable timer 0-100 min, automatic stop, emergency main switch, continuous readout of speed & time on digital display, immersible parts made from stainless steel, multiple choice of mixing heads, such as propeller & rotor/stator, etc.
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Khushboo Scientific Pvt Ltd, Mumbai 400 002. Tel: 022-2203 2174, Fax: 022-2208 1346, Mob: 09820230835 Email: sales@khushbooscientific.com, Website: www.khushbooscientific.com
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REFLECTIVE PHOTOELECTRIC SENSORS ubi Electronics offers Sunx-make (model EQ-34W) dual output adjustable range reflective photoelectric sensors that are specialised for detecting two different levels or surfaces for up to 2meter sensing range. These sensors contain two individual outputs for two sensing distances: far (main) and near (sub). Hence, only one sensor is sufficient enough where earlier two were required. Detectability of the sensors is very stable even if the lens is contaminated by dirt, dust, mist or smoke under an unclear environment. The sensors have IP67 protection and therefore they can also be used in places splashed with water. Main benefit of the sensors is non-contact type detection of the object with two different level outputs, which is most suitable for packaging, pharma and food processing industries. Typical application includes detection of level (upper & lower) in hopper etc.
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Lubi Electronics, Ahmedabad 380 025. Tel: 079-2220 5471, Fax: 079-2220 0660, Mob: 09327497006 Email: info@lubielectronics.com, Website: www.lubielectronics.com
POWER SHEARING MACHINES odson Bending Systems offers power shearing machines that are constructed sturdily and designed for accuracy & dependability by employment of the latest technology and experience. Sidewalls are designed from mild steel to take heavy loads. Beds and upper beams are fabricated from mild steel to withstand and absorb heavy loads designed specially to adjust
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the blade clearance as required. Pressure plates are fabricated from mild spring loaded. Clutches, brakes and drives include revolving key clutch, linked with the main gear that engages every time when the foot pedal is pressed. Back gauges in GSH-1-2-3-4 are screw drives whereas in GSL1-2-3-4 and GSL1-2-3 they are of rack pinion type designed. Blades are generally four-edged and grade-I with single segment. Lubrication oil cups provided are connected with various pipes rendering supply of oil. Standard equipments include: back gauge, front gauges, wheel & gear guards, foot pedal and pulley. Godson Bending Systems Pvt Ltd, Rajkot 360 002. Tel: 0281-2361467, Fax: 0281-2361873, Mob: 09879079267 Email: godsonindia@hotmail.com, Website: www.godson-india.com
ONE-WAY CLUTCHES
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MT Group manufactures and offers one-way clutches (freewheels) that have no driving contact between inner and outer ring in one direction of rotation and there is driving contact between inner and outer ring in the other direction of rotation which transmit torque. Three types of freewheels, viz, sprag (standard, indexing, centrifugal lift off), roller, and
GENERAL PRODUCTS
cam-roller combined, are available with bore diameter of 12 mm to 150 mm. For mounting, clutches are provided with tapped holes on face, with flanged outer diameter with clear holes, with lever arm or key slot on face/outer diameter. Key attributes include: indexing & feeding, over-running, backstopping & holdback, and safe & automatic operations. Applications are in all industries: general drives, hoisting & conveying devices/inclined conveyors, leather, packaging, paper & printing, rubber & plastic, textile, wire processing, fishing net machinery, etc. NMT Group, Ahmedabad 382 330. Tel: 079-2282 1527, Fax: 079-2282 0214 Email: nmtg@nmtgindia.com, Website: www.nmtgindia.com
SURFACE GRINDING MACHINES innacle Engineering Enterprise offers surface grinding machines in a full range from 450 mm x 150 mm table size manual machines; to 1000 mm x 300 mm table size hydraulic machines; and 800 mm x 400 mm and GSH-8 Jumbo with table size of 1000 mm x 500 mm in hydraulic as well as NC/CNC versions. The Sumo series of machines have robust base structure and have internationally accepted fixed column design. Heavy box-type column casting with honeycombed ribbing is rigidly clamped to heavy base casting. The spindle housing supports cartridge type spindle unit and is fitted with super precision bearings grease packed with imported grease to have long trouble-free service. Automatic electronic cross feed is variable from 0.5-6 mm at
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each table reversal with a facility of rapid power positioning and additional safety manual to auto interlocking device. These machines are tested as per IS test-chart. Pinnacle Engineering Enterprise, Surendranagar 363 002. Tel: 02752-231167, Fax: 02752-231913 Email: mail@pinnaclegrinder.com, Website: www.pinnaclegrinder.com
LASER DISTANCE SENSORS he AR200 laser measurement sensor is Acuityâ&#x20AC;&#x2122;s value distance-measuring sensor. Using laser triangulation measurement principles with high-speed CMOS detection arrays, these sensors delivers high accuracy in a very compact model. This model includes both serial and analogue outputs for simple integration. Measuring 54 x 20 x 70 mm the sensor head fits anywhere. With integrated digital, analogue and discrete output signals, the sensors require no external controller or signal conditioner. Simply plug it directing into your PC or PLC. It has sharp resolution. Specifications begin at 1.8 microns. The AR 200 sensors are equipped with RS232, 0-10V analogue, 4-20 mA current loop and NPN and PNP discrete outputs for alarm triggers. AR200 can be used for measuring steel strip thickness, measuring defects on sheets, positioning silicon wafers etc.
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SBS Precision Systems (India) Pvt Ltd, Kolkata 700 053. Tel: 033-3292 0078, Fax: 033-2400 3097, Mob: 09331140202 Email: rajesh@sbsindia.in, Website: No website
LATHE MACHINES remier Lathe Manufacturing Co offers lathe machine that are rigidly designed and suitable for bulk production. These machines combine all the features, which are expected in heavyduty production lathes with great efficiency and are ideal for all sliding, surfacing and screw cutting operation. Various special features of these machines include: lathe hardened & ground bedways; raw materials used are selected and grade quality raw materials are used; main spindle is hardened & ground with double grinding; and all screws made from bright steel with gun metal screw nut. Some of the technical specification are: length of bed 1675-6100 mm, admit between centre 555-4950 mm, centre height available at 330/380 mm, spindle bore available at 55/80/104/130 mm, etc. The lathe machines also have a variety of attachments, like fully or semi Norton gearbox, taper turning attachment, rear tool post and coolant pumps, etc.
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Premier Lathe Manufacturing Co, Rajkot 360 003. Tel: 0281-238 7556, Fax: 0281-238 9248 Email: premierenterprise@rediffmail.com, Website: www.premierlathe.com
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WIRELESS DATA TRANSMISSION SYSTEMS ay Electronique offers TI series wireless data transmission systems. These are of interest for applications where transmission cables cannot be used or generate too high operating costs. The manufacturers point out the possible advantages of these systems, such as a lowering of installation costs and an increase in the reliability of mobile equipment by eliminating the need for wear parts. Also, the flexibility of installations can be increased and operating costs due to maintenance decreased. Applications can include the status indication of isolated detectors to control room as well as the remote control from machine to machine. The systems are mounted in metal housings with protection index IP65 to operate in most harsh environments.
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Jay Electronique, France Tel: +33-476-414400, Fax: +33-476-414444 Email: com@jay.electronique.fr, Website: www.jay-electronique.fr
BENCH WIRE TWISTERS he Eraser Company, Inc manufactures and offers bench wire twisters (model G10S) that are used for many diverse twisting needs. These units can twist pre-stripped stranded wires, twist strands of two or more wires together, twist wrapped shields on coaxial cables and tighten the twist of already twisted wire. They are supplied with one set of three twist length spacers to vary the twist length, depending on the application needs. Twisting inserts can be ordered depending on the wire size to be twisted. Technical specifications are as follows: wire sizes: 12-18 AWG (2.06-1.02 mmø), 18-24 AWG (1.02-0.51 mmø), 22-26 AWG (0.64-0.41 mmø); twist length up to 1” (25.4 mm) depending on the spacers used; twisted pairs do not exceed 2 18 AWG (1.02 mmø); three size spacers: 1/2” (12.7 mm) thick, 1/4” (6.35 mm) thick, 1/8” (3.18 mm) thick; and power of 115 V, 60 Hz or 220/240 V, 50 Hz.
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The Eraser Company, Inc, USA Tel: +1-315-4543237, Fax: +1-315-4543090 Email: info@eraser.com, Website: www.eraser.com
WORK PROCESS MANAGEMENT SOLUTION SOFTWARE E Intelligent Platforms has announced the availability of the latest version of its Proficy Workflow work process management solution software. This new software features validated system support capabilities allowing companies to create a more secure and regulatory compliant environment, ultimately saving time and reducing cost. Proficy Workflow 1.5 also features 64-bit support and better scalability. Furthermore, ISA-95 model additions allow users to manage inventory with materials in lots and sublots. New service method activities permit creating, incrementing, decrementing, querying, reading, changing the status or location of, deleting, and closing lots and sublots. The ISA-95 model additions also offer new resource utilisation feedback for improved business
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reporting, material planning and process optimisation. Version 1.5 features comprehensive response models for reporting resources used/consumed and allows recording of actual people, equipment and materials used during a process. GE Intelligent Platforms, USA Tel: +1-508-6987456 Email: elli.holman@ge.com, Website: www.ge-ip.com
CONNECTORS arting KGaA offers the new Han EEE series that feature highest contact density up to 16 A. Thanks to a very spacesaving and compact design, the Han EEE series impresses with the highest contact density that has ever been possible in a monoblock with Han E crimp contacts. The Han EEE series combines reliability and versatile application possibilities thanks to the combination of the simplest handling, as in the proven Han E series, and the new space-saving contact arrangement. Features include: available in two sizes: Han 40 EEE (40 crimp contacts/size 16 B) and Han 64 EEE (64 crimp contacts/size 24 B); 500 V at 16 A; can be inserted into the housing series: Han B, Han EMC, Han M & Han HPR; and control cabinet assembly with Han-Snap.
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Harting KGaA, Germany Tel: +49-577247-244, Fax: +49-577247-400 Email: wulf.padecken@harting.com, Website: www.harting.com
OVERVOLTAGE ARRESTERS he triple socket TAE-TRAB-FM-NFN from Phoenix Contact GmbH protects analogue telecommunication interfaces against over-voltages. The connecting socket is N-F-N coded so that for instance a telephone, a fax machine and an answering machine can be protected at the same time. These arresters are available both for surface- and flush-mount assembly. Three-electrode gas arresters work as coarse protection in both normal and common mode direction. They are able to arrest a surge current of 5 kA. Quick responding Transorb diodes offer a normal mode fine protection with a residual voltage of only 95 V. The high arresting capability and low values of the limiting voltage offer the biggest protection possible for the interface connected and in so doing, ensure the availability of the telecommunication devices for the exchange of information and data.
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Phoenix Contact GmbH & Co KG, Germany Tel: +49-5235-341512, Fax: +49-5235-341825 Email: info@phoenixcontact.com, Website: www.phoenixcontact.com
STEP MOTION CONTROLLERS
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ow-cost IC-based step motor controllers (series MC2502), offered by Performance Motion Devices, Inc, are the addition to the Navigator Family 2500 series of motion processor chips. Available in one (MC2512), two (MC2522) and four (MC2542) axis configurations, the MC2502 series consist of two components, a 132-pin processor and a 100-pin logic device. Both components are surface-mount CMOS technology and powered by 5 V. The
INTERNATIONAL PRODUCTS
motion processor is driven by a host microprocessor, via an 8-bit or 16-bit bus interface or through an asynchronous bi-directional serial port, giving users the ability to offload resource intensive motion control functions from the applications host. Performance Motion Devices, Inc, USA Tel: +1-781-6749860, Fax: +1-781-6749861 Email: motion-control@pmdcorp.com, Website: www.pmdcorp.com
CLAMPING SYSTEMS lamping and machining of small parts has always been a big problem in manufacturing industries. Witte Bleckede, manufacturer of different clamping systems now offers a further item in their freeze technology range. With a clamping surface of 40 x 40mm ice vice light is especially suitable for machining small parts. Ice vice light enables secure and planeparallel freezing of flat workpieces onto its clamping surface using only a little water and in just a few seconds. An even holding force is effective over the whole surface. Applications include: clamping of small parts, clamping of workpieces with special geometries, and especially suitable and economically viable in modelling, sample machining, prototype machining and single series machining. Preparations for use are kept to a minimum. After the chuck is cooled down to +3째C, some water is sprayed onto the clamping surface and a part is positioned.
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Witte Far East Pte Ltd Tel: +65 6248 5961, Fax: +65 6898 4542 Email: info@witteasia.com, Website: www.witteasia.com
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ACCU-LINE LASERS -Laser Optoelektronik offers accu-line lasers (model Z3A). The power supply of these small lasers is provided by a standard accumulator and is equipped with an on/off switch. There is no transformer or annoying cable any more. The accu-line lasers are developed for small machines like band saws, radial saws, mitre circular sawing machines, etc; and are therefore easy to use and to install. These semiconductor lasers are able to project a very sharp red line of approximately 1 m length. The very precise accu-line laser make the user work a lot easier and help to achieve good quality.
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Z-Laser Optoelektronik GmbH, Germany Tel: +49-761-2964432, Fax: +49-761-2964455 Email: z-laser@t-online.de
AFTERCOOLERS ankison International manufactures and offers aftercoolers in air-cooled & water-cooled types. Air-cooled models use ambient air to lower compressed air temperature, & generally 5 to 20째F, 3 to 11째C above the ambient air temperature. Water-cooled models use cooling water to lower compressed air temperature generally 10 to 20째F, 6 to 11째C above the cooling water temperature. These
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aftercoolers cool the high temperature compressed air exiting a compressor to safe, usable levels. They can be sized as a single source cooler or as a trim cooler for use with an air-cooled aftercooler during hotter weather. By lowering the temperature of the compressed air in downstream airlines, the risk of fires is reduced and the need to insulate piping is eliminated. Also, it is typically necessary to cool the air to a maximum of 120째F (49째C) before introducing it into a dryer or filter for further treatment. Hankison International, USA Tel: +1-724-7451555, Fax: +1-724-7456040 Website: www.hankisonintl.com
MULTI-WIRE WIPERS ontact technology today is advancing the miniaturisation of components while continuously increasing the reliability and quality of the signal produced. In this field of modern contact technology, W C Heraeus GmbH offers multi-wire wipers to meet these high requirements. The multi-wire brush contacts have proven their worth as contact elements in position sensor applications in the automotive, industrial electronics and consumer electronics industry. In all these applications, it is required that the sensor has always a stable and reliable electrical signal under all operating conditions. Electrical noise levels and noise potential decrease by a power of two with the increased number of parallel contact points. As it can be recognised in the name itself, multi-wire wipers offer a much higher amount of contact points compared to conventional stamped wipers (claims the company).
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W C Heraeus GmbH, Germany Tel: +49-6181-35051, Fax: +49-1681-353131 Email: wc-heraeus@heraeus.com, Website: www.wc-heraeus.com
BIMETAL THERMOMETERS wyer Instruments offers bimetal thermometers (series BTO) transmitter output. These bimetal thermometers are designed to take remote readings along with measurements, via a bimetal helix, making them the ideal choice to take accurate temperature measurements in the toughest environments. They eliminate the need for a separate thermometer and transmitter. By only needing one connection, the BTO series reduces installation cost and saves space. The headmount transmitter is located in a weatherproof thermal head located on the side of the stem. The BTO series is ideal for use on power generating boilers, skid mounted compressors, and thermal oxidation systems.
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Dwyer Instruments Inc, USA Tel: +1-219-8798000, Fax: +1-219-8729057 Email: info@dwyer-inst.com, Website: www.dwyer-inst.com
FUSING MACHINES EIT manufactures and offers fusing machines (MultiStar EX series) that are custom-designed and suitable for a wide application of fabric & interlining combinations. Of utmost importance in a fusing machine is control of the fusing parameters. Standard control functions include: set/actual temperature; VEIT power management; standby mode saves energy during downtimes; integrated timer to
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cool belts after use; minimised power peaks during machine warm-up; pressure displayed in bar or N/cm²; belt speed displayed in m/minute & seconds; on/off function; and diagnostic system for heating elements, compressed air supply and belt tracking. VEIT GmbH & Co, Germany Tel: +49-8191-479204, Fax: +49-8191-479199 Email: info@veit.de, Website: www.veit.de
FLEXIBLE EPOXIES otronics Corporation offers Duralco 4538 super flexible epoxies that are so flexible that one can even tie it in a knot. Unlike ever before, there is a solution for applications requiring the ultimate in thermal shock and vibration resistance, sound absorption and excellent adhesion to dissimilar substrates. This completely variable system can be tailored to meet any application requirement just by varying the mix ratio of resin to hardener resulting in the exact degree of flexibility required for any application. Easy to use, one has just to choose the mix ratio desired, dispense resin and hardener, mix to a uniform colour and apply. The epoxies have excellent adhesion to most plastics, metals, ceramics, glass, rubber
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and even treated Teflon and cure at room temperature without any objectionable odors. They can be used from -100째F to +450째F. Cotronics Corporation Tel: +1-718-7885533, Fax: +1-718-7885538 Email: sales@cotronics.com, Website: www.cotronics.com
VISUAL CODE PROGRAMMING SYSTEMS aas Automation Inc offers visual quick code programming system designed to make operating CNC machines easier and faster for the both the novice operator and experienced machinist alike. Visual quick code is a conversational programming system with a graphical interface that makes creating simple Gcode programs nearly effortless. Once the operation is selected, a series of graphical part templates is displayed along with an English description of the operation to be performed for each template. Complex parts can be programmed a piece at a time by selecting individual graphical templates to generate G-code for each feature, then inserting the G-code into the same programme. The visual quick code option also includes standard quick code that allows operators to use a split-screen format to create G-code programmes without having to memorize G and M modes.
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Haas Automation, Inc, USA Tel: +1-805-2781800, Fax: +1-805-9886918 Email: sales@mtscnc.com, Website: www.haascnc.com The information published in this section is as per the details furnished by the respective manufacturer/ distributor. In any case, it does not represent the views of
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To know more about the products in this magazine, refer to our â&#x20AC;&#x2DC;Product Indexâ&#x20AC;&#x2122; or write to us at search@infomedia18.in or call us at +91-22-3003 4684 or fax us at +91-22-3003 4499 and we will send your enquiries to the advertisers directly to help you source better. Product
Pg No
2D to 3D conversion 179 2-wire transmitters 10 3D modelling 179 4-column hydraulic presses 247 Abrasive blast rooms 221 Abrasive blasting machines 202, 221 Absorption drying machines 13 AC geared motors 239 AC motors 59, 215, 239 AC/DC panels 243 Acoustic enclosures 125 Actuators 169 Adapter sleeves 68 Adhesives 109 Adjustable adaptors 79 Adjustable shock absorbers 55 Agitator seals 209 AGVs 147 Air compressors 95, 113, 119, 206, 227 Air dryer & filters 119 Air nozzles 143 Air purifiers 173 Air receivers 227 Air treatments 129 Air-cooled reciprocating compressors 95 Airport passenger baggage trolleys 209 All-geared auto-feed pillar drilling machines 137, 174 All-geared auto-feed radial drilling machines 137 All-geared pillar drilling machines 208, 209 All-geared radial drilling machines 208 Alloy wheels 209 Alu-cera polymers 9, 15 Aluma coat 9, 15 Aluminium oxide ceramic composites 9, 15 Aluminium worm geared motors 176 Aluminum extrusions 174 Ammeters 219 Analogue & digital panel meters 17 Analogue front ends 199 Analogue panel meters 17 Appliance switches 29 Apron conveyors 230 Area sensors 77, 121 Assembly technology 67 Auto drains 216 Auto feeder hydraulic presses 247 Auto-feed radial drilling machines 174 Automated guided vehicles 147 Automatic back spot facing tools 189 Automatic rolling shutters 23 Automation & process controls 107, 145, 253 Automation & security systems 251 Automation & storage systems 49 Automation 85, 266 Automations 10 Automotive paints 184 Auxiliary equipment 231 Aviation cog wheels 143 Back-geared auto-feed radial drills 137 Back-geared fine-feed machines 137 Bags bailing presses 247 Baling presses 247 Ball & roller bearings 8 Ball bearings 229 Ball joints 60 Ball screws 183 Ball transfer units 209 Ball valves 169, 191, 205 Balls 201 Basket strainers 191 Batteries & chargers 107, 145, 253 Battery-operated pallet trucks 81 Bearing bushes 143
Product
Pg No
Bearings 8, 140, 229 Bellow couplings 183 Bench grinding machines 212 Bending machines 171 Best CAD 179 Billet shearing machines 14 Blasting media 221 BLDC motors 239 Bollards 23 Boring machines 209 Brake motors 41, 59, 176, 182 Brass castor wheels 209 Breather valves 191, 210 Brine chillers 219 Bronze wheels 209 Brushless DC motors 20 Brushless DC systems 239 Brushless motor controls 20 Building automation 266 Bust preventives 172 Butterfly valves 205 Cable carriers 140, 183 Cable connectors 140 Cable glands 47 Cable reeling drums 52 Cable tray-cable ladders 230 Cables & leads for fixed instaction 49 Cables for bus systems 49 Cables handling & processing systems 49 Cables scanps 49 Cables 41, 86, 93, 107, 145, 253 CAD programs 179 CAD software 179 CAE software 179 Calendaring Front gatefold Calibrators 10 CAM express 179 CAM 179 Carbide rods 71 Carbon fibre re-enforced products 143 Cast/extruded products 225 Castor wheels 209 Castors 209 CED coating machines 266 Centralised lubrication systems 198 Centreless grinders 229 Centreless grinding machines 245 Centrifugal blowers 95 Centrifugal compressor package 95 Centrifugal fans 211 Centrifugal pumps 39 Ceramic adhesive cements 9, 15 Ceramic electrical heater parts 9, 15 Ceramic processing furnaces 231 C-frame power presses 14 Chain hoists 222 Chain pulley blocks 182 Chain wheels 162 Chains 140 Chair castors 209 Channel magnets 177 Check valves 191 Chemical pump vanes 143 Chemical pumps 210 Chemical-resistant paints 184 Chemicals & adhesives 107, 145, 253 Chemlok coating machines 266 Chillers 58 CI castings 209 Circlips 202 Circuit protection 107, 145, 253 Circular motion vibratory screens 52 Circular vibratory screens 52
Product
Pg No
Circular/gyrator vibro machines 177 Cistern type manometers 191 Close frame hydraulic presses 247 Clutch & brakes 20 CNC cutting machines 266 CNC hydraulic turret punch presses 181 CNC laser cutting machines 266 CNC lathes 165, 175 CNC machine solutions 158, 186 CNC machines Back inside cover CNC mill trainers 202 CNC oxyfuel cutting machines 266 CNC plasma cutting machines 181, 266 CNC press brakes 181 CNC synchro press brakes 181 CNC tap chucks & tap adaptors 79 CNC tap holders & pull studs 79 CNC toolings 73 CNC tools holders & pulley studs 79 CNC turning centres Back inside cover CNC vertical machining centres 19, Back inside cover CNC Back inside cover CNC/VMC machines 135 Coating machines 266 Coating plants 266 Coating systems 266 Coin presses 247 Cold storage dockhouses 23 Cold storage doors 23 Collecting electrodes 230 Colour printers 198 Command panel systems 43 Compressed air division 185, 245 Compressed air filters & regulators 157 Compressed air systems 50 Compression fittings 180 Compressor valve plates 143 Compressors vacuum pumps & air motors 170 Compressors 50, 95, 104, 113 Concrete vibrators 52 Condensate drains 13, 221 Conduits & connector systems 29 Cone pulley heavy-duty lathe machines 163 Cone pulley light-duty lathe machines 163 Cone pulley medium-duty lathe machines 163 Connector accessories 49 Connectors 6, 24, 47, 107, 140, 145, 253 Console systems 43 Contactless in-cylinder transducers 183 Contactless technologies 183 Container cranes 111 Control & automation products 201 Control & automation 93 Control cables 86 Control panel accessories 29 Control valves 205 Controllers 10 Conventional & monoblock pumps 177 Conventional precision lathes 165 Converter planomillers 189 Conveyor castor wheels 209 Conveyor pulleys & rollers 212 Conveyor trolleys 209 Conveyors & automation systems 23 Coolant accessories 177 Coolant pumps 177 Coolant rotary unions 55 Coolant separators 170 Cooling tower motors 176 Cooling towers 129 Cooling water treatments 265 Cordless rechargeable grease guns 241 Coromill 103 Corothread 103
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PRODUCT INDEX
Product
Pg No
Corrosion preventives 172 Corrosion-resistant paints 187 Counter balanced pallet trucks 81 Counters & power supplies 5 Counters rate products 10 Counters 121 Couplings 167 Crab hoists 182 Crane-duty motors 41, 176, 182 Cranes 18, 182, 201 Crimp contacts & tools 49 Cross belt-inline magnetic separators 52 Crystals & oscillators 107, 145, 253 Cushion dock shelters 23 Custom-made cables 49 Cutting machines 266 Cutting tools 71, Front gatefold Cylinders 45, 228 Cylindrical grinders 175, 245 Cylindrical grinding machines 212 Data acquisition modules 192 Data cables 49 DC motors 59 DC power packs 185 DC power supplies 192 Deep drawing hydraulic presses 247 Dehumidifiers 189, 191 Demagnetisers 170 Dessicant dryers 95 Diamond core drilling machines 195 Diamond setting 195 Diaphragm switches 110 Digital almen gauges & almen strips 159 Digital mark sensors 77 Digital multimeters 17 Digital panel meters 121, 206, 219 Digital pressure switches 239 Digital soft starters 215 Dip spin coating machines 266 Disc brakes 239 Discharge electrode assemblies 230 Discharge electrodes 230 Discharge frames 230 Discrete semiconductors 107, 145, 253 Display units 121 Distribution boards 16 Dock levellers 23 Dock shelters 23 Door runners & tracks 209 Door side sensors 121 Doors 23 Dosing feeders 52 Double drum & triple drum magnetic separators 189 Down shop leads 208 Drawer magnets 177, 189 Drill chucks 185, 245 Drill machines 137, 180, 208 Drill sleeves 79 Drilling machines 174, 216, 228 Drilling-cum-milling machines 228 Drilling-cum-vertical milling drill machines 196 Drills 174 Drive motors 210 Drivers & controllers 121 Drives 21, 217 Drum trolleys 209 Drum-type magnetic separators 52, 177 Dry vane pumps 125 Dryers 13 Duplex deburring tools 189 Dust collectors 212, 221 Dust resistance motors 239 Earth resistance testers 192 Electric controls 67 Electric drives 67 Electric forklift trucks 23 Electric wire rope hoists 18, 182, 188 Electrical actuators 199 Electrical connectors 60
Product
Pg No
Electrical measuring instruments 219, 243 Electrical products cable ties 47 Electrical systems 93 Electrical transducers 17 Electricals 107, 145, 253 Electro hydraulics 227 Electromagnetic bin vibrators 52 Electromagnetic chucks 170 Electromagnetic disc brakes 239 Electromagnetic ferrofilters 52 Electromagnetic vibratory feeders 177 Electronic pressure switches 239 Electronic speed switches 215 Electronic timers 30, 32, 34, 36 Electronics For You Expo-2011 226 Electronics products 47 Electrostatic liquid cleaners 72 Embossing rolls Front gatefold Emergency shock absorbers 55 Enclosure cooling units 43 Enclosure systems 43 Enclosures 107, 145, 253 Encoders 5 Energy efficient motors 176 Energy efficient pumps Front inside cover Energy saving gas burners 231 Engineering plastic plugs/sockets 30, 32, 34, 36 Engineering plastics 225 EngineeringExpo 203, 213, 223 EOT cranes 18, 182, 188 EOT jib cranes 201 Everdry 13 Everything About Water Expo-2011 200 Exhibitions 115, 190, 200, 203 213, 223, 226, 242, 246 Explosion-proof valves 227 External & in-cylinders linear position sensing 183 Extra heavy-duty lathes 196 Extra hi-cut lathes 196 Extra-duty lathe machines 196 Fabtec India-2011 115 Factory automation 85, 206 Failsafe brakes 239 Fan & filter units 43 Fans 107, 145, 253 Fasteners & mechanical 107, 145, 253 Fasteners 215 Feed units 228 Femap 179 Ferrous casting 174 Fibre sensors 77 Fibreoptic sensors 121 Filters 13, 45 Filtration technology 13 Filtration 265 Fine & auto feed radial 228 Finishing machines 177 Fire shutters 23 Fittings 45 Fix frame hydraulic presses 247 Flame arresters 191, 210 Flameproof motors 59, 176 Flameproof products 10 Flange flacers 189 Flange motors 41 Flange mounting motors 59 Flanging machines 171 Flat cables for submersible pumps 49 Flat high-tension single-twin igniting electrodes 9, 15 Flexible cables & wires 49 Floating holders 79 Floor plates 209 Floor scrubbers & driers 259 Flooring 231 Flow instruments 197 Flow rate indicators 10 Flow switches 191 Fluid dispensing parts 143 Fluid seal systems 65
Product
Pg No
Fluidised bed coating machines 266 Fluids 122 Flush bottom valves 191 Flux generators 52 Foot mounting motors 41 Force actuation 169 Force feed lubricators 228 Forged components 174 Forging presses 14 Forklift trucks 57 FPGA design flow systems 195 Frequency meters 219, 243 Friction drop hammers 14, 179, 205 Friction screw presses 14 FRL spares valve spares 216 Front casing 210 Funnel magnets 177 Furniture castor wheels 209 Furniture castors 209 Fuse boxes 198 Gantry cranes 182, 201 Gas control & regulators product 205 Gas distribution plates 230 Gas distribution screens 230 Gas springs 55, 188 Gas trains 205 Gauge accessories 197 Gear couplings 162 20, 117, 122, 176, 178, 182, 188 Gear motors Gear seals 143 Gearboxes 20, 117, 122, 162, 178, 187, 188 Geared & flexible couplings 122 Geared head heavy-duty lathe machines 163 Geared head medium-duty lathe machines 163 Geared motors 59 Geared radial drilling machines 228 Geared drilling machines 228 Gears 122, 162 Glass processing furnaces 231 Glass 151 Glide coating machines 266 Global cam indexers 149 Globe valves 191 Goliath cranes 182 Goods lifts 201 Graphic panels 121 Grill magnets 177 Grinding machines 151, 212 Grinding media 9, 15 Grinding tools for hard materials 151 Haconan-free cables 49 Hammers 14, 179, 205 Hand magnets 177 Handheld vibratory motors 52 Hannover-2010 242 Head screws 210 Head washers 210 Heat shrink tubings 47 Heat sinks & HVAC 107, 145, 253 Heat transfer equipment 211 Heat treatment salts 172 Heating elements 247 Heavy job turning & boring machines 196 Heavy-duty castor wheels 209 Heavy-duty castors 209 Heavy-duty drill machines 180 Heavy-duty industrial castors 209 Heavy-duty lathe machines 222 Heavy-duty lathes 196 Heavy-duty radial drill machines 180 Heli-bevel geared motors 176 Helical gearboxes 188 Helical geared motors 18 Helical gears 162 Helical inline geared motors/reducers 178 Helical-worm gear units 20 Heli-worm geared motors 176 H-frame power presses 14 Hi-cut lathes 196
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PRODUCT INDEX
Product
Pg No
High-alumina wear resistant ceramic tiles 9, 15 High-carbon chrome 201 High-carbon steel balls 201 High-discharge pumps 177 High-efficiency standard motors 176 High-intensity induced roll magnetic separators 52 High-intensity rare earth magnetic separators 177 High-intensity roller type magnetic separators 177 High-performance plastics 143 High-pressure ball valves 169 High-pressure blowers 20, 211 High-pressure cleaners 259 High-pressure switches 239 High-pressure transmitters 239 High-speed doors 23 Hi-tech Manufacturing Show 246 HMM technical guidelines 176 HOC dryers 95 Hollow shaft worm gear motors 20 Hooper magnets 177, 189 Horizontal boring & facing machines 208 Horizontal boring machines 208 Horizontal CNC machines Back inside cover Horizontal facing machines 208 Horizontal hydraulic presses 247 Horizontal machining centres Back inside cover Horizontal pipe & tube bending machines 207 Hose clamps 196 Hoses & flexible tubings 45 Hoses 167, 222 Hot oil rotary unions 55 HRC fuse bodies 9, 15 Hump magnets 52, 177, 189 Hydraulic & pneumatic applications 217 Hydraulic and pneumatic valves & fittings 180 Hydraulic centerless grinding machines 245 Hydraulic cylinders 168, 171, 185 Hydraulic cylindrical grinders 168, 245 Hydraulic cylindrical grinding machines 245 Hydraulic dampers 55 Hydraulic dock levellers 23 Hydraulic dock shelters 23 Hydraulic floor cranes 170 Hydraulic floor jib cranes 169 Hydraulic forging hammers 232 Hydraulic gear pumps 185 Hydraulic hand pumps 228 Hydraulic hoses 8 Hydraulic internal grinding machines 245 Hydraulic manual pallet trucks 81 Hydraulic pallet pumps 168, 228 Hydraulic power packs 169, 206 Hydraulic power units 185 Hydraulic press brakes 181 Hydraulic press machines 207 Hydraulic presses 168, 232, 247 Hydraulic pumps & valves 185 Hydraulic pumps 185, 227 Hydraulic punching machines 171 Hydraulic rotary unions 55 Hydraulic seals 133 Hydraulic servo actuators 227 Hydraulic shearing machines 181, 207 Hydraulic shock absorbers 55 Hydraulic splitters 195 Hydraulic steel working machines 171 Hydraulic systems 185 Hydraulic tank accessories 168 Hydraulic valves systems 228 Hydraulics 67 IC counterbalanced forklifts 23 ICS semiconductors 107, 145, 253 Imaging & vision systems 266 Impellers 210 Inclined tube manometers 191 In-cylinder sensors 183 In-cylinder transducers 183 Indexers 149 Indexing machines 221
Product
Pg No
Indicators 10 Inductive proximity switches 29 Industrial automation 85 Industrial batteries 93 Industrial ceramics 9, 15 Industrial connectors 49 Industrial control & sensing devices 5 Industrial coolers 129 Industrial cooling systems 219 Industrial cranes 111 Industrial electric AC motors 20 Industrial electric power distribution systems 16 Industrial floorings 231 Industrial heating elements 247 Industrial hoses 157 Industrial ovens & dryers 231 Industrial overhead doors 23 Industrial paints 188 Industrial pumps 150 Industrial shock absorbers 55, 188 Injection moulding components 198 Inline drum-type magnetic separators 177 Inline helical geared motors 176 Inline shaft mounted helical geared motors/reducers 178 Instrumentation & controls 27 Instrumentation made cables 49 Instrumentation 217 Insulated conductor systems 208 Insulated doors 23 Insulated power rails 208 Insulation testers 17 Interlocking doors 23 Internal grinders 245 Internal grinding machines 245 Internals for electrostatic precipitators 230 Inverter duty motors 176 Inverter/variable frequency drives 5 Investment destination - West Bengal 218 IPVS-2010 190 Isolators 12 Jacks 228 Jib cranes 18, 182 Joinings 169 Kamlok & drylok couplings 150 Kilns & baths 231 Laboratory dissolvers/mixers & mills 228 Laboratory testing rerods 52 Large bearings 8 Large enclosures 43 Large helical & heli-bevel gearboxes 176 Laser distance meters 196 Laser distance sensors 232 Laser markers 77 Laser sensors 77 Laser shaping 151 Lathe machines 210, 239 Lathes 163, 195, 196, 209, 222 Leak detectors 45 LED signal tower lights 30, 32, 34, 36 LEDs 29 Level controllers 5, 199 Level gauges 191 Level indicators 199 Level switches 199 Level transmitters 199 Lift & conveyor cables 49 Lift trucks services 111 Lifting magnets 189 Light lifting 111 Light-duty castors 209 Light-duty lathe machines 222 Light-duty lathes 196 Limit switches 29, 30, 32, 34, 36 Linear motion vibratory screens 52 Linear motion 67 Linear position transducers 183 Linear potentiometers 183 LM guideways 183
Product
Pg No
Load break switches 29 Loaders 57 Loading arms 150 Loading bay equipment 23 Lock nuts 68 Lock washers 68 Long travel machines 228 Loop powered indicators 10 Loop powered isolators 10 Lorry loaders 57 Low lift pallet trucks 23 Low vacuum dehydration & degasification 72 Lubricants 45 Machine tool accessories 79, 183 Machined components 174 Machines 171 Magna roll 52 Magnet cups 210 Magnet drive pumps 210 Magnet pumps 210 Magnetic concentrators 52 Magnetic coolant separators 177 Magnetic floor sweepers 52, 177 Magnetic pulleys 52, 189 Magnetic racks 189 Maintenance sprays 7 Manometers 191 Manual hydraulic crushers 195 Manual pallet trucks 23 Material handling equipment 18, 81, 182 MCBs 12 MCC & PCC enclosures 43 MCCBs 93 Measurement & inspection 107, 145, 253 Measurement sensors 77 Measuring & monitoring relays 5 Measuring instruments 17, 219, 243 Mechanical & hydraulic press brakes 207 Mechanical press brakes 181 Mechanical/hydro-mechanical section bending machines 207 Medical & surgical devices 143 Medical air compressors 227 Membrane drying 13 Metal cutting tools 139 Metal diaphragm pressure switches 239 Metal scrape baling presses 247 Metal treatment chemicals 172 Metallurgical furnaces 231 Metering solutions & relays 93 Meters 93, 219, 243 Micro-milling beads 9, 15 Micro-switches 30, 32, 34, 36 Microwave level switches 110 Mighty tiny series 20 Mill lining blocks 9, 15 Milling cutters 71 Milling grades 103 Milling-cum-drilling machines 137 Miniature modular systems 45 Mitre cutting bandsaw machines 205 Mobile control valves 206 Mobile cylinder hydraulic presses 247 Modernisations 111 Motion controls 5 Motion solutions 149 Motor control centres 93 Motor protection circuit breakers 29 Motorised boom barriers 23 Motorised control valves 205 Motorised vibratory feeders 177 Motors 41, 59 Multi-angle right angle universal milling attachments 189 Multi-core media processors 199 Multi-functional tools 71 Multi-speed motors 176 Multi-stage pumps 177 MV switchgears 93 Needle roller bearings 8 Needle valves 191
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250
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PRODUCT INDEX
Product
Pg No
Non-ferrous casting 174 Nozzles 150 Nuts 68 Office & computers 107, 145, 253 Ohms meters 243 Oil coolers 58 Oil removal 13 Oil seals 172 Oil/coolant coolers 219 On/off controllers 10 One-way clutches 230 Optical touch switches 77 Optoelectronics & displays 107, 145, 253 Oriental motors 239 O-rings 133, 210 Overband magnetic separators 177 Overcrank shearing machines 181 Overhead doors 23 Oversize lathe machines 222 Oxyfuel cutting 181 Paint removers 184 Paint shop equipment 266 Paint shop machines 266 Paint spray booths 221 Paint systems 191 Paints & allied products 184 Paints/thinners & allied products 189 Pallet pumps 228 Pallet stackers 23 Pallet trucks 81 Panel air-conditioners 219 Panel coolers 58 Panels 243 Paperless recorders 206 Parallel cam indexers 149 Parallel shaft helical geared motors 176 Part ejectors 127 Parts for pollution control equipments 230 Passive components 107, 145, 253 PC enclosures 43 PD blowers 95 Pedestrian & rider operated counter balanced pallet trucks 81 Pedestrian low lift pallet trucks 23 Pedestrian pallet stackers 23 Peeing machines 159 Perforated metal screens 230 Peripheral explorer kits 192 Permanent magnetic chucks 170, 189 Permanent magnetic drum pulleys 177 Permanent magnetic drum-type separators 189 Permanent magnetic lifters 52 pH testers 225 Photoelectric sensors 5, 77, 121 Pick & move cranes 57 PID controllers 10 PID temperature controllers 121 Pillar drill machines 174, 180 Pillar-type hydraulic presses 247 Pilot lights 29 Pipe bending machines 171 Piston rings 143 Piston rods 222 Planetary gear heads 183 Planner machines 209 Planners 195 Planning machines 229 Plano millers 209, 195, 229 Plastic hose pipes 157 Plastic mould products 143 Plastic products 143 Plate bending machines 171, 181, 207 Plate castor wheels 209 Plate magnets 52, 177, 189 Plat-trucks 209 PLC-operated hydraulic presses 247 PLCs 217 Plugs & sockets 29 Pneumatic & electric on/off valves 205 Pneumatic clutches & brakes 177
Product
Pg No
Pneumatic control valves 205 Pneumatic cylinders 179, 222 Pneumatic fastening tools 183 Pneumatic feeders 180 Pneumatic nailers 172 Pneumatic piston pumps 184 Pneumatic plug valves 177 Pneumatic products 157, 216 Pneumatic rotary actuators 172 Pneumatic rotary unions 55 Pneumatic seals 65 Pneumatic stirrers 180 Pneumatic valves 174 Pneumatic vices 183 Pneumatics 8, 67 Polishing machines 212 Polyacetal 225 Polyaryletherketone 143 Polyetheretherketone 143 Polypropylene 225 Polyurethane thinners 185 Polyurethane 225 Portable blasters 221 Portable coolant purifying systems 127 Portable oil skimmers 127 Portable turning machines 189 Powder coating & speedy painting equipment 241 Power & line protection 107, 145, 253 Power cables 86 Power chucking cylinders 175 Power controllers 121 Power distribution components 43 Power factor meters 219 Power magnets 189 Power pack units 228 Power packs 228 Power presses 181, 207 Power quality management systems 93 Power shearing machines 229 Power supply for cranes/hoists 208 Power supply for stem material handling 208 Power transducers 17 Pre treatment systems 266 Precision locknuts 183 Precision roll turning lathe machines 196 Precision rolling bearings 8 Precision steels 151 Precision switches 29 Precision universal cylindrical machines 245 Press technology 169 Pressure blasters 221 Pressure boosting 265 Pressure control valves 210 Pressure feed spray guns 202 Pressure gauges 10, 197 Pressure sensors 77, 121 Pressure switches 239 Pressure transducers 239 Pressure transmitters 239 Process controllers 206 Process cranes 111 Process gas blowers 211 Process water treatment 265 Product assemblies 174 Profile projectors 205, 243 Programmable logic controllers 5 Programmable terminals 5 Prong magnets 52 Proportional valves 227 Protective-conduit systems 49 Proximity sensors 5, 30, 32, 34, 36, 77, 121 Proximity switches 215 PTFE/Teflon products 225 Pulleys 162 Pumps 11, 39, 125, 131, 210, Back cover Punching machines 171 Push buttons 29 PVC flap & strip doors 23 Quick connects 45
Product
Quick release couplings 180 Quick-change tapping chucks/tap adaptors 79 Racks & cabinets 107, 145, 253 Radial drill machines 137, 180, 208, 216 Radial drilling 174, 209 Rapid flexible doors 23 Rapid roll-up doors 23 Rapping bar assembly 230 RCCBs 12 Reach trucks 23 Reaming & tapping 79 Rear casings 210 Rear cylinder press brakes 216 Receptacles 150 Reciprocating air compressors 119 Re-crystallised allumina tubes 9, 15 Rectangular lifting magnets 52 Re-drawer magnets 52 Reflective photoelectric sensors 229 Refrigerated dryers 13, 95 Regulators 45 Re-hopper magnets 52 Reliable flooring 231 Relief valves 191 Re-magnetic rods 52 Reversible motors 239 Reversible tapping attachments 79 RFIDs 5 Rigging solutions 99 Right-angled helical bevel geared motors/reducers 178 Right-angled helical worm geared motors/reducers 178 Robotic cables 49 Robotic demolition 195 Rod ends 60 Roll forming machines 207 Roller-type magnetic separators 177 Roots blowers 125 Rotary cam switches 29 Rotary clean flow magnets 52 Rotary dry vacuum pumps 211 Rotary encoders 121 Rotary indexing tables 149 Rotary joints 55 Rotary screens 52 Rotary screw air compressors 95, 119 Rotary shaft seals 133 Rotating unions 55 Round glasses 191 RTD sensors 10 Rubber products 172 Sack trucks 209 Safety laser scanners 77 Safety light curtains 5 Safety protection devices 29 Safety relief valves 191, 210 Safety shock absorbers 55 SCADA & DCS implementation 266 Scanners 10 Scissor lifts 23 Scrap-circular lifting magnets 52 Screw air compressors 119 Screw compressors 227 Screw presses 232 Sealants 45, 109 Sealing systems 222 Seals 8, 172 Section bending machines 207 Sectional overhead doors 23 Security & audio visual 107, 145, 253 Security systems 173 Self-opening die-heads 79 Semiconductor modules 107, 145, 253 Semiconductor tools 107, 145, 253 Semiconductors 107, 145, 253 Sensitive part loading/unloading 127 Sensor controllers 121 Sensors & transducers 107, 145, 253 Sensors 77 Serial converter modules 121
FINALIZE SUPPLIERS @ 252
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Pg No
www.engg-expo.com
PRODUCT INDEX
Product
Pg No
Shaft loading 127 Shaping machines 209 Sheet metal components 198 Sheet metal machines 171 Shipyard cranes 111 Shock & vibration isolation 225 Shoe brakes 239 Shot blasting hoses 221 Shot blasting machines 205 Shot blasting 159 Shrouded DSL systems 208 Shunts 243 Sight flow indicators 191 Sight flow meters 150 Signal isolators 10 Silence flow packages 211 Simplair anodised aluminum piping 95 Single/multiple precision switches 29 Single-pass honing machines 208 Slab demolition 195 Sleeves 68 Slipring crane-duty motors 59 SLS linear displacement sensors 183 Small junction/distribution boxes 43 Sockets & switches 24 Solar water heating systems 231 Solderless terminals 47 Solenoid valves 205, 216 Solid carbide drills & mills 139 Solid carbide reamers 139 Solid carbide special drills & mills 139 Solid carbide special reamers 139 Solid edge 179 Special application motors 176 Special refrigeration equipment 219 Specialised grooving & parting tools 71 Special-purpose machines 195 Speed control motors 239 Spindle nose toolings 71 Spiral bevel gearboxes 20 Spiral cables 49 Spiral-cum-helical gearboxes 122 Spray guns 185, 245 Spur gears 162 Squeezing rolls Front gatefold SSM nuts 79 Stacker pumps 228 Stainless steel valves 227 Stainless steels 201 Standard pyramid-type plate bending machines 207 Static control & site safety 107, 145, 253 Static control devices 77 Steam rotary unions 55 Steel balls 201 Steel working machines 171 Stepper motors 121, 239 Stepping motors & systems 239 Straightening machines 229 Submersible hydraulic presses 247 Suction blasters 221 Super blaster machines 219 Surface grinding machines 231 Surface plates 209 Surface treatments 109 Suspension magnets 52, 177 Sweeping machines 259 Switchboard meters 243 Switches & relays 107, 145, 253 Switches 12 Switchgear products 93 Switching power supplies 121 Switching relays 5 Swivels 150 Synthetic enamels 188 System integrators 217 Tacho/speed/pulse meters 121 Tail lifts 23 Team centres 179 Technical ceramics 9, 15
Product
Pg No
Teflon bushes 210 Telescopic doors 23 Temp/humidity transducers 121 Temperature controllers 5, 206 Temperature instruments 197 Temperature-resistant cables 49 Tension springs 188 Testers 243 Tests 107, 145, 253 Thermic fluid heaters 227 Thermocouples 10 Thread whirling tools 103 Timers 5, 10, 121 Timing belts 162 Timing pulleys drives 162 Timing pulleys 162 Tool holders 73 Tool post belt grinders 212 Tooling solutions 93 Toolings 73 Tools & production supplies 107, 145, 253 Torque motors 20, 176 Totalisers 10 Touchup spray paints 185 Toughened glasses 191 Tower cranes 57 Tower lights 121 Trade fairs-2011 220 Transducers 219 Transformers 107, 145, 243, 253 Transmitters 10 Trap magnets 177 Travel drives 202 Traveling machines 18 Trims 198 Triple drum-type magnetic separators 52 Trolley castor wheels 209 Trolleys 209 Truck blowers 211 Truck loading conveyors 217 Truck-dumper body vibrators 52 Tube magnets 52 Tube sheet assemblies 230 Tubing & tube accessories 45 Turned components 174 Turning holders 71 Turrets 175 Twin spin bearing reducers 183 UF exiter vibratory screens 52 UHMW-PE products 225 Ultrasonic flow meters 206 Ultrasonic thickness gauges 222 Unbalanced vibratory motors 52 Uni-force exciters 52 Unigraphics 179 Universal die-bending machines 202 Universal drilling machines 163 Universal quick-change chucks & adaptors 79 Universal radial drilling machines 228 Universal testing machines 225 U-tube manometers 191 Vacuum blasters 221 Vacuum booster pumps 125 Vacuum boosters 216 Vacuum cleaners 173 Vacuum pumps 227 Vacuum systems 125 Valve position transducers 183 Valve seats 143 Valves 45, 169, 180, 191, 216 Variable speed drives 20 Variable speed pulleys 20 VDI tool holders 73 Ventilators 221 Vertical boring machines 209 Vertical machining centres 175 Vertical order pickers 23 Vertical turning machines 195, 209 Vertical turning-cum-boring machines 195
Product
Pg No
Vibrating motors 177 Vibrating reed type 243 Vibrating screen machines 177 Vibrating tables 192 Vibration motors 20 Vibratory bin activators 52 Vibratory bowls 177 Vibratory conveyors 52 Vibratory feeders 52 Vibratory fluidised bed dryers 52 Vibratory furnace chargers 52 Vibratory grizzly feeders 52 Vibratory knockout tables 52 Vibratory spiral elevators 52 Vibratory tables 52 Vices 185, 245 Vision sensors 5 Voltmeters 219 Wall sawing 195 Washers 68 Wastewater treatments 265 Water analysers & combustible & toxic gas detectors 217 Water chillers 219 Water exhibitions 128 Water faucet & tap parts 9, 15 Water purifiers 173 Water rotary unions 55 Water treatments 265 Water-cooled reciprocating compressors 95 Waterjet cutting Front gatefold Waterproofing & decorative outdoor paints 187 Watertight motors 239 Wattmeters 219 Wear parts 71 Welding equipment 185, 245 Welding systems 45 Wet & dry vacuum cleaners 259 Wet drum-type magnetic separators 52 Wheel assemblies 188 Wheel barrows 209 Winches 201 Wire & assemblies 107, 145, 253 Wire connectors 47 Wire rope drums 188 Wires 86 Wiring connectors 198 Withdrawal sleeves 68 Worm gear speed reducers 20 Worm gears 122, 162 Y-type strainers 191 Zirconia polycrystal ceramics 9, 15
INTERNATIONAL PRODUCTS Accu-line lasers Aftercoolers Analogue front ends Bench wire twisters Bimetal thermometers Clamping systems Connectors Flexible epoxies FPGA design flow systems Fusing machines Hydraulic dock levellers IS interfaces remote Motors Multi-core media processors Multi-wire wipers Overvoltage arresters Screw compressors Step motion controllers Switches Transmitters Truck tailgate lifts Visual code programming systems Wireless data transmission systems Work process management solution software
243 243 199 240 244 241 240 245 195 244 187 171 114 199 244 240 22 240 171 171 187 247 240 240
SOURCE HYDRAULICS PNEUMATICS EQUIPMENT @ www.engg-expo.com
254
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ADVERTISERS’ LIST
To know more about the advertisers in this magazine, refer to our ‘Advertisers’ List’ or write to us at search@infomedia18.in or call us at +91-22-3003 4640 or fax us at +91-22-3003 4499 and we will send your enquiries to the advertisers directly to help you source better Advertisers’ Name & Contact Details
AC Automation T: +91-11-27674839 E: ac@ac-automation.com W: www.ac-automation.com
Pg No
188
Advertisers’ Name & Contact Details
199
Ballkings T: +91-161-2534501 E: ballkings@ballkings.com
Aglow Engineers Pvt Ltd T: +91-120-3917070 E: info@aglowengineers.com W: www.aglowengineers.com
198
Beko Compressed Air Technologies Ltd T: +91-40-23080275 / 23081107 E: info@bekoindia.com W: www.beko.de
6
Amsak Cranes Private Limited T: +91-44--26273486 E: sales@amsakcranes.com W: www.amsakcranes.com
201
Applied Engg Services T: +91-20-24448165 E: info@appliedengg.in W: www.appliedengg.in
241
Ashok Industry T: +91-22-61504150 E: sales@ashokindustry.com W: www.ashokindustry.com
172
Atlas Copco (India) Ltd T: +91-20-30722222 E: marcom@in.atlascopco.com W: www.atlascopco.com
104
Atos Spa T: +91-80-23613840 E: manish@atosindia.in W: www.atos.com
227
Autonics Automation India Pvt Ltd T: +91-22-27814305 E: sjlim@autonics.com W: www.autonics.com
121
Avcon Controls Pvt Ltd T: +91-22-28221505 E: avcon@bom3.vsnl.net.in W: www.avconindia.com
205
Classic Polymers & Resins T: +91-22-24465251 E: sales@classicpolymers.co.in W: www.classicpolymers.com
225
180
266
201
Coatec India T: +91-172-5063436 E: info@coatecindia.com W: www.coatecindia.com
B S Hydro-Pneumatic Pvt Ltd T: +91-22-26861361 E: bshydro@vsnl.com W: www.bshydro.com
Actuators India Pvt Ltd T: +91-22-26736864 E: actuatorsindia2007@rediffmail.com W: www.tscindia.com
13
Bhagirath Heavy Transmission T: +91-11-32222661 E: bht_india1998@yahoo.co.in
188
Boge Compressed Air System T: +91-44--43009610 E: S.Sriram@boge.de W: www.boge.in
50
Bonfiglioli Transmissions (Pvt) Ltd T: +91-44--24781035 E: sales@bonfiglioliin.com W: www.bonfiglioliindia.com
21
Bosch Rexroth (India) Limited W: www.boschrexroth.co.in
67
Buildcon Consultants Pvt Ltd T: +91-141-4012629 E: sales@buildcon.in W: www.buildcon.in
231
C&S Electric Ltd. T: +91-11-30887520-29 E: ravi.gautam@cselectric.co.in W: www.cselectric.co.in Cenlub Systems T: +91-129-4113771 E: sales@cenlub.com W: www.cenlub.com Ceratizit India Pvt Ltd T: +91-33-24947146 E: info@ceratizitindia.co.in W: www.ceratizit.com Champion Industries T: +91-2752-231741 E: champion_ind@yahoo.com
Pg No
191
187
57
Advertisers’ Name & Contact Details
Chemical & Industrial Engineers T: +91-22-28822740
Awwa (I) Technologies T: +91-80-25360784 E: awwa_technologies@rediffmail.com
Action Construction Equipments Ltd T: +91-11-40549900 E: marketing@ace-cranes.com W: www.ace-cranes.com
Allied Electronics Corporation T: +91-22-26616619 E: allied@vsnl.com W: www.aecconnectors.com
Pg No
Connectwell Industries Pvt Ltd T: +91-251-2870636 E: connect@connectwell.com W: www.connectwell.com
24
Cosmos Impex (India) Pvt. Ltd. T: +91-265-3927000 E: sales@cosmos.in W: www.cosmos.in
158, 186
CRI Pumps (Pvt) Ltd T: +91-422-3260011 E: corp@cripumps.com W: www.cripumps.com
11
Darling Pumps Pvt Ltd T: +91-731-2720558 E: darlingin@satyam.net.in W: www.darlingpump.com
131
Deep Pneumatics Pvt Ltd T: +91-79-22803684 E: sandip@deeppneumatics.in W: www.deeppneumatics.in
119
Delair India Pvt Ltd T: +91-124-4091111 E: delairmarketing@pahwa.com W: www.delair.com
191
12
Diamond Metal Screens Pvt. Ltd. T: +91-831-2441295 E: diamondscreens@vsnl.com W: www.diamondscreens.com
230
198
Digital Marketing Systems Pvt Ltd T: +91-731-3046800 E: digicontrols@gmail.com W: www.digitalcontrols.org
217
Dixon Asia Pacific Pvt Ltd T: +91-22-40931555 E: salesindia@dixonvalve.com.au W: www.dixonvalve.com
167
71
170
Dongguan Dacheng Machinery Make Co., Ltd. 187 T: +86-769-8321-7777 E: david@gddacheng.cn W: www.taillift.net
Our consistent advertisers
260
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ADVERTISERS’ LIST
Advertisers’ Name & Contact Details
Pg No
Advertisers’ Name & Contact Details
Pg No
Advertisers’ Name & Contact Details
Dowel Machinery Pvt Ltd T: +91-281-2362465 E: dowel@thedowel.com W: www.thedowel.com
247
Essence Engineering T: +91-09866964469 E: business.essence@gmail.com W: www.essence-india.blogspot.com
239
G W Precision Tools India Pvt Ltd T: +91-80-40431252 E: info@gwindia.in W: www.gwindia.in
Dynascan Inspection Systems Co T: +91-80-41102747 E: dynascan@vsnl.com W: www.dynascan.info
243
Eureka Forbes Limited T: +91-80-30251500 E: fandb@eurekaforbes.com W: www.eurekaforbes.com
173
Gandhi Automations Pvt Ltd T: +91-22-66720200 E: sales@geapl.co.in W: www.geapl.co.in
EA Water Pvt Ltd T: +91-11-43100519 E: enquiry@eawater.com W: www.eawater.com/expo
200
Everest Transmission T: +91-11-45457777 E: info@everestblowers.com W: www.everestblowers.com
125
Gem Equipments Ltd T: +91-22-3267800 E: sales@gemindia.com W: www.gemindia.com
Fabtec India 2011 T: +91-422-2221582 E: fabtecindia@codissia.com W: www.fabtecindia.codissia.com
115
Global Sleeve Solutions T: +91-09501040477 E: info@globalsleeves.com W: www.globalsleeves.com
East India Bearing Co. (P) Ltd. T: +91-22-40939200 E: mumbai@eibc.in W: www.eibc.in
8
EFY Enterprises Pvt Ltd T: +91-11-26810601 E: efyenq@efyindia.com W: www.efyexpo.com
226
Farnell Electronics India T: +91-80-40003800 E: india-sales@farnell.com W: www.farnell.in
Elecon Engineering Company Ltd T: +91-2692-236469 E: infogear@elecon.com W: www.elecon.com
122
Ferrocare Machines Pvt Ltd T: +91-20-26830655 E: info@ferrocare.com W: www.ferrocare.com
Electro Magnetic Indus T: +91-265-3241361 E: sales@electromagneticindia.com W: www.electromagneticindia.com
52
Fluid Energy Controls Inc T: +91-44--42083536 E: sales@fecindia.com W: www.fecindia.com
Electrocraft (Asia) Limited T: +852-3163-2250 E: skwok@electrocraft.com W: www.electrocraft.com
114
Fontus Water Ltd T: +91-11-43100536 E: sales@fontuswater.com W: www.fontuswater.com
Electronica Hitech Engineering Pvt Ltd T: +91-20-30435400 E: hitech@electronicahitech.com W: www.electronicahitech.com
135
Forging Machinery Manufacturing Co T: +91-161-5011755 E: info@nkhhammers.com W: www.nkhhammers.com
Empire Cable Industries Pvt Ltd T: +91-11-23874632 E: empirecables@yahoo.co.in W: www.empirecables.com Endeavour Engineering T: +91-79-65123263 E: info@endeavourengineering.com W: www.endeavourengineering.com Engineering Expo T: +91-9920401226 E: engexpo@infomedia18.in W: www.engg-expo.com
23
129
68
207
Goliya Electricals Pvt Ltd T: +91-22-24120456 E: geplmumbai@mtnl.net.in W: www.goliya.com
243
150
Goliya Instruments Pvt Ltd T: +91-22-24149657 E: goliya@mtnl.net.in W: www.goliyainstruments.com
219
265
Grundfos Pumps India Pvt Ltd T: +91-44--24966800 E: salesindia@grundfos.com W: www.grundfos.in
.BC
14
H G Shah & Co T: +91-79-25621431 E: hgshah2000@rediffmail.com W: www.timingpulley.in
162
Hannover Fairs India Pvt Ltd T: +91-22-40050683 E: tushar.alekar@hmf-india.com W: www.mda-india.com
242
72
Frank Technologies T: +91-422-2646490 E: sales@frankcompressors.com W: www.frankcompressors.com
227
143
Freeze Tech Equipments Pvt Ltd T: +91-44-42152387 E: info@freezetechequip.com W: www.freezetechequip.com
58
110
139
Godson Bending Systems Pvt Ltd T: +91-281-2361467 E: godsonindia@hotmail.com W: www.godson-india.com
86
203, 213, 223
Entech Consultancy Bureau (Madras) Pvt. Ltd. T: +91-44--24421024 E: ecb@vsnl.com W: www.entechconsultancy.com
107, 145, 253
Pg No
Havells India Ltd. T: +1800-11-0303;’+91-11-41660303 E: marketing@havells.com W: www.havells.com
41
G A Industries T: +91-79-25895577 E: gmac@gaindustries.net W: www.gaindustries.net
239
Heattrans Equipments Pvt.Ltd. T: +91-79-25840105 E: info@heattrans.com W: www.heattrans.com
174
G L Brothers T: +91-22-66047000 E: info@pilotindia.com W: www.pilotindia.com
245
Henkel Adhesives Technologies India T: +91-80-25357771 E: marketing@loctite.co.in W: www.loctite.com
109
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261
ADVERTISERS’ LIST
Advertisers’ Name & Contact Details
Hensel Electric India Pvt. Ltd. T: +91-44--24541669 E: henselelectric@vsnl.com W: www.hensel-electric.de
Pg No
16
Advertisers’ Name & Contact Details
Pg No
Advertisers’ Name & Contact Details
Jyoti CNC Automation T: +91-2827-287081 E: info@jyoti.co.in W: www.jyoti.co.in
.BIC
Macro Tech Equipment Pvt Ltd T: +91-33-24666261 E: info@macrotechcal.com W: www.macrotechcal.com
Pg No
81
Hindustan Motor Mfg Co T: +91-22-42500500 E: sales@hindmotors.com W: www.hindmotors.com
176
Jytra Engineering Services T: +91-40-66663747 / 9246553857 E: info@jytra.com W: www.jytra.com
179
Makson Machines Pvt Ltd T: +91-278-2446437 E: makwana_eng@yahoo.com W: www.makwanaeng.com
174
Hitachi India Trading Pvt Ltd T: +91-11-40605252 E: ice@hitachi.co.in W: www.hitachi.com.sg
113
Kapasi Fastners / Inc T: +91-80-22279217 E: kapfast@vsnl.com
215
259
195
HiTech Manufacturing Show T: +91-09820373804 E: hitech@infomedia18.in
246
Keman Enterprises Ltd T: +91-22-25902283 E: keman@vsnl.com W: www.kemangroup.com
Manmachine (India) Private Limited T: +91-120-2422727 E: info@manmachineindia.com W: www.manmachine.in
.FIC
Hi-Tech Robotic Systemz Ltd T: +91-124-4715100 E: marketing@hitechroboticsystemz.com W: www.hitechroboticsystemz.com
147
Klipco Pvt Ltd T: +91-22-28684221 E: klipco@mtnl.net.in W: www.klipcohoseclamps.com
196
Mather And Platt Pumps Ltd T: +91-20-27442100 E: sales@pun.matherplatt.co.in W: www.matherplatt.com
175
Igus India Pvt Ltd T: +91-80-39127800 E: info@igus.in W: www.igus.in
140
Knowell International Pvt Ltd T: +91-33-22304627 E: hktrading@vsnl.com W: www.knowell.co.in
229
Micromatic Machine Tools T: +91-80-41492285 E: mmtblr@acemicromatic.com W: www.acemicromatic.com
197
Konecranes India Pvt Ltd T: +91-20-40047470 E: india.sales@konecranes.com W: www.konecranes.com
111
Millenium Instruments Ltd T: +91-11-22456571 E: miepl@miepl.com W: www.miepl.com
Kryfs Power Components Ltd T: +91-22-67859999 E: sales@slingset.com W: www.slingset.com
99
Ingersoll Rand (India) Ltd T: +91-79-22820123 E: airsolutionsindia@irco.com W: www.ingersollrand.co.in
95
Inter Ads - Brooks Exhibitions Pvt Ltd T: +91-09810042500 E: sunil-chhibber@interadsindia.com W: www.india.aquatechtrade.com
128
Jagdeep Foundry (Regd.) T: +91-1871-242750 E: jagdeepfoundry@rediffmail.com W: www.jagdeepfoundry.in
209
Kushal Udyog Manufacturers & Engineers 221 T: +91-291-2720072 E: kushaludg@sancharnet.in W: www.kushaludhyog.com
Jaibalaji Controlgears Pvt. Ltd., 30, 32, 34, 36 T: +91-44--26251279 E: dchandramohan@jaibalaji.firm.in W: www.jaibalaji.firm.in
Lapp India Pvt Ltd T: +91-80-7826000 E: sales@lappindia.com W: www.lappgroup.com
49
Jayashree Electron Pvt Ltd T: +91-20-46768998 E: sales@jayashree.co.in W: www.jayashree.co.in
215
Larsen & Toubro Ltd T: +91-22-67525656 E: ss-ccd@lth.ltindia.com W: www.larsentoubro.com
93
Jaykrishna Magnetics Pvt Ltd T: +91-79-22970452 E: info@jkmagnetics.com W: www.magneticequipments.com
177
Lubi Electronics T: +91-79-39845300 E: info@lubielectronics.com W: www.lubielectronics.com
77
Maco Corporation India Pvt. Ltd. T: +91-33-40224129 E: rdutta@macocorporation.com W: www.macocorporation.com.com
55
Jyoti Ceramic Industries Pvt Ltd T: +91-253-2350120/338 E: info@jyoticeramic.com W: www.jyoticeramic.com
9, 15
Mitsubishi Electric Asia Pte. Ltd. T: +91-124-4630300 E: marketing@mspl.messung.com W: www.messung.com
85
N K Forging & Rolling Industries T: +91-161-2223666 E: info@forginghammer.com W: www.nkhhammer.com
179
Nanfang Pumps India Pvt Ltd T: +91-22-25425540 E: sales@nanfangpumps.com W: www.nanfangpumps.com
39
Ni Systems India Pvt Ltd T: +91-80-41190000 E: ni.india@ni.com W: www.ni.com
27
Ningbo Xinda Screw Compressor Co., Ltd 22 T: +86-574-8833-6868 E: inquiry@xindaworld.com W: www.augustcompressor.com Oil Seals Mfg Co Pvt Ltd T: +91-22-22047943 E: omcoseal@rediffmail.com Omron Automation Pvt. Ltd. T: +91-80-40726400 E: srirams@ap.omron.com W: www.omron-ap.com
172
5
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262
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Advertisers’ Name & Contact Details
Pg No
Advertisers’ Name & Contact Details
Pg No
Advertisers’ Name & Contact Details
Pg No
Orbitz Corporate & Leisure Travels (I) Pvt. Ltd. 220 T: +91-22-24102801 E: neeraj@orbit-star.com W: www.visittradefairs.com
Premier Enterprise T: +91-281-2387556 E: premierenterprise@rediffmail.com W: www.premierlathe.co.in
196
Rightvision (India) Pvt. Ltd. T: +91-120-4261026 E: lasco@rightvision.biz W: www.rightvision.biz
232
Orbitz Exhibitions Pvt Ltd T: +91-22-24102801 E: info@ipvs.in W: www.ipvs.in
190
Premium Transmission Ltd T: +91-20-27488886 W: www.premiumtransmission.com
117
Rishabh Instruments Pvt Ltd T: +91-253-2202202 E: marketing@rishabh.co.in W: www.rishabh.co.in
17
180
Procon Technologies Pvt Ltd T: +91-79-27492566 E: info@procon.co.in W: www.procon.co.in
206
P Parmar Mechanical Works T: +91-278-2447409 E: info@parmardrill.com W: www.parmardrill.com
Rittal India Pvt Ltd T: +91-80-23519792 E: info@rittal-india.com W: www.rittal-india.com
43
149
Radix Electro Systems Pvt Ltd T: +91-22-42537784 E: sales@radix.co.in W: www.radix.com
10
Packam Controls Pvt Ltd T: +91-22-28771293 E: info@packam.co.in W: www.packam.co.in
177
Pathak Machines International T: +91-161-2510401 E: ritesh12@hotmail.com W: www.pathakeuromachines.com
171
Rajamane Industries Pvt Ltd T: +91-80-43659000 E: coolantpump@rajamane.com W: www.rajamane.com Rajindra Machines (P) Ltd T: +91-1871-242763 E: rajindramachines@yahoo.com W: www.rajindra.net
195
Rattan Hammers T: +91-161-2685235 E: info@hammersindia.com W: www.hammersindia.com
205
Reality Automation And Security Systems Pvt Ltd T: +91-20-32922630 E: sales@vighnaharta.in W: www.vighnaharta.in
251
Sameer Linkages Pvt. Ltd. T: +91-265-2638941 E: response.slpl@sameerlinkages.com W: www.sameerlinkages.com
Regulateurs Georgin T: +33-01-46126000 E: sales.in@georgin.com W: www.georgin.com
171
Samson Extrusion Ind Pvt Ltd T: +91-22-23422238 E: samson7@vsnl.com W: www.samson-grp.com
Reva Industries Ltd T: +91-129-4185400 E: reva@revacranes.com W: www.revacranes.com
18
Pidilite Industries Ltd T: +91-22-33087544 E: sunil.ugalmugale@pidilite.com W: www.pidilite.com
7
Pilot Pneumatics Pvt Ltd T: +91-22-66047000 E: info@pilotindia.com W: www.pilotindia.com
185
Pitroda Utility Industries T: +91-2752-243795 E: response@pitrodautilityindia.com W: www.pitrodautilityindia.com
245
Poly Kraft Machines T: +91-79-22743639 E: pkmdrill@gmail.com W: www.polykraftmachines.com
208
Power Build Ltd T: +91-2692-231070 E: infopbl@elecon.com W: www.pbl.co.in
178
Precise Engineering Works T: +91-278-2470868 E: precisegohil@rediffmail.com Prem Brothers T: +91-11-28117456 E: powrmstr@vsnl.com W: www.powermaster-india.com
73
212
Rexello Castors Pvt Ltd T: +91-22-4091777 E: rexello@vsnl.com W: www.rexellocastors.com
209
Riat Brothers (India) T: +91-9815934018 E: riatgrinders@gmail.com W: www.riatgrinders.com
229
Roto Linear Systems T: +91-080-23572855 E: rotolinearindia@vsnl.net
183
S&T Engineers T: +91-422-2590810 E: stycm@stengineers.com W: www.stengineers.com
19
S.B. Pumps T: +91-22-25784069 E: machbow@gmail.com W: www.machbow.com
210
Sahyog Enterprise T: +91-278-2446848 E: sahyogdrills@dataone.in W: www.siddhapuradrills.com
228
60
157
Sandvik Coromant India 103 T: +91-20-27104725 E: coromantindia.communications@sandvik.com W: www.sandvik.coromant.com/in Satyabhumi Machine Tools T: +91-278-2438241 E: pmwbvn@dataone.in W: www.prakashmachines.co.in
137
Satyaprakash Machine Tools T: +91-278-3012407 W: www.spdrills.com
216
Seal Jet Seals T: +91-20-27121581 E: vswasu@satam.net.in
217
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ADVERTISERS’ LIST
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Search - Investment Destination-West Bengal T: +91-22-30245000 E: spmktg@infomedia18.in Shavo Technologies Pvt Ltd T: +91-20-26059641 E: shavogroup@vsnl.com W: www.shavogroup.com
218
170, 225
Shenoy Engineering Pvt Ltd T: +91-80-28361767 E: info@shenoyengineering.in W: www.shenoyengineering.in
189
Shikovi Heat Gen Technologies Pvt Ltd T: +91-22-27607758 E: sales@shikovi.com W: www.shikovi.com
231
Shilpa International (Impex) Pvt Ltd T: +91-40-27849020, 27840698 E: replysearch@shilpagroup.com W: www.shilpagroup.com/si
183
Shree Prayag Air Controls (P) Ltd T: +91-120-4733333 E: sales@spacpneumatic.com W: www.spacpneumatic.com
216
Shree Saikrupa Hydro Marketing T: +91-79-22800836 E: exports@bosspumps.in W: www.bosspumps.in
185
Shreeram Engineers T: +91-79-22901542 E: shreeram15@hotmail.com W: www.shreeramahmedabad.com
169
Shridhan Automation Pvt Ltd T: +91-80-28431847 E: info@shridhan.com W: www.shridhan.com
199
SKF Economos India Pvt. Ltd. T: +91-11-41098880-89 E: india@economos.com W: www.economos.com
65
Sonal Magnetics T: +91-79-22872349 E: info@sonalmagnetics.com W: www.sonalmagnetics.com
Advertisers’ Name & Contact Details
Statfield Equipments Pvt. Ltd. T: +91-20-22922180-82 E: marketing@statfieldequipments.com W: www.statfieldequipments.com
Pg No
241
Advertisers’ Name & Contact Details
Tox Pressotehnik India Pvt Ltd T: +91-20-66538300 E: RNamboodiri@tox-in.com W: www.tox-de.com
Pg No
169
47
TPG Motors & Drives (India) Pvt Ltd T: +91-44--23634199 E: tpg_in@yahoo.com W: www.tpg-tw.com
20
Sunil Enterprise T: +91-281-2926239 E: microlathes@rediffmail.com
222
Trident Precision International T: +91-11-41425326 E: trident.sales@tridenthydraulics.com W: www.trident-precision.com
222
Surface International T: +91-09413329749 E: info@surfaceint.com W: www.surfaceint.com
159 Trident Products Pvt Ltd T: +91-124-4300626 E: trident.sales@tridenthydraulics.com
230
Susheel Engineering Corporation T: +91-22-25007976 E: safetrack@vsnl.com
208
Tussor Machine Tool Ind Pvt Ltd T: +91-422-3200183 E: info@tussorindia.com W: www.pinachoindia.com
165
U-Tech Associates T: +91-80-23390309 E: udaya@u-techindia.com W: www.u-techindia.com
127
Venus Engineers T: +91-11-32222661 E: enquiry@venusengineers.com W: www.venusengineers.com
182
Vinit Engineering Works T: +91-281-2312091 E: vinit@balajilathe.com W: www.balajilathe.com
163
VKE Valves Industries Pvt Ltd T: +91-22-26763764 E: vke@bom7.vsnl.net.in W: www.vkevalves.com
210
Sumitron Exports Pvt Ltd. T: +91-11-41410631 E: sumitron@vsnl.com W: www.sumitron.com
Swagelok Manufacturing Company T: +91-22-66625984 E: info@bombay.swagelok.com W: www.swagelok.com
45
Swam Pneumatics Pvt Ltd T: +91-120-4696222 E: swamatic@airtelmail.com W: www.swamatics.com
211
Tandem Hydraulics Pvt. Ltd. T: +91-120-4159611 E: info@tandemhydraulics.com W: www.tandemhydraulics.com
206
Techaids T: +91-172-4379995 E: info@techaids.in W: www.techaids.in
.FGF
Teknic T: +91-22-26592392 / 94 E: teknic@vsnl.co.in W: www.teknic.co.in
29
Weldor Engineering Pvt Ltd T: +91-281-2360242 E: weldor@weldor.com W: www.weldor.com
181
189
The Indian Electric Co T: +91-20-24474303 E: icemktg@indianelectric.com W: www.indianelectric.com
59
Wendt India Ltd T: +4344-405500 E: vijayvernekar@wendtindia.com W: www.wendtgroup.com
151
Spareage Seals Ltd T: +91-22-25800972 E: sales@spareage.com W: www.spareage.com
133
Theeta Electricals Pvt Ltd T: +91-124-4387400 E: sales@theeta.com W: www.theeta.com
247
Werner Finley Pvt Ltd T: +91-80-23289889 E: info@wernerfinley.com W: www.wernerfinley.com
219
Sreelakshmi Traders T: +91-44--24343343 E: sreelakshmitraders@gmail.com W: www.sreelakshmitraders.com
221
Tools & Appliances Corp T: +91-2764-233983 E: imi@imitoolsindia.com W: www.imitoolsindia.com
79
Zenith Hydromatic T: +91-79-22812945 E: zenith_amrut@yahoo.com W: www.hydraulicsystemsindia.com
228
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